Hobart Mega-Flex 650 RVS does not work in MIG mode
Ignoramus24189
has a Hobart 25 wire feed, which I actually like a lot.
I rewired this welder to 240v three phase.
The welder works great in stick mode, but refuses to work in MIG
mode.
The welder has two Amphenol receptacles, 19 pin (Wirefeed 1) and 5 pin
(Wirefeed 2). The Hobart 25 is plugged into 5 pin receptacle (Wirefeed
2).
1. Stick mode works great. No problems.
2. There is a Stick/MIG/TIG switch on it. If I switch it to MIG (or
TIG) the voltage indicator drops to zero immediately.
3. Switching Local/Remote output control does not help.
4. Switching Local/Remote voltage sensing does not help.
5. I tried removing the plug and messing with the receptacle, somehow
I was recalling that pins A and B should start welding if shorted. It
did not help.
6. If I press the button on the MIG gun, the wirefeed engages and
starts feeding wire.
I have a feeling that I am missing something simple and the welder is
actually fine. I do not have a manual, which I will order if I do not
get a good answer.
Any ideas? What am I missing?>
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Ernie Leimkuhler
Ignoramus24189 <ignoram...@NOSPAM.24189.invalid> wrote:
> I have this Hobart Mega-Flex 650 RVS, which I am trying to test. It
> has a Hobart 25 wire feed, which I actually like a lot.
>
> I rewired this welder to 240v three phase.
>
> The welder works great in stick mode, but refuses to work in MIG
> mode.
>
> The welder has two Amphenol receptacles, 19 pin (Wirefeed 1) and 5 pin
> (Wirefeed 2). The Hobart 25 is plugged into 5 pin receptacle (Wirefeed
> 2).
>
> 1. Stick mode works great. No problems.
>
> 2. There is a Stick/MIG/TIG switch on it. If I switch it to MIG (or
> TIG) the voltage indicator drops to zero immediately.
>
> 3. Switching Local/Remote output control does not help.
>
> 4. Switching Local/Remote voltage sensing does not help.
>
> 5. I tried removing the plug and messing with the receptacle, somehow
> I was recalling that pins A and B should start welding if shorted. It
> did not help.
>
> 6. If I press the button on the MIG gun, the wirefeed engages and
> starts feeding wire.
>
> I have a feeling that I am missing something simple and the welder is
> actually fine. I do not have a manual, which I will order if I do not
> get a good answer.
>
> Any ideas? What am I missing?>
For one thing, in MIG mode nothing would show on any meter until you
were actually welding.
In Stick mode there is an open-circuit-voltage that will always show on
the meter, but not in MIG.
You have not stated the obvious...
That you pulled the trigger while the wire fed out and touched the
ground clamp.
If you didn't do that then try it.
matthew maguire
>
(snip)
>
> The welder has two Amphenol receptacles, 19 pin (Wirefeed 1) and 5 pin
> (Wirefeed 2). The Hobart 25 is plugged into 5 pin receptacle (Wirefeed
> 2).
The 19 pin is for the Mega-Con and RVS, the 5 pin is for anything else
(RVS needs a separate lead to workpiece).
>
> (snip)
>
> 3. Switching Local/Remote output control does not help.
5 pin should be set to local
>
> 4. Switching Local/Remote voltage sensing does not help.
5 pin should be set to local
>
> 5. I tried removing the plug and messing with the receptacle, somehow
> I was recalling that pins A and B should start welding if shorted. It
> did not help.
>
Usually, 2 pins are power (either 24V DC or 115AC depending on unit),
and 2 pins close the contactor. I assume the contactor is OK in the
machine because it also energizes the mains for stick.
> 6. If I press the button on the MIG gun, the wirefeed engages and
> starts feeding wire.
When you pull the trigger you should get from 15 to 50 volts depending
on the panel voltage setting.
>
> I have a feeling that I am missing something simple and the welder is
> actually fine. I do not have a manual, which I will order if I do not
> get a good answer.
Is there a separate wire and clip? This may be RVS all the time (no
internal voltage sampling) which would require a separate lead along
with the ground, or from the panel to the ground lug on the machine (to
make it act like a normal mig).
The daughter boards are top front left and covered, are the fasteners
scarred up? I think there should be 3 boards with several large wire
bundles everything connected?
Matt
Ignoramus6679
> Ignoramus24189 wrote:
>>
> (snip)
>>
>> The welder has two Amphenol receptacles, 19 pin (Wirefeed 1) and 5 pin
>> (Wirefeed 2). The Hobart 25 is plugged into 5 pin receptacle (Wirefeed
>> 2).
