welder illness diagnosis

[scott_shot]

Help all, i have had it up to here with my MIG haha but seriously it has developed a sort of cold,

Its a SuperMig150 with a Eurotorch conversion done by myself, Which has ran like a dream up until recently. When all set up start a weld no problem get say 100 mm or maybe 20seconds something like that (don't quote me) but then weather im continuing the weld or start another it will act like the wire settings are off. To be honest i reckon its an earth problem.
So the first thing i did was replace the steel liner with a new one with no result.
so i went a bit OCD with prep and de-greasing, I took off de-greased and fixed my heavy duty ground clamp back on and again no joy. I took off and cleaned the wire feed again yep you guessed it.

Anyone Know why its become consistently inconsistent or what could be the problem?

 

[rikrobson]

sounds like a fault with the wire feed. can you hear or see the wirefeed motor turning. if the motor is not turning I suspect it may be a problem with the controller board or the motor. if the motor is turning then the wire will be stuck , but it sounds more like a controller problem.

 

[scott_shot]

yeh the wire spool seems to turn fine and makes the same noise (from memory) as always but i will have to look into it further when i go out later. if the motor is turning, and as i have changed the liner and settings i know are fine then any idea what to check next?

 

[octo0072000]

check all the earth lead back to inside the mig remove the bolts clean up etc
you can use a car jump lead direct from inside mig to earth to rule out problems

 

[rikrobson]

have replaced the tip and is the tip the correct size. You could be getting burn back when you stop welding and therefore the wire is sticking to the tip preventing the wire from feeding when you want to start again. Mine sometimes does this on high currents. usually pick it off with the pliers and carry on welding

 

[scott_shot]

check all the earth lead back to inside the mig remove the bolts clean up etc
you can use a car jump lead direct from inside mig to earth to rule out problems

Do you mean from connect jump lead where the earth is connected inside to weld table and attempt to weld?

have replaced the tip and is the tip the correct size. You could be getting burn back when you stop welding and therefore the wire is sticking to the tip preventing the wire from feeding when you want to start again. Mine sometimes does this on high currents. usually pick it off with the pliers and carry on welding

I am quite sure thats not a issue replaced the tip when i replaced the liner. I know what you mean though that would happen alot when i was learning to weld

Cheers guys im sure i will get too the bottom of this yet lol

 

[rikrobson]

have you tried upping the wire speed at all?

 

[octo0072000]

Do you mean from connect jump lead where the earth is connected inside to weld table and attempt to weld?

yes

 

[the snooper]

not changed gas or wire recently have you ?

 

[coxm]

Is the mig gun trigger working corectly? Mine stoped working about 5 seconds into welding everytime, because the trigger contacts were moving around. It may not be the trigger, and im way off base, but if this sounds like it could be. Service it, or buy a new tourch

 

[arceyered]

Is the tensioner to tight .
Tensioner I hear you say lol'
What can happen is:-
If there is a slight bounce back or burn back the wire stops mommentarily, the feed continues and deforms the wire at the roller and every time it reaches the tip it repeats the cycle ie every 20 secs or so ?
Just a thought

 

[scott_shot]

Sorry forgot about this thread. well mostly down to my dire memory i cannot remember what i did but it started running fine all day. although that may be a bit of a sketchy memory lol shocking i know but im off my tablets on tuesday

Anyway when i next need to weld i will be sure to run a fair few beads along with practice pieces to make sure and if the problem persists i like the suggestions about the tension and the trigger wires. Cheers troops