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TABLE OF CONTENTS

SAFETY PRECAUTIONS - READ BEFORE USING

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1-2. Arc Welding Hazards

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1-3. Additional Symbols For Installation, Operation, And Maintenance

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1-4. California Proposition 65 Warnings

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1-5. Principal Safety Standards

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1-6. EMF Information

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SECTION 2

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CONSIGNES DE SÉCURITÉ

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LIRE AVANT UTILISATION

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2-1. Symboles utilisés

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2-2. Dangers relatifs au soudage à l’arc

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2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

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2-4. Proposition californienne 65 Avertissements

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2-5. Principales normes de sécurité

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2-6. Informations relatives aux CEM

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SECTION 3

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DEFINITIONS

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3-1. Additional Safety Symbols And Definitions

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3-2. Miscellaneous Symbols And Definitions

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SECTION 4

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SPECIFICATIONS

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4-1. Serial Number And Rating Label Location

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4-2. Software Licensing Agreement

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4-3. Unit Specifications

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4-4. Environmental Specifications

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4-5. Dimensions And Weight

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4-6. Duty Cycle And Overheating

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4-7. Static Characteristics

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SECTION 5

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INSTALLATION

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5-1. Selecting A Location

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5-2. Electrical Service Guide

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5-3. Connecting 1-Phase Input Power

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5-4. Wiring Optional 240 Volt Plug (119172) For Connection To Miller Welder/Generator

With Split-Phase 240 Volt Auxiliary Power

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5-5. Generator Or Inverter Requirements

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5-6. Selecting Cable Sizes*

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5-7. Weld Output Terminals

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5-8. MIG Welding Connections

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5-9. Process/Polarity Table

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5-10. MIG Gun Connection Inside Unit

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5-11. Connecting Shielding Gas Supply

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5-12. Installing Wire Spool And Adjusting Hub Tension

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5-13. Threading Welding Wire For MIG Gun

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5-14. Connecting Spoolmatic

15A Or 30A Or Spoolmate 200 Gun

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5-15. Connecting XR-Aluma-Pro Or XR-Aluma-Pro Lite

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5-16. Threading Welding Wire For XR-Aluma-Pro Or XR-Aluma-Pro Lite

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5-17. Threading Welding Wire Through XR Guns

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5-18. Threading Welding Wire For Spoolmate 200

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5-19. Threading Welding Wire For Spoolmatic 15/30A

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5-20. Calibrating Spoolgun

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Содержание Millermatic 255

Страница 1: ...illermatic 255 Processes Processes Description Arc Welding Power Source Wire Feeder File MIG GMAW r For product information Owner s Manual translations and more visit www MillerWelds com MIG GMAW Welding Pulsed MIG GMAW P ...

Страница 2: ...products continue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety Precautions They will help you protect yourself against potential hazards on the worksite We ve made installation a...

Страница 3: ...4 Environmental Specifications 11 4 5 Dimensions And Weight 12 4 6 Duty Cycle And Overheating 13 4 7 Static Characteristics 13 SECTION 5 INSTALLATION 14 5 1 Selecting A Location 14 5 2 Electrical Service Guide 15 5 3 Connecting 1 Phase Input Power 16 5 4 Wiring Optional 240 Volt Plug 119172 For Connection To Miller Welder Generator With Split Phase 240 Volt Auxiliary Power 18 5 5 Generator Or Inve...

Страница 4: ...0 Pulsed MIG Manual Mode 40 6 11 System 41 6 12 Support 42 SECTION 7 WELD PARAMETER CHARTS 43 7 1 MIG And Flux Core Parameters 43 SECTION 8 MAINTENANCE TROUBLESHOOTING 44 8 1 Routine Maintenance 44 8 2 Changing Drive Roll and Wire Inlet Guide 44 8 3 Overheating 44 8 4 Aligning Drive Rolls and Wire Guide 45 8 5 Error Messages 45 8 6 Troubleshooting 48 SECTION 9 PARTS LIST 49 SECTION 10 ELECTRICAL D...

Страница 5: ...f the follow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semi...

Страница 6: ... If this is not possible tightly cover them with approved covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling ...

Страница 7: ...orks to move unit be sure forks are long enough to extend beyond opposite side of unit Keep equipment cables and cords away from moving vehicles when working from an aerial location Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation Publication No 94 110 when manu ally lifting heavy parts or equipment OVERUSE can cause OVERHEATING Allow cooling period follow ra...

