Miller Mark VI Owner's manual

Brand: Miller

Model: Mark VI

Category: Welding System

Type: Owner's manual

This manual is also suitable for

MB020709V

Processes

OM-2211 182 413AB

2011−05

Description

Air Plasma Cutting

and Gouging with Spectrum

Plus

Air Carbon Arc Cutting and

Gouging

DC-Gas Tungsten Arc

(DC-TIG) Welding

Shielded Metal Arc

(Stick) Welding

Flux Cored Arc Welding and

Gas Metal Arc Welding (MIG)

Spray Transfer with Voltage-

Sensing Feeder

Multiple Operator Arc Welding Power

Source

Mark VI



Visit our website at

www.MillerWelds.com

Miller Electric manufactures a full line

of welders and welding related equipment.

For information on other quality Miller

products, contact your local Miller distributor to receive the latest full

line catalog or individual specification sheets. To locate your nearest

distributor or service agency call 1-800-4-A-Miller, or visit us at

www.MillerWelds.com on the web.

Thank you and congratulations on choosing Miller. Now you can get

the job done and get it done right. We know you don’t have time to do

it any other way.

That’s why when Niels Miller first started building arc welders in 1929,

he made sure his products offered long-lasting value and superior

quality. Like you, his customers couldn’t afford anything less. Miller

products had to be more than the best they could be. They had to be the

best you could buy.

Today, the people that build and sell Miller products continue the

tradition. They’re just as committed to providing equipment and service

that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your

Miller products. Please take time to read the Safety precautions. They

will help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quick

and easy. With Miller you can count on years

of reliable service with proper maintenance.

And if for some reason the unit needs repair,

there’s a Troubleshooting section that will

help you figure out what the problem is. The

parts list will then help you to decide the

exact part you may need to fix the problem.

Warranty and service information for your

particular model are also provided.

Miller is the first welding

equipment manufacturer in

the U.S.A. to be registered to

the ISO 9001 Quality System

Standard.

Working as hard as you do

− every power source from

Miller is backed by the most

hassle-free warranty in the

business.

From Miller to You

Mil_Thank 2009−09

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1...................................

1-1. Symbol Usage 1........................................................................

1-2. Arc Welding Hazards 1..................................................................

1-3. Additional Symbols For Installation, Operation, And Maintenance 3.............................

1-4. California Proposition 65 Warnings 4.......................................................

1-5. Principal Safety Standards 4.............................................................

1-6. EMF Information 4......................................................................

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 5............................

2-1. Symboles utilisés 5.....................................................................

2-2. Dangers relatifs au soudage à l’arc 5......................................................

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 7......

2-4. Proposition californienne 65 Avertissements 8...............................................

2-5. Principales normes de sécurité 9..........................................................

2-6. Informations relatives aux CEM 9.........................................................

SECTION 3 − INSTALLATION 11..................................................................

3-1. Serial Number And Rating Label Location 11.................................................

3-2. Specifications 11........................................................................

3-3. Volt-Ampere Curves 12...................................................................

3-4. 60 Hz Duty Cycle And Overheating 13......................................................

3-5. 50 Hz Duty Cycle And Overheating 14......................................................

3-6. Selecting A Location 15...................................................................

3-7. Dimensions And Weights 16...............................................................

3-8. 115 Volts AC GFCI Receptacles And Supplementary Protectors 16..............................

3-9. Weld Output Terminals And Selecting Cable Sizes* 17.........................................

3-10. Common Work Cable Sizes 18.............................................................

3-11. Connecting Weld Output Cables 18.........................................................

3-12. Safety Information For Connecting To Weld Output Terminals 19.................................

3-13. Weld Output Terminals 19.................................................................

3-14. Standard Module Weld Output Connections For CC SMAW And GTAW Welding Processes Without A

Common Work Terminal 20................................................................

3-15. Standard Module Weld Output Connections For CC Smaw And GTAW Welding Processes With A Com-

mon Work Terminal 21....................................................................

3-16. Parallel Module Weld Output Connections For CC SMAW Welding Process Without A Common Work

Terminal 22.............................................................................

3-17. Parallel Module Weld Output Connections For CC SMAW Welding Process With A Common Work Ter-

minal 23................................................................................

3-18. CC/CV Module Weld Output Connections For CV FCAW Welding Process Without A Common Work

Terminal 24.............................................................................

3-19. CC/CV Module Weld Output Connections For CV FCAW Welding Process With A Common Work Ter-

minal 25................................................................................

3-20. Remote 14 Receptacle Information 26.......................................................

3-21. Electrical Service Guide 26................................................................

3-22. Placing Jumper Links 27..................................................................

3-23. Connecting Input Power 28................................................................

SECTION 4 − OPERATION 29....................................................................

4-1. CC Module Controls 29...................................................................

4-2. CC/CV Module Controls 30................................................................

SECTION 5 − MAINTENANCE AND TROUBLESHOOTING 31........................................

5-1. Routine Maintenance 31..................................................................

5-2. Overload Protection 32...................................................................

5-3. Troubleshooting 33......................................................................

