Millermatic 200 Not Working

[GONWHLN]

I just had a millermatic 200 given to me,it`s in pretty rough looking shape. I wired it for 220 volt flipped the switch on ,heard a buzzing noise .Pulled the cover ,noticed the open relay ,up in the top of the maching, not closing the contacts.I replaced the relay(24v ac dpdt relay)still had the same problem,checked voltage to relay ,only have 12v ac .anybody have any ideas where to look next? Also can`t seem to get any open circuit voltage at the gun.
thanks Don (530)870-7607( west coast time)

[crawler]

If you don't get an answer, post up at www.weldingweb.com under Miller.
There is a user, "weldersales" that has lots of knowledge and could help you.

[GONWHLN]

Thanks crawler I`ll give that a try.
Don

[GONWHLN]

still need help

I am still looking for info.

[Steve]

Gonwhln, If you will provide the model and serial number of your machine, I will down load the manual, go over the prints and maybe can give you some more places to look. Steve

[GONWHLN]

thanks steve ,I will write them down when I get home.If I recall correctly it checked out as a 1985 millermatic 200 with all options except spool gun. I will get the numbers and get back to you to verify.

[GONWHLN]

still needing ideas to check out.

[Steve]

Still needing your machine serial number.

[Steve]

Go from the known to the unknown

Ok not waiting. Understand I am using the generic prints for your Machine. This information provided may not be correct for your model.
A recap: Wired for 220, turned on machine and had buzzing noise, Relay in top of machine not closed so replaced it with with same problems. Checked across relay had 12 volts.
Using a generic print for the Millermatic 200, It has 4 relays under the hood not withstanding a few on a circuit card. Relay W takes 115 v off T1 to operate. It is the main contactor used to turn on the welding current. CR 1,2,3 are used to control various unknown functions to me but are 24 volt relays. There power comes crost CB1, CB3 from T1. This should be 24 volts at 30 and 31 from the T1. If you have 12 volts then you need to check S1 5 and 6 for 220. If you have 115, you need to rewire your input plugs. You might be feeding the machine 115 volts and not 220. Happy hunting.

[GONWHLN]

Hi Steve ,sent you a PM with numbers on friday,may not have gone through ,so here are the #s again hope this helps. SER.# JF934816 MOD. MILLERMATIC 200 WITH SKP 35 OPTION.. Thanks for your help Don.

[Jim-TX]

Cut and pasted from Miller Motorsports board:

Sombody on the projects board can't get output on their mm200.
I'd like to suggest they check the input "jumpers", if it came from
a larger shop they may be set for 440volts rather than 220/240.
If anybody can cross post to that board please pass this along.
I don't have time to register right now.
Thanks
Dave P.

[Steve]

Finally caught on to PMs. See public apology thread. Got correct print. This Millermatic, according to the manual and serial number, originally came with three prong polarized plug with outlet provided. The input transformer only shows jumper for 200v or 230v. I think some one else put a different plug on to fit their outlet.

[Miller Kevin]

Don,

I had the serial number checked and the unit you have is a 230/460 volt machine. I am pretty confident that it is linked for 460 at this point and that is why all of your control voltages are halved.

Check the primary link board inside the unit, there is only 3 studs and the jumper should be on the middle and left stud for 230 volt operation.

Kevin

[Steve]

Goodness gracious!

Miller Kevin, Thanks for pointing that out. Makes sense to me.
However we have a problem. I down loaded the operators manual for Don's machine using it's serial number. I checked it twice to be sure and double checked the serial number. The manual refers you to the name plate on the machine for sure I will grant that. But the circuit diagram only shows two input taps, one for 200 and one for 230volts and no taps for 460.
My questions are these:
1. Could you down load the same operators manual that is available to me, read it, and using only that info advise Don correctly?
2. Should I refrain from assisting people with welder problems using only Miller operating manuals as this one is apparently incomplete as far as the circuit diagram goes?
3. How can I use my electronics expertise to effectively render assistance to others?


If Don had the same manual I downloaded, it's no wonder he's scraching his head. Good thing is I got him to the input power even If I didn't know it was a 230/460 machine cause as far as the book goes , It's a 200/230.
Thanks again for setting it straight.

[GONWHLN]

NO FIGHTING NOW!, I downloaded one manual said it was a 1985 machine 230/460 machine.Miss placed that manual ,downloaded a second book when steve asked for the numbers,said it was a 1987 machine 220/230 volt. my machine has 3 jumper lugs,wired center and right ,pulled trigger 12 volt to relay and just buzzing ,thought 230/460 machine wired 460 half voltage etc.,switched jumpers ,loud buzz!!!!!!definatly not right. book says wire according to decal.Surprise ,used in shop all decals long gone.I need to get it going ,so it went the welding repair shop on the 13th. But if you have any ideas please let me know. I will also post the outcome from the repair shop.

Thanks Don