Miller Electric OM-230 manual Typical MIG Process Control Settings, Wire Size Amperage Range

Page 41

8-2. Typical MIG Process Control Settings

.These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be sure they comply to specifications.

Material thickness determines weld

 

 

parameters.

1/8 or

Convert Material

 

.125 in

 

Thickness to

 

 

 

 

Amperage (A)

 

 

(.001 in = 1 ampere)

 

 

.125 in = 125 A

.035 in

Wire Size

Amperage Range

 

 

 

 

.023 in

 

30 − 90 A

.030 in

 

40 − 145 A

.035 in

 

50 − 180 A

 

 

 

 

 

 

 

 

 

 

 

 

Select Wire Size

 

Wire

Recommendation

 

Wire Speed

 

Size

 

(Approx.)

 

 

 

 

 

 

 

 

 

 

 

.023 in

3.5 in per ampere

3.5 x 125 A = 437 ipm

 

.030 in

2 in per ampere

2 x 125 A = 250 ipm

 

.035 in

1.6 in per ampere

1.6 x 125 A = 200 ipm

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Select Wire Speed (Amperage)

125 A based on 1/8 in material thickness

ipm = inch per minute

Low voltage: wire stubs into work

High voltage: arc is unstable (spatter)

Set voltage midway between high/low voltage.

Select Voltage

Voltage controls height and

Wire speed (amperage) controls weld

width of weld bead.

penetration (wire speed = burn-off rate)

 

 

 

 

 

 

 

 

 

 

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Contents Processes OM-230 693CDescription File MIG GmawFrom Miller to You Table of Contents Typical MIG Process Connections − Parts List− MIG Welding Gmaw Guidelines Arc Welding Hazards Symbol UsageElectric Shock can kill HOT Parts can cause severe burnsARC Rays can burn eyes and skin Fumes and Gases can be hazardousWelding can cause fire or explosion Flying Metal or Dirt can injure eyesFire or Explosion hazard Welding Wire can cause injuryFalling Unit can cause injury Moving Parts can cause injuryCalifornia Proposition 65 Warnings Principal Safety StandardsEMF Information About Implanted Medical DevicesUNE Décharge Électrique peut entraîner la mort Symboles utilisésLE Soudage peut provoquer un in cendie ou une explosion DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peuvent être dangereux LES Bouteilles peuvent exploser si elles sont endommagées LE Bruit peut endommager l’ouïeRisque D’INCENDIE OU D’EXPLO LA Chute DE L’APPAREIL peut blesserLE Soudage À L’ARC risque de provoquer des interférences Proposition californienne 65 AvertissementsLES Fils DE Soudage peuvent provoquer des blessures En ce qui concerne les implants médicaux Principales normes de sécuritéInformation EMF OM-230 693 Specifications Symbols And DefinitionsOverheating Welding Power Source Duty Cycle And OverheatingVolt-Ampere Curves Installing Work Cable And Clamp Connecting To Weld Output TerminalsConnecting Spoolmatic 15A Or 30A Gun 32 in 2.4 mm Connecting XR Aluma-Pro, XR Edge, XR-A Gun, Or XR-A PythonGun End Gun Liner Wire Outlet Guide Installing Gas Supply Setting Gun Polarity For Wire TypePolarity Changeover Label Information 11/16Positioning Jumper Links Installing Wire Spool And Adjusting Hub TensionInput Voltage Electrical Service Guide200 230 460 575 127 206L2L1 230 VAC Selecting a Location And Connecting Input Power18 in 457 mm of space for airflow =GND/PE Earth Ground Pressure Threading Welding WireScale Remove gun nozzle and contact tipOM-230 693 Weld Parameters 226 650-B Controls − OperationTrigger and pull the trigger again momentarily one second JOG ModeRun−in Wire Feed Speed Settings Jog Mode Voltmeter And Wire Feed Speed Meter OperationPower Up Status Welding StatusTimers Set Up Push Motor Torque SUP Or Reset rES Unit Overload Routine MaintenanceChanging Drive Roll and Wire Inlet Guide Turn Off power Aligning Drive Rolls and Wire GuideAssembly open View is from top of drive rollsTroubleshooting Trouble Remedy OM-230 693 − Electrical Diagram 229 485-A Typical MIG Process Connections − MIG Welding Gmaw GuidelinesWire Size Amperage Range Typical MIG Process Control SettingsSelect Wire Size Recommendation Wire Speed Select VoltageSide View Of Gun Angle Holding And Positioning Welding GunPush Perpendicular Drag Conditions That Affect Weld Bead ShapeShort Normal Long Slow NormalGun Movement During Welding Poor Weld Bead CharacteristicsGood Weld Bead Characteristics Troubleshooting − Porosity Troubleshooting − Excessive SpatterTroubleshooting − Excessive Penetration Possible Causes Corrective ActionsTroubleshooting − Burn-Through Troubleshooting − Lack Of PenetrationTroubleshooting − Incomplete Fusion Weld bead Troubleshooting − Waviness Of BeadTroubleshooting − Distortion Application Troubleshooting Guide For Semiautomatic Welding EquipmentCommon MIG Shielding Gases Readjust welding parameters Welding arc not stable Wire slipping in drive rollsWelding power source Drive rolls if necessary087 Drive Roll And Wire Guide KitsGrooved 056 0.9 mm 204Support ServiceYour distributor also gives Miller Electric Mfg. Co To locate a Distributor or Service Agency visitFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s
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