Century Wire Welder Troubleshooting

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1. Century 100 Welder
2. Century Wire Welder 110v

1. So, here are some common welding problems that you should watch out: Welding Cracks; Among all those welding problems, crack is the most common and serious in nature. Over the passes of time, such cracks get larger. You can notice a crack on the surface or in the weld metal. There are so many reasons why welding crack happens. One of the prime reason is poor joint design. If your welding speed is high but the current is low, the crack may happen.
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3. May 18, 2011 Pull the welding wire through the welding gun, and then insert the welding tip over the wire. Screw the tip into position, and then try the welder to see if the wire feeds. If not, continue to the next step. Welders that won't feed welding wire typically have one of two things causing the problem.

Intro about Mig Welder Troubleshooting:

Just like all welding processes, mig welding has its own complications. Now, you shouldn’t let common problems slow down your welding process. With a sound knowledge of some troubleshooting skills, you can find the right solution to your welding problems. This article covers in details, the best Mig Welder Troubleshooting for the operators.

Some common/Basic problems:

Machine doesn’t start:

• Cause: When a mig welder machine doesn’t start, it can be due to a lot of reasons. Some common causes may be a dead power circuit, a blown-up fuse or simply a wrong voltage input. It could also be as a result of overloading.

Century MIG Wire Feed Welder Manuals & User Guides. User Manuals, Guides and Specifications for your Century MIG Wire Feed Welder Welding System. Database contains 1 Century MIG Wire Feed Welder Manuals (available for free online viewing or downloading in PDF): Welding instruction manual. Before you do anything unplug the welder from the wall. Put some safety goggles on and short across the two capacitor terminals with a screw driver Twice. If the resistor is bad you may get some large sparks. You may not get any sparks with your current problem.

• Solution: If your machine does not start, first, make sure that it is switched on. If yes, check for the possible cause of the problem and fix it. The voltage input should be checked to ensure that it complies with the manual and avoid overloading. If it is overloading, it’s best you let the device cool off for some time. You can also replace the fuse, if it is blown.

Welding machine starter works but blows fuse:

• Cause: When you turn on the switch and the starter works but the fuse suddenly blows, it may be either as a result of short circuit in the connection or the fuse might be too small for the machine.

• Solutions: Check the connections and correct any short circuit. If the fuse is too small, it should be replaced with a bigger one.

Polarity switch Stop working:

• Cause: If the polarity switch stops working, it may be that the switch is worn out or may be due to use of the switch when the welder is under load.

• Solutions: A worn out switch should be replaced. Also, ensure that you do not use the polarity switch when the welder is under load.

Excess heats up Electrode holder:

• Cause: If the electrode holder heats up, there might be a loose connection or an inappropriate duty cycle of the electrode holder.

• Solutions: Tighten any loose connections and in the case of an inappropriate duty cycle, then the electric holder should be replaced with the appropriate size.

Electrical shocks Occur while touching the welder:

• Cause: Electrical shocks on welder may occur if the frame of the welding machine is not properly grounded.

• Solutions: In case of electrical shocks, you must read the user manual; follow all the instructions about the grounding procedure of the frame. If the frame is grounded properly, you will not experience electrical shocks.

Overheating of Welding cable:

• Cause: If the welding cable gets heated really fast, it could be as a result of incorrect cable size or inappropriate duty cycle.

• Solutions: Replace the cable with the appropriate size stated on the user manual.

Bad ground clamp:

• Cause: The ground clamp may turn bad and begin to malfunction. In most cases this happens when the machine gets coated with oxides which may alter the flow of current and create high resistance on the machine.

• Solutions: Ensure you check and clean your ground clamp regularly to avoid any build-up of oxides and prevent resistance of the machine.

Damaged cable:

• Cause: Cables can get damaged after prolonged use.

• Solutions: if you notice any sign of damage on the cable, it should be replaced immediately. Damaged cables can lead to several problems and can also affect the quality of your work.

Welding machine doesn’t switch off:

• Cause: If you switch off your machine and the mig welder doesn’t go off until you cut off the power supply, it simply means your line switch is worn out.

