Miller Electric MARK VIII-2 Owner'S Manual Download Page 1

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Processes

OM-218

029 920Z

July 2005

MARK VIII-2

Visit our website at

www.MillerWelds.com

Description

Air Carbon Arc (CAC-A) Cut-

ting and Gouging

TIG (GTAW) Welding

Stick (SMAW) Welding

MIG (GMAW) Welding

Arc Welding Power Source

With Optional Equipment:

Air Plasma Cutting

and Gouging

Flux Cored (FCAW) Welding

Summary of Contents for MARK VIII-2

Page 1: ...sit our website at www MillerWelds com Description Air Carbon Arc CAC A Cut ting and Gouging TIG GTAW Welding Stick SMAW Welding MIG GMAW Welding Arc Welding Power Source With Optional Equipment Air P...

Page 2: ...tinue 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...

Page 3: ...And Preparing Weld Output Cables 12 4 4 Weld Cable Size 13 4 5 Connecting Weld Output Cables 14 4 6 Connecting To Weld Output Terminals 14 4 7 Remote Amperage Control Receptacle 17 4 8 Remote Contact...

Page 4: ...Notes...

Page 5: ...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...

Page 6: ...ustibles such as a butane lighter or matches from your person before doing any welding D Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher...

Page 7: ...computers and communicationsequipment D Have only qualified persons familiar with electronic equipment perform this installation D The user is responsible for having a qualified electrician prompt ly...

Page 8: ...ccupational 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 o...

Page 9: ...norme OSHA 29 CFR 1910 147 voir normes de s curit D Installer le poste correctement et le mettre la terre convenablement selon les consignes du manuel de l op rateur et les normes nationales provinci...

Page 10: ...poches telles qu un allumeur au butane ou des allumettes D Suivre les consignes de OSHA 1910 252 a 2 iv et de NFPA 51B pour travaux de soudage et pr voir un d tecteur d incendie et un ex tincteur pro...

Page 11: ...provoquer des interf rences avec les quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs D Demander seulement des personnes qualifi es familiaris es avec d...

Page 12: ...art Q and Part 1926 Subpart J de U S Government Printing Office Superinten dent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux r gionaux le t l phone de la r gion 5 Chicago est 312...

Page 13: ...V DC 220 V 230 V 380 V 440 V 460 V 575 V KVA KW 800 A 40 Volts DC 100 Duty Cycle 1600 A 40 Volts DC 25 Duty Cycle 200 A 40 Volts DC 60 Duty Cycle 80 178 8 170 8 103 5 89 4 85 4 68 3 2 68 3 18 48 6 2 6...

Page 14: ...ts 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 1000 amperes at 60 percent duty cycle This value co...

Page 15: ...4 Line Disconnect Device Locate unit near correct input pow er supply OR 1 3 Movement Location And Airflow 18 in 4 460 mm 18 in 460 mm Do not block airflow to bottom of unit 18 in 460 mm 18 in 460 mm...

Page 16: ...ef ST 144 570 A Ref S 0653 1 Weld Output Cable Determinetotal cable length in weld circuit and maximum welding am peres Use Section 4 4 to select proper cable size Use shortest cables possible Do not...

Page 17: ...4 0 2 2 0 2 3 0 2 4 0 2 4 0 500 4 0 4 0 4 0 2 2 0 2 3 0 2 4 0 1000 1000 600 4 0 4 0 2 2 0 2 3 0 2 4 0 1000 1000 2 750 700 4 0 2 2 0 2 3 0 2 4 0 1000 1000 2 750 2 750 800 2 2 0 2 2 0 2 3 0 2 4 0 1000...

Page 18: ...ve electrical parts Turn Off polyweld system by pressing Power Off push button before making any weld output connections Do not connect welding output of different polarities to the same structure See...

Page 19: ...egative terminal and Frame Connection terminal and connect electrode holder to Positive terminal Tools Needed 1 1 4 in Separate Work Connections Common Work Connections 6 7 3 2 8 9 4 1 5 Y READ SAFETY...

Page 20: ...from Negative terminals to a suitable connection point con necting to a single electrode holder cable For Electrode Positive Reverse Polarity DCEP connect jumper link across Negative terminal and Fra...

Page 21: ...control To connect a remote contactor control proceed as follows 1 Terminal Strip 1T 2 Access Hole Location Drill or punch a hole in lower right rear panel to provide access to terminal strip 1T Hole...

Page 22: ...r ent input voltages and are factory set for the highest input voltage Check input voltage available at site Open rear panel access door to check jumper links 1 Input Voltage Label Look at jumper link...

