How to Troubleshoot MIG Welding Problems

How to Troubleshoot MIG Welding Problems


In welding like everything else, there
are a few problems that can occur. These are a few that you might experience. Birdnesting is a common problem. This happens when the wire becomes obstructed in the
gun and cannot feed properly. When this happens, wire will collect around the
drive rolls. The result: a bird nest. It can be caused by the wrong size contact
tip or a tip in poor condition. Replace the tip with the correct size for the
wire. Birdnesting can be caused by a plugged or kinked gun liner. In this
situation, it will be necessary to replace the gun liner. See your owners
manual for the correct procedure. An obstruction on the wire between the gun
and the drive rolls can also result in birdnesting. Other causes of bird
nesting include too much drive roll tension and the gun not inserted into
the drive housing properly. If you have a birdnest, remove it by flipping up the
drive roll. Pull the wire completely away then refeed the wire making sure that
there are no kinks or strong bends in the wire. Burnback can occur if the wire feed
speed is set too slow or if the gun is set too close to the work. This will
cause the wire to burn back into the contact tip. If this happens you’ll have
to replace the tip. Remove the nozzle and unscrew the tip. Be aware that the tip
may have welded to the wire. Snip the wire off, replace the tip, making sure it
is the same size, and tighten. Reinstall the nozzle making sure that the contact
tip is flush with the nozzle. Shielding gas protects the weld pool
from contaminants in the air. These contaminants can result in poor welds.
Signs of poor welds caused by poor gas coverage include porosity or pinholes in
the weld. Here are a few tips that can help you avoid this problem. Make sure
that the gun is securely tightened with the knob. Make sure that your gas
connections are correct and secure. Then check the flow gauge to make sure that
the tank has sufficient gas. When adjusting your flow, remember that a
typical flow rate is twenty to thirty CFH. All Millermatics® are equipped with
thermal overload protection. This is done to prevent damage to the Millermatic.
The duty cycle of each machine determines how long it can be run in a
ten minute period at its rated output before it must be allowed to cool. This
period will vary, depending upon which Millermatic you were using. Check your
manual to determine what your duty cycle is. When the duty cycle is exceeded,
you’ll be unable to weld while the unit cools. When the unit is cooled down, the
circuit will reset itself and you’ll be able to continue to weld. It’s not
necessary to power down the unit during cool-down. The fan operation will speed
up the cool-down process. Continually subjecting your Millermatic to thermal
overload may cause permanent damage. For other problems you may have in welding,
check the section of this CD titled frequently asked questions.

29 thoughts on “How to Troubleshoot MIG Welding Problems

  1. 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.

  2. what the fuck, you never get rid of your tips, you get plyers and take out the wire, or it should free itself when it cools, what the fuck you cant weld steel to a copper (thus the tip is copper). fuck you miller, thats why i dont get a miller coz of bullshit that wants them to make more money. fuck miller i bought a cigweld transmig 200

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

  4. 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,

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

  6. 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?

  7. 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?

  8. 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

  9. 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

  10. 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.

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

  12. 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?

  13. 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

  14. 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.

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

  16. 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.

  17. 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

  18. 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

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