Miller Electric MARK VI User manual

Processes
Stick (SMAW) CC
TIG (GTAW) CC
Air Carbon Arc (CAC-A)
Cutting and Gouging CC
Flux Cored (FCAW) CV
MIG Spray Transfer (GMAW)
with Voltage-Sensing Feeder CV
Heavy Industrial Applications
Construction
Rental Fleets
Fab Shops
Petro Chemical
Shipbuilding
Training Facilities
Maintenance
Quick
Specs
Rugged and durable enclosure
steel frame protects system.
Mark VI Multiple Arc
Welding System
Issued January 2006 • Index No. DC/9.8
Work connections are electrically isolated
from the frame, and service panels in
chassis provide easy access to internal
parts for routine maintenance.
Capable of four to six welding arcs,
Miller’s unique modules are designed
for easy removal and connection.
If you need only four arcs today,
purchase the Mark VI-2. If you
have a requirement for more arcs,
additional modules (CC or CV)
are available for purchase.
Optional Low OCV in CC/CV modules reduces maximum
open-circuit voltage to 26 volts in CC and CV modes when
not welding.
The Power of Blue® .
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Web Site
www.MillerWelds.com
International Headquarters
Phone: [phone]
USA FAX: [phone]
Canadian FAX: [phone]
International FAX: [phone]
Voltage Range CC: 20–315 A
CV: 10–30 V (with CC/CV Module)
Max. Open-Circuit Voltage
CC: 75 VDC CV: 38 VDC
CC/CV Low OCV Module: 26 VDC ±2 V
Weight Mark VI: 1725 lb (784 kg)
Mark VI-2: 1575 lb (718 kg)
Adjustable arc control lets you get in
tight without sticking the electrode. An
electrode compensation circuit ensures
arc control performance regardless of
the electrode size.
Multiple capabilities CC or CC/CV.
Versatility and outstanding arc
welding performances in both CV
(MIG) and CC (TIG and Stick). The
CC/CV module has a high quality
arc for welding with cored wires.
Miller does not recommend that
the CC/CV module be used for short
circuit transfer MIG welding. The CC
module has the same great arc
characteristic as the Gold Star 302.
Operator identification label helps
operators remember who is using
which module.
Welder is warranted for 3 years, parts and labor.
Original main power rectified parts are warranted for 5 years.
14-pin receptacle provides quick, direct
connection to Miller wire feeders and
accessories.
Weighs less than one ton which
makes it portable when secured on a
flatbed, construction truck, or when
moved by one-ton hoist. Fits through
36 in (914 mm) door opening.
60 Hz models have two 115 V GFCI duplex
receptacles which supply 15 amps of
auxiliary power. 50 Hz models have one
220 V and one 115 V duplex receptacle.
Line voltage compensation keeps
output power constant even if primary
input power varies by ±10%, ensuring
consistent weld performance.
Hot Start™makes it easy to start difficult-
to-start Stick electrodes, such as E-6010
and E-7018.

2
Control Panel
Performance Data
Specifications (Subject to change without notice.)
