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U
Miller®
MODEL
\!ERNIER
RANGE
CONTROL
FILE
COPY
q
RETURN
TO
FOLDER
OWNER’S
MANUAL
IMPORTANT:
Read
and
understand
the entire
contents
of
both
this
Miller
Electric
Mfg.
Co.
manual
and
the
power
source manual
used
with
this
unit,
with
special
emphasis
on
the
safety
material
throughout
both manuals,
before
in- ~o
Box
1079
stalling,
operating,
or
maintaining
this
equipment.
This
unit
and
these
instructions
are
for
use
only
by
persons
trained
and
experienced
in
the
Appleton,
WI
54912
u~-~
Tel
414~734-9821
safe
operation
ofwelding
equipment.
Do
not
allow
untrained
persons
to
install,
operate,
or
maintain
this
unit.
Contact
your
distributor
if you
do
not
fully
understand these
instructions.
PRINTED
IN
U.S.A.
ADDITIONAL
COPY PRICE
20 CENTS
LIMITED
WARRANTY
EFFECTIVE
FEBRUARY
16,
ieee
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with no
other
guarantees
or
warranties
expressed
or implied.
LIMITED
WARRANTY
-
Subject
to
the
terms
and
condi-
In
the
case
of
Miller’s breach
of
warranty
or
any
other
duty
tions
hereof,
Miller
Electric
Mfg. Co., Appleton,
Wisconsin
with
respect
to
the
quality
of
any
goods,
the exclusive remedies
warrants
to
its
Distributor/Dealer that
all
new
and unused
therefore
shall
be,
at
Miller’s
option
(1)
repair
or
12)
replacement
Equipment
furnished
by
Miller
is freefrom
defect
in
workman-
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
(3)
•
ship
and
material
as
of
the time
and
place
of
delivery
by
Miller.
the
reasonable
cost
of
repair
or
replacement
at an
authorized
No
warranty is
made
by
Miller
with
respect
to
engines,
trade
Miller
service
station
or
14)
payment
of or
credit
for
the purchase
accessories
or other
items
manufactured by
others.
Such
price (less
reasonable
depreciation
based
upon
actualumel
upon
engines,
trade
accessories
and
other
items
are
sold
subject
to
return
of
the
goods
at
Customer’s
risk
and
expense.
MILLER’s
•
the
warranties
of
their
respective
manufacturers,
if any . All
option
of
repair
or
replacement
wiN
be
FOB.,
Factory,
at
engines
are
warrantedby their
manufacturer
for
one
year
from
Appleton,
Wisconsin.
or
FOB.,
at
a
MILLER authorized
service
date
of
original
purchase,
except
Tecumseh
engines
which
facility,
therefore,
no
compensation
for
transportation costs
of
have
a
two
year
warranty,
any
kind
will
be
allowed.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
Miller
shall
instruct
the
claimant
on
the
warranty
Except
as
specified
below,
Miller’s warranty
does
not
apply
claim
procedures
to
be
followed.
to
components
having normal
useful
life
of
less
than
one
(11
year,
such
as
spot
welder tips,
relay
and
contactor
points.
•
MILLERMATIC
parts that
come
in
contact with
the
welding
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
wire including
nozzles
and
nozzle
insulators
where failure
does
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTA
-
not
result
from defect
in
workmanship
or
material.
TiON
AS
TO
PERFORMANCE,
AND ANY
REMEDY FOR
BREACH
OF
CONTRACT WHICH,
BUT
FOR
THIS
PROVISION,
Miller
shall
be
required
to
honor warranty
claims
on war-
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
ranted
Equipment
in
the
event
of
failure
resulting
froma defect
CUSTOM
OF
TRADE
OR
COURSE
OF
DEAUNG,
INCLUDING
within the following
periods
from
the
date
of
delivery
of
Equip-
ANY
IMPUED
WARRANTY
OF
MERCHANTABIUTY
OR
OF
ment
to
the
original
user:
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
AND ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EX
-
1.
Arc
weldms,
pcw~er
sourt~,
robots,
and
components
.
1
year
CLUDED
AND
DISCLAIMED
BY
MILLER.
2
Load
banks
. .
1
year
3.
Original
main
power
rectifiers
3
years
(labor
-
1
year
only)
EXCEPT
AS
EXPRESSLY
PROVIDED BY
MILLER
IN
4. All
welding
guns,
feeder/guns
and
torches
90 days
WRITING,
MILLER PRODUCTS
ARE
INTENDED
FOR
5. All other
Millermatic
Feeders
1
year
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
6.
Replacement
or
repair
parts,
exclusive
of
labor
..
60
days
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
7.
Batteries
6
months
EXPERIENCED
IN THE USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT
AND NOT
FOR
CONSUMERS
OR
provided
that
Miller
isnotified
in
writing
within
thirty
1301
days
CONSUMER USE.
MILLER’S WARRANTIES
DO
NOT
EXTEND
of
the
date of such
failure.
