Fine Tuning a Miller Calibration

If you have performed a calibration on a miller machine, and the amps are still off between the machine and hand remote, this is the tutorial for you.

STEP#1 First, with your remote unplugged from the machine, go into each mode ie, 7018, 6010, tig and set the max to the same number (ie, 272).  once done and confirmed, proceed to step#2

STEP#2 We are going to do a calibration <- don't worry if its off. the next step will handle that.

STEP#3 If the calibration is still slightly off, we are going to figure out how off the calibration is and on which end. What I mean is its off because the remote and machine don't share either the same bottom reference, top reference, or both. 

Use the following real world examples as your guide:

EXAMPLE#1

At minimum your machine shows 20 and your hand remote shows 20. But, if you increase your hand remote, and the amps on the machine only move off 20 until you see 25 on the hand remote. This classic scenario shows us the bottom end is off by 5 (25-20). what that means is whatever number you got for minimum from your calibration ie, 20, you must substract 5. so redo calibration with "15" this time.

EXAMPLE#2

At maximum your machine shows 300 and your hand remote shows 300. But, you notice the machine arrives at the max number before the hand remote does. Closer inspection, shows you when the machine initially gets to max, the hand remote shows 288. This scenario found on trailblazers shows us the top end is off by 12 (300-288). What that means is if the max is 300 for example on your machine, you must add 12 to the max calibration. in this case, 312 would be your new number. but leave your machine at 300.

Example#3

Having performed either EXAMPLE#1 or EXAMPLE#2, your calibration is still slightly off. Revisiting example #1 our machine moves off 20 not now when the hand remote is at 25 but 22 which is closer but they are still out. In this case, instead of using the number 15 for minimum calibration from example #1, we go a bit further, and use 14 or 13. 

Example#4

Having performed either EXAMPLE#1 or EXAMPLE#2, your calibration is still slightly off. Revisiting example #2 our machine arrives at max  not now when the hand remote is at 288 but at 297 which is closer but they are still out. In this case, instead of using the number 312 for maximum calibration from example #2, we go a bit further, and use 315 --> (300-297 = 3 + 312 = 315)

These four examples should allow you to achieve an accurate calibration without accessing an advance calibration which currently is only accessible to myself.