Wire size with Lincoln 135

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I am a bit confused.  I just picked up a never used but not new Lincoln 135T with all original equipment.  I went to a local welding shop and got a tank of co2/argon and asked for a spool of wire appropriate for mig welding up to 3/16..  The guy sold me an 8" spool of .030 solid wire.When I got home I looked at the manual and then at the on-line info from Lincoln.  The manual has a chart that seems to indicate that 1) .030 is only useful up to 14gauge or 0.075 inch mild steel (!) and that anything greater requires .035 flux core wire.  The manual chart that dupicates the welder door chart does not even mention .035 solid wire.  That doesn't jive with what I have read in the Lincoln webpage that indicates you can use up to 0.035 solid wire with gas to weld up to 3/16 or even 1/4 inch mild steel.I don't intend to do any welding of 24, 22 or even 20 guage steel but would like to weld up to 3/16 mild steel.1) Is .030 the best wire or should I take it back and get .035?2) Anyone know why the Lincoln 135 manual or the chart on the welder door does not even mention .035 solid wire?Thanks
Reply:.030 is about the best wire for that unit. The current density will give you a hotter and much better weld. .035 is not a wire I would use on a small MIG. .030 is all I use on my MM210 and I go up to 3/8 easily. It will handle up to 1/8 easily with C-25 and .030 wire. Any thicker and you will really need to know what you are doing. IMO, the welds are a tad cold on 1/8. With fc, you can go up to 3/16-1/4...again, 1/4 if you really know what you are doing. The 120v MIGs really do better with .024-.030 wires in solid and .030-.035 in fc.As to the manual...who knows.
Reply:Try some .023 solid wire also. I use a bit of it on my SP175 plus and it's really quite versatile. By the way, I use C02 due to cost and I happen to like the way it runs.
Reply:Thanks guys.  I'll keep the 030 and give it a try.
Reply:Originally Posted by IslandI am a bit confused...I don't intend to do any welding of 24, 22 or even 20 guage steel but would like to weld up to 3/16 mild steel.
Reply:Originally Posted by MAC702I'm a bit confused, too.  You want to make sound GMAW welds on 3/16" steel and you bought a 120V machine?You were probably mislead about the machine's capabilities.
Reply:I'll agree with littlefuzz...I have (2) SP135-Plus machines and have used them for plate up to 3/8". I would not recommend using it all the time nor would I want to use it on a critical component of that thickness...but I would see no problem for 3/16" or even 1/4" for that matter....and like gnm109 said, use C02. It will burn a little hotter, it just won't control spatter as much as a C25 mix.http://all-a-cart.comWelding Cart Kits and accessories
Reply:Single-pass GMAW with .030 wire on 3/16" material is pretty much the limit for any 120VAC machine.  The machine will be running at maximum output.  It will do it, but you're outside of the "sweet spot" so to speak.  This isn't really a problem for an experienced weldor, but could be a problem for someone that doesn't have a good understanding of what's going on and whether they're getting adequate penetration.I've welded a great deal of 3/16" with an MM135.  I'd hit the limit of the machine at which point it would give a cold weld and start stubbing.  Using a short, beefy extension cord helped prevent this, somewhat.  I'm not sure whether the Lincoln would respond similarly, but I guess that it might.In summary, .030 is perfect for that machine.  C25 will help keep the spatter down and CO2 will give you more heat, as already mentioned.  If you're going to continue to use it for heavier materials, it would be easier to learn how to do multipass welds properly, which will save setup time switching back and forth to .035 FCAW.  When you're running near the limits of the machine, everything should be perfect anyway.  The material should be fitup well, very clean, properly beveled, and you should have an excellent ground that is near the area to be welded.  You should also understand that a larger machine will give you more margin for error.-Heath
Reply:Thanks for the additional comments.  I would not plan to use the Lincoln 135 to do "big" stuff as I also have a Lincoln 225 AC/DC tombstone welder.  I was hoping to be able to do up to 3/16 however and it sounds like with care I can do that.  I picked up a small spool of 035 flux cored wire too.To be honest I had originally been thinking I'd buy a 175 MIG rather than 135 but then found a very good deal on the unused 135 with cart and bottle in a local classified ad (go craig's list!) and couldn't resist.  It also gives me the flexibility of not needing 220 everywhere.  I had given some thought to a Miller Passport but decided it was still a bit pricy for the amount I would use it.  I do look forward to some competition from Lincoln for the Passport though.  Nice package and I'd own one if the price dropped 20% or so.
Reply:The 120VAC units certainly have their uses in that they can be plugged in anywhere.  My experience reflects that you can do 3/16" with .030 and C25 and 1/4" with .035FCAW... with care, as you stated.  I'd add that if you're going to run it at max capacity, make sure that your line voltage is good and use a beefy extension cord (12ga will work fine).I gave up my MM135 last year in favor of my current rig and now I'm pining for portability and the ability to weld from a 120VAC outlet.  I can see a Passport in my future.-Heath