Miller Electric Welding System Digi Meter RMS AC DC User Manual

OM-867  
083 696D  
December 1993  
OWNER’S  
MANUAL  
Digi-Meter 1500 RMS (AC/DC)  
Digital Ammeter/Voltmeter For Measuring Weld Output  
Accurately (±1%) Measures DC Or AC (RMS) Output  
Max. Capacity: 1500 Amperes, 100 Volts AC/DC At 100% Duty Cycle  
Includes 8 ft (2.4 m) 115 Volts AC Input Power Cord  
Displays To Nearest Ampere And 1/10 Volt  
Has Hold Feature Which Takes Readings After 10 Seconds Of Welding  
And Holds Displays For 15 Seconds After Welding Stops  
Read and follow these instructions and all  
Give this manual to the operator.  
safety blocks carefully.  
Have only trained and qualified persons  
install, operate, or service this unit.  
For help, call your distributor  
Call your distributor if you do not understand  
the directions.  
or: MILLER Electric Mfg. Co., P.O. Box 1079,  
Appleton, WI 54912  
414-734-9821  
1993 MILLER Electric Mfg. Co.  
cover 7/93 – ST-084 121-A  
PRINTED IN USA  
 
ARC WELDING SAFETY PRECAUTIONS  
ARC WELDING can be hazardous.  
WARNING  
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN  
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.  
In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The  
safety information given below is only a summary of the more complete safety information that will be found in the  
Safety Standards listed on the next page. Read and follow all Safety Standards.  
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY  
QUALIFIED PEOPLE.  
in disconnect box or that cord plug is connected to a properly  
groundedreceptacle outlet.  
ELECTRIC SHOCK can kill.  
Touching live electrical parts can cause fatal shocks  
or severe burns. The electrode and work circuit is  
electrically live whenever the output is on. The input  
power circuit and machine internal circuits are also  
live when power is on. In semiautomatic or automatic  
wire welding, the wire, wire reel, drive roll housing, and  
all metal parts touching the welding wire are  
electrically live. Incorrectly installed or improperly  
groundedequipment is a hazard.  
7. When making input connections, attach proper grounding  
conductor first double-check connections.  
8. Frequentlyinspect input power cord for damage or bare wiring –  
replace cord immediately if damaged bare wiring can kill.  
9. Turn off all equipment when not in use.  
10. Do not use worn, damaged, undersized, or poorly spliced cables.  
11. Do not drape cables over your body.  
1. Do not touch live electrical parts.  
12. If earth grounding of the workpiece is required, ground it directly  
2. Wear dry, hole-free insulating gloves and body protection.  
with a separate cable do not use work clamp or work cable.  
3. Insulate yourself from work and ground using dry insulating mats  
or covers big enough to prevent any physical contact with the  
work or ground.  
13. Do not touch electrode if you are in contact with the work, ground,  
or another electrode from a different machine.  
4. Disconnect input power or stop engine before installing or  
servicing this equipment. Lockout/tagout input power according  
to OSHA 29 CFR 1910.147 (see Safety Standards).  
14. Use only well-maintained equipment. Repair or replace  
damagedparts at once. Maintain unit according to manual.  
15. Wear a safety harness if working above floor level.  
16. Keep all panels and covers securely in place.  
5. Properly install and ground this equipment according to its  
Owners Manual and national, state, and local codes.  
6. Always verify the supply ground check and be sure that input  
17. Clamp work cable with good metal-to-metal contact to workpiece  
or worktable as near the weld as practical.  
power cord ground wire is properly connected to ground terminal  
ARC RAYS  
ARC RAYS can burn eyes and skin;  
NOISE can damage hearing; FLYING  
SLAG OR SPARKS can injure eyes.  
Arc rays from the welding process produce intense  
visible and invisible (ultraviolet and infrared) rays that  
can burn eyes and skin. Noise from some processes  
can damage hearing. Chipping, grinding, and welds  
cooling throw off pieces of metal or slag.  
2. 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 listed in Safety Standards).  
3. Wear approved safety glasses with side shields.  
4. Use protective screens or barriers to protect others from flash  
and glare; warn others not to watch the arc.  
NOISE  
5. Wear protective clothing made from durable, flame-resistant  
material(wool and leather) and foot protection.  
1. Use approved ear plugs or ear muffs if noise level is high.  
5. Work in a confined space only if it is well ventilated, or while  
wearing an air-supplied respirator. Always have a trained  
watchperson nearby. Welding fumes and gases can displace air  
and lower the oxygen level causing injury or death. Be sure the  
breathing air is safe.  
FUMES AND GASES can be hazardous  
to your health.  
Welding produces fumes and gases. Breathing these  
fumes and gases can be hazardous to your health.  
6. Do not weld in locations near degreasing, cleaning, or spraying  
operations.The heat and rays of the arc can react with vapors to  
form highly toxic and irritating gases.  
1. Keep your head out of the fumes. Do not breathe the fumes.  
2. If inside, ventilate the area and/or use exhaust at the arc to  
remove welding fumes and gases.  
3. If ventilation is poor, use an approved air-supplied respirator.  
4. Read the Material Safety Data Sheets (MSDSs) and the  
manufacturers instruction for metals, consumables, coatings,  
cleaners, and degreasers.  
7. Do not weld on coated metals, such as galvanized, lead, or  
cadmium plated steel, unless the coating is removed from the  
weld area, the area is well ventilated, and if necessary, while  
wearing an air-supplied respirator. The coatings and any metals  
containingthese elements can give off toxic fumes if welded.  
4. Never drape a welding torch over a gas cylinder.  
5. Never allow a welding electrode to touch any cylinder.  
6. Never weld on a pressurized cylinder explosion will result.  
7. Use only correct shielding gas cylinders, regulators, hoses, and  
fittings designed for the specific application; maintain them and  
associated parts in good condition.  
CYLINDERS can explode if damaged.  
Shielding gas cylinders contain gas under high  
pressure. If damaged, a cylinder can explode. Since  
gas cylinders are normally part of the welding  
process, be sure to treat them carefully.  
8. Turn face away from valve outlet when opening cylinder valve.  
1. Protect compressed gas cylinders from excessive heat,  
mechanical shocks, slag, open flames, sparks, and arcs.  
9. Keep protective cap in place over valve except when cylinder is  
in use or connected for use.  
2. Install cylinders in an upright position by securing to a stationary  
support or cylinder rack to prevent falling or tipping.  
3. Keep cylinders away from any welding or other electrical circuits.  
10. Read and follow instructions on compressed gas cylinders,  
associated equipment, and CGA publication P-1 listed in Safety  
Standards.  
sr1.1.1 2/94  
 
