Miller Passport tech questions (newb)

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I posted this on another board but seems it's more for industry/professionals, so it went unanswered, and they also blocked a response I made to a thread so I guess they don't really want new guys around. Anyway...So I picked up an older Passport locally. I was pretty much dead set on a new 211 but this popped up locally for 700 so I bit (felt it was a fair price and could sell it for that if needed), I wanted 110/220 and the weight difference is a huge bonus. Before I hunker down and spend some money replacing the previous owners worn gun, replace the lost 220 mvp plug, etc. I had some questions.For practical purposes, besides the ability to use a spoolgun & weld aluminum (not needed for me right now), any power output differences between the Passport vs. Passport Plus? I ask because the Passport has slightly different settings than the Plus model on the instruction manual - was wondering if Miller just tweaked the settings for the later model and if I should print those out and use them instead.From what I've read CO2 has better penetration than 25/75. Why is it then that under the Passport settings, the #'s are higher for CO2 than 25/75? Example 1/4" 230v .035 wire 10/60 for CO2 and 8.5/60 for 25/75. You'd think, logically, it would have been the other way around if CO2 was a hotter gas.Why is flux core limited to 1/4" and less on the Passport? I thought it would have the most penetration?From Miller's online calculator the Passport has no chance in heck of welding 3/8" in real world use. Will it get full penetration with 1/4" without excessive prep work (ie tack and go) or is that even too much for it on 220v? Anything over 1/4" I would use an older stick welder if it came to it. But I wanted the ability to do 1/4" on my "main" welder, which is why I almost pulled the trigger on the 211 till this CL deal popped up. Duty cycle isn't important at this point - I'm a home user.What is the best size wire to use with it? I know .023 is used for thin stuff, which came with the unit. Wondering more about for 1/8" tubing, 0.030 or 0.035? I am using the internal CO2 tank, it seems to last me quite a while for the $3 it cost to refill it.Thanks for the help and newb questions...
Reply:Maybe I can get the ball rolling.I am not sure, but I don't think the older Passport is spoolgun ready. I thought the Passport plus had that capability.I don't know why miller's setup chart is the way it is. But I do know the passport was designed primarily for Co2 gas. I like .030 wire. My migs don't like .023. It is nice that it does drive .023. I love my .030 easygrind wire.Neat machine you have.Weld like a "WELDOR", not a wel-"DERR" MillerDynasty700DX,Dynasty350DX4ea,Dynasty200DX,Li  ncolnSW200-2ea.,MillerMatic350P,MillerMatic200w/spoolgun,MKCobraMig260,Lincoln SP-170T,PlasmaCam/Hypertherm1250,HFProTig2ea,MigMax1ea.
Reply:Thanks for getting the ball rolling!Yes, the Plus model does aluminum but the older (mine) does not. That doesn't concern me much, I guess it would be neat to do it but the $$ sunk into it just isn't worth it - need the spoolgun plus the additional gas plus the more expensive machine. For me, not needed. This is my first welder, I'm taking a class at a local place here next week, hope to at least make something decent. Biggest thing I am worried about is penetration. The welder is sweet because it's so portable, even the 211 at 75# plus wire, gun etc (85+ lbs) isn't anywhere near as portable as this, plus the enclosed CO2 (cheap) bottle is really nice. I'm really happy with it, just wish there was 20-30 more amps at max output for the heavier stuff.I welded my exhaust back together (had some cracks and it was rattling around) yesterday, looks like crap I have no idea what I'm doing, I'm just happy to be able to do it! Had a local guy fix another spot a couple months ago, he used the HF 90 amp w/ flux core, welds look great, goes to show you it's the weldor not the welder!
Reply:Well as far as penetration, there are some techniques that I use. Bevel the heck out of it, and leave a gap with sharp edges. The wire will certainly melt the sharp edge and induce heat into the joint. Now you just have to keep going and not let it cool. Preheat helps to. I use a turkey fryer grill thingy with propane. Good luck and post some pics of your first welds.Weld like a "WELDOR", not a wel-"DERR" MillerDynasty700DX,Dynasty350DX4ea,Dynasty200DX,Li  ncolnSW200-2ea.,MillerMatic350P,MillerMatic200w/spoolgun,MKCobraMig260,Lincoln SP-170T,PlasmaCam/Hypertherm1250,HFProTig2ea,MigMax1ea.
Reply:Originally Posted by shovelonWell as far as penetration, there are some techniques that I use. Bevel the heck out of it, and leave a gap with sharp edges. The wire will certainly melt the sharp edge and induce heat into the joint. Now you just have to keep going and not let it cool. Preheat helps to. I use a turkey fryer grill thingy with propane. Good luck and post some pics of your first welds.
