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TROUBLESHOOTING: GENERAL GUIDE

Possible Solutions

Set the wire feed rate and voltage in accordance with good welding

practices as recommended by a qualified welding engineer.

Adjust the wire feed and voltage so that the arc is in accordance with

good welding practice for the joint to be welded. The distance from

the contact tip to the workpiece should be 15 times the welding wire

diameter. If the arc is too long there will be spatter, usually in the

direction of the weld.

If the contact tip becomes worn the welding wire will not be in con-

stant contact with the tip and the arc will become unstable. A contact

tip contaminated with spatter will cause uneven wire feed resulting in

further spatter.

The angle of the gas nozzle relative to the workpiece should be be-

tween 45 to 90 degrees. If the angle is too small, the wire runs paral-

lel to the weld pool, resulting in spatter in the direction of welding.

Have the power source checked for faulty conditions such as broken

wires and faulty contacts.

A great deal of spatter occurs if the stick-out is too great and if the

welding gun is held too far from the workpiece when striking the arc.

Try to start with as short a stick-out as possible and with the welding

gun as close to the starting point as possible. If a large ball end is

formed on the end of the welding wire, remove it by cutting the wire

with sharp wire cutters. It is helpful if the wire is cut to a point. Always

remove the ball end before striking an aluminum arc. Check the weld-

ing ground connection.

Check the user manual for your power supply or consult a qualified

welding engineer.

Uneven wire feed gives rise to heavy spatter. Find the cause of the

disturbance and correct the condition before proceeding.

Paint, mill scale, rust and other contamination on the base metal form

an insulating layer causing an unstable arc that results in heavy spat-

ter. Clean the surfaces to be welded.

Inspect ground cable for loose connections, fraying and cuts. Correct

any problem areas found and attach the ground cable directly to

the workpiece after having cleaned the contact surface first. POOR

GROUND CONTACT IS THe MOST COMMON CAUSe OF UN-

STABLe MIG WeLDING CONDITIONS.

The stick-out should be 15 times the diameter of the wire electrode be-

ing used. With increasing stick-out, the current is reduced and the arc

voltage rises, giving a longer unstable arc and increased spatter.

Check for correct polarity. Follow the electrode manufacturer’s recom-

mendations.

Problems/Causes

SPATTER

Too fast or too slow wire

feed for the arc voltage.

Too long an arc.

Damaged contact tip.

Inclination of welding

gun too great.

Faulty power source.

Incorrect start.

Incorrect pulse

parameters.

Uneven wire feed.

Impurities on the base

metal.

Poor ground contact.

Too long stick-out

(short-arc welding).

Incorrect polarity.

Содержание ALPHA 1

Страница 1: ...www binzel abicor com ABICOR ALPHA SERIES Instruction Manual ...

Страница 2: ......

Страница 3: ...onnector kit for direct mount models external gas 9 Consumable chart ALPHA 1 10 Consumable charts ALPHA 2 11 12 Consumable charts ALPHA 3 13 14 Consumable charts ALPHA 4 15 16 Trouble shooting Porosity 17 Trouble shooting General guide 18 20 Swanneck dimensions ALPHA 1 20 Swanneck dimensions ALPHA 2 21 Swanneck dimensions ALPHA 3 21 Swanneck dimensions ALPHA 4 22 ...

Страница 4: ...o burrs or obstructions to the inner diameter of the liner 6 Insert the liner into the swanneck fit the swanneck on the gun body in the desired position and tighten the swanneck locking ring If replacing an existing neckliner 1 Unscrew the swanneck remove the old neckliner and measure its length 2 Carefully cut the new neckliner to the same length as the old liner with a pair of sharp cutters 3 Ch...

Страница 5: ...s 078 to 094 run the cable liner to the contact tip 1 Lay the torch out straight and remove the swanneck 2 Remove the liner retaining nut at the wire feed end of the torch and remove the old liner if fitted 3 Check that the new liner has no kinks in it 4 Gently feed the liner through the cable assembly from the machine end of the torch taking care not to kink it in the process 5 With the liner col...

