Related Manuals for Miller Electric OM-230
Summary of Contents for Miller Electric OM-230
- Page 1 Visit our website at www.MillerWelds.com Millermatic 252 OM-230 693C 2007−11 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source and Wire Feeder File: MIG (GMAW)
- Page 2 ISO 9001:2000 Quality System Standard. particular model are also provided. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets.
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Page 3: Table Of Contents
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage ............... . 1-2. - Page 4 TABLE OF CONTENTS SECTION 8 − MIG WELDING (GMAW) GUIDELINES 8-1. Typical MIG Process Connections 8-2. Typical MIG Process Control Settings 8-3. Holding And Positioning Welding Gun 8-4. Conditions That Affect Weld Bead Shape 8-5. Gun Movement During Welding 8-6. Poor Weld Bead Characteristics 8-7.
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Page 5: Section 1 − Safety Precautions - Read Before Using
DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit volt- age. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone! D Disconnect input power or stop engine before installing or servicing this equipment. - Page 6 OM-230 693 Page 2 D Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use.
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Page 7: Additional Symbols For Installation, Operation, And Maintenance
D Be sure this welding machine is installed and grounded according to this manual. D If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area. OM-230 693 Page 3... -
Page 8: California Proposition 65 Warnings
To reduce magnetic fields in the workplace, use the following procedures: OM-230 693 Page 4 For Gasoline Engines: Engine exhaust contains chemicals known to the State of California to cause cancer, birth defects, or other reproduc- tive harm. -
Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation
D Isoler la pince de masse quand pas mis à la pièce pour éviter le contact avec tout objet métallique. D Ne pas raccorder plus d’une électrode ou plus d’un câble de masse à une même borne de sortie de soudage. fre_som_2007−04 Entretenir l’appareil OM-230 693 Page 5... - Page 10 D Porter des vêtements confectionnés avec des matières résistan- tes et ignifuges (cuir, coton lourd ou laine) et des bottes de protection. OM-230 693 Page 6 LE SOUDAGE peut provoquer un in- cendie ou une explosion. Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peu...
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Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance
OM-230 693 Page 7... -
Page 12: Proposition Californienne 65 Avertissements
Californie reconnaît qu’ils provoquent des cancers et des malformations congénitales ou autres problèmes de procréation. Se laver les mains après manipu- lation. OM-230 693 Page 8 LE RAYONNEMENT HAUTE FRÉ- QUENCE (H.F.) risque de provoquer des interférences. -
Page 13: Principales Normes De Sécurité
Les porteurs d’implants doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de soudage par points, de gougeage, du coupage plasma ou de chauffage par induc- tion. Si le médecin approuve, il est recommandé de suivre les procédures précédentes. OM-230 693 Page 9... - Page 14 OM-230 693 Page 10...
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Page 15: Section 3 − Definitions
575 V 0.8* 0.46* Dimensions Net Weight Without Gun H: 30 in (762 mm) 205 lb W: 19 in (483 mm) W: 19 in (483 mm) (93 kg) (93 kg) D: 40 in (1016 mm) OM-230 693 Page 11 0.13*... -
Page 16: Welding Power Source Duty Cycle And Overheating
60% Duty Cycle At 200 Amperes 6 Minutes Welding 4 Minutes Resting Overheating 4-3. Volt-Ampere Curves OM-230 693 Page 12 A complete Parts List is available at www.MillerWelds.com 60 70 80 90 100 % DUTY CYCLE 40% Duty Cycle At 250 Amperes... -
Page 17: Connecting To Weld Output Terminals
Work Cable Boot Route cable through front panel opening. Slide boot onto work cable. Negative (−) Output Terminal Connect cable to terminal and cover connection with boot. Close door. 804 909-A OM-230 693 Page 13... -
Page 18: Connecting Spoolmatic) 15A Or 30A Gun
4-6. Connecting Spoolmatic) 15A Or 30A Gun Tools Needed: 3/4, 5/8 in OM-230 693 Page 14 A complete Parts List is available at www.MillerWelds.com Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar. Weld Cable Shielding Gas Hose Route weld cable through opening in front panel. -
Page 19: Connecting Xr Aluma-Pro, Xr Edge, Xr-A Gun, Or Xr-A Python
Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar. If Aluma-Pro push/pull gun has a listed SUP value, set the power source to match the SUP value (see Section 5-5). Ref. 804 910-A / 804 936-A OM-230 693 Page 15... -
Page 20: Setting Gun Polarity For Wire Type
(FCAW). Drive assembly becomes negative. 4-9. Installing Gas Supply Tools Needed: 1-1/8, 5/8 in OM-230 693 Page 16 A complete Parts List is available at www.MillerWelds.com Work Clamp Lead Negative Terminal Argon Gas Or Mixed Gas... -
Page 21: Installing Wire Spool And Adjusting Hub Tension
Open door. Jumper Link Label Check label − only one is on unit. Input Voltage Jumper Links Move jumper links to match input voltage. Close and secure access door. 153 980-D / 144 916-E / 804 911-A OM-230 693 Page 17... -
Page 22: Electrical Service Guide
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table 310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements. OM-230 693 Page 18 A complete Parts List is available at www.MillerWelds.com... -
Page 23: Selecting A Location And Connecting Input Power
Section 4-12 (fused disconnect switch shown). Connect plug to receptacle if hard wiring method is not used. Close and secure door on disconnect device. Remove lockout/tagout device, and place switch in the On position. OM-230 693 Page 19... -
Page 24: Threading Welding Wire
Press gun trigger until wire comes out of gun. Reinstall contact tip and nozzle OM-230 693 Page 20 A complete Parts List is available at www.MillerWelds.com Hold wire tightly to keep it from unraveling. - Page 25 A complete Parts List is available at www.MillerWelds.com Notes OM-230 693 Page 21...
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Page 26: Weld Parameters
A complete Parts List is available at www.MillerWelds.com 4-15. Weld Parameters OM-230 693 Page 22... - Page 27 A complete Parts List is available at www.MillerWelds.com 226 650-B OM-230 693 Page 23...
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Page 28: Section 5 − Operation
Jog mode − When loading a new roll of wire or if the gun trigger is accidentally pressed, gas will shut off after 1 minute and wire will shut off after 2 minutes saving wire and gas. OM-230 693 Page 24 A complete Parts List is available at www.MillerWelds.com Voltage Control Turn control clockwise to increase voltage. - Page 29 (or the wire feed adjustment knob located on the bottom handle of the spool gun) to the desired setting for the selected gun. To return to weld mode after the Run− in speed change, pull the trigger momen- tarily (one second). OM-230 693 Page 25...
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Page 30: Voltmeter And Wire Feed Speed Meter Operation
Jog wire feed speed for the spool gun and push/pull gun is limited to 300 ipm (7.6 m/min). OM-230 693 Page 26 A complete Parts List is available at www.MillerWelds.com... -
Page 31: Timers
Controls the amount of time that the arc will be inactive after the Spot timer times out. The range is from 0 to 120 seconds. To save settings and exit the TIMERS menu, depress the gun trigger. OM-230 693 Page 27... -
Page 32: Set Up Push Motor Torque (Sup) Or Reset (Res)
Rotate the left knob counterclockwise (CCW) to find the particular item, and rotate the right knob to change the setting. OM-230 693 Page 28 A complete Parts List is available at www.MillerWelds.com The following items can be adjusted by rotating the left knob counterclockwise (CCW): Set up Push Motor Torque (SUP) −... -
Page 33: Section 6 − Maintenance &Troubleshooting
The groove closest to the motor shaft is the proper groove to thread (see Section 4-14). Drive Roll Securing Nut Turn nut one click to secure drive roll. Ref. 804 914-A OM-230 693 Page 29... -
Page 34: Aligning Drive Rolls And Wire Guide
6-4. Aligning Drive Rolls and Wire Guide Tools Needed: OM-230 693 Page 30 A complete Parts List is available at www.MillerWelds.com Correct Incorrect Turn Off power. View is from top of drive rolls looking down with pressure assembly open. Drive Roll Securing Nut... -
Page 35: Troubleshooting
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. A complete Parts List is available at www.MillerWelds.com OM-230 693 Page 31... - Page 36 HL.P 005 appears on meters. Wire feed malfunction. Check wire feed delivery system. Check gun trigger and leads. Repair or replace gun if necessary. Have Factory Authorized Service Agent check main control board. OM-230 693 Page 32 A complete Parts List is available at www.MillerWelds.com...
