Welding Troubleshooting - Miller TRAILBLAZER 302 AIR PAK Owner's Manual

11-2. Welding Troubleshooting

Trouble
No weld output.
Low weld output.
High weld output.
Weld output cannot be adjusted.
Erratic weld output.
No remote voltage/amperage control.
No front panel voltage/amperage
control.
No 24 volt AC power output at Remote
receptacle RC4.
No 115 volt AC power output at Re-
mote receptacle RC4.
Lack of high frequency; difficulty in
establishing Gas Tungsten Arc Weld-
ing arc.
Wandering arc − poor control of arc
direction.
OM-229 930 Page 52
Check weld control settings.
Check weld connections.
Disconnect equipment from generator power receptacles during start-up.
Increase front panel and/or remote voltage/amperage control settings (see Sections 6-3 and 6-7).
Check and secure connections to Remote receptacle RC4 (see Sections 5-11).
Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.
Check control settings.
Increase front panel and/or remote voltage/amperage control settings (see Sections 6-3 and 6-7).
Check and clean air cleaner as necessary (see Section 9-3).
Have Factory Authorized Service Agent check engine speed, brushes, slip rings, and circuit boards PC1
and PC2.
See engine manual.
Check control settings.
Have Factory Authorized Service Agent check engine speed and circuit boards PC1 and PC2.
Have Factory Authorized Service Agent check field current control board PC2.
Check control settings.
Clean and tighten connections both inside and outside unit.
Check and secure lead connections to remote control.
Be sure connection to work piece is clean and tight.
Remove excessive coils from weld cables.
Use dry, properly stored electrodes.
Have Factory Authorized Service Agent check engine speed, brushes, slip rings, and circuit boards PC1
and PC2.
Check shielding gas, ensure proper shielding gas coverage while welding.
Check and tighten connections to Remote receptacle RC4 (see Section 5-11). Check and secure
lead connections to remote control.
Disconnect remote control from Remote receptacle RC4 if not needed for weld process (see Section
5-11).
Reset supplementary protector CB4 (see Section 9-5).
Reset supplementary protector(s) CB1 and/or CB3 (see Section 8-1).
Use proper size tungsten for welding amperage.
Reduce leakage of high frequency from torch or work cable (check grounding, remove excessive
coils from weld cables, use shorter weld cables, etc.).
Check cables and torch for cracked or deteriorated insulation or bad connections. Repair or replace
necessary parts.
Reduce gas flow rate.
Select proper size tungsten. Properly prepare tungsten.
Remedy