Troubleshooting - Miller Electric SuitCase X-TREME 8 HD Owner's Manual

6-3. Troubleshooting

Trouble
Wire does not feed; open-circuit voltage
available.
Wire feeds erratically.
Motor runs slowly.
Unit does not switch out of Soft Start.
Wire feeds when Jog switch is pressed
but not when gun trigger is pressed.
Wire stubbing on low end using a con-
stant current power source or feeder re-
sets.
Gas does not flow or does not stop flow-
ing; wire feeds.
Wire remains energized after trigger is
released.
OM-246 828 Page 24
Check power switch S1 and connections, and replace if necessary.
Check supplementary protector CB1. Reset CB1.
Unit overheated. Allow unit to cool.
Check sensing lead connection.
Check gun trigger plug connection.
Check gun trigger. See gun Owner's Manual.
Have Factory Authorized Service Agent check Control board PC1.
Readjust hub tension.
Readjust drive roll pressure.
Clean or replace dirty or worn drive roll (see Section 4-5).
Remove weld spatter around nozzle opening.
Replace contact tip or liner. See gun Owner's Manual.
Change to correct size and type drive roll (see Section 4-5)
Incorrect size or worn wire guides (see Section 4-5)
Check wire drive motor brushes.
Have Factory Authorized Service Agent check control board PC1.
Hub tension set too high (see Section 4-10).
Check and replace contact tip or liner if necessary.
Have Factory Authorized Service Agent check Control board PC1.
If soft start is not on, motor will switch to slower speed if current is not sensed by HD1.
When soft start is on, motor will run slow until weld current is sensed by HD1.
Hub tension set too high (see Section 4-10).
Check if dual schedule switch activated (if applicable)
Check transducer HD1 and connections, and replace if necessary.
Check gun trigger connection at wire feeder. Check gun trigger leads and trigger switch. See gun Owner's
Manual.
Have Factory Authorized Service Agent check Control board PC1.
Make sure CC/CV switch is in CC position (see Section 5-1).
Increase power source inductance setting if available.
Increase output setting of power source or decrease wire feed speed.
Check gas valve.
Check coil voltage and connections of gas valve GS1. Check continuity of coil. Replace GS1 if necessary.
Have Factory Authorized Service Agent check Control board PC1.
Clear blockage in gas hose or replace hose.
Clear blockage in welding gun.
Check contactor W1 to see if contacts are frozen closed.
Remedy