Preparation of the Workspace
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Preparation of the Workspace
- Best results are obtained with constant voltage equipment. However, constant current systems may be used.
- There are some old systems wherein adjustment of wire feed speed is independent of amperage control. These can be difficult to tune in.
- All electrical connections must be tight, especially the ground connection.
- Increased EE welding is more sensitive to poor grounds. Rotary grounds must be properly adjusted and lubricated with conductive grease.
- Use the lowest required current tap setting on power sources. Most welding can be performed under 500 amperes and higher tap settings (such as 1000 amps) can cause erratic welding at low current levels.
- Always use machines with calibrated ammeters and wire feed speed meters.
- Be sure the welding head is fully insulated from the manipulator or other mounting.
- Both the controller and the power source must be set for constant voltage (e.g. some Lincoln NA-3 controllers have a toggle switch internally that must be on CV, not CC).
- Be sure the power source is set to the correct Polarity, usually Reverse (wire positive).
- Be sure the wire straightener is a properly adjusted. The wire should not be perfectly straight, but should have just a slight curvature so as to assure wire-to-copper tip contact at the bottom of the tip at all times.
- Adjust inch down speed to a moderate amount (nominally 30 to 40 ipm).
- Always remove the ceramic nozzle when threading new wire.
- Never remove the nozzle from the threaded copper tip/adaptor when the assembly is hot. This may strip the threads in the nozzle.
- Run out about six (6) inches of wire before screwing on the nozzle. This way, you can manipulate the curved wire to allow the nozzle to screw on with ease.
- Tighten nozzles only slightly snug by hand against the Teflon washer that is between the nozzle and the copper tip/adaptor.
- Always use sharp pliers to cut wire, so as not to stress the nozzle by wiggling the pliers.
- Always cut welding wire at an angle to give better weld starts.