Miller Electric MARK VIII-2 manual Standard Module Connections, Common Work Cable Size

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A. Standard Module Connections

YREAD SAFETY BLOCKS at start of Section 4-6before 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.

1 Cable Restraint

Route all cables under cable restraint.

Separate Work Connections

See Section 4-4for proper cable size.

2Negative (−) Weld Output Terminal

3Work Cable

4Positive (+) Weld Output Terminal

5Electrode Holder Cable

Separate Work Connections

Common Work Connections

4

2 3

5

1

8

9

6

7

YFor common work connection, work cable must be able to carry combined weld output of all modules using the common work connection terminal (see Table 3-1for proper cable size). When using the common work con- nection terminal, all connections to the common work connection terminal must be of the same polarity.

For Electrode Positive (Reverse Polarity/DCEP), connect work cable to Negative (−) terminal and electrode holder cable to Positive

(+) terminal.

For Electrode Negative (Straight Polarity/DCEN), reverse cable connections.

Common Work Connections

6Common Work Connection Terminal

7Common Work Cable

See Table 3-1for proper cable size.

8Frame Connection Terminal

9Jumper Link

For Electrode Negative (Straight Polarity/DCEN), connect jumper link across Positive (+) terminal and Frame Connection terminal, and connect electrode holder to Nega- tive (−) terminal.

For Electrode Positive (Reverse Polarity/DCEP), connect jumper link across Negative (−) terminal and Frame Connection terminal, and connect electrode holder to Positive (+) terminal.

Tools Needed: 1-1/4 in

ST-144 568-C

Table 3-1. Common Work Cable Size

Common Work Cable Sizes At Main Transformer

Rated Welding Current

Cable Length	Cable Size


50 Feet	2 No. 3/0
100 Feet	2 No. 4/0
150 Feet	3 No. 3/0
200 Feet	3 No. 4/0

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Contents Description OM-218From Miller to You Table of Contents Page Electric Shock can kill Symbol UsageMarks a special safety message Arc Welding HazardsBuildup of GAS can injure or kill ARC Rays can burn eyes and skinWelding can cause fire or explosion Flying Metal can injure eyesCalifornia Proposition 65 Warnings EMF Information Principal Safety StandardsAbout Pacemakers LES Fumées ET LES GAZ peuvent être dangereux UNE Décharge Électrique peut entraîner la mortIndique un message de sécurité particulier DES Pièces Chaudes peuvent provoquer des brûlures graves LE Soudage peut provoquer unIncendie ou une explosion DES Particules Volantes peuvent blesser les yeuxDES Organes Mobiles peuvent provoquer des blessures Risque D’INCENDIE OU D’EXPLOLA Chute DE L’APPAREIL peut blesser ’EMPLOI Excessif peut SUREn ce qui concerne les stimulateurs cardiaques Principales normes de sécuritéAmperes Input at Rated Load Output, 60 Hz − SpecificationsSpecifications Volt-Ampere CurvesOverheating Duty Cycle And OverheatingFor Each Module And Total System For Main TransformerLocation And Airflow − InstallationSelecting a Location And Moving Polyweld System MovementSelecting And Preparing Weld Output Cables Dimensions, Weights And Base Mounting Hole LayoutDimensions Weight150 ft 200 ft 250 ft Weld Cable Size350 ft 400 ft 15m 30m 45 m 60 m 70 m 90 m 105 m 120 m Connecting To Weld Output Terminals Connecting Weld Output CablesSeparate Work Connections Read Safety Blocks at start of -6before proceedingStandard Module Connections Common Work Cable SizeSeparate Work Connections Common Work Parallel Module ConnectionsRemote Contactor Control Connections Optional Remote Amperage Control ReceptacleTE3 TE2 Connecting Input PowerVolts AC Duplex Receptacle Positioning Jumper LinksDisconnect Device Input Power Connec- tions Connecting Input PowerWelding Power Source Input Power Con- nections Close and secure access door on welding power sourceControls Electrical Service GuideTime-Delay − OperationHz Model Shown Amperage Adjustment ControlsPower Switch Push Buttons And Pilot Light Min 35 a Max 125 a Set Switch Set Desired Maximum AmperageOverload Protection − Maintenance & TroubleshootingRoutine Maintenance MonthsControl Fuses F3 And F4 Blank Module PanelModule Fuse Links F11 And F12 Through F81 And F82 Turn Off polyweld system, and disconnect input power TroubleshootingBefore inspecting, maintaining, or servicing OM-218 Circuit Diagram For Polyweld System − Electrical DiagramSD-082 527-C Selecting Tungsten Electrode − Selecting and Preparing Tungsten ElectrodeAmperage Range Gas Type Polarity Preparing Tungsten For DC Electrode Negative Dcen Welding Positioining The Torch − Guidelines for TIG Welding GtawTorch Movement During Welding Butt Weld And Stringer Bead Joint Lap Joint Corner Joint Positioning Torch Tungsten For Various Weld JointsMain Assembly Section a − Parts ListTP1 Main Assembly Section B CR1 194 Panel, Front Module w/Components -1Item Panel, Front Lower w/Components Panel, Front Lower w/Components -1ItemPage Your distributor also gives ServiceSupport Your distributor and/or equipment manufacturer’s To locate a Distributor or Service Agency visitMiller Electric Mfg. Co For assistance in filing or settling claims, contact