>
> The 19 pin is for the Mega-Con and RVS, the 5 pin is for anything else
> (RVS needs a separate lead to workpiece).
ok
>>
>> (snip)
>>
>> 3. Switching Local/Remote output control does not help.
>
> 5 pin should be set to local
>
>>
>> 4. Switching Local/Remote voltage sensing does not help.
>
> 5 pin should be set to local
OK, thanks
>>
>> 5. I tried removing the plug and messing with the receptacle, somehow
>> I was recalling that pins A and B should start welding if shorted. It
>> did not help.
>>
>
> Usually, 2 pins are power (either 24V DC or 115AC depending on unit),
> and 2 pins close the contactor. I assume the contactor is OK in the
> machine because it also energizes the mains for stick.
The contactor is fine as I can stick weld all day long.
>> 6. If I press the button on the MIG gun, the wirefeed engages and
>> starts feeding wire.
>
> When you pull the trigger you should get from 15 to 50 volts depending
> on the panel voltage setting.
That is my issue, when I press the button, the voltage needle does not
move.
>>
>> I have a feeling that I am missing something simple and the welder is
>> actually fine. I do not have a manual, which I will order if I do not
>> get a good answer.
>
> Is there a separate wire and clip? This may be RVS all the time (no
> internal voltage sampling) which would require a separate lead along
> with the ground, or from the panel to the ground lug on the machine (to
> make it act like a normal mig).
I did not see separate wire, and yes I looked (yesterday).
> The daughter boards are top front left and covered, are the fasteners
> scarred up? I think there should be 3 boards with several large wire
> bundles everything connected?
I only opened the top once, to rewire it for 240v. I do not recall,
but I can look.
It is very strange.
Ignoramus6679
> For one thing, in MIG mode nothing would show on any meter until you
> were actually welding.
Even the volt meter?
> In Stick mode there is an open-circuit-voltage that will always show
> on the meter, but not in MIG. You have not stated the obvious...
> That you pulled the trigger while the wire fed out and touched the
> ground clamp. If you didn't do that then try it.
I thought I did, now I doubt myself a little, I will try tonight and
will report on it.
Ignoramus6679
> were actually welding.
> In Stick mode there is an open-circuit-voltage that will always show on
> the meter, but not in MIG.
> You have not stated the obvious...
> That you pulled the trigger while the wire fed out and touched the
> ground clamp.
> If you didn't do that then try it.
Ernie, you were 100% right, there is nothing wrong with this welder
and it works just fine. I simply misunderstood what I was testing, and
was trying to find open circuit voltage.
Grant Erwin
> On 2008-12-05, Ernie Leimkuhler <er...@stagesmith.com> wrote:
>
>>For one thing, in MIG mode nothing would show on any meter until you
>>were actually welding.
>>In Stick mode there is an open-circuit-voltage that will always show on
>>the meter, but not in MIG.
>>You have not stated the obvious...
>>That you pulled the trigger while the wire fed out and touched the
>>ground clamp.
>>If you didn't do that then try it.
>
>
> Ernie, you were 100% right, there is nothing wrong with this welder
> and it works just fine. I simply misunderstood what I was testing, and
> was trying to find open circuit voltage.
>
Ernie is ALWAYS right. :-)
Grant
Ignoramus6679
I consider him to be the prophet of welding
matthew maguire
>
>> When you pull the trigger you should get from 15 to 50 volts depending
>> on the panel voltage setting.
>
> That is my issue, when I press the button, the voltage needle does not
> move.
>
LOL, glad you got it going (saw from above).
BTW, were you pressing the torch trigger or the inch/purge button on the
feeder? When I used to press the torch trigger I got volts....
Mine was the Sub-arc option version not the GTAW version...
Matt
Ignoramus6679
> Ignoramus6679 wrote:
>>
>>> When you pull the trigger you should get from 15 to 50 volts depending
>>> on the panel voltage setting.
>>
>> That is my issue, when I press the button, the voltage needle does not
>> move.
>>
>> It is very strange.
>
> LOL, glad you got it going (saw from above).
>
> BTW, were you pressing the torch trigger or the inch/purge button on the
> feeder? When I used to press the torch trigger I got volts....
Torch trigger. It is very strange to me, I guess it is the correct
behavior, but not something that I expected. If I press the trigger,
the needle does not move. But the arc would go. What I noticed is that
when I did it the first time after starting the welder, the needle
would move momentarily, but only once.
> Mine was the Sub-arc option version not the GTAW version...
