Miller Axcess E 300 - Page 50

OM-244 814 Page 46
Trouble RemedyProbable Cause
Porosity in weld (Continued)
Gun or outlet cable leaking Repair or replace faulty parts
Wire feed speed setting too high Reduce wire feed speed
Contact tip extends too far out of nozzle Adjust or replace parts (max distance should not
exceed 1/8 in (3.2 mm)
Nozzle to work distance too large Reduce nozzle to work distance
Incorrect gun or torch angle Set proper gun angle (porosity or dirty welds mean
gun angle is too large)
Nozzle restriction Clean off spatter or remove restriction
Breeze or drafts in weld zone Shield weld zone from drafts
Low shielding gas cylinder pressure Replace gas cylinder
Gas leak at gun to feeder connection Properly install gun or replace O-rings at gun con-
nector
Excessive spatter
Voltage set too high Reduce voltage setting (reduce trim or arc adjust
for pulse welding)
Incorrect gun or torch angle Set proper gun angle
Too much or too little gas flow Adjust for proper gas flow
Wrong gas for wire type or transfer mode Use correct shielding gas
Wrong electrode wire type or size Use proper electrode wire
Wrong inductance setting Adjust inductance
Electrode wire dirty or old Replace with new electrode wire
Oily or dirty base metal Clean base metal by brushing, grinding or use
chemical cleansing before welding
Excessive wire stick-out or nozzle to work distance
too great
Adjust wire stick-out or reduce nozzle to work dis-
tance
Wrong transfer mode Set proper transfer mode
Travel speed too slow Increase travel speed so that arc is on leading edge
of weld puddle
Wandering, hunting or erratic arc
Restriction in unspooler or drum adapter Replace unspooler or repair restriction
Dirty or worn gun liner or inlet cable Remove gun liner or inlet cable and clean or re-
place
Sharp bends or kinks in gun cable or liner Straighten gun cable and/or replace liner
Loose or worn contact tip Tighten or replace contact tip
Wrong size or type of contact tip Replace with proper size and type contact tip
Gun overheating Use gun with proper amperage rating
Loose power cables or other electrical connections Tighten, repair or replace connections or cables,
also check all rotary or brush type connections
Incorrect gun or torch angle Set proper gun angle
Too much or too little gas flow Adjust for proper gas flow
Moisture in shielding gas Replace gas cylinder or supply
Wrong gas for wire type or transfer mode Use correct shielding gas
Wrong program selection for pulse welding Make proper program selection
Improper or unsteady analog command from robot
controller
Check signal from robot controller (as a trouble-
shooting aid go to power source control of voltage
and wire speed)
Gun or outlet cable leaking Repair or replace faulty parts
Incorrect nozzle to work distance Set proper distance [3/8 in to 5/8 in (9.5 to 15.9 mm)
for short arc, 5/8 in to 1 in (15.9 to 25.4 mm) for
pulse welding, and 3/4 in to 1-1/4 in (19.1 to 31.8
mm) for spray welding]