Miller MA021062A Owner's manual
- Category
- Welding System
- Type
- Owner's manual
This manual is also suitable for
OWNER’ MANUAL
© 2015 MILLER Electric Mfg. Co.
2015−11 FORM: OM-817G
Use above FORM number when ordering extra manuals.
Process Selector Control
1. Safety Symbol Definitions
DANGER! − Indicates a hazardous situation which, if not
avoided, will result in death or serious injury. The pos-
sible hazards are shown in the adjoining symbols or
explained in the text.
DANGER ! - Indique une situation dangereuse qui, si
elle n’est pas évitée, entraînera la mort ou des blessures
graves. Les éventuels risques sont représentés par les
symboles joints ou expliqués dans le texte.
Fsafe1 2013-10
Wear safety glasses with side shields.
Porter des lunettes de sécurité avec écrans latéraux.
Fsafe8 2013-10
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible ha-
zards are shown in the adjoining symbols or explained in
the text.
Indique une situation dangereuse qui, si elle n’est pas
évitée, entraînera la mort ou des blessures graves. Les
éventuels risques sont représentés par les symboles
joints ou expliqués dans le texte.
Fsafe2 2013-10
Have only trained and qualified persons install, operate,
or service this unit. Call your distributor if you do not
understand the directions. For WELDING SAFETY and
EMF information, read owner’s manual(s).
Ne confiez l’installation, l’exploitation ou l’entretien de cet
appareil qu’à des personnes compétentes et qualifiées.
Lire les directives de sécurité au début de ces
instructions et dans chaque section. Appeler votre
distributeur si vous ne comprenez pas les directives.
Lire le(s) manuel(s) d’utilisateur pour des
renseignements sur la SÉCURITÉ DE SOUDAGE et les
champs électromagnétiques.
Fsafe15 2013-10
NOTICE
Indicates statements not related to personal injury.
Signale des consignes non associées aux dommages
corporels.
Indicates special instructions.
Fournit des instructions spéciales.
Fsafe3 2013-10
Hot parts can burn. Allow cooling period before working
on equipment. Do not touch hot parts bare handed. To
handle hot parts, use proper tools and/or wear heavy,
insulated welding gloves and clothing to prevent burns.
Les pièces chaudes peuvent provoquer des brûlures.
Prévoir une période de refroidissement avant de travail-
ler à l’équipement. Ne pas toucher à mains nues les
parties chaudes. Ne pas toucher aux pièces chaudes,
utiliser les outils recommandés et porter des gants de
soudage et des vêtements épais pour éviter les brûlures.
Fsafe13 2015-06
Beware of electric shock from welding electrode or
wiring. Touching the electrode while in contact with the
work or ground can cause electric shock. Always wear
dry gloves. Keep all panels and covers closed.
Attention au risque d’électrocution due au contact avec
l’électrode de soudage ou les fils. Le fait de toucher
l’électrode tout en étant en contact avec la pièce ou la
terre peut provoquer une électrocution. Toujours porter
des gants secs. Tous les panneaux et couvercles
doivent rester fermés.
Fsafe6 2013-10
CALIFORNIA PROPOSITION 65 WARNINGS
PROPOSITION CALIFORIENNE 65 AVERTISSEMENTS
Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth de-
fects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.)
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.
Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de
Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers. (Code de santé et de
sécurité de Californie, chapitre 25249.5 et suivants)
Ce produit contient des produits chimiques, notamment du plomb, dont l’État de Californie reconnaît qu’ils provoquent des cancers,
des malformations congénitales ou d’autres problèmes de procréation. Se laver les mains après utilisation.
Fsafe4 2013-10
OM-817 Page 2
2. Specifications
800 202-A
Process Selector Control For SMAW, GTAW, GMAW, And FCAW Welding Processes
Rated At 100 Volts, 650 Amperes At 30% Duty Cycle
Electrically Isolates Weld Current At Electrodes
Allows Changing Process Without Changing Cable Connections
3. Location And Mounting
1 Welding Power Source
2 Process Selector Control
Place control as shown.
3 Brackets (Optional)
4 Intellitig Unit
Use brackets as shown when at-
taching control to a D-60 model
wire feeder or Intellitig unit.
Tools Needed:
1
2
2
3
4
ST-800 214-A / ST-800 215-A
4. Duty Cycle
3 Minutes Welding 7 Minutes Resting
Duty Cycle is percentage of 10 minutes
that unit can weld at rated load without
overheating.
