bad weld w/ gas

[bobjohnson]

I've got a millermatic 130xp I'm having some problems with. I bought it used and I'm not sure about the history and if everything works. When I'm using gas, co2, I can't turn up the wire speed very high. Above 50 it pops and I can't run a bead. I was doing some t test welds on some 3/16" mild steel. The recommended settings on the machine were volt setting 4 and wire speed 70. Couldn't lay a bead. Switched back to flux core and I was able to put a bead down with whatever wire speed I wanted, on the same metal. The machine seems to work good with gas at the lower wire speeds. I don't have a flowmeter, I have my regulator output set at about 25-30 psi. I did change the polarity. Just looking for tips and opinions on what to check, etc..
Thanks,
Bob

[Thomas Harris]

check to make sure the polarity is set for solid-wire gas. It should be electrode positive for welding with shielding gas. If it does well with flux-core that may be what it's now set at. If it's like my mm172 there are two c-shaped lugs you change position to reverse the polarity. If in doubt you can carefully check it with a meter. Hope that is all the problem.

[bobjohnson]

Yeah I did change the polarity.. Didn't check it with a meter though.

[Thomas Harris]

Most of the gmaw will give you a much larger range of wire speeds with flux-core. The "sweetspot" will be in a smaller wire speed range with the solid wire with gas. If it gives a good arc at a certain speed, just leave it there. You can also adjust power/amps somewhat with stickout length.

[Maxwell]

Same Problem for me as well?

What gives here? I have the same problem! I posted a question about my popping experience last weekend and got little help.

I was using gas (c25) on my HH135 welding .187 steel and could not run a consistant bead at the recommended wire setting and voltage without it making a popping sound. If I welded with a slower wire speed,it seemyed to have poor penetration.

Checked the polarity and it was hooked up correct. (did not check with a meter. How would one do that?)

Bad gas?

Electricity problems?

Switched to flux core, reversed the polarity and welded fine.

How could I verify my wire speed controller is adjusted correct?

Is it me or the welder or something else!?

URGGGH! I can't trust my welds if this is going to happen, HELP.


Maxwell

[Dan]

Bob and Maxwell,

For quite sometime these small 130 amp machines were over rated on the material thickness they could weld with a solid wire. The reality is that 1/8" is the maximum thickness that this size of machine can produce a sound weld on with solid wire. One of my wirefeed machines is a 2003 version of the HH 135. For this version of the HH 135 the maximum recommended material thickness for solid wire and shielding gas is 1/8". 1/8" is also the maximum material thickness recommended for the 2003 version of the MM 135 when using solid wire.

The popping problem that you guys are experiencing is because the machine cannot output a high enough voltage to produce a stable metal transfer with the solid wire at the wire speeds that you are needing to run. The machine can only output close to the same power that is input into to it. So, as you increase the output current (wire speed) your output voltage is going to continually drop. When these machines are outputting around 130 amp they are only outputting about 16 to 16.5 volts, which is to low of a voltage setting to produce a stable metal transfer with solid wire at 130 amps.

The reason the fluxcore wire works on 3/16 is because at 130 amps it requires a lower output voltage then the solid wire.

[Sundown]

My 2002 HH135 chart [on the door] says that you can do 3/16th with C25 & either .30 or .35 soild wire, however the revised chart [downloaded from Hobart web site] for the same machine lists only fluxcore for 3/16th. Another good reason to get a 210 to go along with the HH135 [I will never sell my 135, it's going with me when I go]. Another great answer from Dan...Thanks

[bobjohnson]

I read somewhere that these machines will run better on a 30a circuit. Whats are your opinions on this? I'm now running it on a 20a with 12/2 wire. Thanks for the help.

[morpheus]

Originally posted by bobjohnson
I read somewhere that these machines will run better on a 30a circuit. Whats are your opinions on this? I'm now running it on a 20a with 12/2 wire. Thanks for the help.

are you using an extension cord or do you have the machine plugged directly into the outlet ?

- jack

[bobjohnson]

I'm using a 50ft 10/3 extension that runs from the welder into my bathroom. The bathroom has 12 ga wire that runs about another 50ft to the breaker box. I need to re-wire the garage anyway, its on a 15a circuit.

[Hobart Expert Rock]

GOODAFTERNOON.........GENTLEMEN......... SORRY I KINDA OVER LOOKED THIS PARTICULAR LINK........... HERE IS SOMETHING TO CONSIDER THE REGULATORS THAT COME WITH THE UNITS ARE ARGON OR ARGON/CO2 REGULATORS.......... CO2 AND I BELIEVE C-25 ARE COLD GASSES THAT MAY (WILL CAUSE THE REGULATOR TO FREEZE).............. YOU'VE ELIMINATED YOUR PROBLEM BY CONFIRMING THE FLUX CORED WIRE'S RUN OK......... ANOTHER POSSABILITY IS THE WIRE YOU HAVE MAY OR MAY NOT HAVE LIVED PAST IT'S SHELF LIFE............. THEY GET RUSTY, DRAW MOISTURE, GET BRITTLE. ETC..............BOB JOHNSTON AND MAXWELL SORRY FOR THE DELAY..............DO YOU HAVE SOME ARGON OR 75/25 GAS YOU CAN TRY............ THIS WILL ELIMINATE THE FREEZING REGULATOR..................................SENERIO ..... I ACTUALLY HAVE SOME ONE SIGNED UP TO ANSWER GAS AND PROCESSES NAMED BUTCH............. I'LL CATCH UP TO HIM AND SEE WHAT HE'S DOING....................ROCK................. [email protected]

[Scott V]

First off I never ran co2 with a Miller XP130.I have ran lots of C-25 gas,and that welder does not like .030 solid wire very well.I would stick with .023 wire with C-25 gas.It's in the range that 90 amp machine likes to run.I feel myself that the problem has to do with the wirefeed tracking mostly.I owned two of them,and both did the same thing.I really dislike that feature of the welder the most.It's a night,and day difference with the .023.solid wire.In fact it has a super arc with the small wire.

[bobjohnson]

Rock, do you not agree with what Dan said?
I only have co2 gas, I can try to find a welding supply store that will let me test the mix. I bought the wire new a couple months ago from a general purpose tool store, so it may have been sitting on the shelf. Its Blue Demon er70s-6 .030, a number that might be a date 07/02, is a year too old?
Thanks for the help

[Sberry]

that 50 ft of 12 isnt helping. That machine calls for a dedicated circuit,, not a general. I wouldnt trust a bunch of connections in junction boxes and you are trying to run a machine wide open on a poor wire. Excelent way to start a house fire. Thats one of my biggest concerns with 120v machines. They get plugged in everywhere. I tell friends not to buy them.

[Maxwell]

Rock, I am running C25 mix gas. Will I experience the problem with freezing the regulator? How can I tell if the wire has passed its shelf life?

Dan,

What is the max capacity I should attempt with .03 Hobart ER70S6 wire on mild steel? What is the max. you've successfully done?

How about with .023 wire, as ScottV suggests?

Finally, am I safe to assume that I can do .250 with flux core?

Thanks

Maxwell

PS I am direct into an outlet.