Miller Electric MO-200/200 User manual

June

1976

FORM:

OM-803B

Effective

with

Serial

No.

MEHG003288

MODEL

MO200/200

STOCK

NO.

041

070

MODEL/STOCK

NO.

SERIAL/STYLE

NO.

DATE

PURCHASED

ADDITI:ONAL

COPY

PRICE

:~O

CENTS

OWNERS

MANUAL

MILLER

ELECTRIC

MFG.

CO.

APPLETON,

WISCONSIN,

USA

54911

NWSA

CODE

NO.

4579

,.l~e~TtO

0.90.

LIMITED

WARRANTY

MILLER

Electric

Mfg.

Co.,

Appleton,

Wisconsin,

warrants

all

new

equipment

free

from

defects

material

and

factory

workmanship

for

the

periods

indicated

below,

provided

the

equipment

installed

and

operated

according

manufacturers

instructions.

MILLER

Electric

Mfg.

Co.s

obligation,

underthis

warranty,

expressly

limited

replacing

repairing

any

defective

part

correcting

any

manufacturing

defect

without

charge

during

the

warranty

period

MILLERS

inspection

confirms

the

existence

such

defects.

MILLERS

option

repair

replacement

will

f.o.b.

factory

Appleton,

Wisconsin

f.o.b.

MILLER

authorized

service

facility,

and

therefore

compensation

for

transportation

costs

any

kind

will

allowed.

The

warranty

period,

beginning

the

date

sale

the

original

prchaser.user

the

equipment,

will

follows:

Arc

welders,

power

sources,

and

components



year

Original

main

power

rectifiers



years

(unconditionally)

20E,

20K,

and

all

welding

guns~



days

All

other

Millermatic

Feeders



year

All

engines



year

Engine

Warranties

are

covered

the

engine

manufacturers,

subject

their

procedures

and

handled

through

their

authorized

local

Service

Stations

agencies.

warranty

will

made

respect

trade

accessories,

such

being

subject

the

warranties

their

respective

manufacturers.

MILLER

Electric

Mfg.

Co.

will

not

liable

for

any

loss

consequential

damage

expense

accruing



directly

indirectly

from

the

use

equipment

covered

this

warranty.



This

warranty

supersedes

all

MILLER

warranties

and

exclusive

with

other

guarantees

warranties

expressed

implied.



SECTION

INTRODUCTION

1-1.

GENERAL

This

manual

has

been

prepared

especially

for

use

familiar

izing

personnel

with

the

design,

installation,

operation,

main

tenance,

and

troubleshooting

this

equipment.

All

informa

tion

presented

herein

should

given

careful

consideration

assure

optimum

performance

this

equipment.

Prior

installing

this

equipment,

clean

all

packing

material

from

around

the

Unit

and

carefully

inspect

for

any

damage

that

may

have

occurred

during

shipment.

Any

claims

for

loss

damage

that

may

have

occurred

transit

must

filed

the

purchaser

with

the

carrier.

copy

the

bill

lading

and

freight

bill

will

furnished

the

carrier

request

occasion

file

claim

arises.

When

requesting

information

concerning

this

equipment,

essential

that

Model

Description

and/or

Stock

Number

and

Serial

(or

Style)

Numbers

the

equipment

supplied.

1-3.

DESCRIPTION

This

unit

designed

function

two

operator

welding

control

station

which

remotely

located

from

the

welding

power

source.

This

unit

equipped

with

two

output

ELEC

TRODE

receptacles.

The

output

each

ELECTRODE

recep

tacle

governed

separate

set

amperage

controls.

This

welding

control

station

protected

from

damage

due

ces~ive

overload

fuse

the

input

circuitry.

1-4.

SAFETY

The

following

definition

applies

IMPORTANT

blocks

found

throughout

this

manual.

SECTION

INSTALLATION

2-1.

LOCATION

good

installation

essential

the

welding

control

station

provide

satisfactory

and

dependable

service.

