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OM-210 089 Page 34

7-10. Troubleshooting − Excessive Penetration

Good Penetration

Excessive Penetration − weld metal melting through base metal
and hanging underneath weld.

Excessive Penetration

S-0639

Possible Causes

Corrective Actions

Excessive heat input.

Select lower voltage range and reduce wire feed speed.

Increase travel speed.

7-11. Troubleshooting − Lack Of Penetration

Lack Of Penetration − shallow
fusion between weld metal and
base metal.

Lack of Penetration

Good Penetration

S-0638

Possible Causes

Corrective Actions

Improper joint preparation.

Material too thick. Joint preparation and design must provide access to bottom of groove while
maintaining proper welding wire extension and arc characteristics.

Improper weld technique.

Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.

Keep arc on leading edge of weld puddle.

Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.

Insufficient heat input.

Select higher wire feed speed and/or select higher voltage range.

Reduce travel speed.

7-12. Troubleshooting − Incomplete Fusion

Incomplete Fusion − failure of weld metal to fuse completely with
base metal or a preceeding weld bead.

S-0637

Possible Causes

Corrective Actions

Workpiece dirty.

Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before
welding.

Insufficient heat input.

Select higher voltage range and/or adjust wire feed speed.

Improper welding technique.

Place stringer bead in proper location(s) at joint during welding.

Adjust work angle or widen groove to access bottom during welding.

Momentarily hold arc on groove side walls when using weaving technique.

Keep arc on leading edge of weld puddle.

Use correct gun angle of 0 to 15 degrees.

Содержание MW135

Страница 1: ...Processes OM 210 089B September1998 MW 135 MW 175 And GA16C2 Gun Arc Welding Power Source And Wire Feeder Description MIG GMAW Welding Flux Cored FCAW Welding...

Страница 2: ......

Страница 3: ...30 VAC Model 16 3 8 Installing Wire Spool And Adjusting Hub Tension 16 3 9 Threading Welding Wire 17 SECTION 4 OPERATION 18 4 1 Controls 18 4 2 Weld Parameters For 120 VAC Model 19 4 3 Weld Parameters...

Страница 4: ......

Страница 5: ...is connected to a properly grounded receptacle outlet D When making input connections attach proper grounding conductor first double check connections D Frequently inspect input power cord for damage...

Страница 6: ...welding wire at contact tip when not in use D Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap D Remove any combustibles such as a butane lig...

Страница 7: ...maintained D Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can ca...

Страница 8: ...is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to...

Страница 9: ...rne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre D En effectuant les raccordements d entr e fixer d abord le conducteur de mise la terre appropr...

Страница 10: ...ter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans re vers des chaussures hautes et un couvre chef D Avant de souder retirer...

Страница 11: ...uvrements et dispositifs de protection LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences D Le rayonnement haute frequence peut provoquer des interf rences avec les quipements de...

Страница 12: ...sions g n rales du document intitu l Biological Effects of Power Frequency Electric Magnetic Fields Background Paper OTA BP E 53 Washington DC U S Govern ment Printing Office mai 1989 publi par le Off...

Страница 13: ...Wire Feed Speed Range At No Load Wire Type And Dia 023 030 in 0 6 0 8 mm 030 035 in 0 8 0 9 mm 160 870 IPM 4 1 22 5 m min CSA Rating B 230 VAC Model Rated Welding Output Amperage Range Maximum Open C...

Страница 14: ...fifteen minutes for unit to cool Reduce amperage or duty cycle before welding Y Exceeding duty cycle can damage unit or gun and void warranty Overheating 0 15 A or V OR Reduce Duty Cycle Minutes duty1...

Страница 15: ...he volt ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source Curves of other settings fall be tween the curves shown ssb1 1 10 91 ST 802 082...

Страница 16: ...2 3 3 2 Changing Polarity 1 Lead Connections For Direct Current Electrode Positive DCEP 2 Lead Connections For Direct Current Electrode Negative DCEN Always read and follow wire manufacturer s recomm...

Страница 17: ...rtical 5 Regulator Flowmeter Gas Hose Connection 6 Welding Power Source Gas Hose Connection Connect customer supplied gas hose between regulator flowmeter gas hose connection and fitting on rear of we...

Страница 18: ...dual branch circuit protected by time delay fuses or circuit breaker is required 3 Plug From Unit Select extension cord of 14 AWG for up to 50 ft 15 m or 12 AWG for 50 up to 200 ft 61 m Y Special inst...

Страница 19: ...receptacle 4 Line Disconnect Device See Section 3 7 Y Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 ssb2 2 1 94 Ref ST 802...

Страница 20: ...4 Max Recommended Input Conductor Length In Feet Meters 66 20 Min Grounding Conductor Size In AWG Kcmil 14 Reference 1996 National Electrical Code NEC S 0092 J 3 8 Installing Wire Spool And Adjusting...

Страница 21: ...mm Tighten Remove gun nozzle and contact tip Open pressure assembly Push wire thru guides into gun continue to hold wire Close and tighten pressure assembly and let go of wire Hold wire tightly to ke...

Страница 22: ...on fan runs but there is no weld output 3 Wire Speed Control Use control to select a wire feed speed As Voltage switch setting increases wire speed range also increases see weld setting label in weldi...

