MIG welder problem

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my5thmopar

my5thmopar

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My old cheapo welder won't work anymore. I have 220 volts at outlet. Wire speed, 75/25 gas, ground is good. I'm getting a poor arc and the transformer is stuttering. It sounds like it wants to go but, very poor welding. Almost like I'm not getting enough voltage through the unit. Does this sound like the transformer? I'm guessing the Pri/Sec and be checked with a multimeter. Any suggestions? I know there was a member here that used to work on welders for a living. Found them @toplscuda in this thread: I've been following Mig welder
 
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Have you checked the contact tip for excessive wear?
 
Drive wheels ?
or
Stuff in the air will settle on the wire spool.
That stuff will build up in the liner for the gun and cause resistance to movement. Time for a new gun ?
 
Give me the make and model of it so I can see what I can dig up on it. I am ping some field work now but I is supposed to rain Thursday which will put me back in the shop if I need to access anything.
 
my5thmopar said:
My old cheapo welder won't work anymore. I have 220 volts at outlet. Wire speed, 75/25 gas, ground is good. I'm getting a poor arc and the transformer is stuttering. It sounds like it wants to go but, very poor welding. Almost like I'm not getting enough voltage through the unit. Does this sound like the transformer? I'm guessing the Pri/Sec and be checked with a multimeter. Any suggestions? I know there was a member here that used to work on welders for a living. Found them @toplscuda in this thread: I've been following Mig welder
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Transformer stuttering ???
I doubt that the transformer is the problem. Transformers have no moving parts. Unless you worked longer than the duty cycle and heated it up.
That could have caused the insulation to break down.
 
If you squeeze trigger safely away from ground and wire feeds smoothly its probably your ground. If the wire is "pulsing/stuttering " its your feed system. Some things to check for wirefeed issues are: Typically there is a liner inside the torch that gets clogged with use, rusty wire, loose tension on drive rollers, too small tip for weld wire size, too much tension on spool holder.
 
Thanks folks. I’m traveling today and will look at the suggestions when I get back home.
 
Transformers almost never fail in this way. Usually if they are overloaded, one winding can burn open like a fuse, or it gets internally heated and burns off insulation which can cause inter-winding shorts--and more smell--and smoke. In other words it is likely OK

I would check any and all connections, including those on the ends of the transformer windings, and any other terminations.

I would suspect the diodes/ rectifier. NOTE!!! Regardless of "internet wisdom" you CAN NOT test large amperage diodes with an ohmeter. The ONLY reliable way to check large diodes, such as in welders, large current power supplies or even alternators, is to LOAD them. This might be difficult if you don't have "some junk". "some equipment". "Some knowledge

If you have a carbon pile battery load tester, you could use that. you could remove the diodes, hook them up battery--load tester--diode--battery, and adjust the thing to draw 40-50A or so. measure the voltage drop across the diode with a meter. You should not see less than 1V or not much over a volt drop if that

This might be a potted "bridge" rectifier, and gets more difficult but can be done
 
my5thmopar said:
My old cheapo welder won't work anymore. I have 220 volts at outlet. Wire speed, 75/25 gas, ground is good. I'm getting a poor arc and the transformer is stuttering. It sounds like it wants to go but, very poor welding. Almost like I'm not getting enough voltage through the unit. Does this sound like the transformer? I'm guessing the Pri/Sec and be checked with a multimeter. Any suggestions? I know there was a member here that used to work on welders for a living. Found them @toplscuda in this thread: I've been following Mig welder
Click to expand...
i know this is several days old, but i just went through this with my old weld pac. was within minutes of going after a new one, when i happened to bump the amperage switch. started working again. guess the contacts were dirty. been working fine since.
 
It is done for. I did some troubleshooting and I didn't find anything obvious. I see Tractor Supply has the Hobart 190 on sale. Thinking about buying it. I've not had the need for dual voltage or portability. Any opinions on the Hobart 190?
 
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