Miller Electric Welder MARKVI User Manual

Issued January 2006 • Index No. DC/9.8  
Multiple Arc  
Welding System  
Mark VI  
Heavy Industrial Applications  
Processes  
Voltage Range CC: 20315 A  
CV: 1030 V (with CC/CV Module)  
Construction  
Rental Fleets  
Fab Shops  
Stick (SMAW) CC  
TIG (GTAW) CC  
Max. Open-Circuit Voltage  
Quick  
Air Carbon Arc (CAC-A)  
Cutting and Gouging CC  
Flux Cored (FCAW) CV  
MIG Spray Transfer (GMAW)  
with Voltage-Sensing Feeder CV  
CC: 75 VDC CV: 38 VDC  
Petro Chemical  
Shipbuilding  
Training Facilities  
Maintenance  
CC/CV Low OCV Module: 26 VDC 2 V  
Specs  
Weight Mark VI: 1725 lb (784 kg)  
Mark VI-2: 1575 lb (718 kg)  
®
The Power of Blue.  
Adjustable arc control lets you get in  
tight without sticking the electrode. An  
electrode compensation circuit ensures  
arc control performance regardless of  
the electrode size.  
Multiple capabilities CC or CC/CV.  
Versatility and outstanding arc  
welding performances in both CV  
(MIG) and CC (TIG and Stick). The  
CC/CV module has a high quality  
arc for welding with cored wires.  
Miller does not recommend that  
the CC/CV module be used for short  
circuit transfer MIG welding. The CC  
module has the same great arc  
characteristic as the Gold Star 302.  
Hot Startmakes it easy to start difficult-  
to-start Stick electrodes, such as E-6010  
and E-7018.  
Line voltage compensation keeps  
output power constant even if primary  
input power varies by 10%, ensuring  
consistent weld performance.  
Rugged and durable enclosure  
steel frame protects system.  
Operator identification label helps  
operators remember who is using  
which module.  
Capable of four to six welding arcs,  
Miller’s unique modules are designed  
for easy removal and connection.  
If you need only four arcs today,  
purchase the Mark VI-2. If you  
have a requirement for more arcs,  
additional modules (CC or CV)  
are available for purchase.  
60 Hz models have two 115 V GFCI duplex  
receptacles which supply 15 amps of  
auxiliary power. 50 Hz models have one  
220 V and one 115 V duplex receptacle.  
14-pin receptacle provides quick, direct  
connection to Miller wire feeders and  
accessories.  
Optional Low OCV in CC/CV modules reduces maximum  
open-circuit voltage to 26 volts in CC and CV modes when  
not welding.  
Weighs less than one ton which  
makes it portable when secured on a  
flatbed, construction truck, or when  
moved by one-ton hoist. Fits through  
36 in (914 mm) door opening.  
Work connections are electrically isolated  
from the frame, and service panels in  
chassis provide easy access to internal  
parts for routine maintenance.  
Welder is warranted for 3 years, parts and labor.  
Original main power rectified parts are warranted for 5 years.  
Miller Electric Mfg. Co.  
An Illinois Tool Works Company  
1635 West Spencer Street  
Appleton, WI 54914 USA  
International Headquarters Web Site  
Phone: 920-735-4505  
USA FAX: 920-735-4134  
Canadian FAX: 920-735-4169  
International FAX: 920-735-4125  
 
Performance Data  
(continued)  
50 Hz DUTY CYCLE CHART  
60 Hz DUTY CYCLE CHART  
2000  
1800  
1600  
1400  
1200  
1000  
2000  
1800  
1600  
1400  
1200  
1000  
800  
600  
300  
800  
300  
Total Machine Output  
750 A at 60% Duty Cycle  
Total Machine Output  
750 A at 100% Duty Cycle  
200  
Each Module Output  
194 A at 100% Duty Cycle  
Each Module Output  
194 A at 100% Duty Cycle  
200  
100  
100  
10  
20  
30  
40  
50 60 70 80 90 100  
10  
20  
30  
40  
50 60 70 80 90 100  
% DUTY CYCLE  
% DUTY CYCLE  
Genuine Miller Accessories  
Process Selector Control #042 872  
Allows you to easily change weld processes  
without changing cablesfrom MIG to TIG  
or TIG to Stick. Also for use with dual wire  
feeders and applications where electrical  
isolation and/or polarity reversing of weld  
current is required.  
Wire Feeders  
Remote Controls and Switches  
Stick Hook-up Kit  
RFCS-14 Foot Control #043 554  
Heavy-duty foot current and contactor  
control. Includes 20 ft (6 m) cord and  
14-pin plug.  
#173 851 50 ft (15.2 m) 2/0 cable  
Includes electrode holder, weld cable  
and work cable with clamp.  
SuitCase 8RC #194 938  
SuitCase 12RC #194 940  
Compact, portable, constant-speed wire  
feeder with remote voltage control. For  
MIG Hook-Up Kit  
.030 – 5/64 in (0.8 – 2 mm) hard and flux  
cored wires. Holds up to an 8 in, 14 lb (8RC)  
or 12 in, 44 lb (12RC) spool of wire.  
See Lit. Index No. M/6.5.  
#173 856 25 ft (7.6 m) 2/0 cable  
Includes gas hose assembly, lugged weld  
cable assembly and work cable with clamp.  
RCC-14 Remote Contactor and  
Current Control #151 086  
Rotary-motion fingertip control. Fastens to  
TIG torch using two Velcro strips. Allows  
complete current and contactor control at  
operator’s fingertips. Includes 28 ft (8.5 m)  
cord and plug.  
SuitCase 8VS Wire Feeder #194 890  
SuitCase X-TREME 12VS  
HF-251D-1 High-Frequency Arc  
Starter/Stabilizer #042 388  
Wire Feeder #195 500  
Lightweight, portable, voltage-sensing  
wire feeders include secondary contactor  
and gas valve. Require drive roll kit.  
See Lit. Index Nos. M/6.4 and M/6.41.  
This portable 250 A, 60% duty cycle unit  
adds high frequency to the welding circuit to  
help start the arc when using the TIG (GTAW)  
process. Operates on 115 VAC 50/60/100 Hz.  
See Lit. Index No. AY/5.1.  
RCCS-14 Remote Contactor and  
Current Control #043 688  
Up-and-down rotary-motion fingertip  
control. Great for applications that require  
a finer amperage control. Includes 28 ft  
(8.5 m) control cord.  
3
 
