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Old 05-25-2012, 08:50 AM   #1
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Welder Trouble


Guys I'm new to this forum but am glad I found it.
I recently bought a new welder and am having trouble getting the wire feed to work. I've taken back two units, replaced the last one with another new unit and still am having issues. Now after all the trouble, I think it may be a power issue. It's a Chicago Electric, 180 AMP 240 Volt welder. I'm using a 60 AMP circuit with a 6 - 2 WG wire. I have not checked the current in the plug yet but wander is this set up correct. If so, what else could be the issue?

Thanks for any light you can shine on my situation.

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Old 05-25-2012, 09:10 AM   #2
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Welder Trouble


The current draw on the 240V side is quite a bit less. The 180A is at the welding side after a step down transformer. I have one of these MIG welders (not sure if the exact same model) but I run it from a 15A 240V receptacle (NEMA 6-15 style connector) in my garage. (If I did it again I would run 240V @ 20A, 12AWG, and NEMA 6-20 connectors but that wasn't a good option for me).

If you are using a 60A circuit are you sure the welder is seeing 240V? Maybe you have it hot to neutral instead of hot (phase 1) to hot (phase 2)? It would sort of work but the feed motor would be bothered by the low voltage (120V instead of 240V). Also are you using the wrong tip for the wire you are using. If you are using .035" wire with a .023" nozzle the wire will jam.


Last edited by curiousB; 05-25-2012 at 09:14 AM.
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Old 05-25-2012, 10:47 AM   #3
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Welder Trouble


I have yet to get the cable to feed far enough to reach the tip but I did look at the tip last night and it is a .30, same as the wire I'm using.

As far as the wire connection, I have the hot (black wire) going into the breaker itself, neutral (white wire) going to the opposite side of the panel and the ground attached to the ground bar.

Am I incorrect?

Thanks for the help
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Old 05-25-2012, 11:57 AM   #4
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Welder Trouble


you dont have a neutral in a 240v circuit both black and white wire should be landed on a double or 2 pole breaker. the white wire should also be remarked black at all junctions
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Old 05-25-2012, 01:39 PM   #5
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Welder Trouble


Quote:
Originally Posted by BuB901 View Post
I have yet to get the cable to feed far enough to reach the tip but I did look at the tip last night and it is a .30, same as the wire I'm using.

As far as the wire connection, I have the hot (black wire) going into the breaker itself, neutral (white wire) going to the opposite side of the panel and the ground attached to the ground bar.

Am I incorrect?

Thanks for the help
yes just as I suspected you are only feeding it 120V not the 240 it requires. Sort that out and you should be fine. You need a double pole breaker with two hots. There is no neutral for this circuit.

You'll be splattering sparks in no time..... careful not to burn the house down! I set a trash bin on fire from welding sparks once. Those sparks are hot.......
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