Page 1
YAY
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MODEL
Miller®
\!ERNIER
FILE
RETURN
COPY
TO
RANGE
CONTROL
q
FOLDER
OWNER’S
IMPORTANT:
manual
emphasis
stalling,
instructions
safe
operation
install,
not
fully
PRINTEDINU.S.A.
and
operating,
operate,ormaintain
understand these
on
the
the
are
Read
and
power
safety
or
for
use
ofwelding
understand
source manual
material
maintaining
only
equipment.
instructions.
by
this
throughout
persons
unit.
the entire
used
this
Do
Contact
equipment.
trained
not
MANUAL
contents
with
this
unit,
both manuals,
This
and
experiencedinthe
allow
untrained
your
distributor
unit
of
both
with
before
and
persons
if you
this
special
in- ~o
these
do
to
Miller
Electric
Box
1079
Appleton,WI54912
Tel
414~734-9821
ADDITIONAL
COPY PRICE
Mfg.
u~-~
Co.
20 CENTS
Page 2
LIMITED
WARRANTY
This
warranty
LIMITED
tions
warrantstoits
Equipment
•
ship
No
accessories
engines,
•
the
engines
dateoforiginal
haveatwo
Exceptasspecified
to
components
year,
•
MILLERMATIC
wire including
not
Miller
ranted
within the following
menttothe
1.
2
3.
4. All
5. All other
6.
7.
provided
of
q~ Asamatterofgeneral
the
submittedbythe
supersedes
WARRANTY-Subjecttothe
hereof,
Miller
Electric
Distributor/Dealer that
furnishedbyMiller
and
materialasof
warranty is
warrantiesoftheir
result
or other
trade
are
warrantedby their
year
suchasspot
from defectinworkmanshipormaterial.
shallberequiredtohonor warranty
Equipmentinthe
original
Arc
weldms,
Load
banks
Original
main
(labor-1
welding
Replacementorrepair
Batteries
Millermatic
that
Miller
date of such
the time
madebyMiller
items
accessories
purchase,
warranty,
below,
having normal
welder tips,
parts that
nozzles
and
periods
user:
pcw~er
sourt~,
power
year
only)
guns,
feeder/guns
isnotifiedinwriting
failure.
original
all
previous
and
respective
comeincontact with
nozzle
eventoffailure
rectifiers
Feeders
parts,
policy
user
MILLER
Mfg. Co., Appleton,
is freefrom
and
placeofdeliverybyMiller.
with
respecttoengines,
manufactured by
other
items
manufacturers,
manufacturer
except
Tecumseh
Miller’s warranty
useful
lifeofless
relay
and
insulators
from
within
resulting
the
dateofdeliveryofEquip-
robots,
and
and
torches
exclusiveoflabor..60
within
only,
Miller
the
EFFECTIVE
warranties
terms
and
all
defectinworkman-
components.1
. .
foregoing
Wisconsin
new
and unused
others.
are
sold
subject
if any . All
for
one
year
engines
does
not
than
contactor
the
where failure
claims
on war-
froma defect
90 days
6
thirty
1301
may
honor
periods.
welding
months
FEBRUARY
andisexclusive
condi-
trade
Such
to
from
which
apply
one
(11
points.
does
year
1
year
3
years
1
year
days
days
claims
16,
ieee
with no
other
guaranteesorwarranties
In
the
with
therefore
or,
the
Miller
price (less
returnofthe
optionofrepairorreplacement
Appleton,
facility,
any
defectorfailure,
claim
ANY
TiON
BREACHOFCONTRACT WHICH,
MIGHT
CUSTOMOFTRADEORCOURSEOFDEAUNG,
ANY
FITNESS
ANY
CLUDED
WRITING,
ULTIMATE
USERS
EXPERIENCED
WELDING
CONSUMER USE.