SECTION 6 − ELECTRICAL DIAGRAM 34..........................................................

SECTION 7 − PARTS LIST 36.....................................................................

OPTIONS AND ACCESSORIES

WARRANTY

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OM-2211 Page 1

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

som 2011−01

Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

DANGER! − Indicates a hazardous situation which, if

not avoided, will result in death or serious injury. The

possible hazards are shown in the adjoining symbols

or explained in the text.

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury. The possible

hazards are shown in the adjoining symbols or ex-

plained in the text.

NOTICE − Indicates statements not related to personal injury.

. Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC

SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-

bols and related instructions below for necessary actions to avoid the

hazards.

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual

to call attention to and identify possible hazards. When you

see the symbol, watch out, and follow the related instructions

to avoid the hazard. The safety information given below is

only a summary of the more complete safety information

found in the Safety Standards listed in Section 1-5. Read and

follow all Safety Standards.

Only qualified persons should install, operate, maintain, and

repair this unit.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks

or severe burns. The electrode and work circuit is

electrically live whenever the output is on. The input

power circuit and machine internal circuits are also

live when power is on. In semiautomatic or automatic

wire welding, the wire, wire reel, drive roll housing,

and all metal parts touching the welding wire are

electrically live. Incorrectly installed or improperly

grounded equipment is a hazard.

D Do not touch live electrical parts.

D Wear dry, hole-free insulating gloves and body protection.

D Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work

or ground.

D Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

D Use AC output ONLY if required for the welding process.

D If AC output is required, use remote output control if present on

unit.

D Additional safety precautions are required when any of the follow-

ing electrically hazardous conditions are present: in damp

locations or while wearing wet clothing; on metal structures such

as floors, gratings, or scaffolds; when in cramped positions such

as sitting, kneeling, or lying; or when there is a high risk of unavoid-

able or accidental contact with the workpiece or ground. For these

conditions, use the following equipment in order presented: 1) a

semiautomatic DC constant voltage (wire) welder, 2) a DC manual

(stick) welder, or 3) an AC welder with reduced open-circuit volt-

age. In most situations, use of a DC, constant voltage wire welder

is recommended. And, do not work alone!

D Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to

OSHA 29 CFR 1910.147 (see Safety Standards).

D Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

D Always verify the supply ground − check and be sure that input

power cord ground wire is properly connected to ground terminal in

disconnect box or that cord plug is connected to a properly

grounded receptacle outlet.

D When making input connections, attach proper grounding conduc-

tor first − double-check connections.

D Keep cords dry, free of oil and grease, and protected from hot metal

and sparks.

D Frequently inspect input power cord for damage or bare wiring −

replace cord immediately if damaged − bare wiring can kill.

D Turn off all equipment when not in use.

D Do not use worn, damaged, undersized, or poorly spliced cables.

D Do not drape cables over your body.

D If earth grounding of the workpiece is required, ground it directly

with a separate cable.

D Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

D Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will be

present.

D Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

D Wear a safety harness if working above floor level.

D Keep all panels and covers securely in place.

D Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

D Do not connect more than one electrode or work cable to any

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists in inverter weld-

ing power sources AFTER removal of input power.

D Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section

before touching any parts.

HOT PARTS can burn.

D Do not touch hot parts bare handed.

D Allow cooling period before working on equip-

ment.

D To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves and

clothing to prevent burns.

OM-2211 Page 2

Welding produces fumes and gases. Breathing

these fumes and gases can be hazardous to your

health.

FUMES AND GASES can be hazardous.

D Keep your head out of the fumes. Do not breathe the fumes.

D If inside, ventilate the area and/or use local forced ventilation at the

arc to remove welding fumes and gases.

D If ventilation is poor, wear an approved air-supplied respirator.

D Read and understand the Material Safety Data Sheets (MSDSs)

and the manufacturer’s instructions for metals, consumables,

coatings, cleaners, and degreasers.

D Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watch-

person nearby. Welding fumes and gases can displace air and

lower the oxygen level causing injury or death. Be sure the breath-

ing air is safe.

D Do not weld in locations near degreasing, cleaning, or spraying op-

erations. The heat and rays of the arc can react with vapors to form

highly toxic and irritating gases.

D Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the weld

area, the area is well ventilated, and while wearing an air-supplied

respirator. The coatings and any metals containing these elements

can give off toxic fumes if welded.

Arc rays from the welding process produce intense

visible and invisible (ultraviolet and infrared) rays

that can burn eyes and skin. Sparks fly off from the

weld.

D Wear an approved welding helmet fitted with a proper shade of

filter lenses to protect your face and eyes from arc rays and

sparks when welding or watching (see ANSI Z49.1 and Z87.1

listed in Safety Standards).

D Wear approved safety glasses with side shields under your

helmet.

D Use protective screens or barriers to protect others from flash,

glare and sparks; warn others not to watch the arc.

D Wear protective clothing made from durable, flame-resistant

material (leather, heavy cotton, or wool) and foot protection.

ARC RAYS can burn eyes and skin.

