November
1975
FORM:
OM-802A
Effective
with
serial
No.
MEHFOO21O5
MODEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
OWNER
S
MANUAL
ADDITIONAL
COPY
PRICE
20
CENTS
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
MODEL
MO-395
STOCK
NO.
041
071
NWSA
CODE
NO.
4579
Id_s
Id.
Lg_L~J
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flTbTbTh
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IOT
C
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C
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~
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C
C
~
C)
C)
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~
WARRANTY
MILLER
Electric
Mfg.
Co.,
Appleton,
Wisconsin,
warrants
all
new
equipment
to
be
free
from
defects
in
I
I
material
and
factory
workmanship
for
the
periods
indicated
below,
provided
the
equipment
is
installed
and
C
)
I
,
C)
operated
according
to
manufacturers
instructions.
I
~
C)
C
C)
C)
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
MILLERS
inspec-
C
I
~
C)
tion
confirms
the
existence
of
such
defects.
MILLERS
option
of
repair
or
replacementwill
be
f.o.b.
factory
at
C
Appleton,
Wisconsin
or
f.o.b.
a
MILLER
authorized
service
facility,and
therefore
no
compensation
for
trans
portationcostsofanykindwillbeallowed.
I
~
C)
I
I
C)
The
warranty
period,
beginning
on
the
date
of
sale
to
the
original
purchaser-user
of
the
equipment,
will
be
as
c
I
I
C)
follows:
c
1.
Arc
welders,
power
sources,
and
components
1
year
C
I
C)
2.
Original
main
power
rectifiers
3
years
(unconditionally)
3.
MHFC-L1
Feeder,
MHG.35C1,
20E,
20K,
I
I
and
all
guns
and
torches
90
days
I
I
4.
All
other
Millermatic
Feeders
1
year
5.
Mag-Diesel
engine
on
DEL-200
6
months
6.
All
other
engines
1
year
I
I
I
I
Engine
Warranties
are
covered
by
the
engine
manufacturers,
subject
to
their
procedures
and
to
be
handled
I
I
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.
I
~
(
)
I
C
I
I
~
c
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.
I
I
c
~
I
I
C
I
I
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
c
I
I
C
C
I
warranties
expressed
or
implied.
C
~
I
I C
~
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0
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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
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
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
she
side
panels
with
the
air
vents
or
louvers
are
clear
of
any
obstruction.
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
Cacnlock
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.
Table
2-1.
Welding
Cable
Sizes
Welding
Amperes
Total
Jf2236
of
cable
copeerl
In
We/a
circuit
iso
200
250
300
350
50
100
4ee
too
4
4 4
3
2
1
1/0
1/0
150
3 3 2
1
t/e
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/e
3/0
4/0
4/0
sOaMcM
300
1/0
1/0
2/5
3/0
4/0 4/0
sooMcM
500M~M
350
110 1/0
3/0
4/0
4/0
500MCM
seoMcM
500M~M
450
2/0
2/0
3/0
4/0
500MCM
50051cM
sooMcM
toovciui
500
3/0 3/0 4/0
seOMcM
soovcM
50051cM
soovcM
soovcv
600
4/0
4/0
soovcv
seovc~
soovcM
sooMcv
soovcM
1000McM
Aluminum
Figure
2-1.
Dimensional
Drawing
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,
TB-004
544
OM-802
Page
1
SECTION
3
-
OPERATION
Fuse
400
~
p
Weld
P0wer~
Input
Plug
Rear
View
Figure
3-1.
Component
Locations
TB-004
545
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
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.
3-2.
FUSE
PROTECTION
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.
rn
pe
rat
lye
at
the
f
re
iced
with
one
of
the
same
size,
and
rating.
Failure
to
comply
may
result
in
damage
to
the
welding
control
station..
.50
Q~
FM0l~T
SlEW
+10
3~)5
co.s
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C.OIL
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150
LOC)
250
300
350
0
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PC:
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T000IINAL
0
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3
4
5
t.
7
5
3
0
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lb
IL
0.0
25
30
.M
40
IS
0
1.
7
(.~7
I.,8
7.8
8,3
l.,8,3
7,8,3
L.,7,0.S
(~
2.
.4
0,4
2,0.
4,0
(~8
Z&8
4,0.8
2A,t..~S
RESISTORS
RESITh51C~
W~R(
3IzE
TLJRMS
I
P.. TIlP.LL
R~
040
20
.843
CHITS
.IIC,
.051.
nIDO
S.C.
OHMS
.010
P.,
.04+
0150
1.4
OHMS
.050.
R~o
B:
.005
.100
:2.8
01185
.072.
40
57
4.3
.54
Circuit
Diagram
No.
ME-00364
Figure
3-2.
Circuit
Diagram
COREISE
FD5I1IL(~
Page
2
October
1975
FORM:
OM-802A
Effective
with
serial
No.
MEHFOO21O5
MODEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
PARTS
LIST
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
MODEL
MO-395
STOCK
NO.
041 071
NWSA
CODE
NO.
4579
U
S
0
0
0
N)
-o
C)
(0
CD
7
6~
3
2
1
Includes
Item
39
4
15
-~.
22
23
34
Includes
27
31
32
28
Items
31
and
32
-C---
29
30
A
Figure
A
Complete
Assembly
TD-003
794
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
004057
TUBING,steel
11/32ODx
17/64IDx7/16
10
4
004
362
PANEL,
support
-
front
1
5
R1-7
004
409
RESISTOR,
grid
0.84
ohm
16
Ig
w/tubing
&
pins
7
6
R9
004411
RESISTOR,
grid
4.4
ohm
16
1gw/tubing
&
pins
1
7
R10,R1
1
004
410
RESISTOR,
grid
2.8
ohm
161gw/tubing
&
pins
2
8
R8
004412
RESISTOR,grid9.6ohm
l6Igw/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
17/64IDx2
2
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
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
20
Fl
*004
367
LINK,fuse400amp25Ovolts
1
21
004 070
BUS
BAR,
interconnecting
resistors
22
004 365
PANEL,
heat
exchange
-
rear
1
23
004
363
PANEL,
support-
rear
1
24
004
377
BASE
1
25
Si
004
366
SWITCH,
rotary
45
amp
600
volts
(consisting
of)
26
004
414
.
KNOB,
switch
-
coarse
1
27
004 354
LINK,
jumper
-
switch
7
connector
28
004
355
BUS
BAR,
link
to
receptacle
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
1
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
36
004 360
PANEL,
front
1
37
004
408
BUS
BAR,
switch
to
bus
bar
1
38
S2
004
016
SWITCH,
rotary
25
amp
600
volts
(consisting
of)
1
39
004413
.KNOB,
switch-fine
1
*
Recommended
Spare
Parts
BE
SURE
TO
PROVIDE
STOCK,
MODEL,
AND
SERIAL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-802
Page
2
/