• Solutions: The line switch and connection should be repaired or possibly, replaced.

Welding defects:

If you notice welding defects, it means that some parts of the mig welder itself have malfunctioned and such parts should be adjusted and repaired. Below are some common welding defects including their possible causes and solutions.

Improper wire feeding:

• Cause: A very common welding defect may be as a result of improper wire feeding which is caused by a worn out drive roller.

• Solutions: Periodically remove the drive rolls and clean with a wire brush to remove any dirt on the liner that may affect the pressure and grip it would have on the wire. Also, inspect the drive rolls for wear, and replace if worn-out.

Low welding:

• Cause: Low welding defects occurs when the tip of the welding gun is worn-out. When this happens, the welding will not be properly done.

• Solutions: Replace the tip of the welding gun immediately as this might result in other problems.

Porosity:

• Cause: Porosity may occur on the surface as a result of inadequate gas flow or bad wiring. It is a very common welding defect.

• Solutions: Check the gas line and clear out any obstruction. Also, the gas nuzzle should be plugged in correctly to avoid leakage. Ensure that you check and adjust the wire connections properly.

Shrinkage Cracks on the weld:

• Cause: If you notice shrinkage cracks on your weld, the bead may be too small and concave or the wire is rusty.

• Solutions: Make sure that the beads are of adequate size. Clean the wire to be welded properly. Ensure that you do not leave any dirty or rusted area where the welding is to be done.

Lateral cracks on the weld:

• Cause: If you notice lateral cracks on your weld, it may be due to fast welding speeds or very low current and a high voltage of arc.

• Solutions: Lateral cracks can be avoided by maintaining a steady welding speed and avoid welding too fast. The current flow and arc voltage must also be steady.

Excess spatter:

• Cause: Excess spatter is a very common welding defect and is caused by either excess CO2, high voltage or as a result of inappropriate impedance.

• Solutions: Excess CO2 can be heated up using a gas heater. Excess spatter can also be avoided by applying the correct voltage.

Advanced welding problems:

1. Weld Metal Porosity:

Porosity Problem #1:

• Improper Surface Conditions: A contaminated surface (with rust, oil, grease, etc.), laminated surface or incorrect surface treatments may lead to weld metal porosity. Also, any surface that is open to atmospheric air can be contaminated. Incorrect surface treatments such as zinc coating or galvanizing may lead to porosity problems on your weld.

• Solution: The remedy for contaminated surface is to clean the material following specified surface preparation procedures. Ensure that the weld joint is protected from air crevices to prevent contamination. Also, when welding a laminated work piece, ensure that you prepare an un-laminated parent metal to conduct a quality weld procedure.

Porosity Problem #2:

• Gas Coverage: Inconsistent gas shield may also lead to porosity problems. The shielding gas is supposed to protect the weld puddle from air and at the same time act as its stabilizer. Porosity occurs when the shielding gas is altered and air contaminates the weld puddle.

• Solution: First of all, check the gas hose attachment with the equipment and remove hose contamination, if there is any. If the connection is correct, there will be no loss of gas shield and no air entrapment. Also, use the appropriate amount of shielding gas stated in the user manual and ensure that the shielding gas flow is set properly.

Porosity Problem#3:

• Base Metal Properties : Another common cause of porosity is the chemical properties of the metal. A common example is when your backing bar material does not match the metal you are welding.

• Solution: If your porosity problem is as a result of the base metal properties, the remedies may vary. If you are using a backing bar, for instance, you should ensure that it is made of the same metal you are welding.

2. Improper Weld Bead Profile:

Improper Bead Problem #1:

• Insufficient Heat Inputs: Insufficient heat inputs may lead to improper weld bead. If the bead appears to be ropy or convex, it is an indication that the setting being used is too cold for the width or thickness of the welded material.

