Troubleshooting The Welding Power Source - Miller Syncrowave 250 DX User Manual

7-2. Troubleshooting The Welding Power Source

Trouble
No weld output; unit completely
inoperative.
No weld output; unit on.
Unit provides only maximum or
minimum weld output.
Erratic or improper weld output.
No control of weld output.
No output from duplex receptacle RC2
and no high frequency.
Lack of high frequency; difficulty in
starting GTAW arc.
Wandering arc − poor control of
direction of arc.
Tungsten electrode oxidizing and not
remaining bright after conclusion of
weld.
Fan not operating.
OM-363 Page 52
NOTICE − The remedies listed below are recommendations only. If these remedies do
not fix the trouble with your unit, have a Factory Authorized Service Agent check unit.
There are no user serviceable parts inside unit.
Refer to Section 7-1 for any Help (HLP) message displayed on voltmeter/ammeter.
Place line disconnect switch in On position (see Section 4-22).
Check and replace line fuse(s), if necessary (see Section 4-22).
Check for proper input power connections (see Section 4-22).
Check for proper jumper link position (see Section 4-21).
If using remote control, place Output control in Remote 14 position, and make sure remote control is
connected to Remote 14 receptacle. If remote is not being used, place Output control in On position
(see Section 5-1).
Check, repair, or replace remote control.
Have Factory Authorized Service Agent check unit.
Make sure Amperage control is in proper position (see Section 5-1).
Have Factory Authorized Service Agent check unit.
Use proper size and type of weld cable (see Section 4-9).
Clean and tighten all weld connections.
Check position of Output Selector control (see Section Figure 5-1).
If using remote control, check position of Amperage Adjustment control (see Section 5-1).
If using remote control, place Output control in Remote 14 position, and make sure remote control is
connected to Remote 14 receptacle. If remote is not being used, place Output control in On position
(see Section 5-1).
Make sure Amperage control is in proper position (see Section 5-1).
Reset circuit breaker CB1 (see Section 6-2).
Reset circuit breaker CB1 (see Section 6-2).
Select proper size tungsten (see Section 11).
Be sure torch cable is not close to any grounded metal.
Check cables and torch for cracked insulation or bad connections. Repair or replace.
Check spark gaps (see Section 6-3).
Reduce gas flow rate.
Select proper size tungsten (see Section 11).
Properly prepare tungsten (see Section 11).
Shield weld zone from drafts.
Increase postflow time.
Check and tighten all gas fittings.
Properly prepare tungsten.
Check for water in torch, and repair torch if necessary.
Unit equipped with Fan-On-Demandt. Fans run only when necessary. Unit equipped with circuitry to
protect against overheating.
.
A complete Parts List is available at www.MillerWelds.com
Remedy