Страница 23: ...es Door Hinge Bailers Combines Bumpers Brackets Grain Wagons Wheelbarrows Garage Door Trailers Trailer Frames Fencing Lawnmower Decks Work Auto Door Brackets Galvanized Roofing Trailer Sides Garage Do...

Страница 24: ...EP DCEP DCEP DCEN DCEN DCEN DCEN DCEN DCEN DCEN DCEP 1 2 2 1 2 2 2 1 1 3 3 3 2 2 4 4 4 3or4 3or4 3 2 1 9 6 7 4 5 5 5 4 5 5 4 5 6 7 7 8 4 5 5 6 4 5 4 5 5 5 6 7 5 5 5 4 5 3 4 4 5 5 5 4 5 5 4 5 4 5 5 5 4...

Страница 25: ...e clean monthly Or 5 2 Overload Protection Ref ST 802 081 1 Circuit Breaker CB Circuit breaker CB protects wire feed motor from overload If circuit breaker opens wire stops feeding 2 Circuit Breaker C...

Страница 26: ...of the drive roll The groove closest to the motor shaft is the proper groove to thread see Section 3 9 NOTE when chang ing drive rolls make sure the woodruff key is on the motor shaft and not in the...

Страница 27: ...tall collet onto liner and tighten into gun feeder connector using wrench Cut liner off near collet so that liner end is as close to drive rolls as possible without touching Install nozzle Remove nozz...

Страница 28: ...tions see Section 3 2 Low weld output Connect unit to proper input voltage or check for low line voltage Place voltage switch in desired position see Section 4 1 Electrode wire feeding stops during we...

Страница 29: ...OM 210 089 Page 25 SECTION 6 ELECTRICAL DIAGRAM ST 205 400 53 Figure 6 1 Circuit Diagram For 120 VAC Model...

Страница 30: ...OM 210 089 Page 26 ST 210 011 B 53 17 Overload Feed Motor Figure 6 2 Circuit Diagram For 120 VAC CSA Model...

Страница 31: ...OM 210 089 Page 27 ST 205 423 B 53 53 Figure 6 3 Circuit Diagram For 230 VAC Model...

Страница 32: ...ctions Y Weld current can damage electronic parts in vehicles Disconnect both battery cables before welding on a vehicle Place work clamp as close to the weld as possible Wire Feeder Power Source Work...

Страница 33: ...35 in 023 in 40 145 A 50 180 A 30 90 A 035 in Select Wire Speed Select Voltage Wire Recommendation 030 in 035 in 023 in 2 in per ampere 1 6 in per ampere 3 5 in per ampere Wire Speed 2 x 125 A 250 ipm...

Страница 34: ...13 mm past end of nozzle and tip of wire is positioned correctly on seam NOTE 1 Hold Gun and Control Gun Trigger 2 Workpiece 3 Work Clamp 4 Electrode Extension Stickout 1 4 to 1 2 in 6 To 13 mm 5 Crad...

Страница 35: ...ctrode extension stickout travel speed thickness of base metal wire feed speed weld current and voltage NOTE Short Normal Long Short Normal Long 10 10 GUN ANGLES AND WELD BEAD PROFILES ELECTRODE EXTEN...

Страница 36: ...ment Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode S 0054 A 3 1 2 7 6 Poor Weld Bead Characteristics 1 Large Spatter Deposits 2 Rough Uneven Bead 3 S...

Страница 37: ...or liner 7 9 Troubleshooting Porosity Porosity small cavities or holes resulting from gas pockets in weld metal S 0635 Possible Causes Corrective Actions Insufficient shielding gas at welding arc Incr...

Страница 38: ...f 0 to 15 degrees to achieve maximum penetration Keep arc on leading edge of weld puddle Be sure welding wire extends not more than 1 2 in 13 mm beyond nozzle Insufficient heat input Select higher wir...

Страница 39: ...es Corrective Actions Welding wire extends too far out of nozzle Be sure welding wire extends not more than 1 2 in 13 mm beyond nozzle Unsteady hand Support hand on solid surface or use two hands 7 15...

Страница 40: ...e most commonly used shielding gases are listed in the following table Application Gas Spray Arc Steel Short Circuiting Steel Short Circuiting Stainless Steel Short Circuiting Aluminum Argon All Posit...

Страница 41: ...OM 210 089 Page 37 Notes...

Страница 42: ...OM 210 089 Page 38 SECTION 8 PARTS LIST Hardware is common and not available unless listed ST 802 066 Figure 8 1 Main Assembly...

Страница 43: ...sy 120 VAC model 1 24 184 735 GUIDE wire output 1 25 205 419 TRANSFORMER power assembly 230 VAC model 1 25 210 000 TRANSFORMER power assembly 120 VAC model 1 26 205 398A BRACKET mtg fan motor and heat...

Страница 44: ...LE power assembly 120 VAC model 1 60 201 234 3 LEAD ground 6 1 61 205 424A LABEL door 230 VAC model 1 61 205 406A LABEL door 120 VAC model 1 405 548 LABEL ground screw not shown 1 62 406 636 LABEL mov...

Страница 45: ...9 M154 825 TIP contact 030 1 9 M154 824 TIP contact 035 1 10 110 794 TRIGGER SWITCH ASSEMBLY 1 11 110 792 CABLE 10ft 1 12 110 797 SLEEVE rubber 1 13 167 440 LINER monocoil 023 035 wire 10ft consistin...

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