Genuine Miller Accessories  
Remote Controls and Switches  
(continued)  
Extension Cables for 14-Pin Plugs to  
14-Pin Sockets  
#122 973 25 ft (7.6 m)  
#122 974 50 ft (15.2 m)  
#122 975 75 ft (22.8 m)  
Extension cords make a direct connection  
between the power source and the  
accessory control. No messy splicing or  
adapting required.  
RHC-14 Hand Control  
#129 340  
Miniature hand control  
for remote current and  
contactor control.  
RMLS-14 #129 337  
Momentary- and maintained-contact rocker  
switch for contactor control. Push forward  
for maintained contact and back for momen-  
tary contact. Includes 20 ft (6 m) cord and  
14-pin plug.  
Dimensions: 4 x 4 x  
3-1/4 in (102 x 102 x  
82 mm). Includes 20 ft (6 m) cord and  
14-pin plug.  
Ordering Information  
Power Source and Options  
Stock No.  
#903 588  
Description  
230/460/575 V, 60 Hz  
Qty.  
Price  
Mark VI-2 (Four Modules)  
#903 588-01-1 With Tweco connectors  
Mark VI CC (Six Modules)  
#903 512  
#903 569  
230/460/575 V, 60 Hz  
380/400/415/440-460 V, 50/60 Hz  
Mark VI CC/CV (Six Modules)  
#903 645  
#903 660  
230/460/575 V, 60 Hz  
380/400/415/440460 V, 50/60 Hz  
#903 645-01-1 Low OCV modules  
#903 645-02-1 With Cam-Lok connectors and Low OCV  
Single CC Module  
#903 661  
CC module, 50/60 Hz  
Single CC/CV Modules  
#903 646  
#903 659  
#903 899  
CC/CV module, 60 Hz  
CC/CV module, 50/60 Hz  
CC/CV, Low OCV modules  
Stick Accessories  
Stick Hook-up Kit  
Stick Electrodes  
#173 851  
#042 388  
2/0 cable, 50 ft. Includes electrode holder, weld cable and work cable with clamp  
HF arc starter/stabilizer  
TIG Accessories  
HF-251D-1  
Torch and Consumables  
Tungsten  
MIG Accessories  
SuitCase8RC  
#194 938  
#194 940  
#194 890  
#195 500  
#173 856  
See Lit. Index No. M/6.5  
See Lit. Index No. M/6.5  
See Lit. Index No. M/6.4  
See Lit. Index No. M/6.41  
SuitCase12RC  
SuitCase8VS  
SuitCaseX-TREME12VS  
MIG Hook-Up Kit  
2/0 cable, 25 ft. Includes gas hose, weld cable, work cable w/ clamp, and regulator/flowmeter  
Remote Controls  
RFCS-14  
RCC-14  
RCCS-14  
RHC-14  
#043 554  
#151 086  
#043 688  
#129 340  
#129 337  
Foot control  
Fingertip control  
Fingertip control  
Hand control  
RMLS-14  
Momentary- and maintained-contact switch  
Extension Cords  
#122 973  
#122 974  
#122 975  
25 ft (7.6 m)  
50 ft (15.2 m)  
75 ft (22.9 m)  
Miscellaneous  
Process Selector Control  
Primary Power Cord  
Gas Cylinder  
#042 872  
Gas Hose and Fittings  
Date:  
Total Quoted Price:  
Distributed by:  
Litho in USA  
 

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