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Low welding current - Solar Welding Tools

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  • Chris Brown Sr.
    Chris Brown Sr. Feb 23, 2012

    Thanks Mr. Coleman, I checked that and it was ok. Great suggestion though! I found the problem. It was that the wireing inside the whip had actualy burned out at the gun. I shortened the whip and used a piece of copper pipe as a new crimp. Solved the problem. One of those weird things. I was only getting trickle voltage through the liner. Thanks again.

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I had same problem ckeck the voltage to your outlet and try re-setting the breaker.hope this helps. i had to replace the 50 amp otlet.

Posted on Feb 18, 2012

  • lee coleman Feb 18, 2012

    i had same problem ckeck the voltage to your outlet and try re-setting the breaker.hope this helps. i had to replace the 50 amp otlet.

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6ya6ya
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SOURCE: I have freestanding Series 8 dishwasher. Lately during the filling cycle water hammer is occurring. How can this be resolved

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Posted on Jan 02, 2017

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Welding troubleshooting


You could pass voltage but no welding current if the current carrying cable inside the mig gun has a break in it. Inside the mig gun is a braided copper current passing cable, if it only has a few strands of wire to complete the circuit it will not pass weld current.They usually break where the mig gun has been flexed over time.

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Electric resistance welding (ERW) refers to a group of welding processes such as spot and seam welding that produce coalescence of faying surfaces where heat to form the weld is generated by the electical reistance of material vs the time and the force used to hold the materials together during welding. Some factors influencing heat or welding temperatures are the proportions of the workpieces, the coating or the lack of coating, the electrode materials, electrode geometry, electrode pressing force, weld current and weld time. Small pools of molten metal are formed at the point of most electrical resistance (the connecting surfaces) as a high current (100-100,000 A) is passed through the metal. In general, resistance welding methods are efficient and cause little pollution, but their applications are limited to relatively thin materials and the equipment cost can be high. although in production situations the cost per weld may be as low as $.04 usd per weld depending on application and manufacturing rate.

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Blow air through cabinet to clean out the dust- low pressure. Check for continuity across the reactor. if you connect one test lead to the terminal "R4", should be a tape label on the connection. The other connection is "S1", you should see less than 10,000 ohms.

Check the weld polarity switch to make sure it is not damaged. If you have AC welding but no DC- check L1 the choke in series with the + connection on the bridge rectifiers.

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WHEN I TRY STRIKE AN ARC WITH A ROD YOU HAVE TO HIT IT 5 OR 6 TIMES TO GET IT TO WELD ITS HARD TO KEEP IT GOING BUT AFTER 4 OR 5 SECONDS IT WILL BURN LIKE NORMAL (USING PROPER AMPERAGE)


Is this on new rods as well as one's you'be been already welding with? Depending on rod types, some will "flux over" the end, after welding insulating the tip. When you're welding at a low setting, with a small rod, sometimes it is hard to start an arc. A 7018 rod is a good example of this. Strike the rod like a woodden match, or drag it on the metal, to expose the rod. It also depends on your welder. Some have settings to help start an arc and then control the current. Older transformer welders arn't that smart and are less forgiving on low current thin metal settings.

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poor joint design / and or preparation, electrode diameter too large,
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Solutions: Decrease travel speed, increase welding current, increase root
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I have a problem with **** inclusion in my welds. I am using 3/32 6013 electrodes on a small AC unit. I am welding 1/8 inch mild steel plates in a 2F configuration. When I start the weld I produce is...


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If you weave too wide you will loose the fluidity on the weld metal, meaning you will be welding over the ****.
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Hello there
here are some easy steps to see if these will help you ok
best regards michael
  1. See if the wire is feeding properly. A worn drive roller can affect the feed and cause it to slip. When you're checking, look for debris and dirt on the liner. This can also cause bird nesting. Sometimes troubleshooting welding machines is as simple as cleaning it and allowing the wire to move freely.
  2. Step 2 Look at the tip near the wire exit, inside of the gun. A worn out tip doesn't allow the electricity to efficiently hit and creates a lot more work on the job. Burn back can cause a bad wire.
  3. Step 3 Clean the welding cup of the splatter. This task seems mundane, but troubleshooting welding machines usually involves clean components. Proper gas coverage cannot occur if the cup is plugged.
  4. Step 4 Inspect the ground clamp. When this part is coated with oxides, electrons can't readily transfer. A bad ground **** can cause a lot of resistance and change the way that the current comes back to the machine.
  5. Step 5 Examine the welding cable for worn spots. A badly worn cable can cause problems.
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