TO,
MILLER’S
caseofMiller’s breachofwarrantyorany
respecttothe
shall
where
authorizedinwritingbyMillerinappropriate
reasonable
service
reasonable
Wisconsin.orFOB.,ata
therefore,nocompensation
kind
willbeallowed.
procedurestobe
ANY
EXPRESS
IMPLIED
AS
ARISEBYIMPLICATION,
IMPUED
FOR
AND ALL
AND
EXCEPT
AND
AND
qualityofany
be,atMiller’s
costofrepairorreplacement
stationor14)
depreciation
goodsatCustomer’s
Miller
shall
followed.
WARRANTY
WARRANTY,
TO
PERFORMANCE,
WARRANTYOFMERCHANTABIUTYOROF
PARTICULAR
EQUIPMENT
DISCLAIMEDBYMILLER.
AS
EXPRESSLY
MILLER PRODUCTS
PURCHASE
FOR
OPERATIONBYPERSONS
IN THE USE
EQUIPMENT
MILLER’S WARRANTIESDONOT
NO
RESELLERISAUTHORIZEDTOEXTEND
WARRANTIES
goods,
option
(1)
payment
AND NOT
TO,
of or
based
risk
wiNbeFOB.,
Upon
receiptofnoticeofapparent
instruct
the
NOT
GUARANTYORREPRESENTA
AND ANY
BUT
PURPOSE,
FURNISHEDBYMILLERISEX
PROVIDED BY
BY
COMMERCIAL/INDUSTRIAL
AND
ANY
for
CONSUMER.
expressed
the exclusive remedies
repairor12)
at an
credit
for
upon
actualumel
and
expense.
MILLER authorized
transportation costs
claimantonthe
PROVIDED
REMEDY FOR
FOR
THIS
OPERATIONOFLAW,
WITH
ARE
INTENDED
MAINTENANCE
FOR
CONSUMERS
or implied.
other
replacement
cases,
authorized
the purchase
MILLER’s
Factory,
service
warranty
HEREIN
PROVISION,
INCLUDING
RESPECT
MILLER
TRAINED
EXTEND
duty
(3)
upon
at
of
AND
-
TO
-
IN
FOR
AND
OF
OR
. .
..-
-.
,,~.
•-~.
.
.- .-
Page 3
FIgure
1-1.
GENERAL INFORMATION AND SAFETY
A.
General
Information
bels,
presentedinthis
tags,
and
design, installation,
leshooting which
lowed
for
the
safe
B.
Safety
The
installation,
leshootingofarc
and
procedures which ensure personal
safetyofothers.
stalled, operated,
sonsinaccordance
1-1.
DimensIons
platesonthe
operation,
shouldberead,
and
effective
operation,
welding
Therefore,
and
equipment
this
maintained
with
this
manual
unit
pertaintoequipment
maintenance,
understood,
useofthis
maintenance,
equipmentistobein
onlybyqualified
manual
SECTION
1—INTRODUCTION
TA1-121 783
andonvariousla-
and
troub
-
and
fol
-
equipment.
and
troub
-
requires practices
safety
and
the
-
per-
and
all
applicable
Codes
suCh
as,
but
not
limited
to,
those
of
Section
ing
Power Sourceinthe
1-Safety
Rules
welding
For
OperationOfArC
power
Manual.
Safety
pear
words
ent
WARN
and
carefully
or
carefully
or
tions
ficient
instructions specifically pertainingtothis
throughout
WARNING
levels
ING
maintenance
this
and
of hazard.
statements
proceduresorpractices
manual
followed could
lossoflife.
CAUTION
and
maintenance
statements
proceduresorpractices
followed could
damagetothis
A
third
signal
which
equipment.
word,
IMPORTANT,
need special
operationofthis
1-2.
