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Mig welder overload relay tripping more often..

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Mig welder overload relay tripping more often..

Old 09-13-2013, 05:09 PM
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Default Mig welder overload relay tripping more often..

My brother sold me his Sears Craftsman Mig (model 934.20105) for $100. after he upgraded to some expensive model. It has been a great welder for me and has taught me the basics and I feel like I am now a pretty good shadetree welder! Lately though, it has been tripping more often. It is rated as a 20% duty cycle and lately seems more like probably 0.5% duty cycle! So, before I consider a new welder is there anything maintainance-wise I could do to see if it helps? I have opened it up and blew out the insides which did have some debris, but no rats nests or anything horrible. I did notice that the transformer/windings did have some surface rust, but nothing severe. I also thought the ground clamp could use some cleaning up, so I sanded the contact surface areas to make sure I am making good connections. I am leaning towards a new welder, and obviously I like the sound of that! but It is not like I use it everyday so if I can get this one working better I will.
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Old 09-13-2013, 05:16 PM
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I did not look that welder up to see if its 120 or 220. however I have one of each the 120 blows the circuit breaker all the time with prolonged welding. I think I need a dedicated 20amp breaker to avoid this. For small jobs it is great. Also are you using an extension cord?
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Old 09-13-2013, 05:35 PM
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Originally Posted by mikeloew View Post
I did not look that welder up to see if its 120 or 220. however I have one of each the 120 blows the circuit breaker all the time with prolonged welding. I think I need a dedicated 20amp breaker to avoid this. For small jobs it is great. Also are you using an extension cord?
It is 120vac and I should have it on a 20 amp circuit, but I don't! But I never have before and never had this trouble. And I am using an extension, but have always used one.
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Old 09-13-2013, 05:47 PM
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That is probably your problem, the extension cord. If you have to use one splurge on a good heavy gage cord. I also would bet that as you get better in your new found skill you are holding an arc much longer than when you first started. These 120v units do not like running for prolonged times. I have 2 Lincoln's and the 120 does this when ever I use an extension cord. My 220 never has this issue. On the flip side I have really found the 120v handy as 220 is not available like the 120v outlets. Hope this helps. And weld on.
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Old 09-13-2013, 05:48 PM
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With the information given I would ignore your current welder.

I would sabotage your brother's welder, with an easy fix that you know how to do.

He buys a new welder.

You get the upgrade you want for $200.

That's how our family works.
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Old 09-13-2013, 06:49 PM
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Originally Posted by Johnny Dreamer View Post
With the information given I would ignore your current welder.

I would sabotage your brother's welder, with an easy fix that you know how to do.

He buys a new welder.

You get the upgrade you want for $200.

That's how our family works.
LOL ya I would kick your brother in the go-nads, take a look at this http://www.hobartwelders.com/weldtal...hp/t-4271.html

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Old 09-13-2013, 07:08 PM
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Lately though, it has been tripping more often.
Have a fan blowing on it and you'll get more burning time with it.

Its overheating and shutting down.
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Old 09-13-2013, 07:32 PM
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As stated, 110 welders need a 20 amp circuit and a heavy duty ext. cord otherwise you'll just keep trippen the breaker.
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Old 09-13-2013, 07:42 PM
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Originally Posted by way557 View Post
Have a fan blowing on it and you'll get more burning time with it.

Its overheating and shutting down.
Yeah, the fan is working fine. I can take care of the supply power easy enough, it just never had this problem before. Going back to look at that link posted on the Hobart now....

Edit: okay, that wasn't what I was hoping for!
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Old 09-13-2013, 08:21 PM
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How old is the contact tip? Try a new tip and a good ground to clean metal is essential.
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Old 09-13-2013, 09:33 PM
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20A circuit is the first thing you need to do and 12 Ga or bigger extension cords only. House breakers are notoriously cheap and prone to failure under any kind of sustained load.
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Old 09-14-2013, 04:36 AM
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Originally Posted by PF-88 View Post
How old is the contact tip? Try a new tip and a good ground to clean metal is essential.
Have changed those out too.

Also, I am not tripping the house breaker, it is the built-in overload relay in the welder. It is one of those automatic reset overloads, so once it trips you have to wait until it resets.
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Old 09-14-2013, 05:00 AM
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Originally Posted by PF-88 View Post
As stated, 110 welders need a 20 amp circuit and a heavy duty ext. cord otherwise you'll just keep trippen the breaker.
correct o mundo,,,a dedicated circuit

I have a couple of welders without this set up your welds will be poor and eratic.
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Old 09-14-2013, 05:36 AM
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Change out the breaker and buy a heavy cord.

Another example but the same principle:

I bought an electric deep fryer. I had it on a drop cord. It would cook but it was very slow to recover and I really didn't like it at all. One day I moved it to a different location where it plugged directly into a receptacle. It cooked like a totally different cooker. The temp came up quick and it recovered instantly.
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Old 09-14-2013, 07:34 AM
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How long are you trying to weld before letting the machine cool down? Since it only has a 20% duty cycle, that means you can only weld for 2 minutes out of a 10 minute period then have to let it cool down.
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Old 09-14-2013, 08:26 AM
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Originally Posted by boat_beginner View Post
How long are you trying to weld before letting the machine cool down? Since it only has a 20% duty cycle, that means you can only weld for 2 minutes out of a 10 minute period then have to let it cool down.
You are correct, that is exactly what 20% duty cycle means. I am welding for 20-30 seconds before it kicks off.
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Old 09-14-2013, 08:42 AM
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Well I guess that isn't the problem then.
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Old 09-14-2013, 08:51 AM
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Originally Posted by PF-88 View Post
As stated, 110 welders need a 20 amp circuit and a heavy duty ext. cord otherwise you'll just keep trippen the breaker.
Also, the more load you put on a breaker the weaker it becomes. The weaker the breaker becomes the mor it trips....the more the it trips the weaker it becomes.

Soooo, if your breaker has been tripping more often then I would say it is high time for a new breaker....regardless of anything else.
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Old 09-14-2013, 05:51 PM
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Change out the breaker.
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Old 09-14-2013, 07:14 PM
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Originally Posted by docters oarders View Post
Change out the breaker.
So you mean the overload relay? I was also thinking maybe cleaning all the connections within the welder, not sure if that is worth the hassle though.
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