1

2
10
3
4

5
6

9 8

1. Voltmeter (Optional)
2. Wire Speed Meter (Optional)
3. Schedule A Wire Speed Control
The scale is calibrated in inches per
minute 100 and meters per minute.
4. Schedule A Voltage Control (Optional)
When a digital voltage control is used with
an inverter-type welding power source, the
control functions as a remote digital voltage
control to preset arc voltage.
For dual schedule applications, a dual sche-
dule switch is required for the gun. Obtain a
proper dual schedule switch and install
according to its instructions.
5. Schedule B Indicator Light
6. Schedule B Voltage Control
7. Schedule B Wire Speed Control
8. Press to Set Button
Press and hold button to preset Schedule B
wire-feed speed and/or voltage.
9. Jog/Purge Switch
Push up to momentarily feed welding wire
at speed set on wire speed control without
energizing welding circuit or shielding gas
valve.
Push down to momentarily energize gas
valve to purge air from gun or adjust gas
regulator.
Center position is off.
10. Trigger Hold Switch

Fig. 21-28 Dual schedule control for use with the Miller constant voltage d.c. power sources. It provides two individual preset
voltage and amperage (wire-feed speed) welding settings with one machine and one wire feeder.

Figures 21-29 to 21-32 show the transformer-rectifiers for

different MIG/MAG welding applications. The welder
shown in Fig. 21-32 can be used for stick, MIG/MAG,
and TIG welding. This is possible because of a controlled-
slope characteristic. Controlled slope permits 15 separate
output settings plus fine voltage adjustment control of all
positions.
Inverters Advancements in high power electronics have
allowed these type of power sources to evolve. The pri-
mary advantage of inverters is arc performance, plus their
availability to run all the processes requiring either con-
stant voltage (c.v.) or constant current (c.c.). In the constant
voltage mode, slope is preset electronically while voltage
and inductance are fully adjustable. With the flip of a Fig. 21-29 Shop portable GMAW welding outfit includes
350-ampere c.v. single or three phase input inverter power
switch they can be converted to constant current operation source. It is equipped with up to 35 feet, of 200 amp push-pull
with control over amperage and arc force. Since these type aluminum gun. Note four wheeled cart and single gas cylinder of
of power sources use high speed electronic switching de- argon. As shown being used to weld an aluminum trailer frame.
vices, they are capable of pulsing output for both GMAW Miller Electric Mfg. Co.

and GTAW applications. Some units have total control

over the output waveform for all modes of metal transfer and very portable. Some are designed to adjust themselves
such as short-circuiting and pulse spray. automatically to whatever primary voltage they are sup-
Many inverters are capable of running on single- or plied (within a range). Figures21-31 to 21-32 show various
three-phase input power. They are compact, lightweight, inverter-type machines for MIG/ MAG applications.

672 Chapter 21 Gas Metal Arc and Flux Cored Arc Welding Principles
Fig. 21-30 This 250-ampere, constant voltage solid-state controlled
transformer-rectifier has an output rating of 7 to 32volts and 30 to 300
amperes available in one continuous range. Note the quick twist con-
nections for high and low inductance and the polarity output hook-up.
GMAW and FCAW up to its output capability are the appropriate applica-
tions. Lincoln Electric
Fig. 21-31 A 450-ampere d.c. inverter power source. This machine
has the capability to output c.v.-c.c., so it is multiprocess capable. It is
designed specifically for the GMAW-P process for all position welding
on thick and thin materials without spatter. It has a built-in micropro-
cessor that allows both manual as well as synergic (adaptive or non-
adaptive) control of the pulse output. It is also capable of running all
modes of metal transfer as well as FCAW, GTAW, and SMAW processes.
SAW and CAC-A up to its output capability are also recommended.
Miller Electric Mfg. Co.
Gas Metal Arc and Flux Cored Arc Welding Principles Chapter 21 673
Fig. 21-32 This 450-ampere d.c. inverter power source uses the
digital microprocessor-based feeder for standard MIG synergic pro-
gramming of the following wire sizes: 0.030, 0.035, 0.045, 0.052,
and 116 in. The following wire types are also preprogrammed: steel,
alternate steel, stainless steel, 4000 aluminum, 5000 aluminum,
and silicon bronze. This power source is also multiprocess capable
as it can output both c.v. and c.c. ESAB
Engine-Driven Generators Constant voltage welding gen-
erators usually supply d.c. welding current. They are used
for MIG/MAG, FCAW, SMAW, and GTAW.
Engine-driven welding generators are used in the field
and for emergency work when electric line power is not
available. The engine is usually a gasoline or diesel type.
Fuel is gasoline, diesel oil, or propane gas.
These generators differ from constant current generators
in their controls. Constant voltage generators have controls
for voltage as well as current. Controls for slope and in-
ductance are also available. Controls may be continuous or
tapped. Figure 21-33, page 674 is an engine-driven generator
capable of c.v.-c.c. output.
Machine Selection
Constant voltage machines are used with the GMAW,
MCAW, FCAW, and SAW processes. They are better
 process is very wide, from 25 to over 1,000 amperes.
However, amperage is not the only issue; the machines
must be capable of providing these amperages at spe-
cific voltages. Some of the transformer-rectifiers and
engine-driven generators that are designed for high
output applications (over 450 amperes) may have dif-
ficulty running a 0.030-inch diameter wire in the short
circuit mode of transfer at 16 volts and 60 amperes.
The output volt-amp curve should be consulted to see
if both low end and high end performance is available
from the machine.

