Miller MO-20 Owner's manual

Brand: Miller

Model: MO-20

Category: Welding System

Type: Owner's manual

This manual is also suitable for

November

1975

FORM:

OM-803A

STOCK

NO.

041

070

MODEL/STOCK

NO.

SERIAL/STYLE

NO.

DATE

PURCHASED

OWNER

S

MANUAL

ADDITIONAL

COPY

PRICE

20

CENTS

MILLER

ELECTRIC

MFG.

CO.

APPLETON,

WISCONSIN,

USA

54911

1.5

~.

Effective

with

Serial

No.

MEHFOO21O5

MODEL

MO-200/200

NWSA

CODE

NO.

4579

t

Q~QQQJ_R

C

bTb

b~bTOT~

X~

t

U~*~

mmm

r

ThTh~

~

C

~

CD

C)

CD

C)

CD

a~

c

~

CD

CD

I

)

WARRANTY

MILLER

Electric

Mfg.

Co.,

Appleton,

Wisconsin,

warrants

all

new

equipment

to

be

free

from

defects

in

I

)

material

and

factory

workmanship

for

the

periods

indicated

below,

provided

the

equipment

is

installed

and

C

D

CD

operated

according

to

manufacturers

instructions.

C

CD

CD

CD

MILLER

Electric

Mfg.

Co.s

obligation,

under

this

warranty,

is

limited

to

replacing

or

repairing

any

defective

part

or

correcting

any

manufacturing

defect

without

charge

during

the

warranty

period

if

MILLERS

inspec

I

~

CD

tion

confirms

the

existence

of

such

defects.

MILLERS

option

of

repair

or

replacement

will

be

f.o.b.

factory

at

c

~

I

~

CD

Appleton,

Wisconsin

orf.o.b.a

MILLER

authorized

servicefacility,andthereforenocompensationfortrans-

C

I

I

portation

costs

of

any

kind

will

be

allowed.

I

C

C

D

I

C

CD

The

warranty

period,

beginning

on

the

date

of

sale

to

the

original

purchaser-user

of

the

equipment,

will

be

as

c

C

C

C)

follows:

c

1.

Arc

welders,

power

sources,

and

components



1

year

C

I

~

CD

2.

Original

main

power

rectifiers



3

years

(unconditionally)

3.

MHFC-L1

Feeder,

MHG-35C1,

20E,

20K,

C

I

~

C)

and

all

guns

and

torches



90

days

c

I

C

4.

All

other

Millermatic

Feeders



1

year

5.

Mag-Diesel

engine

on

DEL-200



6

months

6.

All

other

engines



1

year

I

I

C

Engine

Warranties

are

covered

by

the

engine

manufacturers,

subject

to

their

procedures

and

to

be

handled

I

C

through

their

authorized

local

Service

Stations

or

agencies.

No

warranty

will

be

made

in

respect

to

trade

C

~

accessories,

such

being

subject

to

the

warranties

of

their

respective

manufacturers.

C

C

C

I

)

I

C

I

C.

I

MILLER

Electric

Mfg.

Co.

will

not

be

liable

for

any

loss

or

consequential

damage

or

expense

accruing

I

directly

or

indirectly

from

the

use

of

equipment

covered

in

this

warranty.

C

~ C

I

I

C C

C

C

C

This

warranty

supersedes

all

previous

MILLER

warranties

and

is

exclusive

with

no

other

guarantees

or

C

I

C

C

C)

C

warranties

expressed

or

implied.

I

C

C)

Q

Q.Q

Q

QQJ

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a

OThTh

~

~

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

two

operator

welding

control

station

which

is

remotely

located

from

the

welding

power

source.

This

unit

is

equipped

with

two

output

ELEC

TRODE

receptacles.

The

output

at

each

ELECTRODE

recep

tacle

is

governed

by

a

separate

set

of

amperage

controls.

This

welding

control

station

is

protected

from

damage

due

to

ex

cessive

overload

by

a

fuse

in

the

input

circuitry.

1-4.

SAFETY

The

following

definition

applies

to

IMPORTANT

blocks

found

throughout

this

manual.

~llation,operatjjintenance

procedures

practices,

etc.,

which

will

result

in

damage

to

equipment.