Welding on closed containers, such as tanks,

drums, or pipes, can cause them to blow up. Sparks

can fly off from the welding arc. The flying sparks, hot

workpiece, and hot equipment can cause fires and

burns. Accidental contact of electrode to metal objects can cause

sparks, explosion, overheating, or fire. Check and be sure the area is

safe before doing any welding.

WELDING can cause fire or explosion.

D Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

D Do not weld where flying sparks can strike flammable material.

D Protect yourself and others from flying sparks and hot metal.

D Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

D Watch for fire, and keep a fire extinguisher nearby.

D Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

D Do not weld on closed containers such as tanks, drums, or pipes,

unless they are properly prepared according to AWS F4.1 (see

Safety Standards).

D Do not weld where the atmosphere may contain flammable dust,

gas, or liquid vapors (such as gasoline).

D Connect work cable to the work as close to the welding area as

practical to prevent welding current from traveling long, possibly

unknown paths and causing electric shock, sparks, and fire

hazards.

D Do not use welder to thaw frozen pipes.

D Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

D Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

D Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

D After completion of work, inspect area to ensure it is free of sparks,

glowing embers, and flames.

D Use only correct fuses or circuit breakers. Do not oversize or by-

pass them.

D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B

for hot work and have a fire watcher and extinguisher nearby.

FLYING METAL or DIRT can injure eyes.

D Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool,

they can throw off slag.

D Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

D Shut off compressed gas supply when not in use.

D Always ventilate confined spaces or use

approved air-supplied respirator.

ELECTRIC AND MAGNETIC FIELDS (EMF

)

can affect Implanted Medical Devices.

D Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

D Implanted Medical Device wearers should consult their doctor

and the device manufacturer before going near arc welding, spot

welding, gouging, plasma arc cutting, or induction heating

operations.

NOISE can damage hearing.

Noise from some processes or equipment can

damage hearing.

D Wear approved ear protection if noise level is

high.

Compressed gas cylinders contain gas under high

pressure. If damaged, a cylinder can explode. Since

gas cylinders are normally part of the welding

process, be sure to treat them carefully.

CYLINDERS can explode if damaged.

D Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, physical damage, slag, open flames, sparks, and arcs.

D Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

D Keep cylinders away from any welding or other electrical circuits.

D Never drape a welding torch over a gas cylinder.

D Never allow a welding electrode to touch any cylinder.

D Never weld on a pressurized cylinder − explosion will result.

D Use only correct compressed gas cylinders, regulators, hoses,

and fittings designed for the specific application; maintain them

and associated parts in good condition.

D Turn face away from valve outlet when opening cylinder valve.

D Keep protective cap in place over valve except when cylinder is in

use or connected for use.

D Use the right equipment, correct procedures, and sufficient num-

ber of persons to lift and move cylinders.

D Read and follow instructions on compressed gas cylinders,

associated equipment, and Compressed Gas Association (CGA)

publication P-1 listed in Safety Standards.

OM-2211 Page 3

1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

D Do not install or place unit on, over, or near

combustible surfaces.

D Do not install unit near flammables.

D Do not overload building wiring − be sure power supply system is

properly sized, rated, and protected to handle this unit.

FALLING EQUIPMENT can injure.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift and

support unit.

D If using lift forks to move unit, be sure forks are long enough to

extend beyond opposite side of unit.

D Keep equipment (cables and cords) away from moving vehicles

when working from an aerial location.

D Follow the guidelines in the Applications Manual for the Revised

NIOSH Lifting Equation (Publication No. 94−110) when manu-

ally lifting heavy parts or equipment.

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle.

D Reduce current or reduce duty cycle before

starting to weld again.

D Do not block or filter airflow to unit.

FLYING SPARKS can injure.

D Wear a face shield to protect eyes and face.

D Shape tungsten electrode only on grinder with

proper guards in a safe location wearing proper

face, hand, and body protection.

D Sparks can cause fires — keep flammables away.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can injure.

D Keep away from moving parts.

D Keep away from pinch points such as drive

rolls.

WELDING WIRE can injure.

D Do not press gun trigger until instructed to do

so.

D Do not point gun toward any part of the body,

other people, or any metal when threading

welding wire.

MOVING PARTS can injure.

D Keep away from moving parts such as fans.

D Keep all doors, panels, covers, and guards

closed and securely in place.

D Have only qualified persons remove doors, panels, covers, or

guards for maintenance and troubleshooting as necessary.

D Reinstall doors, panels, covers, or guards when maintenance is

finished and before reconnecting input power.

READ INSTRUCTIONS.

D Read and follow all labels and the Owner’s

Manual carefully before installing, operating, or

servicing unit. Read the safety information at

the beginning of the manual and in each

section.

D Use only genuine replacement parts from the manufacturer.

D Perform maintenance and service according to the Owner’s

Manuals, industry standards, and national, state, and local

codes.

H.F. RADIATION can cause interference.

D High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and

communications equipment.

D Have only qualified persons familiar with

electronic equipment perform this installation.

D The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installa-

tion.

D If notified by the FCC about interference, stop using the

equipment at once.

