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  1. #1
    Join Date
    Aug 2013
    Posts
    4

    Default millermatic 200 white face contactor clicking

    I have had this mm 220 white face for about 10 years with never a problem till now. I was welding on high range with the selector switch on 1 and the splatter shorted out in the nozzle to the tip and blew the breaker. I reset the breaker and when I press the trigger the contactor just clicks real fast and blows the breaker. I called Miller service line and the rep told me it was the contactor. I replaced the contactor and it still does the same thing and is really burning up the contactor contacts. If I try to hold the contactor in when pulling the trigger it sounds like a dead short. Welder sounds like it straining. Any ideas thanks.

  2. #2
    Join Date
    Oct 2007
    Location
    Cave Creek Az
    Posts
    965

    Default

    Pull off the gun, then jump the two trigger terminals and see if it still does it.

  3. #3
    Join Date
    Aug 2008
    Location
    Orange, TX
    Posts
    1,191

    Default

    One or more shorted diode(s) in the weld output rectifier. Check them all and it's always a good idea to replace all when any one goes.
    MM200 w/spot controller and Spoolmatic 1
    Syncrowave 180 SD
    Bobcat 225G Plus LPG/NG w/14-pin*
    *Homemade Suitcase Wire Feeder
    *HF-251D-1
    *WC-1S & Spoolmatic 1
    PakMaster 100XL
    Marquette "Star Jet" 21-110

  4. #4
    Join Date
    Aug 2013
    Posts
    4

    Default

    Quote Originally Posted by duaneb55 View Post
    One or more shorted diode(s) in the weld output rectifier. Check them all and it's always a good idea to replace all when any one goes.
    Thanks for the tip! I will try tonight after work and let you know what happens.

  5. #5
    Join Date
    Aug 2013
    Posts
    4

    Default

    Where is the weld out rectifier? Thx

  6. #6
    Join Date
    Oct 2004
    Location
    Edmonton, Alberta
    Posts
    7,623

    Default

    in a circle around the fan motor

  7. #7
    Join Date
    Aug 2013
    Posts
    4

    Default

    I tried a brand new gun and the conactor is still clickibg. Is there a way to test the welding outlet rectifier or just buy a new one. Thx

  8. #8
    Join Date
    Aug 2008
    Location
    Orange, TX
    Posts
    1,191

    Default

    Hope you needed a new gun to begin with.

    Here's a Youtube video on testing the stud style diodes that you'll find in your MM200 output rectifier.
    http://www.youtube.com/watch?v=lhafKFBVYQI
    MM200 w/spot controller and Spoolmatic 1
    Syncrowave 180 SD
    Bobcat 225G Plus LPG/NG w/14-pin*
    *Homemade Suitcase Wire Feeder
    *HF-251D-1
    *WC-1S & Spoolmatic 1
    PakMaster 100XL
    Marquette "Star Jet" 21-110

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