Miller Electric MO-395 User manual

June

1976

FORM:

OM-802B

Effective

with

Serial

No.

MEHGOO32O5

MODEL/STOCK

NO.

SERIAL/STYLE

NO.

DATE

PURCHASED

OWNERS

MANUAL

MILLER

ELECTRIC

MFG.

CO.

APPLETON,

WISCONSIN,

USA

54911

MODEL

MO-395

STOCK

NO.

041 071

ADDITIONAL

COPY

PRICE

CENTS

NWSA

CODE

NO.

4579

U.S.

LIMITED

WARRANTY

MILLER

Electric

Mfg.

Co.,

Appleton,

Wisconsin,

warrantsaIl

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

purchaser-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.

1-2.

RECEIVING-HANDLiNG

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

welding

control

station

remotely

located

from

the

main

power

source.

provides

receptacle

which

the

electrode

cable

connected

and

also

coarse

and

fine

current

Control.

This

welding

con

trol

station

protected

from

damage

due

excess

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

passing

through

the

unit.

IMPORTANT

The

welding

control

station

should

located

that

the

side

panels

with

the

air

vents

louvers

are

clear

any

obstruction.

Figure

2-1.

Dimensional

Drawing

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

of the

welding

control

st3tion

for

connecting

the

electrode

cable

from

the

welding

power

source.

The

corresponding

female

receptacle

for

this

camlock

plug

supplied

with

the

welding

control

station.

female

Camfock

receptacle

provided

the

front

panel

the

welding

control

station

for

making

Connections

from

the

station

the

electrode

holder

cable.

The

corresponding

male

Camlock

receptacle

supplied

with

the

welding

station.

Use

Table

2-1

guide

selecting

the

electrode

holder

cable.

Table

2-1.

Welding

Cable

Sizes

Weldin.

An,peres

tOO 150

Totol~~2~of

200

Cable

(Copper)

250

300

350

400

tOO

1/0

ISO

1/0

2/0

3/0

200

110

2/0 3/0

4/0

250

1/0

2/0

3/0 4/0

4/0

500MCM

300

1/0

2)0

3/0

4/0

SOOMCM

500MCM

350

1/0

3/0

4/0 4/0

500MCM

600MCM

400

2/0 2/0

3/0

4/0

SOOMCM 500MCM

500MCM

SOOMCM

500

3/0 3/0

4/0

500MCM

500McM SOOMCM

500MCM

600

4/0 4/0

500MCM

500McM

500MCM

1000MCM

Aluminum

iMP2~I

Installation,

operating

and

maintenance

procedures,

practices,

etc.,

which

will

result

damage

equip

ment.

NOTE:

Add

2-1/4

dimen

sion

for

protruding

handle

(not

shown)

rear

unit.

TB-004

544-A

OM-802

Page

Weld

Power

Input

Plug

Two

controls

are

provided

the

front

panel

the

welding

control

station

for

adjusting

the

amperage

output

from

the

station.

The

Coarse

Amperage

Control

will

vary

the

amperage

output

ampere

increments

from

350

amperes.

The

Fine

Amperage

Control

will

act

fine

adjustment

within

the

ampere

range

selected

the

Coarse

Amperage

Control.

The

Fine

Amperage

Control

adjust

the

amperage

output

ampere

increments.

This

welding

control

station

protected

from

damage

due

excessive

overload

400

ampere

fuse

connected

the

input

circuitry.

This

fuse

located

behind

the

hinged

rear

access

door.

imp~1~

rative

that

the

fuse

replaced

with

one

the

same

size

and

rating.

Failure

comply

may

result

damage

the

welding

control

station.

~lﬁ~

~:?ﬁ~y

P1001.17

SlEW

355

04Q-

COILS

T(WWIICALS

QEM

~dITCJ4

~ITItN

~Ei%Rt.~

I~MP

COIL

N.0.

SWflLII

1E~J0I0jAL

lOS

ISO

.300

250

.300

2

12.3

(2,;j

l~.3l.5

IL3.~.S.I

l23~f51.,T

2,4

2,41.