• Solution: First, determine whether the amperage is ideal for the thickness of the material you want to weld. If the amperage is high, enough, check the voltage. It may be that the voltage is too low and this may lead to other problems. A good way to test if the voltage is set properly is by listening to the arc sound. A cracking sound, steady hiss or a loud sound are as a result of high amperage, high voltage or low voltage. At normal amperage and voltage, the arc should have a steady buzz.

Improper Bead Problem #2:

• Technique: Using an improper welding technique may also lead to a concave or convex shaped bead.

• Solution: For best results in bead profile, a push angle of 5 to 10 degrees is recommended.

Improper Bead Problem #3:

• Inadequate Work Cable: When the work cable in inadequate, it can result in inadequate voltage at the arc. Inadequate work cable can lead to improper bead shape.

• Solution: When work cables are too small or worn out, they tend to overheat. Such cables should be replaced with the appropriate size and length based on the current being used. For instance, a high current and long distance will require a large cable.

3. Lack of Fusion:

Lack of Fusion Problem:

• Cold Lapping in the Short Arc Transfer Process: Lack of fusion may occur as a result of cold lapping in the short arc transfer process. In this process the wire directly touches the weld pool and the end of the wire melts and detaches a droplet as a result of a short circuit in the system. Fusion problem occurs when the metal in the weld pool melts but there is not enough energy left to fuse it to the main plate. However, it is difficult to detect a lack of fusion visually, unless through bend or ultrasonic testing.

• Solution: First, ensure that you set the amperage and voltage correctly. If the problem persists, you may need to change the welding technique. The spray-arc transfer method is highly recommended.

4. Faulty Wire Delivery:

Faulty Wire Delivery Problem #1:

• Contact Tip: Faulty wire delivery may be as a result of the contact tip. The contact tip can get clogged-up from excess spatter or from touching it on the weld puddle. Also, the wire might wear grooves into the contact tip, in which case may lead to faulty wire delivery. Using oversized tips can also be problematic.

• Solution: The contact tip condition can be fixed by simply replacing the contact tip. Also, ensure that you use the appropriate size of contact tip in the gun and examine it periodically to check for wears.

Faulty Wire Delivery Problem #2:

• Gun Liner: Improper gun liner size can lead to a faulty wire delivery system. Also, over-tensioned wire may also flake-off and place particles inside the liner and clogging it up. When this happens, the delivery will be faulty.

• Solution: Ensure that the gun liner is the proper size for the wire being used and it should also be cleaned periodically to free it from dust and debris. Liners should also be replaced regularly.

Faulty Wire Delivery Problem #3:

• Worn Out Gun: Worn out gun may also lead to wire feeding problems. The copper strands inside the gun eventually breaks and wears off with time and this can lead to a faulty wire delivery problem.

• Solution: A worn out gun should be replaced immediately. You should also ensure that the gun is large enough for the application.

Faulty Wire Delivery Problem #4:

• Drive Roll: Drive roll pressure is a very common problem that leads to faulty wire delivery. When it is too loose or too tight, you either have no wire feeding into the puddle or it can crush the wire, wear out the rolls and damage the motor. Over-tightened drive roll tension leads to all these problems and can also place excessive pressure on the drive shaft.

• Solution: There is no exact pressure needed to ensure proper drive roll pressure. However, drive roll tension should be adjusted such that it is neither too tight nor too loose. The drive rolls can be adjusted side by side to ensure that they are in line with the inlet guide to the gun. Also, drive rolls wear out periodically and should be replaced.

Conclusion:

With constant practice and good equipment care, you can reach a point where your technique and mig welding equipment will enable you to create perfect welds on the first pass. However, until you reach that point, a sound knowledge of Mig Welder Troubleshooting steps can help welders correct technique errors and ascertain equipment issues quickly.