6. Be aware that welding on a ceiling, floor, bulkhead, or partition  
can cause fire on the hidden side.  
WELDING can cause fire or explosion.  
Welding on closed containers, such as tanks, drums,  
or pipes, can cause them to blow up. Sparks can fly off  
from the welding arc. The flying sparks, hot  
workpiece, and hot equipment can cause fires and  
burns. Accidental contact of electrode to metal  
objects can cause sparks, explosion, overheating, or  
fire. Check and be sure the area is safe before doing  
any welding.  
7. Do not weld on closed containers such as tanks, drums, or pipes,  
unless they are properly prepared according to AWS F4.1 (see  
Safety Standards).  
8. Connect work cable to the work as close to the welding area as  
practical to prevent welding current from traveling long, possibly  
unknown paths and causing electric shock and fire hazards.  
9. Do not use welder to thaw frozen pipes.  
1. Protect yourself and others from flying sparks and hot metal.  
2. Do not weld where flying sparks can strike flammable material.  
3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If  
this is not possible, tightly cover them with approved covers.  
4. Be alert that welding sparks and hot materials from welding can  
easily go through small cracks and openings to adjacent areas.  
5. Watch for fire, and keep a fire extinguisher nearby.  
10. Remove stick electrode from holder or cut off welding wire at  
contact tip when not in use.  
11. Wear oil-free protective garments such as leather gloves, heavy  
shirt, cuffless trousers, high shoes, and a cap.  
12. Remove any combustibles, such as a butane lighter or matches,  
from your person before doing any welding.  
ENGINES can be hazardous.  
WARNING  
ENGINE EXHAUST GASES can kill.  
1. Use equipment outside in open, well-ventilated areas.  
Engines produce harmful exhaust gases.  
2. If used in a closed area, vent engine exhaust outside and away  
from any building air intakes.  
3. Do not overfill tank allow room for fuel to expand.  
4. Do not spill fuel. If fuel is spilled, clean up before starting  
engine.  
ENGINE FUEL can cause fire or  
explosion.  
Engine fuel is highly flammable.  
1. Stop engine and let it cool off before checking or adding fuel.  
2. Do not add fuel while smoking or if unit is near any sparks or  
open flames.  
3. Have only qualified people remove guards or covers for  
maintenanceand troubleshooting as necessary.  
MOVING PARTS can cause injury.  
Moving parts, such as fans, rotors, and belts can cut  
fingers and hands and catch loose clothing.  
4. To prevent accidental starting during servicing, disconnect  
negative () battery cable from battery.  
5. Keep hands, hair, loose clothing, and tools away from moving  
parts.  
1. Keep all doors, panels, covers, and guards closed and  
securely in place.  
6. Reinstall panels or guards and close doors when servicing is  
finished and before starting engine.  
2. Stop engine before installing or connecting unit.  
1. Always wear a face shield when working on a battery.  
SPARKS can cause BATTERY  
GASES TO EXPLODE; BATTERY  
ACID can burn eyes and skin.  
2. Stop engine before disconnecting or connecting battery  
cables.  
3. Do not allow tools to cause sparks when working on a battery.  
4. Do not use welder to charge batteries or jump start vehicles.  
5. Observe correct polarity (+ and ) on batteries.  
Batteries contain acid and generate explosive  
gases.  
1. If the engine is warm and checking is needed, follow steps 2  
and 3.  
2. Wear safety glasses and gloves and put a rag over cap.  
3. Turn cap slightly and let pressure escape slowly before  
completely removing cap.  
STEAM AND PRESSURIZED HOT  
COOLANT can burn face, eyes, and  
skin.  
It is best to check coolant level when engine is cold  
to avoid scalding.  
PRINCIPAL SAFETY STANDARDS  
Safety in Welding and Cutting, ANSI Standard Z49.1, from American  
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126  
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,  
from Compressed Gas Association, 1235 Jefferson Davis Highway,  
Suite 501, Arlington, VA 22202.  
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-  
dent of Documents, U.S. Government Printing Office, Washington, D.C.  
20402.  
Code for Safety in Welding and Cutting, CSA Standard W117.2, from  
CanadianStandards Association, Standards Sales, 178 Rexdale Bou-  
levard, Rexdale, Ontario, Canada M9W 1R3.  
Recommended Safe Practices for the Preparation for Weldingand Cut-  
ting of Containers That Have Held Hazardous Substances, American  
Welding Society Standard AWS F4.1, from American Welding Society,  
550 N.W. LeJeune Rd, Miami, FL 33126  
Safe Practices For Occupation And Educational Eye And Face Protec-  
tion, ANSI Standard Z87.1, from American National Standards Institute,  
1430 Broadway, New York, NY 10018.  
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-  
Cutting And Welding Processes, NFPA Standard 51B, from National  
tion Association, Batterymarch Park, Quincy, MA 02269.  
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.  
sr1.1.1 2/94  
 