Wire-Feeding Unit and Control

Fig. 21-33 Engine-drives of this type generator are available up The wire-feeding unit, also called a wire feeder or wire
to 800-amps. For industrial auxiliary strength and weld power in
the field, it has c.v.-c.c. versatility. For stick welding, it also provides drive, drives the electrode wire from the coil automati-
semiautomatic welding with large diameter, high deposition flux cally, Figs. 21-34 and 21-35. It feeds the wire through
cored wires. The welder is using a suitcase type feed, with FCAW-S the cable assembly to the gun, arc, and weld pool. Since
electrode wire, and trailer for mobility. Miller Electric Mfg. Co. a constant rate of wire feed is required, the wire feeder
is adjustable to provide for different welding currents.
suited for welding processes in which the consumable Wire feeders are rated for their minimum and maxi-
electrode wire is fed continuously into the arc at a fixed mum wire-feed speed and the current-carrying capacity
rate of speed because they permit self-regulation of arc of their gun power pickup.
length.
GMAW power source units for both manual and auto-
matic operation are almost always d.c. constant voltage
machines. Alternating current has been found to be gener-
ally unsuitable because the burnoff rate is erratic. A few
a.c. applications are possible but very limited.
Most MIG/MAG welding is done with DCEP which
gives better melting control, deeper penetration, and
good cleaning action. This is especially important in
welding such oxide-forming metals as aluminum and
magnesium. DCEN is seldom used. The wire burnoff
rate is greater with DCEN, and the arc instability and
spatter are problems for most applications.
The selection of the proper machine size for a particu-
lar job is always a problem. It should be pointed out, how-
ever, that each machine has a wide range of application.
Spray arc welding generally requires from 100 to
400 amperes for semiautomatic applications. Automatic
installations may range from 50 to 600 amperes.
Short-circuiting process gas requires only 25 to
250 amperes.
Flux cored wire utilizes from less than 100 up to Fig. 21-34 A typical bench style wire feeder that is designed
500 amperes in applications without shielding gas. With for constant wire-feed speed. This allows it to operate all the
carbon dioxide shielding gas in automatic setups, the cur- GMAW modes of transfer as well as FCAW applications. Input power
rent ranges from 100 to 750 amperes. required from the power source to operate the feeder is 24 V a.c.,
7 amperes, 50/60 hertz. The feeder is designed to handle elec-
Automatic submerged arc welding requires from 75 to
trode wire diameters of 0.023 to 564 inch at wire-feed speeds from
1,000 amperes. 75 to 750 inches per minute with a maximum spool capacity of
As can be seen, the range of current for these con- 60pounds. Note the simple controls for wire-feed speed, trigger
stant voltage machines for the continuous electrode hold, wire jog, and shielding gas purge. Miller Electric Mfg. Co.

