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[ccawgc]

had one do some thing like that and it turned out to be the front panel pcb. now very pricey. you will need a loan to buy one they are almost $3000.

[ccawgc]

Turn slow, if they work correctly when turned slow they are ok. if they jump around wen turned fast they are ok. the encoders do not work well at high speed. If they jump around at slow speed try blowing them clean. if still jumping the UI/ display will have to be replaced. also they will jump if you...

[ccawgc]

From command ground the 4 wire to the lem should read +15 and -15 and 0 and 0 the minus might read -14.4.
If different unplug lem and retest pc1 supply to LEM if voltage jumps up Lem is bad. if it stays low then pc1 is damaged. might also
have something else pulling the voltage down. if...

[ccawgc]

Get your flash light and magnifying glass. take the right side off and and look at the two relays in the plastic boxes.
Pull gun trigger, wire should feed and both relays should pull in. light should go out.
You are going to inspect the relays and look at the wire connection to the relay...

[ccawgc]

help 11 is when polarity switch is not set right.
If the welder is in DC TIG and you are pressing the dig button it will display a help 12. Dig and Balance are not used in DC tig.
Dig is stick and Balance is AC TIG. Also if you are in stick with output on and try to switch to TIG with out...

[ccawgc]

If after you turn the spot timer off and it keeps coming back on and you know you didn't turn it on. You will need to have the control pcb replaced.
Or just keep going in and turning it back off. There is a known problem with some of the older pcbs. The pcb will set a spot time when weldr is powered...

[ccawgc]

If you order the new front panel pcb for your serial number you will get a new tach pcb and your welder will now be a pulse welder.
Plus new software.

[ccawgc]

welder was high with high voltage. kills the voltage regulator on the meter and the MOV across the fan relay. if lucky that's all.
The MOV is a transient suppressor. you may have other parts damaged on the meter pcb....

[ccawgc]

This will sound strange but clean or replace the HF spark gap points. Bench grinder wire brush works great.
Problem is the points have developed a coating. Have seen this before several times in Lincoln welders.

[ccawgc]

The older machines foot control had full control of out put. On the newer machines the panel control sets max out put and the foot control is 0 to panel set. Just like most other tig welders.

[ccawgc]

contamination of some sort. Gas or base metal or filler .

[ccawgc]

You can try measuring the voltage. see if it is AC or DC and what value. Should be very little voltage on the case.
make sure the line plug is wired right. welder doesn't work right if a hot leg and ground are reversed.

[ccawgc]

what you are calling B1 is most likely 81. 115volt supply to fuse holder. If fuse is bad contactor will not pull in with gun trigger.
Drive motor will not run. Fuse F1 powers Sr1 bridge diode which in turn powers the motor control pcb and then Q2.
what is arcing to the frame? From the diagram...

[ccawgc]

call miller tech support. ask them what they think. Then you can decide where to take it to have the parts installed.
Owner installed parts will not be covered by Miller parts warranty.

[ccawgc]

Does the unit have the crank on the top or the front? Crank on the top in the older model. if the brass lead screw is not stripped
probably a better unit than the new one with crank on front and plastic screw. The XL should have plastic screw and a polarity switch.
The older ones had 5 jacks.or...