How to Troubleshoot MIG Welding Problems

Рет қаралды 363,590

16 жыл бұрын

In welding, like everything else, there are a few problems that can occur. Learn how to prevent and fix common problems in MIG welding including: birdnesting of the wire, burnback of the contact tip, poor gas coverage, exceeding the machine duty cycle and thermal overload of the machine.
For more welding resources, visit: www.millerwelds.com/resources...
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Пікірлер: 69

@lltrailers 7 жыл бұрын

thanks...I just bought the miller 252 two days ago...I just hope it works as good as my miller 211 has for me...

@bluefrog8670 8 жыл бұрын

Thank you! Ive watched a lot of welding videos and finally someone tells me what the gas should be set at. Im pretty sure the machines at work are only set at about 15.

@DEXTER941 14 жыл бұрын

Great tips, thanks

@maestrocheck 13 жыл бұрын

Hello, Would it be any problem if I just unblock and clean the contact tip when burnback happens? Thanks..

@bootsy2589 13 жыл бұрын

Hi, I have a problem with my mig welder(I am a hobby welder).The feed wire is not constant the drive motor seems to stop & start .Got a new mother board but this not help (SIP 150 dual propose mig welder) Hoping to hear from you soon,

@MillerWelders 13 жыл бұрын

@bootsy2589 Thanks for the comment bootsy, although we would feel uncomfortable commenting on another company's product line...

@jacintoaguilar446 4 жыл бұрын

How much its de base price in Miller mig welder 252 please thank you have nice day.

@EdBoonSucks 11 жыл бұрын

Burnback is what happened to mine, but I'm having problems trying to replace the contact tip. There is a coil from inside the contact tip that is pushing the replacement, and preventing me to replace it. Can anyone help me here?

@tjstrain280 3 ай бұрын

HELP!!! My 252 won’t turn on, the red digital read outs flicker when i turn the switch on. If i spin the dials it flickers a little faster. Once or twice the fan turned on without anything being hot, (since it won’t run) Any ideas what it could be?? I purchased it new in 2008 as a hobby machine. Barely used at all since i tried to teach myself how to weld and seldom used it. Last time used was about 4 months ago. Thanks for your help, TJ

@nicusorvarmez 5 жыл бұрын

Hi there nice video can you please give me a hint why it won't weld when I touch the metal with the point of the torch it is the second torch I change. I use an older compact 151 s. it can be the liner I left hanging for a while? Thank you

@MillerWelders 5 жыл бұрын

Ni Nico, thank you for reaching out. We recommend getting in touch with our service line to talk this through with a tech. the number is 920-734-9821. Thank you.

@lltrailers 7 жыл бұрын

do you have video that shows the entire setup on miller 252?

@MillerWelders 7 жыл бұрын

We sure do! You can watch it here: kzfaq.info/get/bejne/r9eArZmezLCYnp8.html

@almostfamous9796 3 жыл бұрын

Fedup with bird nest ...my machine does not weld ..wire feed ok power turns on but no weld..plz advise

@MillerWelders 11 жыл бұрын

Assuming the machine you're talking about is the Multimatic 200 with the Q150 gun, a first suggestion would be to make sure the gun is laid out as straight as possible to insure that the liner is not pushing on the contact tip. Outside of trying that, we really recommend that you talk to someone on the phone about this. Miller service is the best option: 920-734-9821. Send us a message if you can't get through. Our video may also help: search for "Replacing your MIG gun liner" - good luck

@riverflyswatter 8 жыл бұрын

I'm not having a nesting problem . It's arcing after the drive wheel. Then nesting. Millermatic 211 flux core setup. Any advice ?

@MillerWelders 8 жыл бұрын

+J. Mike Shelton Thank you for reaching out. It sounds like there is a poor connection somewhere. We recommend the following steps: 1. Check your consumables in the end of your gun to make sure everything is tight. 2. Check your connections on the ground clamp. Also check ground clamp to see if it's worn out. 3. Check the connections of the leads at the location where you change your polarity for welding flux core / solid wire. If all of that looks good, take a scotch bright pad (or emery cloth) and shine up the power pin and aluminum housing. If none of those suggestions work, there is most likely a connection issue within the gun. Therefore, the gun would need to be replaced. We hope this helps. Let us know if you have any further questions. Thank you.

@krankinyankinfishing477 3 жыл бұрын

We just purchased the 255 Autobody and we are working on a Aluminum job right now. My techs keep blowing through the metal. I have been on the phone with tech support to adjust settings for Aluminum and they keep burning through it. Any guidance or video to watch for set up for aluminum would be greatly appreciated.

