Manuals / Miller Electric / Power Tools / Welding System

Miller Electric Welder Maintenance & Troubleshooting, Routine Maintenance, Months

Models: Welder

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SECTION 5 – MAINTENANCE & TROUBLESHOOTING

5-1. Routine Maintenance

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

3 Months

Replace damaged or unreadable label.

Repair or replace cracked cables.

Replace cracked torch body.

Repair or replace cracked cables and cords.

Clean and tighten weld terminals.

6 Months

Blow out inside.

5-2. Blowing Out Inside Of Unit

Y Do not remove case when blowing out inside of unit.

To blow out unit, direct airflow through front and back louvers as shown.

801 914

OM-196 188 Page 25

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Miller Electric Welder Maintenance & Troubleshooting, Routine Maintenance, Blowing Out Inside Of Unit, Months

Contents

Processes OM-196 188KDescription From Miller to You Table of Contents 100 Introduction to Programming101 Control Menu SetupStandards DirectivesElectric 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 explo- sion Flying Metal can injure eyesPrincipal Safety Standards About Pacemakers EMF InformationLES Fumées ET LES GAZ peuvent être dangereux Signification des symbolesConsignes DE Securite Lire Avant Utilisation UN Choc Électrique peut tuerLE Bruit peut affecter l’ouïe LE Soudage peut provoquer un incendie ou une explosionDES Particules Volantes peuvent blesser les yeux DES Pièces Chaudes peuvent pro- voquer des brûlures gravesDES Organes Mobiles peuvent provoquer des blessures Risque D’INCENDIE OULA Chute DE L’APPAREIL peut blesser ’EMPLOI Excessif peutInformation sur les champs électromagnétiques Principales normes de sécuritéConsignes relatives aux stimulateurs cardiaques Manufacturer’s Warning Label Definitions Definitions60 s ∠ =Harmonic Data per IEC 61000-3-12, draft Symbols And DefinitionsManufacturer’s Rating Label Harmonic DataSpecifications InstallationDimensions And Weight Tipping Connection DiagramSelecting a Location Movement LocationDuty Cycle Weld Output Terminals And Selecting Cable SizesVolts AC Duplex Receptacle And Circuit Breakers 10 100% Duty CycleAlways connect grounding conductor first Electrical Service GuideConnecting Input Power Three-PhaseExample Receptacle Rear Panel ConnectionsSocket Information Peripheral Receptacle FunctionsFront Touch Sensor Board PC18 Switch S1 SettingsTouch Sensor Operation Top ViewTurn Off welding power source and weld control Connecting Setup Pendant To Welding Power SourceOperational Terms OperationMeter Functions Lower Front Panel ControlsUpper Front Panel Controls Volt-Ampere Curves Duty Cycle And OverheatingOverheating Increase Button Setup Pendant ControlsMonths Maintenance & TroubleshootingRoutine Maintenance Blowing Out Inside Of UnitRemoving Case and Measuring Input Capacitor Voltage Help 1 Display Voltmeter/Ammeter Help DisplaysFront Panel Error Displays LED2 LED4 LED8 LED10 LED11 LED6 LED3 LED5 LED7 LED9 LED12 Weld Interface Board PC12 Diagnostic LED’sStatus Diagnosis Diagnostic LED’s On Weld Interface Board PC12Customer Interface Board PC14 Diagnostic LED’s Diagnostic LED’s On Customer Interface Board PC14 Motor Board PC13 Diagnostic LED’s Troubleshooting Diagnostic LED’s On Motor Board PC13Trouble Remedy OM-196 188 Circuit Diagram For Welding Power Source Electrical Diagrams203 505-A Circuit Diagram For Control Board PC1 Part 1 203 311 1 Circuit Diagram For Control Board PC1 Part 2 203 311 2 Circuit Diagram For Control Board PC1 Part 3 203 311 3 Circuit Diagram For Function/Meter Board PC3 190 Circuit Diagram For Interconnect Board PC2 OM-196 188 Circuit Diagram For Interface Module 193 709-A Circuit Diagram For Microprocessor Board PC11 191 10. Circuit Diagram