DC Amperage/
Voltage Range
20–315 A
in CC Mode
10–30 V in
CV Mode with
CC/CV Module
Max. Open-Circuit
Voltage (DC)
75 VDC in CC Mode
38 VDC in CV Mode
with CC/CV Module
26 VDC ±2 V
with CC/CV Module
and low OCV
Amps Input at 750 Amps Output, 50/60 Hz
230 V 380 V 400 V 415 V 440 V 460 V 575 V KVA KW
164 97 92 91 84 82.5 66.1 65.2 41.9
Dimensions
H: 65 in
(1651 mm)
W: 56-3/4 in
(1442 mm)
D: 34-1/4 in
(870 mm)
Net
Weight
Mark VI :
1725 lb
(784 kg)
Mark VI-2:
1575 lb
(718 kg)
Rated Welding Output
at 44 Volts DC
Single Module
250 A at 60% Duty Cycle
Main Transformer
60 Hz: 750 A at 100% Duty Cycle
1500 A at 25% Duty Cycle
50 Hz: 750 A at 60% Duty Cycle
1160 A at 25% Duty Cycle
8
7
UPPER PANEL FOR CC UNITS
LOWER PANEL
6
4
5
1
2
3
SINGLE MODULE
VOLTS 30
AMPERES 250
DUTY CYCLE 60%
MAX OCV 75VDC
TOTAL MACHINE
60Hz - 750 Amps @ 100% Duty Cycle
50Hz - 750 Amps @ 60% Duty Cycle
6
8
4
5
7
1
2
3
UPPER PANEL FOR CC/CV UNITS
LOWER PANEL
SINGLE MODULE
VOLTS 30
AMPERES 250
DUTY CYCLE 60%
MAX OCV 75VDC
TOTAL MACHINE
60Hz - 750 Amps @ 100% Duty Cycle
50Hz - 750 Amps @ 60% Duty Cycle
1. Arc Force Control
2. Remote/On Output Contactor Control
3. Remote/Panel Output Amperage Control
4. Hot Start On/Off Switch
5. Amperage Adjustment Control
6. High-Temperature Shut Off Indicator
7. 14-Pin Remote Receptacle
8. Power On/Off Switch
1. Arc Force Control
2. Remote/On Output Contactor Control
3. Remote/Panel Output Amperage Control
4. Process Selector
5. Amperage/Voltage Adjustment Control
6. High-Temperature Shut Off Indicator
7. 14-Pin Remote Receptacle
8. Power On/Off Switch
CC VOLT/AMP CURVES
FOR EACH MODULE
DC VOLTS
DC AMPS
80
60
40
20
00 100 200 300 400 500
CV VOLT/AMP CURVES
FOR EACH MODULE
VOLTS
AMPS
80
70
60
50
40
30
20
10
00 100 200 300 400 500 600 700

3
Process Selector Control #042 872
Allows you to easily change weld processes
without changing cables—from MIG to TIG
or TIG to Stick. Also for use with dual wire
feeders and applications where electrical
isolation and/or polarity reversing of weld
current is required.
Stick Hook-up Kit
#173 851 50 ft (15.2 m) 2/0 cable
Includes electrode holder, weld cable
and work cable with clamp.
MIG Hook-Up Kit
#173 856 25 ft (7.6 m) 2/0 cable
Includes gas hose assembly, lugged weld
cable assembly and work cable with clamp.
HF-251D-1 High-Frequency Arc
Starter/Stabilizer #042 388
This portable 250 A, 60% duty cycle unit
adds high frequency to the welding circuit to
help start the arc when using the TIG (GTAW)
process. Operates on 115 VAC 50/60/100 Hz.
See Lit. Index No. AY/5.1.
Wire Feeders
SuitCase™8RC #194 938
SuitCase™12RC #194 940
Compact, portable, constant-speed wire
feeder with remote voltage control. For
.030– 5/64 in (0.8 – 2 mm) hard and flux
cored wires. Holds up to an 8 in, 14 lb (8RC)
or 12 in, 44 lb (12RC) spool of wire.
See Lit. Index No. M/6.5.
SuitCase™8VS Wire Feeder #194 890
SuitCase™X-TREME™12VS
Wire Feeder #195 500
Lightweight, portable, voltage-sensing
wire feeders include secondary contactor
and gas valve. Require drive roll kit.
See Lit. Index Nos. M/6.4 and M/6.41.
Remote Controls and Switches
RFCS-14 Foot Control #043 554
Heavy-duty foot current and contactor
control. Includes 20 ft (6 m) cord and
14-pin plug.
RCC-14 Remote Contactor and
Current Control #151 086
Rotary-motion fingertip control. Fastens to
TIG torch using two Velcro strips. Allows
complete current and contactor control at
operator’s fingertips. Includes 28 ft (8.5 m)
cord and plug.
