456P Invision weld not wetting out

[B&M Welding Inc.]

Hi, I have a Miller 456P Invision (SN. LA269472) I am in the middle of a project, layed down my gun, flipped the part over, and after 20 min picked the gun up to continue welding, and it welds bad! Weld bead looks dry, puddle is small when welding, bead is not wetting out at all unless I weave! My gas bottle was low so thinking it could be the gas I swapped in a full bottle, no change. Tried changing the ground clamp around on the work piece, swapped out the gun to an almost new Miller M25, powered off unit for couple min. I tried all different power settings and feed speeds, in short circ., pulse spray, and spray transfer. Any help would be appreciated! Thanks, Brian

[cruizer]

Are you running single or 3 phase. if 3 phase ,you could have dropped one.

[B&M Welding Inc.]

Are you running single or 3 phase. if 3 phase ,you could have dropped one.

I do have 3 ph. I hadn't thought off that. It seemed like I had decent power. Just didn't have a fluid weld puddle. I will let it sit till Mon. then I'll check my service if it still acts up. Thanks!
Update: I just ran out to the shop and pulled the side panel. Input voltage is good 249v. across any of the 3legs. still welds bad!

[cruizer]

It's wierd as the machine isn't showing any errors, unlikely to be the feeder, sounds like a hall issue telling the machine that amps are too high. Or a failed switch. Going to be an easy fix, best remove the top cover ,unplug it and meter out the switch

[B&M Welding Inc.]

It's wierd as the machine isn't showing any errors, unlikely to be the feeder, sounds like a hall issue telling the machine that amps are too high. Or a failed switch. Going to be an easy fix, best remove the top cover ,unplug it and meter out the switch

Thanks for the reply, Cruizer! Could you explain farther how to "meter out the switch"? The power switch? I assumed that to be ok, because the main relay is closing completely.
BTW, I tried changing the Arc Control knob. I could tell it was effecting the weld fluidity but it wouldn't go near far enough!

[B&M Welding Inc.]

sounds like a hall issue telling the machine that amps are too high.

What should my amps be? I was showing about 148 when short circuiting with .035 @ 22v.

[cruizer]

See that's pretty low, should be up on the 170-180 mark, course it depends on what the wire speed is as that determines amperage. Might want to open it up and check the right side. Near the front is the blue hall (lem) this is quite likely the problem, but it's just a guess.

[B&M Welding Inc.]

See that's pretty low, should be up on the 170-180 mark, course it depends on what the wire speed is as that determines amperage. Might want to open it up and check the right side. Near the front is the blue hall (lem) this is quite likely the problem, but it's just a guess.

Is there a way to test the hall? I just tried welding at 22v. I held a steady arc on a plate and watched the amp reading. It fluctuated from approx. 110-155 on a steady 2 sec. cycle. That make sense? the sound of the arc coordinated with the amp reading. Thanks for your input!

[cruizer]

Best to order a new hall. just go by your serial # and order a new one from :www.miller4less.com

[B&M Welding Inc.]

Best to order a new hall. just go by your serial # and order a new one from :www.miller4less.com

My local repair shop had a transducer in stock. Installed it and just ran some welds. Still no change. I'm really starting to question my gas now. Weird thing is it just started at the end of a bottle of gas and now I'm on a new one! I will get some 75/25 and see how it acts.

[cruizer]

Its tough t-shooting over the net, I can only tell you what I think the problem could be machine wise. I know there is no error codes for a wonky hall, or front board. And the problem is not with the front board, so hall was my guess, or dropping a phase. And yes if the gas was straight Argon, then it wouldn't weld well

[B&M Welding Inc.]

Cruizer, don't blame yourself if we haven't got it fixed! I did call Miller this morning before I bought the hall, and they were stumped as well. Having just went from a nearly empty to a full bottle of gas I thought I had ruled out that possibility. Now after playing with it all afternoon I'm starting to think it can't be anything but the gas! My supplier is going to deliver another bottle of 90/10 tomorrow am. I also borrowed a bottle of 75/25 from a different supplier. We'll give those a shot and I will post a solution once I get the problem solved. Thanks again Cruizer! Your great!!

[B&M Welding Inc.]

Problem Solved!!

Bad gas. Third bottle is a charm! It's great to have a welder again. BTW this Invision rocks! This is by far the best Miller product I have owned! Just too bad I wasted a day trying to fix something that wasn't broke. Never assume 1 out of 2 bottles of gas is going to be good!