Miller Electric XR A, XR W manual Troubleshooting, Wire Feeder Trouble

6-13. Troubleshooting

A. Wire Feeder Trouble

Trouble	Remedy
Pressing gun trigger does not energize	Secure plug from gun control cable into Gun Control receptacle on feeder (see Section 4-6).
feeder. Welding wire is not energized.
Shielding gas flows.
	Secure 115 VAC input plug connection (see Section 4-11).
	Check fuse F1 (see Section 6-11).
	Check water connection to feeder or gun (see Sections 4-6and 4-8).
	Check for kinks in water hose.
	Be sure coolant supply is turned On (see Section 5-14).
	Have nearest Factory Authorized Service Station/Service Distributor check optional water flow switch,
	if applicable (see Section 6-12).
Wire feeds, shielding gas flows, but	Secure 115 VAC/contactor control plug connection (see Section 4-11).
welding wire is not energized.
	See Troubleshooting section in welding power source manual.
	Check plug PLG50, PLG51 and PLG52 connections (see Section 4-12).
Wire feeds erratically.	Check position of Motor Torque switch (see Section 5-11).
	Adjust drive roll pressure if necessary (see Section 4-14).
	Replace or clean drive rolls as necessary (see Sections 6-2and 6-3).
	Align drive roll with opening in gun conduit fitting and groove in bearing (see Section 6-3).
Arc varies and welding wire is kinked	Place Motor Torque switch in low torque position if welding with .030 (0.8 mm) aluminum welding wire (see
when feeding out gun.	Section 5-11).
Pressing gun trigger will not feed wire,	Reset circuit breaker CB1 (see Section 6-11).
wire is not energized, shielding gas
flows, and Jog switch activates motor.
Feeder feeds wire but remains in run-in	Route weld cable through current sensing relay (see Section 4-8).
mode after arc initiation.
	If constant current (CC) welding, be sure PLG5 is in EXT. position on PC1, and voltage sensing lead is
	connected (see Section 4-10).
	If constant voltage (CV) welding, be sure PLG5 is in INT. position on PC1, and that voltage sensing lead
	is not connected (see Section 4-10).
Feeder feeds wire, but switches from	Be sure PLG5 is in INT. position on PC1. Disconnect voltage sensing clamp from workpiece (see Section
weld mode to run-in mode while CV	4-10).
welding with voltage sensing lead
installed.
Shielding gas leak through gas valve in	Reduce shielding gas pressure at regulator flowmeter. Do not exceed 50 psi (345 kPa).
gun.

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