handy core welder

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I have a handy core welder  and  it's not giving enough amperage (I think) to weld. I checked all my connections  and  replaced the tip, cleaned the steel to bare  and  all contacts.I only have used the machine from new about 5-6 times. What would cause the welder to clump the weld and not penetrate? The wire feeds out and once it arcs it only drops blobs of melted weld onto the work and won't melt or penetrate the steel.
Reply:Pardon my ignorance, but what is a "core welder?"Any brand name or model number?  Ratings?awright
Reply:It's a wire feed 115 v arc welder. From 35-88amps and Handy Core is the name of the unit. The smallest of teh Lincolns. Also the metal I was welding was about 1/8 thick.
Reply:what wire and what are the settings?  Probably needs to be near max.Polarity?   Electrode - ?DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:wire is 0.035 and the settings are 1 or 2 and high or low. no positive negative setting. clamp the work with the one cable and pull the trigger which provides the auto feed weld.
Reply:IIRC HC's are flux units only. Dunno what to suggest. Check the cable connection and work ground.Craftsman 230a Buzz-box,  Lincoln 140T & 180T, Century K2789, PUROX W202 O/A14" cheapo chop saw that cuts straight and square!A toolbox of the cheapest Chinese tools money can buy"Real" tools all old reliable Husky/Craftsman/Proto stuff
Reply:Do you know what the polarity is presently?  Polarity is usually changed by switching the connections to the wire feeder and the ground lead inside the machine.Do you have the knowledge and equipment to check the rectifier diodes individually?  (May require disconnecting some leads.)  Check for voltage at the main transformer output terminals.  Look for signs of overheated connections and terminals.  If everything looks OK check for voltage drop across the connectors, inductor, and any other component in the welding current path.  someone will have to actuate the wire feed and simulate welding to check current and voltage drops.Are you clipping the tip of the flux core to get a good contact and clean arc start with a clean workpiece?Do you have a manual for the welder so you can be sure it is set up correctly?Are you sure you are getting a solid ground connection to clean metal?  Try a better bolted ground lug or a strong cast brass ground clamp.awrightLast edited by awright; 03-13-2007 at 02:39 AM.
Reply:Ah, how old is the wire? If you've only used the machine 5-6 times over the years the wire may be corroded.Craftsman 230a Buzz-box,  Lincoln 140T & 180T, Century K2789, PUROX W202 O/A14" cheapo chop saw that cuts straight and square!A toolbox of the cheapest Chinese tools money can buy"Real" tools all old reliable Husky/Craftsman/Proto stuff
Reply:I could check the voltage but the polarity can't be checked because this little machine is hooked up to a circuit board and no reverse polarity is possible. As for the wire (core flux), it's brand new as of January.
Reply:How about posting a few sharp pictures of the unit?  It would help to know what you are dealing with.  Any manual or schematic?awright
Reply:Well the problem was solved by the company. I checked the local dealers and they wouldn't touch me for a month at the earliest. So I called the Lincoln company in Toronto and they told me to bring it in. The tech saw right away that instead of me putting in a new role of 0.035 flux core wire I put in 0.035 aluminum wire. (oops) I went home with a new spool and the machine didn't even give a spark this time. Back I go and they figured that the circuit board went. I leftwith a new welder, a welder's hat and b.ball cap for $0. Now that's service and a company who stands behind their product. Lincoln for life.