Miller Electric MARK VIII-2 Owner's Manual
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Miller Electric MARK VIII-2 Owner's Manual

Miller Electric MARK VIII-2 Owner's Manual

Arc welding power source
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www.MillerWelds.com
MARK VIII-2
OM-218
029 920Z
July 2005
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Air Carbon Arc (CAC-A) Cut-
ting and Gouging
With Optional Equipment:
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Air Plasma Cutting
and Gouging
Description
Arc Welding Power Source

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Summary of Contents for Miller Electric MARK VIII-2

  • Page 1 MARK VIII-2 Visit our website at www.MillerWelds.com OM-218 029 920Z July 2005 Processes TIG (GTAW) Welding Stick (SMAW) Welding Air Carbon Arc (CAC-A) Cut- ting and Gouging With Optional Equipment: MIG (GMAW) Welding Flux Cored (FCAW) Welding Air Plasma Cutting...
  • Page 2 ISO 9001:2000 Quality System Standard. particular model are also provided. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage ............... . 1-2.
  • Page 4 Notes...

  • Page 5: Section 1 − Safety Precautions - Read Before Using

    DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit volt- age. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone! D Disconnect input power or stop engine before installing or servicing this equipment.
  • Page 6 D Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over, or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit.

  • Page 8: Principal Safety Standards

    1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Recommended Safe Practices for the Preparation for Welding and Cut- ting of Containers and Piping, American Welding Society Standard F4.1 from Global...

  • Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés Symbole graphique d’avertissement ! Attention ! Cette pro- cédure comporte des risques possibles ! Les dangers éven- tuels sont représentés par les symboles graphiques joints.
  • Page 10 LES RAYONS D’ARC peuvent entraî- ner des brûlures aux yeux et à la peau. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provo- quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLO- SION. D Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces inflammables. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surcharger l’installation électrique −...

  • Page 12: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : www.global.ihs.com). Recommended Safe Practices for the Preparation for Welding and Cut- ting of Containers and Piping, American Welding Society Standard AWS F4.1 de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com).

  • Page 13: Section 3 − Specifications

    SECTION 3 − SPECIFICATIONS 3-1. Specifications Rated Welding Rated Welding Output For Main Output For Main Output For Each Output For Each Transformer Module 800 A @ 40 Volts DC, 100% Duty Cycle; 200 A @ 40 Volts DC, 1600 A @ 40 Volts DC, 60% Duty Cycle 25% Duty Cycle *While idling...

  • Page 14: Duty Cycle And Overheating

    3-3. Duty Cycle And Overheating For Each Module And Total System For Main Transformer The main transformer of the polyweld system has dual duty cycle ratings, each for a specific amperage output range. If the unit is operated in the 800 ampere range, the unit is rated at 100% duty cycle.

  • Page 15: Section 4 − Installation

    SECTION 4 − INSTALLATION 4-1. Selecting A Location And Moving Polyweld System Y Disconnect input power conductors from deenergized supply BEFORE moving polyweld system. Movement Location And Airflow 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) 18 in...

  • Page 16: Dimensions, Weights And Base Mounting Hole Layout

    4-2. Dimensions, Weights And Base Mounting Hole Layout NOTE Overall dimensions (A, B, and C) include lifting eye, handles, hardware, etc. Front 4-3. Selecting And Preparing Weld Output Cables 10 ft (3 m) 10 ft (3 m) OM-218 Page 12 Ref.

  • Page 17: Weld Cable Size

    4-4. Weld Cable Size 50 ft Or Less 100 ft (15m) (30m) Welding Amperes 2-2/0 2-2/0 2-2/0 2-3/0 2-3/0 1000 2-3/0 2-3/0 1250 2-4/0 2-4/0 1500 1750 1000 2000 1000 *Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. Contact your distributor for the mm equivalent weld cable sizes.

  • Page 18: Connecting Weld Output Cables

    4-5. Connecting Weld Output Cables Tools Needed: 3/4 in (19 mm) Y Turn off power before connecting to weld output terminals. Y Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your ma- chine.
  • Page 19 A. Standard Module Connections Y READ SAFETY BLOCKS at start of Section 4-6 before proceeding. INADEQUATE WORK CABLE CONNECTIONS can cause serious damage to input power service and create a hazardous condition. Connect an electrical cable of adequate size between the common work connection terminal and the workpiece whenever any mod- ule(s) is connected to use the frame connection terminal and the common work connection terminal.
  • Page 20 B. Parallel Module Connections Y READ SAFETY BLOCKS at start of Section 4-6 before proceeding. UNDERSIZED WELDING CABLES can cause fire. Use single cables of adequate capacity to carry the total combined am- perage of the paralleled modules (see Section 4-4) . Securely cover common connections with proper insulating materials.

  • Page 21: Remote Amperage Control Receptacle

    4-7. Remote Amperage Control Receptacle 4-8. Remote Contactor Control Connections (Optional) Y Turn Off polyweld system, and disconnect input power before making contactor control connections. Whenever the Remote Contactor switch is closed with Power switch On button pressed, input power is applied to all modules.

