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Hey all,I have an older Millermatic 200 welder that I have had since the beginning of this year. I have not used it a lot yet but it has been welding fine.A couple weeks ago I had done the most welding I have sine purchasing it, at one point the contactor made a kind of loud buzzing/clicking noise and then the breaker tripped. I reset the breaker and it did the same thing. I took the contactor apart and cleaned the contacts and reinstalled it, I fired it up with the cover off and it looked like contactor was arcing when the trigger was depressed. I turned the welder to the lowest setting and depressed the gun trigger (not welding, but just depressing the trigger on the gun for a few seconds) The contactor was not arcing but the winding directly below the contactor got extremely hot in those few seconds. I shut it off and unplugged it and now just trying to determine the first thing to look at to try and fix?Does this sound like an issue with the contactor? Something else? Any help is appreciated.
Reply:You need a new contactor.
Reply:I'm no expert, I haven't looked at a schematic and don't know the wiring (even though I have the same machine), but would think, with no arc being run, the current through the contactor should be minimal so the excess heat shows something is wrong. It's better to diagnose the problem first, rather than replacing parts until it's fixed. If you wait a while, others here with more knowledge (such as Duane) will surely give specific instructions of how to proceed with troubleshooting.Do you have the manual for your version? It should be downloadable from the Miller site using your serial number.
Reply:I think being a welding company they would look there own welding on the transformer. Dave
Originally Posted by generalgopher
Hey all,I have an older Millermatic 200 welder that I have had since the beginning of this year. I have not used it a lot yet but it has been welding fine.A couple weeks ago I had done the most welding I have sine purchasing it, at one point the contactor made a kind of loud buzzing/clicking noise and then the breaker tripped. I reset the breaker and it did the same thing. I took the contactor apart and cleaned the contacts and reinstalled it, I fired it up with the cover off and it looked like contactor was arcing when the trigger was depressed. I turned the welder to the lowest setting and depressed the gun trigger (not welding, but just depressing the trigger on the gun for a few seconds) The contactor was not arcing but the winding directly below the contactor got extremely hot in those few seconds. I shut it off and unplugged it and now just trying to determine the first thing to look at to try and fix?Does this sound like an issue with the contactor? Something else? Any help is appreciated.
Reply:
Originally Posted by smithdoor
I think being a welding company they would look there own welding on the transformer. Dave
Reply:I also have an older Millermatic 200 and a few years ago I started a new project, the welder had been working fine before that. when i started the welder up everything seemed fine also until I pulled the trigger and started welding. The welder started making a loud buzzing sound and the weld bead was cold and lumped up. I posted and was told it might be the contactor so I picked one up and replaced it. The buzzing still continued and the weld bead was still humped up and cold looking. What I found on mine was that all 4 of the large diodes had failed and was letting AC current pass through to the gun. After replacing the defective diodes the welder started working fine.Using your photo, the diodes are located in the frame the red arrow is pointing to. You'll need to remove each diode and test it individually with a multi-meter with diode check. There are 4 large diodes. I'm not saying that the problem you are having is the same as the one I had but its' another possibility to check. Here's a link to the problem I was having. Sorry there are no photos, it's due to that thing with Photo Bucket. https://weldingweb.com/vbb/threads/6...illermatic-200This is a link to the follow up on the same problem. https://weldingweb.com/vbb/threads/6...c-200-TroublesHope this helps.
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Doug Millermatic 200 Lincoln AC-225 Syncrowave 250 |
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发表于 2022-9-16 15:52:30