Reply:Originally Posted by wheelsupI posted this on another board but seems it's more for industry/professionals, so it went unanswered, and they also blocked a response I made to a thread so I guess they don't really want new guys around. Anyway...So I picked up an older Passport locally. I was pretty much dead set on a new 211 but this popped up locally for 700 so I bit (felt it was a fair price and could sell it for that if needed), I wanted 110/220 and the weight difference is a huge bonus. Before I hunker down and spend some money replacing the previous owners worn gun, replace the lost 220 mvp plug, etc. I had some questions.For practical purposes, besides the ability to use a spoolgun & weld aluminum (not needed for me right now), any power output differences between the Passport vs. Passport Plus? I ask because the Passport has slightly different settings than the Plus model on the instruction manual - was wondering if Miller just tweaked the settings for the later model and if I should print those out and use them instead.From what I've read CO2 has better penetration than 25/75. Why is it then that under the Passport settings, the #'s are higher for CO2 than 25/75? Example 1/4" 230v .035 wire 10/60 for CO2 and 8.5/60 for 25/75. You'd think, logically, it would have been the other way around if CO2 was a hotter gas.Why is flux core limited to 1/4" and less on the Passport? I thought it would have the most penetration?From Miller's online calculator the Passport has no chance in heck of welding 3/8" in real world use. Will it get full penetration with 1/4" without excessive prep work (ie tack and go) or is that even too much for it on 220v? Anything over 1/4" I would use an older stick welder if it came to it. But I wanted the ability to do 1/4" on my "main" welder, which is why I almost pulled the trigger on the 211 till this CL deal popped up. Duty cycle isn't important at this point - I'm a home user.What is the best size wire to use with it? I know .023 is used for thin stuff, which came with the unit. Wondering more about for 1/8" tubing, 0.030 or 0.035? I am using the internal CO2 tank, it seems to last me quite a while for the $3 it cost to refill it.Thanks for the help and newb questions...
Reply:Originally Posted by Broccoli1Higher numbers do not mean more heat.basic formula for heat inputV*A*60/TRAVEL SPEED
Reply:.030 wire is good for this machine.Ed Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:OK so doing a little research. I might be wrong, please correct. But it appears as though CO2 requires higher input to keep a stable arc. That must be where the idea that "CO2 penetrates more than 75/25". Well it does, but only because the settings must be higher to maintain a stable arc. Looks like it doesn't have anything to do with the gas. OK that solves that mystery, looks like 75/25 is the preferred gas (75% Argon 25% CO2) but CO2 is so much cheaper (for me).Last edited by wheelsup; 02-14-2013 at 05:06 PM.
Reply:Originally Posted by wheelsupOK so doing a little research. I might be wrong, please correct. But it appears as though CO2 requires higher input to keep a stable arc. That must be where the idea that "CO2 penetrates more than 75/25". Well it does, but only because the settings must be higher to maintain a stable arc. Looks like it doesn't have anything to do with the gas. OK that solves that mystery, looks like 75/25 is the preferred gas but CO2 is so much cheaper (for me).
Reply:Originally Posted by Broccoli1Actually on the Passport machines the preferred gas is CO2- they designed the machine for CO2.
Reply:Just a couple notes.  I have the Multimatic which is supposed to be very very similar arc characteristics.1) The machine runs fantastic on C25.2) I pickup .030 wire from Home Depot (or was it Lowes?)  They are open till 10pm around here - very convenient.3)110V still has its limits.  Respect it.  Miller says 1/4" with the Multimatic, I find that on 1/8 when I turn the voltage up, when I run, the voltage doesn't actually go up.  Never tried thicker on 110V.  What I've come to like best about the machine is the smaller gun.  Combined with a very low spatter arc, its a precision welder.  I'm still trying to dial in the 350 to be as precise.  In comparison, the 350 is like wearing too thick gloves.  Oh and if you turn up the volts on the 350, you will burn through.I mostly use the 200 on a 50ft,  12 gauge extension cord.  I do plug it in to a 20Amp circuit (my house is 100% 12 gauge with 20Amp GFI on the outside or wet areas) but the plug is actually a 15 Amp plug.  I have successfully run it off a 15Amp circuit - just make sure nothing else is on (at a friends garage, seem to recall popping the breaker when he something else plugged in - maybe work light? - roughly 1/8" plate, in the flat)Con Fuse!Miller Dynasty 350Millermatic 350P-Spoolmatic 30AMiller Multimatic 200Hypertherm PowerMax 1000G3Miller Maxstar 200DX