Miller Electric 140 Auto-Set Troubleshooting − Burn-Through, Troubleshooting − Waviness Of Bead

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8-13. Troubleshooting − Burn-Through

	Burn-Through − weld metal melting completely through base metal
	resulting in holes where no metal remains.
	S-0640
Possible Causes	Corrective Actions
Excessive heat input.	Select lower voltage range and reduce wire feed speed.
	Increase and/or maintain steady travel speed.
Wrong polarity.	Configure polarity as shown in Section 4-5. Always read and follow wire manufacturer’s
	recommended polarity, and see Section 4-5.

8-14. Troubleshooting − Waviness Of Bead

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

S-0641

Possible Causes

Corrective Actions

Welding wire extends too far out of nozzle.

Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.

Unsteady hand.

Support hand on solid surface or use two hands.

8-15. Troubleshooting − Distortion

Distortion − contraction of weld metal during welding that forces base metal to move.

Base metal moves in the direction of

the weld bead.

S-0642

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 voltage range and/or reduce wire feed speed.

Increase travel speed.

Weld in small segments and allow cooling between welds.

OM-225 311 Page 51

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Contents File MIG Gmaw OM-225 311CProcesses DescriptionFrom Miller to You Table of Contents − Parts List − Maintenance &TROUBLESHOOTINGElectric Shock can kill Symbol UsageMarks a special safety message Arc Welding HazardsBuildup of GAS can injure or kill ARC Rays can burn eyes and skinWelding can cause fire or explosion Flying Metal can injure eyesCalifornia Proposition 65 Warnings EMF Information Principal Safety StandardsAbout Pacemakers LES Fumées ET LES GAZ peuvent être dangereux UNE Décharge Électrique peut entraîner la mortIndique un message de sécurité particulier LE Bruit peut endommager l’ouïe LE Soudage peut provoquer un incendie ou une explosionDES Particules Volantes peuvent blesser les yeux DES Pièces Chaudes peuvent provoquer des brûlures gravesDES Organes Mobiles peuvent provoquer des blessures Risque D’INCENDIE OU D’EXPLOLA Chute DE L’APPAREIL peut blesser ’EMPLOI Excessif peut SUREn ce qui concerne les stimulateurs cardiaques Principales normes de sécuritéVAC Model w/Auto−SetE − SpecificationsSpecifications VAC ModelOverheating Duty Cycle And Overheating115 VAC Model 230 VAC ModelAmperage Volt-Ampere CurvesInstalling Welding Gun − InstallationIncorrect Process/Polarity Table Work Cable Routing Inside UnitChanging Polarity Installing Gas Supply See NEC Article 511 or CEC Special installation may beRequired where gasoline or Volatile liquids are present −Do not move or operate unit where it could tip Installing Wire Spool And Adjusting Hub Tension Electrical Service Guide For 230 VAC ModelInput Voltage 230 Input Amperes At Rated Output Remove gun nozzle and contact tip Threading Welding WireCut Off End Of Wire Open Pressure Assembly Knob Removing MIG Gun From Welding Power SourceEnd Of Wire To Spool Operation Installing Optional Spool Gun Switch In Welding Power SourceConnecting Spool Gun To Millermatic 140/180 Controls For 115 VAC Model w/Auto-SetE − Operation115V Controls For 115 VAC Model230V Controls For 230 VAC ModelOM-225 311 Weld Parameter Chart For 115 VAC Model w/Auto−SetE 10/90 10/65 10/80 10/60 10/50 10/95 10/75 10/100 Aluminum 100% Argon 4043ER 030 0.8 mm 035 0.9 mm10/32 OM-225 311 10/90 10/45 10/60 10/30 10/32 10/80 035 0.9 mm 030 0.8 mm#220179 #202926 #220179Dcep Dcen 024 0.6 mm #220179 030 0.8 mm #202926 035 0.9 mm 045 1.2 mm 100 10/60 10/45 10/40 10/20 10/50Drive Motor Protection − Maintenance &TROUBLESHOOTINGRoutine Maintenance Overload ProtectionTurn Off power before replacing contact tip Changing Drive Roll Or Wire Inlet GuideReplacing Gun Contact Tip Disconnect gun from unit Cleaning Or Replacing Gun LinerTo Reassemble Gun Replacing Switch And/Or Head Tube Trouble Remedy Troubleshooting TableOM-225 311 Circuit Diagram − Electrical Diagram234 419-B Typical MIG Process Connections − MIG Welding Gmaw GuidelinesSelect Voltage Typical MIG Process Control SettingsWire Recommendation Wire Speed Select Wire SizeHolding And Positioning Welding Gun Conditions That Affect Weld Bead Shape Good Weld Bead Characteristics Poor Weld Bead CharacteristicsGun Movement During Welding Troubleshooting − Porosity Troubleshooting − Excessive SpatterPossible Causes Corrective Actions Troubleshooting − Lack Of Penetration Troubleshooting − Excessive PenetrationTroubleshooting − Incomplete Fusion Troubleshooting − Waviness Of Bead Troubleshooting − Burn-ThroughTroubleshooting − Distortion Application Common MIG Shielding GasesFlat & Horizontal1 Fillet Options − Parts ListRecommended Spare Parts Optional Drive RollsPage Support ServiceMiller Electric Mfg. Co Owner’s Record

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