Isn't subarc like MIG welding, only bigger?
matthew maguire
>
>
>> Mine was the Sub-arc option version not the GTAW version...
>
> Isn't subarc like MIG welding, only bigger?
Depends on who is building the machine, but sub-arc usually works better
with a more drooping volt/amp curve. Normal CV "mig" volts=X and at
short circuit amps=MAX(NOW), the voltage doesn't collapse like CC (stick).
With sub-arc the voltage collapses a bit more and the rate (speed) of
amp rise is slowed. The wire is actually sliding into a molten pool a
bit before burning off and the arc is extinguished. If set right 3/16"
wire will cause solution 1 1/2" to 2" deep.
Above 750 amps sub-arc is usually done CC.
How do you like the mig?
Matt
Ignoramus6679
>>
>>
>>> Mine was the Sub-arc option version not the GTAW version...
>>
>> Isn't subarc like MIG welding, only bigger?
>
> Depends on who is building the machine, but sub-arc usually works better
> with a more drooping volt/amp curve. Normal CV "mig" volts=X and at
> short circuit amps=MAX(NOW), the voltage doesn't collapse like CC (stick).
>
> With sub-arc the voltage collapses a bit more and the rate (speed) of
> amp rise is slowed. The wire is actually sliding into a molten pool a
> bit before burning off and the arc is extinguished. If set right 3/16"
> wire will cause solution 1 1/2" to 2" deep.
I got it.
> Above 750 amps sub-arc is usually done CC.
>
> How do you like the mig?
I like it, but the reel of fluxcore that I have (Lincoln wire cage)
does not fit the 51mm spindle and does not like to spin in general. So
I let a little bit of loose wire to try, but not enough to get any
experience. Hopefully early next week I will get a proper reel.
matthew maguire
>
>
> I like it, but the reel of fluxcore that I have (Lincoln wire cage)
> does not fit the 51mm spindle and does not like to spin in general. So
> I let a little bit of loose wire to try, but not enough to get any
> experience. Hopefully early next week I will get a proper reel.
>
You can get an adapter for those redi-reels from lincoln, but to be
honest if you are just "puttering" around I would get a 10lb spool of
something.
Did you get extra feed rolls for the type 27 feeder?
Matt
Ignoramus6012
I bought a 33 lbs spool, and will sell that redi-reel as I do not need
it. The wirefeed comes with 0.035-0.045 rolls, which should work OK.
Gunner Asch
<ignora...@NOSPAM.6679.invalid> wrote:
>On 2008-12-06, Grant Erwin <gr...@NOSPAMkirkland.net> wrote:
>> Ignoramus6679 wrote:
>>> On 2008-12-05, Ernie Leimkuhler <er...@stagesmith.com> wrote:
>>>
>>>>For one thing, in MIG mode nothing would show on any meter until you
>>>>were actually welding.
>>>>In Stick mode there is an open-circuit-voltage that will always show on
>>>>the meter, but not in MIG.
>>>>You have not stated the obvious...
>>>>That you pulled the trigger while the wire fed out and touched the
>>>>ground clamp.
>>>>If you didn't do that then try it.
>>>
>>>
>>> Ernie, you were 100% right, there is nothing wrong with this welder
>>> and it works just fine. I simply misunderstood what I was testing, and
>>> was trying to find open circuit voltage.
>>>
>>
>> Ernie is ALWAYS right. :-)
>>
>
>I consider him to be the prophet of welding
Indeed!!
I cant believe though..that Iggy didnt try to start an arc. At times I
consider him an idiot savant.
<G>
Gunner
"They couldn't hit an elephant at this dist..."
Maj. Gen. John Sedgewick, killed by a sniper in 1864 at the battle of Spotsylvania
Ignoramus6012
> On Fri, 05 Dec 2008 21:01:38 -0600, Ignoramus6679
><ignora...@NOSPAM.6679.invalid> wrote:
>
>>On 2008-12-06, Grant Erwin <gr...@NOSPAMkirkland.net> wrote:
>>> Ignoramus6679 wrote:
>>>> On 2008-12-05, Ernie Leimkuhler <er...@stagesmith.com> wrote:
>>>>
>>>>>For one thing, in MIG mode nothing would show on any meter until you
>>>>>were actually welding.
>>>>>In Stick mode there is an open-circuit-voltage that will always show on
>>>>>the meter, but not in MIG.
>>>>>You have not stated the obvious...
>>>>>That you pulled the trigger while the wire fed out and touched the
>>>>>ground clamp.
>>>>>If you didn't do that then try it.
