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  1. #1
    Join Date
    Jun 2014
    Posts
    2

    Default millermatic 200 stoped working woes

    I've have had a millermatic 200 serial #jd7322347 since buyin it new. Great machine, but has now developed a problem.
    I was welding tacks and when I let off the trigger the wire stuck, no problem except this time I had to cut the wire.
    Everything works,fan feder,gas flow, but NO WELDING POWER. I do get a small spark when I pull trigger but no welding power.
    I would like to ba able to fix it myself verses hauling it 30miles and payin.
    HELP. Doug

  2. #2
    Join Date
    Aug 2009
    Location
    Ankeny, Iowa
    Posts
    45

    Default

    Its still in warranty correct? I think a phone call to Miller would be in order if you haven't already done so. I'd think some sort of reset would be the answer.
    Miller MultiMate 200 MIG/ Stick/TIG
    Retired
    Journeyman Refrigeration Pipefitter
    Master Electrician
    Amateur Home shop Machinist & Welder

  3. #3
    Join Date
    Feb 2012
    Location
    Wa
    Posts
    551

    Default

    I don't think it's possible for a 200 to have a warranty. There has been two successors to it now...

  4. #4
    Join Date
    Aug 2009
    Location
    Ankeny, Iowa
    Posts
    45

    Default

    Oops my bad, thought it was a Multimatic 200.

    Does the contractor click in? Wire feed motor run?
    Miller MultiMate 200 MIG/ Stick/TIG
    Retired
    Journeyman Refrigeration Pipefitter
    Master Electrician
    Amateur Home shop Machinist & Welder

  5. #5
    Join Date
    Nov 2003
    Posts
    3,112

    Default

    Quote Originally Posted by izzydog View Post
    I've have had a millermatic 200 serial #jd7322347 since buyin it new. Great machine, but has now developed a problem.
    I was welding tacks and when I let off the trigger the wire stuck, no problem except this time I had to cut the wire.
    Everything works,fan feder,gas flow, but NO WELDING POWER. I do get a small spark when I pull trigger but no welding power.
    I would like to ba able to fix it myself verses hauling it 30miles and payin.
    HELP. Doug
    With that serial number it is a 20 year old unit... (Not too bad an interval before it needed service..)

    can you hear the contactor "CLUNK"...?? when you pull the trigger..??

    there are a whole bunch of MM200 troubleshooting threads.. that are worth searching and reading...
    Last edited by H80N; 07-09-2014 at 07:54 AM.
    .

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  6. #6
    Join Date
    Aug 2007
    Location
    Oklahoma Indian Land
    Posts
    23

    Default

    Quote Originally Posted by izzydog View Post
    I've have had a millermatic 200 serial #jd7322347 since buyin it new. Great machine, but has now developed a problem.
    I was welding tacks and when I let off the trigger the wire stuck, no problem except this time I had to cut the wire.
    Everything works,fan feder,gas flow, but NO WELDING POWER. I do get a small spark when I pull trigger but no welding power.
    I would like to ba able to fix it myself verses hauling it 30miles and payin.
    HELP. Doug
    Diagnosis...

    Machine ON, pull gun trigger feed wire out 2", set wire speed to "0". Get an ohm meter set it to voltage, connect + to gun and - to ground, pull trigger on gun and read voltage. With machine power set to 6 on the control you should have a reading around 26 volts on the wire. If not the rectifier bridge is bad most likely. It is located in the top of the machine about mid way, it has 4 wires and is held in place with 1 screw in the center. what ever you do don't mix the wires up when changing, change them one at a time. Just my best guess

  7. #7
    Join Date
    Oct 2007
    Location
    Cave Creek Az
    Posts
    973

    Default

    Most likely is not a rectifier bridge. Most likely is contactor points burned, then female connectors burned, then some other stuff, then rectifier. Start with the cheap, easy, and common problems first.

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