Miller 907439002, Owner'S Manual

Page: 47 / 90

General
OM-249474 Page 41
Trouble Remedy Probable Cause
Shutdown at arc initiation using power
source and feeder or interface.
No voltage feedback signal. Broken or disconnected voltage feedback lead, no
open circuit voltage, check power source.
No current feedback signal. Poor parameters, open in weld circuit, faulty hall
device, check power source.
No tachometer sensing. No wire speed command from robot, material
jammed in drive gears, faulty tachometer in drive
motor, wire feed drive circuit board, or motor cable,
check wire feed system.
Poor parameters preventing arc stability. Check for proper pulse program, material, welding
wire, shielding gas, voltage setting, and wire speed
setting.
Arc start error. Check contact tip, wire feed system and weld
circuit.
No start signal from robot. Check robot setup and interconnect cable connec-
tion between robot controller and interface.
No wire feed with wire feed motor running. Wire stuck in contact tip, worn or wrong size drive
rolls, improper drive roll pressure setting, or wire
not unspooling or restriction in drum adapter, check
wire feed system.
Shutdown at arc initiation using robot
controller.
No arc detected. Check for arc detect signal coming from interface.
Robot times out before arc detected. Add more time for robot arc detect input, verify weld
parameters, and check weld circuit.
Robot command scaling not set properly. Set proper robot command scaling.
Time between welds too short. Adjust welding cycle time.
Welding sequence problems. Power source should energize and welding wire
should start feeding at the same time.
No wire feed speed command. Set wire feed speed.
No voltage command. Set voltage.
Shutdown at arc initiation due to weld cir-
cuit condition.
Poor part fit up at weld joint, wire not making contact
with workpiece.
Check part consistency for fitup and/or position gun
so wire always contacts part.
Poor connection in weld circuit. Check welding gun, torch, contact tip adapter, con-
tact tip, weld cable connections and any rotary or
brush type connection.
Improper gas flow causing start and timeout
issues.
Check for correct shielding gas and flow
adjustment.