Miller Electric OM-230 manual Troubleshooting

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

6-5. Troubleshooting



Trouble		Remedy

No weld output; wire does not feed.		Be sure line disconnect switch is On (see Section 4-13).

		Replace building line fuse or reset circuit breaker if open (see Section 4-13).

		Secure gun trigger connections (see welding gun Owner’s Manual).

		HL.P 001 appears on meters. Turn power switch off and back on, if HL.P 001 appears on meters again,
		have Factory Authorized Service Agent check unit.

		HL.P 002 appears on meters. Thermistor T is detecting an overheating condition. Wait for unit to cool
		allowing the fan to run. After unit is cool, if HL.P 002 message remains, have Factory Authorized Service
		Agent check for an open Thermistor T (see Section 6-2).

		HL.P 004 appears on meters. Reset message by releasing the trigger or removing stuck wire causing
		short circuit (see Section 5-2) . If message remains, have Factory Authorized Service Agent check for
		shorted trigger leads.

		Have Factory Authorized Service Agent check Power switch.

		Have Factory Authorized Service Agent check all board connections and main control board.

No Weld Output; wire feeds.		Connect work clamp to get good metal to metal contact.

		Replace contact tip (see welding gun Owner’s Manual.

		HL.P 003 appears on meters, have Factory Authorized Service Agent check main control board and main
		rectifier.

Low weld output.		Connect unit to proper input voltage or check for low line voltage (see Section 4-13).

		Check input voltage jumper links and correct position if necessary (see Section 4-11).

		Have Factory Authorized Service Agent check main control board.

Fan motor does not run.		Have Factory Authorized Service Agent check fan-on-demand circuit.

Low, high, or erratic wire speed.		Readjust front panel settings (see Section 5-1).

		Change to correct size drive rolls (see Section 6-3).

		Readjust drive roll pressure (see Section 4-14).

		Replace inlet guide, contact tip, and/or liner if necessary (see welding gun Owner’s Manual).

		Check position of input jumper links (see Section 4-11).

		Have Factory Authorized Service Agent check main control board.

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Contents File MIG Gmaw OM-230 693CProcesses DescriptionFrom Miller to You Table of Contents Typical MIG Process Connections − Parts List− MIG Welding Gmaw Guidelines HOT Parts can cause severe burns Symbol UsageArc Welding Hazards Electric Shock can killFlying Metal or Dirt can injure eyes Fumes and Gases can be hazardousARC Rays can burn eyes and skin Welding can cause fire or explosionMoving Parts can cause injury Welding Wire can cause injuryFire or Explosion hazard Falling Unit can cause injuryAbout Implanted Medical Devices Principal Safety StandardsCalifornia Proposition 65 Warnings EMF InformationUNE Décharge Électrique peut entraîner la mort Symboles utilisésLE Soudage peut provoquer un in cendie ou une explosion DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peuvent être dangereux LA Chute DE L’APPAREIL peut blesser LE Bruit peut endommager l’ouïeLES Bouteilles peuvent exploser si elles sont endommagées Risque D’INCENDIE OU D’EXPLOLE Soudage À L’ARC risque de provoquer des interférences Proposition californienne 65 AvertissementsLES Fils DE Soudage peuvent provoquer des blessures En ce qui concerne les implants médicaux Principales normes de sécuritéInformation EMF OM-230 693 Specifications Symbols And DefinitionsOverheating Welding Power Source Duty Cycle And OverheatingVolt-Ampere Curves Installing Work Cable And Clamp Connecting To Weld Output TerminalsConnecting Spoolmatic 15A Or 30A Gun 32 in 2.4 mm Connecting XR Aluma-Pro, XR Edge, XR-A Gun, Or XR-A PythonGun End Gun Liner Wire Outlet Guide 11/16 Setting Gun Polarity For Wire TypeInstalling Gas Supply Polarity Changeover Label InformationPositioning Jumper Links Installing Wire Spool And Adjusting Hub Tension127 206 Electrical Service GuideInput Voltage 200 230 460 575L2L1 230 VAC Selecting a Location And Connecting Input Power18 in 457 mm of space for airflow =GND/PE Earth Ground Remove gun nozzle and contact tip Threading Welding WirePressure ScaleOM-230 693 Weld Parameters 226 650-B Controls − OperationTrigger and pull the trigger again momentarily one second JOG ModeRun−in Wire Feed Speed Settings Welding Status Voltmeter And Wire Feed Speed Meter OperationJog Mode Power Up StatusTimers Set Up Push Motor Torque SUP Or Reset rES Unit Overload Routine MaintenanceChanging Drive Roll and Wire Inlet Guide View is from top of drive rolls Aligning Drive Rolls and Wire GuideTurn Off power Assembly openTroubleshooting Trouble Remedy OM-230 693 − Electrical Diagram 229 485-A Typical MIG Process Connections − MIG Welding Gmaw GuidelinesSelect Voltage Typical MIG Process Control SettingsWire Size Amperage Range Select Wire Size Recommendation Wire SpeedSide View Of Gun Angle Holding And Positioning Welding GunSlow Normal Conditions That Affect Weld Bead ShapePush Perpendicular Drag Short Normal LongGun Movement During Welding Poor Weld Bead CharacteristicsGood Weld Bead Characteristics Possible Causes Corrective Actions Troubleshooting − Excessive SpatterTroubleshooting − Porosity Troubleshooting − Excessive PenetrationTroubleshooting − Burn-Through Troubleshooting − Lack Of PenetrationTroubleshooting − Incomplete Fusion Weld bead Troubleshooting − Waviness Of BeadTroubleshooting − Distortion Application Troubleshooting Guide For Semiautomatic Welding EquipmentCommon MIG Shielding Gases Drive rolls if necessary Welding arc not stable Wire slipping in drive rollsReadjust welding parameters Welding power source0.9 mm 204 Drive Roll And Wire Guide Kits087 Grooved 056Support ServiceYour distributor also gives Your distributor and/or equipment manufacturer’s To locate a Distributor or Service Agency visitMiller Electric Mfg. Co For assistance in filing or settling claims, contact