Страница 8: ...er Way Suite 103 Chantilly VA 20151 phone 703 788 2700 website www cga net com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Mississauga Ontario Canada L4W 5NS phone 800 463 6727 website www csagroup org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 fro...

Страница 9: ...ctrique s avère nécessaire se servir de la fonction de télécommande si l appareil en est équipé D autres consignes de sécurité sont nécessaires dans les condi tions suivantes risques électriques dans un environnement humideou si l on porte des vêtements mouillés sur des structures métalliquestelles que sols grilles ou échafaudages en position coincée comme assise à genoux ou couchée ou s il y a un...

Страница 10: ...rc de soudure La projection d étincelles des pièces chaudes et des équipements chauds peut provoquer des incen dies et des brûlures Le contact accidentel de l électrode avec des objets métalliques peut provoquer des étincelles une explosion un sur chauffement ou un incendie Avant de commencer le soudage vérifier et s assurer que l endroit ne présente pas de danger Déplacer toutes les substances in...

Страница 11: ...ant de mettre l appareil en service LA CHUTE DE L ÉQUIPEMENT peut provoquer des blessures Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout autre accessoire Utilisez les procédures correctes et des équipements d une capa cité appropriée pour soulever et supporter l appareil En utilisant des fourches de levage pour déplacer l unité s ...

Страница 12: ...ard AWS A6 0 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Quincy MA 02169 phone 1 800 344 3555 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 14501 George Carter Way Suite 103 Chantilly VA ...

Страница 13: ...electric shock from wiring Safe94 2012 08 When power is applied failed parts can explode or cause other parts to explode Safe26 2012 05 Become trained and read the instructions before working on the machine or welding Safe40 2012 05 5min V V V Hazardous voltage remains on input capacitors after power is turned off Do not touch fully charged capacitors Always wait 5 minutes after power is turned of...

Страница 14: ...tection Rating Single Phase Unlocked Locked Remote Circuit Breaker Positive Negative X Duty Cycle Line Connection S Suitable for Some Hazardous Locations Increase Hz Hertz Single Phase Static Frequency Converter Transformer Rectifier Wire Feed Slow Run In Gas Metal Arc Welding GMAW Gas Metal Arc Welding GMAW MIG Gun Control Self Shielded Flux Cored Arc Welding FCAW Wire Feed Spool Gun Gas Postflow...

Страница 15: ...rvice requirements See Sections 5 2 and 5 3 for information on con necting input power This equipment will deliver rated output at an ambient air temperature up to 1045F 405C Rated Welding Output Amperage Range Maximum Open Circuit Voltage DC Amperes Input At Rated Load Output 50 60 Hz Single Phase 208 VAC 240 VAC 260 A 27 volts DC 40 Duty Cycle 20 350 A 87 47 8 41 1 230 A 25 5 volts DC 60 Duty Cy...

Страница 16: ...www MillerWelds com OM 279299 Page 12 26 25 in 667 mm 4 5 Dimensions And Weight 13 75 in 349 mm 19 25 in 489 mm 84 lb 38 1 kg Weight 907734 Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual ...

Страница 17: ...warranty 4 Minutes Welding 6 Minutes Resting Overheating 0 15 A or V OR Reduce Duty Cycle Minutes duty1 4 95 279044 B 60 Duty Cycle At 230A 40 Duty Cycle At 260A 6 Minutes Welding 4 Minutes Resting 4 7 Static Characteristics The static output characteristics of the welding power source can be described as flat during the GMAW process Static characteristics are also affected by control settings inc...

Страница 18: ...ids are present see NEC Article 511 or CEC Section 20 1 Lifting Handles Use handles to lift unit 2 Line Disconnect Device Locate unit near correct input power supply 18 in 460 mm 18 in 460 mm 2 Do not move or operate unit where it could tip Movement Location And Airflow loc_smallmig2 2018 09 161 122 1 Do not lift unit by strap threaded through both handles Do not lift unit with cart attached ...