TO,
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
q~ As
a
matter
of
general
policy
only,
Miller
may
honor
claims
MILLER’S
WARRANTIES
TO,
ANY
CONSUMER.
submitted
by
the
original
user
within
the
foregoing
periods.
. .
..-
-.
,,~.
•-~.
.
.- .-
SECTION
1
—
INTRODUCTION
Codes
suCh
as,
but
not
limited
to,
those
listed
at
the
end
of
Section
1
-
Safety
Rules
For
Operation
Of
ArC
Weld
-
ing
Power Source
in
the
welding
power
source
Owner’s
Manual.
Safety
instructions specifically pertaining
to
this
unit
ap-
pear
throughout
this
manual
highlighted
by
the
Signal
words
WARNING
and
CAUTION
which
identify
differ
-
ent
levels
of hazard.
WARN
ING
statements
include installation,
operation,
and
maintenance
procedures
or
practices
which if
not
carefully
followed could
result
in
serious
personal
injury
or
loss
of
life.
CAUTION
statements
include installation,
operation,
and
maintenance
procedures
or
practices
which
if
not
carefully
followed could
result
in
serious
personal
injury
or
damage
to
this
equipment.
A
third
signal
word,
IMPORTANT,
highlights
instruc
-
tions
which
need special
emphasis
to
obtain
the
most
ef
-
ficient
operation
of
this
equipment.
TA1-121 783
1-2.
RECEIVING-HANDLING
FIgure
1-1.
DimensIons
1-1.
GENERAL INFORMATION AND SAFETY
A.
General
Information
presented
in
this
manual
and
on
various
la
-
bels,
tags,
and
plates
on
the
unit
pertain
to
equipment
design, installation,
operation,
maintenance,
and
troub
-
leshooting which
should
be
read,
understood,
and
fol
-
lowed
for
the
safe
and
effective
use
of
this
equipment.
B.
Safety
The
installation,
operation,
maintenance,
and
troub
-
leshooting
of
arc
welding
equipment
requires practices
and
procedures which ensure personal
safety
and
the
safety
of
others.
Therefore,
this
equipment
is
to
be
in
-
stalled, operated,
and
maintained
only
by
qualified
per-
sons
in
accordance
with
this
manual
and
all
applicable
Before
installing this
equipment,
clean
all
packing
mate
-
rial
from
around the
unit,
and
carefully inspect
for
any
damage
that
may
have
occurred
during
shipment.
Any
claim
for
loss
or
damage
that
may
have
occurred
in
tran-
sit
must be
filed
by
the
purchaser
with the
carrIer.
A
copy of
the
bill
of
lading
will
be
furnished
by
the
manu
-
facturer
on
request
if
occasion
to
file
claim
arises.
When
requesting
information concerning
this
equip
-
ment,
it
is
essential
that
Model
Description
and
Style
Number
of
the
equipment
be
supplied.
1-3.
DESCRIPTION
This
unit
is
a
Vernier
Range
Control
potentiometer
for
the
ARC
PAK
welding
power
source.
When
properly
connected,
it
functions
as
a
maximum
amperage
selec
-
tion
control,
and
thereby
limits
the
maximum
amperage
output
of
the
welding
power
source.
OM-541 Page
1
SECTION
2-
INSTALLATION
2-1.
LOCATION
Remove
one of
the
wrapper
screws,
and
install
the
Ver-
nier Range
Control
directly
onto
left
or
right
side
of
the
power
source with
the
face
plate
facing the
same
direc
-
tion
as
the
front panel
of
the
welding
power
source.
2-2.
INTERCONNECTIONS
A
WARNING: ELECTRIC
SHOCK
can
kill.
•
Do
not
touch live electrical
parts.
•
Shut
down
high
frequency
unit
and
welding
power
source
and
disconnect
input
power
em-
ploying
“lockout/tagging
procedures”
before
in
-
specting,
installing,
or
adjusting.
Connect
the
17-pin
twistlock plug
from
the
Vernier
Range
Control
into
the
Remote
Control
Receptacle
on
welding
power
source
as follows:
align
keyway,
insert
plug,
and rotate
threaded
collar
fully
clockwise.
Connect
the 5-pin
twistlock plug
from
the
Vernier
Range
Control
into
the
REMOTE
IN
receptacle
on
the
rear
of
the
high
frequency
unit
on
welding
power
source
as
fol
-
lows:
align
keyway,
insert
plug,
and rotate
threaded
col-
lar
fully
clockwise
(see
Figure 2-1).
Lockout/tagging
procedures
consist
of
padlo
-
cking
line
disconnect
switch
in
open
position,
re
-
moving
fuses
from
fuse box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
-
ing
device.
ARC PAKWeldIng
17-PIn
ConnectIon
From’
Process
Control To
ARC PAK
Remote
Control
Receptacle
(see
SectIon
2-2)
Remole
Hand
or
Foot
Control
Switch
High Frequency
Range
Control
5-Socket
ConnectIon
From
Process
Control
To
High
Frequency
Unit
Remote
In
Receptacle
TA- 122 004
Figure
2-1.
