Question about Campbell Hausfeld MIG / Flux Core Wire Feed Welder

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Flux core welders are burning up tips, insulators, and leads

We've changed whips numerous times, doubled up on the grounds, replaced the feed wheels and checked the feed wheel pressure, which is good, double checked the liners in the whips, and now we are at a standstill. Also checked our argon supply gas and mixing valves, which are all fine.

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  • NobleLumpkin May 11, 2010

    Are you using argon with flux core wire?

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Try to turn up the wire feed and the volts and pull the cup 1/8 inch past the tip

Posted on Jan 16, 2009

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Diagram of diode plate layout


You should have one contactor for the wire feed. And the tip should be hot all of the time. Trace the connections. The conductive strap from the gun whould go to one side of the main transformer secondary winding- usually to the current selector center contact.

If you disregard the diodes for a moment- the circuit completes through the ground lead. Somewhere, and it may be where the gun assembly attaches to the feed mechanism that the whole unit is shorting out- Is part of the cable from the assembly contacting the cabinet? Did you remove the feed assembly and were there insulating washers present? One of those may be knicked. Did a screw of the wrong length get put in?

The rectifiers can go into the circuit either way depending how you want it polarized- or omitted even to weld AC. Normally the rectifiers would go on the supply side, and not the ground- so it would be located betwee the current/heat switch and the strap that goes to the gun. Unless you put the insulting hardware on to islate the rectifiers from the heat sink. That heat sink is likely live that the rectifiers are mounted on, and as a result, you are shorting out the transformer. You can either iloate the heat sink with phenolic board and plasticscrews and nuts to attach to frame Or get the isolating hardware and iaolate the rectifers from the heat sink.

The grounding cable is the only thing that should be a metal to metal contact with the frame of the welder.

Sep 12, 2012 | Campbell Hausfeld MIG / Flux Core Wire...

1 Answer

Mig gas conversion for JobSmart 125 Flux Wire Welder


The other difference between gas/gasless is the ability to reverse the gun polarity which you can't do with a gasless only welder. You can get it to work but not safely and reliability could be an issue also.

Mar 06, 2012 | MIG Welders

1 Answer

SMALL PUDDLES NO PENATRATION WELDER IS FARM HAND 115 VOLT MIG//FLUX CORE WIRE FEED PUT ON ANY SETTING NO DIF CANT FIND MODLE IT HAS CHPOWER.COM WEB ADDRESS


Hi:

If you are using flux core wire you need to switch the polarity of the machine. With flux core wire, your ground clamp becomes positive (lead) and your gun the ground. All you need to do is switch the cables above the feed rolls.

That will take care of the problem

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Mar 20, 2011 | Campbell Hausfeld MIG Welders

1 Answer

I have a wg2020 campbell hausfeld flux core mig welder I have to turn my wire feed all the way on max to get the wire to feed. It seems like to motor is getting weak. Sometimes it seems to work right but...


Hi:

Sometimes the drive motor collect a lot of metal dust from the environment and it requires a clean up. Take the tensor off and remove all wire, try to apply compressed air into it and then apply WD40 and run it. Make sure your tensor wheel it's not to tight and that you are using the right wheel size for the wire in use. Another problem rely on the gun liner if this one hasn't been change in 12 months, it is time to replace it, or, if it is not kinked at all, try to use clean air to blast out all metal particles from it. (take off you gas nozzle and gas mixer also known as contact tip holder).
Good luck.
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Feb 25, 2011 | Campbell Hausfeld MIG / Flux Core Wire...

1 Answer

Just purchased and tried to use my flux welder. It jams before flux even comes out the handle.


have you tried adjusting the tension on the flux wire? before you start feeding the wire into it make sure there isnt any kinks in the wire. seems like it doesnt take much for it to bind up once you get start welding with it im sure you will run into this problem quite allot. usually its from welding the wire to the tip. i have to be honest it can ve a pain in the ***

Dec 30, 2010 | Firepower Flux Core Wire Feed Welder 88...

1 Answer

I have a problem with a jerking motion while Im trying to weld. the wire feeds out good without the tip on. I replace the tip but I havent replaced the cup but Im using flux core wire also. What could be...


I have found that keeping the gun lead as straight as possible fixes this problem. Also it is sometimes recommended to use one tip size bigger when welding with flux core wire. My last spool was radnor flux core wire .030, and a .035 tip keeping the lead as straight as possible and it welded extremely well. If that doesn't solve it you should take everything apart and clean it / blow it out with compressed air.

Oct 27, 2010 | Hobart Handler 140 Mig Welder

2 Answers

I am using flux core wire. The wire comes out. I


Is your grab rollers tight? Is it a new liner in the lead? If you are using .035 wire you can use a .045 tip. I generally use one size larger then what is required. You have a lot less problems that way. When you use flux core wire on most wirefeeds you have to reverse your positive and negative leads inside of the welder I assume you did that? If there is any moisture inside of the liner it can stick because it is grounding out when you start to weld.

Sep 11, 2009 | MIG Welders

4 Answers

My sp 135 welder is burning the wire


Check all the grounds, sounds like something is definetly grounding, check them all

Aug 30, 2009 | MIG Welders

1 Answer

Flux wire on Dual Mig Welder not feeding.


Change the contact tip.This is the most common problem. The tip gets burned and keeps the wire from feeding. You should always have extra tips on hand.

Aug 03, 2009 | RTO Flux Wire Welder Dual Mig 131 Ti 1 Gas...

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