problems with my lincoln mig

I was working on my truck on Satuday night when my welder quit getting hot enough to create a penetrating weld. Have you guys ever had this happen before. Its only a 110V, but it usually gets the job done. I had it on the highest heat setting (4), with the gas at 12-15, and the wire speed at 3.5. Any ideas???

 

check your 110 supply make sure nothing else ls on that circut

 

Are you using an extension cord? If so they cause resistance and rob power,If not refer to Hilo.

 

Good tips already. Here's one more.

A 15A circiut isn't going to cut it, either. You need to have it plugged into a 20A for good performance.

 

Mine did the same thing when it was almost new. It had to go to the welder Dr. for some help.

 

Did you install a different roll of filler wire?
Maybe of a different gauge?

 

If its a newer model, then the circut board could've died & that's pricey....like you just need to buy a new welder pricey. If it's an older model....it couldv'e blown a di-ode in it, which can be fixed relatively cheap if you know someone who can work on welders. I blew a diode in my 110 & it was unbelievably small compared to the replacement put back in which came out of a 3phase unit.

There's also an extremely small duty cycle on 110 units, so you kinda need to watch the watch when burning wire....cause you can over run that duty cycle like it's nothing. Especially when your only looking at 2 minutes of continual weld time out of 10 minute cycle...leaving your machine plugged in and in the on position with the fan going for the other 8 minutes to cool the machine down to 'restart' your duty cycle.

Carl Hagan

 

My money is on the duty cycle. Infuriating when trying to get something done but all 110 units do it. Lincolns and Hobarts/Thermadynes are 1.5-2 min burn time max with 8+ cool down.
Small lincolns work or don't so the duty cycle is likely the only culprit. An extension cord will greatly exagerate the problem.

 

Thanks for the insight. I think it might have been duty cycle, but I am going to look at the boards tomorrow. I have wired my garage with 3 20 amp circuits and each circuit only has a 4 plug outlet on it. Nothing else was on. I try not to use an extension cord with the welder, knowing how hungery it is. I hope its not the board, the welder is only 5 years old, and I just switched it from flux core to a real mig and have been so happy I did.

 

Check ALL the cable connections. Often the ground clamp cable connection gets frayed or loose. Check all the connections back to the transformer. There are cable connections inside the unit that may need attention. The handle should not get warm when welding. If a connection is warm or hot, there is some arcing taking place where it shouldn't be. A little arc here, a little arc there...pretty soon there is nothing left for the business end. Pull the cover of the machine and strike an arc with the lights off. Clean and tighten anything that arcs. (with the unit unplugged of course)

It can be much the same as battery cables... a good battery and starter but dirty cable connections keep them from working correctly.

 

it sounds like you exceeded the "duty cycle" which is with a 110v machine is easy to do. every welder i looked at for someone needed the ic board replaced which resulted in throwing the welder out and replacing it. i have seen brand new welders with added cooling fans and problem is componets on ic boards just won't handle the heat and melt.

 

Clean the contacts on the groundclamp to the frame. Often they become arked /curroded.
Choose the shortest path from the groundclamp to your work.
Clamp to clean steel, not paint.
NO extension cords.

My 110 Lincoln is fussy that way also. It WILL penetrate when evertyhing is done right. If not...its a grab bag.

 

Just let it cool down, those 110's don't have a long duty cycle. I turn up the power to the next step,when that happens. But don't do that if you are welding a frame or something important. And don't use a extension cord!