Settings for Bobcat 225G w/30A

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Ok, I need a little help figuring this out.  First, here is what I'm working with:Bobcat 225GWC-115A w/contactorSpoolmatic 30ABackground:I am a hobby welder that self taught growing up on a ranch fixing equipment and making things.  When I bought my property the previous owner left behind a 30A which I have just rebuilt.  I got a WC-115A from a member here, (THANK YOU 74749!!)  I have just got them all hooked up and tried it a little tonight, and it works.  My questions though, are about adjusting settings.Here is what I think I know:Since I am running off of the CV output on the 225G, then volts are set at the machine, and amps are controlled by wire speed, and I need to be on DC/electrode +.  My understanding is that in CV mode the fine adjustment knob is how I will adjust my volts.  Here is my control panel: On the CV setting it says, "17-28V".  I wanted to verify that the fine knob was going to vary my volts, so I put a multi-meter on the work and CV leads.  I found that it has a range of 1 volt up to 62.9 volts.  That's a lot more that 17-28V!So, here are my questions:    1.    Do I need to mark the range 17-28 and stay within that, or just set it where ever it works best for what I am doing?     2.    How do I figure what my amps are?  I know the rule of 1 amp per .001 material thickness, so how would I figure this since I don't have a setting for it?    3.    Wire speed?  Do I need to just run the gun for a set amount of time on each setting and then measure the wire?  Or is there a rule of thumb for the 1-10 on the dial?    4.    "Run in Speed" on WC-115A.  What am I looking for with this to know when it is right?  The manual only tells you it adjusts the wire speed before the arc starts, and then your main WFS control takes over.    5.    What will be a realistic range for this equipment with steel?  Thinnest to thickest?  Assuming proper wire size and gas, of course.Thanks for any help, and thanks for all the help so far leading up to this!  I am really looking forward to playing with this set-up.  Once I get my argon bottle filled I will have to find some aluminum to play with too!
Reply:Those high voltage numbers are open circuit volts.If you are using .035 wire try around 6 on the spoolgun (somewhere around375-400 on wire speed ) and around 30 on your machine dial and you should be somewhat close for 1-8 inch. from that point dial in your settings.Miller xmt304,  Miller S22 p12, Miier Maxstar SD, Miller 252 w 30A, Miller super32p12, Lincoln Ranger 9, Thermal Arc 181I with spoolgun, Hypertherm 10000 ,Smith torches. Esab 161lts miniarc.
Reply:Originally Posted by M J DThose high voltage numbers are open circuit volts.If you are using .035 wire try around 6 on the spoolgun (somewhere around375-400 on wire speed ) and around 30 on your machine dial and you should be somewhat close for 1-8 inch. from that point dial in your settings.
Reply:OCV in CV mode is not going to behave the same way it does in CC.  Specifically, you're not going to see the same drastic drop in voltage from OCV to arc as with CC mode.I suspect the reason you're seeing such a broad range on your machine may be due to someone replaced the original rheostat with one of a different value.Testing at the CV and WORK output studs, DC/CV OCV should be approximately 26-32VDC from minimum to maximum Fine Current Control respectively @ weld/power speed.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Hmmm.  So I would need to check it and mark that range then, to stay within it.  Sent from my C811 4G using Tapatalk
Reply:I would figure out why you have such an incorrect voltage range in CV mode.Is the machine wired wrong?Is the rheostat the correct one?Did you have your meter on the correct function/voltage?Is the meter functioning properly?Did you have the machine set to CV for the voltage checks?Even the CC/DC and CC/AC OCV values don't drop to 1V on a properly functioning machine.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Originally Posted by duaneb55I would figure out why you have such an incorrect voltage range in CV mode.Is the machine wired wrong?Is the rheostat the correct one?Did you have your meter on the correct function/voltage?Is the meter functioning properly?Did you have the machine set to CV for the voltage checks?Even the CC/DC and CC/AC OCV values don't drop to 1V on a properly functioning machine.
Reply:One other thing I ran into;  I hooked the gas line up to the regulator that came with my HH140.  The only control it has is for volume, so it is obviously internally regulated to some PSI.  However, this must be too high of a PSI for the 30A.  When I release the trigger you hear the gas stop for just a second and then you hear it start hissing, leaking past the rubber cup valve.  I took the rubber off and cleaned it and the metal body really well, and they are in great shape.  I tried pushing on the rubber valve with my finger with the gas on and I can't stop it from pressuring past.  That made me curious about my HH140, so I took the panel off it and found it actually has a solenoid valve that turns the gas on and off, so that is why there is no issue there.Anyone know what the max pressure is the 30A can handle?  Can't be much!
Reply:Well there you go.  I knew there had to be something amiss.  Make sure the replacement is of the correct ohm and wattage values for the machine.  Typical for the Bobcat 225G is 100W. 10ohm.  Also check to confirm trim resistor R2 is connected in the field supply voltage circuit and is not by-passed.  You may need to adjust the tap location to dial in OCV once you replace the bad rheostat.As for the 30A gas valve issue, typical gas flow should be ~20cfh and a "pressure" type meter may be the problem.  You may have to switch to a needle valve flow control type to rectify the matter IF there isn't a problem with your current regulator.  I'm leaning toward a problem with the regulator as I believe I've used both types with my Spoolmatic 1 without the described leakage.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:I recieved the new Miller rheostat and installed it today.  It now reads 27 at "0" and 38 at "10".  Seems odd that it is exactly 10 volts higher than the range should be.  ????  I guess I'll call the tech guys again tomorrow and see what they say.  As for the gas, they told me that there is a stiffer/stronger spring that they use on the trigger that will probably fix that issue.  I did find that if I pull the trigger forward a little to put a little more pressure on the rubber valve, it stops leaking by.  So I think a stronger spring will do it.  What about the "Run in Speed" on the WC-115A?  What is the goal in adjusting that?  The manual pretty much only tells you what it is.  I just want to make sure I don't mess something up once I start burning wire with this thing.
Reply:You're not that far off.  CV OCV should be from 26-32VDC from "0" to "10".Could be engine speed is a little too fast or the field voltage trim resistor R2 tap is in the wrong location or both.What voltage do you have at the rotor brush leads at WELD/POWER speed?  Should be approximately 13-29.5VDC from "0" to "10".MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:You mean the brushes on the main shaft?Sent from my C811 4G using Tapatalk
Reply:Yes.  That would be an indicator of engine speed and R2 tap location but more important is being able to confirm proper engine speed and then adjust R2 tap to result in the correct maximum OCV at the CV and WORK output studs.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:To set engine speed, go to Home Depot or Lowes and get one of these:Plug it in to one of the 115VAC outlets, select Hz and set no load engine speed to give a reading of 62-62.5Hz.Then check CV OCV and adjust the R2 tap location as/if needed to produce the proper output OCVs listed above.  Make sure you shut down before adjusting R2.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Awesome!  Thanks.  I'll probably get to that Saturday.  Unless I can get home early tomorrow!Sent from my C811 4G using Tapatalk
Reply:Originally Posted by JustmeWhat about the "Run in Speed" on the WC-115A?  What is the goal in adjusting that?  The manual pretty much only tells you what it is.  I just want to make sure I don't mess something up once I start burning wire with this thing.
Reply:Thanks!  Sent from my C811 4G using Tapatalk