April
1974
FORM:
OM-803
MODEL
MO-200/200
STOCK
NO.
041
070
PILE
COP~
RE~UR~
W
\~OLD
ADDITIONAL
COPY
PRICE
20
CENTS
MODEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
OWNERS
MANUAL
MH.LER
ELECTR~C
MFGL
CO.
APPLETON,
WISCONSIN,
USA
54911
NWSA
CODE
NO.
4579
I,
S
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.
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.
~I
M
P0
R
TAN
I
The
welding
control
station
should
be
located
so
that
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
not
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
not
supplied
with
the
welding
station.
Use
Table
2-1
as
a
guide
in
selecting
the
electrode
holder
cable.
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.
Welding
Amperes
I
~5~of
Cable
(Cope
at)
In
Weld
Circuit
50
100
150
200
250
300
350
400
100
4 4
4
3
2
1
1/0
1/0
isO
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
1/0
1/0
3/0
4/0
4/0
500MCM
sooMCv
500MCM
400
2/0
2/0
3/0
4/0
500MCM
SOOMCM 500MCM
SO0MCM
500
3/0
3/0
4/0
seovcv
500MCM
500MCM
SOOMCM
SOOMCM
eoo
4/0
4/0
SOOMCM
500MCM
SOOMCM
SOOMCM
500MCM
1000MCM
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
S
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.
2-1.
LOCATION
IMPORTANT
SECTION
2
-
INSTALLATION
Installation,
operating,
and
maintenance
procedures,
practices,
etc.,
which
will
result
in
damage
to
equipment.
Figure
2-1
-
Dimensional
Drawing
Table
2-1.
Welding
Cable
Sizes
Aluminum
OM-803
Page
1
02
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CC
CD
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C)
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03
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CD
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CD
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--3
9
April
1974
FORM:
OM-803
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
NWSA
CODE
NO.
4579
Item
Dia.
Factory
No.
Mkqs.
Part
No.
Description
Quantity
*Recommended
Spare
Parts.
BE
SURE
TO
PROVIDE
STOCK,
MODEL,
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
Figure
A
041
070
Complete Assembly
1
R5-l0
030 327
RESISTOR,
grid
0.84
ohm
w/tubing
&
cotter
pins
6
2
R3,4,13,14
030
328
RESISTOR,
grid
2.8
ohm
w/tubing
&
cotter
pins
4
3
R2,12
030
329
RESISTOR,
grid
4.4
ohm
w/tubing
&
cotter
pins
2
4
R1,1
1
030
330
RESISTOR,
grid
9.6
ohm
w/tubing
&
cotter
pins
2
5
027
102
INSULATOR,
stand
off
4
6
031
137
BUS
BAR,
interconnecting
1
7
028
454
TUBING,
steel
1/2
OD
x
17
ga
x
1/2
long
4
8
031
123
WRAPPER
1
9
031
260
TUBING,
steel
1/2
OD
x
17
ga
x
2
long
4
10
056271
PLUG,twistlock
1
11
039
633
CONNECTOR,
quick
connect
-
twistlock
female
1
12
031
135
FRAME
1
13
010907
NUT,lockingl
3
14
Fl
*027
267
LINK,fuse
300
ampere
250
volt
1
15
031
136
BUS
BAR,
jumper
I
16
031
209
LINK,connecting
switch
1
17
031
207
BUS
BAR,
switch
to
secondary
18
031
206
BUS
BAR,
switch
19
S1,2
605 778
SWITCH,
rotary
3
position
50
ampere
600
volt
20
S3,4
027
101
SWITCH,
rotary
16
ampere
600
volt
21
NAMEPLATE
(order
by
stock,
model
and
serial
number)
22
031
210
PANEL,front
23
039 628
RECEPTACLE,
twistlock
24
039
630
PLUG,
twistlock
-
male
25
010828
HANDLE
26
031
208
BUS
BAR,
switch
to
secondary
27
011
789
SWITCH,
toggle
3PST
60
ampere
28
031
205
LINK,connecting
switch
0
S5
2
2
2
2
2
OM-803
Page
1
/