June
1976
FORM:
OM-801B
Effective
With
Serial
No.
MEHG003535
MODEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
ADDITIONAL
COPY
PRICE
20
CENTS
OWNERS
MANUAL
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
MODEL
MO-295
STOCK
NO.
040
997
NWSA
CODE
NO.
4579
O~S
A.
gggggugg~Qqguuu~uuuu~uouuuuuuuuuuuuuuuuuuuuu~JO*OOOOOOOOOOOOOOOQOOOOOOOOOUUUUO
p
C
I
p
C
p
LIMITED
WARRANTY
MILLER
Electric
Mfg.
Co.,
Appleton,
Wisconsin,
warrants
all
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
manufacturers
instructions.
C
C
C
C
MILLER
Electric
Mfg.
Co.s
obligation,
underthis
warranty,
is
expressly
limited
to
replacing
or
repairing
any
defective
part
or
correcting
any
manufacturing
defect
without
charge
during
the
warranty
period
if
MILLERS
inspection
confirms
the
existence
of
such
defects.
MILLERS
option
of
repair
or
replacement
c
will
be
f.o.b.
factory
at
Appleton,
Wisconsin
or
f.o.b.
a
MILLER
authorized
service
facility,
and
therefore
c
no
compensation
for
transportation
costs
of
any
kind
will
be
allowed.
~
CD
~
CD
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.
C~
C)
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
c
C
warranties
expressed
or
implied.
c
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.
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.
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
trl
station
is
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
2-2.
INPUT
AND
OUTPUT
CONNECTIONS
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.
con
t
rol
un
shou
Id
be
located
so
th
at
the
side
panels
with
the
air
vents
or
louvers
are
clear
of
any
obstruction.
A
male
Camlock
plug
is
provided
on
the
rear
panel
of
the
welding
control
station
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
Camlock
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.
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.
N
Figure
2-1.
Dimensional
Drawing
TB-003
704-A
Table
2-1.
Welding
Cable
Sizes
Welding
Amperes
To
tal
Len
gth
of
Cable
I
copper
)
in
W
eld
Circuit
50
100
150
200 250
300
350
400
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
250
1 1
1/0
2/0
3/0
4/0
4/0
2-2/0
300
1/0 1/0
2/0
3/0
4/0
4/0
2-2/0
2-3/0
350
1/0
1/0
3/0
4/0
4/0
2-2/0
2-3/0
2-3/0
400
2/0 2/0
3/0
4/0
2-2/0
2-3/0 3-2/0 2-4/0
500
3/0
3/0 4/0
2-2/0
2-3/0 2.3/0
2-4/0
3-3/0
600
4/0
4/0
2-2/0
2-3/0 3-2/0
2-4/0
3-3/0
3-4/0
700
4/0
4/0
2-3/0
2-4/0
3-3/0
3-4/0
4-4/0
4-4/0
AA-900
561-3
NOTE:
A.
5ofeetorless
B.
Cable
size
is
based
on
direct
current
(dc),
60%
duty
cycle
and
either
a
4
volts
or
lass
drop
or
a
current
density
of
not
over
300
circular
MILS
per
amp.
C.
Weld
cable
insulation
with
~
voltage
rating
to
withstand
the
open
circuit
voltage
(OCV)
of
the
welding
machine
must
be
used.
While
most
welding
machines
have
an
open
circuit
voltage
of
less
than
100
volts,
some
welding
machines
of
special
design
may
have
higher
open
circuit
voltage.
SECTION
1
-
INTRODUCTION
1-3.
DESCRIPTION
1-2.
RECEIVING-HANDLING
IMPORTANT
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.
OM-801
Page
1
SECTION
3
-
OPERATION
TB-003
705-A
3-1.
COARSE
AND
FINE
AMPERAGE
CONTROL
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
250
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
adjusts
the
amperage
output
in
5
ampere
increments.
3-2.
FUSE
PROTECTION
This
welding
control
station
is
protected
from
damage
due
to
excessive
overload
by
a
fuse
connected
in
the
input
circuitry.
This
fuse
is
located
behind
the
hinged
rear
access
door.
