Millermatic Problems

[Jeepermat]

Just got a brand new Millermatic DVI, I used it a little last weekend, it worked OK but sometimes the thing would sound like there was a air chisel going off inside the thing, when this happened the wire would hardly come out the gun, and just get hot enough to melt it to my workpiece.

I figured my wire speed was too fast so I slowed it down a little, now it either sounds like an air chisel, or I cant keep an arc cause my wire speed is a little slow.

I am gonna call miller, but I figured they are closed right now and would like to finish my project this weekend.
Any suggestions?

[Travis Waldher]

:confused:

have you adjusted the roller tension? almost sounds like you don't have enough.

[Jeepermat]

Yea, I tried all that, I had it cranked all the way down, and it still does it.

I wish I had my old HH135 back right about now

[Travis Waldher]

is the wire sticking to itself for some reason?

are you using the right notch on the rollers for the right wire diameter?

[Jeepermat]

I dont understand what you mean by sticking to itself?
But yes I have checked that I am using the .030 slot.
Could the liner be bad?

I have the gun as straight as possible, I dont notice any difference from it being coiled or straight though.

Thanks for the help

[Hickeyjones]

Is your tip loose? Any other connections loose?

[Travis Waldher]

meaning if you unspool some of that wire by hand, is it snagging on the reel. That could affect the feeding.

now.. the getting just hot enough to stick but not weld to the metal. I agree double check and make sure all connections are snug.


(would polarities being reversed cause a problem like that?)

[John H]

If it's making a noise like that the output rectifier is shorted.

[Jeepermat]

I have checked the connections multiple times, I did not change the polarity from the factory.

The noise is definatley coming from the inside of the machine, not the wire feeding side. If the output rectifier is shorted, then that sounds like it will be going back to miller, it is not operator error right?

[Twisted Minis]

Mine had trouble feeding a bit when I first got it, after a weeks use. I pulled apart the liner, blew it out, made sure it wasnt bent, and put it back together, and it worked fine. Maybe try that? I've had to do it a couple times, just from grinding dust getting inside I guess.

[John H]

I have checked the connections multiple times, I did not change the polarity from the factory.

The noise is definatley coming from the inside of the machine, not the wire feeding side. If the output rectifier is shorted, then that sounds like it will be going back to miller, it is not operator error right?

It most likely is not operator error. Call Miller and explain what is going on. They have excellent customer service.