Diagnostics - Miller SuitCase X-TREME 8VS CE Owner's Manual

Trouble
Gun trigger is pressed, gas does not
flow, wire is not energized, wire feeds.
Display on display board does not light. Have Factory Authorized Service Agent check Control board PC1.
Segments on the display board are
missing.
Arc voltage on display board is not
accurate.
Weld amperage on display board is not
accurate.
Software and weld time information on
display board is not accurate.

5-4. Diagnostics

Shown On Display
HLP 11
HLP 12
HLP 14
HLP 15
Error Indications
Error conditions are indicated by a "HLP" message on the (optional) display, or by the blinking of the Red LED on
Motor Board PC1. To view the Red LED, turn Off power source, remove shroud, and turn power source On. The
Red LED blinks in a 2.5 second cycle. The number of blinks in this period indicates the type of error. If an error
condition does not exist on the motor board, the Red LED is on steady.
Communication Error
The communication error occurs 2.5 seconds after a loss of communication between the motor board and the
meter board. The user may continue to weld with this error. The error may be cleared by turning power Off, wait-
ing a minimum of two seconds, and turning power On.
Trigger Error
The trigger error occurs if the user has the trigger held for more than two minutes without striking an arc. The
error may be cleared by releasing the trigger.
Motor Overload Error
The motor overload error can indicate that the motor has been drawing too much current for too long, To remedy
this, reduce the wire feed speed or the wire feeder torque load/duty cycle. The error may be cleared by turning
power Off, waiting a minimum of two seconds, and turning power On.
Bus Bar Overheat Error
The bus bar overheat error can be caused by the arc drawing too much current for too long. To remedy this, re-
duce the weld amperage or duty cycle.
OM-226 288 Page 24
If a welding arc is not established in 3 seconds, after the gun trigger is activated, the unit will feed wire
without energizing the contactor or gas valve. If the gun trigger is still activated after two minutes, the wire
will stop feeding. This is to prevent complete despoolling of the wire, as in the case of a damaged gun.
Replace display board.
Replace display board.
Arc voltage on the display board will show weld voltage at the feeder. Due to voltage drops in the weld
cables, arc voltage at the feeder will not match arc voltage at the welding power source. Due to averaging
of arc voltage, if weld time is less than 8 seconds the displayed arc voltage at the feeder may not be accur-
ate.
Check Motor Control PC1 and connections, replace if necessary.
Weld amperage displayed on the feeder will not match exactly with the weld amperage displayed on the
welding power source.
Check DIP switch settings on Display board PC20 (see Section 3-10).
Check trasducer HD1 and connections, and replace contactor assembly if necessary.
Check Motor Control PC1 and connections, replace if necessary.
Check DIP switch settings on Display board PC20 (see Section 3-10).
Check Motor Control PC1 and connections, replace if necessary.
Error Indicators
RED LED on Motor Board PC1
1 Blink
2 Blinks
4 Blinks
(Constant Blinking)
3 Blinks
Remedy
Error
Communication Error
Trigger Error
Motor
Overload Error
Bus Bar
Overheat Error