Miller MPG-395 Owner's manual
- Category
- Welding System
- Type
- Owner's manual
This manual is also suitable for
MODEL
STOCK
NO.
MPG-395
003
932
ERS
MANUAL
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
NWSA
CODE
NO.
4579
U~
A.
June
1976
FORM:
OM-804A
Effective
with
Serial
No.
MEHGOO3136
ADDITIONAL
COPY
PRICE
20
CENTS
LIMITED
WARRANTY
:
:
MILLER
Electric
Mfg.
Co.,
Appleton,
Wisconsin,
warrants
all
new
equipment
to
be
free
from
defects
in
c
material
and
factory
workmanship
for
the
periods
indicated
below,
provided
the
equipment
is
installed
and
operated
according
to
manufacturers
instructions.
I
)
MILLER
Electric
Mfg.
Co.s
obligation,
underthis
warranty,
is
expressly
limited
to
replacing
or
repairing
any
defective
part
or
correcting
any
manufacturing
defect
without
charge
during
the
warranty
period
if
MILLERS
inspection
confirms
the
existence
of
such
defects.
MILLERS
option
of
repair
or
replacement
will
be
f.o.b.
factory
at
Appleton,
Wisconsin
or
f.o.b.
a
MILLER
authorized
service
facility,
and
therefore
no
compensation
for
transportation
costs
of
any
kind
will
be
allowed.
The
warranty
period,
beginning
on
the
date
of
sale
to
the
original
purchaser-user
of
the
equipment,
will
be
as
follows:
1.
Arc
welders,
power
sources,
and
components
1
year
2.
Original
main
power
rectifiers
3
years
(unconditionally)
3.
20E,
20K,
and
all
welding
guns.
90
days
4.
All
other
Millermatic
Feeders
1
year
5.
All
engines
1
year
Engine
Warranties
are
covered
by
the
engine
manufacturers,
subject
to
their
procedures
and
to
be
handled
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.
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.
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
C
)
warranties
expressed
or
implied.
c
p
SECTION
1
-
INTRODUCTION
1-1.
GENERAL
This
manual
has
been
prepared
especially
for
use
in
familiar
izing
personnel
with
the
de~ign,
installation,
operation,
main
tenance,
and
troubleshootii~g
of
this
equipment.
All
informa
tion
presented
herein
should
be
given
careful
consideration
to
assure
optimum
performande
of
this
equipment.
RECEIVING.HANDLIIs1G
Prior
to
installing
this
equibment,
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
car1rier.
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
informatiop
concerning
this
equipment,
it
is
essential
that
Model
Description
and/or
Stock
Number
and
Serial
(or
Style)
Numbers
o
the
equipment
be
supplied.
lteL~uu~L.1i~uJ
Under
this
heading,
ins
tallation,
operating,
and
main
tenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
create
a
safety
hazard
to
personnel.
flTAfl
LU
Under
this
heading,
installation,
operating,
and
main
tenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
result
in
damage
to
equip
ment.
SECTION
2
-
INSTALLATION
2-1.
LOCATION
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.
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
Weidier
Torn
!!22!b.1
Cable
(cope
sri
i~
Weld
Circuit
Amperes
50
100
150
200
250
300 350
400
tOO
4 4 4
3
2
t
1/0
tie
ise
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
SO0McM
aoo
tie tie
2/0
3/0
4/0
4/0
sooMcM
seeMcM
350
1/0 i/o
3/0
4/0
4/0
SOOMCM
sOeMcM
seOMcM
400
2/0
2/0
3/0
4/0
550McM
500McM
500McM
sOOMcM
500
3/0
3/0 4/0
seOMcM
500MCM
SOOMCM
SOOMcM
500MCM
eee
4/0
4/0
500MCM seOMcM
50051cM
SOOMCM
500McM
1000McM
Aiumieum
1-2.
U
U
1-3.
DESCRIPTION
This
unit
is
designed
to
fun
remotely
located
from
the
receptacle
to
which
the
elei
and
also
a
coarse
and
fine
trol
station
is
protected
fro
by
a
fuse
in
the
input
circuil
1-4.
SAFETY
The
following
definitions
ai
and
NOTE
blocks
found
thi
ction
as
a
welding
control
station
nain
power
source.
It
provides
a
trode
cable
is
to
be
connected
to
urrent
control.
This
welding
con
~n
damage
due
to
excess
overload
ry.
iply
to
CAUTION,
IMPORTANT,
oughout
this
manual:
NOTE
Under
this
heading,
explanatory
statements
will
be
found
that
need
special
emphasis
to
obtain
the
most
efficient
operation
of
the
equipment.
A
good
installation
is
esseniial
if
the
welding
control
station
is
to
provide
satisfactory
and
dependable
service.
Proper
operating
temperatures
ar~
maintained
by
the
air
stream
passing
through
the
unit.
*Add
2-1/4
For
Handle
On
Rear
C
Unit.
Figure
2-1.
Dimensional
Drawing
TB-004
287-A
OM-804
Page
1
SECTION
3
-
OPERATION
400
Amp
Fuse
Weld
Power
Input
Plug
TB-004
288-A
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.
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.
