Section 10 - Troubleshooting; 10-1. Troubleshooting - Miller Fusion 160 Owner's Manual

SECTION 10 – TROUBLESHOOTING

10-1. Troubleshooting

A. Welding
Trouble
No weld output or generator power
output at AC receptacles; fan does not
run; no power light.
No weld output; generator power out-
put okay at AC receptacles.
No weld output; fan motor continues to
run.
Low weld output.
High weld output.
Erratic weld output.
B. Error Messages
Message
Overtemp LED is on steady.
Overtemp LED blinks 2 times.
Overtemp LED blinks 3 times.
Overtemp LED blinks 4 times.
OM-279105 Page 40
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Complete Parts List is available at www.MillerWelds.com
Ensure power cord is securely connected to 240V receptacle inside power shift box (if using genera-
tor power).
Be sure all equipment is disconnected from receptacles when starting unit.
Have Factory Authorized Service Agent flash the rotor. Then check brushes, slip rings, rotor, stator,
and PC3.
Secure power cord plug in receptacle (if using utility power) (see Section 6-2).
Replace building line fuse or reset circuit breaker if open.
Place Power switch in On position (see Section 7-1).
Reset welding power source supplementary protector if open (see Section 8-1).
Check Weld Output control setting (On/Off switch).
Ensure power cord is securely connected to 240V receptacle inside power shift box (if using genera-
tor power).
Connect work clamp to get good metal to metal contact.
Check for loose connections.
Check for proper polarity connections (see Section 5-7).
Thermostat TP1 open (overheating). Allow fan to run; thermostat closes when unit has cooled.
Check Weld Output control setting.
Check engine speed, and adjust if necessary (see Section 9-7).
Service engine air cleaner (see Section 9-3). Service engine fuel filter (see Section 9-4).
Check weld cable size and length.
Connect unit to proper input voltage or check for low line voltage.
Place Power switch in On position (see Section 7-1).
Check Weld Output control setting.
Check engine speed, and adjust if necessary (see Section 9-7).
Check Weld Output control setting.
Tighten and clean connections to electrode and workpiece.
Use dry, properly stored electrodes for Stick welding.
Remove excessive coils from weld cables.
Clean and tighten connections both inside and outside welder/generator.
Check engine speed, and adjust if necessary (see Section 9-7).
Check throttle/governor linkage for smooth, non-binding operation.
Service engine air cleaner (see Section 9-3). Service engine fuel filter (see Section 9-4).
Error
Internal temperature of welder has exceeded the
maximum limit.
Primary voltage is above 310 volts.
The primary voltage is below 90 volts.
The fan blades are obstructed.
The fan wiring harness is disconnected.
Remedy
Remedy
Wait for unit to cool down. If the fan is not run-
ning, contact Miller Electric Mfg. LLC service
department.
Reduce primary voltage below 310 volts.
Increase primary voltage above 90 volts.
Clear obstruction from fan.
Reconnect the fan.