  • Page 22: 115 Volts Ac Duplex Receptacle

    4-9. 115 Volts AC Duplex Receptacle 4-10. Connecting Input Power A. Positioning Jumper Links Y Turn Off polyweld system, and disconnect input power 230 VOLTS Tools Needed: 3/8, 1/2 in OM-218 Page 18 115V 115V OVERLOAD BREAKER before inspecting or installing. 460 VOLTS 115 Volts AC Duplex Receptacle RC2...
  • Page 23 B. Connecting Input Power Tools Needed: 1-1/16 in 3/8 in Y Installation must meet all National and Local Codes − have only qualified per- sons make this installation. Y Disconnect and lockout/tagout input power before connecting input con- ductors from unit. Y Make input power connections to the welding power source first.

  • Page 24: Electrical Service Guide

    4-11. Electrical Service Guide Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Rating In Amperes Min Input Conductor Size In AWG Max Recommended Input Conductor Length In Feet (Meters) Min Grounding Conductor Size In AWG Reference: 2005 National Electrical Code (NEC) 1 Consult factory for circuit breaker applications.

  • Page 25: Amperage Adjustment Controls

    5-2. Amperage Adjustment Controls 60 Hz Model Shown Example Of Combination Remote Amperage Control Set Switch 5-3. Power Switch Push Buttons And Pilot Light Control can be adjusted while welding. Set Desired Maximum Amperage Remote Amperage Control Switch For front panel control of a module, place switch on that module in Off position.

  • Page 26: Section 6 − Maintenance & Troubleshooting

    SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance 3 Months Clean Tighten Weld Section Terminals Tape Or Replace Cracked Cables − − Replace Unreadable Labels 6-2. Overload Protection A. Overload Supplementary Protector CB1 And Module Supplementary Protectors CB11 Through CB81 OM-218 Page 22 Y Turn Off polyweld system, and disconnect input power before inspecting, maintaining, or servicing.

  • Page 27: Blank Module Panel

    B. Control Fuses F3 And F4 C. Module Fuse Links F11 And F12 Through F81 And F82 Tools Needed: 3/8, 1/2 in 6-3. Blank Module Panel A blank module panel is included with each polyweld system. If a module is removed, install the blank module panel in the location where the module was removed before using the remaining modules.

  • Page 28: Troubleshooting

    6-4. Troubleshooting Trouble No weld output from any module; fan Place line disconnect device in On position (see Section 4-10). motors off; pilot light off. Check line fuse(s), and replace if needed. Reset circuit breakers (see Section 4-10). Check for proper input connections (see Section 4-10). Check position of input voltage jumper links (see Section 4-10).
  • Page 29 Notes OM-218 Page 25...

  • Page 30: Section 7 − Electrical Diagram

    SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram For Polyweld System OM-218 Page 26...
  • Page 31 SD-082 527-C OM-218 Page 27...

  • Page 32: Section 8 − Selecting And Preparing

    SECTION 8 − SELECTING AND PREPARING TUNGSTEN ELECTRODE NOTE For additional information, see your distributor for a handbook on the Gas Tungsten Arc Welding (GTAW) process.Wear clean gloves to prevent contamination of tungsten electrode. 8-1. Selecting Tungsten Electrode Electrode Diameter DC −...

  • Page 33: Preparing Tungsten For Ac Or Dc Electrode Positive (Dcep) Welding

    8-2. Preparing Tungsten For AC Or DC Electrode Positive (DCEP) Welding 8-3. Preparing Tungsten For DC Electrode Negative (DCEN) Welding Ideal Tungsten Preparation − Stable Arc Wrong Tungsten Preparation − Wandering Arc 1-1/2 Times Electrode Diameter 2-1/2 Times Electrode Diameter Tungsten Electrode Balled End Y Understand...

  • Page 34: Section 9 − Guidelines For Tig Welding (Gtaw)

    SECTION 9 − GUIDELINES FOR TIG WELDING (GTAW) 9-1. Positioining The Torch 10−15 9-2. Torch Movement During Welding Tungsten Without Filler Rod Welding direction Form pool Tungsten With Filler Rod Welding direction Form pool OM-218 Page 30 10−25 Tilt torch Tilt torch Remove rod of pool.

  • Page 35: Positioning Torch Tungsten For Various Weld Joints

    9-3. Positioning Torch Tungsten For Various Weld Joints Butt Weld And Stringer Bead “T” Joint Lap Joint Corner Joint ST-162 003 / S-0792 OM-218 Page 31...

  • Page 36: Section 10 − Parts List

    SECTION 10 − PARTS LIST Hardware is common and not available unless listed. OM-218 Page 32 Figure 10-1. Main Assembly (Section A) ST-144 531-D...
  • Page 37 Item Dia. Part Mkgs..FM1,2 ..032 605 ....071 763 ..
  • Page 38 Hardware is common and not available unless listed. ST-144 660 Figure 10-2. Main Assembly (Section B) OM-218 Page 34...
  • Page 39 Item Dia. Part Mkgs... . . 194 307 ....092 324 ..
  • Page 40 Item Dia. Part Mkgs....034 253 ..... 032 477 .
  • Page 41 Item Dia. Part Mkgs....+086 855 ....217 136 .
  • Page 42 Notes...
  • Page 43 Warranty Questions? Call LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to 1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after for your local the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.
  • Page 44 File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. 2005 Miller Electric Mfg. Co. 1/05 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA...

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