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Miller Electric MOG-250 manual

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Table of contents for the manual

  • Page 1

    Processes Description TIG (GT A W ) W elding Stick (SMA W) W elding Multiple Operator Resistance Grids (MOG), Racks, And Remote Controls OM-808 081 904F January 1997 MOG-250/250, MOG-300, MOG-350/350, MOG-400, MOG-Pak, And RGC Controls Visit our website at www.MillerWelds.com[...]

  • 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 catalog sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .MillerW eld[...]

  • Page 3

    The following terms are used interchangeably throughout this manual: TIG = GT AW Stick = SMAW T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 4

    [...]

  • Page 5

    OM-808 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 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 message. . Means “Note”; not safety related. This group of symbols means W arning! Watch O[...]

  • Page 6

    OM-808 Page 2 Arc rays from the welding 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 a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87[...]

  • Page 7

    OM-808 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-808 Page 4 1-5. EMF Information Considerations About Welding And The Ef fects Of Low Frequency Electric A n d M a g netic Fields W elding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields. However , after examining more than 500 studies spanning 17 years o[...]

  • Page 9

    OM-808 Page 5 SECTION 1 – CONSIGNES DE SECURITE – LIRE A V ANT UTILISA TION som _nd_fre 5/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette proc é dure pr é sente des risques de danger ! Ceux-ci sont identifi é s par des symboles adjacents aux directives. Y Identifie un message de s é curit é particulier . [...]

  • Page 10

    OM-808 Page 6 Le rayonnement de l ’ arc du proc é d é de soudage g é n è re des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des br û lures dans les yeux et sur la peau. Des é tincelles sont projet é es pendant le soudage. LES RA YONS DE L ’ ARC peuvent pro- voquer des br û lures dans le[...]

  • Page 11

    OM-808 Page 7 1-3. Dangers suppl é mentaires en relation avec l ’ installation, le fonctionnement et la maintenance Risque D ’ INCENDIE OU D ’ EXPLOSION. D Ne pas placer l ’ appareil sur , au-dessus ou à proxi- mit é de surfaces infllammables. D Ne pas installer l ’ appareil à proximit é de produits inflammables D Ne pas surcharger l[...]

  • Page 12

    OM-808 Page 8 1-4. Principales normes de s é curit é Safety in W elding and Cutting, norme ANSI Z49.1, de l ’ American W el- ding Society , 550 N.W . Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Of fice, Washington, D.C. 20402. Recommended Safe Practice for the[...]

  • Page 13

    OM-808 Page 9 SECTION 2 – SPECIFICA TIONS 2-1. Resistance Grid Specification Description T ype Of Output Coarse: 50 Ampere Steps; Fine: 5 Ampere Steps; Optional: 2-1/2 Ampere* Overall Dimensions Height: 16 in (406 mm); Width: 16-1/2 in (419 mm); Length: 26 in (71 1 mm) 300 Ampere 400 Ampere 250/250 Ampere 350/350 Ampere Rated Welding Amperes Outp[...]

  • Page 14

    OM-808 Page 10 SECTION 3 – INST ALLA TION 3-1. T ypical Multiple Operator System Component Relationships W ARNING ELECTRIC SHOCK can kill; TWO TIMES NORMAL OPEN-CIRCUIT VOL TS exists between electrode holders of opposite polarity . • Do not touch live electrical parts. • Do not touch electrode holders of opposite polarity at the same time. ?[...]

  • Page 15

    OM-808 Page 1 1 3-2. Selecting A Location And Moving Resistance Grid Or Multi-Grid Rack Ref. ST-124 643-A / Ref. ST -151 556 / ST-161 154-A Y T urn Off welding power source BEFORE moving grid or rack. Locate grid(s) near welding power source. Resistance Grid 1 18 in (460 mm) Open Space On Front Side Location should allow operation of controls. 2 Ha[...]

  • Page 16

    OM-808 Page 12 3-3. W eld Input/Output Cables For Resistance Grid (Dual Model Shown) Y T urn Off welding power source, and disconnect in- pu t power before making a n y weld output connections. 1 Weld Input Cable 2 W ork Cable 3 Weld Output Cable If necessary , use Section 3-7 to select proper cable size. Use shortest cables possible. Do not use da[...]