NOTICE − 30% Duty Cycle at 650 Am-
peres. Exceeding duty cycle can damage
unit and void warranty.
OM-817 Page 3
5. Weld Cable Connections
.
See welding power source Owner’s Manual for weld cable and connection location information. See wire feeder Owner’s Manual for connection
location information as applicable. See High-Frequency unit Owner’s Manual for connection location information as applicable.
A. Connections For One Electrode Positive (+) And One Electrode Negative (−)
Ref. 099 082-C / Ref. 098 115-B
! Turn off welding power
source and disconnect input
power before making any in-
put or output weld cable con-
nections.
1 Electrode 1
2 Electrode 2
3 A Terminal
4 B Terminal
5 C Terminal
1
E #2
E #1
C
B
A
( + )
( − )
FROM ELECTRODE 2
FROM ELECTRODE 1
FROM WORK
FROM
POWER
SOURCE
S1
2 345
Tools Needed:
13/16 in.
B. Connections For One Electrode Either Polarity
Ref. 099 082-C / Ref. 098 115-B
! Turn off welding power
source and disconnect in-
put power before making
any input or output weld
cable connections.
1 Electrode 1
2 Bus Bar
3 Electrode 2
4 A Terminal
5 B Terminal
6 C Terminal
Tools Needed:
13/16 in.
E #2
E #1
C
B
A
( + )
( − )
CONNECT BUS BAR
FROM ELECTRODE
FROM WORK
FROM
POWER
SOURCE
S1
E #1 TO E #2
13 4562
OM-817 Page 4
C. Connections For Two Electrodes Same Polarity Connection (Electrode Positive Shown)
Ref. 099 082-C / Ref. 098 115-B
! Turn off welding power
source and disconnect in-
put power before making
any input or output weld
cable connections.
1 Electrode 1
2 Electrode 2
3 A Terminal
4 Bus Bar
5 B Terminal
6 C Terminal
Tools Needed:
13/16 in.
E #2
E #1
C
B
A
( + )
FROM ELECTRODE 2
FROM ELECTRODE 1
FROM
POWER
SOURCE
S1
CONNECT WORK TO POWER SOURCE ( − )
CONNECT BUS BAR
A TO B
12 3 564
D. Connections For One Electrode CV And One Electrode CC Connection (For Welding Power Source With
CV And CC Terminals)
Ref. 099 082-C / Ref. 098 115-B
! Turn off welding power
source and disconnect in-
put power before making
any input or output weld
cable connections.
1 Electrode 1
2 Electrode 2
3 A Terminal
4 B Terminal
5 C Terminal
Tools Needed:
13/16 in.
E #2
E #1
C
B
A
MIN. IND.
MAX. IND.
FROM ELECTRODE 2
FROM ELECTRODE 1
FROM
POWER
SOURCE
S1
CONNECT WORK TO POWER SOURCE ( − )
12 345
OM-817 Page 5
6. Remote 14 Receptacles Information
AJ
B
K
I
C
L
NH
D
M
G
E
F
Socket* Socket Information
Remote Contactor
A 24 volts AC.
B Contact closure to A completes 24 volts AC contactor control
circuit.
I 115 volts AC.
J Contact closure to I completes 115 volts AC contactor control
circuit.
G Circuit common for 24 and 115 volts AC circuits.
Remote
Amperage/Voltage
Control
C Command reference; +10 volts DC output to remote control.
D Remote control circuit common.
E 0 to +10 volts DC input command signal from remote control.
K Chassis common.
Remote Output Control
H Voltage feedback; +1 volt DC per 10 output (arc) volts.
L Not used.
M Mode select.
N Remote inductance control.
F Current feedback; +1 volt DC per 100 amperes.
7. Welding Power Source Remote 14 Receptacle And 115 Volt Receptacle Connections
ST-800 201-B / Ref. 800 101
1 Remote Control Plug
Connect to the welding power
source Remote 14 receptacle.
2 115 Volt Receptacle
Connect the 115 volt plug from
high frequency unit to this recep-
tacle.
3 Circuit Breaker CB1–Protects
unit from overload.
Y Pin K in welding power
source must be grounded.
See welding power source
circuit diagram to be sure.
1
2
3
OM-817 Page 6
8. Operation
ST-800 202-A / Ref. ST-162 505-B
1 Process Selector Switch
Make connections according to
Section 5. Place switch in correct
position for application. For GTAW
DC Electrode Negative (DCEN),
use Process 2 position. For GMAW
or SMAW DC Electrode Positive
(DCEP), use Process 1 position.
