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Miller Electric MARK VIII-2 manual

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Table of contents for the manual

  • Page 1

    Proces ses OM -218 029 920Z July 2005 MARK VIII-2 V isit our website at www.MillerWelds.com Description Air Carbon Arc (CAC-A) Cut- ting and Gouging TIG (GT A W ) W elding Stick (SMAW ) W elding MIG (GMAW) W elding Arc Welding Power Source With Optional Equipment: Air Plasma Cutting and Gouging Flux Cored (FCA W ) W elding ®[...]

  • Page 2

    Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mille[...]

  • Page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . [...]

  • Page 4

    Notes[...]

  • Page 5

    OM-218 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety messag[...]

  • Page 6

    OM-218 Page 2 Arc rays from the w elding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RA YS can burn eyes and skin. D Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching (se[...]

  • Page 7

    OM-218 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. F A[...]

  • Page 8

    OM-218 Page 4 1-5. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American Welding Society Standard A WS F4[...]

  • Page 9

    OM-218 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION som _3/05 Y A vertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symbo les uti lisés Sy mbole graphique d’avert iss ement ! Att ention ! Cette pro - cédur e comporte d es risques poss ibles ! [...]

  • Page 10

    OM-218 Page 6 Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provo- quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. LES RA YONS D’ARC peuvent entraî- ne r des brûlures aux yeux et à la peau. [...]

  • Page 11

    OM-218 Page 7 2-3 . Dange rs suppléme ntaires en r e lation avec l’installa tion, le f onc tionnement et l a maintenanc e Risque D’INCENDIE OU D’EXPLO- SION. D Ne pas placer l’appareil sur , au-dessus ou à proximité de surfaces inflammables. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surcharger l’i[...]

  • Page 12

    OM-218 Page 8 2-5. Princi pales nor mes de sécur ité Safety in W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : www .global.ihs.com). Recommended Safe Practices fo r the Preparati on for W elding and Cut- ting of Containers and Piping , American W elding[...]

  • Page 13

    OM-218 Page 9 SECTION 3 − SPECIFICA TIONS 3-1. Specifications Rated Welding Output For Main Rated W elding Output For Each Amperes Input at Rated Load Output, 60 Hz, Three-Phase O utput For Main T ransformer O utput For Each Module Max OCV DC 220 V 230 V 380 V 440 V 460 V 575 V KV A KW 800 A @ 40 V olts DC, 100% Duty Cycle; 1600 A @ 40 V olts DC,[...]

  • Page 14

    OM-218 Page 10 3-3. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding. Y Exceeding duty cycle can damage unit and void[...]

  • Page 15

    OM-218 Page 1 1 SECTION 4 − INST ALLA TION ssb9.1 5/94 − ST -801 180 / ST-144 567-A 1 Lifting Eye 2 Lifting Forks Use lifting eye or lifting forks to move unit. If using lifting forks, extend forks beyond opposite side of unit. 3 Rating Label Use rating label to determine input power needs. 4 Line Disconnect Device Locate unit near correct inpu[...]

  • Page 16

    OM-218 Page 12 4-2. Dimensions, Weights And Base Mounting Hole Layout Overall dimensions (A, B, and C) include lifting eye, handles, hardware, etc. NOTE Dimensions A 77-1/4 in (1943 mm) B 72 in (1829 mm) H A C 40 in (1016 mm) C D 52-1/2 in (1334 mm) D Front B C E 3/4 in (19 mm) F 38-1/2 in (978 mm) G G 26-1/4 in (667 mm) H 36 in (914 mm) J 1/2 in D[...]

  • Page 17

    S-0008-C OM-218 Page 13 4-4. W eld Cable Size T otal Cable (Copper) Length In Weld Circuit Not Exceeding* 50 ft Or Less (15m) 100 ft (30m) 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m) W elding Amperes 10 Thru 100% Duty Cycle 100 4 4 4 3 2 1 1/0 1/0 150 3 3 2 1 1/0 2/0 3/0 3/0 200 2 2 1 1/0 2/0 3/0 4/0 4/0 25[...]

  • Page 18

    OM-218 Page 14 4-5. Connecting Weld Output Cables 803 778-B Y T urn off power before connecting to weld output terminals. Y Failure to properly connect weld cables may cause excessive heat an d start a fire, or damage your ma- chine. 1 Weld Output T erminal 2 Supplied Weld Output T erminal Nut 3 Weld Cable T erminal 4 Copper Bar Remove supplied nut[...]