- Page 37 Notes OM-230 693 Page 33...
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Page 38: Section 7 − Electrical Diagram
SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram OM-230 693 Page 34... - Page 39 229 485-A OM-230 693 Page 35...
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Page 40: Section 8 − Mig Welding (Gmaw) Guidelines
SECTION 8 − MIG WELDING (GMAW) GUIDELINES 8-1. Typical MIG Process Connections Regulator/ Flowmeter Shielding Gas OM-230 693 Page 36 Wire Feeder/ Power Source Work Clamp Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. -
Page 41: Typical Mig Process Control Settings
Thickness to Amperage (A) (.001 in = 1 ampere) .125 in = 125 A Select Wire Size Select Wire Speed (Amperage) 125 A based on 1/8 in material thickness ipm = inch per minute Select Voltage OM-230 693 Page 37... -
Page 42: Holding And Positioning Welding Gun
Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in (13 mm) past end of nozzle, and tip of wire is positioned correctly on seam. End View Of Work Angle End View Of Work Angle OM-230 693 Page 38 0 -15 Side View Of Gun Angle GROOVE WELDS... -
Page 43: Conditions That Affect Weld Bead Shape
Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed (weld current), and voltage. Short Short FILLET WELD ELECTRODE EXTENSIONS (STICKOUT) Slow Push Perpendicular GUN ANGLES AND WELD BEAD PROFILES Normal ELECTRODE EXTENSIONS (STICKOUT) Normal Normal GUN TRAVEL SPEED Drag Long Long Fast OM-230 693 Page 39 S-0634... -
Page 44: Gun Movement During Welding
Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads works better. 8-6. Poor Weld Bead Characteristics 8-7. Good Weld Bead Characteristics OM-230 693 Page 40 Stringer Bead − Steady Movement Along Seam Weave Bead − Side To Side... -
Page 45: Troubleshooting − Excessive Spatter
Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle. Excessive Penetration − weld metal melting through base metal and hanging underneath weld. Corrective Actions Select lower voltage range and reduce wire feed speed. Increase travel speed. S-0636 S-0635 S-0639 OM-230 693 Page 41... -
Page 46: Troubleshooting − Lack Of Penetration
Insufficient heat input. Improper welding technique. 8-13. Troubleshooting − Burn-Through Possible Causes Excessive heat input. OM-230 693 Page 42 Lack Of Penetration − shallow fusion between weld metal and base metal. Corrective Actions Material too thick. Joint preparation and design must provide access to bottom of groove while maintaining proper welding wire extension and arc characteristics. -
Page 47: Troubleshooting − Waviness Of Bead
Use restraint (clamp) to hold base metal in position. Make tack welds along joint before starting welding operation. Select lower voltage range and/or reduce wire feed speed. Increase travel speed. Weld in small segments and allow cooling between welds. S-0641 S-0642 OM-230 693 Page 43... -
Page 48: Common Mig Shielding Gases
Restriction in gas line. Loose or broken wires to gas solenoid. Gas solenoid valve not operating. Incorrect primary voltage connected to welding power source. OM-230 693 Page 44 Application Short Circuiting Short Circuiting Steel Stainless Steel Increase pressure setting on wire feed rolls. - Page 49 Gun in poor shape or loose connection inside gun. Remedy Adjust pressure setting on wire feed rolls. Replace worn drive rolls if necessary. Match liner and contact tip to wire size and type. Readjust welding parameters. Repair or replace gun as necessary. OM-230 693 Page 45...
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Page 50: Section 9 − Parts List
.023/.025 in. .023/.025 in. .030/.035 in. .030/.035 in. .030 in. .030 in. .035 in. .035 in. .045 in. .045 in. OM-230 693 Page 46 Drive Roll Kit No. Metric Part No. 0.6 mm 087 131 087 130 0.8/0.9 mm 204 579 203 526 0.8 mm... - Page 51 Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to 1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in for your local material and workmanship at the time it is shipped by Miller.
- Page 52 File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. 2007 Miller Electric Mfg. Co. 2007−01 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA...