Miller 225G problems

[Vitaliykit]

Hi there. I am brand new member and even though I followed your posts as none member for probably couple of years, just today became a member and have some questions about my Miler 225g. I got good deal on the welder so I bought it and use it for maintenance purposes, may use it only several hrs per month, so problems that I have now didn't bother me much, but things changed.
1. When I start welder, it runs on idle, but would not idle up when switched to run, or may be it runs hi and would idle down (do not know as I am not familiar with motor driven welders at all).
2. Battery would not be charged by welder, so I have to charge it overnight before I could use it on my 225g, if I disconnect it, welder dies, and I do not believe it is normal, as it should only need battery to start it and engine should generate enough power to run with out battery.
3. Now, I am thinking on buying probably MM211 to run from this welder and kind of scared as I do not know if my 115/230 output has proper voltage so I wouldn't kill my mm211.
So my questions are what is wrong with #1 and 2 and how do I check #3.
My 225g powered by onan performer 16xsl I think s# 8(6?)923886455 and s# for welder is KC200308 I think.
Be patient with me as I am good with mechanical things, but not so with electrical.
Thank you for all of your help.

[Vitaliykit]

Update to #3.
Went to local hardware store and bought digital multimeter to check some outputs. My 115/230 show about 116/231.8 with no load. Under small (grinder) load it came down about 2-3 volts and went back up in few seconds. It got late tonight, so I will hook some heavier loads tomorrow and update. While I have my top of (was rewiring my 230 outlet) what else should I check for?

[duaneb55]

1. I'm not following you on what is actually happening. Is it not increasing to weld speed on RUN or is it? Your description appears to be contradictory.

2. That's what it would do as the voltage regulator on the Onan "turns" off when the battery is disconnected.

[Vitaliykit]

Originally, when I bought the welder, it would only run in idle position, when switched to run position, it would die. Now (i didn't do a thing to it), it would run in both run and run/idle position at the same speed and would not increase during welding, so that's why I think it runs at high rpm (?), but I am not sure as originally it would only run in idle position. (hope you can follow me) as I am confused as well. I did take it to as high as about 130 amp and do not think that idle speed would do it.

[duaneb55]

It sounds as if you MAY have a bad RUN/START/OFF switch. Poor connections at the switch plugs may be a contributing factor as well but the fact it died when you switched from IDLE to RUN could be due to bad contact inside the switch. That is, if it's an ignition problem and it didn't die due to a carburation issue.

[Vitaliykit]

Thank you for your help.
Just checked my battery while running the welder, it shows little over 14 volts, so that looks normal (I think).
How do I check my switch? I assume it would have some dc voltage going through it?
It sounds like it runs hi, and has no idle.

[Vitaliykit]

As a side question, I planned to get mm211 with spool gun to weld 1/8 aluminum once in a while, but I could pick up mm252 used locally for about the price of new 211, so I have 2 questions...
1. Can I possibly run 252 (at about half the power) from my bobcat 225g (8000 watt) and
2. can I use spoolmate 100 with mm252 as it is a lot cheaper and I only need to weld thin aluminum may be once every few months.

[Vitaliykit]

According to this: http://www.millerwelds.com/products/...powerguide.pdf (in contractor tools section) I could probably run mm212 (Millermatic® 212 MIG Welder (30−210 amps, 230 volt)) as it needs 6500 watt starting/running. Can not find any info about mm252 and weather it will run from 30A or 8kw generator if I only use it at bellow 150amps.

[Vitaliykit]

If you know answer to post #7, please reply as it may be helpful to someone else, as far as me, I just ordered mm211 with spool gun from welders-direct web for $1,250 total with few free items. I talked to some guy in the neighborhood and he sold me on multi-voltage machine, so here I am cash poor, welder rich.

[duaneb55]

Sorry I didn't reply sooner. Lost track of your thread.

To answer your question regarding power source/spoolgun compatibility, a look at Miller's spoolgun hook up chart http://www.millerwelds.com/products/...gun-chart.html will show the Spoolmate 100 and MM252 is a no go. It's a control circuitry requirement thing.

[Vitaliykit]

Little update:

Ordered my welder (MM211 and spool gun) on the 24th, but by the time it was processed and holiday weekend it wasn't mailed till Tuesday the 29th and I received it Th the 31st.
Wanted to show some pix, but couldn't figure out how to post them , oh well. Because I got them around 7 pm, had no chance to play with my new toys, so today is the day