Miller Electric XLT 165, XLT 135 Troubleshooting − Excessive Spatter, Troubleshooting − Porosity

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7-8.

Troubleshooting − Excessive Spatter

 

 

Excessive Spatter − scattering of molten metal particles that

 

 

cool to solid form near weld bead.

 

 

S-0636

 

Possible Causes

Corrective Actions

Wire feed speed too high.

Select lower wire feed speed.

Voltage too high.

Select lower voltage range.

Electrode extension (stickout) too long.

Use shorter electrode extension (stickout).

Workpiece dirty.

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

Insufficient shielding gas at welding arc.

Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.

Dirty welding wire.

Use clean, dry welding wire.

 

 

Eliminate pickup of oil or lubricant on welding wire from feeder 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.

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 shielding gas; change to different gas.

Dirty welding wire.

Use clean, dry welding wire.

 

 

Eliminate pick up of oil or lubricant on welding wire from feeder or liner.

Workpiece dirty.

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

 

 

Use a more highly deoxidizing welding wire (contact supplier).

Welding wire extends too far out of nozzle.

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

7-10. Troubleshooting − Excessive Penetration

 

 

Excessive Penetration − weld metal melting through base metal

 

 

and hanging underneath weld.

 

Excessive Penetration Good Penetration

 

 

S-0639

 

Possible Causes

Corrective Actions

Excessive heat input.

Select lower voltage range and reduce wire feed speed.

 

 

Increase travel speed.

OM-198 076 Page 34

 

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Contents Description OM-198 076AProcesses AprilPage Table of Contents Page Arc Welding Hazards Symbol UsageMarks a special safety message Electric Shock can killFlying Metal can injure eyes ARC Rays can burn eyes and skinWelding can cause fire or explosion Buildup of GAS can injure or killPrincipal Safety Standards EMF Information About PacemakersUN Choc Électrique peut tuer Signification des symboles− Consignes DE Securite − Lire Avant Utilisation LES Fumées ET LES GAZ peuvent être dangereuxDES Pièces Chaudes peuvent pro- voquer des brûlures graves LE Soudage peut provoquer un incendie ou une explosionDES Particules Volantes peuvent blesser les yeux LE Bruit peut affecter l’ouïe’EMPLOI Excessif peut Risque D’INCENDIE OULA Chute DE L’APPAREIL peut blesser DES Organes Mobiles peuvent provoquer des blessuresConsignes relatives aux stimulateurs cardiaques Principales normes de sécuritéInformation sur les champs électromagnétiques VAC Model − SpecificationsSpecifications Output Amperes Duty Cycle And OverheatingOutput Duty Cycle % OverheatingVolt-Ampere Curves − Installation Installing Welding Gun Installing Work ClampProcess/Polarity Table Changing PolarityCO2 Adapter Customer Sup- plied Installing Gas SupplyFlow Adjust Regulator/flowmeter and CO2 cylinder CO2 GasVolt, 20 ampere individual Rating LabelGrounded Receptacle Up to 200 ft 61 mReceptacle Do not move or operate unit where it could tipPlug See SectionStandard Wire Spool 8 Lb Wire Spool 4 Electrical Service Guide For 230 VAC ModelInstalling Wire Spool And Adjusting Hub Tension Adjusting Hub TensionThreading Welding Wire − Operation Voltage SwitchPower Switch OM-198 076 ControlsWeld Parameters For 115 VAC Model Weld Parameters For 230 VAC Model Overload Protection − Maintenance &TROUBLESHOOTINGRoutine Maintenance Drive Motor ProtectionReplacing Gun Contact Tip Changing Drive Roll Or Wire Inlet GuideTurn Off power before replacing contact tip To Reassemble Gun Cleaning Or Replacing Gun LinerDisconnect gun from unit Replacing Switch And/Or Head Tube Does not run Troubleshooting TableTrouble Remedy − Electrical Diagram Circuit Diagram For 115 VAC ModelCircuit Diagram For 230 VAC Model − MIG Welding Gmaw Guidelines Typical MIG Process ConnectionsSelect Wire Size Recommendation Wire Speed Typical MIG Process Control SettingsWire Size Amperage Range Select VoltageHolding And Positioning Welding Gun Short Normal Long Conditions That Affect Weld Bead ShapePush Perpendicular Drag ShortNormalLongGun Movement During Welding Poor Weld Bead CharacteristicsGood Weld Bead Characteristics Troubleshooting − Excessive Penetration Troubleshooting − Excessive SpatterTroubleshooting − Porosity Possible Causes Corrective ActionsTroubleshooting − Burn-Through Troubleshooting − Lack Of PenetrationTroubleshooting − Incomplete Fusion Base metal to move Troubleshooting − Waviness Of BeadTroubleshooting − Distortion DirectionFlat & Horizontal1 Fillet Common MIG Shielding GasesApplication − Parts List Main AssemblyDia Part Description Quantity Mkgs Gun 024 .6 and .045 042024 .6 and .030/.035 .8 Page Warranty Owner’s Record
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