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10
6.1 Feeding Wire Electrode
Note when triggering, the electrode and drive mechanism are
electrically “LIVE” relative to work and ground and remain
“LIVE” several seconds after the gun trigger is released.
WARNING
When using an open arc process, it is necessary to use correct
eye, head, and body protection.
1. Position wire over joint. The end of the wire may be lightly
touching the work.
2. Lower welding helmet, operate gun trigger, and begin
welding. Hold the gun so the contact tip to work distance is
about 3/8” (10 mm).
3. To stop welding, release the gun trigger and then pull the gun
away from the work after the arc goes out.
4. When no more welding is to be done, close valve on gas
cylinder (if used), momentarily operate gun trigger to release
gas pressure and turn o the machine.
6.2 Optimising Weld Parameters
NOTE These settings are guidelines only. Material and wire
type, joint design, t up, position, shielding gas, etc. aect
settings. Produce test welds to be sure they comply to
specications.
Material thickness determines weld parameters.
1. Convert Material Thickness to Amperage (A) (0.25mm= 1
Amp) 3.2mm = 125 A
2. Select Wire Size
Amperage Range Wire Size
40 - 145 A 0.8 mm
50 - 180 A 1.0 mm
75 - 250 A 1.2 mm
3. Select Wire Speed (Amperage)
Wire Size Feed speed
0.8 mm 0.05m/min per Amp
1.0 mm 0.04m/min per Amp
1.2 mm 0.025m/min per Amp
So based on 3.2 mm material thickness amperage should be 125A if
using 1.0mm wire then the wire feed speed should be
0.04 X 125= 5m/min
Wire speed (amperage) controls weld penetration
4. Select Voltage. Voltage controls height and
width of weld bead.
Low Voltage: wire stubs into work
High Voltage: arc is unstable (spatter)
Set voltage midway between high/low voltages, and then ne
tune accordingly
NOTE These settings are guidelines only. Material and wire
type, joint design, t up, position, shielding gas, etc. aect
settings. Produce test welds to be sure they comply to
specications.
6.3 Additional Welding Controls
Burn back adjustment. When welding at high amperages the wire
can often burn back onto or close to the contact tip to prevent this
happening you can increase the burn back control (18) located
inside the wire spool cover.
Soft Start. The soft start control slows the acceleration of the wire
feed motor as the act starts and so reduces wire snubing and spatter
at the weld start. This control should be adjusted to give a smoother
start to the weld. (17).
Inductance setting XTM404S. This allows 2 levels of inductance to
give the desired arc characteristics typically for low amperage with
dip transfer you should use the low inductance setting as this speeds
the burn o of the wire in dip transfer mode. For higher amperages
and spray transfer the higher inductance setting is preferable.
7.0 Fault Finding
Problem Cause/Corrective Action
Porosity - small cavities or holes
Resulting from gas
pockets in weld metal.
Inadequate shielding
gas coverage. Check for
proper gas ow rate.
Remove spatter
from gun nozzle.
Check gas hoses for leaks.
Eliminate drafts
near welding arc.
Place nozzle 6-13 mm from
work piece Hold gun near
bead at end of weld until
molten metal solidies.
Wrong gas. Use welding
grade shielding gas; change
to dierent gas.
Dirty welding wire. Use
clean, dry welding wire.
Eliminate pickup of oil or
lubricant on welding wire from
feeder or liner.
Work piece 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 13
mm beyond nozzle.
Incomplete fusion to base metal Work piece dirty. Remove all
grease, oil, moisture, rust,
paint, coatings, and dirt from
work surface before welding.
Insucient heat input. Select
higher voltage range and/or
adjust wire feed speed.
Improper welding technique.
Place stringer bead in
proper locations) at joint
during welding.
Adjust work angle or widen
groove to access bottom
during welding.
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