674 Chapter 21 Gas Metal Arc and Flux Cored Arc Welding Principles
 Drive Roll Pressure
Adjustment
Quick Change
Geared Drive Rolls

Wire Guide
from Spool
Receptacle for
Quick Change Gun
Connection and
Outlet Guide from
Drive Rolls

Inlet Guide to
Quick Change
Drive Rolls
Gun Release Knob

Gun Trigger
Receptacle

Electrode Power Cable

Connection Stud

Fig. 21-35 The internal construction of the wire feeder in Fig. 21-34. The relationship of the
wire guides to the wire drive rolls is essential for good feeding. There should be as little unsup-
ported wire as possible. The guides should be of the appropriate size and be placed as close to
the drive rolls as possible. Miller Electric Mfg. Co.

Usually, the machine is a one-piece unit. A control

cabinet wire feeder and wire mount are attached to an
all-welded frame. The wire feeder is mounted with the
power source in a portable unit, Fig. 21-36. In some
cases the unit is separate from the power source and is
mounted on an overhead crane to allow the welder to
cover a greater area. For field or maintenance work, the
unit is small and portable and may be a great distance
from the power source, Fig. 21-37 (p. 676).
The portable feeder shown in Fig. 21-38, page 676 is of
the voltage sensing variety. Most wire feeders are of the
constant speed variety and work off of a fixed voltage,
such as 115, 42, or 24 volts. They have electronic control
circuits and drive motors designed to work off of these
set voltages to deliver a very accurate constant wire-
feed speed rate. Voltage sensing feeders are designed to Fig. 21-36 This digital wire feeder allows much more rapid setup
work off of the open circuit voltage of the power source for a welding procedure and keeps the process in control by accurately
and while welding the load or arc voltage of the power controlling and displaying voltage and wire-feed speed. It operates
from input power (24 V a.c., 10 amperes, 50/60 hertz) provided by the
source. They can be much more simplified and compact
power source. It is capable of handling electrode wire diameters of
in design than constant speed feeders. The basic volt- 0.023 to 18 inch and wire-feed speeds of 50 to 780 inches per minute.
age sensing feeder works directly off of the voltage being Note the digital readout on voltage and wire-feed speed and the simple
supplied to it. A high voltage will cause the wire-feed controls. Miller Electric Mfg. Co.

Gas Metal Arc and Flux Cored Arc Welding Principles Chapter 21 675

Fig. 21-37 This highly portable control-feeder weighs less than
25 pounds and fits through a 18x24 inch porthole. The small modu-
lar design and tough flame-retardant, nonmetallic case materials
will withstand burning, breaking, or loss of rigidity with heat or
sun. This is a voltage sensing feeder and so operates on the open
circuit arc voltage of the power source and must be supplied 15 to
100 V d.c. The clamp and cable shown must be connected to the
work piece. Electrode wire diameter capacity is 0.023 to 0.052 inch.
Wire-feed speed is from 50 to 700 inches per minute depending on
the arc voltage supplied. The maximum spool size on this feeder is
8 inches and 14 pounds. Digital display of voltage, wire feed speed,
and also amperage if desired. Meters can be seen clearly even in
direct sunlight. Miller Electric Mfg. Co.
motor to speed up, causing the wire to accelerate to-
ward the weld pool. This will shorten the arc and lower
the voltage. Since this feeder motor works directly off
of the arc voltage, the motor will see less voltage and
begin to slow down. As less wire is being fed toward
the weld pool, the arc will get longer, the voltage will go
up, and the wire-feed speed will increase accordingly.
This simple form of voltage sensing feeder is being self-
regulated off of the arc voltage and will quickly stabilize
to a steady arc length. When the feeder is being operated
in this voltage sensing mode, it is generally only used
676 Chapter 21 Gas Metal Arc and Flux Cored Arc Welding Principles
Fig. 21-38 This voltage sensing feeder is powered across
the arc by the welding current. As with all voltage sensing feed-
ers no control cables are needed. To operate, simply connect
the weld cable and attach the work clip, and the feeder is ready
to weld. This portable unit is designed for MIG/MAG or flux
cored wire diameters of 0.023 to 564 inch with a wire-feed speed
range from 50 to 700 inches per minute. The totally enclosed
case accepts 10- to 44-pound wire packages. The feeder dimen-
sions are 16 15 31 inches with a net weight of 65 pounds.
Lincoln Electric
for GMAW spray arcs and FCAW, because the short-
circuiting mode of transfer and the pulse mode of transfer
place too many various arc load voltage conditions on the
wire-feed motor to get the constant wire-feed speed that
is required for these two modes of metal transfer. Many
voltage sensing feeders have a switch that can place them
into a constant wire-feed speed mode. They are still
working on load (arc) voltage, but electronic circuits are
used to filter this power and supply a relatively constant
voltage to the drive motor. This allows such equipped
voltage sensing feeders to run the short-circuiting and
pulse modes of transfer.
Voltage sensing feeders also have the advantage of
being usable off of the constant current type of welding
machine. This type of feeder can compensate for the re-
duced short circuit current and slower response time of
the constant current machines. Again only solid and metal
cored electrodes with spray arcs should be used; flux
cored electrodes can also be used as long as the electrode
selected is not too voltage sensitive. This type of setup
works very well with the voltage sensing spool gun and a
constant current power source for GMAW of aluminum.
 Table 21-3 Arc Length (Voltage) and Amperage Settings with Various Types of Wire Feeders
and Power Sources