EMF INFORMATION  
Considerations About Welding And The Effects Of Low Frequency Electric And  
Magnetic Fields  
NOTE  
The following is a quotation from the General Conclusions Section of  
the U.S. Congress, Office of Technology Assessment, Biological  
Effects of Power Frequency Electric & Magnetic Fields –  
Background Paper, OTA-BP-E-53 (Washington, DC: U.S.  
GovernmentPrinting Office, May 1989): . . . there is now a very large  
volume of scientific findings based on experiments at the cellular  
level and from studies with animals and people which clearly  
establish that low frequency magnetic fields can interact with, and  
produce changes in, biological systems. While most of this work is  
of very high quality, the results are complex. Current scientific  
understandingdoes not yet allow us to interpret the evidence in a  
single coherent framework. Even more frustrating, it does not yet  
allow us to draw definite conclusions about questions of possible risk  
or to offer clear science-based advice on strategies to minimize or  
avoid potential risks.”  
To reduce magnetic fields in the workplace, use the following  
procedures:  
1. Keep cables close together by twisting or taping them.  
2. Arrange cables to one side and away from the operator.  
3. Do not coil or drape cables around the body.  
4. Keep welding power source and cables as far away as practical.  
5. Connect work clamp to workpiece as close to the weld as  
possible.  
About Pacemakers:  
The above procedures are among those also normally  
recommended for pacemaker wearers. Consult your doctor for  
complete information.  
mod10.1 4/93  
TABLE OF CONTENTS  
SECTION 1 SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
SECTION 2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
SECTION 3 INSTALLATION  
1
1
3-1.  
3-2.  
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
2
3
SECTION 4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
4
SECTION 5 MAINTENANCE & TROUBLESHOOTING  
5-1.  
5-2.  
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
5
5
SECTION 6 ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
6
SECTION 7 PARTS LIST  
Figure 7-1. Complete Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
8
OM-867D 12/93  
 
