I have a wg2020 fluxcore welder that makes a grunting noise when trying to initiate the weld. wire runs out fine but the heat seems to be low.
http://www.chpower.com/IMAGES/pdfs/manual08/212800_0799.pdf
T1 or T2 may be in the early stages of failure from shorting out. If you are getting a burned varnish smell that persists around the welder, that is the likely cause. Check open circuit voltage, it should measure around 24 volts. If you only measure 12 volts, the bridge has failed.
Otherwise, open it up and check all connections to make they are sound. There is a protective device on the bridge rectifier across the terminals to the ground clamp and gun. This device may be failing in a short circuit mode. Or the bridge rectifier may be failing.
In the event it is the bridge that failed, a workaround is to construct or provide a 24 volt supply to the motor speed control, move the AC connections one to the "+" and one ot the minus terminal thus bypassing the bridge rectifier completely, and use the welder as an AC welder. Or alternately a new one can be constructed from 4 high current rectifiers.
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