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

pass

ing

through

the

unit.

~lding

cont

rol

st

non

thd

be

located

so

th

at

the

side

panels

with

the

air

vents

or

louvers

are

clear

of

any

obstruction.

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

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.

Two

female

Camlock

receptacles

are

provided

on

the

front

panel

of

the

welding

control

Station

for

making

connections

from

the

station

to

the

electrode

holder

cables.

The

corres

ponding

male

Camlock

receptacles

are

supplied

with

the

weld.

ing

Station.

Use

Table

2.1

as

a

guide

in

selecting

the

electrode

holder

cable.

Figure

2-1.

Dimensional

Drawing

Table

2-1

-

Welding

Cable

Sizes

TB-004

547

Weldiop





iota

I!~2~of

cable

(Copp

er)

In

Weld

Circait

Amperes

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

500MCM

300

1/0

1/0

2/0

3/0

4/0

4/0

500McM

500MCM

350

I/O

1/0

3/0

4/0

4/0

500MCM

500MCM

SOOMCM

400

2/0

2/0

3/0

4/0

500MCM

500MCM

sooMcM 500MCM

500

3/0

3/0 4/0

500MCM

500McM

500MCM

500MCM

SOOMCM

600

4/0

4/0

500MCM

500MCM

500MCM

500MCM

500McM

I000McM

Aluminum

SECTION

3

-

OPERATION

3-1.

SINGLE-PARALLEL

SWITCH

The

SINGLE-PARALLEL

Switch,

when

in

the

SINGLE

posi

tion,

allows

two

operators

to

weld

simultaneously;

each

having

an

adjustable

amperage

range

from

5

to

195

amperes.

When

in

the

PARALLEL

position,

Only

one

operator

may

weld

at

a

time.

Also

in

the

PARALLEL

position,

the

amper

age

range

will

be

doubled

from

5

to

195

amperes

to

10

to

390

amperes

for

the

ELECTRODE

Receptacle

being

used.

3-2.

COARSE

AND

FINE

AMPERAGE

CONTROLS

Four

controls

are

provided

on

the

front

panel

of

the

welding

control

station

for

selecting

the

amperage

output.

A

Coarse

and

a

Fine

Amperage

Control

is

provided

for

each

of

the

two

ELECTRODE

Receptacles.

The

Coarse

Amperage

Control

will

vary

the

amperage

output

at

its

respective

ELECTRODE

Receptacle

in

50

ampere

incre

ments,

from

50

to

150

amperes,

when

the

SINGLE-

PARALLEL

Switch

is

in

the

SINGLE

position.

When

in

the

PARALLEL

position

the

Coarse

Amperage

Control

will

vary

the

amperage

output

in

100

ampere

increments

from 100

to

300

amperes.

The

Fine

Amperage

Controls

will

act

as

a

fine

amperage

ad

justment

within

the

coarse

range

selected

by

its

respective

Coarse

Amperage

Control.

The

Fine

Amperage

Controls

will

adjust

the

amperage

output

in

5

ampere

increments

when

the

SINGLE

-

PARALLEL

Switch

is

in

the

SINGLE

position.

When

in

the

PARALLEL

position,

the

Fine

Amperage

Con

trol

will

adjust

the

amperage

output

in

10

ampere

increments.

3-3.

FUSE

PROTECTION

This

welding

control

station

is

protected

from

damage

due

to

excessive

overload

by

a

600

ampere

fuse

connected

in

the

input

circuitry.

This

fuse

is

located

behind

the

hinged

rear

access

door.

NOTE:

Add

2-1/4

to

dimen

sion

for

protruding

handle

(not

shown)

at

rear

of

unit.

OM-803

Page

1

imperative

t

hat

the

~:e

be

replaced

w

ith

one

of

the

same

size

and

rating.

Failure

to

comply

may

result

in

damage

to

the

welding

control

station.

600

Amp

Fuse

Figure

3-1.

Location

Drawing

o



TERM~L5

Q(OC.0~

TB-004

548

i~L~

R

IL

S

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Figure

3-2.

Circuit

Diagram

Circuit

Diagram

No.

