Hi, I have an older Miller aead200le welder sn. HG075237, which runs and welds great, both on dc and ac. it makes 120v dc on the little 100 hz. plug at weld speed. The problem I have is that it outputs 215 Volts at theDuplex plug (not the 120 volts it is supposed to) when operate at "power" rpm (1860 rpm). If I check voltage across the terminal strip under the right side removable panel, I read around 440v. across what is supposed to bethe 220v terminals, and 215 volts across what is supposed to be the 115v ac output terminals. It doesn't seem to be affected by setting the rheostat at different output levels. Has anyone ever encountered this? Any thoughts or ideas would be appreciated! Thanks in advance.
Reply:Sounds like your voltage regulator is running away. That's not a very easy thingto make happen, so take what I'm writing with several grains of salt.I'd start by double-checking the voltage and speed measurements, making sureyou're using the correct schematic for your particular welder. A Kill-A-Watt is thecheapest voltage/frequency meter I know of. Once you're sure the observations reported are correct (meter ok, speed ok,test points as intended) I'd pull out the voltage regulator board and startlooking for overheated components, cracked solder joints and mechanical damage. Damaged regulator boards can be fixed, but they're constructedin a way that makes them quite difficult to work on. You really want to besure of what's wrong, efforts to make repairs can easily cause more damage.If my hunch is right, you'll find something amiss in the components connecteddownstream from terminal C.There are folks on this forum much, much more knowledgeablethan I, let's hope they chime in. Good luck,bob prohaska
Reply:Im haveing this happen on my Blue Star180K but it is the welder and auxand it is infact the board....My question is is there a chance the changed to an improved board?I have not been able to locate a replacement anywhere?
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