Welder Specifications
| Processes | MIG (GMAW), Flux Cored (FCAW) |
|---|
Troubleshooting
19Fault codes
| Code | Meaning | Cause | Remedy |
|---|---|---|---|
| HLP 11 | Communication Error — 1 Blink; The communication error occurs 2.5 seconds after a loss of communication between the Motor Control Board (PC1) and the meter board PC20. The user may continue to weld with this error. The error may be cleared by turning power Off, waiting a minimum of two seconds, and turning power On | The error may be cleared by turning power Off, waiting a minimum of two seconds, and turning power On | |
| HLP 12 | Trigger Error — 2 Blinks; The trigger error occurs if the user has fed approximately 35 feet (10.7 meters) of wire without striking an arc | The error may be cleared by releasing the trigger | |
| HLP 13 | Tach Error — 3 Blinks; May indicate motor is overloaded | May indicate motor is overloaded | |
| HLP 14 | Motor Overload Error — 4 Blinks; The motor overload error can indicate that the motor has been drawing too much current for too long | The motor has been drawing too much current for too long | Reduce the wire feed speed or the wire feeder torque load/duty cycle; The error may be cleared by turning power Off, waiting a minimum of two seconds, and turning power On |
| HLP 15 | Bus Bar Overheat Error — 5 Blinks; The bus bar overheat error can be caused by the arc drawing too much current for too long | The arc drawing too much current for too long | Reduce the weld amperage or duty cycle |
Symptoms & remedies
| Symptom | Cause | Remedy |
|---|---|---|
| Wire does not feed; open-circuit voltage available | Check power switch S1 and connections, and replace if necessary; Check supplementary protector CB1. Reset CB1; Unit overheated. Allow unit to cool; Check sensing lead connection; Check gun trigger plug connection; Check gun trigger. See gun Owner's Manual; Have Factory Authorized Service Agent check Motor Control Board (PC1) | |
| Wire feeds erratically | Readjust hub tension (see Section 5-7); Readjust drive roll pressure (see Section 5-7); Clean or replace dirty or worn drive roll (see Section 5-2); Remove weld spatter around gun nozzle opening; Replace contact tip or liner. See gun Owner's Manual; Change to correct size and type drive roll (see Section 5-2); Check that DIP switches on Motor Control Board (PC1) are set correctly (see Section 5-8); Have Factory Authorized Service Agent check Motor Control Board (PC1) | |
| Motor runs slowly | When soft start is on, motor will run slow until weld current is sensed by HD1; Readjust hub tension (see Section 5-7); Check if wire speed dual schedule switch is activated (if applicable, See Section 6-3); Check and replace contact tip or liner if necessary. See gun Owner's Manual; Check that DIP switches on Motor Control Board (PC1) are set correctly (see Section 5-8); Have Factory Authorized Service Agent check Motor Control Board (PC1) | |
| Unit does not switch out of Soft Start | Check transducer HD1 and connections, and replace if necessary | |
| Wire feeds when Jog switch is pressed but not when gun trigger is pressed | Check gun trigger connection at wire feeder. Check gun trigger leads and trigger switch. See gun Owner's Manual; Have Factory Authorized Service Agent check Motor Control Board (PC1) | |
| Wire stubbing on low end using a constant current power source or feeder resets | Make sure CC/CV switch is in CC position (see Section 6-1 or 6-2); Increase power source inductance setting if available; Increase output setting of power source or decrease wire feed speed | |
| Gas does not flow or does not stop flowing; wire feeds | Clear blockage in gas hose or replace hose; Clear blockage in welding gun; Clear blockage in filter (see Section 7-3); Check gas valve; Check coil voltage and connections of gas valve GS1. Check continuity of coil. Replace GS1 if necessary; Have Factory Authorized Service Agent check Motor Control Board (PC1) | |
| Wire remains energized after trigger is released | Check setting of trigger hold switch, if applicable; Check contactor W1 to see if contacts are frozen closed | |
| Gun trigger is pressed, gas does not flow, wire is not energized, wire feeds | If a welding arc is not established in 3 seconds, after the gun trigger is activated, the unit will feed wire without energizing the contactor or gas valve. The unit will feed approximately 35 feet (10.7 meters) of wire, then stop feeding. This is to prevent complete de-spooling of the wire, as in the case of a damaged gun | |
| Display on meter board PC20 does not light | Have Factory Authorized Service Agent check Motor Control Board (PC1); Replace meter board PC20 | |
| Segments on the meter board PC20 are missing | Replace meter board PC20 | |
| Arc voltage on meter board PC20 is not accurate | Arc voltage on the meter board PC20 will show weld voltage at the feeder. Due to voltage drops in the weld cables, arc voltage at the feeder will not match arc voltage at the welding power source. Due to averaging of arc voltage, if weld time is less than 8 seconds the displayed arc voltage at the feeder may not be accurate | Check Motor Control (PC1) and connections, replace if necessary |
| Weld amperage on meter board PC20 is not accurate | Amperage displayed at feeder is approximate. Refer to power source for actual amperage (see Section 5-9) | Check DIP switch settings on meter board PC20 (see Section 5-9); Check transducer HD1 and connections, and replace if necessary; Check Motor Control (PC1) and connections, replace if necessary |
| Software and weld time information on meter board PC20 is not accurate | Check DIP switch settings on meter board PC20 (see Section 5-9); Check Motor Control (PC1) and connections, replace if necessary |
Fault codes and symptom→remedy steps extracted from this unit’s service/owner documentation; verify against the official manual before servicing.
Available documents
Parts manual
About
Miller Electric PLG6 — welder. Specifications and parts compiled from manufacturer documents.