@MillerWelders 2 жыл бұрын

Thanks for reaching out. There are a few things to consider with the process for the very thin material, but it will all come down to what you are working on specifically since each manufacturer is different in their requirements. The most common thing I have seen on the extremely thin material is keeping the gun 90 degrees to the work. A slight push can lead to burn through on a 19 ga. butt with no backer. If you have further questions please email us at info@millerwelds.com and ask it to be directed to Travis W.

@jtb3797 12 жыл бұрын

Should of bought a Miller

@elizabethvandermaarel1342 7 жыл бұрын

Am using a Miller Millermatic 210 welder - my problem is the wire is live even before the trigger is pulled. How can I fix this

@MillerWelders 7 жыл бұрын

Hi, Leo. It sounds like your contactor is stuck shut and needs to be replaced. The replacement part number is 196600. Let us know if you have any questions.

@justonbusby996 8 жыл бұрын

got a miller 130 115 v. it hums and very little ark at tip

@sammycordelljr5235 6 жыл бұрын

Millermatic130 no fan no weld

@mastacor 11 жыл бұрын

what if the welder does not attempt to feed? nor does it spark on the metal? btw the ground is connected and clean, an also plugged in

@pizzapizzapizza7825 3 жыл бұрын

Did you ever find out what it was??

@mastacor 3 жыл бұрын

I'm pretty sure it was tension on feed or something along those lines

@pizzapizzapizza7825 3 жыл бұрын

@@mastacor thank you.

@somanynamesilltrythis0180 3 жыл бұрын

I'm having a frustrating issue, I just bought a welder it's brand new. It's rated for 230 volts but I don't have a 230v plug adapter so I bought an adapter to allow me to plug into a regular wall outlet. I did this before with a Cornwell welder I had and had no issues at all. But this one just pops and just isn't giving me good power even when it's maxed out. I don't know much about welding so any info is greatly appreciated.

@miketost6552 3 жыл бұрын

wire feeds but no arc. Grounds have been checked and are tight. The ground wire gets hot and shows signs of oxidation. What can the problem be ?

@MillerWelders 3 жыл бұрын

Please send us a more detailed description of your problem to info@millerwelds.com. What machine are you running, base material, settings etc. As for the ground or work lead connection, if it is getting hot before an arc is established the wire may have an internal issue you cant see that is not letting the current travel through the conductor. It is possible that the signs of oxidation you see on the wire are worse internally and breaking the electrical circuit. Swapping out that work lead cable would be a good place to start troubleshooting.

@tinagarces4285 2 жыл бұрын

I'm getting no power when I press the trigger but the fan comes on

@TheLightningStalker 15 жыл бұрын

Usually once the tip cools a little bit, the wire will break free and start feeding again. Just flick the trigger a couple times and it should break. Don't hold it down or you could end up with a birds nest. Check out more MIG troubleshooting vids in my channel.

@omarcisneros1337 Жыл бұрын

I have a millermatic 255 and my wire keeps birdnesting I have already changed the liner but it still spools up, any suggestions?

@MillerWelders Жыл бұрын

Thanks for reaching out, Omar. We're sorry to hear about this issue. Could you please provide us with your machine's serial number with any additional comments on your machine? Our team would like to look further into this. Thank you!

@jayc1716 4 жыл бұрын

I have a Millermatic 255 and been having trouble with it. Wire comes and and it sparks but won't lay any beads. Ive checked everything at least twice. Not sure what the problem is smh

@MillerWelders 4 жыл бұрын

Hi Jay. We are sorry to hear you are having issues with your machine. Quality and reliability are very important to us, and we are always working to improve our products and service. We would like to discuss this with you further. Can you please give us a call at 920-734-9821? Thank you!

@edbergeron 3 жыл бұрын

I have the same unit and am having the same issue, did you get it resolved?

@eancola6111 5 жыл бұрын

My millermatic almost sputters, it’s not a wire feed issue either, it will weld, stop, weld, it’s kind of pulsing, but not a full power

@MillerWelders 5 жыл бұрын

Hi, thank you for sharing your feedback. We recommend giving our service line a call to talk this through with a tech. The number is 920-734-9821. If there’s anything else we can help with, just let us know. Thank you.

