Mig feed rate too high ? How do I know ?

[Mrwurm]

I bought a Hobart Handler 140 last summer and I'm really loving using a Mig compared to my old stick welder. But lately, I've found that the wire stops feeding. The wire is not birdnesting at the pinch rollers, the pinch rollers simply turn and the wire goes nowhere. I checked the coil tension and that is nice and loose with no binding. To get things started again, I simply grab the wire at the nozzle with pliers, pull out an inch or two and I'm welding again. I've only had this problem when I'm using the higher wire feed rates. If I slow down the wire, I have no problems.

The pinch rollers have a range of adjustment from 0 to 4. Per the instructions, I use a tension of about 2.5 to 3. I have tested the rig at max tension and it does feed with no jamming. But, the instructions say that this is not a good solution.

I have also changed my contact tips several times and I am using the correct size. .03 with .03 flux core wire. I have found that if I use a .035 tip with the .03 wire, it never jams, but I don't know if this is bad for the welder.

Any thoughts ?

 

[Mrwurm]

I bought a Hobart Handler 140 last summer and I'm really loving using a Mig compared to my old stick welder. But lately, I've found that the wire stops feeding. The wire is not birdnesting at the pinch rollers, the pinch rollers simply turn and the wire goes nowhere. I checked the coil tension and that is nice and loose with no binding. To get things started again, I simply grab the wire at the nozzle with pliers, pull out an inch or two and I'm welding again. I've only had this problem when I'm using the higher wire feed rates. If I slow down the wire, I have no problems.

The pinch rollers have a range of adjustment from 0 to 4. Per the instructions, I use a tension of about 2.5 to 3. I have tested the rig at max tension and it does feed with no jamming. But, the instructions say that this is not a good solution.

I have also changed my contact tips several times and I am using the correct size. .03 with .03 flux core wire. I have found that if I use a .035 tip with the .03 wire, it never jams, but I don't know if this is bad for the welder.

Any thoughts ?

 

[Hib]

I would suggest tightening the rollers. As long as it does not pinch wire so much as to leave imprints or make it out of round you should be fine. How about disconnecting the gun/hose and blowing it out real good with compressed air? That should be done periodically. If not, a dirty line can lead to feed problems.

 

[Hib]

I would suggest tightening the rollers. As long as it does not pinch wire so much as to leave imprints or make it out of round you should be fine. How about disconnecting the gun/hose and blowing it out real good with compressed air? That should be done periodically. If not, a dirty line can lead to feed problems.

 

[RonMar]

Well you might have crud buildup in the cable liner. The spools have a small ammount of dust/metal powder on them. This material will be wiped off inside the cable liner and will buildup. Carefully remove the weld wire from the handgun/feedline and blow compressed air through it, tapping the weld cable along it's length. The extra drag on the wire from this buildup could be causing you problems. You could also replace the cable liner. Don't let go of the weld wire back by the spool or it will birdsnest on the spool and you will not be able to use the rest of the wire(Don't ask me how I know this. There are companies that make clip on wire wipers/brushes that remove most of this dust between where the cable rolls off the spool and where it enters the rollers/liner.

Are the groves in the feed roller worn? Weld wire is pretty hard stuff and if it has slipped much, they may need replacing.

Turning up the tension slightly should not hurt things as long as you are not distorting the wire. My Lincoln dosn't have a indexed tension setting, just a wingnut that squeezes a spring. You set it to the lowest tension that still gives a reliable feed.

 

[RonMar]

Well you might have crud buildup in the cable liner. The spools have a small ammount of dust/metal powder on them. This material will be wiped off inside the cable liner and will buildup. Carefully remove the weld wire from the handgun/feedline and blow compressed air through it, tapping the weld cable along it's length. The extra drag on the wire from this buildup could be causing you problems. You could also replace the cable liner. Don't let go of the weld wire back by the spool or it will birdsnest on the spool and you will not be able to use the rest of the wire(Don't ask me how I know this. There are companies that make clip on wire wipers/brushes that remove most of this dust between where the cable rolls off the spool and where it enters the rollers/liner.

Are the groves in the feed roller worn? Weld wire is pretty hard stuff and if it has slipped much, they may need replacing.

Turning up the tension slightly should not hurt things as long as you are not distorting the wire. My Lincoln dosn't have a indexed tension setting, just a wingnut that squeezes a spring. You set it to the lowest tension that still gives a reliable feed.

 

[Charlie_in_TX]

One last tip, keep the lead as straight as possible. If the lead makes a sharp or too many bends, it will cause problems.

 

[Charlie_in_TX]

One last tip, keep the lead as straight as possible. If the lead makes a sharp or too many bends, it will cause problems.

 

[Freds]

Have you always used this size wire? Most welders have two grooves in the one pinch roller to accomodate different size wires and pinching the wire into too small of a groove accomplishes the same thing as having the tension too loose, it just won't feed, especially with flux core which has more feeding problems than regular wire. Too tight a tension will cause flat spots, also.

I've always set the tension by feeding the wire into a gloved hand. it should push a little on your hand, then the rollers should slip. Keep your eye on things in the machine to be sure it isn't backing up in there while doing this and like one poster said.... keep the lead as kink free as possible, espepcially in these litte machines.

Don't they make special liners for flux-core, too? Seems I remember always changing liners when I got a new portable mig for the shop.

Some folks clamp a piece of Scotch brite cloth onto the wire between the rollers and where it enters the lead to keep it clean using one of those "clamp style paper holder thingies" and in such a way not to put too much extra friction on the wire.

 

[Freds]

Have you always used this size wire? Most welders have two grooves in the one pinch roller to accomodate different size wires and pinching the wire into too small of a groove accomplishes the same thing as having the tension too loose, it just won't feed, especially with flux core which has more feeding problems than regular wire. Too tight a tension will cause flat spots, also.

I've always set the tension by feeding the wire into a gloved hand. it should push a little on your hand, then the rollers should slip. Keep your eye on things in the machine to be sure it isn't backing up in there while doing this and like one poster said.... keep the lead as kink free as possible, espepcially in these litte machines.

Don't they make special liners for flux-core, too? Seems I remember always changing liners when I got a new portable mig for the shop.

Some folks clamp a piece of Scotch brite cloth onto the wire between the rollers and where it enters the lead to keep it clean using one of those "clamp style paper holder thingies" and in such a way not to put too much extra friction on the wire.