ME-00365

Weld

Power

Input

Plug

Rear

View

Page

2

October

1975

FORM:

OM-803A

Effective

with

serial

No.

MEHFOO21O5

MODEL

MO-200/200

STOCK

NO

041

070

MODEL/STOCK

NO.

SERIAL/STYLE

NO.

DATE

PURCHASED

PARTS

LIST

MILLER

ELECTRIC

MFG.

CO.

APPLETON,

WISCONSIN,

USA

54911

I,

S

NWSA

CODE

NO.

4579

0

0

-~

CD

.9

3

46

4

3

f

Includes

44

Item

45

2

43.

41

31

45

8

25

34

26

27

28

29

Includes

32

35

Figure

A



Complete

Assembly

TO-003

827

Item

Dia.

Factory

No.

Mkgs.

Part

No.

Description

Quantity

Figure

A

Complete

Assembly

1

004

375

PANEL,

heat

exchange

-

front

1

2

004055

INSULATOR,wire

22

3

004057

TUBING,steel

11/32

00

x

17/64

ID

x

7/16

10

4

004 373

PANEL,

support

-

front

1

5

R5,12

004052

RESISTOR,grid4.4ohm

16-i/4lgw/tubing&pins

2

6

R6,7,13,14

004

051

RESISTOR,

grid

2.8

ohm

16-1/4

1gw/tubing

&

pins

4

7

R4,1

1

004

053

RESISTOR,

grid

9.6

ohm

16-1/4

1gw/tubing

&

pins

2

8

Ri,2,3,8,9,i0

004

050

RESISTOR,

grid

0.84

ohm

16-1/4

1gw/tubing

&

pins

6

9

004371

WRAPPER

1

10

004056

INSULATOR,busbar

2

11

004059

TUBING,steel

11/32ODx

17/64IDx2

2

12

004

353

BUS

BAR,

fuse

link

to

plug

1

13

004

361

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

010907

.

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

387

LINK,

fuse

600

amp

250

volts

1

21

004

070

BUS

BAR,

interconnecting

resistors

1

22

004

376

PANEL,

heat

exchange

-

rear

1

23

004

374

PANEL,

support

-

rear

1

24

004377

BASE

1

25

004419

LINK,jumper-

switch

RH

3

connector

1

26

004

370

LINK,

jumper.

switch

2

27

004

369

LINK,

jumper-

switch

RH

2

connector

28

004

416

BUS

BAR,

link

to

receptacle

2

29

004

420

BUS

BAR,

interconnecting

switch

2

30

Si

,4

004

378

SWITCH,

rotary

45

amp

600

volts

(consisting

of)

2

31

004414

.

KNOB,

switch-coarse

1

32

004

417

BUS

BAR,

switch

to

bus

bar

2

33

S2,3

004

016

SWITCH,

rotary

25

amp

600

volts

(consisting

of)

2

34

004

413

.

KNOB,

switch

-fine

1

35

004

637

RECEPTACLE,

with

components

(consisting

of)

2

36

601

837

.

NUT,

brass

-

hex

jam

3/8-16

37

602

213

.

WASHER,

lockS

steel

split

3/8

38

010

907

.

NUT,

locking

1

inch

39

039 628

.

RECEPTACLE,

twistlock

-

female

insulated

1

40

039

630

PLUG,

twistlock

-

male

insulated

2

41

NAMEPLATE

(order

by

stock,

model,

and

serial

numbers)

42

004

372

PANEL,

front

1

43

004

418

LINK,

jumper

-

switch

LH

3

connector

1

44

S5

004

415

SWITCH,

rotary

70

amp

600

volts

(consisting

of)

45

004

414

.

KNOB,

switch

-

paralleling

1

46

004

368

LINK,

jumper.

switch

LH

2

connector

1

*

Recommended

Spare

Parts

BE

SURE

TO

PROVIDE

STOCK,

MODEL,

AND

SERIAL

NUMBERS

WHEN

ORDERING

REPLACEMENT

PARTS.

OM-803

Page

2

1
2
3
4
5
6
7
8

Miller MO-20 Owner's manual

Brand: Miller

Model: MO-20

Category: Welding System

Type: Owner's manual

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