Miller MPG-395B Owners manual

March

1981

MPG-395B

MODEL

FORM:

OM-807A

OWN

ERS

MANUAL

MILLER

S.

718

APPLETON,

ADDITIONAL

ELECTRIC

BQUNDS

NWSA

PRINTED

WI

COPY

CODE

ST.

IN

P.O.

54912

PRICE

NO.

U.S.A.

4579

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Trademark

of

Proctor

&

Gamble.

OM-807

Page

3

2.

Electrode

insulated

Fully

use

holders

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Connectors

insulated

Fully

welding

4.

Cables

Frequently

IMMEDIATELY

damaged

bared

cable.

resistance

cable

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hot

metal

5.

Terminals

Terminals

have

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6.

Electrode

Electrode

switch

of

gun

trigger

HOT

other

7.

Safety

devices

Safety

not

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OFF

all

switches)

nect

all

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line-cord

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with

cable

lengths.

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wire

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parts.

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power

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REPLACE

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Page

4

SECTION

-

2

INTRODUCTION

Rated

Model

Amperes

395

Ampere

2-1.

GENERAL

A.

General

Information

labels,

ment

tags,

design,

presented

and

installation,

troubleshooting

followed

ment.

B.

The

installation,

for

Safety

the

troubleshooting

practices

and

be

persons

plicable

the

Arc

Safety

pear

words
different

WARNING

____________

and

carefully

loss

or

and

the

safety

installed,

end

accordance

in

codes

Section

of

operated,

Welding

instructions

throughout

I~Li:hII~IeI

levels

maintenance

followed

life.

of

procedures

such

Power

statements

Welding

100%

395

INFORMATION

plates

which

safe

and

operation,

of

arc

of

others.

and

as

-

1

Source.

specifically

this

manual
and

of

hazard.

procedcures

could

Current

Duty

Cycle

in

this

manual

the

on

unit

operation,

should

be

read,

effective

maintenance,

welding

which

ensure

Therefore,

maintained

with

this

not

Satety

limited

Rules

but

pertaining

highlighted

IsLtIIlIi]il

include

resultinserious

installation,

or

practices

Welding

Coarse

Ranges

50

Ampere

Increments

Figure

AND

SAFETY

and

pertains

maintenance,

understood,

this

of

use

equipment

personal

this

equipment

only

by

those

to,
For

Operation

to

and

this

manual

by

which

which

personal

Current

Ranges

5

Increments

2-1.

various

on

to

equip

and

and

equip-

and

requires

safety

is

to

qualified

all

ap

listed

at

Of

unit

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the

signal

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Fine

Ampere

Height

Width

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tq~tiiIIIhI

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to

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signal

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RECEIVING-HANDLING

equipment,

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unit

occurred

carrier.

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willbefurnished

file

claim

requesting

it

is

Style)

DESCRIPTION

function

from

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also

by

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-

-

12-1/2

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22-1 /4

statements

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to

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arises.

essential

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as

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electrode

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equipment.

IMPORTANT

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of

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the electrode

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mm

306mm

565

mm

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packing

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Model

Description

equipment

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damage

input

circuitry.

Net

48.75

22.1

minor

highlights

obtain

to

Prior

material

damage

by

of

lading

request

be

grid

station

source.

cable

is

to

Weight

53

lb.

24

kg.

operating,

which

personal

instruc

the

to

installing

from

around

that

the

purchaser

and

freight

if

occasion

this

equip

and

supplied.

is

designed

remotely

It

provides

from

a

receptacle

be

connected,

Control.

due

to

excess

Ship

lb.

kg.

if

not

injury

most

may

Serial

the

This

a

1/2

(12.7

in.

Figure

3-1.

Dimensional

SECTION

Drawing

TC-070

3-

INSTALLATION

840

3-1.

LOCATION

-

The

3-1)

maintenance

for

per

consists

inside

dust

IMPORTANT

______________

unit

for

legibility.

tained

necessary.

tionary

The

when

in

labels.

service

the

moisture,

location

of

removing

the

a

clearly

See

life

unit

corrosive

MAINTENANCE

&

should

unit.

and

the

allow

repair.

wrapper

Periodically

All

precautionary

readable

Parts

List

for

and

efficiency

is

subjectedtohigh

vapors

and

room

Preventive

and

inspect

labels

state

number

part

this

of

extreme

the

and

levels

remove

to

maintenance

blowing

labels

must

replaced

of

unit

are

of

heat.

(Figure

out

on

be

all

precau

reduced

dust,

OM-807

wrap

main

when

dirt,

Page

the

the

5

3-2.

INPUT

~



Do



Shut

it

cannot

input

A

male

Camlock

of

the

resistance

from

the

female

plug

resistance

WELD

3-3.

the

full

rated

select,

Failure

than

The

install,

to

satisfactory

A.

Welding

steps

welding

1.