D Have the installation regularly checked and maintained.

D Keep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to

minimize the possibility of interference.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere with

sensitive electronic equipment such as

computers and computer-driven equipment

such as robots.

D Be sure all equipment in the welding area is

electromagnetically compatible.

D To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according to this manual.

D If interference still occurs, the user must take extra measures

such as moving the welding machine, using shielded cables,

using line filters, or shielding the work area.

OM-2211 Page 4

1-4. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases

which contain chemicals known to the State of California to

cause birth defects and, in some cases, cancer. (California

Health & Safety Code Section 25249.5 et seq.)

Battery posts, terminals and related accessories contain lead

and lead compounds, chemicals known to the State of

California to cause cancer and birth defects or other

reproductive harm. Wash hands after handling.

This product contains chemicals, including lead, known to

the state of California to cause cancer, birth defects, or other

reproductive harm. Wash hands after use.

For Gasoline Engines:

Engine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproduc-

tive harm.

For Diesel Engines:

Diesel engine exhaust and some of its constituents are

known to the State of California to cause cancer, birth

defects, and other reproductive harm.

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,

from Global Engineering Documents (phone: 1-877-413-5184, website:

www.global.ihs.com).

Safe Practices for the Preparation of Containers and Piping for Welding

and Cutting, American Welding Society Standard AWS F4.1, from Glob-

al Engineering Documents (phone: 1-877-413-5184, website:

www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec-

tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:

www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

from Compressed Gas Association, 4221 Walney Road, 5th Floor,

Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).

Safety in Welding, Cutting, and Allied Processes, CSA Standard

W117.2, from Canadian Standards Association, Standards Sales, 5060

Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:

800-463-6727, website: www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protec-

tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-

site: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, NFPA Standard 51B, from National Fire Protection Association,

Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.

OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,

and Part 1926, Subpart J, from U.S. Government Printing Office, Super-

intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954

(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—

phone for Region 5, Chicago, is 312-353-2220, website:

www.osha.gov).

U.S. Consumer Product Safety Commission (CPSC), 4330 East West

Highway, Bethesda, MD 20814 (phone: 301-504-7923, website:

www.cpsc.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The Na-

tional Institute for Occupational Safety and Health (NIOSH), 1600

Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:

www.cdc.gov/NIOSH).

1-6. EMF Information

Electric current flowing through any conductor causes localized electric

and magnetic fields (EMF). Welding current creates an EMF field

around the welding circuit and welding equipment. EMF fields may inter-

fere with some medical implants, e.g. pacemakers. Protective

measures for persons wearing medical implants have to be taken. For

example, access restrictions for passers−by or individual risk assess-

ment for welders. All welders should use the following procedures in

order to minimize exposure to EMF fields from the welding circuit:

1. Keep cables close together by twisting or taping them, or using a

cable cover.

2. Do not place your body between welding cables. Arrange cables

to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep head and trunk as far away from the equipment in the

welding circuit as possible.

5. Connect work clamp to workpiece as close to the weld as

possible.

6. Do not work next to, sit or lean on the welding power source.

7. Do not weld whilst carrying the welding power source or wire

feeder.

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the

device manufacturer before performing or going near arc welding, spot

welding, gouging, plasma arc cutting, or induction heating operations.

If cleared by your doctor, then following the above procedures is recom-

mended.

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OM-2211 Page 9

2-5. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,

de Global Engineering Documents (téléphone : 1-877-413-5184, site

Internet : www.global.ihs.com).

Safe Practices for the Preparation of Containers and Piping for Welding

and Cutting, American Welding Society Standard AWS F4.1, de Global

Engineering Documents (téléphone : 1-877-413-5184, site internet :

www.global.ihs.com).

National Electrical Code, NFPA Standard 70, de National Fire Protec-

tion Association, Quincy, MA 02269 (téléphone : 800-344-3555, site

Internet : www.nfpa.org et www.sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chan-

tilly, VA 20151 (téléphone : 703-788-2700, site Internet :

www.cganet.com).

Safety in Welding, Cutting, and Allied Processes, CSA Standard

W117.2, de Canadian Standards Association, Standards Sales, 5060

Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (téléphone :

800-463-6727, site internet : www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protec-

tion, ANSI Standard Z87.1, de American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (téléphone : 212-642-4900,

site Internet : www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, NFPA Standard 51B, de National Fire Protection Association,

P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000,

site Internet : www.nfpa.org).

OSHA, Occupational Safety and Health Standards for General

Industry, Title 29, Code of Federal Regulations (CFR), Part 1910,

Subpart Q, and Part 1926, Subpart J, de U.S. Government Printing

Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA

15250-7954 (téléphone : 1-866-512-1800) (il y a 10 bureaux

régionaux−le téléphone de la région 5, Chicago, est 312-353-2220, site

Internet : www.osha.gov).

U.S. Consumer Product Safety Commission (CPSC), 4330 East West

Highway, Bethesda, MD 20814 (téléphone : 301-504-7923, site inter-

net : www.cpsc.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The

National Institute for Occupational Safety and Health (NIOSH), 1600

Clifton Rd, Atlanta, GA 30333 (télé[hone : 1-800-232-4636, site internet:

www.cdc.gov/NIOSH).

