Miller Electric MOG-250 Owner's Manual
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Miller Electric MOG-250 Owner's Manual

Miller Electric MOG-250 Owner's Manual

Multiple operator resistance grids (mog), racks, and remote controls
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www.MillerWelds.com
MOG-250/250, MOG-300, MOG-350/350,
MOG-400, MOG-Pak, And RGC Controls
OM-808
081 904F
January 1997
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
Multiple Operator Resistance Grids
(MOG), Racks, And Remote Controls

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Summary of Contents for Miller Electric MOG-250

  • Page 1 MOG-250/250, MOG-300, MOG-350/350, MOG-400, MOG-Pak, And RGC Controls Visit our website at www.MillerWelds.com OM-808 081 904F January 1997 Processes TIG (GTAW) Welding Stick (SMAW) Welding Description Multiple Operator Resistance Grids (MOG), Racks, And Remote Controls...
  • Page 2 ISO 9001 Quality System Standard. service information for your 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 catalog sheets.

  • Page 3: Table Of Contents

    The following terms are SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING used interchangeably 1-1. Symbol Usage throughout this manual: 1-2. Arc Welding Hazards TIG = GTAW 1-3. Additional Symbols for Installation, Operation, and Maintenance Stick = SMAW 1-4. Principal Safety Standards 1-5.

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

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. Means “Note”; not safety related. 1-2.
  • 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: Emf Information

    1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields 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 years of research, a special blue ribbon committee of the National Research Council concluded that: “The body of evidence, in the committee’...

  • Page 9: Section 1 - Consignes De Securite - Lire Avant Utilisation

    SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT 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. Y Identifie un message de sécurité particulier. Signifie NOTA ;...
  • Page 10 LES RAYONS DE L’ARC peuvent pro- voquer des brûlures dans les yeux et sur la peau. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer 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

    1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLOSION. D Ne pas placer l’appareil sur, au-dessus ou à proxi- mité de surfaces infllammables. D Ne pas installer l’appareil à proximité de produits inflammables D Ne pas surcharger l’installation électrique –...

  • Page 12: Principales Normes De Sécurité

    1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402.

  • Page 13: Section 2 - Specifications

    SECTION 2 – SPECIFICATIONS 2-1. Resistance Grid Specification 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 Rated Welding Amperes...

  • Page 14: Section 3 - Installation

    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.

  • Page 15: Selecting A Location And Moving Resistance Grid Or Multi-Grid Rack

    3-2. Selecting A Location And Moving Resistance Grid Or Multi-Grid Rack Have two persons of adequate physical strength lift individual grids at handles. Front Rear Front Y Turn Off welding power source BEFORE moving grid or rack. Locate grid(s) near welding power source.

  • Page 16: Weld Input/Output Cables For Resistance Grid (Dual Model Shown)

    3-3. Weld Input/Output Cables For Resistance Grid (Dual Model Shown) Tools Needed: OM-808 Page 12 Y Turn Off welding power source, and disconnect in- put power before making any weld output connections. Weld Input Cable Work Cable Weld Output Cable If necessary, use Section 3-7 to select proper cable size.

  • Page 17: Weld Input/Output Cables For Multi-Grid Rack

    3-4. Weld Input/Output Cables For Multi-Grid Rack Y Turn Off welding power source, and disconnect input power before making any weld output connections. Tools Needed: Weld Input Cable Work Cable Weld Output Cable If necessary, use Section 3-7 to select proper cable size. Use shortest cables possible.

  • Page 18: Female Camlok Connector Assembly

    3-5. Female Camlok Connector Assembly 1 in (26 mm) Tools Needed: 3-6. Male Camlok Connector Assembly 1 in (26 mm) Tools Needed: OM-808 Page 14 7/32 in 7/32 in Weld Input Cable Strip insulation as shown. Copper Strip (Two Included) Connector Body Wrap strip around bare weld cable (use two on small diameter cable),...

  • Page 19: Weld Cable Size

    3-7. Weld Cable Size* 100 ft (30 m) Or Less Welding 10 To 60% 60 Thru 100% Amperes Duty Cycle Duty Cycle 2-2/0 2-2/0 *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. 3-8.

  • Page 20: Section 4 - Operation

    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.

  • Page 21: Work Clamp

    4-3. Work Clamp 4-4. Optional Polarity Switch 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.

  • Page 22: Amperage Controls

    4-5. Amperage Controls CAUTION ARCING can damage switch. Do not change position of any Amperage control or switch while welding or under load. Arcing inside switch can damage contacts, causing switch to fail. In Example: Total Amperage Output = 122.5 A (100 A + 2.5 A) OM-808 Page 18 Coarse Amperage Control...