NOTICE − Arcing can damage
switch. Do not change Process Se-
lector switch position while weld-
ing.
NOTICE − Using unit with switch
between positions can damage
switch. Place switch lever fully left
or right.
1
OM-817 Page 7
9. Routine Maintenance
Y Disconnect power before maintaining.
3 Months
Replace
Unreadable
Labels
Repair
Or
Replace
Cracked
Cables
Clean
And
Tighten
Weld
Terminals
6 Months
Blow Out
Or
Vacuum
Inside
During Heavy
Service,
Clean Monthly
OR
When Necessary
Use a high temperature grease such as MILLER Part No. 156 738 to grease the switch mechanism.
10. Troubleshooting
Trouble Remedy
Switch does not work. Check connections and Process Selector switch position for desired application. If switch still does
not work, contact nearest Factory Authorized Service Agent.
OM-817 Page 8
11. Electrical Diagram
191 353-A
Figure 11-1. Circuit Diagram
OM-817 Page 9
12. Parts List
ST-801 362-B
1
2 3
4
5
6
7
8
10
11
12
13
14
15
16
17
18
19
9
20
Figure 12-1. Complete Assembly
OM-817 Page 10
Description
Part
No.
Dia.
Mkgs.
Item
No.
Figure 12-1. Complete Assembly
Quantity
1 134 327 LABEL, warning general precautionary 1... ...................... .. .....................
2 +159 588 WRAPPER 1... ..................... .. .............................................
3 159 587 DOOR, rear 1... ...................... .. ............................................
4 099 255 TERMINAL, pwr output neutral 5... ...................... .. ...........................
5 010 916 CONNECTION, cable clamp .075 1... ...................... .. .........................
6 190 156 CABLE, extension 11ft 1... ...................... .. ..................................
7 191 351 PLATE, control 1... ...................... .. ..........................................
8 PC1 197 769 CIRCUIT CARD ASSY, Relay 1... ...... ........... .. .............................
9 097 132 STAND-OFF, no 6 x 32, .31 hex .20h stl p 3... ...................... .. ..................
10 117 913 BRACKET, mtg switch 1... ...................... .. ...................................
11 S1 117 914 SWITCH, selector 1... ....... ........... .. .......................................
12 LS1 603 946 SWITCH, mag blwt lim 10A 125/250VDC SPDT 1... ...... ........... .. .............
13 RC3 134 837 RECEPTACLE, str grd 2P3W 15A 125V 1... ...... ........... .. ....................
14 190 153 CASE SECTION, front/bottom/rear 1... ...................... .. ........................
15 NAMEPLATE, (order by model and serial number) 1... ................................. ...........
16 239 388 MOUNT, nprn 15/16 OD 4... ...................... .. ..................................
17 010 650 PIN, spring CS .125 x 1.000 1... ...................... .. ..............................
18 019 603 KNOB, ball 1... ...................... .. .............................................
19 091 597 HANDLE, switch 1... ...................... .. ........................................
098 471 BUS BAR, interconnecting (1/8 x 1-1/4 x 3-3/8) 1............................ .. ..............
098 468 BUS BAR, interconnecting (1/8 x 1” x 2-1/8) 2............................ .. ................
098 466 BUS BAR, interconnecting (1/8 x 1” x 2-5/8) 1............................ .. ................
098 465 BUS BAR, interconnecting (1/8 x 1” x 3-1/4) 2............................ .. ................
098 469 BUS BAR, interconnecting (1/8 x 1” x 3-3/4) 1............................ .. ................
098 467 BUS BAR, interconnecting (1/8 x 1” x 4-1/2) 4............................ .. ................
059 805 TUBING, cop .540 OD x .123 wall x .312 lg 3............................ .. .................
059 804 TUBING, cop .540 OD x .123 wall x .437 lg 2............................ .. .................
049 633 TUBING, cop .540 OD x .123 wall x .500 lg 3............................ .. .................
049 611 TUBING, cop .540 OD x .123 wall x .687 lg 2............................ .. .................
145 898 BRACKET, mtg PR/IC rear 1............................ .. ...............................
145 900 BRACKET, mtg PR/IC front 1............................ .. ...............................
20 CB1 083 431 CIRCUIT BREAKER, 5 AMP, 250 VAC 1... ...... ........... .. .....................
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
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Miller MA021062A Owner's manual
- Category
- Welding System
- Type
- Owner's manual
- This manual is also suitable for
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