Miller Electric 300, 225 manual Excessive Penetration, Burn-Through, Waviness Of Bead, Distortion

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	Table 6-5. Excessive Penetration
	Excessive Penetration − weld metal melt-
	ing through base metal and hanging un-
	derneath weld.
Excessive Penetration	Good Penetration
Possible Causes	Corrective Actions
Excessive heat input.	Select lower amperage. Use smaller electrode.
	Increase and/or maintain steady travel speed.
	Table 6-6. Burn-Through
	Burn-Through − weld metal melting com-
	pletely through base metal resulting in
	holes where no metal remains.

Possible Causes	Corrective Actions


Excessive heat input.	Select lower amperage. Use smaller electrode with lower amperage.
	Increase and/or maintain steady travel speed.

Table 6-7. Waviness Of Bead

Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal.

Possible Causes	Corrective Actions


Unsteady hand.	Use two hands. Practice technique.

Table 6-8. Distortion

Distortion − contraction of weld metal dur- ing welding that forces base metal to move.

			Base metal moves
			in the direction of
			in the direction of
			the weld bead.

Possible Causes			Corrective Actions


Excessive heat input.	Use restraint (clamp) to hold base metal in position.
	Make tack welds along joint before starting welding operation.
	Select lower amperage for electrode.
	Increase travel speed.
	Weld in small segments and allow cooling between welds.

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Contents Description ProcessesVisit our website at OM-316087 083Q August Stick Smaw WeldingFrom Miller to You Table of Contents Page Marks a special safety message Symbol UsageArc Welding Hazards Electric Shock can killWelding can cause fire or explosion ARC Rays can burn eyes and skinFlying Metal can injure eyes Buildup of GAS can injure or killCalifornia Proposition 65 Warnings About Pacemakers Principal Safety StandardsEMF Information − Consignes DE Sécurité − À Lire Avant Utilisation Signification des symbolesLES Décharges Électriques peuvent être mortelles LES Fumées ET LES GAZ peuvent être dangereuxLES Particules Projetées peu- vent blesser les yeux LE Soudage peut causer un incen- die ou une explosionLES Pièces Chaudes peuvent cau- ser des brûlures graves LE Bruit peut affecter l’ouïeLA Chute DE L’APPAREIL peut blesser Risque D’INCENDIE OU D’EXPLO’EMPLOI Excessif peut Faire LES Pièces Mobiles peuvent cau- ser des blessuresInformation sur les champs électromagnétiques Principales normes de sécuritéRexdale, Rexdale Ontario Canada M9W 1R3 téléphone Consignes relatives aux stimulateurs cardiaquesManufacturer’s Rating Labels Symbols And Definitions− Definitions Specifications − InstallationAC/DC Models AC ModelsVoid warranty Duty Cycle ChartsFor AC/DC Models For AC ModelsFor 220, 230/400, And 460 Volt Models 300/200 Amperes Volt-Ampere CurvesFor 115/230, 230 And 460 Volt Models 225/150 Amperes AC Amperes For 115/230 And 230 Volt Models 225 AmperesFor 220 Volt Model For 230/400 Volt Model Amperes 18 in 457 mm for airflow Selecting a LocationInstalling Electrode Cable and Barrel onto Electrode Holder Installing Electrode Holder And Work ClampInstalling Work Cable onto Work Clamp Weld Output Cables115 220 230 400 460 Electrical Service Guide47.5 15010 115 V Input Power Cord White Lead Turn Off unit and disconnect input powerTools Needed 16, 3/8 Cut tie wraps Wrapper Remove wrapper Jumper LeadsConnected For 400 Volts Connected For 230 Volts Connecting Input Power Controls − OperationControls For AC/DC Models For DC Weld OutputControls For AC Models Routine Maintenance − Maintenance & TroubleshootingLubricating Shunt Block And Anti-Noise Adjustment MonthsTorx Reinstalling Amperage Adjustment IndicatorWrapper Remove wrapper from unit Crank Handle Shunt Shaft Trouble Remedy TroubleshootingCircuit Diagram For AC/DC 230 Volts Models − Electrical DiagramsCircuit Diagram For AC/DC 115/230 Volts Models Circuit Diagram For 300/200 AC/DC 230/400 Volts Models Circuit Diagram For 225 230 Volts Models Circuit Diagram For 300 220 Volts Models Welding Methods Shielded Metal Arc Welding Smaw Procedure − Welding Methods & TroubleshootingElectrode And Amperage Selection Chart 10−30 Striking An ArcPositioning The Electrode Holder Conditions That Affect Weld Bead Shape Weld Bead CharacteristicsElectrode Angle Arc Length Butt Joints Electrode Movement During Welding Do not let weave width Tack WeldsLap Joints Welding TroubleshootingTee Joints PorosityLack Of Penetration Excessive SpatterIncomplete Fusion Burn-Through Excessive PenetrationWaviness Of Bead DistortionMain Assembly AC/DC model illustrated − Parts ListMain Assembly Page Work like a Pro TM-188 304 Invision 354MP Support ServiceYour distributor also gives For assistance in filing or settling claims, contact Miller Electric Mfg. CoYour distributor and/or equipment manufacturer’s Transportation Department