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
20
CENTS
NWSA CODE NO.
4579
U.S.
U.

LIMITED
WARRANTY
MILLER
Electric
Mfg.
Co.,
Appleton, Wisconsin,
warrantsaIl
new
equipment
to
be
free from
defects
in
material
and
factory
workmanship
for
the
periods
indicated
below,
provided
the
equipment
is
installed
and
operated
according
to
manufacturers
instructions.
C
~
MILLER
Electric
Mfg.
Co.s
obligation,
underthis
warranty,
is
expressly
limited
to
replacing
or
repairing
any
defective
part
or
correcting
any
manufacturing
defect
without
charge
during
the
warranty
period
if
MILLERS
inspection
confirms
the
existence of such
defects.
MILLERS
option
of
repair
or
replacement
will
be
f.o.b.
factory
at
Appleton,
Wisconsin
or
f.o.b.
a
MILLER
authorized service
facility,
and
therefore
no
compensation
for
transportation
costs
of
any
kind
will
be
allowed.
The
warranty
period,
beginning
on
the
date
of
sale
to
the
original purchaser-user
of
the
equipment,
will
be
as
follows:
1.
Arc
welders,
power
sources,
and
components

1
year
2.
Original
main
power
rectifiers

3
years
(unconditionally)
3.
20E, 20K,
and all
welding
guns.

90
days
4.
All other
Millermatic Feeders

1
year
5.
All
engines

1
year
Engine
Warranties
are
covered
by
the
engine
manufacturers,
subject
to
their
procedures
and
to
be
handled
through
their
authorized local
Service Stations
or
agencies.
No
warranty
will
be made
in
respect
to
trade
accessories,
such
being
subject
to
the
warranties
of their
respective
manufacturers.
MILLER
Electric
Mfg.
Co. will
not
be liable
for
any
loss
or
consequential
damage
or
expense
accruing
directly
or
indirectly
from the
use
of
equipment
covered
in
this
warranty.
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.

SECTION
1
-
INTRODUCTION
1-1.
GENERAL
This manual has
been
prepared
especially
for
use
in
familiar
izing personnel
with
the
design, installation,
operation,
main
tenance,
and
troubleshooting
of
this
equipment.
All
informa
tion
presented
herein
should be
given
careful consideration
to
assure
optimum performance
of this
equipment.
1-2.
RECEIVING-HANDLiNG
Prior
to
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
or
damage
that
may
have
occurred
in
transit
must
be
filed
by
the
purchaser
with the carrier.
A
copy
of the bill of
lading
and
freight
bill
will be
furnished
by
the
carrier
on
request
if
occasion
to
file
claim arises.
When
requesting
information
concerning
this
equipment,
It
is
essential
that
Model
Description
and/or
Stock
Number and
Serial
(or
Style)
Numbers
of the
equipment
be
supplied.
1-3.
DESCRIPTION
This
unit
is
designed
to
function
as
a
welding
control
station
remotely
located
from the
main
power
source.
It
provides a
receptacle
to
which
the electrode cable
is
to
be
connected
to
and
also
a
coarse
and fine
current
Control.
This
welding
con
trol
station
i~
protected
from
damage
due
to
excess
overload
by
a
fuse
in the
input
circuitry.
1-4.
SAFETY
The
following
definition
applies
to
IMPORTANT blocks
found
throughout
this
manual.
SECTION
2
-
INSTALLATION
2-1.
LOCATION
A
good
installation
is
essential
if
the
welding
control
station
is
to
provide
satisfactory
and
dependable
service.
Proper
operating
temperatures
are
maintained
by
the air
stream
passing
through
the
unit.
IMPORTANT
The
welding
control
station
should
be
located
so
that
the side
panels
with the air
vents
or
louvers
are
clear
of
i
any
obstruction.
Figure
2-1. Dimensional
Drawing
U
I
The location
should
be
such
that
a
minimum
amount
of dust
and
dirt
will
be
drawn into
the
air
stream.
Preventive
main
tenance
consists
of
removing
the
wrapper
from
the
welding
control
station
and
blowing
Out
the
dust
accumulation
inside
the unit.
2-2. INPUT AND OUTPUT
CONNECTIONS
A male
Camlock
plug
is
provided
on
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
is
supplied
with
the
welding
control
station.
A
female
Camfock
receptacle
is
provided
on
the
front
panel
of the
welding
control station
for
making
Connections
from
the station
to
the
electrode
holder cable.
The
corresponding
male
Camlock
receptacle
is
supplied
with the
welding
station.
Use
Table
2-1
as
a
guide
in
selecting
the
electrode
holder
cable.
Table
2-1.
Welding
Cable
Sizes
Weldin.
An,peres
50
tOO 150
Totol~~2~of
200
Cable
(Copper)
250
300
350
400
tOO
4
4
4
3
2
1
1/0
1/0
ISO 3
3 2
1
1/0
2/0
3/0
3/0
200 22
1
110
2/0 3/0
4/0
4/0
250
1
1
1/0
2/0
3/0 4/0
4/0
500MCM
300
1/0
1/0
2)0
3/0
4/0
4/0 SOOMCM
500MCM
350 1/0
1/0
3/0
4/0 4/0
500MCM 500MCM
600MCM
400
2/0 2/0
3/0
4/0
SOOMCM 500MCM
500MCM
SOOMCM
500
3/0 3/0
4/0 500MCM
500MCM
500McM SOOMCM
500MCM
600
4/0 4/0
500MCM 500MCM
500MCM
500McM
500MCM
1000MCM
Aluminum
I~ iMP2~I
I
Installation,
operating
and
maintenance
procedures,
practices,
etc.,
which will result
in
damage
to
equip
ment.
NOTE:
Add
2-1/4
to
dimen
sion
for
protruding
handle
(not
shown)
at
rear
of
unit.
TB-004
544-A
OM-802
Page
1

