Miller Electric MARK VIII-2 User Manual

ProcessesOM-218 029 920ZJuly 2005MARK VIII-2Visit our website atwww.MillerWelds.comDescriptionAir Carbon Arc (CAC-A) Cut-ting and GougingTIG (GTAW) We

OM-218 Page 6Le rayonnement de l’arc du procédé de soudagegénère des rayons visibles et invisibles intenses(ultraviolets et infrarouges) susceptibles

OM-218 Page 72-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenanceRisque D’INCENDIE OU D’EXPLO-SION.D Ne p

OM-218 Page 82-5. Principales normes de sécuritéSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,de Global Engineering Documents

OM-218 Page 9SECTION 3 − SPECIFICATIONS3-1. SpecificationsRated WeldingOutput For MainRated WeldingOutput For EachAmperes Input at Rated Load Output,

OM-218 Page 103-3. Duty Cycle And OverheatingDuty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overheating.If unit overh

OM-218 Page 11SECTION 4 − INSTALLATIONssb9.1 5/94 − ST-801 180 / ST-144 567-A1 Lifting Eye2 Lifting ForksUse lifting eye or lifting forks tomove unit.

OM-218 Page 124-2. Dimensions, Weights And Base Mounting Hole LayoutOverall dimensions (A, B, and C) include lifting eye, handles, hardware, etc.NOTED

S-0008-COM-218 Page 134-4. Weld Cable SizeTotal Cable (Copper) Length In Weld Circuit Not Exceeding*50 ft Or Less(15m)100 ft(30m)150 ft(45 m)200 ft(60

OM-218 Page 144-5. Connecting Weld Output Cables803 778-BY Turn off power before connecting toweld output terminals.Y Failure to properly connect weld

OM-218 Page 15A. Standard Module ConnectionsST-144 568-C1 Cable RestraintRoute all cables under cablerestraint.Separate Work ConnectionsSee Section 4-

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-218 Page 16B. Parallel Module Connections1 Cable RestraintRoute all cables under cablerestraint.Separate Work ConnectionsSee Section 4-4 for proper

OM-218 Page 17ST-144 570-A / Ref. ST-174 1431 Remote Amperage ControlReceptacles RCX1 (“X”Represents The Number OfThe Applicable Module 1−8)The twistl

OM-218 Page 18Ref. ST-144 570-A / Ref. SC-085 3821 115 Volts AC DuplexReceptacle RC2This receptacle supplies up to 10amperes of 115 volts ac power.The

OM-218 Page 19B. Connecting Input Powerssb2.4* 1/94 − Ref. ST-144 569-BTools Needed:3/8 in1-1/16 in7108496Y Installation must meet all National andLoc

OM-218 Page 204-11. Electrical Service GuideInput Voltage220 230 380 440 460 575Input Amperes At Rated Output178 170 103 89 85 68Max Recommended Stand

OM-218 Page 21Ref. ST-174 1431 Remote Amperage ControlSwitchFor front panel control of a module,place switch on that module in Offposition.For remote

OM-218 Page 22SECTION 6 − MAINTENANCE & TROUBLESHOOTINGST-144 567-A3 MonthsCleanAndTightenWeldTerminals6 MonthsTape OrReplaceCrackedCablesReplaceU

OM-218 Page 23B. Control Fuses F3 And F4Ref. ST-144 569-B / Ref. ST-146 126-CTurn Off polyweld system and dis-connect input power.1 Input Terminal Boa

OM-218 Page 246-4. TroubleshootingY Turn Off polyweld system, and disconnect input powerbefore inspecting, maintaining, or servicing.Trouble RemedyNo

OM-218 Page 25Notes

TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbo

OM-218 Page 26SECTION 7 − ELECTRICAL DIAGRAMFigure 7-1. Circuit Diagram For Polyweld System

OM-218 Page 27SD-082 527-C

OM-218 Page 28SECTION 8 − SELECTING AND PREPARINGTUNGSTEN ELECTRODEgtaw 7/97For additional information, see your distributor for a handbook on the Gas

OM-218 Page 298-2. Preparing Tungsten For AC Or DC Electrode Positive (DCEP) WeldingRef. S-01611 Tungsten Electrode2 Balled EndY Understand and follow

OM-218 Page 30SECTION 9 − GUIDELINES FOR TIG WELDING (GTAW)9-1. Positioining The TorchST-161 892Y Weld current can damageelectronic parts in vehicles.

OM-218 Page 319-3. Positioning Torch Tungsten For Various Weld JointsST-162 003 / S-079270°70°90°20°20°10°20°70°40°30°20°70°90°20°Butt Weld And String

OM-218 Page 32SECTION 10 − PARTS LIST1234567891016171819202324856ST-144 531-D25. Hardware is common andnot available unless listed.12111526Figure 10-1

OM-218 Page 33DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 10-1. Main Assembly (Section A)Quantity1 FM1,2 032 605 MOTOR, cap perm SP 1/4hp 230VAC 1625RPM

OM-218 Page 3412345689107ST-144 660. Hardware is common andnot available unless listed.Figure 10-2. Main Assembly (Section B)

OM-218 Page 35DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 10-2. Main Assembly (Section B)Quantity1 CR1 194 307 CONTACTOR, def prp 40A 3P 120V 1. . . . .

Notes

OM-218 Page 36DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 10-3. Panel, Front Module w/Components (Fig 10-1 Item 24)Quantity1 034 253 DOOR, access pwr out

OM-218 Page 37DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 10-4. Panel, Front Lower w/Components (Fig 10-1 Item 25)Quantity1 +086 855 PANEL, front lower 1

Notes

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 1/05Your distributor also givesyou ...ServiceYou always get the fa

PRINTED IN USA © 2005 Miller Electric Mfg. Co. 1/05Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

OM-218 Page 1SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USINGsom _3/05Y Warning: Protect yourself and others from injury — read and follow these pre

OM-218 Page 2Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Sparks

OM-218 Page 31-3. Additional Symbols For Installation, Operation, And MaintenanceFIRE OR EXPLOSION hazard.D Do not install or place unit on, over, or

OM-218 Page 41-5. Principal Safety StandardsSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,from Global Engineering Documents (p

OM-218 Page 5SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATIONsom _3/05Y Avertissement : se protéger et protéger les autres contre le risque