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[Bushytails]

I would say that, yes, that's just coincidence. Batteries are about the least-fryable thing on a vehicle. You could hook the welder right across one and it'd survive for a minute. And if you hooked it up dc backwards, you'd probably burn out the welder before the battery....

[Bushytails]

Yeah, having the ground close is a good idea. Don't accidentally have the ground path be through anything other than solid metal. Don't, say, ground on the frame, then weld on the body, and burn off the ground straps followed by the wiring harness...

[Bushytails]

Easy fixes are good!

You might want to inspect the connector for any overheating or loose contacts or anything like that, and if it came unplugged because a broken latch, add a couple zip ties.

[Bushytails]

From what I've seen, "none" is the typical answer....

[Bushytails]

I just went out and checked my 200dx, and at least when not welding, C-D is always 10V regardless of the current set on the front panel. So, instead of looking for the front panel setting on the pedal connector, you'd want to check for 10V C-D and, with the pedal down, 10V E-D as well....

[Bushytails]

I'm not sure what the part in the first picture is, but it sure doesn't look healthy, and the red wire probably should be connected to something, possibly itself...

The second picture is your voltage regulator for the charging system. It's not directly connected to the parts that aren't...

[Bushytails]

A failing transzorb on the control board might be able to cause that. Since you're just testing, put it in stick mode, set the output to "on", and do not connect a pedal. I'm not sure if that actually bypasses all the zeners on the plug, but it's worth trying.

But, before poking...

[Bushytails]

Is the gauge itself (i.e. pressure gauge, flow gauge) leaking, or are you using "gauge" to refer to the entire regulator assembly? If the regulator (the brass part) is leaking, there's nothing you can do without a rebuild kit. If a pressure gauge is leaking, as MAC702 said, you can use a...

[Bushytails]

If the unit starts with the front panel switch and stays running, but has no hour meter and no power at all to the field, I'd look for a loose, corroded, or burnt plug4, loose or corroded connections near it, bad chassis grounds near it, etc. I'd also check the diode between the ignition power and...

[Bushytails]

When welding, does the display show approximately the current you set before welding, or a lower number? (may need a helper, setting your phone to record a video, or a load bank, unless you can weld while looking at the screen not the weld...)...

[Bushytails]

When doing the pre-power checks, did you check the IGBTs on the underside of the machine and the resistance checks for the gate drivers for those IGBTs that are on the board screwed to them? Does it have low power only on AC, or on DC as well?

Also, visually inspect for overheated connections,...

[Bushytails]

If it's immediately tripping the breaker, chances are PC1 is toasted. I haven't worked on one of those, but I'd suspect the input rectifiers, boost IGBTs if it uses them, filter capacitors, or primary IGBTs as being shorted.

[Bushytails]

See what's on your local craigslist.

[Bushytails]

As someone who regularly uses ohm's law... I have absolutely no clue what that triangle is supposed to tell you to do or how it's supposed to help you in any way. lol...

[Bushytails]

It happens whenever I edit a post... I fixed a typo and the post vanished. And now there's two of them. Oh well...

[Bushytails]

Seems the spam filter is working overtime lately, let's try again...


Are you asking about the voltage and amperage on the primary side or the secondary side of the welder?

On the primary/input side, it's because the welder needs a fixed amount of power, and since power...

[Bushytails]

It's worth more as a complete unit for re-sale than as scrap, unless there's something terminally wrong with it.

[Bushytails]

I recently got one, and love it. I posted a review thread of it:
https://forum.millerwelds.com/forum/...ts-of-pictures

If you just want on/off control without the current control, there's cheaper options, but while I've...

[Bushytails]

Check that it's running at the proper RPM. Does it idle down and back up correctly? Could also be failing output diodes, a bad internal connection (such as the range switch), bad exciter capacitors, a bad connection on the fine amperage adjust, or another issue. Sometimes a load bank and a 'scope...

[Bushytails]

I despise flux core, and would not suggest it for any application where MIG is an option....