Страница 19: ...ting Fuses 3 100 90 Min Input Conductor Size In AWG mm2 4 8 10 8 10 Max Recommended Input Conductor Length In Feet Meters 54 17 73 22 Min Grounding Conductor Size In AWG mm2 4 8 10 8 10 Reference 2017 National Electrical Code NEC including article 630 1 If a circuit breaker is used in place of a fuse choose a circuit breaker with time current curves comparable to the recommended fuse 2 Time Delay ...

Страница 20: ... complete Parts List is available at www MillerWelds com OM 279299 Page 16 5 3 Connecting 1 Phase Input Power Ref Input13 2015 08 Tools Needed L1 L2 240 VAC 1 2 1 GND PE Earth Ground 9 1 L1 L2 7 8 3 4 5 6 ...

Страница 21: ...n and connect plug to receptacle or direct con nect input power as follows 3 Input Power Cord 4 Disconnect Device switch shown in the OFF position 5 Disconnect Device Grounding Terminal 6 Disconnect Device Line Terminals 7 Black And White Input Conductor L1 And L2 8 Green Or Green Yellow Grounding Conductor Connect green or green yellow grounding conductor to disconnect device grounding terminal f...

Страница 22: ... 240 V 2 Wire Load 3 Neutral Brass Terminal And Prong Not Used 4 Load 1 Brass Terminal And Prong 5 Load 2 Brass Terminal And Prong 6 Ground Brass Terminal And Prong 7 Black And White Input Conductors 8 Green Or Green Yellow Ground Conductor Always connect green or green yellow wire to ground terminal never to a load terminal Connect black L1 and white L2 wires to load terminals Tools Needed 7 Gree...

Страница 23: ...ine Control Switch must be set at RUN position not RUN IDLE Set generator Voltage Amperage Control to 10 or max for maximum auxiliary power Generator settings if applicable 5 5 Generator Or Inverter Requirements For maximum output Miller recom mends 12kW or greater generator Notes ...

Страница 24: ...2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x2 0 2x70 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x3 0 2x95 2x3 0 2x95 350 1 0 60 2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x3 0 2x95 2x3 0 2x95 2x4 0 2x120 400 1 0 60 2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x3 0 2x95 2x4 0 2x120 2x4 0 2x120 This chart is a general guideline and may not suit all applications If cable overheats use next size larger cable Weld cable siz...

Страница 25: ...ng Gas Connection Connect supplied gas hose between regu lator flowmeter gas hose connection and fitting on rear of welding power source See Section 11 16 for gas selection MIG FCAW G DCEP Direct Current Electrode Positive FCAW S DCEN Direct Current Electrode Negative 1 4 3 2 4 3 2 8 1 6 7 5 5 9 Process Polarity Table Process Polarity Cable Connections Wire Drive Assembly Cable Work Cable GMAW Sol...

Страница 26: ...onnection Inside Unit 1 Gun Securing Knob 2 Gun Block 3 Gun Outlet Wire Guide 4 Gun End Loosen knob Insert end of gun through opening in front panel until gun end bottoms against gun block Tighten knob Correct Incorrect Be sure that gun end is tight against drive assembly 4 4 282950A 3 2 1 4 ...

Страница 27: ...t and dirt from valve Close valve 3 Cylinder 4 Regulator Flowmeter Install so face is vertical 5 Regulator Flowmeter Gas Hose Connection 6 Welding Power Source Gas Hose Connection 7 Flow Adjust Typical flow rate for shielding gas is 20 to 30 CFH cubic feet per hour Check wire manufacturer s recommended flow rate 8 CO2 Adapter Customer Supplied 9 O Ring Customer Supplied Install adapter with O ring...

Страница 28: ...a slight force is needed to turn spool tension is set 282945A Installing 1 Or 2 lb Wire Spool To install either a 1 lb or 2 lb wire spool follow the procedure as shown in the illustration Remove these components from spindle Spindle Spindle Install these components onto spindle Order additional spring Part No 186437 Order two additional 5 8 washers Part No 605941 ...

Страница 29: ... into gun continue to hold wire Close and tighten pressure assembly and let go of wire Remove gun nozzle and contact tip Turn On Feed wire to check drive roll pressure Tighten knob enough to prevent slipping Cut off wire Close and latch door 801083 Ref 800924 D 282950 A Tighten 1 2 3 4 Pressure Indicator Scale Tighten 1 2 3 4 7 Use pressure indicator scale to set a desired drive roll pressure Begi...

