Generators and Electric Motors
[Home] - [HELP] - [Forums] - [Groups] - [Classified Ads] - [Subscribe] - [Books] - [Sponsors] -

Go Back   SmokStak > SmokStak® Shop Equipment Tools and Techniques > Welding Shop
Forgot Password? Join Us!

Notices

Welding Shop Welder generators, equipment, weld practice, techniques, troubles and solutions. See our TERMS of SERVICE prior to reading!

Welding Shop

Millermatic 200 help needed


this thread has 11 replies and has been viewed 3935 times

Reply
 
Thread Tools Display Modes
  #1  
Old 09-28-2015, 06:19:40 PM
Roger Roger is offline
Subscriber
 
Join Date: Nov 2004
Location: Diller, Nebraska, USA
Posts: 23
Thanks: 0
Thanked 9 Times in 3 Posts
Default Millermatic 200 help needed

My millermatic 200 worked fine until it lost contact on the ground wire in the
supply plug . Now the transformers will hum but the 5 amp fuse on the front
panel will blow as soon as the welder is turned on . Any ideas or help please .
Roger
Reply With Quote
Sponsored Links
  #2  
Old 09-28-2015, 09:28:41 PM
IronworkerFXR IronworkerFXR is offline
Subscriber
 
Join Date: Dec 2010
Location: Stamford, Connecticut
Posts: 495
Thanks: 3
Thanked 185 Times in 140 Posts
Default Re: Millermatic 200 help needed

Humm, was that a 5 or 10 amp fuse, will have to check mine
Reply With Quote
  #3  
Old 09-28-2015, 10:36:34 PM
dkamp dkamp is offline
eMail NOT Working
 
Join Date: Oct 2007
Location: LeClaire, Iowa, USA
Posts: 1,733
Thanks: 34
Thanked 934 Times in 605 Posts
Default Re: Millermatic 200 help needed

I'm having difficulty with my network bandwidth right now, otherwise I'd be downloading one of the MillerMatic 200 manuals.

Miller is very good about putting manuals WITH SCHEMATIC DIAGRAMS on their website... if I had that schem in front of me (and there's probably several different variations of the MillerMatic 200, so I'd need to determine the right one to be certain), I could probably have the issue figured out without more than a few tests on your end.

If I have opportunity to download it tomrrow, I'll do so. In the meantime, take a picture of the ID plate (says model and serial number) so I can determine the appropriate manual.
Reply With Quote
  #4  
Old 09-29-2015, 10:32:02 PM
Roger Roger is offline
Subscriber
 
Join Date: Nov 2004
Location: Diller, Nebraska, USA
Posts: 23
Thanks: 0
Thanked 9 Times in 3 Posts
Default Re: Millermatic 200 help needed

The fuse on the front is a 5 amp . The serial number is JA414292
constant potential dc arc welding power source and wire control /feeder system
Do you need any more info on the welder. I have a wiring diagram but that does not help me much as I don't do electronics .
Roger
Reply With Quote
  #5  
Old 10-02-2015, 11:52:50 PM
Jim McIntyre's Avatar
Jim McIntyre Jim McIntyre is offline
Subscriber
 
Join Date: Nov 2004
Location: Mooresville, Indiana, USA
Posts: 4,563
Thanks: 890
Thanked 2,734 Times in 1,561 Posts
Default Re: Millermatic 200 help needed

I'd start by disconnecting wires 24 and 25 from the SR1 rectifier. If the fuse still blows, the problem is probably the SR1 rectifier itself. Google on testing bridge rectifiers - pretty easy if you have an ohmmeter.
Attached Thumbnails
Click image for larger version

Name:	Capture.JPG
Views:	73
Size:	50.4 KB
ID:	235931  
Reply With Quote
  #6  
Old 10-03-2015, 02:24:06 AM
Toesmack's Avatar
Toesmack Toesmack is offline
Subscriber
 
Join Date: Aug 2011
Location: Sparks, Nevada
Posts: 525
Thanks: 295
Thanked 357 Times in 207 Posts
Default Re: Millermatic 200 help needed

My Millermatic 200 was having a similar problem blowing the fuse. I pulled the sheet metal and found a wire near the bottom front (don't remember which side for sure, I think the spool side) shorting out to the sheet metal skin. Moved it over and resecured it. Problem solved.
Reply With Quote
  #7  
Old 10-03-2015, 09:29:32 AM
dkamp dkamp is offline
eMail NOT Working
 
Join Date: Oct 2007
Location: LeClaire, Iowa, USA
Posts: 1,733
Thanks: 34
Thanked 934 Times in 605 Posts
Default Re: Millermatic 200 help needed

Okay, so here's page 21 of the owner's manual.

F1 powers essentially every control aspect INCLUDING the wire drive motor... they're all on a 115v isolated winding... and there are no 'intentional' grounds in this winding's circuit, so the presence or lack of ground should NOT have any impact on it's operation.