Proper

operating

temperatures

are

maintained

the

air

stream

pass

ing

through

the

unit.

IMPORTANT

The

welding

control

station

should

located

that

the

side

panels

with

the

air

vents

louvers

are

clear

any

obstruction.

The

location

should

such

that

minimum

amount

dust

and

dirt

will

drawn

into

the

air

stream.

Preventive

main

tenance

consists

removing

the

wrapper

from

the

welding

control

station

and

blowing

out

the

dust

accumulation

inside

the

unit.

2-2.

INPUT

AND

OUTPUT

CONNECTIONS

male

Camlock

plug

provided

the

rear

panel

the

welding

control

station

for

connecting

the

electrode

cable

from

the

welding

power

source.

The

Corresponding

female

receptacle

for

this

camlock

plug

Supplied

with

the

welding

control

station.

Two

female

Camlock

receptacles

are

provided

the

front

panel

the

welding

control

Station

for

making

connections

from

the

Station

the

electrode

holder

cables.

The

corres

ponding

male

Camlock

receptacles

are

Supplied

with

the

weld

ing

station.

Use

Table

2-1

guide

selecting

the

electrode

holder

cable.

Figure

2-1.

Dimensional

Drawing

Table

2-1

Welding

Cable

Sizes

TB-004

547-A

Woldinp

Tota

Cable

lCopn

sri

Weld

Circuit

Amperes

100

150

200 250

300

350

400

100

1/0

150

I/O

2/0

3/0

200

1/0

2/0 3/0

4/0 4/0

250

1 1

1/0

2/0

3/0

4/0

500MCM

300

1/0

2/0

3/0

4/0

500MCM

350

1/0 1/0

3/0 4/0 4/0

500MCM

400

2/0 2/0

3/0

4/0

SOOMCM

500MCM

500McM

SOOMCM

500

3/0 3/0 4/0

500MCM

600

4/0 4/0

500MCM

500MCM 500McM 500MCM

1000MCM

Aluminum

SECTION

OPERATION

3-1

SINGLE-PARALLEL

SWITCH

The

SINGLE-PARALLEL

Switch,

when

the

SINGLE

posi

tion,

allows

two

operators

weld

simultaneously;

each

having

adjustable

amperage

range

from

195

amperes.

When

the

PARALLEL

position,

only

one

operator

may

weld

time.

Also

the

PARALLEL

position,

the

amper

age

range

will

doubled

from

195

amperes

390

amperes

for

the

ELECTRODE

Receptacle

being

used.

3-2.

COARSE

AND

FINE

AMPERAGE

CONTROLS

Four

controls

are

provided

the

front

panel

the

welding

control

station

for

selecting

the

amperage

output.

Coarse

and

Fine

Amperage

Control

provided

for

each

the

two

ELECTRODE

Receptacles.

The

Coarse

Amperage

Control

will

vary

the

amperage

output

its

respective

ELECTRODE

Receptacle

ampere

incre

ments,

from

150

amperes,

when

the

SINGLE-

PARALLEL

Switch

the

SINGLE

position.

When

the

PARALLEL

position

the

Coarse

Amperage

Control

will

vary

the

amperage

output

100

ampere

increments

from

100

300

amperes.

The

Fine

Amperage

Controls

will

act

fine

amperage

justment

within

the

coarse

range

selected

its

respective

Coarse

Amperage

Control.

The

Fine

Amperage

Controls

will

adjust

the

amperage

output

ampere

increments

when

the

SINGLE

PARALLEL

Switch

the

SINGLE

position.

When

the

PARALLEL

position,

the

Fine

Amperage

Con

trol

will

adjust

the

amperage

output

ampere

increments.

3-3.

FUSE

PROTECTION

This

welding

control

station

protected

from

damage

due

excessive

overload

600

ampere

fuse

connected

the

input

circuitry.

This

fuse

located

behind

the

hinged

rear

access

door.

1-2.

