Initial settings for 30A Spoolgun

[Dr Gas]

Just got a Miller 30A spoolgun attached to my Millermatic 250. I will be practicing on 1/8 Al coupons using .035 wire, Argon at 20cfm. As the control module I bought doesn't have any knobs it looks like the 250 will control wire speed and voltage. Does anyone have any suggestions for initial settings or general tips for learning to use the spoolgun for Al??

[FusionKing]

Isn't there a red knob on the bottom of the handle? That adjusts wire feed.
Also I prefer bigger .064 wire myself. It has a lot less wire feed associated problems.

[tenfingers]

Short circuit transfer for Aluminum (ER4043)

Wire Voltage WFS ipm Amps Shielding gas
.030 16-19 250-550 50-120 Argon
.035 17-20 240-425 65-140 Argon
.045 17-22 160-325 75-170 Argon

Spray Transfer for Aluminum (ER4043)

Wire Voltage WFS ipm Amps Shielding gas
.030 20-27 550-1200 95-200 Argon
.035 20-27 425-850 110-220 Argon
.045 22-31 250-650 130-290 Argon



From GMAW book in Miller student package.

[rmack898]

I would get some 1/4" material to start out with. If you are just starting out with a spoolgun on aluminum, 1/8" stock may be a little difficult until you get a feel for it. I just recently went through this same process.

[Frank865]

Isn't there a red knob on the bottom of the handle? That adjusts wire feed.
Also I prefer bigger .064 wire myself. It has a lot less wire feed associated problems.

Wire size shouldn't be a problem with a spoolgun

[elpincel signs]

spoolgun 30A PROBLEMS INTALLATION

Hio I just bought a spoolgun 30 with remote control ,I have a old millermatic 250 ,so I have problem installing the remote control becuase I cant find the pg7 plug from the welder I need help if anyone can help me please reply Thanks Ernest

[Dmaxer]

Dr. Gas, regarding a connection for your spoolgun....did you install or was there already installed on your welder the optional receptacles module for connection of a spool gun? For info check the owner's manual for your welder or if you don't have one, download one from this site by inputting your model and serial number at http://www.millerwelds.com/service/ownersmanuals.php

No hijack intended here. Can anyone translate the WFS ipm settings copied above by tenfingers into the 0-10 control settings on the handle of the 30A? The best I've heard on this so far is to adjust the 30A on-the-fly. Is there an equivalency chart somewhere for those of us connecting the 30A to a power source with no ipm readout?

[gordfraser]

measure how much wire comes out in 6 seconds and multiply it by 10= IPM
or 12 secs and X 5

G

[GilaSlim]

The owner's manual states 70 To 875 ipm wire feed speed. At a zero setting you should be getting 70 ipm and at a 10 setting, 875 ipm. I would expect it to be a linear progression in between. If that's true, at a 5 setting, you should be getting 502.5 ipm. You can verify that by using the technique gordfraser posted.

GS

[Portable Welder]

I dont see the need to know that, Set the voltage or temputure and then fine tune wire speed as your welding.
Doing it this way will by far give you better results that a pre determined setting by the factory.
In put voltage from the utility and what machine your using will vary.
Using settings that the factory recommends will however get you close.

[Dmaxer]

The owner's manual states 70 To 875 ipm wire feed speed. At a zero setting you should be getting 70 ipm and at a 10 setting, 875 ipm. I would expect it to be a linear progression in between. If that's true, at a 5 setting, you should be getting 502.5 ipm. You can verify that by using the technique gordfraser posted.

GS

I dunno, that doesn't quite make sense to me. It seems that IF the progression of wire speed is linear, figuring out what a "5" means might go something like this:

Since there are 11 numerical settings on the 30A, including the the "0" and the "10", then "5" is .4545 of maximum. Multiply .4545 times 805 (possible inches per minute settings between min of 70 and max of 875) and you get about 366 ipm. To 366 add 70 (baseline minimum) and you get the answer that "5" = 436 ipm.

Does anyone know for sure if 30A wfs settings are linear?

[Dmaxer]

I dont see the need to know that, Set the voltage or temputure and then fine tune wire speed as your welding.
Doing it this way will by far give you better results that a pre determined setting by the factory.
In put voltage from the utility and what machine your using will vary.
Using settings that the factory recommends will however get you close.

Portable Welder, I believe you're right about final settings being based on fine-tuning the wfs. I'm just trying to get close to the factory recommendation with the initial setting lacking a wfs readout.

[vpd66]

Ok, I have a 1995 millermatic 250 and the 30A spoolgun. Here are some settings that will get you in the ball park. 3/16" aluminum- 24.75 volts, wirespeed set to 4.25 on spoolgun, 1/8" aluminum-20.75 volts, wirespeed 3.75 on spoolgun. these two settings are with .035 4043 wire. Never weld thicker then 3/16" aluminum with .035 wire. You should use .047 (3/64") on 1/4" and bigger. With .047 4043 wire a good setting for 1/4" aluminum is: 25.75 volts, wirespeed 4 on spoolgun. Like someone else suggusted, get some scarp and practice. This setup will weld aluminum real nice once you get it dailed in. Watch out on welding aluminum. It is very easy to have a good looking weld, but when you break it there will be no penetration in the root of the weld. Do a couple practice tee joint welds and break them and check for penetration in the root. Hot and fast is the saying we use at work when it comes to welding aluminum. Good luck

[Dmaxer]

Thanks! That's helpful, vpd66.

[vpd66]

Hey, no problem
I went through the samething when I bought my 30A. I think I wrecked about 5 tips before I found some settings that welded decent. Another tip, stay away from 5356 wire. I never had any luck running on a 30A, but 4043 runs great.