  • Page 17

    OM-808 Page 13 3-4. W eld Input/Output Cables For Multi-Grid Rack S-0799-A 1 Weld Input Cable 2 W ork Cable 3 Weld Output Cable If necessary , use Section 3-7 to select proper cable size. Use shortest cables possible. Do not use damaged cables. 4 T erminal Lug Use lugs of proper amperage ca- pacity and hole size for connecting to common work, elect[...]

  • Page 18

    OM-808 Page 14 3-5. Female Camlok Connector Assembly sb6.6* – ST -159 028 1 Weld Input Cable Strip insulation as shown. 2 Copper Strip (T wo Included) 3 Connector Body W rap strip around bare weld cable (use two on small diameter cable), and insert into connector body . 4 Setscrew T ighten setscrew against copper strip. 5 Handle 6 Pin Slide handl[...]

  • Page 19

    OM-808 Page 15 3-7. W eld Cable Size* T otal Cable (Copper) Length In Weld Circuit Not Exceeding 100 ft (30 m) Or Less 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 T o 60% Duty Cycle 60 Thru 100% Duty Cycle 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 3 [...]

  • Page 20

    OM-808 Page 16 SECTION 4 – OPERA TION W ARNING ELECTRIC SHOCK can kill. • Keep all panels and covers securely in place. • Do not touch electrode holders of opposite polarity at the same time. • Separate electrode holders of opposite polarity to prevent contact. • See ANSI Z49.1 and OSHA TITLE 29, CHAPTER XVII, P ART 1910, Subpart Q. 4-1. [...]

  • Page 21

    OM-808 Page 17 4-3. W ork Clamp 1 Work Clamp Connect work clamp to a clean, paint-free location on workpiece, as close to weld area as possible. Use wire brush or sandpaper to clean metal at weld joint area. Use chipping hammer to remove slag after welding. sb4.1 2/93 T ools Needed: 1 4-4. Optional Polarity Switch W ARNING ELECTRIC SHOCK can kill; [...]

  • Page 22

    OM-808 Page 18 4-5. Amperage Controls CAUTION ARCING can damage switch. • Do not change position of any Amperage control or switch while welding or under load. Arcing inside switch can damage contacts, causing switch to fail. 1 Coarse Amperage Control Use control to select coarse weld amperage output. T o set amperage using only the Fine Amperage[...]

  • Page 23

    OM-808 Page 19 4-6. Optional Remote Grid Amperage Control ST-080 370-A / Ref. ST -122 903-D Remote amperage control only works when Fine Amperage control and optional 2-1/2 Ampere switch are in the Of f position (see Section 4-5). 1 Remote Grid Amperage Control See Section 3-8 for installation. 2 Fine Amperage Control Use control to add amperage, i[...]

  • Page 24

    OM-808 Page 20 4-8. Sequence Of Shielded Metal Arc Welding (SMA W) Begin W elding ssb7.1 9/92 Install & Connect Equipment Select Electrode Put On Personal Safety Equipment Set Controls Insert Electrode Into Holder T urn On W elding Power Source 4-9. Sequence Of Gas T ungsten Arc Welding (GT A W) T urn On Shielding Gas ssb8.1* 12/92 Install &[...]

  • Page 25

    OM-808 Page 21 5-2. Overload Protection Ref. ST-124 643-A / Ref. ST -161 156-A Fuse link F1, or fuse links F1 and F2 for dual models, protect the grid from overload damage. If weld output stops, check link(s) as follows: Turn Of f welding power source and disconnect input power . 1 Fuse Link (See Parts List For Rating) Check and replace fuse link(s[...]

  • Page 26

    OM-808 Page 22 SECTION 6 – ELECTRICAL DIAGRAMS SA-044 882-A Figure 6-1. Circuit Diagram For 300 Ampere Model SA-096 447-A Figure 6-2. Circuit Diagram For 300 Ampere Model With Polarity Reversing[...]

  • Page 27

    OM-808 Page 23 SA-044 884-A Figure 6-3. Circuit Diagram For 400 Ampere Model SA-096 445-A Figure 6-4. Circuit Diagram For 400 Ampere Model With Polarity Reversing[...]

