Miller Electric Renegade 180 manual Troubleshooting − Excessive Penetration

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12-10. Troubleshooting − Excessive Penetration

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

Excessive Penetration			Good Penetration
				S-0639

Possible Causes				Corrective Actions

Excessive heat input.				Select lower voltage range and reduce wire feed speed.

				Increase travel speed.

Wrong polarity.				Configure polarity as shown in Section 5-8. Always read and follow wire manufacturer’s
				recommended polarity, and see Section 5-7.

12-11.	Troubleshooting − Lack Of Penetration

				Lack Of Penetration − shallow
				fusion between weld metal and
				fusion between weld metal and
				base metal.
				base metal.
	Lack of Penetration			Good Penetration
				S-0638

	Possible Causes			Corrective Actions

Improper joint preparation.				Material too thick. Joint preparation and design must provide access to bottom of groove while
				maintaining proper welding wire extension and arc characteristics.

Improper weld technique.				Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.

	Keep arc on leading edge of weld puddle.

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

Insufficient heat input.	Select higher wire feed speed and/or select higher voltage range.

	Reduce travel speed.

Wrong polarity.	Configure polarity as shown in Section 5-8. Always read and follow wire manufacturer’s
	recommended polarity, and see Section 5-7.

12-12. Troubleshooting − Incomplete Fusion

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

	S-0637

Possible Causes	Corrective Actions

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

Insufficient heat input.	Select higher voltage range and/or adjust wire feed speed.

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.

	Use correct gun angle of 0 to 15 degrees.

Wrong polarity.	Configure polarity as shown in Section 5-8. Always read and follow wire manufacturer’s
	recommended polarity, and see Section 5-7.

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Contents OM-228 042B ProcessesDescription File Engine DriveFrom Miller to You Table of Contents − Maintenance 10-1Symbol 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 spécifiquesLES Fumées ET LES GAZ peuvent être dangereux DES Pièces Chaudes peuvent provoquer des brûlures gravesLE Soudage peut provoquer un in cendie ou une explosion ’EXPLOSION DE LA Batterie peu LE Bruit peut affecter l’ouïeDES Organes Mobiles peuvent pro voquer des blessures ’AIR Comprimé peut provoquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendieRisque D’INCENDIE OU D’EXPLO- Sion LE Surchauffement peut endom- mager le moteur électrique DES Organes Mobiles peuvent provoquer des blessuresLES Fils DE Soudage peuvent provoquer des blessures ’EMPLOI Excessif peutPrincipales normes de sécurité Proposition californienne 65 AvertissementsInformation EMF − Specifications Symbol DefinitionsWeld, Power, And Engine Specifications − DefinitionsGun Specifications Dimensions, Weights, And Operating AnglesOptional Lifting Eye Weight Rating Volt-Ampere CurvesPower Source Duty Cycle Fuel ConsumptionGenerator Power Curve Gun Duty Cycle And OverheatingVolts AC Amperes− Installation Installing Welding GeneratorMovement Airflow ClearanceGrounding Generator When Supplying Building Systems Use ground device as stated in electrical codesConnecting The Battery Electric Start Models Only Engine Prestart Checks+ − OilInstalling Welding Gun Work Cable Routing Inside UnitWeld Process/Polarity Table Changing Weld PolarityShown with optional cylinder rack Connecting Single−Phase, 230 Volt AC Utility Input PowerThis unit can provide weld out Electrical Service Guide Installing Wire Spool And Adjusting Hub TensionWhen a slight force is needed to turn spool, tension is set AdapterWeld Position Threading The Welding Gun Stamped Stamped .030/.035 Tighten Pressure Indicator ScaleTools Needed 150 mm 030/.035 Groove Wood − Operating the Welding Generator Controls See SectionTo Start Description Of Controls See SectionTo Stop Weld Parameter Chart Stainless Steel And 100% CO2 Weld Parameters 20 ga 18 ga 16 ga 14 gaGenerator power decreases as weld current increases Generator Power Panel Receptacles− Operating Auxiliary Equipment − Maintenance Power Source Routine MaintenanceGun Routine Maintenance Welding Power Source Overload ProtectionDrive Motor Protection Tip Saver/Short Circuit ProtectionTurn Off power before replacing contact tip Changing Drive Roll Or Wire Inlet GuideReplacing Gun Contact Tip Turn off welding power source/wire feeder Maintaining GunReplacing Switch And/Or Head Tube Tools Needed 19 mmServicing Air Cleaner Precleaner Paper ElementDo not wash paper element or clean with compressed air Standard Model Shown Stop engineAdjusting Engine Speed Stop engine. Close fuel valve− Troubleshooting TroubleshootingGenerator Power WeldingEngine Wire FeederDoes not run Recommended Spare Parts − Parts ListRecommended Spare Parts − Electrical Diagrams OM-217 454Regulator Flowmeter Wire Feeder Power Source Shielding Gas − MIG Welding Gmaw GuidelinesTypical MIG Process Connections Gun Work Clamp WorkpieceTypical MIG Process Control Settings These settings are guidelines only. MaterialWire Suggested Wire Speed Material thickness determines weld parametersNozzle, and tip of wire is posi Holding And Positioning Welding GunTioned correctly on seam Groove WeldsConditions That Affect Weld Bead Shape Gun Angles And Weld Bead ProfilesElectrode Extensions Stickout Fillet Weld Electrode Extension StickoutGood Weld Bead Characteristics Poor Weld Bead CharacteristicsGun Movement During Welding Troubleshooting − Porosity Troubleshooting − Excessive SpatterPossible Causes Corrective Actions 12-11 Troubleshooting − Lack Of Penetration Troubleshooting − Excessive PenetrationTroubleshooting − Incomplete Fusion Troubleshooting − Waviness Of Bead 12-13 Troubleshooting − Burn-ThroughTroubleshooting − Distortion Application Common MIG Shielding GasesFlat & Horizontal1 Fillet Selecting Equipment − Generator Power GuidelinesGrounding Generator To Truck Or Trailer Frame Grounding When Supplying Building Systems How Much Power Does Equipment Require?Approximate 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 Cord Lengths for 120 Volt LoadsCurrent Load Watts Amperes Cord Lengths for 240 Volt LoadsSOCKET/WRENCH Selection Table Standard Metric Your distributor also gives ServiceSupport 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