  • Page 19

    OM-218 Page 15 A. Standard Module Connections ST-144 568-C 1 Cable Restraint Route all cables under cable restraint. Separate W ork Connections See Section 4-4 for proper cable size. 2 Negative ( − ) W eld Output T erminal 3 Work Cable 4 Positive (+) Weld Output T erminal 5 Electrode Holder Cable For Electrode Positive (Reverse Polarity/DCEP), co[...]

  • Page 20

    OM-218 Page 16 B. Parallel Module Connections 1 Cable Restraint Route all cables under cable restraint. Separate W ork Connections See Section 4-4 for proper cable size. 2 Negative ( − ) W eld Output T erminal 3 Electrode Holder Cable 4 Positive (+) Weld Output T erminal 5 Work Cable 6 Connection Point For Electrode Negative (Straight Polarity/DC[...]

  • Page 21

    OM-218 Page 17 ST-144 570-A / Ref. ST -174 143 1 Remote Amperage Control Receptacles RCX1 (“X” Represents The Number Of The Applicable Module 1 − 8) The twistlock receptacle in each module provides a connection point for an optional remote amperage control. T o connect to one of these receptacles, insert plug from re- mote amperage control an[...]

  • Page 22

    OM-218 Page 18 Ref. ST-144 570-A / Ref. SC-085 382 1 1 15 V olts AC Duplex Receptacle RC2 This receptacle supplies up to 10 amperes of 1 15 volts a c pow er . The duplex receptacle is protected from overload by supplementary protector CB1 (see Section 6-2). 1 15V AC 10A 1 15V AC OVERLOAD BREAKER CLOSED OPEN 1 4-9. 1 15 V olts AC Duplex Receptacle 4[...]

  • Page 23

    OM-218 Page 19 B. Connecting Input Power ssb2.4* 1/94 − Ref. ST-144 569-B T ools Needed: 3/8 in 1-1/16 in 7 10 8 4 9 6 Y Installation must meet all National a nd Local Codes − have only qualified per- sons make this installation. Y Disconnect and lockout/tagout input power before connecting input con- ductors from unit. Y Make input power conne[...]

  • Page 24

    OM-218 Page 20 4-1 1. Electrical Service Guide Input V oltage 220 230 380 440 460 575 Input Amperes At Rated Output 178 170 103 89 85 68 Max Recommended Standard Fuse Rating In Amperes 1 T ime-Delay 2 200 200 125 11 0 100 80 Normal Operating 3 250 250 150 125 125 100 Min Input Conductor Size In A WG 4 3/0 2/0 2 3 3 4 Max Recommended Input Conductor[...]

  • Page 25

    OM-218 Page 21 Ref. ST-174 143 1 Remote Amperage Control Switch Fo r front panel control of a module, place switch on that module in Off position. For remote control, place switch in On position. See Example below . 2 Amperage Adjustment Control Use control at each module to select weld amperage for that mod- ule. The numbers are weld amperes. 3 Re[...]

  • Page 26

    OM-218 Page 22 SECTION 6 − MAINTENANCE & TROUBLESHOOTING ST-144 567-A 3 Months Clean And T ighten W eld T erminals 6 Months T ape Or Replace Cracked Cables Replace Unreadable Labels Fan Motor Sealed Bearings − No Oil Needed OR During Heavy Service, Clean Monthly Blow Out Or V acuum Inside See Section 4-6 − − 10 − − − − 6-1. Rout[...]

  • Page 27

    OM-218 Page 23 B. Control Fuses F3 And F4 Ref. ST-144 569-B / Ref. ST -146 126-C T urn Off polyweld system and dis- connect input power . 1 Input T erminal Board 2 Fuses F3 And F4 Location 3 Fuse F3 Or F4 (See Parts List For Rating) 4 Fuse Holder Check F3 or F4, and replace if needed. Use proper tool when re- moving fuse. Close rear access door . T[...]

  • Page 28

    OM-218 Page 24 6-4. T roubleshooting Y T urn Off polyweld system, and disconnect input power before inspecting, maintaining, or servicing. T rouble Remedy No weld output from any module; fan motors of f; pilot light off. Place line disconnect device in On position (see Section 4-10 ). Check line fuse(s), and replace if needed. Reset circuit breaker[...]