2-6. Informations relatives aux CEM

Le courant électrique qui traverse tout conducteur génère des champs

électromagnétiques (CEM) à certains endroits. Le courant de soudage

crée un CEM autour du circuit et du matériel de soudage. Les CEM

peuvent créer des interférences avec certains implants médicaux

comme des stimulateurs cardiaques. Des mesures de protection pour

les porteurs d’implants médicaux doivent être prises: par exemple, des

restrictions d’accès pour les passants ou une évaluation individuelle

des risques pour les soudeurs. Tous les soudeurs doivent appliquer les

procédures suivantes pour minimiser l’exposition aux CEM provenant

du circuit de soudage:

1. Rassembler les câbles en les torsadant ou en les attachant avec

du ruban adhésif ou avec une housse.

2. Ne pas se tenir au milieu des câbles de soudage. Disposer les

câbles d’un côté et à distance de l’opérateur.

3. Ne pas courber et ne pas entourer les câbles autour de votre

corps.

4. Maintenir la tête et le torse aussi loin que possible du matériel du

circuit de soudage.

5. Connecter la pince sur la pièce aussi près que possible de la

soudure.

6. Ne pas travailler à proximité d’une source de soudage, ni

s’asseoir ou se pencher dessus.

7. Ne pas souder tout en portant la source de soudage ou le

dévidoir.

En ce qui concerne les implants médicaux :

Les porteurs d’implants doivent d’abord consulter leur médecin avant

de s’approcher des opérations de soudage à l’arc, de soudage par

points, de gougeage, du coupage plasma ou de chauffage par induc-

tion. Si le médecin approuve, il est recommandé de suivre les

procédures précédentes.

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OM-2211 Page 11

SECTION 3 − INSTALLATION

. A six module unit is illustrated throughout this Owner’s manual. Four module units are available. Installation and operation is similar to that of a

six module unit.

3-1. Serial Number And Rating Label Location

The serial number and rating information for this product is located on the front. Use rating label to determine input power requirements and/or rated

output. For future reference, write serial number in space provided on back cover of this manual.

3-2. Specifications

Rated Output At 44 Volts DC

DC Amperage/Voltage

Range

Max. Open

Circuit Voltage

Six Or

Four

Module

Units

Each Module Main Transformer

20 − 315 A In CC Mode

10 − 30 V In CV Mode

With CC/CV Module

75 VDC In CC

Mode

38 VDC In CV

Mode With CC/CV

Module

60 Or 50 Hz

250 A @ 60% Duty

Cycle

60 Hz

750 A @ 100% Duty Cycle

1500 A @ 25% Duty Cycle

50 Hz

750 A @ 60% Duty Cycle

1160 A @ 25% Duty Cycle

Open Circuit Voltage is 26 VDC 2 Volts With Low OCV Module While IN CC Or CV Mode.

Amps Input At Rated Output of 750 A,

50 Or 60 Hz, Three-Phase

230 V 380 400 415 440 460 V 575 V KVA KW

164

12.5*

7.5*

6.5*

82.5

6.2*

66.1

65.2

41.9

3.2*

* While idling

Notes

OM-2211 Page 12

3-3. Volt-Ampere Curves

184 158 / 190 886

The volt-ampere curves show the

normal minimum and maximum

voltage and amperage output capa-

bilities of the welding power source.

Curves of other settings fall be-

tween the curves shown.

CC Mode

CV Mode With

CC/CV Module

Notes

OM-2211 Page 13

3-4. 60 Hz Duty Cycle And Overheating

2-1/2 Minutes Welding 7-1/2 Minutes Resting

6 Minutes Welding 4 Minutes Resting

Continuous Welding

Duty Cycle is percentage of 10 min-

utes that unit can weld at rated load

without overheating.

If unit overheats, thermostat(s)

opens, output stops, and cooling

fan runs. Wait fifteen minutes for

unit to cool. Reduce amperage or

voltage, or duty cycle before

welding.

NOTICE − Exceeding duty cycle

can damage unit and void warranty.

The main transformer of the poly-

weld system has dual duty cycle

ratings, each for a specific amper-

age output range. If the unit is oper-

ated in the 750 ampere range, the

unit is rated at 100% duty cycle.

This means the polyweld system

can be operated at 750 amperes

continuously. When the unit is oper-

ated in the 1500 ampere range, it is

rated at 25% duty cycle.

The sum of the outputs of each

module should not exceed the rated

duty cycle of the main transformer.

For example, the polyweld system

can be safely operated at a load of

800 amperes at 80 percent duty

cycle. This value could be obtained

by operating four modules at a load

of 200 amperes at 80 percent duty

cycle, or by operating six modules

at a load of 135 amperes at 80 per-

cent duty cycle.