Page 23: ...r Supplied Route conductors cord through strain relief and tighten screws 3 Machine Grounding Terminal 4 Green Or Green Yellow Grounding Conductor Connect green or green yellow grounding conductor to...

Page 24: ...Consult factory for circuit breaker applications 2 Time Delay fuses are UL class RK5 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amp and UL cl...

Page 25: ...le The numbers are weld amperes 3 Remote Hand Control Example Of Combination Remote Amperage Control Set Switch Adjust Remote Control Set Desired Maximum Amperage Min 35 A Max 125 A Control can be adj...

Page 26: ...085 382 1 Overload Supplementary Protecotr CB1 Supplementary protector CB1 pro tects the 115 volts ac windings of control transformer T3 from over load If CB1 opens the 115 volts ac duplex receptacle...

Page 27: ...ype fuses FX1 and FX2 X represents the number of the appli cable module 1 8 If one fuse link for a module opens low weld output is available at the applicable mod ule If both fuse links open no weld o...

Page 28: ...only Check fuse links and replace if needed see Section 6 2 Low weld output from one module only No amperage control Place Remote Amperage control switch in Off position or connect remote amperage co...

Page 29: ...OM 218 Page 25 Notes...

Page 30: ...OM 218 Page 26 SECTION 7 ELECTRICAL DIAGRAM Figure 7 1 Circuit Diagram For Polyweld System...

Page 31: ...OM 218 Page 27 SD 082 527 C...

Page 32: ...210 100 180 5 32 360 450 40 55 200 275 160 240 3 16 450 720 55 80 250 350 190 300 1 4 720 950 80 125 325 450 250 400 2 Thorium Alloyed Tungsten Red Band 010 Up to 25 Up to 20 Up to 15 020 15 40 15 35...

Page 33: ...1 1 1 2 Times 2 Electrode Diameter 8 3 Preparing Tungsten For DC Electrode Negative DCEN Welding Ref S 0161 Ref S 0162 1 Tungsten Electrode 2 Tapered End Grind end of tungsten on fine grit hard abras...

Page 34: ...Select and prepare tungsten according to Sections 8 1 and 8 2 or 8 3 Tungsten extension is the distance the tungsten extends out gas cup of torch Arc length is the distance from the tungsten to the wo...

Page 35: ...OM 218 Page 31 9 3 Positioning Torch Tungsten For Various Weld Joints ST 162 003 S 0792 70 70 90 20 20 10 20 70 40 30 20 70 90 20 Butt Weld And Stringer Bead T Joint Lap Joint Corner Joint...

Page 36: ...OM 218 Page 32 SECTION 10 PARTS LIST 1 2 3 4 5 6 7 8 9 10 16 17 18 19 20 23 24 8 5 6 ST 144 531 D 25 Hardware is common and not available unless listed 12 11 15 26 Figure 10 1 Main Assembly Section A...

Page 37: ...18 102 207 PLATE adapter power cord 1 19 087 124 FRAME mtg module center 2 020 279 CLAMP stl cush 750dia x 281mtg hole 6 087 318 CLAMP stl cush 1 000dia x 203mtg hole 6 20 T1 128 492 TRANSFORMER pwr...

Page 38: ...OM 218 Page 34 1 2 3 4 5 6 8 9 10 7 ST 144 660 Hardware is common and not available unless listed Figure 10 2 Main Assembly Section B...

Page 39: ...13 WASHER lock stl split 375 3 038 804 STUD brs 375 16 x 2 500 3 010 913 WASHER flat brs 218 ID x 460 OD x 031thk 4 8 F11 82 012 237 FUSE PANEL module includes 4 038 888 STUD pri bd brs 250 20 x 1 500...

Page 40: ...red 1 9 182 665 TERMINAL pwr output neutral 1 10 181 246 TERMINAL pwr output black 1 11 CB11 083 432 SUPPLEMENTARY PROTECTOR man reset 1P 10A 250V 1 12 R11 222 736 RHEOSTAT WW 150W 15 ohm 1 13 RC11 0...

Page 41: ...073 690 PLUG str grd armd 2P3W 15A 125V P S 5266DF 14 CB1 083 432 SUPPLEMENTARY PROTECTOR man reset 1P 10A 250V 1 15 026 758 BOOT circuit breaker 1 16 038 805 COVER rcpt weatherproof duplex 1 17 004 4...

Page 42: ...Notes...

Page 43: ...nd Blankets APT SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Co...

Page 44: ...retain with your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal S...

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