  • Page 29

    OM-218 Page 25 Notes[...]

  • Page 30

    OM-218 Page 26 SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram For Polyweld System[...]

  • Page 31

    OM-218 Page 27 SD-082 527-C[...]

  • Page 32

    OM-218 Page 28 SECTION 8 − SELECTING AND PREP ARING TUNGSTEN ELECTRODE gtaw 7/97 For additional information, see your distributor for a handbook on the Gas T ungs ten Ar c W elding (G T AW) process.Wear clean gloves to prev ent contamination of tungsten electrode. NOTE 8-1. Selecting T ungsten Electrode Amperage Range - Gas T ype ♦ - Polarity E[...]

  • Page 33

    OM-218 Page 29 8-2. Preparing T ungsten For AC Or DC Electrode Positive (DCEP) Welding Ref. S-0161 1 T ungsten Electrode 2 Balled End Y Understand and follow safety symbols at start of Section 9-1 before preparing tungsten. Ball end of tungsten before welding by applying either an ac amperage slightly higher than what is recom- mended for a given e[...]

  • Page 34

    OM-218 Page 30 SECTION 9 − GUIDELINES FOR TIG WELDING (GT A W) 9-1. Positioining The T orch ST-161 892 Y W eld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Pl ace wor k cl amp as close t o the weld as possible. 1 W orkpiece Make sure workpiece is clean before welding. 2 Work Clamp Pl[...]

  • Page 35

    OM-218 Page 31 9-3. Positioning T orch T ungsten For V arious Weld Joints ST-162 003 / S-0792 70 ° 70 ° 90 ° 20 ° 20 ° 10 ° 20 ° 70 ° 40 ° 30 ° 20 ° 70 ° 90 ° 20 ° Butt Weld And Stringer Bead “T” Joint Lap Joint Corner Joint[...]

  • Page 36

    OM-218 Page 32 SECTION 10 − P ARTS LIST 1 2 3 4 5 6 7 8 9 10 16 17 18 19 20 23 24 8 5 6 ST-144 531-D 25 . Hardware is common and not available unless listed. 12 11 15 26 Figure 10-1. Main Assembly (Section A)[...]

  • Page 37

    OM-218 Page 33 Description Part No. Dia. Mkgs. Item No. Figure 10-1. Main Assembly (Section A) Quantity 1 FM1,2 032 605 MOTOR, cap perm SP 1/4hp 230V AC 1625RPM 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 071 763 FRAME, mtg fan motor 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 38

    OM-218 Page 34 1 2 3 4 5 6 8 9 10 7 ST-144 660 . Hardware is common and not available unless listed. Figure 10-2. Main Assembly (Section B)[...]

  • Page 39

    OM-218 Page 35 Description Part No. Dia. Mkgs. Item No. Figure 10-2. Main Assembly (Section B) Quantity 1 CR1 194 307 CONT ACTOR, def prp 40A 3P 120V 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 T3 092 324 TRANSFORMER, kV A 1 1 15-230/460/575 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 40

    OM-218 Page 36 Description Part No. Dia. Mkgs. Item No. Figure 10-3. Panel, Front Module w/Components (Fig 10-1 Item 24) Quantity 1 034 253 DOOR, access pwr output (includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 032 477 INSULA TOR, cover secondary 1 . . . . . . . . . . . . . . . . . . .[...]

  • Page 41

    OM-218 Page 37 Description Part No. Dia. Mkgs. Item No. Figure 10-4. Panel, Front Lower w/Components (Fig 10-1 Item 25) Quantity 1 +086 855 P ANEL, front lower 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 217 136 LABEL, warning electric shock 1 . . . . . . . . . [...]

  • Page 42

    Notes[...]

  • Page 43

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 1/05 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expertise o[...]

  • Page 44

    PRINTED IN USA © 2005 Miller Electric Mfg. Co. 1/05 Miller Elect ric Mfg. Co. An Illinois T ool W orks Compa ny 1635 West S pencer S treet Applet on, WI 5 4914 US A International He adquarters − US A USA Phone: 920-735-4505 Aut o-At tended USA & Canada F AX : 920-735-4134 Int ernati onal F A X: 920-735-4125 European Headqua rters − United [...]