Miller Electric Welder-Generator User Manual

Miller Du-Op®

		Heavy Industrial Applications	Processes
		Pipe Welding	Stick (SMAW)
Quick		Structural	MIG (GMAW)
			Flux Cored (FCAW)
			DC TIG (GTAW)
Specs			Air Carbon Arc (CAC-A)
			Single Weld Mode:
			3/8 in (9.5 mm) Carbons
			Dual Weld Mode:
			1/4 in (6.4 mm) Carbons

Issued May 2008 • Index No. ED/10.9

Engine-Driven

Welder/Generator

Output Range

Single Weld Mode: (Right side) CC/DC 30 – 600 A Dual Weld Mode: (Both sides) CC/DC 15 – 300 A

CV/DC 10 – 32 A

Weld Output Rated at 104°F (40°C)

Single Weld Mode: 550 A at 30 VDC, 40% Duty Cycle Dual Weld Mode: 275 A at 31 VDC, 40% Duty Cycle

Generator Output Rated at 104°F (40°C)

5,500 Watts Peak — 4,000 Watts Continuous

Weight Net: 2115 lb (959 kg) Ship: 2150 lb (975 kg)

The Power of Blue®.

Multi-arc welding is here! One dependable engine and two highperformance arcs allow operators to work independent of each other. It’s a one-of-a-kind, go-anywhere engine drive.

Increase profits with this multi-arc machine by completing even your most demanding jobs in half the time compared to conventional engine-driven welders. With two arcs in one engine drive, fewer machines are required for a job.

Double the amperage output with a switch that parallels both outputs to a single side. This provides a safe and easy way to run large electrodes, stud weld, or carbon-arc gouge.

5,500 watts of AC generator power independent of welding output. Two 120 V, 20 A GFCI duplex receptacles. Two 230 V, 20 A duplex receptacles.

Welder/generator is warranted by Miller for 3 years, parts and labor.

Engine is warranted by Deutz for 2 years.

Two 14-pin remote controls can be used for precise adjustment of amperage or voltage along with contactor.

Hot Start™ provides positive stick electrode starts to make it easy to start all types of electrodes.

Weld meters — digital ammeter and presettable voltmeter allow monitoring of welding output for each welder.

Arc control (DIG) allows the arc characteristics to be changed for specific applications and electrodes. Smooth running 7018 or stiffer, more penetrating 6010 electrodes.

Thermal overload protection prevents machine damage if the duty cycle is exceeded or airflow is blocked.

Miller Electric Mfg. Co.	International Headquarters	Web Site
An Illinois Tool Works Company	Phone: [phone]	www.MillerWelds.com
1635 West Spencer Street	USA FAX: [phone]
Appleton, WI 54914 USA	Canadian FAX: [phone]
	International FAX: [phone]

Specifications (Subject to change without notice.)

	Weld		Weld				Max. Open-		Sound Levels at
Welding	Stations	Weld	Output		Weld Output Rated		Circuit	Generator Output Rated	Rated Output,		Weight
Mode	Available	Output	Range		at 104˚ F (40˚ C)		Voltage	at 104˚ F (40˚ C)	7 m (23 ft)	Dimensions	Without Fuel*
Single	1	CC/DC	30	– 600 A	550 A at 30 VDC,		85	Peak: 5500 watts	83 dB (108 Lwa)	H: 47-5/8 in	Net: 2005 lb
	(Right side)				40% Duty Cycle			Continuous: 4000 watts,		(1210 mm)	(909 kg)
								34/17 A, 120/240 VAC,		W: 31-1/4 in	Ship: 2032 lb
Dual	1 or 2	CC/DC	15	– 300 A	275 A at 31 VDC,		85
								while welding		(794 mm)	(922 kg)
	(Both sides)	CV/DC	10	– 32 V	40% Duty Cycle		49
										D: 60-1/2 in
										(1537 mm)

*Additional 176 lb (80 kg) when fuel tank is full.

Engine (Subject to change without notice.)

						Weld	Fuel	Oil	Coolant	Automatic Engine
Engine Brand			Features	HP	Type	Speed	Capacity	Capacity	Capacity	Shutdown
			Tier IV: EPA-certified, direct-injected, air-	49.3	Three-cylinder,	1800 RPM	25 gal	9 qt	Air	High oil
			cooled engine. Right-side service access with		industrial, air-	Idle: N/A	(95 L)	(8.5 L)		temperature
			service intervals of 500 hours for oil and		cooled, diesel					Low oil pressure
Deutz, F3L-914			filters.

Control Panel

	Front Panel		Side Panels
	1	1	3
			4
			5
	2		6
		2	7
	3
			8
	4
			9
	5		10
	6		11
			12
	7
	8

1.	120	VAC, 20	A GFCI Duplex Receptacle and Circuit Breakers	1.	Process Selector Switch	8.	Remote Amperage/Voltage
2.	240	VAC, 20	A Duplex Receptacle and Circuit Breakers	2.	Arc Force (DIG) Control		Control Switch
3.	Battery Charging Warning Light			3.	Hot Start Switch	9.	Output (Contactor) Switch
4.	Engine Hour Meter			4.	Ammeter	10.	Negative Weld Output Terminal
5.	Engine Start Button			5.	Voltmeter	11.	CC Weld Output Terminal
6.	Manual Stop Control			6.	Amperage/Voltage Control	12.	CV Weld Output Terminal
7.	Ether Starting Aid Switch (Optional)			7.	High Temperature
8.	Separate/Parallel Switch				Shutdown Light

Performance Data

DUTY CYCLE

	1000
	800				SINGLE
AMPERES	600
	500
	400						DUAL
	300
	250
WELD
	200
	150
	100
	10	15	20	25	30	40	50	60	80	100

100% DUTY CYCLE

AUXILIARY POWER

	150	300
	125	250
VOLTS	100	200
	75	150
AC	50	100
	25	50
	0	0
		0	5	10	15	20	25	30

AC AMPERES IN 240V MODE

0

10

20

30

40

50

60

AC AMPERES IN 120V MODE

FUEL CONSUMPTION

	7.57	1.70	2.00
	6.62	1.46	1.75
	5.67	1.25	1.50
	4.73	1.04	1.25
	3.78	0.83	1.00		CC
	2.84	0.62	0.75		CV
	1.98	0.40	0.50
	0.95	0.21	0.25
			0	0	50 100 150 200 250 300 350 400 450 500 550 600
	LITERS/HR.	IMP. GAL./HR.	U.S. GAL./HR.
					DC WELD AMPERES AT 40% DUTY CYCLE

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