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OM-808 081 904F
January 1997
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
Multiple Operator Resistance Grids
(MOG), Racks, And Remote Controls
MOG-250/250, MOG-300, MOG-350/350,
MOG-400, MOG-Pak, And RGC Controls
Visit our website at
www.MillerWelds.com
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From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that bu
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TABLE OF CONTENTS The following terms are SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 used interchangeably 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 throughout this manual: 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 TIG = GTAW 1-
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SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions Means “Note”; not safety related. to avoid the hazards. 1-2. Arc Welding
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ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays Always ventilate confined spaces or use that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator. weld. Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87.1 li
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1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. Do not install or place unit on, over, or near Keep away from moving parts such as fans. combustible surfaces. Keep all doors, panels, covers, and guards Do not install unit near flammables. closed and securely in place. Do not overload building wiring – be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING UNIT can cau
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1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 3. Do not coil or drape cables around your body. years of resea
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SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 5/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Identifie un message de sécurité particulier. risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous au
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LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation. (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées Veiller toujours à bien aérer les espaces
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1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. Ne pas placer l’appareil sur, au-dessus ou à proxi- Rester à l’écart des organes mobiles comme le mité de surfaces infllammables. ventilateur. Maintenir fermés et fixement en place les portes, Ne pas installer l’appareil à proximité de produits inflammables panneaux, recouvrements et dispositifs de Ne pa
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1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. Règles de sécurité en soudage, coupage et procédés conne
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SECTION 2 – SPECIFICATIONS 2-1. Resistance Grid Specification Description Type Of Output Coarse: 50 Ampere Steps; Fine: 5 Ampere Steps; Optional: 2-1/2 Ampere* Overall Dimensions Height: 16 in (406 mm); Width: 16-1/2 in (419 mm); Length: 26 in (711 mm) 300 Ampere 400 Ampere 250/250 Ampere 350/350 Ampere Rated Welding Amperes 295 Amperes, 100% Duty 395 Amperes, 100% Duty 245 A, 490 A If Paralleled, 345 A, 690 A If Paralleled, Output Cycle Cycle 100% Duty Cycle 100% Duty Cycle Net Weight With Case
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SECTION 3 – INSTALLATION 3-1. Typical Multiple Operator System Component Relationships WARNING ELECTRIC SHOCK can kill; TWO TIMES NORMAL OPEN-CIRCUIT VOLTS exists between electrode holders of opposite polarity. • Do not touch live electrical parts. • Do not touch electrode holders of opposite polarity at the same time. • Separate electrode holders of opposite polarity to prevent contact. • Consult ANSI Z49.1 for common grounding safe practices. 1 Common Work Connection 2 Welding Power Source 3 L
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3-2. Selecting A Location And Moving Resistance Grid Or Multi-Grid Rack Turn Off welding power source BEFORE moving grid or rack. Locate grid(s) near welding power source. Resistance Grid Have two persons of adequate physical strength lift individual grids at handles. 1 18 in (460 mm) Open Space On Front Side Location should allow operation of controls. 2 1 2 Handles Use handles to lift unit. Multi-Grid Rack 3 Minimum 20 in (508 mm) Open Space On Front And Rear Sides Location should allow acce
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3-3. Weld Input/Output Cables For Resistance Grid (Dual Model Shown) Turn Off welding power source, and disconnect in- put power before making any weld output connections. 1 Weld Input Cable 2 Work Cable 3 Weld Output Cable If necessary, use Section 3-7 to select proper cable size. Use shortest cables possible. Do not use damaged cables. 4 Terminal Lug 9 Use lugs of proper amperage ca- pacity and hole size for connecting to common work, electrode hold- er(s), and weld output terminals (if 8 ap
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3-4. Weld Input/Output Cables For Multi-Grid Rack 1 Weld Input Cable Turn Off welding power source, and disconnect input 2 Work Cable power before making any weld output connections. 3 Weld Output Cable If necessary, use Section 3-7 to select proper cable size. Use shortest cables possible. Do not use damaged cables. 4 Terminal Lug Use lugs of proper amperage ca- pacity and hole size for connecting to common work, electrode hold- er(s), and weld output terminals (if applicable). 5 Common Work
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3-5. Female Camlok Connector Assembly 1 Weld Input Cable Strip insulation as shown. 1 2 2 Copper Strip (Two Included) 3 Connector Body 4 Wrap strip around bare weld cable (use two on small diameter cable), and insert into connector body. 3 4 Setscrew Tighten setscrew against copper 1 in strip. (26 mm) 5 Handle 6 Pin 6 Slide handle over connector body so holes align; secure by tapping pin into place. 5 Tools Needed: 7/32 in sb6.6* – ST-159 028 3-6. Male Camlok Connector Assembly 1 Weld Output Cab
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3-7. Weld Cable Size* Total Cable (Copper) Length In Weld Circuit Not Exceeding 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 100 ft (30 m) Or Less (45 m) (60 m) (70 m) (90 m) (105 m) (120 m) Welding 10 To 60% 60 Thru 100% 10 Thru 100% Duty Cycle Amperes Duty Cycle Duty Cycle 100 4 4 4 3 2 1 1/0 1/0 150 3 3 2 1 1/0 2/0 3/0 3/0 200 3 2 1 1/0 2/0 3/0 4/0 4/0 250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0 300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0 400 1/0 2/0 3/0 4/0 2-2/0
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SECTION 4 – OPERATION WARNING ELECTRIC SHOCK can kill. • Keep all panels and covers securely in place. • Do not touch electrode holders of opposite polarity at the same time. • Separate electrode holders of opposite polarity to prevent contact. • See ANSI Z49.1 and OSHA TITLE 29, CHAPTER XVII, PART 1910, Subpart Q. 4-1. Controls (Dual Model Shown) 1 Coarse Amperage Control 2 Paralleling Switch 1 2 1 Included on dual models only. 3 Optional Polarity Switch 4 2-1/2 Ampere Switch This switch is inc