Страница 6: ...t as this can result in wire feed problems Do not cut the excess liner yet 5 With the plastic liner still protruding from the rear of the torch feed the torch into the feeder mounting block Lift the feed rollers of the wire feeder to enable the excess liner material to pass through Using a sharp tool cut the liner so that it butts up to the feed rollers This will provide the needed wire support to...

Страница 7: ...stic liner still protruding from the adaptor plug feed the liner through the inlet of the central adaptor until the adaptor plug on the torch is butted against the central adaptor Fasten into position with the plastic adaptor nut Lift the feed rollers of the wire feeder to enable the excess liner to pass through Cut the liner using a sharp knife so that it butts up to the feed rollers thereby supp...

Страница 8: ...nect the appropriate end of the trigger lead jumper supplied in the kit to the con nector exiting the torch the trigger lead may also differ from the one shown 4 Install the gun liner supplied with the torch as per the liner installation instructions on pages 4 5 5 The torch is now ready to install into the feeder Finally hook up the trigger connector on the feeder side Trigger lead jumper Assembl...

Страница 9: ... to the threads if so desired but use care to avoid sealant getting inside the block 4 Slide the gas hose over the gas nipple and clamp with the clamps supplied 5 Connect the appropriate end of the trigger lead jumper supplied in the kit to the con nector from the torch rear end 6 Install the liner supplied with the torch as per installation instructions on pages 4 5 7 The torch is now ready to in...

Страница 10: ...Nozzle Neckliner Cable Liner Slip On Type Part Part Part Part Part Part 024 Steel 140 0005 N A N A 145 0075 S2435 SI 2435 17PT 030 Steel 140 0051 N A N A 145 0075 S2435 SI 2435 17PT Factory Set up 035 Steel 140 0169 N A N A 145 0075 S2435 SI 2435 17PT 030 Aluminum 141 0001 N A N A 145 0075 B2440 127 9009 035 Aluminum 141 0004 N A N A 145 0075 B2440 127 9003 ...

Страница 11: ...I 2435 17PT 035 Steel 140 0169 H2T 6 N A N2T R 50 S3545 SI 3545 17PT 040 Steel 140 0242 H2T 6 N A N2T R 50 S3545 SI 3545 17PT Factory Set up 045 Steel 140 0379 H2T 6 N A N2T R 50 S3545 SI 3545 17PT 030 Aluminum 141 0001 H2T 6 N A N2T R 50 B2440 127 9009 035 Aluminum 141 0004 H2T 6 N A N2T R 50 B2440 127 9003 040 Aluminum 141 0006 H2T 6 N A N2T R 50 B4052 127 9003 045 Aluminum 141 0010 H2T 6 N A N2...

Страница 12: ...el 140 0051 142 0003 012 0017 145 0080 S2435 SI 2435 17PT 035 Steel 140 0169 142 0003 012 0017 145 0080 S3545 SI 3545 17PT 040 Steel 140 0242 142 0003 012 0017 145 0080 S3545 SI 3545 17PT 045 Steel 140 0379 142 0003 012 0017 145 0080 S3562 SI 3545 17PT 030 Aluminum 141 0001 142 0003 012 0017 145 0080 B2440 127 9009 035 Aluminum 141 0004 142 0003 012 0017 145 0080 B2440 127 9003 ...

Страница 13: ...62 S3545 SI 3545 17PT Factory Set up 045 Steel 140 0442 H3T 8 N A N3T R 62 S3545 SI 3545 17PT for 034 045 052 Steel 140 0533 H3T 8 N A N3T R 62 S4562 SI 5262 17PT Factory Set up 062 Steel 140 0587 H3T 8 N A N3T R 62 S4562 SI 5262 17PT for 1 16 035 Aluminum 141 0043 H3T 8 N A N3T R 62 B2440 127 9003 040 Aluminum 141 0008 H3T 8 N A N3T R 62 B4052 127 9003 045 Aluminum 141 0015 H3T 8 N A N3T R 62 B40...

Страница 14: ...21 145 0078 S3545 SI 3545 17PT for 035 045 052 Steel 140 0533 142 0020 014 0021 145 0078 S4562 SI 5262 17PT Factory Set up 062 Steel 140 0587 142 0020 014 0021 145 0078 S4562 SI 5262 17PT for 052 062 035 Aluminum 141 0043 142 0020 014 0021 145 0078 B2440 127 9003 040 Aluminum 141 0008 142 0020 014 0021 145 0078 B4052 127 9003 045 Aluminum 141 0015 142 0020 014 0021 145 0078 B4052 127 9003 052 Alum...