  • Page 23: Optional Remote Grid Amperage Control

    4-6. Optional Remote Grid Amperage Control 4-7. Paralleling Switch (Dual Models Only) CAUTION ARCING can damage switch. Do not change Paralleling switch position while welding or under load. Arcing inside switch can damage contacts, causing switch to fail. Remote amperage control only works when Fine Amperage control and optional 2-1/2 Ampere switch are in the Off position (see Section...

  • Page 24: Sequence Of Shielded Metal Arc Welding (Smaw)

    4-8. Sequence Of Shielded Metal Arc Welding (SMAW) Install & Select Connect Electrode Equipment Begin Welding 4-9. Sequence Of Gas Tungsten Arc Welding (GTAW) Install & If Applicable, Connect Install High_ Equipment Frequency Unit Turn On If Applicable, Shielding Gas Turn On High- Frequency Unit SECTION 5 –...

  • Page 25: Fuse Link Location

    5-2. Overload Protection Grid Rear Panel Multi-Grid Rack 5-3. Troubleshooting Trouble No weld output. Check and replace open fuse link(s), if necessary (see Section 5-2). Check electrical input and output connections (see Section 3-3). Erratic or improper weld output. Select correct size weld cables according to Section 3-7. Clean and tighten weld cable connections (see Section 3-3).

  • Page 26: Section 6 - Electrical Diagrams

    SECTION 6 – ELECTRICAL DIAGRAMS SA-044 882-A Figure 6-1. Circuit Diagram For 300 Ampere Model SA-096 447-A Figure 6-2. Circuit Diagram For 300 Ampere Model With Polarity Reversing OM-808 Page 22...
  • Page 27 SA-044 884-A Figure 6-3. Circuit Diagram For 400 Ampere Model SA-096 445-A Figure 6-4. Circuit Diagram For 400 Ampere Model With Polarity Reversing OM-808 Page 23...
  • Page 28 SA-044 886-A Figure 6-5. Circuit Diagram For 250/250 Ampere Model SB-124 202 Figure 6-6. Circuit Diagram For 250/250 Ampere Model With Polarity Reversing OM-808 Page 24...
  • Page 29 SA-087 783-A Figure 6-7. Circuit Diagram For 350/350 Ampere Model SA-095 027-A Figure 6-8. Circuit Diagram For Remote Grid Controls OM-808 Page 25...

  • Page 30: Section 7 - Parts List

    SECTION 7 – PARTS LIST Hardware is common and not available unless listed. ST-124 640-A Figure 7-1. Main Assembly OM-808 Page 26...
  • Page 31 Item Dia. Part Mkgs. Figure 7-1. Main Assembly ... . 049 472 . . . RAIL, grid ... . 049 470 .
  • Page 32 Item Dia. Part Mkgs. Figure 7-1. Main Assembly (Continued) ... 049 563 . . . RESISTOR ASSEMBLY, current (Fig 3) ... 049 615 .
  • Page 33 Item Dia. Part Mkgs. Figure 7-2. Panel, Front w/Components ..011 609 . . . SWITCH, tgl SPDT 15A 125V S8,9 011 609 . . . SWITCH, tgl SPDT 15A 125V ..... . . NAMEPLATE, (order by model and serial number) .
  • Page 34 Item Dia. Part Mkgs....049 479 ..... 059 841 .
  • Page 35 Item Dia. Part Mkgs....049 570 ....049 570 ....049 480 .
  • Page 36 Hardware is common and not available unless listed. OM-808 Page 32 Figure 7-4. MOG-Pak 6 APR SD-080 254-E...
  • Page 37 Item Part Figure 7-4. MOG-Pak 2, 4, & 6 049 758 ANGLE, guard 049 690 ANGLE, guard 049 541 ANGLE, guard 123 154 LABEL, general precautionary +085 342 ROOF ..........+085 341 ROOF .
  • Page 38 Item Part Figure 7-5. Remote Control ..080 194 . . . WRAPPER ... . 138 033 . . . CONNECTOR, circ clamp .
  • Page 39 Warranty Questions? Call LIMITED WARRANTY – Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants 1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold for your local after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.

  • Page 40: Options And Accessories

    Parts) Circuit Diagrams Welding Process Handbooks File a claim for loss or damage during shipment. 2000 Miller Electric Mfg. Co. 6/00 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters–USA USA Phone: 920-735-4505 Auto-Attended USA &...

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