Error Code Troubleshooting Description And Tables - Miller Auto Continuum 500 Owner's Manual

9-4. Error Code Troubleshooting Description And Tables

RED LED LCD Display
Display Message
BOOT ERROR System Booting
or BOOT FAIL
Status bar
stopped at 1%,
2%, 3%, or 4%
No Display LCD is blank
ERR THERM or ERROR
ERR Thermal Sys-
OVERTEMP tem Problem
Welding Power
Source has
overheated
Allow unit to
cool. Cycle
power on the
power source.
CYCLE The unit re-
POWER quires a power
cycle.
Cycle power on
power source.
ERR COMMS ERROR
System com-
munication loss
Cycle power on
the power
source.
ERR COMMS ERROR
Internal comms
loss:
ERR ERROR
WIRSTUK Wire Stuck Er-
ror
Wire stuck to
workpiece at
the end of the
weld.
ERR ARC ERROR
Arc error oc-
curred.
Check wire
feeder and pow-
er source.
ERR TRG ERROR
STUK Trigger held
during power
up.
Release trigger
and press but-
ton to clear er-
ror.
OM-277115 Page 48
Description
One of the components in the
system is not connected to
the network or the rest of the
system.
Feeder is not powering up,
white power light is illuminat-
ed and power source contac-
tor is energized.
The power source is over
heating.
The overtemp light is on con-
stant.
This message may display if
the settings changed in the
configuration of the system.
User Interface is not connect-
ed to the rest of the system.
There are many communica-
tion errors in the system indi-
cating where the problem
may be. The communication
could be lost from the power
source, wire feeder, ROI, or
wire drive. The detailed mes-
sage in the LCD screen will
give the proper details for the
servicing technician.
Wire stuck to work piece at
the end of the weld.
The arc produced was not a
valid arc, weld voltage was
too high or too low for the pa-
rameters set on the User In-
terface.
Trigger Stuck error occurs if
the trigger is held when the
feeder is powered up. The er-
ror may be cleared by releas-
ing the trigger.
Possible Causes
Wires in the interconnecting
cable are disconnected.
There is a pin or socket in
one of the communication re-
ceptacles that is broken.
Internal circuit board failure.
Bad communication cable.
Internal circuit board failure.
The fan louvers/wind tunnel
openings are blocked.
The fan motors are not turn-
ing on or cannot rotate.
The heat sinks are dirty.
Bad communication cable be-
tween the feeder and power
source.
Poor connection in the com-
munication cable between the
wire feeder and the power
source.
Open connection in the inter-
connecting cable on the back
of the power source, wire
feeder, ROI, or wire drive.
Database in the system may
be corrupted.
Broken or disconnected weld
cable.
Wire delivery is too slow, arc
length too long.
Trigger or trigger wires in the
MIG gun may be shorted to-
gether.
Potential Solutions
Replace the interconnecting cable from
the power source to the wire feeder, or
between the ROI and wire drive, if it is a
Swingarc system.
Replace the power source, ROI, wire
drive, or wire feeder to have serviced.
Replace communication cable between
power source and wire feeder.
Replace the power source, ROI, wire
drive, or wire feeder to have serviced.
Ensure that there is a minimum of 18
inches distance between power source
and other objects.
The power source must be serviced/re-
paired before proper operation.
Blow out inside of wind tunnel per the
preventative maintenance section.
Cycle power on the power source.
Replace interconnecting cable.
Replace the communication cable.
The power source, ROI, wire drive, or
wire feeder must be serviced/repaired
before proper operation.
Reinstall the system software.
Break/Cut away from the work piece.
Repair or replace weld cable.
Repair or replace work clamp or cable
connection.
Check/Replace gun liner.
Check drive roll pressure is properly set
for the application
Repair or replace the MIG gun.