@elizabethvandermaarel1342 7 жыл бұрын

But if the contactor was stuck wouldn't it feed continuously? It doesn't do that

@MillerWelders 7 жыл бұрын

Leo - please give our service line a call for assistance. The number is: 920-734-9821

@kenjenkerson2332 8 жыл бұрын

mm 350P won't weld- it keeps giving me a tip saver help code. The tip is recessed about 1/4" and is not touching the base metal at all which the code implies. I've checked the ground, changed the contact tip, nozzle, gas diffusser, liner, and none of these fixed it. Any ideas on how to troubleshoot this?

@MillerWelders 8 жыл бұрын

Thanks for reaching out, Ken. We recommend giving our service line a call to talk this through with a tech. The number is: 920-734-9821. Let us know if you have any issues getting through. Thank you!

@michel0broekmeulen 5 жыл бұрын

Ken Jenkerson j

@JLA-gq8um 5 жыл бұрын

Anyone else having arcing issues at the entry point of liner by the tension roller

@MrBaweld 4 жыл бұрын

if your getting arcing out there, check that your euro adapter or drive motor are not touching case. this is caused by welding current to the machines case

@shootinmcgee640 3 жыл бұрын

Howcome my Miller 255 seems to burn hotter when I turn the voltage down?

@MillerWelders 3 жыл бұрын

Hi there. Can you give us a call at 920-734-9821 and ask for Millermatic 255 service? Thank you!

@perceive8159 7 жыл бұрын

Hi On my millermatic 251 . I just notice when my ground clamp is grounded to a piece and then turn on the machine it sets off a high 4 code, when I remove ground clamp it clicks and then goes to a normal display and then I can clamp the ground again and proceed as normal to wield , It only does this when the ground clamp is clamped on start up, this unit never did this before. What might be the problem ( a short may be ) Thanks for the informative vid.

@MillerWelders 7 жыл бұрын

We would suggest having the unit checked at a service center for primary to secondary, primary to ground and secondary to ground shorts: www.millerwelds.com/where-to-buy?buy=1

@jesselawson1169 4 жыл бұрын

I have a millermatic vintage, it's not flowing the shielding gas... where do I start to try to fix the problem?

@MillerWelders 4 жыл бұрын

Hi Jesse. Thank you for reaching out,. We recommend giving our service line a call to talk this through with a tech. The number is 920-734-9821. If there’s anything else we can help with, just let us know.

@jesselawson1169 4 жыл бұрын

Thanks I appreciate the reply

@matttimmer9959 7 жыл бұрын

JUST GOE MY 141. I HAVE IT ALL SET UP BUT WHEN I PULL THE TRIGGER IT WON'T FEED THE WIRE. I CAN'T GET THE TO ROLL EVEN WITHOUT THE WIRE AND I PULL THE TRIGGER.

@MillerWelders 7 жыл бұрын

Thanks for reaching out, Matt. We recommend taking a look at the following video that has steps for setup: kzfaq.info/get/bejne/p76qfsp-0sy7ZXk.html If you continue to have issues, please give our service line a call at 920-734-9821 to talk this through with a tech.

@bosalter3245 6 жыл бұрын

Miller Welders I was looking for robot welding programing

@willg9620 4 жыл бұрын

Trying to find out why my millermatic 140 clicks on speeds 7 to 9. Doesn't feed

@willg9620 4 жыл бұрын

Doesn't At those speed settings and clicks instead

@MillerWelders 4 жыл бұрын

Hi Will. Thanks for reaching out. We recommend giving our service line a call to talk this through with a tech. The number is 920-734-9821. If there’s anything else we can help with, just let us know.

@adammoss613 8 жыл бұрын

can not get wire feed to come on

@MillerWelders 8 жыл бұрын

+Adam Moss Sorry you are having issues. We are happy to help. Could you describe the equipment you are using and the application you are working on?

@SPACECADET2U 15 жыл бұрын

JMHO....if you are birdnesting, the feed rollers are too tight.....

@ported7 6 жыл бұрын

I’m not the only person great don’t buy a nu tec unit

@2112jeff 13 жыл бұрын

@dimmyrocks I don't know where you're buying your tips, but you'er getting ripped of if you're paying $2 a piece.

@dabbgk 3 жыл бұрын

Mine keeps showing the over temp light whenever I press the trigger even though it’s not hot, I’ve had it off all night and it’s still doing it. Miller’s are junk, my harbor freight welder was more reliable

@MillerWelders 3 жыл бұрын

Thank you for reaching out. We recommend giving our service line a call to talk this through with a tech. The number is 920-734-9821. If there’s anything else we can help with, just let us know.

@EdBoonSucks 11 жыл бұрын