To Set Arc Length (Voltage), Adjust To Set Amperage, Adjust

C.V. power source when used in conjunction with Constant speed wire feeder
Voltage sensing wire feeder when used in conjunction with C.C. power source
C.V. power source when used in conjunction with Voltage sensing wire feeder in
the constant speed mode

V-Groove U-Groove for V Knurled U Cogged for

for Hard Wire Soft Wire or for Hard-Shelled Extremely Soft
Soft-Shelled Cored Wires Wire or Soft-
Cored Wires Shelled Cored
Wires (i.e., Hard-
Facing Types)

Fig. 21-39 Drive roll types and applications. Miller Electric Mfg. Co.

Adjustment of the wire feeder and power source is just the

opposite of that of the constant voltage power source and
constant speed wire feeder. See Table 21-3.
The welder has trigger control over gas flow, wire feed,
and the welding-current contactor right at the work. When
the welder presses the torch trigger, gas and water flow
and wire feed start automatically. The arc strikes as the
wire touches the workpiece. When the trigger is released,
gas, water, and wire feed stop. The wire-feed rate and
electrical variables are set on the wire feeder before weld-
ing and are automatically controlled during welding.
Wire drives are manufactured so that different sizes
of drive rolls can be installed quickly. All sizes of wire
can be used, thus making it possible to weld a wide range
of metal thicknesses. Different rolls are required for hard
wires than for soft wires. Figure21-39 shows the various
types of drive rolls and the application for each. The size
and type of drive roll used is critical for good feedability
of the continuous electrode.
Most wire-feeding units push the wire through the
Fig. 21-40 This push-pull wire-feed system is designed
cable to the torch. The push type of drive is generally used
specifically for aluminum MIG welding. There is a pull drive motor
with hard wires such as carbon steel and stainless steel. A in the gooseneck gun, while the control and wire spool housing
number of torches have an internal mechanism that pulls has a push motor. Guns are available from the spool supply hous-
the wire from a wire reel unit through the torch to the arc. ing of 15, 25, and 35 feet for maximum reach. The maximum al-
Figures 21-40 through 21-42, pages 677678 show two lowable spool diameter is 12 inches. This water-cooled version is
types of wire-drive, pull-type guns. The pull type of drive rated at 400 amperes at 100 percent duty cycle. It has an electrode
wire diameter capacity of 0.030 to 0.047 inch with a wire-feed
is preferable for use with soft wires such as aluminum and speed range of 70 to 875 inches per minute. Note the gun trig-
magnesium. Other torches have a small spool of wire and ger and wire-feed speed control located in the base of the gun
a drive motor in the torch which feeds the wire directly handle. Miller Electric Mfg. Co.

Gas Metal Arc and Flux Cored Arc Welding Principles Chapter 21 677
 XR-Control Panel
17
13
2
3 18
1
4
5
14
6
19
7
8

9 15

10 16
24
11 Side Panel Detail
12
20 25

21 26
27
22

Front Panel
23

Side Panel

1. Gas Flowmeter*
2. Voltage/Wire Speed Meter
3. Voltage/Wire Speed Switch
4. Voltage Control*
5. Wire Speed Control
6. Schedule A Indicator LED*
7. Press To Set Push Button*
8. Schedule B Indicator LED*
9. Wire Speed B Control*
10. Remote Volts B Control*
11. Wire Jog/Gas Purge Switch
12. Trigger Hold Switch
13. Run-In Speed Control
14. Burnback Time Control*
15. Continuous/Spot Time Control* 21. Weld Cable Terminal in Feeder
16. Spot Time Range Switch* 22. Reed Relay
17. Fuse F1 23. Weld Cable
18. Circuit Breaker CB1 24. Gas Hose
19. Motor Torque Switch 25. Gun Connector
20. Drive Tensioner Adjustment 26. Gun Securing Knob
Knob 27. Gun Connector Block
*Optional

