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We use Miller Auto Axcess 450 integrated with ABB robot. The problem is the Robot suddenly stop welding and the Miller Welding set indicate 'Over Current'.But after off and on,the robot works for a while and then goes back to the same problem mentioned above. From the manual, it stated that we have to press Purge/Jog buttons to clear the error and set the current value lower. Unfortunately we have tried that but no effect.

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6 Suggested Answers

6ya6ya
  • 2 Answers

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Posted on Jan 02, 2017

  • 2 Answers

SOURCE: Trying to weld with Hobart 125 EZ

If you are using flux wire and not shielding gas, your clamp should be positive and the wire should be negative. Heat is provided by the electrical arc that happens between the wire and the material. Your welder by itself does not pre heat the material and with 3/16 material you should not need to preheat anyway.

The electrical arc is kept consistent by adjusting the wire feed rate and the current applied. You will need to experiment with these settings to find what works best with your welder. For this welder and 3/16 material, I would suggest you start at the upper end of the current scale and about a third of the way up on wire speed. The welder might have a chart for these settings in the manual or inside cover.

If the wire feeds too fast, it will push the probe around and you will feel pressure as the wire feeds out. If the speed is too slow you will get large spatters and intermittent arcs. When properly adjusted the arc will sound even and consistent. The arc gap should always be about 1/8 of an inch.

To maintain enough heat for good penatration, do not move the probe too fast, work in a pattern and watch the weld pool (melted metal) and not the arc. Watching the weld pool will clue you in if you are moving too fast or too slow.

I hope this helps.

-Scott

Posted on Feb 03, 2009

  • 7 Answers

SOURCE: Miller Big 40 will not weld and has no current at the A/C outlet

open inspection door,which also the fine tuner knob is ,there's a 2x4 size circut board that snaps out with little force to remove,this is the voltage regulator board,look for 4700 ohm resisitor burnt into,tv tech can fix or order new board at $227.00 what i paid.

Posted on Feb 04, 2009

  • 11 Answers

SOURCE: Welding current traveling over electrical equipment grounds.

Are you saying that the Ground cable in your extention cables are overheating / melting the insulation

Posted on Feb 04, 2009

  • 5 Answers

SOURCE: handler 140 wire jerky when welding

make sure rollers are clean and slots not wore out check alignment
do not over tighten wire feed so it smashes the wire
flux wire is hard to get a good setting
make sure if you can set it for gas welding it is not on this setting

Posted on Apr 08, 2009

mamicheddy
  • 79 Answers

SOURCE: miller bobcat 225g plus welding problem

If the idle is not working, then it is either you idle solenoid attached to the carberator or your idle board is bad. If you apply 12Vdc to the idle solenoid is should move, if not then the solenoid is shot, no good. If it works then you idle board is bad. Also, check to see if you are 60Hertz by measuring at the outlet with a frequency meter. I recommend a Fluke meter. You should have 120Vac and 60HZ at the outlet. If the frequency is low then your engine speed needs to be increased. The idle solenoid could be causing all these problems.

Posted on May 08, 2009

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