Troubleshooting - Miller Electric XR Control Owner's Manual

7-13. Troubleshooting

Trouble
Pressing gun trigger does not energize
feeder. Welding wire is not energized.
Shielding gas does not flow. Shielding gas does not flow
Wire feeds, shielding gas flows, but
welding wire is not energized.
Wire feeds erratically.
Arc varies and welding wire is kinked
when feeding out gun.
No weld output; gun/feeder does not
work. work
Erratic weld output.
Wire does not feed; burnback in contact
tip. tip
Wire feeds erratically.
Gun overheating (water-cooled
models). models)
Voltmeter does not display voltage
OM-1594 Page 40
Y Disconnect power before troubleshooting.
Secure plug from gun control cable into Gun Control receptacle on feeder (see Section 5-3 or 5-5 as appli-
cable).
Have nearest Factory Authorized Service Agent check optional water flow switch, if applicable.
See Troubleshooting section in welding power source manual.
Check position of Motor Torque switch (see Section 6-2).
Adjust drive roll pressure if necessary (see Section 5-12).
Clean or replace drive rolls as necessary (see Sections 7-2 and 7-6).
Place Motor Torque switch in low torque position if welding with .030 (0.8 mm) aluminum welding wire (see
Section 6-2).
Check gun trigger plug connection on wire feeder front panel (see Sections 5-3 and 5-5).
Place Power switch on welding power source in the On position.
Tighten and clean all connections.
Check drive roll pressure in wire feeder and gun (see Section 5-12).
Check and replace liner if necessary (see Section 7-3 and 7-8).
Check drive roll pressure in wire feeder and gun (see Section 5-12).
Check and replace liner if necessary (see Section 7-3 and 7-8).
Reinstall voltage sensing lead (see Section 5-1).
Check drive roll pressure in wire feeder and gun (see Section 5-12).
Clean or replace drive rolls as necessary (see Sections 7-2 and 7-6).
Check and replace liner if necessary (see Section 7-3 and 7-8).
Be sure coolant flow rate is at least 1 qt/min.
Corrosion buildup in gun decreasing coolant flow rate. Backflush coolant system, clean coolant system
filter, and clean fittings.
If welding power source does not support pins F and H, a volt sense lead kit must be installed in feeder
(see Section 5-7 and 5-8). Volt sensing lead kit 209867.
Remedy