RECEIVING-HANDLING
Before
rial
damage
claim
sit
copy of
installing this
from
around the
that
for
lossordamage
must be
filed
the
billoflading
may
by
equipment,
unit,
have
the
highlightedbythe
CAUTION
which
include installation,
resultinserious
include installation,
resultinserious
emphasistoobtain
equipment.
clean
and
carefully inspect
occurred
that
may
during
have
purchaser
willbefurnishedbythe
factureronrequestifoccasiontofile
When
ment,itis
Numberofthe
1-3.
This
the
connected,itfunctionsasa
tion
outputofthe
requesting
information concerning
essential
equipmentbesupplied.
DESCRIPTION
unitisa
ARC
control,
PAK
and
Vernier
welding
thereby
welding
that
Model
Range
power
limits
power
Description
Control
source.
maximum
the
maximum
source.
listedatthe
source
Owner’s
unit
identify
operation,
which if
personal
operation,
whichifnot
personal
highlights
all
instruc
the
mostef-
packing
shipment.
occurredintran-
with the
claim
carrIer.
arises.
this
and
potentiometer
When
properly
amperage
amperage
end
Weld
ap-
Signal
differ
not
injury
injury
mate
for
any
Any
manu
equip
Style
for
selec
-
-
-
-
A
-
-
-
OM-541 Page
1
Page 4
SECTION
17-PIn
ConnectIon
Process
ARC PAK
Receptacle
High Frequency
Remote
(see
From’
Control To
Control
SectIon
2-
INSTALLATION
ARC PAKWeldIng
2-2)
Range
Control
Remole
2-1.
Remove
nier Range
power
tionasthe
2-2.
A
HandorFoot
Control
Switch
LOCATION
one of
the
Control
source with
front panelofthe
INTERCONNECTIONS
WARNING: ELECTRIC
•
Do
not
touch live electrical
•
Shut
down
power
ploying
specting,
source
“lockout/tagging
installing,oradjusting.
Lockout/tagging
cking
line
disconnect
moving
fuses
red-tagging
ing
device.
wrapper
directly
the
face
high
and
procedures
from
circuit
Figure
screws,
onto
plate
welding
and
install
leftorright
facing the
power
SHOCK
can
sideofthe
same
source.
kill.
parts.
frequency
disconnect
unit
and
input
procedures”
power
beforein-
consistofpadlo
switchinopen
position,re-
fuse box,orshutting
breakerorother
disconnect
2-1.
the
Ver-
direc
welding
em-
off
and
InstallatIon
Connect
Range
welding
plug,
Connect
Control
the
lows:
lar
-
-
the
Control
power
and rotate
the 5-pin
into
high
frequency
align
fully
clockwise
5-Socket
Process
Frequency
17-pin
into
source
the
keyway,
ConnectIon
ControlToHigh
Unit
Receptacle
From
Remote
twistlock plug
the
Remote
as follows:
threaded
twistlock plug
collar
Control
align
fully
from
REMOTEINreceptacleonthe
unitonwelding
insert
plug,
(see
Figure 2-1).
power
and rotate
In
from
the
Receptacle
keyway,
clockwise.
the
Vernier
sourceasfol
threaded
TA- 122 004
Vernier
on
insert
Range
rear
of
col-
-
OM-541
Page
2
Page 5
3-1.
AMPERAGE CONTROL
This
control
provides
SECTION
the meansofadjusting the
3—
OPERATOR
amper-
CONTROLS
age
output
from
capability.
weld output.
minimumtomaximumofpower
Rotating
this
control
clockwise increases
source
SECTION
4-1.
OPERATION
Whenaremotehandorfootcontrolswitchandhighfre-
quency
source,
5-1.
Usage
and
A
1.
2.
5-2.
A
unit
are
used with
the control
switch
the
functions
SECTION
MAINTENANCE
and
shop
conditions
typeofmaintenance.
WARNING: ELECTRIC
.
Do
not
touch
•
Shut
down high
power
Range
or
Every
interconnecting cords
insulation jacket,
replace
Remove
ture
from electrical
TROUBLESHOOTING
WARNING: ELECTRIC
0
•
powersource
Control
leshooting,orservicing.