Overheating

A or V

Reduce Duty Cycle

Minutes

duty1 4/95 − 184 107-C

Main Transformer − 25% Duty Cycle at 1500 Amperes

Single Module − 60% Duty Cycle at 250 Amperes

Main Transformer − 100% Duty Cycle at 750 Amperes

OM-2211 Page 14

3-5. 50 Hz Duty Cycle And Overheating

2-1/2 Minutes Welding 7-1/2 Minutes Resting

6 Minutes Welding 4 Minutes Resting

Duty Cycle is percentage of 10 min-

utes that unit can weld at rated load

without overheating.

If unit overheats, thermostat(s)

opens, output stops, and cooling

fan runs. Wait fifteen minutes for

unit to cool. Reduce amperage or

voltage, or duty cycle before

welding.

NOTICE − Exceeding duty cycle

can damage unit and void warranty.

The main transformer of the poly-

weld system has dual duty cycle

ratings, each for a specific amper-

age output range. If the unit is oper-

ated in the 750 ampere range, the

unit is rated at 60% duty cycle. This

means the polyweld system can be

operated at 750 amperes for six out

of every ten minutes. When the unit

is operated in the 1160 ampere

range, it is rated at 25% duty cycle.

The sum of the outputs of each

module should not exceed the rated

duty cycle of the main transformer.

For example, the polyweld system

can be safely operated at a load of

650 amperes at 80 percent duty

cycle. This value could be obtained

by operating four modules at a load

of 165 amperes at 80 percent duty

cycle, or by operating six modules

at a load of 110 amperes at 80 per-

cent duty cycle.

Overheating

A or V

Reduce Duty Cycle

Minutes

duty1 4/95 − 193 918

Main Transformer − 25% Duty Cycle at 1160 Amperes

Single Module − 60% Duty Cycle at 250 Amperes

6 Minutes Welding 4 Minutes Resting

Main Transformer − 60% Duty Cycle at 750 Amperes

OM-2211 Page 15

3-6. Selecting A Location

loc_1 3/96 Ref. 801 627-A

1 Lifting Eye

2 Lifting Forks

Use lifting eye or lifting forks to

move unit.

If using lifting forks, extend forks

beyond opposite side of unit.

3 Line Disconnect Device

Locate unit near correct input pow-

er supply.

Movement

Location

Do not block airflow

to sides of unit.

36 in.

(920mm)

36 in.

(920mm)

Air Out

Air In

! High center of gravity − always securely tie

down unit with adequate chains or other

proper restraints when moving to prevent

tipping. Do not place unit where it could tip.

! Special installation may be required where

gasoline or volatile liquids are present − see

NEC Article 511 or CEC Section 20.

NOTICE − This unit contains fan blades with

different airflow directions to provide proper

cooling of components. Consult Owner’s

Manual for correct Part No. and location.

OM-2211 Page 16

3-7. Dimensions And Weights

Dimensions

Height* 65 in. (1651 mm)

Width 56-3/4 in. (1442 mm)

Depth 34-1/4 in. (870 mm)

*72 in. (1829 mm) with lifting eye

Weight

Each Module Four Unit Module Six Module Unit

125 lb (57 kg) 1575 lb (718 kg)

60 Hz − 1825 lb (828 kg)

50 Hz − 1870 lb (848 kg)

3-8. 115 Volts AC GFCI Receptacles And Supplementary Protectors

Ref. 801 627-A

1 115 V 15 A AC GFCI

Receptacles RC9 And RC10

These receptacles supply up to 15

amperes of 115 volts AC power. In

50 Hz models, RC9 is 220 volts, 15

amps AC.

If a ground fault is detected, the

GFCI Reset button pops out and

the circuit opens to disconnect the

faulty equipment. Check for dam-

aged tools, cords, plugs, etc. con-

nected to the receptacle. Press but-

ton to reset receptacle and resume

operation.

. At least once a month, test but-

ton to verify GFCI is working

properly.

2 Supplementary Protector CB1

CB1 protects RC9 from overload. If

CB1 opens, no output is available

from RC9.

3 Supplementary Protector CB2

CB2 protects RC10 from overload.

If CB2 opens, no output is available

from RC10.

4 Supplementary Protector CB3

CB3 protects the 115 volts AC

portion of Remote 14 receptacle

RC8 from overload.

5 Supplementary Protector CB4

CB4 protects the 24 volts AC

portion of Remote 14 receptacle

RC8 from overload.

Press button to reset protector.

2345

OM-2211 Page 17

3-9. Weld Output Terminals And Selecting Cable Sizes*

NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is

100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable

size.

! Turn off power be-

fore connecting to

weld output termi-

nals.

! Do not use worn,

damaged, under-

sized, or poorly

spliced cables.