RCCS-14 Remote Contactor and
Current Control #043 688
Up-and-down rotary-motion fingertip
control. Great for applications that require
a finer amperage control. Includes 28 ft
(8.5 m) control cord.
Genuine Miller Accessories
Performance Data (continued)
60 Hz DUTY CYCLE CHART
WELD AMPS
% DUTY CYCLE
80 90 100
Total Machine Output
750 A at 100% Duty Cycle
Each Module Output
194 A at 100% Duty Cycle
70605040302010
1000
2000
1800
1600
1200
1400
800
300
200
100
50 Hz DUTY CYCLE CHART
WELD AMPS
% DUTY CYCLE
80 90 100
Total Machine Output
750 A at 60% Duty Cycle
Each Module Output
194 A at 100% Duty Cycle
70605040302010
1000
2000
1800
1600
1200
1400
800
300
600
200
100

Litho in USA
Distributed by:
Ordering Information
Power Source and Options Stock No. Description Qty. Price
Mark VI-2 (Four Modules) #903 588 230/460/575 V, 60 Hz
#903 588-01-1 With Tweco connectors
Mark VI CC (Six Modules) #903 512 230/460/575 V, 60 Hz
#903 569 380/400/415/440-460 V, 50/60 Hz
Mark VI CC/CV (Six Modules) #903 645 230/460/575 V, 60 Hz
#903 660 380/400/415/440 – 460 V, 50/60 Hz
#903 645-01-1 Low OCV modules
#903 645-02-1 With Cam-Lok connectors and Low OCV
Single CC Module #903 661 CC module, 50/60 Hz
Single CC/CV Modules #903 646 CC/CV module, 60 Hz
#903 659 CC/CV module, 50/60 Hz
#903 899 CC/CV, Low OCV modules
Stick Accessories
Stick Hook-up Kit #173 851 2/0 cable, 50 ft. Includes electrode holder, weld cable and work cable with clamp
Stick Electrodes
TIG Accessories
HF-251D-1 #042 388 HF arc starter/stabilizer
Torch and Consumables
Tungsten
MIG Accessories
SuitCase™8RC #194 938 See Lit. Index No. M/6.5
SuitCase™12RC #194 940 See Lit. Index No. M/6.5
SuitCase™8VS #194 890 See Lit. Index No. M/6.4
SuitCase™X-TREME™12VS #195 500 See Lit. Index No. M/6.41
MIG Hook-Up Kit #173 856 2/0 cable, 25 ft. Includes gas hose, weld cable, work cable w/ clamp, and regulator/flowmeter
Remote Controls
RFCS-14 #043 554 Foot control
RCC-14 #151 086 Fingertip control
RCCS-14 #043 688 Fingertip control
RHC-14 #129 340 Hand control
RMLS-14 #129 337 Momentary- and maintained-contact switch
Extension Cords #122 973 25 ft (7.6 m)
#122 974 50 ft (15.2 m)
#122 975 75 ft (22.9 m)
Miscellaneous
Process Selector Control #042 872
Primary Power Cord
Gas Cylinder
Gas Hose and Fittings
Date: Total Quoted Price:
Genuine Miller Accessories (continued)
Remote Controls and Switches
RHC-14 Hand Control
#129 340
Miniature hand control
for remote current and
contactor control.
Dimensions: 4 x 4 x
3-1/4 in (102 x 102 x
82 mm). Includes 20 ft (6 m) cord and
14-pin plug.
RMLS-14 #129 337
Momentary- and maintained-contact rocker
switch for contactor control. Push forward
for maintained contact and back for momen-
tary contact. Includes 20 ft (6 m) cord and
14-pin plug.
Extension Cables for 14-Pin Plugs to
14-Pin Sockets
#122 973 25 ft (7.6 m)
#122 974 50 ft (15.2 m)
#122 975 75 ft (22.8 m)
Extension cords make a direct connection
between the power source and the
accessory control. No messy splicing or
adapting required.