2.1,o,s

tL,!?,~

FINE

PC~

ITIC~J

0CM

SWIItH

P05111

CNJ

DESIaEO

ASP

COIL

5ldIF~.fl

TEEO,IItJAL

..~

.30

(.~7

1.,8

7,8

8,5

I.,8.O

7,E,.5

l.,7,0.5

~

.3,4

2,4,

4,1.

Z1~,S

4,0..8

2,4,1.,R

RE~I5T0RS

RI5T80~CE

WIRE

5I!EI

P..

TARU

R.~

.04.3.20

.840

01401.

.I4(~

.0111.

nIOt

S.C.

OMM1.

.010

.044

SIOO

~1.i

014011.

.050.

4.3

.02.8

.I0O

0.5

01151.

.07.3

.114

Figure

3-2.

Circuit

Diagram

Circuit

Diagram

No.

ME-00364

SECTION

OPERATION

Rear

View

3-1.

COARSE

AND

FINE

AMPERAGE

CONTROL

Figure

3-1.

Component

Locations

TB-004

545-A

3-2.

FUSE

PROTECTION

CORII1.L

P01.ITICN

Page

June

1976

FORM:

OM-802B

STOCK

NO.

041 071

MODEL/STOCK

NO.

SERIAL/STYLE

NO.

DATE

PURCHASED

PARTS

LIST

MILLER

ELECTRIC

MFG.

CO.

APPLETON,

WISCONSIN,

USA

54911

Effective

with

Serial

No.

MEHGOO32O5

MODEL

MO-395

NWSA

CODE

NO.

4579

-v

Includes

Items

and

TD-003

794-A

Figure



Complete

Assembly

Item

Dia.

Factory

No.

Mkgs.

Part

No.

Description

Quantity

Figure

Complete

Assembly

004

364

PANEL,

heat

exchange

front

004

055

INSULATOR,

wire

004

057

TUBING,

steel

11/32

17/64

7/16

004

362

PANEL,

support

front

R1-7

004

409

RESISTOR,

grid

0.84

ohm

161gw/tubing

pins

004411

RESISTOR,

grid

4.4

ohm

w/tubing

pins

R10,R1

004

410

RESISTOR,

grid

2.8

ohm

161gw/tubing

pins

004~412

RESISTOR,

grid

9.6

ohm

1gw/tubing

pins

004371

WRAPPER

004

056

INSULATOR,

bus

bar

004 353

BUS

BAR,

fuse

link

plug

004059

TUBING,steel

11/32ODx

17/64lDx2

006

781

PANEL,

rear

039

633

CONNECTOR,

quick

connect

twistlock

female

004

636

PLUG,

with

components

(consisting

of)

056

271

PLUG,

twistlock

010

907

NUT,

locking

inch

602 213

WASHER,

lock

steel

split

3/8

19 601

837

NUT,

brass

hex

jam

3/8-16

*004

367

LINK,fuse400amp250volts

004

070

BUS

BAR,

interconnecting

resistors

004

365

PANEL,

heat

exchange

rear

004

363

PANEL,

support

rear

004

377

BASE

006

788

SWITCH,

rotary

amp

600

volts

(consisting

of)

006

784

KNOB

004

354

LINK,

jumper

switch

connector

004

355

BUS

BAR,

link

receptacle

004

637

RECEPTACLE,

with

components

(consisting

of)

010

907

NUT,

locking

inch

601

837

NUT,

brass

hex

jam

3/8-16

32 602 213

WASHER,

lock

steel

split

3/8

039

628

RECEPTACLE,

twistlock

female

insulated

039

630

PLUG,

twistlock

male

insulated

NAMEPLATE

(order

stock,

model,

and

serial

numbers)

006 780

PANEL,

front

006791

SPACER

38 004

408

BUS

BAR,

switch

bus

bar

39 S2

006 789

SWITCH,

rotary

amp

600

volts

(consisting

of)

006

790

KNOB

Recommended

Spare

Parts

SURE

PROVIDE

STOCK,

MODEL,

AND

SERiAL

NUMBERS

WHEN

ORDERING

REPLACEMENT

PARTS.

OM-802

Page

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