Страница 15: ...62 S4 3545 SI4 3545 17PT Factory Set up 045 Steel 140 0442 H4T 8 N A N4T 62 S4 3545 SI4 3545 17PT for 035 045 052 Steel 140 0533 H4T 8 N A N4T 62 S4 5262 SI4 5262 17PT Factory Set up 062 Steel 140 0587 H4T 8 N A N4T 62 S4 5262 SI4 5262 17PT for 052 062 078 Steel 140 0653 H4T 8 N A N4T 62 N A SI4 7894 17PT Factory Set up 094 Steel 140 0677 H4T 8 N A N4T 62 N A SI4 7894 17PT for 078 094 When using 0...

Страница 16: ...5 17PT 040 Steel 140 0348 H4T 10 N A N4T 62 S4 3545 SI4 3545 17PT 045 Steel 140 0481 H4T 10 N A N4T 62 S4 3545 SI4 3545 17PT 052 Steel 140 0547 H4T 10 N A N4T 62 S4 5262 SI4 5262 17PT 062 Steel 140 0616 H4T 10 N A N4T 62 S4 5262 SI4 5262 17PT 078 Steel 140 0665 H4T 10 N A N4T 62 N A SI4 7894 17PT 094 Steel 140 0698 H4T 10 N A N4T 62 N A SI4 7894 17PT When using 078 094 wire do not use a neckliner ...

Страница 17: ...g venturi effect at the end of the nozzle leading to atmospheric contamination 3 Excessively wide weld pool for nozzle I D 4 Arc voltage too high 5 Too high a travel speed Possible Solutions a Remove contamination clean surfaces b Use of specific wire gas mix for specific types of impurities a Replace wire b Install wire cleaning system c Prevent industrial dust dirt grit from contaminating wire d...

Страница 18: ... it protected with a cover Make sure spare wire rolls are stored in a clean dry place Set the brake so that the coil immediately stops rotating as soon as welding is interrupted If the brake is applied too hard it will cause the feed rolls to slip resulting in uneven wire feed If it is too loose over run of the wire will occur causing wire tangles inconsistent tension on the feed mechanism and irr...

Страница 19: ...e end of the welding wire remove it by cutting the wire with sharp wire cutters It is helpful if the wire is cut to a point Always remove the ball end before striking an aluminum arc Check the weld ing ground connection Check the user manual for your power supply or consult a qualified welding engineer Uneven wire feed gives rise to heavy spatter Find the cause of the disturbance and correct the c...

Страница 20: ...ck is tight Visually inspect the Bikox assembly for cuts and tears Replace the Bikox assembly if necessary Remove nozzle from gun and inspect contact tip and tip holder gas diffuser for wear and tightness replace or tighten as necessary Note complete weld parameters including welding current Amps welding voltage wire feed speed type and size of wire type of gas and fIow rate of gas and consult you...

Страница 21: ...nd y measurements are in millimeters and are taken from the end of the contact tip with spray arc set up SWANNECK DIMENSIONS ALPHA 2 THREADED A2T 22 A2T 45 A2T 60 SWANNECK DIMENSIONS ALPHA 3 THREADED A3T 45 A3T 22 A3T 60 ...

Страница 22: ...22 SWANNECK DIMENSIONS ALPHA 4 THREADED Approximate x and y measurements are in millimeters and are taken from the end of the contact tip with spray arc set up A4T 45 A4T 22 A4T 60 ...

Страница 23: ......

Страница 24: ...Municipio de Pabellon de Arteaga 102 Valle de Aguascalientes 20358 San Francisco de los Romo Ags MX R F C BSC 980824 R84 Tel 52 449 9730133 Fax 52 449 9731388 Email info binzel com mx Alexander Binzel Canada Inc 5200 Dixie Rd Unit 13 Mississauga ON L4W 1E4 Tel 905 428 1611 Fax 905 428 1598 Email info binzel ca INT 9007 08 01 Rev 05 12 Printed in USA Copyright Alexander Binzel Corporation 650 Medim...

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