Troubleshooting, Trouble Remedy | Miller Electric 1000, 1250

6-3. Troubleshooting



	Trouble		Remedy

No weld output; unit completely		Place line disconnect device in On position (see Section 4-13).
inoperative; pilot light PL1 off.

		Check for open line fuse(s), and replace if open (see Section 4-13).

		Check for proper input power connections (see Section 4-13).

		Check for proper jumper link position (see Section 4-13).

		Check fuse F1, and replace if necessary (see Section 6-2).

No weld output; pilot light PL1 on.		Unit overheated. Allow unit to cool with fan On (see Section 4-2).

		If using remote control, place Output (Contactor) switch in Remote 14 position, and connect remote
		control (see Sections 4-9and 4-10). If remote is not being used, place switch in On position (see
		Section 5-1).

		Check, repair, or replace remote control.

No weld output; power switch pilot light		Check for proper input power connections (see Section 4-13).
on; fan off.
on; fan off.		Check for open line fuse(s), and replace if open, or reset circuit breaker (see Section 4-13).


		Turn power switch off then back on. If no output condition remains, have Factory Authorized Service
		agent check SCR’s.

Limited weld output and low		Check position of Remote Amperage/Voltage Control switch (see Section 5-1).
open-circuit voltage.
open-circuit voltage.		Check for open line fuse(s), and replace if open (see Section 4-13).


		Check for proper input power connections (see Section 4-13).

		Check for proper jumper link position (see Section 4-13).

		Clean and tighten all weld output connections.

Unit provides only maximum or		Have Factory Authorized Service Agent check control board PC1 and hall device HD1.
minimum weld output.
minimum weld output.		Check position of Remote Amperage/Voltage Control switch (see Section 5-1).


Erratic or improper weld output.		Use proper size and type of weld cable (see Section 4-8).

		Clean and tighten all weld connections.

		Check wire feeder installation according to Owner’s Manual.

		Check position of Process selector switch (see Section 5-1).

		Have Factory Authorized Service Agent check control board PC1 and hall device HD1.

No 115 volts ac output at duplex recep-		Reset circuit breaker CB1 (see Section 4-7).
tacle, Remote 14 receptacle,
or terminal strip 1T.

No 24 volts ac output at Remote 14 re-		Reset circuit breaker CB2 (see Section 4-7).
ceptacle or terminal strip 1T.

Fan not operating. Note: fan only runs		Check for and remove anything blocking fan movement.
when cooling is necessary.
when cooling is necessary.		Have Factory Authorized Service Agent check fan motor.
		Have Factory Authorized Service Agent check fan motor.

Wandering arc; poor control of arc		Reduce gas flow rate.
direction.
direction.		Select proper size tungsten.
		Select proper size tungsten.

		Properly prepare tungsten.

Tungsten electrode oxidizing and not		Shield weld zone from drafts.
remaining bright after conclusion of
remaining bright after conclusion of		Increase postflow time.
weld.		Increase postflow time.

		Check and tighten all gas fittings.

		Properly prepare tungsten.

		Check for water in torch, and repair torch if necessary. See torch Owner’s Manual.

Digital meter not working properly.		Have Factory Authorized Service Agent check control board PC1 and connections, and replace if
		necessary.

OM-2223 Page 25

1250, 1000 specifications

Miller Electric is a renowned name in the welding and fabrication industry, providing high-quality machines and equipment that cater to a range of applications. Among its impressive line of products are the Miller Electric 1000 and 1250 arc welding machines, designed to offer exceptional performance in both industrial and commercial environments.

One of the main features of the Miller Electric 1000 model is its robust construction, making it ideal for heavy-duty welding tasks. It boasts a powerful output that provides a significant range of welding power, accommodating various electrode sizes and types. This flexibility allows for effective use in a variety of welding processes, including Stick, TIG, and MIG, ensuring that users can tackle a wide array of jobs without needing multiple machines.

The Miller Electric 1250 takes things a step further, delivering even more power and efficiency. With advanced inverter technology, the 1250 offers increased duty cycles and improved energy efficiency, which can lead to cost savings over time. The inverter design also allows for a lighter weight compared to traditional transformer-based machines, enhancing portability and ease of use on job sites.

Both models are equipped with intuitive digital controls and advanced monitoring systems, allowing users to make precise adjustments easily. Features like the Auto-Set functionality simplify the setup process, enabling welders to select materials and thicknesses, and the machine automatically adjusts parameters for optimal results. This is especially beneficial for those who may not have extensive experience, providing a level of confidence in achieving high-quality welds.

Another important characteristic of both the 1000 and 1250 is their adaptability to different environments. They are designed to withstand challenging conditions, including extreme temperatures and dust, making them suitable for outdoor applications and remote job sites. Additionally, Miller Electric prioritizes user safety and comfort, incorporating features like integrated thermal overload protection and ergonomic designs that reduce operator fatigue during prolonged use.

In summary, the Miller Electric 1000 and 1250 arc welding machines represent the pinnacle of modern welding technology. With their powerful output, advanced features, and durable construction, they are well-suited for a range of industrial applications. Whether for routine maintenance or heavy fabrication tasks, these machines deliver reliability and precision, essential for any professional welder.