Miller Electric Big Blue 600D manual Troubleshooting, Welding

Page 32

7-10. Troubleshooting

A. Welding

Trouble

Remedy

 

 

No weld output.

Be sure Ampere Range switch is not set between positions.

 

 

 

Disconnect equipment from generator power receptacles during start-up.

 

 

 

Reset circuit breaker CB3 and/or CB4 (see Section 7-6).

 

 

 

Place A/V Control switch in Panel position, or place switch in Remote position and connect remote control

 

to Remote A/V Control receptacle RC3 (see Sections 4-7 and 4-8).

 

 

 

Place Output (Contactor) switch in On position, or place switch in Remote position and connect remote

 

contactor to optional Remote 14 receptacle RC3 or terminal strip 3T (see Sections 4-7 and 4-8).

 

 

 

Check and secure connections to Remote 14 receptacle or terminal strip 3T (see Sections 4-7 and

 

4-8).

 

 

 

Check fuse F6, and replace if necessary (see Section 7-6).

 

 

 

Have Factory Authorized Service Agent check brushes and slip rings, and circuit boards PC1 and/or

 

PC2.

 

 

Erratic weld output.

Check and tighten connections both inside and outside unit.

 

 

 

Be sure connection to work piece is clean and tight.

 

 

 

Use dry, properly stored electrodes.

 

 

 

Remove excessive coils from weld cables.

 

 

 

Tighten lead connections to Ampere Range switch.

 

 

 

Have Factory Authorized Service Agent check circuit boards PC1 and/or PC2.

 

 

High or low weld output voltage.

Check engine speed, and adjust if necessary (see Section 7-5).

 

 

 

Check CC/CV switch position.

 

 

 

If low weld output, check fuse F6, and replace if necessary (see Section 7-6).

 

 

 

Have Factory Authorized Service Agent check circuit board PC1.

 

 

Wire feeder not operating.

Reset circuit breaker CB3 and/or CB4 (see Section 7-6).

 

 

 

Check and secure connections to Remote 14 receptacle or terminal strip 3T (see Sections 4-7 and

 

4-8).

 

 

 

Repair or replace wire feeder.

 

 

No amperage control or voltage control.

Place Amperage/Voltage Control switch in correct position.

 

 

 

Check connections to optional Remote 14 receptacle RC3 and terminal strip 3T (see Sections 4-7 and

 

4-8).

 

 

 

Repair or replace remote control device.

 

 

 

Have Factory Authorized Service Agent check optional CV regulator board PC2.

 

 

Low CV weld output.

Set Ampere Range switch to highest range.

 

 

Min or max CV weld output only.

Check position of Amperage/voltage control and Amperage/Voltage Control switch.

 

 

 

Repair or replace remote control device.

 

 

 

Have Factory Authorized Service Agent check optional CV regulator board PC2.

 

 

OM-481 Page 28

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Contents Description OM-481Processes From Miller to You Table of Contents Page Symbol Usage Arc Welding HazardsElectric Shock can kill ARC Rays can burn eyes and skinEngine Hazards Battery Explosion can Blind Moving Parts can cause injuryEngine Exhaust Gases can kill Engine Heat can cause firePrincipal Safety Standards EMF InformationRadiation can cause interference ARC Welding can cause interferenceSignification des symboles Consignes DE SÉ Curité Lire Avant UtilisationUN Choc É Lectrique peut tuer LES Fumé ES ET LES GAZ peuvent ê tre dangereuxLE Soudage peut provoquer un in- cendie ou une explosion DES Particules Volantes peuvent blesser les yeuxDES PIÈ CES Chaudes peuvent provoquer des brû lures graves LE Bruit peut affecter l’ouïeDES Organes Mobiles peuvent provoquer des blessures ’EXPLOSION DE LA Batterie peutLA Chaleur DU Moteur peut pro- voquer un incendie LA Chute DE L’APPAREIL peut blesserPrincipales normes de sé curité Information sur les champs é lectromagné tiquesLE Soudage À L’ARC risque de provoquer des interfé rences Consignes relatives aux stimulateurs cardiaquesSpecifications Symbols And DefinitionsWeld, Power, And Engine Specifications DefinitionsDimensions, Weights, And Operating Angles Do not move or operate unit where it could tipFuel Consumption Do not exceed operating anglesAC Generator Power Exceeding duty cycle can damage unit and void warrantyDuty Cycle And Overheating 100% Duty Cycle At 600 AmperesFor Constant Current CC Mode For Constant Voltage CV Mode Volt-Ampere CurvesConnecting The Battery InstallationInstalling Welding Generator Installing Exhaust Pipe And Rain Cap Engine Prestart ChecksConnecting To Weld Output Terminals Selecting Weld Cable SizesRemote 14 Receptacle RC3 Information SocketOpen right side door Terminal Strip 3T Strain Relief Terminal Strip 3T ConnectionsStop engine Do not switch under load Do not run engine until problem is fixedOperating the Welding Generator Front Panel ControlsVolt Duplex Gfci Receptacles Operating Auxiliary EquipmentExample Of Remote Amperage Control Maintenance & Troubleshooting Routine MaintenanceVolt Duplex Receptacle Optional 50 h100 h 200 h250 h 500 hMaintenance Label Servicing Air Cleaner By the warrantyTo clean air filter Do not clean housing with air hoseServicing Fuel And Lubrication Systems Adjusting Engine Speed Overload ProtectionTo adjust belt tension Checking And Replacing Engine BeltServicing Optional Spark Arrestor To replace beltAdjusting Overspeed Shutdown Valve Speed Control Lever Overspeed Shutdown ValveTroubleshooting WeldingGenerator Power Trouble EngineElectrical Diagram Circuit Diagram For Welding Generator194 139-B Welding Generator RUN-IN ProcedureWetstacking Run-In Procedure Using Load Bank Procedure at less thanStop engine Do not touch hot exhaust From flammables Do not PerformRun-In Procedure Using Resistance Grid Bank/gridFrom flammables Do not perform run-inGrounding Generator To Truck Or Trailer Frame Generator Power GuidelinesSelecting Equipment Grounding When Supplying Building Systems How Much Power Does Equipment Require?Earth ground if supplying Amperes x Volts = WattsApproximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsPower Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP xTypical Connections To Supply Standby Power Work like a ProSelecting Extension Cord Use Shortest Cord Possible Current Load Watts AmperesParts List 66 71 74 7360Fig Dia Part Description Mkgs Quantity Shunt Panel, Front w/Components Panel, Front w/Components -1 Item Panel, Front Lower w/Components 13 14 23 22 21 2524Panel, Front Lower w/Components -1 Item Control Box -1 Item Generator -1 Item OM-481 Page Page Support ServiceYour distributor also gives Owner’s Record Miller Electric Mfg. Co