Miller Electric 180 Troubleshooting − Excessive Penetration, Troubleshooting − Incomplete Fusion

Page 54

8-10. 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.

 

 

 

Wrong polarity.

 

Configure polarity as shown in Section 4-5. Always read and follow wire manufacturer’s

 

 

 

 

recommended polarity, and see Section 4-5.

 

 

 

 

 

8-11. 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.

 

 

Wrong polarity.

Configure polarity as shown in Section 4-5. Always read and follow wire manufacturer’s

 

recommended polarity, and see Section 4-5.

8-12. 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.

 

 

Wrong polarity.

Configure polarity as shown in Section 4-5. Always read and follow wire manufacturer’s

 

recommended polarity, and see Section 4-5.

 

 

OM-225 311 Page 50

 

Page 53 Page 55
Image 54
Page 53 Page 55
Contents Description OM-225 311CProcesses File MIG GmawFrom Miller to You Table of Contents − Maintenance &TROUBLESHOOTING − Parts ListArc 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 killCalifornia Proposition 65 Warnings Principal Safety Standards EMF InformationAbout Pacemakers UNE Décharge Électrique peut entraîner la mort LES Fumées ET LES GAZ peuvent être dangereuxIndique un message de sécurité particulier DES Pièces Chaudes peuvent provoquer des brûlures graves LE Soudage peut provoquer un incendie ou une explosionDES Particules Volantes peuvent blesser les yeux LE Bruit peut endommager l’ouïe’EMPLOI Excessif peut SUR Risque D’INCENDIE OU D’EXPLOLA Chute DE L’APPAREIL peut blesser DES Organes Mobiles peuvent provoquer des blessuresPrincipales normes de sécurité En ce qui concerne les stimulateurs cardiaquesVAC Model − SpecificationsSpecifications VAC Model w/Auto−SetE230 VAC Model Duty Cycle And Overheating115 VAC Model OverheatingVolt-Ampere Curves Amperage− Installation Installing Welding GunIncorrect Work Cable Routing Inside Unit Process/Polarity TableChanging Polarity Installing Gas Supply Volatile liquids are present − Special installation may beRequired where gasoline or See NEC Article 511 or CECDo not move or operate unit where it could tip Electrical Service Guide For 230 VAC Model Installing Wire Spool And Adjusting Hub TensionInput Voltage 230 Input Amperes At Rated Output Threading Welding Wire Remove gun nozzle and contact tipRemoving MIG Gun From Welding Power Source Cut Off End Of Wire Open Pressure Assembly KnobEnd Of Wire To Spool Installing Optional Spool Gun Switch In Welding Power Source OperationConnecting Spool Gun To Millermatic 140/180 − Operation Controls For 115 VAC Model w/Auto-SetEControls For 115 VAC Model 115VControls For 230 VAC Model 230VOM-225 311 Weld Parameter Chart For 115 VAC Model w/Auto−SetE 10/90 10/65 10/80 10/60 10/50 10/95 10/75 10/100 030 0.8 mm 035 0.9 mm Aluminum 100% Argon 4043ER10/32 OM-225 311 10/90 10/45 10/60 10/30 10/32 10/80 030 0.8 mm 035 0.9 mm#220179 #220179 #202926Dcep Dcen 100 10/60 10/45 10/40 10/20 10/50 024 0.6 mm #220179 030 0.8 mm #202926 035 0.9 mm 045 1.2 mmOverload Protection − Maintenance &TROUBLESHOOTINGRoutine Maintenance Drive Motor ProtectionChanging Drive Roll Or Wire Inlet Guide Turn Off power before replacing contact tipReplacing Gun Contact Tip Cleaning Or Replacing Gun Liner Disconnect gun from unitTo Reassemble Gun Replacing Switch And/Or Head Tube Troubleshooting Table Trouble RemedyOM-225 311 − Electrical Diagram Circuit Diagram234 419-B − MIG Welding Gmaw Guidelines Typical MIG Process ConnectionsSelect Wire Size Typical MIG Process Control SettingsWire Recommendation Wire Speed Select VoltageHolding And Positioning Welding Gun Conditions That Affect Weld Bead Shape Poor Weld Bead Characteristics Good Weld Bead CharacteristicsGun Movement During Welding Troubleshooting − Excessive Spatter Troubleshooting − PorosityPossible Causes Corrective Actions Troubleshooting − Excessive Penetration Troubleshooting − Lack Of PenetrationTroubleshooting − Incomplete Fusion Troubleshooting − Burn-Through Troubleshooting − Waviness Of BeadTroubleshooting − Distortion Common MIG Shielding Gases ApplicationFlat & Horizontal1 Fillet Optional Drive Rolls − Parts ListRecommended Spare Parts OptionsPage Service SupportOwner’s Record Miller Electric Mfg. Co
Related manuals
Manual 60 pages 41.57 Kb
Top Page Image Contents