InstallatIon
OM-541
Page
2
SECTION
3—
OPERATOR
CONTROLS
3-1.
AMPERAGE CONTROL
age
output
from
minimum
to
maximum
of
power
source
capability.
Rotating
this
control
clockwise increases
This
control
provides
the means
of
adjusting the
amper-
weld output.
SECTION
4-SEQUENCE
OF
OPERATION
4-1.
OPERATION
adjustment
of
the
Amperage Control setting.
For
exam
pIe,
an
Amperage Control
setting
of
200
amperes
will
Whenaremotehandorfootcontrolswitchandhighfre-
provide
a
fine
amperage
adjustment
of
0
to 200
am
quency
unit
are
used with
the
ARC
PAK
welding
power
peres
(minimum
to
maximum
position)
on
the
hand
or
source,
the control
switch
functions
as a
fine
amperage
foot
control switch.
SECTION
5—
MAINTENANCE
&
TROUBLESHOOTING
5-1.
MAINTENANCE
Usage
and
shop
conditions
will
determine
the
frequency
and
type
of
maintenance.
WARNING: ELECTRIC
SHOCK
Can
kill.
A
.
Do
not
touch
live
electrical
parts.
•
Shut
down high
frequency
unit
and
welding
power
source,
and
disconnect
the
Vernier
Range
Control
before
inspecting,
maintaining,
or
servicing.
1.
Every
six
months inspect
the
Vernier
Range
Control
interconnecting cords
for
damage
to or
breaks
in
the
insulation jacket,
particularly
at
the
plug.
Repair
or
replace
cords as necessary.
2.
Remove
grease
and grime
from
components;
mois
-
ture
from electrical
parts
and
cord.
5-2.
TROUBLESHOOTING
WARNING: ELECTRIC
SHOCK
can
kill.
A
0
Do
not
touch
live
electrical
parts.
•
Shut
down high
frequency
unit
and
welding
powersource
and
disconnect
the
Vernier
Range
Control
before inspecting,
maintaining,
troub
-
leshooting,
or
servicing.
Troubleshooting
to
be
performed
only
by
quali
-
fied
persons.
It
is
assumed
that
the
unit
was properly
installed
accord
-
ing
to
Section
2
of
this
manual, the
operator
is
familiar
with
the
function
of
controls,
the
welding
power
source
and
high
frequency
unit
were
working properly,
and
the
trouble
is
not related
to
the
welding
process.
The
follow
-
ing
information
is
supplied
to
diagnose
and
provide
remedies
for some
of
the
troubles
that
may
develop
in
this
unit.
Check
the
welding
power
source
and
high
fre-
quency
unit
Owner’s
Manual for
possible problems
caused
by welding
power
source
malfunctions.
Use
this
information
in
conjunction
with
the
circuit
dia-
gram while
performing
troubleshooting procedures.
If
the
trouble
is not
remedied
after
performing
these
pro
-
cedures,
the
nearest Factory
Authorized
Service
Sta-
tion
should
be
contacted.
In
all
cases
of
equipment
mal
-
function,
the
manufacturer’s
recommendations
should
be
strictly
followed.
Problems
with
this
unit
fall
into
two
categories:
1)
front
panel
Components,
or
2)
the
interconnecting cord
and
plug.
If
the control does not
function,
the
plug may
be
loose
in
the
receptacle,
or
the
cord
may
be
damaged internally,
thereby
interrupting
signals
between
the
welding
power
source
and
this
unit.
Check
plug
connections,
and
tighten
if
applicable.
Check
continuity
of
cord,
and
re
-
place,
if
necessary.
OM-541
Page
3
SECTION
6-
ELECTRICAL DIAGRAMS
A
P
+
I
OV.
C
D
COMMAND
CONTACTOR
Circuit
Diagram
No.
A-117
502
Diagram 6-1.
CIrcuit
Diagram
PARTS
LIST
Dia.
Part
Mkgs. No.
Description
Quantity
042 155
Complete Assembly
035 897
POTENTIOMETER,
carbon
1
turn
2
watt
1000
ohm
097866
PLUG,
17
pin
M5-3106A-20-29P
073 296
CLAMP,
cable
97-3057-12-6
090 890
CABLE,
No,
20
8/C
(order
by
ft)
097 994
RECEPTACLE,
5
socket
M5-3106A-165-BS
039
685
CLAMP,
cable
AN-3057-8
600 343
CABLE,
No.
16
5/C
(order
by
ft)
097 922
KNOB
115
104
CONNECTOR,
clamp-cable
1/2
inch
NAMEPLATE
(order
by
model
&
serial
number)
117231
CASE
SECTION,
front/end
099 124
CASE
SECTION,
back/sides/end
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
B
H
PLG
I
<B
PLG2
Ri
PLG1
PLG2
1
1
1
2
ft
1
1
15
ft
1
2
1
1
1
OM-541
Page
4
/