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Welder problems

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TMiller/NC View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote TMiller/NC Quote  Post ReplyReply Direct Link To This Post Topic: Welder problems
    Posted: 21 Sep 2021 at 8:03pm
I have a Millermatic 175  wire feed welder that feeds gas as soon as power switch is turned on, only should feed gas when trigger is pulled, wire does not feed until trigger is pulled.   Checked leads on gas valve coil and has 240 volts as soon as power switch is turned on.  Anyone have experience with this problem??????
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dee_veloper View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote dee_veloper Quote  Post ReplyReply Direct Link To This Post Posted: 21 Sep 2021 at 8:21pm
You may also want to take that specific type of question to a Miller forum. 

https://forum.millerwelds.com/forum/welding-discussions
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steve(ill) View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote steve(ill) Quote  Post ReplyReply Direct Link To This Post Posted: 21 Sep 2021 at 8:31pm
Tim... i believe the unit has a control board... Power goes into the board.... control switch feeds into the board.. output is to the wire feeder... another output is to the gas valve..

If all this is correct, you might have a control board problem.. Look at the gas valve wires and see if they both run to a circuit / control board... If yes, the BRAIN is on the board.


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steve(ill) View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote steve(ill) Quote  Post ReplyReply Direct Link To This Post Posted: 21 Sep 2021 at 8:35pm
closeup ............. gun trigger shows 2 wires... dont know if that is two switches ( one failed ??) .... or if two leads for one circuit ??




Edited by steve(ill) - 21 Sep 2021 at 8:37pm
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TMiller/NC View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote TMiller/NC Quote  Post ReplyReply Direct Link To This Post Posted: 21 Sep 2021 at 8:50pm
Steve, the wires for gas valve do come from control board,  I've looked the board for discolored or burn mark finding none.  Thinking of installing a relay with 24v coil using wire from gun trigger and a common and breaking the gas valve circuit with the contacts.

Thanks for the response.
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steve(ill) View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote steve(ill) Quote  Post ReplyReply Direct Link To This Post Posted: 21 Sep 2021 at 9:44pm
that would work... the only other question is the gun trigger... is it actually TWO switches, one for the wire and one for the gas... ?  You might unplug ONE of the wires at a time and see if the other wire actually controls something...... what if it is two switches and one is STUCK ON causing the gas valve to say open ?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote DMiller Quote  Post ReplyReply Direct Link To This Post Posted: 22 Sep 2021 at 5:01am
Relay will not work to replace the Card if that is bad, will close on first impulse and lock in just as the card did.  Buddy of mine tried similar, and ended up almost cooking his welder.
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steve(ill) View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote steve(ill) Quote  Post ReplyReply Direct Link To This Post Posted: 22 Sep 2021 at 8:57am
he is thinking of using the GUN SWITCH as a trigger for the solenoid.. It would then be an ON- OFF controlled by the trigger, not the board.
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TMiller/NC View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote TMiller/NC Quote  Post ReplyReply Direct Link To This Post Posted: 22 Sep 2021 at 4:16pm
Update..............  After messing with it for sometime decided to re install board hooked everything back as should be,  gave it a try, works as it should.  I think relay contacts are sticking, if I can determine which one will try changing it.  Miller isn't very forth coming with diagrams.  Thanks for the response!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Ken(MI) Quote  Post ReplyReply Direct Link To This Post Posted: 22 Sep 2021 at 4:43pm
Gas valve is probably sticking, usually the case with those little Millers, never had a problem with the electronics in that respect.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote jaybmiller Quote  Post ReplyReply Direct Link To This Post Posted: 22 Sep 2021 at 5:53pm
re: relays...
if possible find who actually made them, cross ref for ones with gold plated contactc, even better gold/palladium (?). Be nice to find a true 'sealed' relay, retorofit to SSR even better.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote DaveKamp Quote  Post ReplyReply Direct Link To This Post Posted: 27 Sep 2021 at 9:18pm
Originally posted by TMiller/NC TMiller/NC wrote:

Update..............  After messing with it for sometime decided to re install board hooked everything back as should be,  gave it a try, works as it should.  I think relay contacts are sticking, if I can determine which one will try changing it.  Miller isn't very forth coming with diagrams.  Thanks for the response!


If you haven't found the proper diagram, it is NOT because Miller is hesitant to provide diagrams.  You can get diagrams for basically ANY Miller product, EVEN ones that predate 1970, simply by sending an Email and asking...

But search their document system FIRST, because they publish them in convenient PDF format.

I've used their site literally THOUSANDS of times in my 3-phase to single-phase conversion series... they're unmatched by ANY in the industry for document support.

I second Ken's assessment- it is more likely that the gas valve got a little bit contaminated, and it managed to free itself.  It is NOT a high pressure valve, nor is it a very powerful electromagnet.  A little contamination will prevent the cutoff needle from seating... a few cycles of the gun frequently knocks it clear.
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