Weld Output

Terminals

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit

Not Exceeding***

100 ft (30 m) or Less

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

300 ft

(90 m)

350 ft

(105 m)

400 ft

(120 m)

Welding

Amperes

10 − 60%

Duty

Cycle

AWG (mm

)

60 − 100%

Duty

Cycle

AWG (mm

)

10 − 100% Duty Cycle

AWG (mm

)

100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)

150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)

200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)

250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)

2x2/0

(2x70)

2x2/0

(2x70)

300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)

2x2/0

(2x70)

2x3/0

(2x95)

2x3/0

(2x95)

350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)

2x2/0

(2x70)

2x3/0

(2x95)

2x3/0

(2x95)

2x4/0

(2x120)

400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)

2x2/0

(2x70)

2x3/0

(2x95)

2x4/0

(2x120)

2x4/0

(2x120)

500 2/0 (70) 3/0 (95) 4/0 (120)

2x2/0

(2x70)

2x3/0

(2x95)

2x4/0

(2x120)

3x3/0

(3x95)

3x3/0

(3x95)

600 3/0 (85) 4/0 (120)

2x2/0

(2x70)

2x3/0

(2x95)

2x4/0

(2x120)

3x3/0

(3x95)

3x4/0

(3x120)

3x4/0

(3x120)

700 4/0 (110) 2x2/0 (2x70)

2x3/0

(2x95)

2x4/0

(2x120)

3x3/0

(3x95)

3x4/0

(3x120)

3x4/0

(3x120)

4x4/0

(4x120)

800 4/0 (110) 2x2/0 (2x70)

2x3/0

(2x95)

2x4/0

(2x120)

3x4/0

(3x120)

3x4/0

(3x120)

4x4/0

(4x120)

4x4/0

(4x120)

900 2x2/0 (2x70) 2x3/0 (2x95)

2x4/0

(2x120)

3x3/0

(3x95)

1000 2x2/0 (2x70) 2x3/0 (2x95)

2x4/0

(2x120)

3x3/0

(3x95)

1250 2x3/0 (2x95)

2x4/0

(2x120)

3x3/0

(3x95)

4x3/0

(4x95)

1500 600 (310) 750 (380) 1000 (510)

2x750

(2x380)

1750 750 (380) 1000 (510)

2x750

(2x380)

2x1000

(2x510)

* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.

**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.

( ) = mm

for metric use

***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).

Ref. S-0007-H 2011−05

OM-2211 Page 18

3-10. Common Work Cable Sizes

Common Work Cable Sizes At Main Transformer

Rated Welding Current

Cable Length Cable Size

50 ft (15 m) 2 No. 3/0

100 ft (30.5 m) 2 No. 4/0

150 ft (46 m) 3 No. 3/0

200 ft (61 m) 3 No. 4/0

3-11. Connecting Weld Output Cables

803 778-B

! Turn off power before connecting to

weld output terminals.

! Failure to properly connect weld

cables may cause excessive heat

and start a fire, or damage your ma-

chine.

1 Weld Output Terminal

2 Supplied Weld Output Terminal Nut

3 Weld Cable Terminal

4 Copper Bar

Remove supplied nut from weld output ter-

minal. Slide weld cable terminal onto weld

output terminal and secure with nut so that

weld cable terminal is tight against copper

bar. Do not place anything between weld

cable terminal and copper bar. Make

sure that the surfaces of the weld cable

terminal and copper bar are clean.

Tools Needed:

3/4 in (19 mm)

Do not place

anything between

Correct Installation

Incorrect Installation

weld cable terminal

and copper bar.

OM-2211 Page 19

3-12. Safety Information For Connecting To Weld Output Terminals

! ELECTRIC SHOCK can kill; ARCING can burn skin or damage electrical connections.

Turn Off welding power source before making any weld output connections.

Do not connect welding output of different polarities to the same structure.

See ANSI Z49.1 and OSHA Title 29, Chapter XVII, Part 1910, Subpart Q (addresses at beginning of manual).

When using Common Work terminal, all connections to the Common Work terminal must be of the same polarity. Also, when welding on the same

work piece, all connections to the work piece must be of the same polarity.

Remove jumper link from any module where work and electrode connections are made directly to the Positive and Negative output terminals.

Do not handle or come in contact with two live electrodes at the same time.

Connect all paralleled modules for the same polarity.

ELECTRIC SHOCK can kill; TWO TIMES NORMAL OPEN-CIRCUIT VOLTS exist between electrode holders of opposite polarity.

Do not touch electrode holders of opposite polarity at the same time.

Separate electrode holders of opposite polarity to prevent contact.

Consult ANSI Z49.1 for common grounding safe practices.

3-13. Weld Output Terminals

Ref. 801 627-A

! Read and understand safety

information in Section 3-12

before proceeding.

1 Positive (+) Weld Output

Terminal

2 Negative (−) Weld Output

Terminal

3 Positive (+) High Inductance

Weld Output Terminal For CC

SMAW And GTAW Welding

Processes

4 Positive (+) Low Inductance

Weld Output Terminal For The

CV FCAW Welding Process

5 Negative (−) Weld Output

Terminal

6 Weld Output Terminal Cover

(Typical For All Weld Output

Terminals)

Cover all weld output terminals with

weld output terminal covers.

Go to Section 3-14 and/or 3-15 for

standard module weld output con-

nections, or Section 3-16 and/or

3-17 for parallel module weld output

connections. Go to Section 3-18

and/or 3-19 for CV FCAW weld out-

put connections.

