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Issue with autoset

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  • Issue with autoset

    I’ve always called this issue burn back, miller seems to call it something else. Basically my wire is hunting and pecking in the puddle. It will hit and burn back halfway to the contact tip and hit again. I can control it fine if i turn autoset off and manually adjust the wire feed speed.

    My question is if this is common on Miller Autoset? Do people have feed issues with the wire not staying an even distance from the puddle and burning back?

    My drive roller is not slipping. It’s been ran everywhere from loose to nearly crushing just to be sure that is not my issue. It feeds perfectly and is currently set to where it barely slips under high tension (right before it would birds nest).

    Is this how Autoset normally behaves?

  • #2
    I think you have a problem with the equipment. I know, it's not the words you wanted to hear, but from my chair, and what you describe, and with the little I know, my money is on that's not normal auto-set behaviour?
    I guess the alternative is that it is normal and what fun is that from your description of things?


    • #3
      Machine is doing great. If autoset doesn’t present this issue to many people I’ll change wire.


      • #4
        Autoset in the Miller 211 inverter does not produce that effect when the wire is feeding correctly. In that machine the Auto-set is pretty much darn near perfect for a T /lap joint.
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        • #5
          I am pretty sure he has the pre-inverter 211. Mine ran pretty consistently, though I normally adjusted the voltage and wire feed speed. I kept a pretty close work to contact tip distance for that machine, but that was probably just me getting used to it. It sounds like the wire feed speed is a little low for the voltage for that particular wire and shielding gas?

          That board has a microcontroller, with the autoset specs coded in software. I can't remember how much flexibility there was between thickness settings in autoset. Have you tried moving the thickness dial up and down up bit in a given thickness range? Is there any change when doing that?
          Last edited by jjohn76; 10-09-2019, 05:28 PM.


          • #6
            Yes it went much smoother when i gave it more heat, though it was borderline hot. We have preferences on how we weld, but i really think the miller autoset prefers running hot from this experience.


            • #7
              To be clear it isn’t totally fixed, but better. Here is the video from just regular use.



              • #8
                I have both of the 211's and no issues...…….you can adjust the auto set as if it was the manual settings and yes it seems to run hot.


                • #9
                  Well that video beats a picture any day. Well done One 1!

                  With some further thinking on what's the problem, causing the problem...? Well not knowing anything about much when it comes to such things as electronics, after watching the video I'd rule out a couple things and leave room for a couple of questions.

                  You appear to support the gun to keep consistent stick out so that rules out that. Now are you moving fast enough forward or are you piling up a bit from travel speed or lack of? With auto-set, I'd be inclined to go from A to B , not zig zag much side to side, but I'm not an Auto-set owner, just opinion based on thoughts from what I've read of it functioning.

                  I see it as a surging? Is there a change in the arc length, or a noticeable change assuming a slower travel speed followed by a movement forward might play havoc with the amperage response rate being adjusted? As you're watching the wire melt does the wire start burning up, spray more? Glob more?

                  But if you haven't, double check the simple before putting much stock in my theory's of gloom and doom. Could be a bad spool of wire causing that as well? What size is the roll? Wire size? How's your contact tip looking?

                  And once again, good effort on the video. But next time when you're done the weld, zoom in for a money shot.


                  • #10
                    I have the old transformer 211; what you show in the video is definitely not normal. I agree, as do many, that the autoset runs pretty hot, but not unuseable. I usually tweak it a bit. At any rate, it should not be varying wire speed that much. Bad wire? Crud in the liner? Burr or some other hangup in the way the wire reel turns? Bent shaft on the wire reel hub? Try changing the tension on the reel nut. I had an old Lincoln/Century machine that did that; tried all sorts of things and could not get it to feed consistently. A new roll of wire solved the problem. I could not understand why--the old wire seemed fine--but the problem went away.


                    • #11
                      I’ve done everything i can short of replace parts. I’ve put a new tip on, next will be a new liner. What stumped me was that i can control it manually. It only does this on autoset. Now I’ll say that it’s not perfect manually. However it’s worth noting that it’s 80% cured. I should be able to get an arc shot as i have used my gooro hero 5 session inside my lincoln 3350 before.


                      • #12
                        I believe Oscar had a problem with his and it turned out to be a wobble in the drive motor shaft.


                        • #13
                          I'm not sure if looking at things from the perspective of a welder is going to help or hinder this, but if your manual adjustment of weld parameters improves to an 80% cure over the factory Auto-set function, 20% suggests a problem still exists even if it isn't largely apparent.

                          So the welder is going to ask the dumb question, if the wire comes out, touches to short, current rises for a duration of time, wire heats, magnetism squeezes, droplet falls with the expectation this will be repeated, what's failing to function? One of those electrical gates needing grease? Electrical storage tanks developing a leak? A magnetic spring gone weak?

                          I haven't a clue? My failing in this is the grasp on how it flows to function. How to test that it does.

                          All said, I'd bet that if that was pictured on a scope, it would reveal a clue to what's going on. It's a heart beat with a arrhythmia. It might need a specialist?


                          • #14
                            I’m going to post the video for others to use in the future for reference when they search this issue, but the bottom line is Miller said don’t use autoset and flux core. I’ll do the field work i need to do and switch back to c25 and hardwire when I’m done.

                            Last edited by One1; 10-10-2019, 12:28 PM.


                            • #15
                              I can almost explain that. Variation in the voltage being sensed using the flux cored wire.
                              Click image for larger version

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ID:	603206No one wants to see this picture again but it almost explains it. You now mention flux core and frankly, that was hard to tell by the first video, for me anyways? That's like going to the doctor because your poops red and failing to mention you just tried Borst for the first time. You'll live spincters fine and the machine is fine as well I now think.

                              If your still in doubt however, I'm willing to try a further explanation.