 
SECTION 1 SAFETY INFORMATION  
mod1.1 2/93  
Read all safety messages throughout this manual.  
Obey all safety messages to avoid injury.  
Learn the meaning of WARNING and CAUTION.  
1
2
Safety Alert Symbol  
Signal Word  
1
2
2
WARNING means possible death  
or serious injury can happen.  
WARNING  
CAUTION  
3
4
CAUTION means possible minor  
injury or equipment damage can  
happen.  
ELECTRIC SHOCK can kill.  
MOVING PARTS can injure.  
Do not touch live electrical parts.  
Keep away from moving parts.  
Disconnect input power before  
Keep all panels and covers closed  
3
Statement Of Hazard And Re-  
sult  
installing or servicing.  
when operating.  
4
Safety Instructions To Avoid  
Hazard  
5
5
6
Hazard Symbol (If Available)  
Safety Banner  
READ SAFETY BLOCKS at start of  
Section 3-1 before proceeding.  
WARNING  
Read safety blocks for each sym-  
bol shown.  
6
7
7
NOTE  
Special instructions for best oper-  
ation not related to safety.  
Turn Off switch when using high frequency.  
NOTE  
Figure 1-1. Safety Information  
SECTION 2 SPECIFICATIONS  
Table 2-1. Meter Specifications  
Specification  
Description  
Type Of Input Power  
Input Power Cord With Plug  
Voltage Sensing Cord With Clamp  
Overall Dimensions  
115 Volts AC, 50/60 Hz  
8 ft (2.4 m)  
21 ft (6.4 m)  
See Figure 3-1  
Weight  
Net: 13.5 lb (6.1 kg); Ship: 15 lb (7 kg)  
Max. Capacity At 100% Duty Cycle  
1500 Amps At 100 Volts AC/DC  
OM-867 Page 1  
 
SECTION 3 INSTALLATION  
WARNING  
ELECTRIC SHOCK can kill.  
FUMES can be hazardous; LACK OF  
FRESH AIR AND PROPER  
VENTILATION can be harmful.  
Do not touch live electrical parts.  
Turn Off welding power source and disconnect input  
power before inspecting or installing. Stop engine on  
welding generator.  
Do not breathe welding fumes.  
Place unit only where there is a good fresh air supply  
and proper ventilation.  
swarn11.1* 3/93  
3-1. Location  
Turn Off welding power source.  
1
Meter  
Place meter on bench, welding  
power source, or other convenient  
location.  
Inches  
6
Millimeters  
A
B
C
152  
295  
213  
11-5/8  
8-3/8  
1
A
B
C
ST-084 121-A  
Figure 3-1. Overall Dimensions  
OM-867 Page 2  
 
3-2. Connection Diagram  
WARNING  
READ SAFETY BLOCKS at start of  
Section 3 before proceeding.  
1
2
Welding Power Source  
Weld Cable (Customer  
Supplied)  
Using meter in applications where high-fre-  
quency output is used may cause poor arc  
starting and unreliable meter readings.  
See power source Owners Manual  
for proper size cable. Keep cable  
length between meter and arc as  
short as possible for more accurate  
readings.  
3
4
5
6
7
8
Meter  
Access Door  
Shunt Terminal  
SMAW Electrode Holder  
GTAW Torch  
Wire Feeder  
2
Open access door and connect  
weld cable from power source to  
either shunt terminal. Connect weld  
cable from electrode holder, torch  
or wire feeder to other shunt termi-  
nal.  
1
4
2
Close access door.  
9
115 VAC Cord/Plug  
OR  
10 115 VAC Grounded  
Receptacle  
Connect input power plug to weld-  
ing power source or other 115 VAC  
receptacle.  
3
11 Voltage Sensing Cord/Clamp  
12 Workpiece  
8
6
Connect voltage sensing clamp to  
workpiece.  
7
4
2
10  
12  
5
11  
9
ST-154 610-B / ST-155 327  
Figure 3-2. Connection Diagram  
OM-867 Page 3  
 
