MM250X burn in

[fyoung]

Hi, I have a MM250X without meters KK 1999 model with very little run time on it but I have a lot of problems with the burn in? It's real bad about poping back to the tip and burning off when I start out it may do it 10 times out of 20 starts. I try to start with the wire cut about about 1/2 to 3/4 of an inch long(stick out) I was told by a couple people that adjusting the burn in might cure it and I was also told that the 251's have an easy way to adjust the burn in..do any of you know how I can adjust it on my 250x? I've had a lot of electrical experience as I used to wire new homes and I've built-repaired computers for the last 10 years so going inside adjusting wouldn't be a problem for me if I knew where to go. I'm running 035 ER 70S6 solid wire and 75/25 gas with a new Bernard Q-200 amp gun 15` Any and all help appreciated!
Thanks, Farris Young

[gdad]

I know from past experience that there is an adjustment that can easily be made on a board inside the machine to help your problem. I have done probably a dozen or more of them in the past, but unfotunately it's been long enough ago that I'm afraid I can't walk you through it without looking at a machine. I know you have to turn a dial with a small screwdriver one way or the other. My advise would be to contact a local Miller distributor that you do business with. If they ever sold many 250X's, I'm sure they've done this many times.

[fyoung]

OK..I'll try to remember to go by the distributor the next time I'm that way..it's about an hour drive from where I am but I go there a few times a year.. I think I remember reading somewhere how to do this but it was before i bought my welder and don't remember...someone else said on a 250x this was a common problem.
Thanks again!

[fyoung]

Someone tole me that there is a user named kevin Miller and he would know where the pot is that i can adjust..you guys know this user? Thanks!

[Miller Kevin]

Farris,

Popping back on the starts is typically caused by drive roll slippage. There are some adjustments that can be made on the board inside the unit but I would suggest eliminating all of the possible external causes first.

1) Bad or incorrect gun liner (kinked, plugged or wrong size).
2) Worn, incorrect or mis-aligned drive rolls.
3) Spool brake tension to tight.
4) Bad work clamp or loose connection to the clamp.
5) Bad mig gun.
6) Rusty welding wire.

If you are still having trouble after you have checked all of these items and resolved any issues you find please give me a call and we can discuss the internal adjustments.

Kevin
Ph: (920)735-4505

[fyoung]

Farris,

Popping back on the starts is typically caused by drive roll slippage. There are some adjustments that can be made on the board inside the unit but I would suggest eliminating all of the possible external causes first.

1) Bad or incorrect gun liner (kinked, plugged or wrong size).
2) Worn, incorrect or mis-aligned drive rolls.
3) Spool brake tension to tight.
4) Bad work clamp or loose connection to the clamp.
5) Bad mig gun.
6) Rusty welding wire.

If you are still having trouble after you have checked all of these items and resolved any issues you find please give me a call and we can discuss the internal adjustments.

Kevin
Ph: (920)735-4505

Kevin, i appreciate the reply..I'll try all the suggested things and I'll get back to you if that don't cure it. i have a new bernard Q200 gun and the wire pulls freely thru it when doing it by hand..i try to keep my cable straight as possible etc. . I'll go from here...Thanks again, Farris

[jniolon]

Farris,

would it be in the manual ??? I've never had to do this before so I'm lost, but I know you can download PDF manuals on Miller machines on this site... just a wild thought from someone who hasn't got a clue..

john

[fyoung]

Farris,

would it be in the manual ??? I've never had to do this before so I'm lost, but I know you can download PDF manuals on Miller machines on this site... just a wild thought from someone who hasn't got a clue..

john

John, the manual don't show you how to adjust the burn in on a 250x it does on the 251 ..i was told on the 250x you have to take the cover off and go inside the machine and adjust a pot play with the welding some and readjust till you get it like you want it... I'm going to try all the things suggested before adjusting the pot..thanks!

[fyoung]

Guys, I just wanted to update you on my problem. I did a modification to the 250x and it's working a lot better now. I appreciate all the help and especially thank Kevin for all the great info on this project/repair. I might add that I did more than was necessary to fix my problem, The quickest and easiest solution would been "Cut one end of diode and maybe adjust Ramp Speed" That would have curd my problem and took about 5 minutes but as my wife is always saying "You go over board" I've always messed with electronics building things experimenting Etc. so this wasn't a problem once Kevin told me where to look on my board....I will caution you here! I could have blown my board very easily with static electricity Etc. even though I always try to use a ground strap. Thanks again. Farris

[fyoung]

That fixed it..it's still welding like a Miller is known for..Miller makes some great welders..I've used their AC/DC units for 35 years without any problems..they really hold up under tough conditions.
Thanks Miller and Thanks guys, Farris