Miller Electric OM-842 Background Relay Test, Arc Starter Relay Test, Gas Solenoid Relay Test

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J. Background Relay Test

This procedure tests the internal dc background current source.

1.When the repeating test displays are shown (see Sec- tion 7-2C), press Right/Increase or Left/Decrease until the display shows:

L. Arc Starter Relay Test

This procedure tests the arc starter relay. Indirectly, the Arc Starter Board PC8 is also tested.

1.When the repeating test displays are shown (see Sec- tion 7-2C), press Right/Increase or Left/Decrease until the display shows:

B A C K G R O U N D

R E L A Y T E S T

A R C S T A R T E R

R E L A Y T E S T

2.Press Parameter Select to begin the test. This ener- gizes the background relay. The display shows:

C H E C K V O L T M E T E R F O R

4 2 T O 5 4 V O L T S D C

2.Press Parameter Select to energize the arc starter relay. The display shows:

A R C S T A R T E R R E L A Y

I S E N E R G I Z E D

3.The Voltage meter on the control unit should indicate a voltage within the specified range.

If an acceptable voltage is not indicated, contact the nearest Factory Authorized Service Station/Service Distributor.

4.When the background relay tests okay, press Parame- ter Select to deenergize the relay and exit the test. Use the Right/Increase or Left/Decrease push button to ac- cess another test, or stop the diagnostics program.

K.Gas Solenoid Relay Test

This procedure tests the gas solenoid relay. Indirectly, the gas solenoid is also tested.

1.When the repeating test displays are shown (see Sec- tion 7-2C), press Right/Increase or Left/Decrease until the display shows:

G A S S O L E N O I D

R E L A Y T E S T

2.Press Parameter Select to energize the gas solenoid relay. The display shows:

G A S S O L E N O I D R E L A Y I S E N E R G I Z E D

3.If gas flows, the gas solenoid relay and gas solenoid are working correctly. In this case, go to Step 4.

If gas does not flow, contact the nearest Factory Autho- rized Service Station/Service Distributor.

4.When the gas solenoid relay tests okay, press Parame- ter Select again to deenergize the relay. The program automatically returns to the repeating test displays. Use the Right/Increase or Left/Decrease push button to access another test, or stop the diagnostics pro- gram.

3.If a crackling sound can be heard inside the welding power source, the relay is working correctly. In this case, go to Step 4.

If a crackling sound is not heard inside the welding power source, contact the nearest Factory Authorized Service Station/Service Distributor.

4.When the relay tests okay, press Parameter Select again to deenergize the relay. The program automati- cally returns to the repeating test displays. Use the Right/Increase or Left/Decrease push button to access another test, or stop the diagnostics program.

M.User Relays

This procedure tests the user relays (see Section 2-3). Since the procedure is the same for each of the user relays, one ex- ample is presented that applies to all the user relays.

1.When the repeating test displays are shown (see Sec- tion 7-2C), press Right/Increase or Left/Decrease until the display shows the test display for the desired relay.

For example, if the initial time relay is being tested, the display would show:

I N I T I A L T I M E

R E L A Y T E S T

2.Press Parameter Select to begin the test. The display shows:

I N I T I A L T I M E R E L A Y

I S E N E R G I Z E D

After a short pause, the relay energizes.

3.Use a suitable VOM (volt-ohmmeter) to check the re- sistance across the relay terminals as shown in Figure 7-1.

