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Need help with welder tip

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  • camire09
    started a topic Need help with welder tip

    Need help with welder tip

    We are running a XMT 304 CC/CV to weld our wheels. The weld is about 20" long. Recently we have run into a problem with our tips on the one welder getting tight and the wire either gets stuck or slows to a crawl. Our original settings were as follows 27.3V and 600 wire speed, tip was about 3/4" away from the part. That was getting a little hot on the 1/8" material so I changed it to 21.5V, 430 wire speed and tip is about 1/2" away. Originally we thought that dirt was tight in the liner and changed it, matter a fact I even changed the entire cable hose gun assembly. I tried tightening the feed rollers but then the wire gets kinked. Also we are running wire out of a drum and getting below the half way point so I tried putting on a fresh spool of wire but no change. Any ideas would be great.

  • camire09
    replied
    Okay gonna check that. I was just working on it a little while ago. The first weld looked like it wasn't feeding wire. As soon as I turn to look at the feeder it takes off and welds fine. Same for the next weld. Weld after that got I saw the rollers were at a crawl. I undid the tensioner and it was still crawling along. The next weld it fired up just fine and welded. The wire never got stuck to the tip. Any way to check the motor or PC1 Board?

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  • cruizer
    replied
    Its the center one you need to be concerned with as well as the others, For that one you'll need to pull the outer drive housing off

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  • camire09
    replied
    I changed the gears out early on but I couldn't tell if they were new gears or used ones. They had a bunch of them here. I will try to order some and see how it goes. Thanks.

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  • cruizer
    replied
    Well, it more sounds to me that its time you changed the drive gears and center gear on your feeder, cause if you notice, your drive is bouncing around. This causes the wire not to pass straight. And naturally binds with the liner, tips wear out fast and a not so good final weld.

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  • camire09
    replied
    Well no luck again. As soon as production did a couple welds it screwed up again. I even tried replacing the potentiometer for the wire speed adjustment. This thing is driving me nuts.

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  • camire09
    replied
    Well no luck. I think the settings are fine. There has to be a problem with either the wire feeder, turn table or welder.

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  • Diversion180beads
    replied
    Need help with welder tip

    You should be between 20-25 cfh...

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  • camire09
    replied
    Okay well so far I tried it at 19v 280 and went up till I got to about 22v 465. At 19 it ran okay but the weld was too narrow for the job. Basically we are covering 40 1/4"pins line up in holes in an 1/8" plate. We set it on a turn table and the arm comes down and welds while the wheel is turning. I tried a different tip and insulated the arm to reduce any current draw. And lowered the gas flow to about 40-45, they had it wide open. I ran about 26 welds without doing anything. Didn't clean the torch or anything. I just moved it out a 1/4" every time i went to weld and the back again. That way I would be putting a strain on the welder. So far so good. I will have to see what happens on Monday when production gets their hands on it.

    Fingers crossed

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  • Diversion180beads
    replied
    Need help with welder tip

    Ya try the 19v and 280 wire and go from there....

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  • camire09
    replied
    .035 wire

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  • Diversion180beads
    replied
    Need help with welder tip

    Wut size wire r u using??

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  • camire09
    replied
    I'll give it a try. Any ideas as to why the original settings worked for years and work on the other welder (same equipment and material)?

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  • Diversion180beads
    replied
    Need help with welder tip

    Try goin down to about 19v and 270-290 ipm and go from there....

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  • camire09
    replied
    1/8" low carbon steel

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