Fig. 21-41 Note the control panel callouts. This system can be set up for dual schedule operation. A dual schedule switch will be
required. Source: Miller Electric Manufacturing Company. Copyright Miller Electric Manufacturing Company. All rights reserved. Used with permission

Welding Guns and Accessories

4 5 6 7 8 9 10 11 12 The function of the gun, Fig. 21-46 (p. 680), is to deliver the
electrode wire and the shielding gas from the wire feeder
1. Head Tube Liner 7. Gas Defuser
3 2. Liner O-ring 8. Collet Nut and the welding current from the power source to the weld-
2
3. Head Tube O-ring 9. Contact Tip ing area through the contact tube (tip). The MIG/MAG gun
4. Head Tube 10. Adapter Jam Nut
1 5. Lock Nut 11. Nozzle Adapter
is comparable to the electrode holder used for stick elec-
6. Insulator 12. Nozzle trode welding.
Guns are rated for the minimum and maximum wire di-
Fig. 21-42 Note the callouts on the working end of this gun from
the push-pull system shown in Figs. 21-40 and 21-41. These are the ameters on which they are designed to run, current-carrying
gun parts that are in the closest proximity to the welding arc and capacity, and the type of shielding gas this current rating
will require the most maintenance. Source: Miller Electric Manufac- is based on, Table 21-4 (p. 680). A typical 200-ampere
turing Company. Copyright Miller Electric Manufacturing Company. All air-cooled GMAW gun may have a rating of 0.035- to
rights reserved. Used with permission
0.045-inch diameter, 200 amperes 100 percent duty cycle
through the torch, Figs. 21-43 and 21-44. Still another with CO2 gas. The amperage rating should be reduced ap-
type of torch acts as a feeder gun and operates in connec- proximately 50 percent if argon is substituted for the CO2
tion with a canister, Fig.21-45. shielding gas. Guns are also sized by their reach from the

678 Chapter 21 Gas Metal Arc and Flux Cored Arc Welding Principles
 Fig. 21-43 This spool gun provides reach and ac-
cessibility. The gun contains the wire and the drive
motor system. Since the wire is pushed only a few
inches, smooth feeding of difficult-to-feed wire like
aluminum is easily accomplished. Ideal for light indus-
trial applications, the gun is rated for 150 amperes at
60 percent duty cycle and has a 20-foot weld control/
cable. The electrode wire diameter capacity is 0.023
to 0.035 inches for aluminum, steel, and stainless
steel, with wire-feed speeds of from 115 to 715 inches
per minute. The maximum spool size capacity is
4inches. Miller Electric Mfg. Co.

Fig. 21-44 For more industrial type applica-

tions this spool gun is rated for 200 amperes and
100percent duty cycle. The electrode wire diameter
capacity is 0.023 to 116 inch for aluminum wire and
stainless steel and steel wire up to 0.045 inch,
with wire-feed speeds of from 70 to 875 inches
per minute. The maximum spool size is 4 inches.
Miller Electric Mfg. Co.

Fig. 21-45 A group of welders MIG welding an alumi-

num boat hull. The push-pull gun and power source can be
up to 35 feet apart, allowing extreme flexibility and reach for
projects like this one. Miller Electric Mfg. Co.
ELECTRIC SHOCK can kill.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulat-
ing mats or covers big enough to prevent any physical
contact with the work or ground.
Additional safety precautions are required when any of the
following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures
such as floors, gratings, or scaffolds; when in cramped posi-
tions such as sitting, kneeling, or lying; or when there is a high
risk of unavoidable or accidental contact with the workpiece or
ground. For these conditions, use the following equipment in
order presented: 1) a semiautomatic DC constant voltage (wire)
welder, 2) a DC manual (stick) welder, or 3) an AC welder with
reduced open-circuit voltage. In most situations, use of a DC,
constant voltage wire welder is recommended.

Gas Metal Arc and Flux Cored Arc Welding Principles Chapter 21 679