Miller Electric Renegade 180 Troubleshooting − Burn-Through, Troubleshooting − Waviness Of Bead

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12-13.	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 5-8. Always read and follow wire manufacturer’s
		recommended polarity, and see Section 5-7.

12-14. 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.

12-15. Troubleshooting − Distortion

				Distortion − contraction of weld metal during welding that forces
				base metal to move.
			Base metal moves
			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-228 042 Page 49

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Contents Processes OM-228 042BDescription File Engine DriveFrom Miller to You Table of Contents 10-1 − MaintenanceArc Welding Hazards Symbol UsageElectric Shock can kill HOT Parts can cause severe burnsBuildup of GAS can injure or kill Fumes and Gases can be hazardousARC Rays can burn eyes and skin Welding can cause fire or explosionCompressed Air Hazards Engine HazardsHOT Parts can cause burns and injury Welding Wire can cause injuryFire or Explosion hazard Falling Unit can cause injuryCalifornia Proposition 65 Warnings Principal Safety StandardsEMF Information Radiation can cause interference− Consignes DE Sécurité − Lire Avant Utilisation Signification des symbolesUN 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 DES Organes Mobiles peuvent provoquer des blessures LE Surchauffement peut endom- mager le moteur électriqueLES Fils DE Soudage peuvent provoquer des blessures ’EMPLOI Excessif peutInformation EMF Proposition californienne 65 AvertissementsPrincipales normes de sécurité Symbol Definitions − SpecificationsWeld, Power, And Engine Specifications − DefinitionsDimensions, Weights, And Operating Angles Gun SpecificationsOptional Lifting Eye Weight Rating Volt-Ampere CurvesFuel Consumption Power Source Duty CycleGun Duty Cycle And Overheating Generator Power CurveVolts AC AmperesInstalling Welding Generator − InstallationMovement Airflow ClearanceUse ground device as stated in electrical codes Grounding Generator When Supplying Building SystemsEngine Prestart Checks Connecting The Battery Electric Start Models Only+ − OilWork Cable Routing Inside Unit Installing Welding GunChanging Weld Polarity Weld Process/Polarity TableThis unit can provide weld out Connecting Single−Phase, 230 Volt AC Utility Input PowerShown with optional cylinder rack Installing Wire Spool And Adjusting Hub Tension Electrical Service GuideWhen a slight force is needed to turn spool, tension is set AdapterWeld Position Tools Needed 150 mm 030/.035 Groove Stamped Stamped .030/.035 Tighten Pressure Indicator ScaleThreading The Welding Gun Wood Controls See Section − Operating the Welding GeneratorTo Stop Description Of Controls See SectionTo Start Weld Parameter Chart 20 ga 18 ga 16 ga 14 ga Stainless Steel And 100% CO2 Weld Parameters− Operating Auxiliary Equipment Generator Power Panel ReceptaclesGenerator power decreases as weld current increases Power Source Routine Maintenance − MaintenanceWelding Power Source Overload Protection Gun Routine MaintenanceDrive Motor Protection Tip Saver/Short Circuit ProtectionReplacing Gun Contact Tip Changing Drive Roll Or Wire Inlet GuideTurn Off power before replacing contact tip Maintaining Gun Turn off welding power source/wire feederTools Needed 19 mm Replacing Switch And/Or Head TubePrecleaner Paper Element Servicing Air CleanerDo not wash paper element or clean with compressed air Standard Model Shown Stop engineStop engine. Close fuel valve Adjusting Engine SpeedTroubleshooting − TroubleshootingGenerator Power WeldingDoes not run Wire FeederEngine Recommended Spare Parts − Parts ListRecommended Spare Parts OM-217 454 − Electrical Diagrams− MIG Welding Gmaw Guidelines Regulator Flowmeter Wire Feeder Power Source Shielding GasTypical MIG Process Connections Gun Work Clamp WorkpieceThese settings are guidelines only. Material Typical MIG Process Control SettingsWire Suggested Wire Speed Material thickness determines weld parametersHolding And Positioning Welding Gun Nozzle, and tip of wire is posiTioned correctly on seam Groove WeldsGun Angles And Weld Bead Profiles Conditions That Affect Weld Bead ShapeElectrode Extensions Stickout Fillet Weld Electrode Extension StickoutGun Movement During Welding Poor Weld Bead CharacteristicsGood Weld Bead Characteristics Possible Causes Corrective Actions Troubleshooting − Excessive SpatterTroubleshooting − Porosity Troubleshooting − Incomplete Fusion Troubleshooting − Excessive Penetration12-11 Troubleshooting − Lack Of Penetration Troubleshooting − Distortion 12-13 Troubleshooting − Burn-ThroughTroubleshooting − Waviness Of Bead Flat & Horizontal1 Fillet Common MIG Shielding GasesApplication Grounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesSelecting Equipment How Much Power Does Equipment Require? Grounding When Supplying Building SystemsApproximate Power Requirements For Farm/Home Equipment Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentHow Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 / Volts = Starting AmperageTypical Connections To Supply Standby Power Cord Lengths for 120 Volt Loads Selecting Extension Cord Use Shortest Cord PossibleCurrent Load Watts Amperes Cord Lengths for 240 Volt LoadsSOCKET/WRENCH Selection Table Standard Metric Support ServiceYour distributor also gives Miller Electric Mfg. Co To locate a Distributor or Service Agency visitFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s