Miller Electric OM-842 manual Table of Contents

Page 3

The following terms are used interchangeably throughout this manual:

TIG = GTAW

Stick = SMAW

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING

1

1-1.

Symbol Usage

1

1-2.

Arc Welding Hazards

1

1-3. Additional Symbols for Installation, Operation, and Maintenance

3

1-4.

Principal Safety Standards

3

1-5.

EMF Information

4

SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION

5

1-1.

Signification des symboles

5

1-2.

Dangers relatifs au soudage à l’arc

5

1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement

 

 

et la maintenance

7

1-4.

Principales normes de sécurité

8

1-5.

Information sur les champs électromagnétiques

8

SECTION 2 – INSTALLATION

9

2-1.

Connecting Remote Pendant Or Equivalent User-Wired Control

9

2-2.

Remote 4 Socket Information

9

2-3.

User Relay Contacts

10

2-4.

Setting DIP Switch SW1

11

SECTION 3 – OPERATION

12

3-1.

Controls

12

3-2.

Safety Equipment

12

3-3.

Work Clamp

12

3-4.

Ammeter And Voltmeter

13

3-5.

Digital Display

13

3-6.

Mode Selector Switch

13

3-7.

Program/Run/Reset Keyed Switch

14

3-8.

Parameter Select Push Button

14

3-9.

Right/Increase Push Button

14

3-10. Left/Decrease Push Button

14

3-11.

Purge Push Button

15

3-12.

Remote Pendant

15

3-13.

Shielding Gas

15

SECTION 4 – INTRODUCTION TO PROGRAMMING

16

4-1.

General

16

4-2.

Weld Sequence

16

4-3.

Balance Control

16

4-4.

Modes Of Operation

17

SECTION 5 – PROGRAMMING

21

5-1.

General

21

5-2.

Automatic Mode

22

5-3.

Semi-Automatic Mode

25

5-4.

Manual GTAW Mode

29

5-5.

SMAW Mode

31

5-6.

Editing A Program

31

5-7.

Dry Run Feature

32

5-8.

Stop Watch Feature

32

5-9.

Linking Programs

32

5-10.

Combining Programs

33

SECTION 6 – SEQUENCE OF OPERATION

34

6-1. Gas Tungsten Arc Welding (GTAW) In The Automatic Mode

34

6-2.

Gas Tungsten Arc Welding (GTAW) In The Semi-Automatic Modes

34

6-3.

Gas Tungsten Arc Welding (GTAW) In The Manual Mode

36

6-4. Shielded Metal Arc Welding (SMAW)

37

6-5.

Executing Linked Programs

37

6-6. Executing Combined Programs

37

6-7. Shutting Down

38

6-8.

Overheating Protection

38

SECTION 7 – DIAGNOSTICS

38

7-1.

Introduction

38

7-2.

Diagnostics Program

39

SECTION 8 – ELECTRICAL DIAGRAMS

48

SECTION 9 – PARTS LIST

52

WARRANTY

 

