Miller Electric DS-75D12 Troubleshooting, Disconnect power before troubleshooting, Trouble Remedy

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6-4. Troubleshooting

 

 

 

 

Y Disconnect power before troubleshooting

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Trouble

Remedy

 

 

Wire feeds, shielding gas flows, but

Check cable connections. Check cables for continuity, and repair or replace cables if necessary

electrode wire is not energized.

(see Section 4-6).

 

 

Wire feeder is on, display does not light

Check and reset circuit breaker at welding power source.

up, motor does not run, gas valve and

 

welding power source contactor do not

 

pull in.

 

 

 

Electrode wire feeding stops or feeds

Check gun trigger connection. See gun Owner’s Manual.

erratically during welding.

 

Check gun trigger. See gun Owner’s Manual.

 

 

 

 

 

 

 

 

 

 

 

 

 

Readjust hub tension and drive roll pressure (see Section 4-16).

 

 

 

 

 

 

 

 

 

Change to correct size drive roll (see 4-12).

 

 

 

 

 

 

 

 

 

Clean or replace dirty or worn drive roll.

 

 

 

 

 

 

 

 

 

Incorrect size or worn wire guides.

 

 

 

 

 

 

 

 

 

Replace contact tip or liner. See gun Owner’s Manual.

 

 

 

 

 

 

 

 

 

Remove weld spatter or foreign matter from around nozzle opening.

 

 

 

 

 

 

 

 

 

Check brushes in drive motor. If brush length is less than 1/4 inch, replace brushes.

 

 

 

 

 

 

 

 

 

Have Factory Authorized Service Agency check drive motor or motor control board PC1.

 

 

Wire birdnests between feeder and

Gun liner has to large of diameter opening, is clogged, or the end of the gun is not close enough

gun.

to the front set of drive rolls.

 

 

Motor runs slowly.

Check for correct input voltage.

 

 

Wire feeder power is on, displays light

Check welding gun trigger leads for continuity, and repair leads or replace gun.

up, but unit is inoperative.

 

 

 

When triggered wire feeds but no gas,

If the welding arc does not establish in 3 seconds after the gun trigger is activated the unit will feed

no contactor.

wire, but turns off contactor and gas valve. If the gun trigger is still activated after two minutes, the

 

 

 

 

wire will stop feeding.

 

 

 

 

 

OM-230 300 Page 26

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Contents Description OM-230 300AProcesses File MIG GmawFrom Miller to You Table of Contents Page Arc Welding Hazards Symbol UsageMarks a special safety message Electric Shock can killFlying Metal can injure eyes ARC Rays can burn eyes and skinWelding can cause fire or explosion Buildup of GAS can injure or killCalifornia Proposition 65 Warnings Principal Safety Standards EMF InformationAbout Pacemakers UNE Décharge Électrique peut entraîner la mort LES Fumées ET LES GAZ peuvent être dangereuxIndique un message de sécurité particulier DES Particules Volantes peuvent blesser les yeux LE Soudage peut provoquer unIncendie ou une explosion DES Pièces Chaudes peuvent provoquer des brûlures graves’EMPLOI Excessif peut SUR Risque D’INCENDIE OU D’EXPLOLA Chute DE L’APPAREIL peut blesser DES Organes Mobiles peuvent provoquer des blessuresPrincipales normes de sécurité En ce qui concerne les stimulateurs cardiaquesDo not remove Safety Collar until instructed to SpecificationsInstalling Swivel Into Pipe Post RatingInstalling Control Box And Adjusting Tilt Installing Boom And Reel SupportInstalling Wire Guide Extension Installing GuardEquipment Connection Diagram Control Box Connections Pin Plug InformationPin Information Motor Speed Wire Type Wire Size Feed Speed Capability Removing Safety Collar And Adjusting BoomWire Type, Size, And Feed Speed Capability Table Gun Recommendation TableInstallation Installing Drive RollsDrive Roll Carrier Ejector Button Pressure Door Assembly RemovalInstalling PD Continuous Wire Guides Installing PD continuous wire guides with PD drive rollsInstalling Non-PD Old Style Wire Guides Installing wire guides with non- PD old- style drive rollsInstalling gun with Accu-Mate connec- tion Installing Welding GunInstalling gun without Installing gun without Accu-Mate con- nectionInstall gun. Lay gun cable out straight. Cut off Above To adjust drive roll pressure, hold nozzleSettings When installing gun, the liner should extend Cut wire offManually Adjusted Run-In S1-1 And S1-2 Setting Internal DIP Switches On Motor BoardsRun-In Disabled S1-1 Left Side Motor Control Board PC101 Right Side MotorEquipment DIP Switch Settings For Models With Meters Only Digital Meter DIP Switch SettingPower Switch Left/Right Select SwitchJog/Purge Voltage Control And Digital Meters Trigger Hold SwitchTrigger Hold Switches Voltage ControlsDisconnect power before maintaining Routine MaintenanceBrush Inspection And Replacement = Check ~ = Clean = Replace Reference EveryDiagnostics Troubleshooting Disconnect power before troubleshootingTrouble Remedy OM-230 300 − Electrical Diagram 204 716-B − Parts List Quantity Control Box Harness Connectors/Receptacles 193 Knob, Pointer 1.250 Dia x .250 Id W/Two Set ScrewsBoom Assembly Boom Assembly -1 Item Drive Roll & Wire Guide Kits See -1 ForDrive Assembly With Motor Left Side Shown Support, Hub & Reel PD-V Page Page Page Service Your distributor also givesSupport For assistance in filing or settling claims, contact To locate a Distributor or Service Agency visitMiller Electric Mfg. Co Your distributor and/or equipment manufacturer’s