Thread: Troubleshooting the Transmig 195

I would be quite surprised if it were a gas issue. A mig will run with a decent arc and not just soften the wire as you describe with no gas, (bottle turned off). The weld however will be fluffy and porous.
If the wire is simply melting and getting soft it is an electrical issue of some type. Try earth lead/clamp, connection onto work, (rust, paint etc) or perhaps we get back to the original thought of a faulty power source. It pays to check the internal high current connections also.
A few pictures of the bead would help.

I have just tested two cigweld 250 machines at work and one of them did just what you described. We then had a local electronics guru look at it and he diagnosed the recifier is shot. This machine is only a few years old and we are unable to source a new rectifier to suit. I would be saying good luck in your quest to get that old machine working again.

Robert

Originally Posted by specialist

I have just tested two cigweld 250 machines at work and one of them did just what you described. We then had a local electronics guru look at it and he diagnosed the recifier is shot. This machine is only a few years old and we are unable to source a new rectifier to suit. I would be saying good luck in your quest to get that old machine working again.

Robert

What type of rectifier is it?
I would be very surprised if you cannot get a rectifier to suit. More likely someone wants to sell you a new welder.

Should it turn out to be a rectifier i have one which you can have in exchange for the old one (I can fix it )

We are a cigweld reseller, they have no reason not to sell us parts, they have before and can't see any reason that they wouldn't this time.

Robert

Originally Posted by specialist

We are a cigweld reseller, they have no reason not to sell us parts, they have before and can't see any reason that they wouldn't this time.

Robert

Are you trying to source a genuine part or a generic one? Often the generic part is available long after the manufacturer has ceased supply.
There is a company near me specialising in welder repair and they have been able to source parts for absolutely ancient machines.
As long as the rectifier is of sufficient capacity then the style should not matter greatly, so perhaps it may be feasible to modify the rectifier bank to a different style.

I only have a dslr to hand, so photos only for the time being. But as requested, here's a run of melts with the six different power levels, one at the left and six to the right, all at wire speed 7.

Photo 1 is before wire brush application, photo 2 is post wire brush.

What happens on power 1/2/3 happens on 1.6mm steel as well, so I doubt the thickness of this piece (approx. 10mm) has had an affect in this instance.

Dubman, that would be absolutely fantastic. Lets see if these photos help with diagnosis.

I think the machine might be alright
try adjusting the wire speed to feed the wire in slower (much slower in the case of the first weld)
Normally with a diode problem you will get a weld that looks like brd sht Diodes are never an intermittent problem and I doubt if you could get the last weld with faulty ones
Also

If it is a case of user error, I'm going to be mildly embarrassed and greatly relieved
Will respond with how it goes when I get home. Fingers crossed that I'm a cheery doofus

looking at you photos my guess is your wire feed is all very wrong.i have a mid 90s rural pack 195 and your welds on upper two settings are just fine and middle weld is also almost normal.try your wire feed(voltage) on about two on 1.6 mm sheet and go from there.good luck. dont forget more photos.

Who's an incredibly large dingleberry?
Me, that's who

Wire feed it is!

Only a quick test, but I'm getting fairly decent beads on a piece of steel from a 44gal drum on 1 & 2 with low low wire feed speed. I'll test some thicker metal when I have a bit more time, but I'm happy to have been reminded that troubleshooting should start with the simplest things first

I'm too happy to have things working to be blushing thankfully

Thanks for putting up with me, and please don't throw too many rotten tomatoes

I am coming into this way late, but we spoke about your welder when you first got it as I have one as well.
I am no good on the electrics, but my wire feed is always between 2.5 and 3 and I use 0.9mm wire. I find I never go below or above these settings no matter what amp range, but the dial is sensitive so just a small amount of movement makes a big difference.

The last welder I had was a Due mig and I was running the wire speed flat out welding aluminum, where this welder is so much faster I don't need to run it that high on the dial now.

Dave