Страница 30: ...drill with pilot dim ple in plastic bezel visible from inside wire drive compartment 9 Gas Hose Fitting Route shielding gas hose through wire drive compartment out opening in rear panel and up to regulator flowmeter Connect gas hose fitting to regulator flowmeter 8 5 15 Connecting XR Aluma Pro Or XR Aluma Pro Lite 803463 282952A 1 Gun End 2 Gun Liner 3 Wire Outlet Guide Trim excess liner from end ...

Страница 31: ...re tightly to keep it from unraveling Open pressure assembly Pull and hold wire cut off end Push wire thru guides into gun continue to hold wire Close and tighten pressure assembly and let go of wire See Section 5 17 for threading welding wire through XR guns 282952 A S 0627 A Tighten 1 2 3 4 Pressure Indicator Scale 6 7 3 5 2 1 4 Thread hub tension nut loosely Use pressure indicator scale to set ...

Страница 32: ... end of contact tip Cut off wire Close and latch door XR Aluma Pro and XR Aluma Pro Lite gun drive roll pressure should be set to match the alloy being used For XR Aluma Pro Gun Turn On Welding Power Source 1 5 18 Threading Welding Wire For Spoolmate 200 Ref 243 740 C 1 Cover 2 Canister 3 Thumbscrew Cover Loosen thumbscrew and rotate cover open 4 Wire Spool Loosen wire from spool cut off bent wire...

Страница 33: ...l assembly 7 Canister Inlet Guide 8 Drive Roll Groove For wire sizes 035 in 0 9 mm and smaller use small groove and 047 in 1 2 mm and 1 16 in 1 6 mm use large groove 9 Contact Tip Thread wire through canister inlet guide along drive roll groove and out contact tip Install spool so wire feeds off bottom 10 Spool Brake Thumbnut If necessary turn thumbnut counter clockwise slightly to install spool 1...

Страница 34: ...t the spoolgun be ing used To begin the slow speed calibration pull the spoolgun trigger The wire will feed and au tomatically stop Cut wire flush at nozzle and measure run out If wire length is not 24 in use right knob to enter the amount that the wire was short long Pull spoolgun trigger again to verify the ad justment Repeat these steps until satisfied with accuracy Press Next to access fast sp...

Страница 35: ... ror codes The USB port can also be used to charge cell phones and similar de vices 4 Power Switch Use switch to turn unit On or Off 5 Color LCD Display 6 Left Knob Use left knob to adjust voltage in MIG mode arc length in Pulsed MIG mode or change parameter values in Setup Mode 7 Right Knob Use right knob to adjust wire feed speed or change parameter values in Setup Mode 8 Soft Keys Multiple func...

Страница 36: ... If a programmed value requires adjustment after the arc is extinguished and during the 5 second display of actual values turning either knob will cause actual values in the displays to be replaced by programmed values for adjustment purposes D MIG Gun On Demand MIG guns spool guns and push pull guns can be used with this unit To switch from one gun to another momentarily press the trigger on the ...

Страница 37: ...ht Button Use to select material thickness Left but ton moves cursor to the left right button moves cursor to the right 8 Left Knob Use left knob to fine tune voltage in MIG mode or arc length in Pulsed MIG mode 9 Right Knob Use right knob to fine tune wire feed speed When using a spoolgun or push pull gun in Auto Set the potentiometer on the gun is deactivated Wire feed speed is controlled on the...

Страница 38: ...ve favorite weld pro grams up to four programs per weld process See Section 6 7 5 Jog Button Feed wire without turning on weld output and energizing gas solenoid See Section 6 2 6 Purge Button Energizes gas solenoid without turning on weld output or feeding wire 7 Left Knob Use left knob to adjust voltage in MIG mode or arc length in Pulsed MIG mode 8 Right Knob Use right knob to adjust wire feed ...

Страница 39: ...default setting The other options are Disabled or Manual Manual settings range from 5 to 150 of the welding wire feed speed FasTackt Enabling FasTack reduces arc start time by automatically increasing the run in speed when doing repetitive arc starts FasTack automatically uses a slower wire feed speed when the wire is cool and a faster wire feed speed when the wire is hot Default setting is Disabl...