RECEIVING-HANDLING

IM~T

Installation,

operating,

and

maintenance

procedures,~

practices,

etc.,

which

will result

damage



equipment.

NOTE:

Add

2-1/4

dimen

sion

for

protruding

handle

(not

shown)

rear

unit.

OM-803

Page

I-

(i~9

(

\~i~

cv)

C.)

oil.



o-~



-D

Q~,W

a



-j



C.,

C.)

~s1C,

~II

C~4

a

June

1976

FORM:

OM-803B

Effective

with

Serial

No.

MEHG003288

MODEL

MO-200/200

STOCK

NO.

041

070

MODEL/STOCK

NO.

SERIAL/STYLE

NO.

DATE

PURCHASED

PARTS

LIST

MILLER

ELECTRIC

MFG.

CO.

APPLETON,

WISCONSIN,

USA

54911

NWSA

CODE

NO.

4579

pIJf0

0

~~4O

393$37~

TD-003

827-A

Figure



Complete

Assembly

Item

Dia.

No.

Mkgs.

Figure

Factory

Part

No.

Recommended

Spare

Parts

SURE

PROVIDE

STOCK,

MODEL,

AND

SERIAL

NUMBERS

WHEN

ORDERING

REPLACEMENT

PARTS.

Complete

Assembly

Description

Quantity

004

375

PANEL,

heat

exchange

front

004

055

INSULATOR,

wire

004057

TUBING,steel

11/32ODx

17/64IDx7/16

004 373

PANEL,

support

front

R5,1

004

052

RESISTOR,

grid

4.4

ohm

16-1/4

w/tubing

pins

...

R6,7,13,14

004

051

RESISTOR,

grid

2.8

ohm

16-1/4

1gw/tubing

pins

....

R4,1

004

053

RESISTOR,

grid

9.6

ohm

16-1/4

1gw/tubing

pins

....

Ri,2,3,8,9,i0

004

050

RESISTOR,

grid

0.84

ohm

16-1/4

1gw/tubing

pins

...

004371

WRAPPER

004 056

INSULATOR,

bus

bar

004059

TUBING,steel

1i/32ODx

17/64IDx2

004 353

BUS

BAR,

fuse

link

plug

006779

PANEL,rear

039

633

CONNECTOR,

quick

connect

twistlock

female

004

636

PLUG,

with

components

(consisting

of)

056

271

PLUG,

twistlock

010907

.NUT,

locking

inch

602

213

WASHER,

lock

steel

split

3/8

601

837

NUT,

brass

hex

jam

3/8-16

*004

387

LINK,fuse600amp25ovolts

004

070

BUS

BAR,

interconnecting

resistors

004

376

PANEL,

heat

exchange

rear

004

374

PANEL,

support

rear

004 377

BASE

004419

LINK,jumper-

switch

connector

004370

LINK,jumper-switch

004369

LINK,jumper-switch

2connector

004 416

BUS

BAR,

link

receptacle

29 004

420

BUS

BAR,

interconnecting

switch

006

786

SWITCH,

rotary

amp

600

volts

(consisting

of)

006

784

KNOB

004

417

BUS

BAR,

switch

bus

bar

S2,3

004

016

SWITCH,

rotary

amp

600

volts

(consisting

of)

006 790

KNOB

006791

SPACER

004

637

RECEPTACLE,

with

components

(consisting

of)

601

837

NUT,

brass

hex

jam

3/8-16

38 602

213

WASHER,

lock

steel

split

3/8

010

907

NUT,

locking

inch

039 628

RECEPTACLE,

twistlock

female

insulated

039

630

PLUG,

twistlock

male

insulated

NAMEPLATE

(order

stock,

model,

and

serial

numbers)

006

778

PANEL,

front

004

418

LINK,

jumper

switch

connector

006

787

SWITCH,

rotary

amp

600

volts

(consisting

of)

006

784

KNOB

004

368

LINK,

jumper

switch

connector

OM-803

Page

Table of contents

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