Welding Tips and Tricks

i have a miller 140 (115 volt) mig machine that has
started to trip the 20amp breaker after about 4"
of weld (machine at almost max setting)
i tired different outlets and get the same
results. any ideas?
craig

Any chance of a poor connection or frayed wire at the ground clamp?

"Any chance of a poor connection or frayed wire at the ground clamp?"


nope, replaced junk ground clap right away.
wires all good, plug doesn't even get warm.
im thinking of wiring an outlet with 10ga wire
and a 30amp breaker.
craig

Craig
I have a Lincoln 180 dual voltage at work, ran into a similar problem when using the 110 plug. I'm now working off a 220 line and all is well.

Richard
this machine is a 110 only.
if a bigger breaker doesn't fix it
i'll buy one that runs on 220.
I'm wondering if its an internal problem?
craig

Check your breaker. She. They start to pop under load the breaker could be bad. Had an issue with a new stove. Thing ran great we canned a bunch on it (3 burners and oven going most of the day) no issues then one day it tripped with two burners then when the oven and a burner was on. I noticed a funny smell a few times but could never trace its location. Well after the 3rd or 4th time it went I pulled the breaker to check here the thing was over heating and had the oily fishy smell to it that that I would smell now and then. Replaced it with a new one and no issues now. Also had a breaker go bad in my buddies garage one of the contacts on a 220 breaker was corroded bad.

Try replacing the breaker before you spend money on all the other stuff

Sent from my SM-N950U using Tapatalk

Does your welder have to share any of those 20amps with anything else? Do you have lights and a stereo running off of that circuit, maybe a shop refridge on it also? For metal working I have dedicated circuits that allow me to weld and grind or run my drill press with nothing else drawing while in operation. I also ran 12gauge for the 20amp and 6gauge for the 50amp. Never had a problem with either.

i have dedicated circuits for my tig, lathe, mill, plasma cutter, delta grinder but
not the mig since its 110 but thats where i think I'm going with this.
10 wire 30amp breaker.
craig

Breakers will get weak over time, especially if your concistantly drawing over 80% of there rated capacity.

Poland308 wrote:Breakers will get weak over time, especially if your concistantly drawing over 80% of there rated capacity.

I reread the OP and you are probably right, he said it has started to trip the breaker, I take that as meaning it didn't before. His plan to rewire is sound any ways.

You should size your breaker by the machine’s need, not a random choice. A 110v welding machine should not be drawing 30amps. And 10ga wire is much thicker than you need. If it is not a dedicated circuit, that would be better than over-provisioning the devices on that circuit. Breakers are for device protection and exceeding the devices needs with more amperage is bound to fry your device.

Turn everything but the welder on, close the breaker to identify exactly what’s connected. Turn those OFF, breaker ON, then run the welder. Problem persist? If so it’s the machine. If not, it’s over loaded. Don’t guess with electricity, deduce for safety.

You should size your breaker by the machine’s need, not a random choice. A 110v welding machine should not be drawing 30amps. And 10ga wire is much thicker than you need. If it is not a dedicated circuit, that would be better than over-provisioning the devices on that circuit. Breakers are for device protection and exceeding the devices needs with more amperage is bound to fry your device.

Turn everything but the welder on, close the breaker to identify exactly what’s connected. Turn those OFF, breaker ON, then run the welder. Problem persist? If so it’s the machine. If not, it’s over loaded. Don’t guess with electricity, deduce for safety.

Cj
good advise. ill take a step to the right and create a 20amp 12 wire line for this machine and try it.
it will be close (within 18" of panel which is less then two years old (100 amp) and try the welder.
like I've said before if it still trips the breaker ill buy one that runs on 220
craig

latest on mig welder issue:
ran short line (less then 18") of 12 wire, new breaker, new outlet.
same issues. emailed Miller tech waiting for reply.
craig

motox wrote:latest on mig welder issue:
ran short line (less then 18") of 12 wire, new breaker, new outlet.
same issues. emailed Miller tech waiting for reply.
craig

Bummer, sorry to hear that Craig, hopefully they can help.

motox wrote:latest on mig welder issue:
ran short line (less then 18") of 12 wire, new breaker, new outlet.
same issues. emailed Miller tech waiting for reply.
craig

If you had run the simple test I set out for you first, then you would have known it’s a machine issue, not a service issue. At least now when you get your machine working properly, you’ll have dedicated service for it.

Breakers don’t get “weak” over time, they either work or they don’t. They fail when overloaded regularly as they should. A breaker tripping is not normally a sign of a faulty breaker (rare unless they’re rather old) but a sign off too much demand, or damaged wiring/poor connections.

CJ
took your advise and shut down everything but the new designated line
20 app 12 wire new outlet.
guess its a machine issue.
waiting for Miller to get back to me.(email)
tried calling but 25 min on hold is not in my comfort zone.
craig

motox wrote:CJ
took your advise and shut down everything but the new designated line
20 app 12 wire new outlet.
guess its a machine issue.
waiting for Miller to get back to me.(email)
tried calling but 25 min on hold is not in my comfort zone.
craig

You can try to reach the Support guys at IOC (weldingsuppliesfromioc.com). I have found them to be very good, very helpful. And if you need to reach Miller TS, they provide a direct number into the Support line instead of through the switchboard.