For Motor Board PC13 212 354-A 11. Circuit Diagram For Switch Board PC15 12. Circuit Diagram For Junction Board PC16 13. Circuit Diagram For Interface Board PC12 Part 1 191 843-A Part 1 14. Circuit Diagram For Interface Board PC12 Part 2 191 843-A Part 2 15. Circuit Diagram For Customer Interface Board PC14 Part 1 Pensar 86147s03 Part 1 16. Circuit Diagram For Customer Interface Board PC14 Part 2 Pensar 86147s03 Part 2 17. Circuit Diagram For Customer Interface Board PC14 Part 3 Pensar 86147s03 Part 3 18. Circuit Diagram For Touch Sensor Board PC18 19. Circuit Diagram For Setup Pendant 200 21. Circuit Diagram For Power Distribution Board PC20 Complete Assembly Parts ListPLG21 RC10 Optional 194 Setup PendantOM-196 188 Programming Instructions for Standard Pulse Welding Programs Program Hardwire Selected Softwire SelectedIntroduction to Programming Pulse MIG ProgramsProgram 2 1.0 mm Steel .040, 80-20 Argon-CO2 Program 1 1.2 mm Steel .045, 98-2 Argon-OxyProgram 4 .8 mm 316 .030, 98-2 Argon-CO2 Program 3 1.2 mm Steel .045, 80-20 Argon-CO2Gas Ar CO2 / 19 L/min 40 CFH Program 6 1.2 mm 316 .045, 98-2 Argon-CO2 Program 5 1.0 mm 316 .040, 98-2 Argon-CO2Program 8 1.2 mm 308L .045, 98-2 Argon-CO2 Program 7 1.0 mm 308L .040, 98-2 Argon-CO2Program 2 1.4 mm Metal Core .052, 95-5 Argon-CO2 Program 1 1.2 mm Metal Core .045, 95-5 Argon-CO2Program 4 1.0 mm ER 4043 .040, Argon Wire Size/Type 1.2 mm .045 ER Gas Ar / 19 L/min 40 CFHWire Size/Type 1.0 mm .040 ER Gas Ar / 19 L/min 40 CFH Program 3 1.2 mm ER 4043 .045, ArgonProgram 6 1.2 mm ER 5356 .045, Argon Program 5 1.0 mm 5356 .040, ArgonProgram 8 1.0 mm Steel .040, 98-2 Argon-Oxy Program 7 .8 mm Steel .030, 98-2 Argon-OxyGas Ar Oxy/ 19 L/min 40 CFH Setup Pendant Mode Select Button Setup Pendant Parameter Select Button Setup Pendant Parameter Increase And Decrease Buttons Getting Started for Pulse Welding Setting Preflow Sequence DisplayWeld Cycle For Pulse Welding Setting Crater Sequence Display Setting Weld Sequence DisplayTeaching a Pulse Welding Program Setting Postflow Sequence DisplayPulse Waveform Explained IPM Teach Points ExplainedPage Setting Teach Point Parameters For Pulse Welding Program Sec Run-In Trim Wire Size/Type GasCard # Gun Model Flowrate PWms VpkChanging To Adaptive Pulse Welding Teaching a MIG Welding ProgramWeld Cycle For Mig Welding Changing To Mig Welding Setting Start Sequence Display Setting Retract Sequence Display Poflw Sec Parameter Select Postflow Parameters Display Setting Run-in Sequence DisplaySelecting And Adjusting SharpArcE Control Setting SharpArcE ControlInstalling Data Card Using the Optional Data CardUsing The Data Card Yes Naming Programs And Writing To CardReading From Card Deleting Programs From Card Reading Or Deleting From An Empty CardSelecting Security Lock Security lock works only when a data card is insertedDisplay Features Settings Default SetupSetup Flow Chart Features Settings Default SectionT u p Using Setup DisplaysZWX Selecting Or Changing Access CodeSelecting Auxiliary Output Selecting Voltage CorrectionSelecting Voltage Sensing Method Selecting Arc Start Method Resetting Arc TimeSelecting Units For Wire Feed Speed And Motor Type Defining Display Value Selecting Wire TypeSelecting Arc Start/Volt Sense Error Shutdown Resetting MemoryProgram No Output a Output B Output C Selecting Program Name FeatureRemote Program Setting Remote Program SelectFlow Selection Jog Wire Feed Speed SelectionStick Check Selection Arc Voltage Error SelectionExiting The Setup Menu Setting Ramps FunctionSoftware Version Number Control Menu Using Menu DisplaySetting Adaptive Parameters Setting Rise Time ParameterSetting Auto Configure Parameter Setting Sharp Start On/Off Setting Retract On/OffExiting The Control Menu Page Support ServiceMiller Electric Mfg. Co Owner’s Record