Miller Electric 500DX R, OM-129 manual Troubleshooting, Welding

7-11. Troubleshooting

A. Welding

Trouble	Remedy
No weld output.	Check position of Ampere Range switch.
	Check position of optional polarity switch.
	Disconnect equipment from auxiliary power receptacles during start-up.
	Place A/V Control switch in Panel position, or place switch in Remote position and connect remote con-
	trol to Remote A/V Control receptacle RC3 (see Sections 4-9and 5-1).
	Check and secure connections to Remote A/V Control receptacle RC3 (see Section 4-9).
	Place optional Output/Contactor Control switch in On position, or place switch in Remote position and
	connect remote contactor to optional Remote 14 receptacle RC3 or terminal strip 2T (see Sections 4-10
	and 4-11).
	Have Factory Authorized Service Agent check brushes and slip rings, field excitation circuit, and
	optional field current regulator board PC1.
Erratic weld output.	Check and tighten connections 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.
	Check Ampere Range switch connections and contacts.
High or low weld output.	Check engine speed, and adjust if necessary (see Section 7-5).
	Check optional CC/CV switch position.
Low open-circuit voltage.	Check engine speed, and adjust if necessary (see Section 7-5).
	Check optional CC/CV switch position.
	Have Factory Authorized Service Agent check optional field current regulator board PC1 and CV
	regulator board PC2.
Maximum weld output only in each	Have Factory Authorized Service Agent check Amperage/Voltage control R1, capacitor C8, diode D8,
ampere range.	integrated rectifier SR4, control relay CR2, and optional CV regulator board PC2.
Wire feeder does not work (models with	Reset circuit breaker CB3 and/or CB4 (see Section 7-10).
CV option).
	Check connections to optional Remote 14 receptacle RC3 and terminal strip 2T (see Sections 4-10and
	4-11).
	Repair or replace wire feeder.
No amperage control (or voltage control	Place A/V Control switch in correct position.
on models with CV option).
	Check connections to optional Remote 14 receptacle RC3 and terminal strip 2T (see Sections 4-10and
	4-11).
	Repair or replace remote control device.
	Have Factory Authorized Service Agent check optional CV regulator board PC2.
Low CV weld output (models with CV	Set Ampere Range switch to highest range.
option).
Min or max CV weld output only (models	Check position of Amperage/voltage control and Amperage/Voltage Control switch.
with CV option).

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