Страница 40: ...te the right knob to select Manual The following Crater variables can be ad justed Crater Time Time range is 0 1 to 5 sec onds Crater Voltage MIG settings or Arc Length Pulse settings Voltage range is 10 to 32 volts Arc length range is 0 to 99 Crater Wire Feed Speed Wire feed speed range is 50 to 800 ipm Crater Delay This setting is for spot or stitch welding without crater fill if the arc time is...

Страница 41: ...to Set Mode Program mode cannot be accessed from Auto Set mode To save settings note the weld parameters and return to Manual mode to access Program mode Recalling Programs Push the Program button to select desired program The selected Program tab will turn blue and the proper setting will be dis played Weld parameters may be changed while using the program with the left and right knobs If the set...

Страница 42: ...ich program is active Tap the gun trigger to se lect the program The number of lit LEDs on the gun indicates the selected program and allows the operator to know which program is being used without going back to or see ing the machine Tap the trigger once LED 1 on the gun illu minates Program 1 is selected Tap the trigger twice LEDs 1 and 2 on the gun illuminate Program 2 is selected Tap the trigg...

Страница 43: ... soft key to select wire diameter 5 Material Thickness Use soft keys to move cursor to left or right to select material thickness 6 Left Knob Use left knob to fine tune arc length Arc length defaults to 50 7 Right Knob Use right knob to fine tune wire feed speed Arc Length Arc length can be adjusted from 0 99 All Pulse MIG programs are set with a value of 50 Adjusting the Arc Length will vary the ...

Страница 44: ... If alternate gases are used adjust arc length and or arc con trol to adjust arc characteristics Arc Length Arc length can be adjusted from 0 99 All Pulse MIG programs are set with a value of 50 Adjusting the arc length will vary the length of the welding arc cone 0 Setting 99 Setting Low Setting High Setting If a gas is used other than what is listed on the Pulse MIG welding program chart the Arc...

Страница 45: ...s tem timers Save Log Insert USB thumb drive into USB port on front of welder Press soft key to download all system timers to the drive This system information can then be load ed into an Excel spreadsheet 3 Software Press soft key to display the system soft ware versions This information is used by factory authorized service agents License Press soft key to display Miller Li censing Agreement 4 R...

Страница 46: ... 12 Support The Support screen allows the oper ator to quickly access the Miller web site and phone number to obtain more product information or get ser vice support Access the Support screen from the manual MIG home screen by press ing Setup then Support See Section 6 5 297061 D ...

Страница 47: ... A complete Parts List is available at www MillerWelds com OM 279299 Page 43 SECTION 7 WELD PARAMETER CHARTS 7 1 MIG And Flux Core Parameters 282495 D ...

Страница 48: ...w Slide tip as close to drive rolls as possible without touching Tighten screw 3 Drive Roll The drive roll consists of two different sized grooves The stamped markings on the end surface of the drive roll refers to the groove on the opposite side of the drive roll The groove closest to the motor shaft is the proper groove to thread see Section 5 13 4 Drive Roll Securing Nut Turn nut one click to s...

Страница 49: ...y Overtemp Please wait while the welder cools down Inverter Module Output Rectifier Secondary Magnetics Internal temperature of welder has exceeded the maximum limit Wait for unit to cool down If the fan is not run ning contact authorized Miller service center Trigger Error Release MIG gun trigger MIG gun trigger is engaged on power up Release 4 pin trigger to clear error MIG gun is held during jo...

Страница 50: ...as stalled Internal motor has drawn too much current Remote motor has stalled Motor tach is running too slow or is damaged Too much pressure on pressure adjust knob Reduce pressure on the pressure adjust knob The gun liner is obstructed Clear obstruction or replace gun liner The gun contact tip is obstructed Clear obstruction or replace contact tip The welding wire is entangled Untangle welding wi...

Страница 51: ...s Network Error Inverter communications down The two microcontrollers on the control board are no longer communicating Cycle power to clear error If this error persists after a power cycle contact authorized Miller ser vice center Network Error Primary communications down Network Error UI Control communications down The wiring harness between the control board and interface board is damaged Contac...

Страница 52: ... No weld output unit is on Check and secure loose weld cable s into receptacle s Check and correct poor connection of work clamp to workpiece Erratic or improper welding arc or output Use proper size and type of weld cable see your Distributor Clean and tighten weld connections Verify electrode polarity check and correct poor connections to workpiece Fan not operating Unit not warmed up enough to ...