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Contents OM-842162074B ProcessesDescription From 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 eyesPrincipal Safety Standards About Pacemakers EMF InformationLES Fumé ES ET LES GAZ peuvent ê tre dangereux Signification des symbolesConsignes DE Securite Lire Avant Utilisation UN Choc É Lectrique peut tuerLE Soudage peut provoquer un incendie ou une explosion DES Particules Volantes peuvent blesser les yeuxLE Bruit peut affecter l’ouïe DES Organes Mobiles peuvent provoquer des blessures Risque D’INCENDIE OULA Chute DE L’APPAREIL peut blesser ’EMPLOI Excessif peutPrincipales normes de sé curité Information sur les champs é lectromagné tiquesConsignes relatives aux stimulateurs cardiaques Installation Connecting Remote Pendant Or Equivalent User-Wired ControlRemote 4 Socket Information User Relay Contacts Pulse signal, and for a wire feederRocker Switch Settings = On = Off Setting DIP Switch SW1Work Clamp Safety EquipmentOperation ControlsMode Selector Switch Ammeter And VoltmeterDigital Display Left/Decrease Push Button Program/Run/Reset Keyed SwitchParameter Select Push Button Right/Increase Push ButtonPurge Push Button Remote PendantShielding Gas Balance Control Introduction to ProgrammingGeneral Weld SequenceStart Level Not Shown Time & level programmed Automatic Mode SequenceSemi-Automatic Mode Sequence Modes Of OperationWeld/Peak Initial Current C Final Slope Current B Current D PreflowWeld/Peak Initial Current C Final SlopeSlope Current B Weld/Peak Initial C Current D Final SlopeSlope Current B Semi-Automatic 4 Mode SequenceInitial Slope Weld/Peak Current Final Slope Final Current Smaw ModeWeld/Peak Initial Current B Final Slope Slope Preflow PostflowProgramming Procedure Up To Pulse Mode Selection Automatic ModeProcedure With Pulse Mode On, Pulses Defined In Time Values S T F L O W Procedure With Pulse Mode On, Pulses Defined As a FrequencyProcedure Following Pulse Mode Definition N a LE R E M O T E T O A R T Semi-Automatic ModeA R T O P# 0 X I N I T I a L P S = X X X Procedure With Pulse Mode On, Pulses Defined As a Frequency X X X X X X X O P B U T T O N D E T E C TManual Gtaw Mode X X X X R R E N T C O N T R O LSmaw Mode Editing a Program# 0 X a R C C O N T R O L R C E N T a G E = 0 0 0 % N K P O S I T I O N X X X X X X X Dry Run FeatureStop Watch Feature Linking ProgramsM B I N E P O S I T I O N X X I S X X X X X X Combining ProgramsM B I N E M O D E O G R a M L I N K M O D EGas Tungsten Arc Welding Gtaw In The Semi-Automatic Modes Gas Tungsten Arc Welding Gtaw In The Automatic ModeShared Initial Procedure Sequence of OperationOperation Procedures For Semi-Automatic 4 Mode Operation Procedures For Semi-Automatic 1 ModeOperation Procedures For Semi-Automatic 2 Mode Operation Procedures For Semi-Automatic 3 ModeOperation Procedures For Semi-Automatic 5 Mode Gas Tungsten Arc Welding Gtaw In The Manual ModeShutting Down Shielded Metal Arc Welding SmawExecuting Linked Programs Executing Combined ProgramsDiagnostics Overheating ProtectionIntroduction Diagnostics Program Programming Push Button TestsRAM Test Repeating Test Displays Program/Run/Reset Keyed Switch TestsMode Selector Switch Test Output Selector Switch TestR G E B U T T O N S T W O R K I N G O P E R L YE a S E T U R N K N O B T O Purge Push Button Test+10 Volt DC Reference Test User Relays Background Relay TestArc Starter Relay Test Gas Solenoid Relay TestS H D E C R E a S E B U T T O N R E M O T E Remote Pendant TestM O T E P E N D a N T S T R E M O T EInput Contactor Test Current Detect TestP U T C O N T a C T O R I S T D E T E C T E D P U T C O N T a C T O R D E T E C T E DCircuit Diagram For Remote Pendant Electrical DiagramsWiring Diagram For MPC Module Circuit Diagram For Welding Power Source And MPC SC-182 947-B Main Assembly Parts List110 Dia Part Mkgs Description QuantityNAMEPLATE, order by model and serial number 158 078 010132 Page Page Page Page Support ServiceModel Name Serial/Style Number Purchase Date Distributor Address City State ZipMiller Electric Mfg. Co

OM-842 specifications

The Miller Electric OM-842 is a versatile and powerful multi-process welding machine designed for professional welders who demand efficiency and reliability on the job. This industrial-grade welder is capable of handling various welding processes, including MIG, TIG, stick, and flux-cored welding, making it an ideal choice for a wide range of applications.

One of the standout features of the OM-842 is its robust output capability. With a maximum output of 400 amps, it can tackle thick materials with ease while maintaining exceptional arc stability. This output range allows for adaptability in different welding scenarios, whether working on heavy fabrication projects or lighter home repairs.

The OM-842 is also equipped with advanced inverter technology. This technology enhances the machine's efficiency and reduces energy consumption. Inverter machines are known for their lightweight design compared to traditional transformer welders, which makes the OM-842 more portable and easier to transport between job sites.

User-friendliness is paramount in the design of the OM-842. Its intuitive control panel features a digital display that provides real-time information on parameters such as voltage and amperage. This allows users to make quick and precise adjustments on the fly, enhancing productivity and ensuring optimal welding results.

Additionally, the OM-842 offers sophisticated weld control features, such as Auto-Set, which simplifies the setup process for beginners and experienced users alike. This technology automatically selects optimal parameters based on the material type and thickness, minimizing trial and error during welding.

The machine also includes a durable and rugged design, suitable for tough working conditions. The protective case and high-quality components ensure longevity and reliability even in adverse environments.

Safety is another critical aspect of the OM-842, with features such as over-temperature protection and a built-in fan to prevent overheating during extended use.

With its powerful performance, advanced technology, and robust design, the Miller Electric OM-842 stands out as an exceptional choice for welders seeking reliability and versatility in their welding operations, ultimately creating high-quality welds across various applications. Whether in a shop or on a construction site, the OM-842 is engineered to deliver outstanding results every time.
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