Keep

cØssive

reduces

CONNECTIONS

ELECTRIC

live

touch

not

down

the

welding

be

accidentally

connections.

receptacle

grid

welding

for

power

this

grid.

OUTPUT

output

and

maintain

comply

in

any

welding

Cables

listed

should

performance:

electrode

cable

output.

Welding

Amperes,

NOTE:

DC

100

150
200
250
300
350

400

500
600

700
800
900

1000

1250

1500
1750

2000

A.

B.

C.

SHOCK

electrical

power

is

for

provided

connecting

source.

receptacle

CONNECTIONS

from

this

of

these

performance.

followed

be

cables

as

length

~50

4
2

1

1/0

2/0 2/0

3/0

3/0

4/0

4/0

4/0

22/0

2-3/0

2-3/0
2-4/0

500MCM
1000MCM
1000MCM

FEET

50
CABLE

4

VOLTS

PER

AMP.

~NELD

CIRCUIT
MOST

100

VOLTS,

ER

OPEN-CIRCUIT

kill.

can

parts.

source

energized

the

The

is

unit,

proper

areas

to

short

adds

and

before

the

rear

on

electrode

corresponding

-

is

necessary

with

To

supplied

it

welding

result

may

ensure

as

resistance

the

possible.

Table

100 150

1/0

3/0

3/0

4/0
4/0
4/0

2-2/0 2-3/0 2-4/0

2-3/0

2-3/0

2-4/0

500MCM

1000MCM

1000MCM 1000MCM

OR

LESS.

SIZEISBASED

OR

LESS

CABLE

VOLTAGE

WELDING

SOME

Total

4

2

1 1

500MCM
1000MCM
1000MCM 1000MCM

ON

DROP

INSULATION

IOCV)

POWER

WELDING

VOLTAGE.

be

sure

making

panel

cable

the

obtain

cables.

in

less

best

Ex

which

3-1.

Length

2

2

1/0

2/0

3/0

3/0

4/0

2-2/0
2-3/0

2-4/0
2-4/0

DIRECT

OR

A

WITH

OF

SOURCES

POWER

to

Welding

Of

Cable

200 250

2

1

1/0

2/0
3/0

4/0
4/0

2-2/0
2-3/0
2-4/0

500MCM
1000MCM
1000MCM
1000MCM

CURRENT

CURRENT

A

THE

WELDING

HAVE

SOURCES

2.

Select

ticipated

to

resistance

3.

Do

4.

Install

adequate

select

not

maximum

the

grid

use

electrode

manufacturers

trode

holder

safety.

5.

Install

supplied

of

____

not

electrode

ELECTRIC

touch

that

making

male

B.

WARNING:



Do



Ensure

before

1.

end

Installation

Connect

receptacle.

Cable

DENSITY

VOLTAGE

AN

Size

Weld

In

(Copper)

2

1/0

2/0
3/0 4/0
4/0

2-2/0

2-2/0

2-3/0

2-4/0

SOOMCM

1000MCM
1000MCM
1000MCM 1000MCM 1000MCM
1000MCM

1000MCM

100%

(DC),

OF

RATING

POWER

OPEN-CIRCUIT

OF

SPECIAL

Circuit

2-2/0

2-3/0 2-3/0 2-4/0

2-3/0

2-4/0

500MCM

1000MCM

1000MCM
1000MCM

1000MCM

DUTY

NOT

OVER

TO

SOURCE

size

and

damaged

instructions.

must

male

holder

(Figure

live

electrical

the

unit

any

Camlock

300

1

2/0

3/0

CYCLE

300

WITHSTAND

MUST

VOLTAGE

DESIGN

size

welding

weld

current.

needed

cable

electrode

the

or

frayed

holder

to

An

used

be

to

Camlock

cable.

4-1)

SHOCK

can

parts.

is

completely

weld

output

to

plug

350

1/0 1/0
3/0
4/0

2-2/0

2-3/0

2-4/0 2-4/0

500MCM

1000MCM

1000MCM
1000MCM 1000MCM

1000MCM

AND

CIRCULAR

BE

MAY

OF

USED.

HAVE

THE

LESS

1000MCM
1000MCM
1000MCM

1000MCM

EITHER

OPEN-

WHILE

THAN

HIGH

for

cable

Table

Use

between

holder.

cables.

cable

following

insulated

ensure

plug

operator

to

remaining

kill.

shut

connections.

female

400

3/0

4/0

2-2/0

2-3/0

TA-052

MILS

Camlock

764

A

the

an

3-1

the

elec

down

can

4-1.

(Figure

panel

Page

WARNING

cause






6

HOT

burns.

Allow

equipment

vicing.

Wear

correct

Do

not

place

operation.

