Miller Electric 145 DX Troubleshooting − Incomplete Fusion, Troubleshooting − Lack Of Penetration

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12-16. Troubleshooting − Incomplete Fusion

 

 

 

Incomplete Fusion − failure of weld metal to fuse completely with

 

 

 

base metal or a preceeding weld bead.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Possible Causes

 

Corrective Actions

 

 

 

Insufficient heat input.

 

Increase amperage. Select larger electrode and increase amperage.

 

 

 

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.

 

 

 

Workpiece dirty.

 

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

 

 

 

welding.

 

 

 

 

12-17. Troubleshooting − Lack Of Penetration

 

 

 

Lack Of Penetration − shallow fusion between weld metal and

 

 

 

base metal.

 

 

 

 

Lack of Penetration

Good Penetration

Possible Causes

Corrective Actions

Improper joint preparation.

Material too thick. Joint preparation and design must provide access to bottom of groove.

Improper weld technique.

Keep arc on leading edge of weld puddle.

Insufficient heat input.

Increase amperage. Select larger electrode and increase amperage.

 

 

 

Reduce travel speed.

12-18. Troubleshooting − Excessive Penetration

 

Excessive Penetration − weld metal melting through base metal and

 

hanging underneath weld.

Excessive Penetration

Good Penetration

Possible Causes

Corrective Actions

Excessive heat input.

Select lower amperage. Use smaller electrode.

 

Increase and/or maintain steady travel speed.

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Contents OM-4417210 403C ProcessesDescription File Engine DriveFrom Miller to You Table of Contents Page Symbol Usage Arc Welding HazardsEngine Hazards Compressed Air Hazards Principal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interferenceSignification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in- cendie ou une explosion DES Particules Volantes peuvent blesser les yeuxDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïe’AIR Comprimé peut provoquer des blessures ’EMPLOI Excessif peutLE Surchauffement peut endom- mager le moteur électrique LES Étincelles Volantes risquent de provoquer des blessuresLE Soudage À L’ARC risque de provoquer des interférences Pour les moteurs à essencePour les moteurs diesel Boulevard, Rexdale, Ontario, Canada M9W 1R3 téléphone− Specifications Symbol DefinitionsWeld, Power, And Engine Specifications − DefinitionsDimensions, Weights, And Operating Angles DimensionsVolt-Ampere Curves Fuel Consumption Generator Power Curve Duty Cycle100% Duty Cycle at 80 Amperes CC/DC − Installation Installing Welding GeneratorGrounding Generator To Truck Or Trailer Frame Grounding Generator When Supplying Building Systems Engine Prestart Checks − Standard Model13 mm Full Gasoline Fuel Valve Open valveConnecting The Battery DX Models Only Engine Prestart Checks − DX Model+ − Tools Needed 1/2Connecting To Weld Output Terminals Selecting Weld Cable Sizes150 ft 200 ft 250 ft 350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 mMaterial Thickness Reference Chart − Operating the Welding Generator Controls Standard Models See SectionDescription Of Controls Standard Models See Section Stop engine and add oil if light goes on see SectionTo Start Controls DX Models See Section Description Of Controls DX Models See Section Generator Power Panel Receptacles − Operating Auxiliary EquipmentAC Receptacle RC1 − Maintenance Routine MaintenanceServicing Air Cleaner Stop engineStandard Model Shown Adjusting Engine Speed Standard Models Only Stop engine. Close fuel valveTools Needed Adjusting Engine Speed DX Models Only Weld/Power Speed AdjustmentIdle Speed Adjustment − Troubleshooting TroubleshootingGenerator Power WeldingEngine − Electrical Diagrams Circuit Diagram For Standard ModelsCircuit Diagram for DX Models − Generator Power Guidelines Selecting EquipmentGrounding When Supplying Building Systems How Much Power Does Equipment Require?Earth ground if supplying Amperes x Volts = WattsApproximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsPower Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Current Load Watts AmperesStick Welding Procedure Weld current starts when electrode touches work- piece− Stick Welding Smaw Guidelines Electrode and Amperage Selection Chart Striking an Arc − Scratch Start TechniqueStriking an Arc − Tapping Technique Poor Weld Bead Characteristics Good Weld Bead CharacteristicsPositioning Electrode Holder 10-30 9090 End View of Work AngleConditions That Affect Weld Bead Shape Electrode Movement During WeldingButt Joints Lap JointTee Joint 16 in 30 1.6 mm Tack WeldsTroubleshooting − Porosity Troubleshooting − Excessive SpatterWeld Test Possible Causes Corrective ActionsTroubleshooting − Incomplete Fusion Troubleshooting − Lack Of PenetrationTroubleshooting − Excessive Penetration Troubleshooting − Burn-Through Troubleshooting − Waviness Of BeadTroubleshooting − Distortion − Parts List Main Assembly Standard ModelDia Part Description Quantity Mkgs Main Assembly DX Model 4546 51 41Main Assembly OM-4417 Service Your distributor also givesSupport To locate a Distributor or Service Agency visit Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s
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Manual 4 pages 16.38 Kb

145 DX specifications

Miller Electric has established itself as a leading name in the welding industry, and the Miller Electric 145 DX and 145 are notable additions to its lineup of innovative welding machines. Designed to offer versatility and efficiency, these units cater to both novice welders and seasoned professionals seeking reliable equipment for various welding applications.

One of the key features of the Miller Electric 145 DX and 145 is their advanced welding technology. Both models utilize inverter technology, which allows for a compact design while delivering exceptional power. This inverter design not only increases efficiency but also reduces energy consumption, making it an environmentally friendly choice. The lightweight nature of these units makes them highly portable, allowing users to easily transport them to job sites or move them around the workshop.

The Miller Electric 145 DX model incorporates a digital interface that simplifies set-up and operation. This user-friendly digital display shows critical parameters such as voltage and amperage, helping the operator make quick adjustments on-the-fly for optimal results. The advanced Auto-Set feature adjusts the machine settings automatically based on the material thickness and type, significantly reducing the learning curve for inexperienced welders.

Both the 145 DX and 145 models can handle a variety of welding processes, including MIG and TIG welding. This versatility makes them suitable for a wide range of applications, from automotive repair and fabrication to metal sculpture and DIY projects. The machines are capable of welding aluminum, stainless steel, and mild steel with ease, providing excellent penetration and bead appearance.

Another noteworthy characteristic of the Miller Electric 145 series is their reliability and durability. Designed with robust components that can withstand challenging working environments, these machines are built to last. The thermal overload protection feature ensures the units do not overheat, safeguarding the internal components and ensuring a longer operational life.

In summary, the Miller Electric 145 DX and 145 stand out in the welding equipment market due to their advanced inverter technology, user-friendly digital interfaces, versatile capabilities, and durability. They are ideal choices for anyone looking to elevate their welding experience, delivering consistent and reliable performance across a variety of projects.
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