  • Page 28

    OM-808 Page 24 SA-044 886-A Figure 6-5. Circuit Diagram For 250/250 Ampere Model SB-124 202 Figure 6-6. Circuit Diagram For 250/250 Ampere Model With Polarity Reversing[...]

  • Page 29

    OM-808 Page 25 SA-087 783-A Figure 6-7. Circuit Diagram For 350/350 Ampere Model SA-095 027-A Figure 6-8. Circuit Diagram For Remote Grid Controls[...]

  • Page 30

    OM-808 Page 26 SECTION 7 – P ARTS LIST ST-124 640-A 1 234 5 6 7 8 9 10 11 1 2 13 14 15 16 17 18 16 15 19 13 20 10 21 22 23 6 24 1 25 26 27 28 29 30 Fig 7-2 31 Fig 7-3 . Hardware is common and not available unless listed. Figure 7-1. Main Assembly[...]

  • Page 31

    OM-808 Page 27 Figure 7-1. Main Assembly Description Quantity Part No. Dia. Mkgs. Item No. Model 300 400 250/250 350/350 A AC A AC A/B AC/BC A AC 1 049 472 RAIL, grid 2 222222 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 049 470 BRACKET , side frame 2 222222 2 . . . . . . . [...]

  • Page 32

    OM-808 Page 28 Figure 7-1. Main Assembly (Continued) Description Quantity Part No. Dia. Mkgs. Item No. Model 300 400 250/250 350/350 A AC A AC A/B AC/BC A AC 31 049 563 RESISTOR ASSEMBL Y , current (Fig 3) 1 111111 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 049 615 RESIST OR ASSEMBL Y , current (Fig 3) 1 1 . . . . . . . . . [...]

  • Page 33

    OM-808 Page 29 Figure 7-2. Panel, Front w/Components (Fig 7-1 Item 30) Description Quantity Part No. Dia. Mkgs. Item No. Model 300 400 250/250 350/350 A AC A AC A/B AC/BC A AC 1S 4 ♦ 01 1 609 SWITCH, tgl SPDT 15A 125V 1 1 1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 S8,9 ♦ 01 1 609 SWITCH, tgl SPDT 15A 125V 2 2 . . . . . [...]

  • Page 34

    OM-808 Page 30 Description Quantity Part No. Dia. Mkgs. Item No. Model 300 400 250/250 350/350 049 563 049 615 049 562 089 729 Figure 7-3. Resistor Assembly , Current (Fig 7-1 Item 31) 1 049 479 BUS BAR, connecting resistors 1 5 6 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 059 841 BUS BAR, connecting[...]

  • Page 35

    OM-808 Page 31 Description Quantity Part No. Dia. Mkgs. Item No. Model 300 400 250/250 350/350 049 563 049 615 049 562 089 729 Figure 7-3. Resistor Assembly , Current (Fig 1 Item 31) 8 ♦♦ 049 570 BUS BAR, interconnecting resistors 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 049 570 BUS BAR, inte[...]

  • Page 36

    OM-808 Page 32 SD-080 254-E 12 3 4 5 6 7 8 9 10 11 12 . Hardware is common and not available unless listed. Figure 7-4. MOG-Pak 6 APR[...]

  • Page 37

    OM-808 Page 33 Description Part No. Item No. Figure 7-4. MOG-Pak 2, 4, & 6 Quantity P AK 2A P AK 4A P AK 6A Single Polarity Dual Polarity Single Polarity Dual Polarity Single Polarity Dual Polarity 1 049 758 ANGLE, guard 1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 049 690 ANGLE, guard 1 1 . . . . . . . . . . [...]

  • Page 38

    OM-808 Page 34 Description Part No. Item No. Figure 7-5. Remote Control Quantity Model 2.5 Amp 5 Amp 1 080 194 WRAPPER 1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 033 CONNECTOR, circ clamp 1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 39

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 7/00 Y ou r 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 [...]

  • Page 40

    PRINTED IN USA  2000 Miller Electric Mfg. Co. 6/00 Miller Elect ric Mfg. Co. An I l li noi s T ool Works Com pany 1635 W est S pencer St reet Applet on, WI 54914 USA International He adquarters – USA USA Phone: 920-735-4505 Auto-A t t ended USA & Canada F A X : 920-735-4134 Int ernati onal FAX: 920-735-4125 European Headqua rters – Unite[...]