Troubleshootingtobe
fied
source,
Control
servicing.
six
months inspect
cords as necessary.
grease
Do
not
touch
Shut
down high
before inspecting,
persons.
will
live
frequency
and
before
for
particularlyatthe
and grime
parts
live
frequency
and
disconnect
ARC
PAK
as a
5—
determine
SHOCK
electrical
disconnect
inspecting,
the
Vernier
damage
from
components;
and
cord.
SHOCK
electrical
maintaining,
performed
4-SEQUENCE
welding
fine
power
amperage
MAINTENANCE&TROUBLESHOOTING
the
frequency
Can
kill.
parts.
unit
and
welding
the
Vernier
maintaining,
Range
Control
to or
breaksinthe
plug.
can
parts.
unit
and
the
Vernier
onlybyquali
Repair
or
mois
kill.
welding
Range
troub
-
-
-
OF
OPERATION
adjustmentofthe
pIe,anAmperage Control
provideafine
peres
(minimumtomaximum
foot
control switch.
Itisassumed
ingtoSection2of
with
the
functionofcontrols,
and
high
frequency
troubleisnot relatedtothe
ing
informationissuppliedtodiagnose
remedies
this
quency
caused
Use
gram while
the
cedures,
tion
function,
be
Problems
panel
plug.
If
the control does not
the
thereby
source
tightenifapplicable.
place,ifnecessary.
for someofthe
unit.
Check
unit
by welding
this
informationinconjunction
trouble
the
shouldbecontacted.Inall
the
strictly
followed.
with
Components,or2)
receptacle,orthe
interrupting
and
Amperage Control setting.
settingof200
amperage
that
the
this
the
Owner’s
performing
is not
remedied
nearest Factory
manufacturer’s
this
this
unit.
adjustmentof0
position)onthe
unit
was properly
manual, the
the
unit
were
working properly,
welding
troubles
welding
power
unit
signals
power
Manual for
source
troubleshooting procedures.
after
Authorized
casesofequipment
recommendations
fall
into
the
interconnecting cord
function,
cord
Check
the
maybedamaged internally,
between
Check
continuityofcord,
two
plug
For
exam
amperes
to 200
hand
installed
operatorisfamiliar
welding
process.
that
may
source
possible problems
malfunctions.
with
the
performing
categories:1)front
plug maybeloose
the
welding
connections,
power
The
and
develop
and
high
circuit
these
Service
accord
source
and
follow
provide
should
andre-
will
am
or
the
in
fre-
dia-
If
pro
Sta-
mal
and
in
power
and
-
-
-
-
OM-541
Page
3
Page 6
SECTION
A
6-
ELECTRICAL DIAGRAMS
+
I
OV.
C
Dia.
Part
Mkgs. No.
042 155
Ri
PLG1
PLG2
035 897
097866
073 296
090 890
097 994
039
600 343
097 922
115
117231
099 124
685
104
P
B
COMMAND
H
CONTACTOR
PLG
I
Diagram 6-1.
CIrcuit
PARTS
Description
Complete Assembly
POTENTIOMETER,
PLUG,17pin
CLAMP,
CABLE,
RECEPTACLE,5socket
CLAMP,
CABLE,
KNOB
CONNECTOR,
NAMEPLATE
CASE
CASE
cable
No,208/C
cable
No.165/C
SECTION,
SECTION,
carbon1turn2watt
M5-3106A-20-29P
97-3057-12-6
(orderbyft)
AN-3057-8
(orderbyft)
clamp-cable
(orderbymodel&serial
front/end
back/sides/end
<B
PLG2
Diagram
LIST
1000
M5-3106A-165-BS
1/2
inch
number)
D
Circuit
ohm
Diagram
No.
A-117
Quantity
1
1
1
2
1
1
15
1
2
1
1
1
502
ft
ft
BE
SURE
OM-541
Page
TO
PROVIDE
4
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
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