TipMate™ Systems

Welding Recommendations

• 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 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. appearance.
  Do not exceed the recommended amperage for TipMate™ Nozzles!
• Never let the welding wire drag on the workpiece!
• The recommended starting sequence is to start relative motion between the wire and the part first (e.g. start pipe groove welds rolling first). Then, push the weld start button. This results in more positive starts.
• Carefully attention must assure that the distance between the bottom of the ceramic nozzle and the puddle (standoff distance)remains reasonably constant.
• Put nozzles for 3/32" (2.4 MM) and 1/8" (3.2 MM) diameter wires inside the flux cone about ¼" to 3/8". This aids in controlling the standoff to the required 5/8" to 1" range.
• Standoff can go up to 1-1/4" for 5/32" diameter wire with a range of 5/8" to 1-1/4".
• However, control of standoff for 5/64" diameter wire is more critical. It should be maintained between ½" and 7/8" at all times to assure good nozzle and tip life.
• Increased EE causes an additional voltage drop in the electrical system that robs the arc of voltage. Therefore, meter voltage must be increased to compensate for the loss. A nominal 1 - 2 volts must be added to meter voltage.
• The threshold of current for a stable arc goes up with increased EE. As an example, at 2-1/4" EE for 3/32" carbon steel wire, the lower threshold is nominally 275 amperes.
• Keep in mind that amperage decreases as EE is increased. If the machine was set at about 300 amperes with 3/32" diameter wire at 1"EE, amperage may drop below the threshold for a stable arc when EE is increased to 2-1/4". That is, the machine should be properly preset to arrive within the recommended current range with increased EE.
• The use of machines where wire feed speed may be preset digitally (e.g. Lincoln NA-5) makes adjustment easy when coupled with wire feed charts from TipMate™ Systems.
• The lower base material heat input with increased EE means that maximum interpass temperature requirements are easier to maintain. You must take care to maintain any required preheat when welding heavy wall and/or large diameter weldments.
• For thin sections and/or small diameters, the increased deposition rate with increased EE may be more successfully applied by increasing travel speeds with the original count of weld beads in lieu of decreasing the number of passes.
• The welder should continue to use the same judgments in adjusting travel speed, voltage and head offset to maintain proper bead appearance.