Il
UI
Weld
Power
Input
Plug
Two
controls
are
provided
on
the
front
panel
of
the
welding
control
station for
adjusting
the
amperage
output
from
the
station. The
Coarse
Amperage
Control
will
vary
the
amperage
output
in
50
ampere
increments from 50
to
350
amperes.
The Fine
Amperage
Control will
act
as a
fine
adjustment
within the
50
ampere
range
selected
by
the
Coarse
Amperage
Control.
The Fine
Amperage
Control
adjust
the
amperage
output
in
5
ampere
increments.
This
welding
control
station
is
protected
from
damage
due
to
excessive overload
by
a
400
ampere
fuse
connected
in
the
input
circuitry.
This
fuse
is
located
behind
the
hinged
rear
access
door.
it
is
imp~1~
rative that
the fuse
be
replaced
with
one
of
the
same
size and
rating.
Failure
to
comply
may
result
in
damage
to
the
welding
control
station.
.1
I
I
~
~lfi~
~
~:?fi~y
03
I
~
P1001.17 SlEW
80
355
04Q-
COILS
0
T(WWIICALS
QEM
~dITCJ4
P0
~ITItN
~Ei%Rt.~
I~MP
COIL
N.0.
SWflLII
1E~J0I0jAL
0
I
.3
.3
4
.3
(~
7
0
50
lOS
ISO
.300
250
.300
MO
0
I
2
12.3
(2,;j
l~.3l.5
IL3.~.S.I
l23~f51.,T
0
.3
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
0
I
L
..~
4
5
1.
7
5
S
0
.5
10
IS
.30
25
.30
3S
40
IS
0
i.
7
(.~7
1.,8
7,8
8,5
I.,8.O
7,E,.5
l.,7,0.5
(7
a
~
.3,4
2,4,
4,1.
48
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(~
40
R.
.0111. nIOt
S.C. OMM1. .010 57
RN .044 SIOO
~1.i
014011. .050.
4.3
R.
I
B.
.02.8 .I0O 0.5 01151. .07.3
.114
Figure
3-2.
Circuit
Diagram
Circuit
Diagram
No.
ME-00364
SECTION
3
-
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
2

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
U
S
L

0
a,
0
N)
-v
DC
Co
CD
39
1
3
4
Includes
Items
31
and
32
~Q
5.
25
9
3
10
11
12
13
20
j
I
TD-003
794-A
29
Figure
A

Complete
Assembly

Item
Dia.
Factory
No.
Mkgs.
Part No.
Description
Quantity
Figure
A
Complete Assembly
1
004 364
PANEL,
heat
exchange
-
front
1
2 004
055
INSULATOR,
wire
19
3
004
057
TUBING,
steel
11/32
OD
x
17/64
ID
x
7/16
10
4
004
362
PANEL,
support
-
front
1
5 R1-7 004 409
RESISTOR,
grid
0.84
ohm
161gw/tubing
&
pins
7
6 R9 004411
RESISTOR,
grid
4.4 ohm
16
Ig
w/tubing
&
pins
1
7
R10,R1
1 004 410
RESISTOR,
grid
2.8
ohm
161gw/tubing
&
pins
2
8 R8
004~412
RESISTOR,
grid
9.6
ohm
16
1gw/tubing
&
pins
1
9 004371
WRAPPER 1
10
004 056
INSULATOR,
bus
bar
2
11
004 353 BUS
BAR,
fuse
link
to
plug
1
12
004059
TUBING,steel
11/32ODx
17/64lDx2
2
13
006
781
PANEL,
rear
1
14
039
633
CONNECTOR,
quick
connect
-
twistlock female
1
15 004 636
PLUG,
with
components
(consisting
of)
1
16
056
271
.
PLUG,
twistlock
1
17
010 907
.
NUT,
locking
1
inch
1
18 602 213
.
WASHER,
lock
-
steel
split
3/8 1
19 601
837
.
NUT,
brass
-
hex
jam
3/8-16
1
20 Fl
*004
367
LINK,fuse400amp250volts
21
004
070
BUS
BAR,
interconnecting
resistors
1
22 004
365
PANEL,
heat
exchange
-
rear
1
23
004 363
PANEL,
support
-
rear
1
24
004 377
BASE
1
25
Si
006
788
SWITCH,
rotary
45
amp
600
volts
(consisting
of)
26
006
784
-
KNOB
1
27
004 354
LINK,
jumper
-
switch
7
connector
1
28 004
355
BUS
BAR,
link
to
receptacle
1
29
004 637
RECEPTACLE,
with
components
(consisting
of)
1
30
010 907
-
NUT,
locking
1 inch
31
601 837
.
NUT,
brass
-
hex
jam
3/8-16
1
32 602 213
-
WASHER,
lock
-
steel
split
3/8
33
039 628
-
RECEPTACLE,
twistlock
-
female insulated
34 039 630
PLUG,
twistlock
-
male
insulated
1
35
NAMEPLATE
(order
by
stock,
model,
and
serial
numbers)
1
35
006 780
PANEL,
front
1
37
006791
SPACER
2
38 004 408
BUS
BAR,
switch
to
bus
bar
39 S2
006 789
SWITCH,
rotary
25
amp
600
volts
(consisting
of)
1
40
006 790
-
KNOB
*
Recommended
Spare
Parts
BE SURE TO
PROVIDE
STOCK,
MODEL,
AND
SERiAL
NUMBERS
WHEN ORDERING REPLACEMENT PARTS.
OM-802
Page
2