In modern life, advance technology attaches to us everywhere. Among the technology, a MIG welder is an essential tool. What is a Mig welder, and why you need this? A Mig welder helps your devices making the job more straightforward. To develop home tools like furniture or construction sites, need several tools to prepare for design and build a well living condition. In this condition, a Mig helps to make or resize tools in a quick moment. Where it used most? Most of the construction sites, furniture develop mills, and tools developer well renown about Mig. By its using sides, they face some mig welding troubleshooting issues. In this troubleshooting issues, have some common problems and solution. The expert well recognized the common issues and resolution. Like a beginner, they can’t suitably find out the issues. Let’s see the matter according to experts views:

Cause: There are several features and types of Mig in this century. Some uses for tools are shaping and some applications to develop new tools. In the examples of the machine, they may not start or become hang for many reasons. The reason are :

-Power Supply Problem
-Power Cod or wire burned
-Internal coil, fuse, and circuit get jammed and dead
-Get water wet – so that causes electric function may burn
-Overloading power voltage

Solution:First, all of to make sure your machine performance, its switch getting works or not. If the switch is okay then plugs and rest function will work correctly, to get swift action, use digital Mig that helps you to monitor self the power supply and your machine overall loading performance. If you want to work for several hours a day, then don’t run your machine for a long time. Give rest self and your device after running 20 minutes at once shift. Then start after 10 minutes break and find your machine as newer as like the first touch.

Cause: If you switch off your device and the Mig welder doesn’t go off until you cut off the power supply, it means merely your liner needs to switch out.

Solution: By switching liner and connection, it helps to replace things, worn and get back your job in quick time.

Welder become defected :If you notice your welder get jammed or not turn on, it means that some parts of the MIG itself need to malfunction. These parts need to take some actions and repaired. Below are some common welding defects discuss with solutions.

Cause: A widespread welding defect may be as a result of improper wire feeding, which is caused by a worn-out the drive roller from a welder.

Solution: Periodically remove the drive rolls to clean up your welder to use it next time as fresh. Use a wire brush to remove the dirt on the liner. By doing this, it removes pressure and helps to hold in hand smoothly and operate. Also, inspect the drive rolls time to time for wear, and replace if it is worn-out.

Cause : Small welding defects occur when the tip of the welding gun is worn-out. When this happens, the solder will not process correctly.

Solutions: Replace the tip from the welding gun immediately.

Cause : Permeability may occur on the surface as a result of inadequate gas flow or bad wiring. It is a prevalent welding defect. There is another reason is, gas permeability factor it arises due to Inconsistent gas shield. It also happens by over lead to constant problems. Permeability occurs when the shielding gas altered and air contaminates the weld puddle. We suggest, use shielding gas to protect the weld puddle from the wind. At the same time, it works as a stabilizer.

Solutions: Check every use before the gas line and clear out the obstruction. Also, the gas shield needs to be plugged correctly to avoid leakage. Ensure first, your wire connections stay appropriately. First of all, check the gas hose with the tools and remove hose contamination. If the link set correct, there will be no loss of a gas shield. It helps to secure the body and environment. So, check the appropriate amount of shielding gas stated in the Mig; for this, you can follow the user manual to ensure your best handling.

Cause : Metal is a tool which used for many purposes like made hardware tools, furniture likes bed, almirahs, building construction sites, etc. purposes. To use Mig on metal, a welder needs high voltage electric power supply as well as its functional power to cut in a simple touch. It doesn’t so, a machine can damage sooner.

Solution: So from the facts sides, the solution is to advise you, don’t give to pressure on the metal side either on the device, both may disrupt your job and reason for the machine.

Cause: Check out your machine wire, voltage performance, and overall machine sides before every work.

Solution: Drive rolls tend to wear out eventually, and so they need regular replacement. Also, I need to check the grooves on the rolls for any visual indications of wear.

Cause : Bird nesting is a big issue for welder function. It involves tangled wire, which leads to halting the wire feed.

Solution : To avoid the problems, you need to Flip up the drive roll and pull the wire out first. Make tangled trim wire and re-thread from back part. Also, make sure that it does not stay at higher. By this method, your nest and welder both become fresher.

Cause : The backside of welder may burn by overloading voltage. Another cause of cooking, if the welder built-in hardware, they cause of burn by running.

Solution: By using plodding wire feed speed with a gun, it helps to close the base metal, which leads to wire melting and fusing with the contact tip. Then replacing the damaged contact tips and increase the wire feed speed to make sure that you maintain an appropriate distance between your gun and work piece. Let's startup with a new mood!