R
TIfRa
R-v
3~0
z?.O
*C
.~~17x~fl3
-
=
~
(~MS
.Ofi7~/C~O
L?~70~flS
Coarse
Amperage
Control
Electrode
Receptacle
Figure
3-1.
Component
Location
3-1.
COARSE
AND
FINE
AMPERAGE
CONTROL
Rear
View
3-2.
FUSE
PROTECTION
IMPORTANT
It
is
imperative
that
the
fuse
be
replaced
with
one
of
the
same
size
and
rating.
Failure
to
comply
may
result
in
damage
to
the
welding
control
station.
0.11.
M
5Y~lTLH
Pri~lT1c1\l
I
-~
ELE
CTR.LCE
..~_)
~
.~
_,
L
~
-
COILS
()
I
?
-~
4
5
~
7
o
30
lCO
153
&33
~5Q
300
-
3~0
o
I
l,~
J~3
(~a~
1L3f,5
?,2,3.~S,L.
l,2~3;1,.~j
Z~
?,4
~
2./,~
?,4I~SiC
~4,2,/i~
2~4,h~s~I,l~?I4
flNE
POSITICfJ
O.E.m
~WIr~H
-POSII1DPJ
DESI
.E~
AT\~P
~3IL
.S~VIT~fi
TEP.f~1IfJ~L
c
I
Z.
3
4
S
~
7
3
.::~
o
~S
10
I~
?JJ
Z5
31.
3.~
40
~.S
t~
~
~
8~
E,iO
~IO
lU~,Il
5,10)11
5~lC
.1/
~S~.Q~il
r
-
Z
~
2,4
2,~
4~.
~
Z,Io,P,
4,&.f~
~
RE~ISTOR~.
~(,.
I7~
Circuit
Diagram
No.
ME-00367
Page
2
Figure
3-2.
Circuit
Diagram
June
1976
FORM:
OM-804A
Effective
with
Serial
No.
MEHGOO3136
MODEL
STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
PARTS
LIST
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
MODEL
MPG-395
STOCK
NO.
003
932
NWSA
CODE
NO.
4579
.0
E
(0
(0
C.
E
0
0
a)
I-
N
I-
C
e-.
c.,l
L~)
cJ
0
0
O
I-
N-
CD
CD
C.,
N
N
N
N
N
C)
N
C
C.,
OM-804
Page
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
004
767
004
055
004
057
004
763
004
764
004
059
004
760
004
353
Fl
*004
367
006
783
039
633
004 636
056
271
010
907
602
213
601
837
004
056
004
766
004 772
004
773
004
771
004
770
004
762
004
759
004
768
004
417
006 789
006 790
006
791
004
637
601
837
602 213
010
907
039 628
039 630
006
782
004
769
006
788
006
784
19
10
2
1
1
1
1
1
1
1
2
1
2
7
1
1
1
1
1
1
2
1
1
1
1
1
1
1
BE
SURE
TO
PROVIDE
STOCK,
MODEL,
AND
SERIAL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
Item
Dia.
Factory
No.
Mkgs.
Part
No.
Figure
A
omplete
Assembly
WRAPPER
I~NSULATOR,
wire
TUBING,steel
l1/32ODx
17/64lDx7/16
F~ANEL,
support
-
rear
IfANEL,
heat
exchange
-
rear
~UBlNG,
steel
11/32
OD
x
17/64
ID
x
2
US
BAR,
interconnecting
resistors
BUS
BAR,
fuse
link
to
plug
ILINK,
fuse
400
amp
250
volts
FfIANEL,
rear
CONNECTOR,
quick
connect
-
twistlock
female
F~
LUG,
with
components
(consisting
of)
PLUG,
twistlock
NUT,
locking
1
inch
WASHER,
lock
-
steel
split
3/8
NUT,
brass
-
hex
1am
3/8-16
INSULATOR,
bus
bar
~ASE
F~ESISTOR,
grid
2.15
ohm
16
Ig
w/tubing
&
pins
F~ESISTOR,
grid
4.70
ohm
16
Ig
w/tubing
&
pins
ESISTOR,
grid
1.37
ohm
16
1gw/tubing
&
pins
~ESlSTOR,grid
0.40
ohm
16
lg
w/tubing
&
pins
F~ANEL,
support
-
front
F~ANEL,
heat
exchange
-
front
ILINK,
jumper
-
switch
7
connector
~
US
BAR,
switch
to
bus
bar
~WITCH,
rotary
25
amp
600
volts
(consisting
of)
.~KNOB
SPACER
AECEPTACLE,
with
components
(consisting
of)
NUT,
brass
-
hex
jam
3/8-16
WASHER,
lock
-
steel
split
3/8
NUT,
locking
1
inch
RECEPTACLE,
twistlock
-
insulated
I
LUG,
twistlock
-
male
insulated
NAMEPLATE
(order
by
stock,
model,
and
serial
numbers)
F~ANEL,
front
~US
BAR,
link
to
receptacle
SWITCH,
rotary
45
amp
600
volts
(consisting
of)
JKNOB
R9
R8
R10,Rll
Ri
-7
S2
Si
OM-804
Page
2
.1
-
1
-
2
-
3
-
4
-
5
-
6
-
7
-
8
Miller MPG-395 Owner's manual
- Category
- Welding System
- Type
- Owner's manual
- This manual is also suitable for
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