Suitcase Puzzler

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For years I have used a Linclon LN-25. Some you get run fine, some have been so abused that I need to replace half the works before I can run a decent pass. I am not complaining about the product, most damage is due to ignorance and neglect rather than product quality. (Which is not to say that I haven't wanted to chuck the thing straight to the bottom of the sea on several occaisions!) So I am familiar with the innards and can usually get one up and running when they break down.Last month we turned a couple in for repair/overhaul (no time to do it ourselves) and the distributor we use brought out two shiny new Miller Extremes. I was thrilled to have a brand new feeder... There are several great features about these things... a large and clear digital readout (it will hold a reading of actual welding voltage for about 10 seconds after you break the arc so you don't need a second person to dial in the wire speed), the casing and latches are sturdy and can be opened with gloves on, and my favorite, a trigger lock so that your hand is not frozen into a claw by lunchtime.  BUT.....And this is a BIG but...After welding continously for maybe 45 minutes (well, not continuosly, but several 18" - 24" passes in a row, stopping the arc long enought to shift positions), I find that the damn thing will not spark for another pass. The wire feeds out fine, just NO SPARK! IT QUITS WELDING! It will start again, but you have to wait about 5 minutes till it decides it's ready. This happens with both of them, both brand new.I checked everything. Leads in good repair, work clamp secure, clean place to strike, nobody flipped the polarity switch (a favorite trick with the jokers around here) all settings, switches, dials and widgets in proper order. This is so frustrating! I mean really, I have used every bad word I know (and there are many!)  Obviously I haven't checked EVERYTHING... I am missing something... there is some tidbit of info out there that will make me feel stupid when I find out that I  overlooked it .  So please, somebody make me feel dumb... Won't be the first time!
Reply:I just bought a similar suitcase a few months ago, the 12vs.  I haven't had this problem at all, but it sounds like a thermal fuse or something is tripping and resetting itself.  Get the manual and check the trouble shooting guide and if that doesn't help, send miller tech support a note.  They take a day or so to get back, but they always get back.Smithboy...if it ain't broke, you ain't tryin'.
Reply:I agree, He beat me to the post.Drivesector Hobart Handler 140Hobart Handler 180Ready Welder 2Hobart Air Force 400Airco Stinger 225Of all the things I've lost, I miss my mind the most."OZZY"
Reply:tregasskess makes trigger locks for guns that go on ln-25's as for your problem I'm certain the miller is a voltage sensing machine you may want to see if there is something in trouble shooting in manual.
Reply:It does sound like a thermal trip at that. Odd. I have a 8VS and a Super S-32P and neither one does that. Of course I'm not running but 200a. How hot were you running? You should post this on Ask Andy tomorrow. Maybe a Miller tech will see it on Monday and answer you quickly. It has happened. If you can, get the number for the application dept and give them a call. They have helped me a lot in the past.
Reply:Forgive me if this sounds too simplistic, but do you know the machine's duty cycle? Does the machine restart after a few minutes on its own? I have a Miller machine that has a 30% cycle, and I have tripped it once or twice.  Just have to wait for the machine to catch up (spelled "cool down") and you are back in business.Last edited by Clanweld; 10-08-2006 at 08:45 AM.
Reply:60% at 425 amps.
Reply:I know that would make me hoppin' mad  but I still think your duty cycle is the pincher here. Now I see you said the machine starts back up after 5 min, sorry I missed that. Give a call to your distributor if your still unsure, these guys usually know their business.Last edited by Clanweld; 10-08-2006 at 10:45 AM.
Reply:Okay, update:Sorry this took so long, I actually forgot about this thread. Power source was Lincoln Commander 500 with about 320-340 amps reading at the Miller feeder. Nobody I spoke with could give an answer that fixed my problem. One thing I forgot to mention in my original post was the sometimes the stinger would get so hot that I would have to set it down. Literally too hot to handle!Anyway, by accident I fixed my problem. At least, it doesn't happen any more! I replaced the gooseneck I normally use (the kind with the brown woven cover) with one that is aluminum clad. Never a problem since. By the way, DDA52, who and where is "ask andy"?
Reply:Good to hear you got it fixed. Ask Andy is the Miller Motorsports forum. It is supposed to be motorsports questions and stuff, but it more general welding than anything. Good place to visit.http://www.millermotorsports.com/mbo...isplay.php?f=3
Reply:Glad you found the problem and the feeder is working good!  So the answer was -- the torch was heating up too much ??   Maybe a water cooled torch would help?I have melted and deformed the plastic at the end of the swan neck on one of my MIG torches from running too many high amp beads one after another then making the mistake of tapping the nozzle on the work to free up some spatter from the nozzle.    I should have used the stick welder on that project, or invest in a heavier duty torch for the MIG I use for steel.   The machine is 200 amps but the torch is small and light duty.   I like how small and manueverable it is, but it's best used for lower heat jobs.A good used feeder setup to consider if you're still into messing with old equipment and have any need to MIG aluminum are the green MK Cobramatic feeders with the push-pull Cobra, Gooseneck or Python torch or the pistol-grip Prince gun.   They work good for high-duty MIG, feed aluminum nicely and can be water cooled for high-amp use.   We use to weld with them in fast paced high volume production at work untill we got new machines with more bells and wistles.  They worked good for 20+ years in that capacity.  I still use them at home for aluminum mig.