IMPORTANT
It
is
imperative
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.
U
I
Figure
3-2.
Circuit
Diagram
0
~EPt~EJ~T
TtT.MI~AL~
O~1~
Circuit
Diagram
No.
ME-00265
Weld
Power
Input
Plug
Rear
View
Figure
3-1.
Component
Locations
~db
~iSTOR5
HE~LtTF,r:c~
f~PRE
titL
I
It.
THItU
~1t~
04a
.~
.f-~C
-~
It.
O~
,jrO
-
~.t.
~2~wl1
t-~J .57
A-,
.O44
,JC~
44
O~PL~
C3L
li
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~
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~
~
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~
.5~
Page
2
June
1976
FORM:
OM-801B
Effective
With
Seria
No.
MEHG003535
MODEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
PARTS
LIST
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
MODEL
MO-295
STOCK
NO.
040 997
NWSA
CODE
NO.
4579
E
C,
U,
C)
4-.
a)
a.
E
0
C.)
C,
C,
LI.
Cs1
Lfl
a,
a
0
a
I-
tn
C~4
CD
Cy,
C~.1
I-.
OM-801
Page
1
Item
Dia.
Factory
No.
Mkgs.
Part
No.
Description
Quantity
Figure
A
Complete
Assembly
PANEL,
heat
exchange
-
front
TUBING,
steel
11/32ODx
17/64IDx
7/16
INSULATOR,
wire
PANEL,
support
-
front
RESISTOR,
grid
0.84
ohm
16-1/4
1gw/tubing
&
pins
RESISTOR,
grid
4.4
ohm
16-1/4
1gw/tubing
&
pins
RESISTOR,
grid
2.8
ohm
16-1/4
1gw/tubing
&
pins
RESISTOR,
grid
9.6
ohm
16-1/4
Ig
w/tubing
&
pins
WRAPPER
TUBING,
steel
11/32
OD
x
17/64
ID
x
2
INSULATOR,
bus
bar
LINK,
fuse
300
amp
250
volts
BUS
BAR,
fuse
link
to
plug
PANEL,
rear
CONNECTOR,
quick
connect
-
twistlock
female
PLUG,
with
components
(consisting
of)
PLUG,
twistlock
NUT,
locking
1
inch
WASHER,
lock
-
steel
split
3/8
NUT,
brass-
hex
jam
3/8-16
BUS
BAR,
interconnecting
resistors
PANEL,
heat
exchange
-
rear
PANEL,
support-
rear
BASE
SWITCH,
rotary
25
amp
600
volts
(consisting
of)
KNOB
BUS
BAR,
switch
to
bus
bar
SWITCH,
rotary
45
amp
600
volts
(consisting
of)
KNOB
LINK,
jumper
-
switch
3
connector
LINK,
jumper
-
switch
2
connector
BUS
BAR,
receptacle
to
links
RECEPTACLE,
with
components
(consisting
of)
NUT,
brass
-
hex
jam
3/8-16
WASHER,
lock
-
steel
split
3/8
NUT,
locking
1
inch
RECEPTACLE,
twistlock
-
insulated
PLUG,
male
-
twistlock
insulated
NAMEPLATE
(order
by
stock,
model,
and
serial
numbers)
PANEL,
front
SPACER
2
3
4
5
6
7
8
9
10
11
12
Fl
13
14
15
16
17
18
19
20
21
22
23
24
25
S2
26
27
28
51
29
30
31
32
33
34
35
36
37
38
39
40
006
776
41
006790
Recommended
Spare
Parts
BE
SURE
TO
PROVIDE
STOCK,
MODEL,
AND
SERIAL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
Rl-R5
R7
R
8,
R
9
R6
004 064
004
057
004
055
004
066
004
050
004
052
004
051
004
053
004
068
004
059
004
056
*027
267
004
069
006
777
039 663
004
636
056
271
010
907
602
213
601
837
004 070
004
067
004
065
004
054
006
789
006
790
004
072
006
785
006 784
004
071
004
060
004
061
004
637
601
837
602
213
010
907
039
628
039
630
10
15
1
5
2
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
OM-801
Page
2
/