i just got my millermatic 180 about a month ago
i am using flux wire with it
i alreaddy reversed the polarity
and its on a more than capable circuit

the problem is when im going at the weld it seem to pulsate the power so to speak
and you can hear it too zap.zap.zap.zap.zap

is this kind of thing normal? my lincoln 120v diddnt do that

and if i look at the wire as its welding it looks as if it feeds out a segment, burns it up to the tip, and then feeds it out again

this would leave me to believe that i have the fire speed set too low, but if i turn it up, the same thing happens, except now the wire will feed out and contact the surface and push the gun away a little bit and then burn up, and repeat


i can kind of eliminate it if i hold the tip much closer to the work piece but then its so close that the slightest movement will contact and short it out, or it will just burn the wire to the inside of the tip, almost ruining it



im not sure what to do here

 

I had a similar problem at first with my lincoln 140 Mig welder. I was using flux wire as well, at first I thought it was the heat but it turned out I had the wire speed too high. I keep the wire speed around 1.5 or 2 most of the time, seems to keep that pulsating effect away

 

UPDATE: Found a reference to burn back problems when the wire spool was installed upside down (feeding from the top) . I would check to make sure all your feed side stuff is set-up correctly - feed spool oriented correctly, spool tenison not too tight, roller tension per the test on the wood block.

You probably already have but... Replace the tip that had the last burn back... It might also be hanging up the wire feed. Your tip size matches your flux wire right?

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Original:

I would check the feed roller tension. Miller recommends feeding wire against a wood block at an angle...blah, blah. Check the manual it has a great description to ensure you have the proper pressure for feeding and no slippage.

Have you tried welding with solid wire and gas? Do you get similar results?

You didn't mention the wire size but with flux core I would guess .30 or .35. If you found a thinner flux cored, what is the brand?

I would also test your ground and weld areas - make sure they are prepped well and there is good raw metal. I know that my Miller 211 came with the clamp and wire separate - make sure they have a tight connection.

Lastly, trim your wire before starting and see if that helps. When the wire balls up on the end you can get inconsisitent starts.

 

yes i have the spool installed underhand style
the wire and the tips are .035 hobart wire
the same thing occoured with .030 wire

the wire does feed out smoothly even against a concrete block
i have a v (k)notched wheel

i dont have gas to do any solid wire

and yes the ground clamp is tightened


despite all this the bead does come out pretty good

 

Sounds like you covered all the bases I would.

Maybe check the liner by pulling wire with the machine off and no tension on the drive rollers to make sure it is nice and smooth... Other than that???

Maybe have the dealer take alook and service it?

 

ARe you direct to the plug or do you use and extension cord?

 

north or south of the canal???

 

im on an extension cord
the cord on the unit is only like 6 feet long and thats shorter than the outlet is to the door of the shop
and when i say shop i mean a 6X6 room with a compressor in it

so to even really use this machine i have to have it on an extension

however the extension is made with 6 guage wire

newark




it could be just me

im gonna keep going at it and see if i just need more practice i have another piece that needs welding for monday and ill see if i can make any adjustments to help better

 

I had the same issue with my welder. I found lowering the speed of the wire feed helped me get a better burn and not the popping. GL

 

As stated above, sounds like the wire speed is to high.