Got 50 volts open circuit DC. Would appreciate wiring diagram for that model if possible. Checked the selector switch in all 4 positions and 'off'. Small spark on the wire, that's all.
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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.
switch from tig welding to mig by switching your current from AC to DC for mig. change from your tig gun to your mig gun. turn water flow off. proper ground and weld away.
Hi:
27 volts is enough to weld. Have you check the polarity connection according to the wire you are using?
Solid wire: Ground clamp to negative pole.
Flux cored wire: Ground clamp to positive side of the pole.
Since you did not mention here brand or model of welder; I'm pretty sure that your machine it's an AC/DC machine, the series of slotted plates means that the machine will output 50 amps in AC or 80 on DC. 60 in AC or 125 in DC. If you want to work with lowest amps available, just put the selector on AC and connect your cables to the 50/80 amp side. You should have a selector lever to switch back and forth from AC to DC in front of the unit.
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.
Also check cable A4 that connects between the bridge rectifiers and the current selector switch. Make sureit is intact, and clean terminations.
Check your input line voltage. 115 volt Mig welders / plasma cutters need stable voltage / current. Test to see if the voltage drops to below 100 volts when welding. If so, find a more stable power supply.
Maybe you can get lucky like I did . Some times the acr volt selector switch gets corrosion in it and wont let the circuit board know to send power to the wire feed motor. You can cycle this arc volt. switch in my case it is the a,b,c,d,e, switch back and fourth a few times and this will brake the corrosion and your wire might feed again as mine did . This corrosion build up happens from not using and or sollecting the switch much usually on a welder at hm that gets very little use. it is common good luck .
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