SECTION 4 OPERATION  
WARNING  
ELECTRIC SHOCK can kill.  
Always wear dry insulating gloves.  
Insulate yourself from work and ground.  
Do not touch live electrical parts.  
ARC RAYS can burn eyes and skin;  
NOISE can damage hearing.  
Wear welding helmet with correct shade of filter.  
Wear correct eye, ear, and body protection.  
Keep all panels and covers securely in place.  
MOVING PARTS can cause injury.  
FUMES AND GASES can be hazardous  
to your health.  
Keep away from moving parts.  
Keep all doors, panels, covers, and guards closed  
Keep your head out of the fumes.  
and securely in place.  
Ventilate area, or use breathing device.  
Read Material Safety Data Sheets (MSDSs) and  
MAGNETIC FIELDS FROM HIGH CUR-  
RENTS can affect pacemaker operation.  
Pacemaker wearers keep away.  
manufacturers instructions for material used.  
WELDING can cause fire or explosion.  
Do not weld near flammable material.  
Wearers should consult their doctor before going  
near arc welding, gouging, or spot welding opera-  
tions.  
Watch for fire; keep extinguisher nearby.  
Do not locate unit over combustible surfaces.  
Do not weld on closed containers.  
See Safety Precautions at beginning of manual for ba-  
Allow work and equipment to cool before handling.  
sic welding safety information.  
swarn6.1 10/91  
1
2
3
1
2
InsulatingGloves  
Safety Glasses With Side  
Shields  
3
Welding Helmet  
Wear dry insulating gloves, safety  
glasses with side shields, and a  
weldinghelmet with a correct shade  
of filter (see ANSI Z49.1).  
sb3.1 10/91  
Figure 4-1. Safety Equipment  
1
Voltmeter  
Displays to nearest 1/10 volt.  
Ammeter  
Displays to nearest ampere.  
Std./Hold Switch  
1
2
3
VOLTS  
2
HOLD  
3
STD.  
Use switch to select meters display  
function.  
AMPS  
In Std. (Standard) position, meters  
continuously display actual volts/  
amps while welding; preset value  
while idling.  
Example:  
STD.  
In Hold position, meters measure  
volts/amps after 10 seconds of  
welding and holds values on dis-  
plays for 15 seconds after welding  
stops.  
OCV  
OCV  
HOLD  
6 0 . 0  
5 0 . 0  
1 0 0  
6 0 . 0  
0 0 0  
0 0 0  
STD.  
Hold function does not work when  
welding amperage is less than  
60 A.  
Idling Value  
Start Welding Displays New Value Stop Welding  
Clears Value  
HOLD  
OCV  
OCV  
HOLD  
STD.  
6 0 . 0  
5 0 . 0  
5 0 . 0  
1 0 0  
6 0 . 0  
0 0 0  
1 0 0  
0 0 0  
After 10  
Seconds  
For 15  
Idling Value  
Start Welding  
Displays New Value Stop Welding  
Holds Value Seconds Clears Value  
ST-154 616  
Figure 4-2. Voltmeter/Ammeter And Std./Hold Switch  
OM-867 Page 4  
 
SECTION 5 MAINTENANCE & TROUBLESHOOTING  
WARNING  
ELECTRIC SHOCK can kill.  
HOT PARTS can cause severe burns.  
Do not touch live electrical parts.  
Allow cooling period before maintaining or servicing.  
Turn Off welding power source, and disconnect  
input power before inspecting, maintaining, or  
servicing. Stop engine on welding generator.  
Maintenanceand troubleshooting to be performed only  
by qualified persons.  
swarn8.1* 10/91  
5-1. Routine Maintenance  
3 Months  
Turn Off all power before maintaining.  
6 Months  
Blow Out  
Replace  
Unreadable  
Labels  
OR  
Or  
Vacuum  
Inside  
See  
Section  
7
– –  
Tape Or  
Replace  
Cracked  
Weld  
– –  
Cable  
Clean  
And  
Tighten  
Weld  
Terminals  
3-2  
ST-084 121-A  
Figure 5-1. Maintenance Schedule  
5-2. Troubleshooting  
WARNING  
READ SAFETY BLOCKS at start of  
Section 5 before proceeding.  
Table 5-1. Welding Trouble  
Trouble  
Remedy  
Section  
Unit completely inoperative; no meter  
display.  
Be sure input power cord is plugged in and that receptacle is receiv-  
ing input power.  
3-2  
Incorrect meter display.  
Check weld cable, input power, and voltage sensing connections.  
Turn off high frequency, if applicable.  
3-2  
3-2  
No display on one meter only; other me-  
ter works.  
Check connections to meter module; tighten or clean if necessary.  
Check and replace meter module if necessary.  
– –  
– –  
– –  
Have Factory Authorized Service Station/Service Distributor check  
digital meter board PC1.  
Erratic meter display.  
Check connections to meter shunt; tighten or clean if necessary.  
– –  
Meters do not hold display with Std./Hold  
switch in Hold position.  
Place switch in Std. position when welding amperage is below re-  
quired minimum.  
Figure 4-2  
Have Factory Authorized Service Station/Service Distributor check  
digital meter board PC1.  
– –  
OM-867 Page 5  
 