COARSE

-

Two

4-1)

the

of

resistance

SURFACES

hand

anything

AND

controls

to

and

FINE

grid

cool

on

AND

before

body

protection.

near

or

AMPERAGE

are

provided

for

adjusting

SECTION

EQUIPMENT

inspecting

unit

the

CONTROL

the

on

the

current

4

ser

or

during

front

-

OPERATION

output

vary

Fine

ampere

provide

selected
the

Amperage

85

of

the

current

Amperage

increments.

weld

by

Coarse

amperes.

the

unit.

Control

output

Coarse

the

Amperage

Control

The

output

in

is

set

Coarse

in

50

adjusts

The

Fine

addition

Amperage

Control

at

ampere

is

35,

Amperage

increments.

the

current

Amperage

50

the

to

Control.

set

at

available

50

weld

ampere

and

Control

output

Control

range

Example:

the

output

will

The

in

will

Fine

5

If

is

CAUTION

tacts.

I

Arcing

tually

Coarse

ARCING

Do

not

causes

change

while

we/ding

the

trols

inoperative.

the

contacts

can

damage

posit/on

under

or

become

to

of

any

load.

switch

Amperage

and

pitted

con-

Con

even

4-2.

FUSE

resistance
cessive
behind

the

grid

overload

hinged

PROTECTION

is

protected

fuse

by

rear

access

link

from

Fl.

panel.

(Figure

damage

This

fuse

4-1)

due

is

-

This

to

ex

located

WELD

OFF

54

104.

154.

204.
254

304.

35

40

454

INPUT

FINE

A.

A

POWER

-

Fine

POSITIONS

Amperage

Control

RESISTORS

1

2

2

1&2

~.3

4

3&

2,3&$

1,2,3&4

TC-070

840

Figure

4-1.

Component

Locations

QR6Q

OUTPUT

ELECTRODE

IN

PARALLEL

COARSE

OFF

504

ICCA

1

5~

CA

3

20

2504.

3004.

35C4

POSITIONS

5

A,

6

5&

6

&

8

5,7&8

6,7&8
5,6,&8

Circuit

e
0

IfiQ

L

OIEWED

Diagram

QR7QQ

C~~0

P

RESISTOR

FROM

No.

GRID

SWITCH

A-070

I

I

-J



END

472

Figure

4-2.

Circuit

Diagram

OM-807

Page

7

March

1981

MPG-395B

MODEL

FORM:

OM-807A

PARTS

LIST

813

10-070

Assembly

Complete

-

A

Figure

I

--

13

0

0

-u

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure

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

R5-8

37

38
39
40

R2,3

*

Recommended

tWhen

BE

SURE

A

Fl

*027

RC2

t070

S2

RC1

Si

Ri
R4

ordering

TO

PROVIDE

070 272
070 616

070

279

049

478

070

271
070 273
070 406
049

585

267

070 268

070413
010

854
764

059

010855

853

010

271

056
039

633

010

907

497

047

782

070

525

663

070

059 807
059804

059

803

070 269

631

070

006

790

039

628

630

039
059

773

010

647

613

049

199

010

070

290

070 270
070 366

349

070

070

365

Spare

a

component

BAR,

resistor

BAR,
BAR,

BAR,

BAR,

rear

BAR,

link

BAR,

rear

speed

Assembly

connecting

connecting
connecting
connecting
connecting

input

300

input

No.2clipon

carrying

Complete

BUS

FRAME,

BUS

BUS

BUS

BUS

BAFFLE,

BUS

FUSE,

BUS

PANEL,
NUT,

HANDLE,

RETAINER,screw-No.2

FASTENER,

screw

RECEPTACLE,
CONNECTOR,
NUT,

locking

LABEL,

WRAPPER

BASE

BAFFLE,
SWITCH,
TUBING,

TUBING,

BUS

BAR,

PANEL,
KNOB,

1

general

front

current

copperl/4

copperi/4

output

front

switch

RECEPTACLE,

-

twistlock

PLUG,

HANDLE,

NAMEPLATE

PIN,
SWITCH,
TUBING,

RESISTOR,

BUS

RESISTOR,
RESISTOR,

RESISTOR,

Parts.

MODEL

male

switch

(order

spring-

compression

current

steel

25

BAR,

connecting

5

amp

20

10

originally

AND

displayingaprecautionary

SERIAL

-

resistors

-

resistors

-

resistors

-

resistors

-

resistors

250

-

slotted

volts

-

male

hd

amp

twistlock

twistlock-female

inch

precautionary

-

low

lPSx7/16

IPSx3/16

-

fine

-

twistlock

-

high

.275

amp

amp
amp

insulated

insulated

model&serial

by

5/32x1-1/4

IDx.O48wallxi

-

resistors

NUMBERS

No.

2

WHEN

numbers)

label,

ORDERING

the

label

should

REPLACEMENT

also

be

PARTS.

3

1

2
2

1

2

1

2

2

1

1

4

1

1

2

1

1

1

1

4

1

2

1

1

1

1

1

1
1

14

1

2

ordered.

OM-807

Page

2

r