Miller Dialarc HF : settings seem high according to charts.

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I am a total newb, and secound time practicing burning E7018 4HR , 1/8" on some 1/2" a36 steel. Started in the medium setting, on DCEP, and the amp percentage dial at 50%,Would not light, added 10% at a time, until able to light, at 94%. That is about 187 amps, 37 amps higher than the highest suggested setting. What am I doing wrong. I am not sure if I was burning too hot or the machine is not calibrated well. Checked the two jumpers, and were in position for 230volts. Any help would be greatly appreciated. Thanks,Raf
Reply:Tried scratching the tip of your rod? Sometimes 7018 can get contaminants stuck onto it. Takes a good scratch with a file or a broken grinding wheel to pull it off.
Reply:oops - read it wrong Last edited by MinnesotaDave; 04-27-2015 at 03:42 PM.Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:check your connections. Ground clamp and electrode holder. Make sure your leads are in good shape. Are you cleaning the scale off the metal? Doesn't need to be TIG clean, but it needs to be cleaner than 6010/6011. Also grind to bright shiny metal where you are placing your ground clamp. Are you sure you are on DCEP? How far is the welder from your main panel, and what size wire are you feeding it with?Miller Multimatic 255
Reply:Connections are good, ground clamp is on my new portable table, i did not clean the mill scale , but will try on clean piece, on DCEP, welder is only 5 -7 feet from subpanel of 100 amps and about 75 feet from main panel in basement.  A # 3 wire is feeding the welder. I did check the line input, and it was 212 amps instead of 220, but the jumpers are set for 230, because I was expecting 220. If I change the jumpers to 208, then at top end of dc 270, it will draw 103 amps instead of 90 amps. Any advice would be appreciated,Raf
Reply:That might be your problem. I think you want to have less than 3% voltage drop. Your panel should be supplying 240 volts. If you are measuring 212 volts, that's an issue. It is way too much of a voltage drop. You need an electricianMiller Multimatic 255
Reply:Originally Posted by Louie1961That might be your problem. I think you want to have less than 3% voltage drop. Your panel should be supplying 240 volts. If you are measuring 212 volts, that's an issue. It is way too much of a voltage drop. You need an electrician
Reply:There is chart for that?My Dialarc simply said percentage and range.Medium DC was about 40-190 Amps.    So a range of 150 amps.   At 50%, that would be .5 * 150 + 40 or 115Amps.  At 90%, thats .90 *150 + 40 or 175Amps..95 would be 182.5 Amps.I ended up making a spreedsheet and leaving a copy on the machine.As for input power.  Most houses are actually about 120 (1/2 of single phase) and typically 240 ish on a full phase.  My house was running 126V last time I measured.  Seems like I was replacing light bulbs monthly.  The power company has since replaced whatever regulators they have and I have not rechecked since.So... you may be a little light on power and a little optimistic on how much current your actually putting out.I don't typically run 7018 at 1/8" so I'll leave others to comment on that.  The machine itself is super simple inside, can't imagine anything actually failing unless you got the transformer really really hot (enough to melt the insulation off the wires).  Maybe borrow clamp style current meter and see what you are really pulling?Con Fuse!Miller Dynasty 350Millermatic 350P-Spoolmatic 30AMiller Multimatic 200Hypertherm PowerMax 1000G3Miller Maxstar 200DX
Reply:Thanks to all of you,My electrical company I hired did all the work, upgrade from 100 amps to 200 amps. Also set up the welder as far as connectint to a line disconnect and into the 100 amp breaker, letting the line disconnect be the switch. The guy I hired turned out to be a real alpha hotel. He yells all the time, and never gives me a straight answer. But his workers are super nice and do nice work. It sounds like I need to check the leads with ampmeter while burning an electrode to see the draw. Btw, The dial was set to 94%, so probably close to 185?I will check draw, and recheck incoming with no load , and if still at 212, will move the twp jumpers to the end positions shown in the manual for 208. I will let you know how it goes,Thank you all for the help,RF
Reply:Check to volts on the line side, not the amps. On the output side you could check the amps with a clamp on ammeterMiller Multimatic 255
Reply:Most machines allow for 10% voltage fluctuation. There could be some kind of adjustment in the machine to have the readings on the dial closer to actual amps. Our local repair guru on here would know.
Reply:212V is well within the acceptable range for 208V service. "Upgrading" the service will not appreciably change the voltage unless they change the type of service going from the pole to your building.If you are reading 212V at no load then you should change the jumpers on your Dialarc to the 208V position.JohnA few weldersA lot of hammersA whole lot of C-clamps
Reply:Changing the jumpers may work, but it is a hack. The voltage is supposed to be 240v, and there is a problem with the panel or wiring if it is only delivering 212v. Something is wrong somewhere. If it were me I would want to fix it, just to be sure there isn't a fire hazard lurkingMiller Multimatic 255
Reply:Originally Posted by Louie1961Changing the jumpers may work, but it is a hack. The voltage is supposed to be 240v, and there is a problem with the panel or wiring if it is only delivering 212v. Something is wrong somewhere. If it were me I would want to fix it, just to be sure there isn't a fire hazard lurking
Reply:that could be part of the issue. All other things being equal, a voltage drop is due to increased resistance which usually translates to conductors that are too small, bad connections, wire runs that are too long for the size of the wire, etc. If they haven't changed the service from the pole, that may be the issue.Miller Multimatic 255
Reply:Originally Posted by Louie1961that could be part of the issue. All other things being equal, a voltage drop is due to increased resistance which usually translates to conductors that are too small, bad connections, wire runs that are too long for the size of the wire, etc. If they haven't changed the service from the pole, that may be the issue.