SECTION 6 ELECTRICAL DIAGRAMS  
SB-131 649  
Figure 6-1. Circuit Diagram  
OM-867 Page 6  
 
SC-132 589  
Figure 6-2. Wiring Diagram  
OM-867 Page 7  
 
SECTION 7 PARTS LIST  
1
2
7
6
5
4
3
29  
28  
30  
31  
8
9
10  
29  
13  
14  
15  
16  
17  
18  
12  
25  
26  
11  
24  
27  
19  
23  
28  
20  
21  
22  
ST-083 851-D  
Figure 7-1. Complete Assembly  
OM-867 Page 8  
 
Item  
No.  
Dia.  
Mkgs.  
Part  
No.  
Description  
Quantity  
Figure 7-1. Complete Assembly  
. . . 1 . . . . . . . . . . . . . . +082 980 . . . WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 2 . . . . . . . . . . . . . . . . 134 327 . . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 3 . . . . . . . . . . . . . . . . 025 248 . . . STAND-OFF, insul .250-20 x 1.250 lg x .437thk . . . . . . . . . . . . . . . . . . . 4  
. . . 4 . . . . . Shunt . . . . . 072 425 . . . SHUNT, meter 50MV 1500A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 5 . . . . . . . . . . . . . . . . 083 082 . . . BUS BAR, jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . . . . . . . . . . . . . . . . . . . . 604 126 . . . SCREW, cap stl hexhd .500-13 x 1.000 (connecting cables to  
digimeter shunt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . . . . . . . . . . . . . . . . . . . . 602 216 . . . WASHER, lock stl split .500 (connecting cables to digimeter shunt) . . 2  
. . . . . . . . . . . . . . . . . . . . . . 602 247 . . . WASHER, flat stl SAE .500 (connecting cables to digimeter shunt) . . . 2  
. . . . . . . . . . . . . . . . . . . . . . 601 879 . . . NUT, stl hex full .500-13 (connecting cables to digimeter shunt) . . . . . . 2  
. . . 6 . . . . C53,54 . . . . 143 461 . . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 7 . . . . . . . . . . . . . . . . 082 983 . . . WRAPPER, shunt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 8 . . . . . . . . . . . . . . . . 600 848 . . . WIRE, lead mot 12ga strd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21ft  
. . . 9 . . . . . . . . . . . . . . . . 601 226 . . . INSULATOR, vinyl clamp univ 25A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 10 . . . . . . . . . . . . . . . . 601 228 . . . CLAMP, univ 25A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 11 . . . . PLG50 . . . . 073 690 . . . PLUG, str grd armd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 12 . . . . . . . . . . . . . . . . 604 825 . . . CABLE, port No. 18 3/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8ft  
. . . 13 . . . . . . . . . . . . . . . . 131 708 . . . PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 14 . . . . . . . . . . . . . . . . 603 107 . . . HOSE, nprn slit bk .156 ID x .343 OD (order by ft) . . . . . . . . . . . . . . . . . 1ft  
. . . 15 . . . . . . . . . . . . . . . . 010 476 . . . BUSHING, strain relief .625 ID x .570mtg hole . . . . . . . . . . . . . . . . . . . . 1  
. . . 16 . . . . . . . . . . . . . . . . 131 709 . . . CASE SECTION, bottom/front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 17 . . . . . PC1 . . . . . 132 299 . . . CIRCUIT CARD, digital meter AC/DC models . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . PLG1 . . . . . 135 559 . . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . . . 079 747 . . . . CONNECTOR, rect skt 24-18ga Amp 350980-1 . . . . . . . . . . . . . . . . . 12  
. . . 18 . . . . . . . . . . . . . . . . 080 509 . . . GROMMET, scr No. 8/10 panel hole .312sq .375 high . . . . . . . . . . . . . . 2  
. . . 19 . . . . . . . . . . . . . . . . 131 762 . . . BRACKET, mtg PC card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 20 . . . . . FL1-3 . . . . . 084 171 . . . FILTER, line pwr 115/250V 50-400Hz at 2A . . . . . . . . . . . . . . . . . . . . . . . 3  
. . . 21 . . . . . . . . . . . . . . . . 132 124 . . . STAND-OFF, 6-32 x 1.000 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 22 . . . . . . . . . . . . . . . . 094 484 . . . STAND-OFF, 6-32 x 1.000 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 23 . . . . . . . . . . . . . . . . 019 663 . . . MOUNT, nprn 15/16 OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
. . . 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and style number) . . . . . . . . . . . . . . . . . 1  
. . . 25 . . . . C50,51 . . . . 122 723 . . . CAPACITOR, cer mono .1uf 50VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 26 . . . . . D1,2 . . . . . 026 202 . . . DIODE, rect 1A 400V SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 27 . . . . PLG2,3 . . . . 028 598 . . . CONNECTOR, edge 15skt plug Amp 582772-3 . . . . . . . . . . . . . . . . . . . 2  
. . . 28 . . . . . Amp . . . . . 083 722 . . . METER, digital 0 to 19.99V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 29 . . . . . Volt . . . . . . 081 798 . . . METER, digital 0 to 19.99V LED 115VAC . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 30 . . . . . T50 . . . . . . 131 685 . . . TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 31 . . . . . S50 . . . . . . 011 609 . . . SWITCH, tgl SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
+When ordering a component originally displaying a precautionary label, the label should also be ordered.  
BE SURE TO PROVIDE MODEL AND STYLE NUMBER WHEN ORDERING REPLACEMENT PARTS.  
OM-867 Page 9  
 