Cause: It can be liner blockages, the use of a wrong-sized ship or improperly trimmed coatings.

Solution: The gun liner must shape according to the way to use the wire fed through. In case of a blockage, need to check and clean or replace the liner. Also, check the manufacturer’s directions before receive your order.

Cause : Check copper strands that located inside the gun. It helps to work fine. So use manual and check the break and wear out with same time — the results come faulty by wire and electric power supply.

Solution : During use, if you notice that a particular area is getting very hot, it’s a clear indication of internal gun damage. To prevent the issues, immediately replace the firearm.

Cause: If the electrode holder gets overheated, there might be a loose connection or an inappropriate duty cycle. So, replace the electric line.

Solution: Tighten the loose connections, in the case it faulty plugs or inappropriate duty cycle occurs. Then the electric holder needs to change.

• ​​​​​Problem #7. Electrical shocks Occur while touching the welder

Cause : Electrical shocks on welder may occur if the frame of the welding machine is not grounded correctly.

Solution: In the case of electrical shocks, you must follow all the instructions with the user manual first. Also looks welder frame how it attaches on the ground. The framework of welder needs to ground correctly, that prevent you from electrical shocks.

Cause: If the welding cable gets heated fast, it results in incorrect cable size or duty-cycle.

Solution : Replace the cable and follow the user manual.

Cause : The welder cables might damage by over-usage.

Solution: By notice any sign of damage in the cable, you have to change cable as soon as possible. It is so advised to replace damaged wire quick to get quality time work.

Cause: During running the welder, shrinkage cracks on your weld may occur. It happens by the bead may be too small and concave, or the wire gets rusty. By insufficient heat from inputs, may lead to weld bead. If the dot appears to be ropy or convex, it is an indication that the setting needs to use too cold for the width or thickness of the welded material.

Solution: First, determine the amperage disrupt. It is ideal for the thickness of the material that you want to weld. If the amperage gets higher, check the voltage. It may be that the energy is too low, and this may lead to other problems — an excellent way to test if the tension set correctly by listening to the arc sound. You find cracking sound, steady hiss, or a loud noise are by the result of high amperage, high voltage or low voltage. Arc average amperage and tension, the arc should have a steady buzz. Make sure the beads are adequate in size. Clean the wire before every weld in the right way. It helps to work in better form and keep you safe.

Cause : If you notice oblique cracks on your weld, it may be due to fast welding speeds by the high voltage of arc.

Solution: Lateral cracks avoided by maintaining a steady welding speed and avoid over speeding running. The electric flow and arc voltage need to stay and run in constant tension.

Cause :Excess spatter is a widespread welding defect and caused by either excess CO2, high voltage, or as a result of inappropriate impedance. The weld puddle can melt the metal and leave the spatter along with the bead. It may disrupt the weld appearance and lower the strength by damage fusion.

Soluation: Excess CO2 can be the reason for overheating up using a gas heater. Excess spatter can also avoid by applying the correct voltage. Essential to use accurate contact tips and nozzles, as it can lead to an erratic arc and result in excessive spatter.

Cause: Using a forehand technique often in a flatter bead shape.

Solution: for this often, the ideal technique is to use an angle between 5-10 degrees.

Use Cold Lapping Short-Arc Transfer Process: Lack of fusion occurs by cold lapping through the short arc transfer process. In this process, the wire should touch the weld pool in the right forms. The end of the wire get melts and detaches by short circuit system. Fusion happens due to the metal weld pool melts.

Century 100 Welder

Solution : First, set the amperage and voltage power correctly. If the problem persists, though, you may need to change the welding technique. The spray-arc transfer method highly recommended.

Century Wire Welder 110v

In summary to say, until you cover a sound knowledge of Mig Welding Troubleshooting steps can clear and help you to handle the machine properly. By following the guideline, it allows welders to correct use technique and stay away from disrupting things to complete job smoothly and smartly.