Burnt Wire?

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Was cleaning out the Lincoln AC/DC and noticed this scorched wire. The ground clamp lead was sitting against this area. Any suggestions on how big of an issue this is? Doesn't appear to be burnt through, just looks like discoloration. The most I ran it was about 4 minutes on 95 amps over 10 minutes, while cleaning welds in between. May have ran over the duty cycle, but not by an extreme amount.Thank You


Reply:

Originally Posted by TooNew

Was cleaning out the Lincoln AC/DC and noticed this scorched wire. The ground clamp lead was sitting against this area. Any suggestions on how big of an issue this is? Doesn't appear to be burnt through, just looks like discoloration. The most I ran it was about 4 minutes on 95 amps over 10 minutes, while cleaning welds in between. May have ran over the duty cycle, but not by an extreme amount.Thank You


Reply:It isn’t crumbly at all. Hoping you are right. Wasn’t sure if this was normal after use or if I was pushing it too hard. Worth getting it checked out?
Reply:Wouldn't even worry about it unless you smell something funny. The rubber on the welding leads can stain things they are in contact with for long periods.
Reply:Comforting news. Thank you!  I never smelled burning wires or smoke.
Reply:Looks harmless, but you might want to stop it from continuing.... tape, hose, wire loom cover.... no point on waiting for it to rub through if there's vibration etc....The harder you fall, the higher you bounce...250 amp Miller DialArc AC/DC StickF-225 amp Forney AC Stick230 amp Sears AC StickLincoln 180C MIGVictor Medalist 350 O/ACut 50 PlasmaLes
Reply:

Originally Posted by TooNew

Was cleaning out the Lincoln AC/DC and noticed this scorched wire. The ground clamp lead was sitting against this area. Any suggestions on how big of an issue this is? Doesn't appear to be burnt through, just looks like discoloration. The most I ran it was about 4 minutes on 95 amps over 10 minutes, while cleaning welds in between. May have ran over the duty cycle, but not by an extreme amount.Thank You
Reply:Mine has a duty of whole handful of 1/8 lo hy for hour at a time on occasion.   ha   4 minutes at 95 over 10 aint nuthin for that bad boy.www.urkafarms.com
Reply:

Originally Posted by Meltedmetal

Just for the sake of interest which "Lincoln AC/DC" has a duty cycle under 40% at 95 amps?I also wouldn't be too concerned about the black mark.
Reply:Unlike a lot of modern stuff they didnt stretch the math when they invented these and they were better than their listing.  The ambient was 104 I believe.  Mine is as low as 45 but I ran them in the hot too.  I worked a couple AC buzzers hard and know some others were brutalized, rarely see them in the scrap and usually due to a dipstick switching while welding.   Ran  a cou8ple as fast as you can chuck them in there, no chip stop etc but blkazing for hour a time at 120 and almost steady at 145 or 150.www.urkafarms.com
Reply:My first inclination might be to unbundle the cable from it but,,,,,,, this is a very good machine they made fussy for a long time and takes almost an act of Congress to make any kind of change, extreme forensic follow up over decades and hundreds of thousands of units. If this would have been a problem they would have changed it.www.urkafarms.com
Reply:The more I think about it the more I believe it is discolor and not a burn. I used about 4 sticks with 30 seconds between each. Ambient temp was 70 degrees. Although I may have overdone it according to the manual, others’ experience leads me to believe I didn’t damage the machine.
Reply:At that rate you could burn 40 sticks.www.urkafarms.com
Reply:I never counted the sticks but can use a 50 pound box in under a week.Dave

Originally Posted by Sberry

At that rate you could burn 40 sticks.
Reply:I'm an electrician. Seeing a wire burn like that there'd be an explanation. Mostly, they don't overheat mid run. A wire overheating will be at one end or the other. Thoughts come to mind:Is it paint?Did something hot contact it?Is this lightning damage?An optimist is usually wrong, and when the unexpected happens is unprepared. A pessimist is usually right, when wrong, is delighted, and well prepared.
Reply:The other cable was against it for years. I dont think this is a big mystery.www.urkafarms.com
Reply:You could run it for a few passes and measure the temp at that point with a laser thermometer to see what is happening.
Reply:Wire is white in color. its light brown from transformer varnish when it was dipped. Black spot appears to be from the weld lead rubber insulation. Rubber insulation will stain lighter colored insulation it comes in contact with.Measure the temp after a couple of sticks. if it is just warm forget about it.
Reply:

Originally Posted by ccawgc

its light brown from transformer varnish when it was dipped.
Reply:Yes, this maybe, no.

That doesn't look like anything to be concerned with, your machine needs more grinder dust. In fact that machine looks "too new". Hopefully it hasn't stopped you from welding. Have you tried any 7018, or 7014 yet ?Good LuckAirco 250 ac/dc Heliwelder Square waveMiller Synchrowave 180 sdMiller Econo Twin HFLincoln 210 MPDayton 225 ac/dcVictor torchesSnap-On YA-212Lotos Cut60DPrimeweld 225 ac/dcPrimeweld mig180Miller AEAD-200