Miller Electric 250 Troubleshooting − Incomplete Fusion, Troubleshooting − Lack Of Penetration

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15-16. Troubleshooting − Incomplete Fusion

			Incomplete Fusion − failure of weld metal to fuse completely with
			base metal or a preceeding weld bead.




	Possible Causes		Corrective Actions

Insufficient heat input.			Increase amperage. Select larger electrode and increase amperage.

Improper welding technique.			Place stringer bead in proper location(s) at joint during welding.

			Adjust work angle or widen groove to access bottom during welding.

			Momentarily hold arc on groove side walls when using weaving technique.

			Keep arc on leading edge of weld puddle.

Workpiece dirty.			Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
			welding.

15-17. Troubleshooting − Lack Of Penetration

				Lack Of Penetration − shallow fusion between weld metal and
				base metal.

Lack of Penetration			Good Penetration

Possible Causes				Corrective Actions

Improper joint preparation.				Material too thick. Joint preparation and design must provide access to bottom of groove.

Improper weld technique.				Keep arc on leading edge of weld puddle.

Insufficient heat input.				Increase amperage. Select larger electrode and increase amperage.

				Reduce travel speed.

15-18. Troubleshooting − Excessive Penetration

				Excessive Penetration − weld metal melting through base metal and
				hanging underneath 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.

OM-217 455 Page 64

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Contents OM-217 455H File Engine DriveVisit our website at 2007−05−21From Miller to You Table of Contents 13-2 13-313-4 13-5Symbol Usage Arc Welding HazardsElectric Shock can kill HOT Parts can cause severe burnsFumes and Gases can be hazardous Buildup of GAS can injure or killARC Rays can burn eyes and skin Welding can cause fire or explosionEngine Hazards Compressed Air HazardsWelding Wire can cause injury HOT Parts can cause burns and injuryFire or Explosion hazard Falling Unit can cause injuryPrincipal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interferenceSignification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer Indique des instructions spécifiquesLE Soudage peut provoquer un in cendie ou une explosion DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peuvent être dangereux DES Organes Mobiles peuvent pro voquer des blessures LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peu Risque D’INCENDIE OU D’EXPLO- Sion LA Chaleur DU Moteur peut pro- voquer un incendie’AIR Comprimé peut provoquer des blessures LE Surchauffement peut endom- mager le moteur électrique DES Organes Mobiles peuvent provoquer des blessuresLES Fils DE Soudage peuvent provoquer des blessures ’EMPLOI Excessif peutProposition californienne 65 Avertissements Principales normes de sécuritéInformation EMF En ce qui concerne les implants médicaux− Specifications Symbol DefinitionsWeld, Power, and Engine Specifications − DefinitionsDimensions Dimensions, Weights, and Operating AnglesDimensions For Units With Optional Running Gear − Installation Installing Welding GeneratorVehicle frame. Always connect a ground wire MountingInstalling Exhaust Pipe Connecting the Battery+ − Stop engine and let coolOverview And Engine Prestart Checks Engine Left Side Engine Right Side Starting engine for the first timeRun-in period first 100 hours Daily pre-start checksConnecting to Weld Output Terminals Correct InstallationWork Weld Output Terminal Tools Needed Do not placeSelecting Weld Cable Sizes Engine Control Switches Place switch in Run position to operate most MIG equipment− Operating the Welding Generator Do not use glow plugs longer than 20 secondsWeld Output Controls Typical Stick Welding Connections And Control Settings Typical Settings For 7018 1/8 ElectrodeStop engine Work Clamp Electrode HolderTypical MIG Welding Connections And Settings Set Weld Process Selector switch to Wire + Dcep positionSet Weld Process Selector switch to Wire + position Set Weld Process Selector switch to Wire − position DcenTools Needed 3/4 Work Not Used To Work Left Side View Generator Power Receptacles − Operating Auxiliary EquipmentAt least once a month, run engine at To verify Gfci is working properlySimultaneous Weld And Power Determining Battery Charging Current − Operating Optional Battery ChargerBattery Charge Controls Battery Charge Cable Connections Battery Charging Procedure MinutesStart Your Professional Welding Career Now − Maintenance and Troubleshooting Routine MaintenanceMaintenance Label And Engine Maintenance Activities Stop engine and let cool Oil And Fuel804 197-A / Ref 803 111-A / 227 Cleaner or with dirty element. Engine Ment is not covered by the warrantyAir cleaner primary element can Damage when determining whetherAdjusting Engine Speed Adjusting Fuel Solenoid PositionStop screw is factory-set and should not be adjusted Checking Fuel SolenoidAdjusting Throttle Solenoid Checking Throttle Solenoid16 mm Check for non-bindingAdjusting Weld/Power Speed Making Engine Speed AdjustmentsAdjusting Idle Speed Overload Protection Component Panel Stop engineFuse F1 Supplementary Protector CB8Troubleshooting Tables Generator PowerWelding Trouble RemedyMaintenance Display Action Engine− Parts List Recommended Spare PartsRecommended Spare Parts Current transformer CT1, and throttle solenoid TS1− Electrical Diagrams Circuit Diagram For Welding Generator228 719-B OM-217 455 231 607-B − RUN-IN and Wetstacking Run-In And Wetstacking− Performance Data Fuel Consumption CurvesUS Gal./Hr IdleGenerator Power Curve Duty CycleVolts AC Amperes At 120 VoltsAC Amps Stick Mode Volt-Ampere CurvesDC Amps CC/AC Stick Mode AC Volts MIG Mode Volt-Ampere Curve DC AmpsGrounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesSelecting Equipment Grounding When Supplying Building Systems How Much Power Does Equipment Require?Use ground device as stated in electrical codes Amperes x Volts = WattsApproximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsPower Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 / Volts = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible − Stick Welding Smaw Guidelines Stick Welding ProcedureWeld current starts when electrode touches work- piece Striking an Arc − Tapping Technique Electrode and Amperage Selection ChartStriking an Arc − Scratch Start Technique Poor Weld Bead Characteristics Good Weld Bead CharacteristicsPositioning Electrode Holder 10-30 9090 End View of Work AngleConditions That Affect Weld Bead Shape Electrode Movement During WeldingButt Joints Lap JointTee Joint 16 in 30 1.6 mm Tack WeldsTroubleshooting − Porosity Troubleshooting − Excessive SpatterWeld Test Possible Causes Corrective ActionsTroubleshooting − Excessive Penetration Troubleshooting − Incomplete FusionTroubleshooting − Lack Of Penetration Troubleshooting − Distortion Troubleshooting − Burn-ThroughTroubleshooting − Waviness Of Bead Work like a Pro Support ServiceYour distributor also gives To locate a Distributor or Service Agency visit Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s