CC Module

CC/CV Module

OM-2211 Page 20

3-14. Standard Module Weld Output Connections For CC SMAW And GTAW Welding

Processes Without A Common Work Terminal

Ref. 801 641-A

! Read and understand safety

information in Section 3-12

before proceeding.

See Section 3-9 for proper cable

size.

1 Electrode Holder Cable

2 Work Cable

For Electrode Positive (Reverse

Polarity/DCEP), connect work

cable to Negative (−) terminal and

electrode holder cable to Positive

(+) terminal (see Section 3-13).

For Electrode Negative (Straight

Polarity/DCEN), reverse cable

connections.

3 Weld Output Terminal Cover

(Typical For All Weld Output

Terminals)

Cover all weld output terminals with

weld output terminal covers.

4 Cable Restraint

Route cables through restraints as

shown.

. When using a CC/CV module

(not shown) for CC operation,

use Positive (+) High Induc-

tance weld output terminal (see

Section 3-13). Process Selec-

tor switch (see Section 4-2)

must be in SMAW Hot Start On,

or SMAW Hot Start Off

position.

Tools Needed:

3/4, 7/8 in.

OM-2211 Page 21

3-15. Standard Module Weld Output Connections For CC Smaw And GTAW Welding

Processes With A Common Work Terminal

Ref. 801 641-A

! Read and understand safety

information in Section 3-12

before proceeding.

See Section 3-9 for proper cable

size.

1 Electrode Holder Cable

2 Work Jumper Cable

3 Common Work Terminal

4 Common Work Cable

For Electrode Positive (Reverse

Polarity/DCEP), connect work

jumper cables from Negative (−)

terminals to Common Work termi-

nal, and connect electrode holder

cables to Positive (+) terminals

(see Section 3-13).

For Electrode Negative (Straight

Polarity/DCEN), connect work

jumper cables from Positive (+) ter-

minals to Common Work terminal,

and connect electrode holder

cables to Negative (−) terminals

(see Section 3-13).

Connect as many modules as re-

quired. Do not exceed duty cycle of

machine.

5 Cable Restraint

Route cables through restraints as

shown.

6 Weld Output Terminal Cover

(Typical For All Weld Output

Terminals)

Cover all weld output terminals with

weld output terminal covers.

. When using a CC/CV module

(not shown) for CC operation,

use Positive (+) High Induc-

tance weld output terminal (see

Section 3-13). Process Selec-

tor switch (see Section 4-2)

must be in SMAW Hot Start On,

or SMAW Hot Start Off

position.

Tools Needed:

. For common work connection, work cable must be able to carry combined weld out-

put of all modules using the Common Work Terminal (see Section 3-10 for proper

cable size). The Common Work Terminal is isolated from the unit frame.

3/4, 7/8 in.

Connect a weld cable of adequate size between the Common

Work Connection and the workpiece whenever any mod-

ule(s) is connected to use the Common Work terminal.

When using Common Work terminal, all connections to the

Common Work terminal must be of the same polarity.

Do not exceed duty cycle of machine.

! INADEQUATE WORK CABLE CONNECTIONS can

cause serious damage to input power service and

create a hazardous condition.

OM-2211 Page 22

3-16. Parallel Module Weld Output Connections For CC SMAW Welding Process Without

A Common Work Terminal

Ref. 801 641-A

! Read and understand safety

information in Section 3-12

before proceeding.

See Section 3-9 for proper cable

size.

1 Electrode Holder Cable

2 Work Cable

3 Connection Point

For Electrode Positive (Reverse

Polarity/DCEP), connect separate

cables of same size and length from

Positive (+) terminals (see Section

3-13) to a suitable connection point

connecting to a single electrode

cable. Connect separate cables of

same size and length from Nega-

tive (−) terminals to a suitable con-

nection point connecting to a single

work cable.

For Electrode Negative (Straight

Polarity/DCEN), reverse cable

connections.

Connect as many modules as re-

quired. Do not exceed duty cycle of

machine.

4 Cable Restraint

Route cables through restraints as

shown.

5 Weld Output Terminal Cover

(Typical For All Weld Output

Terminals)

Cover all weld output terminals with

weld output terminal covers.

. When using a CC/CV module

(not shown) for CC operation,

use Positive (+) High Induc-

tance weld output terminal (see

Section 3-13). Process Selec-

tor switch (see Section 4-2)

must be in SMAW Hot Start On,

or SMAW Hot Start Off

position.

Tools Needed:

. Single work cable or electrode holder cable must be able to carry combined weld output

of all modules connected in parallel (see Section 3-9).

Set Amperage/Voltage Adjustment controls on all paralleled modules for the same out-

put.

! UNDERSIZED WELD CABLES can cause fire.

Use single cable of adequate capacity to carry the total combined amper-

age of the paralleled modules.

Securely cover common connections with proper insulating material.

Do not exceed duty cycle of machine.

3/4, 7/8 in.

! Securely cover con-

nection with proper

insulating material.

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Miller Mark VI Owner's manual

Brand: Miller

Model: Mark VI

Category: Welding System

Type: Owner's manual

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