Welder settings

[Locoweed]

First off, let me preface this by saying that I am not picking on Miller. I have a Lincoln & the recommended settings in the book & what the welder it's self recommend are similar to what the manual for the Miller. Miller just happens to have a online calculator that I can use for comparison.

So, my question is about comparing what is the book setting vs the online Miller Calculator recommend. MIG Flux-Cored Weld Setting Calculator

Let's compare the settings for 1/8" metal & using .035" wire. No shielding gas. Here is part of a screen shot from the pdf manual.




Here is a screen shot from the online calculator.



I have a lot better luck with the settings from the calculator. Why is there such a difference?

 

[WranglerX]

I usually use door chart on my Hobart to get a ball park setting, then dial in according to what my test beads show me....

Dale

 

[BrokenTrack]

Numbers are just there to get a welder-person close, but it really depends on so many factors, that in all practicality, you just set your welder for how you weld.

The best setting indicator I have found, is a black Sharpie pen. Once you reach a setting that you like, mark it with a black line so that you can return to that spot. I do this with my junk AC stick welder because I found a setting where I can weld in all positions. Sometimes my father will use the welder and adjust the settings, so I have the little black line to return too.

 

[Locoweed]

The root of my question lies in the fact that the "book settings" are not very close. In this instance the book says 19.9V & 294IPS. The calculator says 14-15V & 175-185IPS. That is a lot of difference IMHO & both sets of numbers are from the same company. One of the attractions of buying a new welder for me was that it would automatically get you in the ball park after setting the wire size, type of wire & thickness of the metal. That turned out to be a bunch of advertising dross. At least Miller does give access to the calculator. Lincoln doesn't provide anything comparable.

 

[WranglerX]

Keep in mind, a lot of how you weld (handle gun and stick out) has a lot of difference in what voltage and IPM for wire and wire size is.... Again charts are ballpark for starting point, the skill of the weldor (person who welds, not the machine) is how successful the welds are.....

As years go by and as I weld more its easier to look work to be done, make voltage setting (amperage) and sort of dial in wire speed, if weld does no seem correct I change setting as to what the feed back is from experience...

It's like driving a tractor, we all know how the manual explains how we should dive it, yet we all fudge (adjust) things a bit to suit our needs....

The real problem here is did the engineer that gave the information to graphics dept get it right for the particular welder... Or the did the person who wrote the calculator bases on theatricals get it right...Only the actual application (test) of both specification/theories will derive correct settings because end result will lie with weldor doing the "work".... Neither source is Absolute...Correct answer is probably somewhere in middle of both "information" sources....

Another issue here may also be is welder a stepped voltage machine or a infinite voltage machine.... IF I have stepped voltage and calculator give me a value for infinite machine that is somewhere in between my stepped voltages do I go up or sown.... Only experience can answer that....

Dale

 

[yomax4]

I'd guess it's a material thickness typo on Millers part. The longer you have the welder the less you will need the chart.

 

[FTG-05]

What MIG welders show the voltage and/or the inches per minute wire speed. My Lincolns have always had the 1-10 dial or 1-4 click settings.

 

[dragoneggs]

What MIG welders show the voltage and/or the inches per minute wire speed. My Lincolns have always had the 1-10 dial or 1-4 click settings.

That is my only gripe with my Miller 211. I wish I could read voltage and ipm. I think that would be much more informative and maybe allow you to pick up another machine you never used and get going.

 

[WranglerX]

What MIG welders show the voltage and/or the inches per minute wire speed. My Lincolns have always had the 1-10 dial or 1-4 click settings.

Newer welders in the 250 amp class.....


POWER MIG(R) 256 MIG Welder

Slightly less expensive unit....

Millermatic(R) 211 MIG Welder


Dale

 

[WranglerX]

That is my only gripe with my Miller 211. I wish I could read voltage and ipm. I think that would be much more informative and maybe allow you to pick up another machine you never used and get going.

Lincoln 256 has digital diaplay....

Dale