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Contents OM-842162074B ProcessesDescription From Miller to You Table of Contents Page Symbol Usage Marks a special safety messageArc Welding Hazards Electric Shock can killARC Rays can burn eyes and skin Welding can cause fire or explosionFlying Metal can injure eyes Buildup of GAS can injure or killPrincipal Safety Standards EMF Information About PacemakersSignification des symboles Consignes DE Securite Lire Avant UtilisationUN Choc É Lectrique peut tuer LES Fumé ES ET LES GAZ peuvent ê tre dangereuxLE Soudage peut provoquer un incendie ou une explosion DES Particules Volantes peuvent blesser les yeuxLE Bruit peut affecter l’ouïe Risque D’INCENDIE OU LA Chute DE L’APPAREIL peut blesser’EMPLOI Excessif peut DES Organes Mobiles peuvent provoquer des blessuresPrincipales 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 Pulse signal, and for a wire feeder User Relay ContactsSetting DIP Switch SW1 Rocker Switch Settings = On = OffSafety Equipment OperationControls Work ClampMode Selector Switch Ammeter And VoltmeterDigital Display Program/Run/Reset Keyed Switch Parameter Select Push ButtonRight/Increase Push Button Left/Decrease Push ButtonPurge Push Button Remote PendantShielding Gas Introduction to Programming GeneralWeld Sequence Balance ControlAutomatic Mode Sequence Semi-Automatic Mode SequenceModes Of Operation Start Level Not Shown Time & level programmedWeld/Peak Initial Current C Final Slope Current B Current D PreflowWeld/Peak Initial Current C Final SlopeSlope Current B Semi-Automatic 4 Mode Sequence Weld/Peak Initial C Current D Final SlopeSlope Current BSmaw Mode Weld/Peak Initial Current B Final Slope SlopePreflow Postflow Initial Slope Weld/Peak Current Final Slope Final CurrentProgramming Automatic Mode Procedure Up To Pulse Mode SelectionProcedure With Pulse Mode On, Pulses Defined In Time Values Procedure With Pulse Mode On, Pulses Defined As a Frequency Procedure Following Pulse Mode DefinitionN a L S T F L O WSemi-Automatic Mode A R TO P E R E M O T E T O A R T# 0 X I N I T I a L P S = X X X Procedure With Pulse Mode On, Pulses Defined As a Frequency O P B U T T O N D E T E C T X X X X X X XManual Gtaw Mode R R E N T C O N T R O L X X X XSmaw 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 % Dry Run Feature Stop Watch FeatureLinking Programs N K P O S I T I O N X X X X X X XCombining Programs M B I N E M O D EO G R a M L I N K M O D E M B I N E P O S I T I O N X X I S X X X X X XGas Tungsten Arc Welding Gtaw In The Automatic Mode Shared Initial ProcedureSequence of Operation Gas Tungsten Arc Welding Gtaw In The Semi-Automatic ModesOperation Procedures For Semi-Automatic 1 Mode Operation Procedures For Semi-Automatic 2 ModeOperation Procedures For Semi-Automatic 3 Mode Operation Procedures For Semi-Automatic 4 ModeGas Tungsten Arc Welding Gtaw In The Manual Mode Operation Procedures For Semi-Automatic 5 ModeShielded Metal Arc Welding Smaw Executing Linked ProgramsExecuting Combined Programs Shutting DownDiagnostics Overheating ProtectionIntroduction Diagnostics Program Programming Push Button TestsRAM Test Program/Run/Reset Keyed Switch Tests Repeating Test DisplaysOutput Selector Switch Test Mode Selector Switch TestW O R K I N G O P E R L Y E a S E T U R N K N O B T OPurge Push Button Test R G E B U T T O N S T+10 Volt DC Reference Test Background Relay Test Arc Starter Relay TestGas Solenoid Relay Test User RelaysRemote Pendant Test M O T E P E N D a N T S TR E M O T E S H D E C R E a S E B U T T O N R E M O T ECurrent Detect Test Input Contactor TestP U T C O N T a C T O R D E T E C T E D P U T C O N T a C T O R I S T D E T E C T E DElectrical Diagrams Circuit Diagram For Remote PendantWiring Diagram For MPC Module Circuit Diagram For Welding Power Source And MPC SC-182 947-B Parts List Main AssemblyDia Part Mkgs Description Quantity NAMEPLATE, order by model and serial number 158078 010 110132 Page Page Page Page Service SupportModel 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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