Notes  
OM-867 Page 10  
 
Notes  
OM-867 Page 11  
 
Notes  
OM-867 Page 12  
 
Effective January 1, 2000  
(Equipment with a serial number preface of LAor newer)  
This limited warranty supersedes all previous Miller warranties and is exclusive with no other  
guarantees or warranties expressed or implied.  
Warranty Questions?  
LIMITED WARRANTY Subject to the terms and conditions  
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants  
to its original retail purchaser that new Miller equipment sold  
after the effective date of this limited warranty is free of defects  
in material and workmanship at the time it is shipped by Miller.  
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER  
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE  
WARRANTIES OF MERCHANTABILITY AND FITNESS.  
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting  
Torches  
Call  
1-800-4-A-MILLER  
for your local  
Miller distributor.  
*
*
*
*
*
Remote Controls  
Accessory Kits  
Replacement Parts (No labor)  
Spoolmate 185 & Spoolmate 250  
Canvas Covers  
Within the warranty periods listed below, Miller will repair or  
replace any warranted parts or components that fail due to  
such defects in material or workmanship. Miller must be  
notified in writing within thirty (30) days of such defect or  
failure, at which time Miller will provide instructions on the  
warranty claim procedures to be followed.  
Your distributor also gives  
you ...  
Millers True Blue Limited Warranty shall not apply to:  
1. Consumable components; such as contact tips,  
cutting nozzles, contactors, brushes, slip rings,  
relays or parts that fail due to normal wear.  
Service  
You always get the fast,  
reliable response you  
need. Most replacement  
parts can be in your  
hands in 24 hours.  
Miller shall honor warranty claims on warranted equipment  
listed below in the event of such a failure within the warranty  
time periods. All warranty time periods start on the date that  
the equipment was delivered to the original retail purchaser, or  
one year after the equipment is sent to a North American  
distributor or eighteen months after the equipment is sent to an  
International distributor.  
2. Items furnished by Miller, but manufactured by others,  
such as engines or trade accessories. These items are  
covered by the manufacturers warranty, if any.  
Support  
3. Equipment that has been modified by any party other  
than Miller, or equipment that has been improperly  
installed, improperly operated or misused based upon  
industry standards, or equipment which has not had  
reasonable and necessary maintenance, or equipment  
which has been used for operation outside of the  
specifications for the equipment.  
Need fast answers to the  
tough welding questions?  
Contact your distributor.  
The expertise of the  
distributor and Miller is  
there to help you, every  
step of the way.  
1. 5 Years Parts 3 Years Labor  
*
*
Original main power rectifiers  
Inverters (input and output rectifiers only)  
MILLER PRODUCTS ARE INTENDED FOR PURCHASE  
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND  
PERSONS TRAINED AND EXPERIENCED IN THE USE  
AND MAINTENANCE OF WELDING EQUIPMENT.  
2. 3 Years Parts and Labor  
*
*
*
*
*
*
Transformer/Rectifier Power Sources  
Plasma Arc Cutting Power Sources  
Semi-Automatic and Automatic Wire Feeders  
Inverter Power Supplies  
In the event of a warranty claim covered by this warranty, the  
exclusive remedies shall be, at Millers option: (1) repair; or (2)  
replacement; or, where authorized in writing by Miller in  
appropriate cases, (3) the reasonable cost of repair or  
replacement at an authorized Miller service station; or (4)  
payment of or credit for the purchase price (less reasonable  
depreciation based upon actual use) upon return of the goods  
at customers risk and expense. Millers option of repair or  
replacement will be F.O.B., Factory at Appleton, Wisconsin, or  
F.O.B. at a Miller authorized service facility as determined by  