Страница 53: ...ored wires 3 U Cogged rolls for extremely soft shelled wires usually hard surfacing types 4 V Knurled rolls for hard shelled cored wires 5 Drive roll types may be mixed to suit particular requirements example V Knurled roll in combination with U Grooved Wire Diameter Kit No Drive Roll Inlet Wire Guide Fraction Decimal Metric Part No Type 0 023 0 025 in 0 023 0 025 in 0 6 mm 087131 087130 V Grooved...

Страница 54: ...OM 279299 Page 50 SECTION 10 ELECTRICAL DIAGRAM Figure 10 1 Circuit Diagram ...

Страница 55: ...OM 279299 Page 51 279043 C ...

Страница 56: ...ess to amperage A 0 001 in 0 025 mm 1 ampere 0 0625 in 1 59 mm 0 001 62 5 A 2 Select Wire Size See table below 3 Select Wire Feed Speed Amperage Wire feed speed amperage controls weld pene tration See table below 4 Select Voltage Voltage controls height and width of weld bead Low Voltage wire stubs into work High Voltage arc is unstable spatter Set voltage midway between high and low voltage 1 16 ...

Страница 57: ...0 0 15 45 45 1 0 15 S 0421 A End View of Work Angle Side View of Gun Angle Groove Welds End View of Work Angle Side View of Gun Angle Fillet Welds 11 3 Holding And Positioning Welding Gun Slow Fillet Weld Electode Extensions Stickout Electrode Extensions Stickout Gun Angles And Weld Bead Profiles 10 10 S 0634 Push Perpendicular Drag Short Normal Long Short Normal Long Normal Fast Weld bead shape d...

Страница 58: ... weave patterns to cover a wide area in one pass of the electrode S 0054 A 3 1 2 11 5 Gun Movement During Welding 11 6 Poor Weld Bead Characteristics 1 Large Spatter Deposits 2 Rough Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap 5 Poor Penetration 5 4 2 3 1 S 0053 A 11 7 Good Weld Bead Characteristics 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or laye...

Страница 59: ...s in weld metal S 0635 Possible Causes Corrective Actions Insufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc Remove spatter from gun nozzle Check gas hoses for leaks Place nozzle 1 4 to 1 2 in 6 13 mm from workpiece Hold gun near bead at end of weld until molten metal solidifies Wrong gas Use welding grade shieldin...

Страница 60: ...welding power source 11 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 I...

Страница 61: ...port hand on solid surface or use two hands 11 15 Troubleshooting Distortion Distortion contraction of weld metal during welding that forces base metal to move Base metal moves in the direction of the weld bead S 0642 Possible Causes Corrective Actions Excessive heat input Use restraint clamp to hold base metal in position Make tack welds along joint before starting welding operation Select lower ...

Страница 62: ...GMAW P Stainless Steel Spray Arc Aluminum Short Circuiting Aluminum GMAW P Aluminum Argon All Positions All Positions All Positions All Positions Argon 1 O2 Flat Horizontal Fillet All Positions Flat Horizontal Fillet Argon 2 O2 Flat Horizontal Fillet All Positions Flat Horizontal Fillet Argon 5 CO2 Flat Horizontal Fillet All Positions Argon 10 CO2 Flat Horizontal Fillet All Positions All Positions...

Страница 63: ...ch wire feed rolls Dirty or damaged kinked liner Replace liner Wire feeds but no gas flows Gas cylinder empty Replace empty gas cylinder Gas nozzle plugged Clean or replace gas nozzle Gas cylinder valve not open or flowmeter not adjusted Open gas valve at cylinder and adjust flow rate Restriction in gas line Check gas hose between flowmeter and wire feeder and gas hose in gun and cable assembly Lo...

Страница 64: ...Notes ...

Страница 65: ...Notes ...

Страница 66: ...Notes ...

Страница 67: ...ssemblies TIG Torches No Labor Tregaskiss Guns No Labor Water Cooling Systems Wireless Remote Foot Hand Controls and Receivers Work Stations Weld Tables No Labor 5 6 Months Parts Batteries 6 90 Days Parts Accessories Kits Canvas Covers Induction Heating Coils and Blankets Cables and Non Electronic Controls M Guns MIG Guns Subarc SAW Torches and External Cladding Heads Remote Controls and RFCS RJ45...

Страница 68: ...th your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to...

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