Miller Electric OM-230 manual Routine Maintenance, Unit Overload

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.A complete Parts List is available at www.MillerWelds.com

SECTION 6 − MAINTENANCE &TROUBLESHOOTING

6-1. Routine Maintenance

!	Disconnect power	. Maintain more often
	before maintaining.	during severe conditions.

n = Check	Z = Change	~ = Clean	l = Replace
* To be done by Factory Authorized Service Agent

Every

3 Months

	l Unreadable Labels	~ Weld Terminals	nl Weld Cables
Every
6	OR
Months	OR
Months
	~ Inside Unit	n Apply Light Coat Of Oil
		Or Grease To Drive Motor
		Shaft

Reference

6-2. Unit Overload

Thermistor T in SCR1 protects the unit from damage due to overheating. If HL.P 002 is displayed on the meters, wait for unit to cool allowing fan motor to run before trying to weld. If unit is cool and no weld output continues, contact Factory Authorized Service Agent.

6-3. Changing Drive Roll and Wire Inlet Guide

2

4

1

3

Tools Needed:

7/16 in

1Securing Screw

2Inlet Wire Guide

Loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw.

3 Drive Roll

The drive roll consists of two different sized grooves. The stamped markings on the end surface of the drive roll refers to the groove on the opposite side of the drive roll. The groove closest to the motor shaft is the proper groove to thread (see Section 4-14).

4 Drive Roll Securing Nut

Turn nut one click to secure drive roll.

Ref. 804 914-A

OM-230 693 Page 29

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Contents Processes OM-230 693CDescription File MIG GmawFrom Miller to You Table of Contents − Parts List − MIG Welding Gmaw GuidelinesTypical MIG Process Connections Arc Welding Hazards Symbol UsageElectric Shock can kill HOT Parts can cause severe burnsARC Rays can burn eyes and skin Fumes and Gases can be hazardousWelding can cause fire or explosion Flying Metal or Dirt can injure eyesFire or Explosion hazard Welding Wire can cause injuryFalling Unit can cause injury Moving Parts can cause injuryCalifornia Proposition 65 Warnings Principal Safety StandardsEMF Information About Implanted Medical DevicesUNE Décharge Électrique peut entraîner la mort Symboles utilisésDES Pièces Chaudes peuvent provoquer des brûlures graves LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in cendie ou une explosion LES Bouteilles peuvent exploser si elles sont endommagées LE Bruit peut endommager l’ouïeRisque D’INCENDIE OU D’EXPLO LA Chute DE L’APPAREIL peut blesserProposition californienne 65 Avertissements LES Fils DE Soudage peuvent provoquer des blessuresLE Soudage À L’ARC risque de provoquer des interférences Principales normes de sécurité Information EMFEn ce qui concerne les implants médicaux OM-230 693 Specifications Symbols And DefinitionsWelding Power Source Duty Cycle And Overheating Volt-Ampere CurvesOverheating Installing Work Cable And Clamp Connecting To Weld Output TerminalsConnecting Spoolmatic 15A Or 30A Gun Connecting XR Aluma-Pro, XR Edge, XR-A Gun, Or XR-A Python Gun End Gun Liner Wire Outlet Guide32 in 2.4 mm Installing Gas Supply Setting Gun Polarity For Wire TypePolarity Changeover Label Information 11/16Positioning Jumper Links Installing Wire Spool And Adjusting Hub TensionInput Voltage Electrical Service Guide200 230 460 575 127 206Selecting a Location And Connecting Input Power 18 in 457 mm of space for airflow =GND/PE Earth GroundL2L1 230 VAC Pressure Threading Welding WireScale Remove gun nozzle and contact tipOM-230 693 Weld Parameters 226 650-B Controls − OperationJOG Mode Run−in Wire Feed Speed SettingsTrigger and pull the trigger again momentarily one second Jog Mode Voltmeter And Wire Feed Speed Meter OperationPower Up Status Welding StatusTimers Set Up Push Motor Torque SUP Or Reset rES Routine Maintenance Changing Drive Roll and Wire Inlet GuideUnit Overload Turn Off power Aligning Drive Rolls and Wire GuideAssembly open View is from top of drive rollsTroubleshooting Trouble Remedy OM-230 693 − Electrical Diagram 229 485-A Typical MIG Process Connections − MIG Welding Gmaw GuidelinesWire Size Amperage Range Typical MIG Process Control SettingsSelect Wire Size Recommendation Wire Speed Select VoltageSide View Of Gun Angle Holding And Positioning Welding GunPush Perpendicular Drag Conditions That Affect Weld Bead ShapeShort Normal Long Slow NormalPoor Weld Bead Characteristics Good Weld Bead CharacteristicsGun Movement During Welding Troubleshooting − Porosity Troubleshooting − Excessive SpatterTroubleshooting − Excessive Penetration Possible Causes Corrective ActionsTroubleshooting − Lack Of Penetration Troubleshooting − Incomplete FusionTroubleshooting − Burn-Through Troubleshooting − Waviness Of Bead Troubleshooting − DistortionWeld bead Troubleshooting Guide For Semiautomatic Welding Equipment Common MIG Shielding GasesApplication Readjust welding parameters Welding arc not stable Wire slipping in drive rollsWelding power source Drive rolls if necessary087 Drive Roll And Wire Guide KitsGrooved 056 0.9 mm 204Service Your distributor also givesSupport Miller Electric Mfg. Co To locate a Distributor or Service Agency visitFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s