Miller. Therefore no compensation or reimbursement for  
transportation costs of any kind will be allowed.  
Intellitig  
Engine Driven Welding Generators  
(NOTE: Engines are warranted separately by  
the engine manufacturer.)  
3. 1 Year Parts and Labor  
*
*
DS-2 Wire Feeder  
Motor Driven Guns (w/exception of Spoolmate  
185 & Spoolmate 250)  
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES  
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE  
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR  
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR  
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF  
PROFIT), WHETHER BASED ON CONTRACT, TORT OR  
ANY OTHER LEGAL THEORY.  
*
*
*
*
*
*
*
*
*
*
*
*
*
*
Process Controllers  
Positioners and Controllers  
Automatic Motion Devices  
RFCS Foot Controls  
Induction Heating Power Sources  
Water Coolant Systems  
HF Units  
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN  
AND ANY IMPLIED WARRANTY, GUARANTY OR  
REPRESENTATION AS TO PERFORMANCE, AND ANY  
REMEDY FOR BREACH OF CONTRACT TORT OR ANY  
OTHER LEGAL THEORY WHICH, BUT FOR THIS  
Grids  
Maxstar 140  
PROVISION,  
MIGHT  
ARISE  
BY  
IMPLICATION,  
Spot Welders  
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE  
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF  
MERCHANTABILITY OR FITNESS FOR PARTICULAR  
PURPOSE, WITH RESPECT TO ANY AND ALL  
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND  
DISCLAIMED BY MILLER.  
Load Banks  
Miller Cyclomatic Equipment  
Running Gear/Trailers  
Plasma Cutting Torches (except APT & SAF  
Models)  
Some states in the U.S.A. do not allow limitations of how long  
an implied warranty lasts, or the exclusion of incidental,  
indirect, special or consequential damages, so the above  
limitation or exclusion may not apply to you. This warranty  
provides specific legal rights, and other rights may be  
available, but may vary from state to state.  
*
Field Options  
(NOTE: Field options are covered under True  
Blue for the remaining warranty period of the  
product they are installed in, or for a minimum of  
one year whichever is greater.)  
In Canada, legislation in some provinces provides for certain  
additional warranties or remedies other than as stated herein,  
and to the extent that they may not be waived, the limitations  
and exclusions set out above may not apply. This Limited  
Warranty provides specific legal rights, and other rights may  
be available, but may vary from province to province.  
4. 6 Months Batteries  
5. 90 Days Parts  
*
*
MIG Guns/TIG Torches  
Induction Heating Coils and Blankets  
miller_warr 7/00  
 
Owners Record  
Please complete and retain with your personal records.  
Model Name  
Purchase Date  
Distributor  
Address  
Serial/Style Number  
(Date which equipment was delivered to original customer.)  
City  
State  
Zip  
For Service  
to locate a DISTRIBUTOR or SERVICE AGENCY near you.  
Always provide Model Name and Serial/Style Number.  
Contact your Distributor for:  
Welding Supplies and Consumables  
Options and Accessories  
Personal Safety Equipment  
Service and Repair  
Miller Electric Mfg. Co.  
An Illinois Tool Works Company  
1635 West Spencer Street  
Appleton, WI 54914 USA  
Replacement Parts  
Training (Schools, Videos, Books)  
International HeadquartersUSA  
USA Phone: 920-735-4505 Auto-Attended  
USA & Canada FAX: 920-735-4134  
International FAX: 920-735-4125  
Technical Manuals (Servicing Information  
and Parts)  
Circuit Diagrams  
European Headquarters –  
United Kingdom  
Phone: 44 (0) 1204-593493  
FAX: 44 (0) 1204-598066  
Welding Process Handbooks  
www.MillerWelds.com  
Contact the Delivering Carrier for:  
File a claim for loss or damage during  
shipment.  
For assistance in filing or settling claims,  
contact your distributor and/or equipment  
manufacturers Transportation Department.  
PRINTED IN USA  
2000 Miller Electric Mfg. Co. 6/00  
 

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