Notice that the 24v winding (above) and the welding output winding (below) are also isolated... the chassis ground connection therefore, has NO relationship to any of the three secondaries.

If a short occurs that puts some aspect of any of the secondaries at ground, it doesn't appear that it'll have any significant impact on anything, so I'd be more likely to suspect that some other issue is at hand.

So let's troubleshoot this thing methodically.

First, does yours have the "spot welding' control board? If so, remove it... this will reduce the machine's operation to most simple state... then see if it blows the fuse. If it doesn't, put it back in, if it blows, the problem is within the spot welding board.

If it blows F1 without spot welding board, try each of these possibilities:

- disconnecting the fan motor
- Checking for shorts in contacts of CR1 AND CR2.
- Disconnecting wires to bridge rectifier SR1.

The problem source should be pretty obvious when you get to that point.
Attached Thumbnails
Click image for larger version

Name:	MM200 SN JA414292.jpg
Views:	72
Size:	77.1 KB
ID:	235952  
Reply With Quote
  #8  
Old 12-13-2015, 06:31:39 PM
Roger Roger is offline
Subscriber
 
Join Date: Nov 2004
Location: Diller, Nebraska, USA
Posts: 23
Thanks: 0
Thanked 9 Times in 3 Posts
Default Re: Millermatic 200 help needed

Thanks for the help . The problem was the bridge rectifier SR1 .Got it replaced and it works.I still have a question --the large capacitors above the fan tested bad . What kind of effect will this have on welding ? Roger
Reply With Quote
  #9  
Old 12-13-2015, 08:30:01 PM
dkamp dkamp is offline
eMail NOT Working
 
Join Date: Oct 2007
Location: LeClaire, Iowa, USA
Posts: 1,733
Thanks: 34
Thanked 934 Times in 605 Posts
Default Re: Millermatic 200 help needed

Large capacitors... above the fan in the drawing, or in the unit?

How about identifying the capacitors by their identity on the diagram... that should make it easier to ascertain. Also... what testing method did you use to check them?
Reply With Quote
  #10  
Old 12-14-2015, 12:51:33 AM
Roger Roger is offline
Subscriber
 
Join Date: Nov 2004
Location: Diller, Nebraska, USA
Posts: 23
Thanks: 0
Thanked 9 Times in 3 Posts
Default Re: Millermatic 200 help needed

There are 6 large alum. can capacitors above the cooling fan in the rear of the machine above in the top area of the welder . I think the capacitors were 6000 mfd. We used a capacitor tester to test and the readings ranged all over --no readings close to what we expected. We took all of the capacitors off of the bracket to disconnect them from the circuit. Roger
Reply With Quote
  #11  
Old 12-24-2015, 09:16:34 PM
dkamp dkamp is offline
eMail NOT Working
 
Join Date: Oct 2007
Location: LeClaire, Iowa, USA
Posts: 1,733
Thanks: 34
Thanked 934 Times in 605 Posts
Default Re: Millermatic 200 help needed

My GUESS is that those big caps might be C18 and C19 in the schem- output smoothing probably. Easiest way to find out for certain, is look in the parts section of your Miller manual, find it in the expoded diagram, and match the callout to the parts list. Typically, the parts list also includes the component ID... if it says that callout is C18, then you know for certain where it is in the schem, and from that, can determine most likely function.

If it's output filtering, it's probably going to work without them, but would probably work better WITH them.
Reply With Quote
  #12  
Old 12-29-2015, 07:14:49 PM
Roger Roger is offline
Subscriber
 
Join Date: Nov 2004
Location: Diller, Nebraska, USA
Posts: 23
Thanks: 0
Thanked 9 Times in 3 Posts
Default Re: Millermatic 200 help needed

Thanks for your help . I will change the caps and try it.
Roger
Reply With Quote
Reply

Bookmarks


Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

F o r u m Jump

Similar Threads Chosen at Random
Thread Thread Starter F o r u m Replies Last Post
Millermatic 251 - Fair Price? krc002 Welding Shop 0 01-19-2014 10:09:27 PM
Millermatic 212 Jim Sherman Welding Shop 7 06-14-2011 12:41:38 AM
Running a Millermatic 185 off a 6kw Generator torque454 Welding Shop 0 04-10-2010 01:54:29 AM
130 Millermatic wirefeed will s Welding Shop 3 01-06-2010 09:36:02 AM
Millermatic 251 Welder MCanady Welding Shop 7 04-05-2007 12:35:35 PM


Use "Ctrl" mouse wheel to change screen size.
All times are GMT -4. The time now is 05:35:52 AM.

Smokstak and Enginads site search!


All use is subject to our TERMS OF SERVICE
SMOKSTAK® is a Registered Trade Mark - A Community of Antique Engine Enthusiasts
Copyright © 2000 - 2019 by Harry Matthews P.O. Box 5612 - Sarasota, FL 34277