>>>>
>>>>
>>>> Ernie, you were 100% right, there is nothing wrong with this welder
>>>> and it works just fine. I simply misunderstood what I was testing, and
>>>> was trying to find open circuit voltage.
>>>>
>>>
>>> Ernie is ALWAYS right. :-)
>>>
>>
>>I consider him to be the prophet of welding
>
>
> Indeed!!
>
> I cant believe though..that Iggy didnt try to start an arc. At times I
> consider him an idiot savant.
I was trying to be careful and measure everything before starting.
Pete C.
Ignoramus6012 wrote:
>
> On 2008-12-06, Gunner Asch <gun...@NOSPAMlightspeed.net> wrote:
> > On Fri, 05 Dec 2008 21:01:38 -0600, Ignoramus6679
> ><ignora...@NOSPAM.6679.invalid> wrote:
> >
> >>On 2008-12-06, Grant Erwin <gr...@NOSPAMkirkland.net> wrote:
> >>> Ignoramus6679 wrote:
> >>>> On 2008-12-05, Ernie Leimkuhler <er...@stagesmith.com> wrote:
> >>>>
> >>>>>For one thing, in MIG mode nothing would show on any meter until you
> >>>>>were actually welding.
> >>>>>In Stick mode there is an open-circuit-voltage that will always show on
> >>>>>the meter, but not in MIG.
> >>>>>You have not stated the obvious...
> >>>>>That you pulled the trigger while the wire fed out and touched the
> >>>>>ground clamp.
> >>>>>If you didn't do that then try it.
> >>>>
> >>>>
> >>>> Ernie, you were 100% right, there is nothing wrong with this welder
> >>>> and it works just fine. I simply misunderstood what I was testing, and
> >>>> was trying to find open circuit voltage.
> >>>>
> >>>
> >>> Ernie is ALWAYS right. :-)
> >>>
> >>
> >>I consider him to be the prophet of welding
> >
> >
> > Indeed!!
> >
> > I cant believe though..that Iggy didnt try to start an arc. At times I
> > consider him an idiot savant.
>
> I was trying to be careful and measure everything before starting.
With that much potential current out of the thing for the few seconds
before it trips your breakers, it's good to be careful.
Leon Fisk
<ignora...@NOSPAM.6012.invalid> wrote:
<snip>
>I bought a 33 lbs spool, and will sell that redi-reel as I do not need
>it. The wirefeed comes with 0.035-0.045 rolls, which should work OK.
If you have/saved an old empty reel that fits your machine
it really isn't all that hard to transfer the wire from one
to the other. At least that is what I did to finish off a
Lincoln cage wheel on my Millermatic.
Though, I have been called a cheap screw ;-)
--
Leon Fisk
Grand Rapids MI/Zone 5b
Remove no.spam for email
Ignoramus14844
> On Sat, 06 Dec 2008 09:12:28 -0600, Ignoramus6012
><ignora...@NOSPAM.6012.invalid> wrote:
>
><snip>
>>I bought a 33 lbs spool, and will sell that redi-reel as I do not need
>>it. The wirefeed comes with 0.035-0.045 rolls, which should work OK.
>
> If you have/saved an old empty reel that fits your machine
> it really isn't all that hard to transfer the wire from one
> to the other. At least that is what I did to finish off a
> Lincoln cage wheel on my Millermatic.
>
> Though, I have been called a cheap screw ;-)
>
Good point, but I do not have one.
Terry Coombs
> On 2008-12-07, Leon Fisk <lf...@no.spam.iserv.net> wrote:
>> On Sat, 06 Dec 2008 09:12:28 -0600, Ignoramus6012
>> <ignora...@NOSPAM.6012.invalid> wrote:
>>
>> <snip>
>>> I bought a 33 lbs spool, and will sell that redi-reel as I do not
>>> need it. The wirefeed comes with 0.035-0.045 rolls, which should
>>> work OK.
>>
>> If you have/saved an old empty reel that fits your machine
>> it really isn't all that hard to transfer the wire from one
>> to the other. At least that is what I did to finish off a
>> Lincoln cage wheel on my Millermatic.
>>
>> Though, I have been called a cheap screw ;-)
>>
>
> Good point, but I do not have one.
I use the core and one flange of a small (2 lb ?) roll to mount the bigger
rolls in my baby MIG .
--
Snag
every answer
leads to another
question
AJ
I have one for sale if interested here At Helidon Spar SE Qld.It was in shed
as a walk in walk out situation. I have not the power to run it or know how.
Money back garentee if not working but feel it would. can ring me on
0427420805 if interested. or mail me and I will send a pic.
--
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