Flux Core keeps getting stuck at tip

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I have a Millermatic 135  and am running 035 flux core wire. I have been having the wire get stuck in the tip regularly. If I let the wire get out a ways from the tip it seems to get stuck less but I think it's a burr spitting and getting stuck in the tip. BUT... I'm a rookie and there may be more than I know going on. The welder was a used machine and all I've done is put new wire in it and flipped the polarity for flux core.Also... any tips on not having the new spool of wire unravel itself when opened. Every time I reload I look like a little kid surprised by a jack in the box when I open the new spool. Thanks for the helps!Millermatic 135
Reply:Originally Posted by nicksorensonI have a Millermatic 135  and am running 035 flux core wire. I have been having the wire get stuck in the tip regularly. If I let the wire get out a ways from the tip it seems to get stuck less but I think it's a burr spitting and getting stuck in the tip. BUT... I'm a rookie and there may be more than I know going on. The welder was a used machine and all I've done is put new wire in it and flipped the polarity for flux core.Also... any tips on not having the new spool of wire unravel itself when opened. Every time I reload I look like a little kid surprised by a jack in the box when I open the new spool. Thanks for the helps!
Reply:I had this same problem with some hobart flux core I bought at tractor supply.  It kept jamming up.  When I'd pull the jammed piece out it looked like it had a row of burrs on it.  I switched to lincoln flux core on the same machine, same liner, same rollers, the same tip, and it works beautifully.Dynasty200DX w/coolmate1MM210MM VintageESAB miniarc161ltsLincoln AC225Victor O/A, Smith AW1ACutmaster 81IR 2475N7.5FPRage3Jancy USA1019" SBAEAD-200LE
Reply:You'll often get a little burr right at the lip of the tip that restricts the wire and it's not unusual to get a little burnt burrs down in the tip from it getting jammed and arching in the first place.  Just as a test take the tip out, cut a short piece of wire and run it into the tip from both directions and see if you don't feel the (an) obstruction in the tip. Those can often be pushed out by repeated jabs with a piece of wire. Another parallel consideration is that every time the wire gets stuck at the tip, or anywhere, the drive wheels are scarfing the heck out of a spot or section of the wire. So every time the wire stutters, sticks and stops, you're going to have a scarfed up spot headed for the tip."The things that will destroy America are prosperity at any price, peace at any price, safety first instead of duty first, the love of soft living and the get rich quick theory of life." -Theodore Roosevelt
Reply:Yes, adding to what Sandy said, sometimes you just have to pull  wire out same length as the liner, plus a little, snip it, toss it, and start over.
Reply:another thing to add is that the drive wheels might be too tight and scuffing up the wire. i think they make guid wheels different for solid wire and fluxcore because the fluxcore tends to bow a little when tention is high. not 100% on this, just seem to remember something about this from somewhere
Reply:I've also found the nozzle will get slag buildup in the insulation at the back of it which will let current pass thru to the nozzle. I was having the same problem 'til I put a new nozzle on.                                                   MikeOl' Stonebreaker  "Experience is the name everyone gives to their mistakes"Hobart G-213 portableMiller 175 migMiller thunderbolt ac/dc stick Victor O/A setupMakita chop saw
Reply:Originally Posted by AndyAI had this same problem with some hobart flux core I bought at tractor supply.  It kept jamming up.  When I'd pull the jammed piece out it looked like it had a row of burrs on it.  I switched to lincoln flux core on the same machine, same liner, same rollers, the same tip, and it works beautifully.
Reply:Hey Nick,The other responses are well stated & I will add a few more suggestions. With a 135A welder, I would suggest go with .030 dia. wire & use the .035 tip. I use a .005 larger tip with both f/c & aluminum & that really helps reduce burnback & birdnesting. Also, as suggested, check your wire tensioner as excessive pressure will deform the wire a bit. I also recommend to cut the end of the wire prior to each start for a more positive start. I use Lincoln NR211MP most of the time & also use Esab E71T-1/11 with best results.DennyComplete Welding/Machine/Fab. ShopMobile UnitFinally retired*Moderator*"A man's word is his honor...without honor there is nothing.""Words are like bullets.... Once they leave your muzzle, you cannot get them back."
Reply:I will also agree with everyone that suggested the lincoln consumables...not only do you get to use 99% of the roll, I believe there is less smoke and spatter. Around here ( Charlotte, N.C.) Lowes has the best price on it.
Reply:I have always used Hobart wires (both solid and fluxcore) and never had a problem that was the fault of the wire.  With fluxcore, you should use knurled, v-groove drive rolls.  You should always use the proper size tip and not an oversized one and with fluxcore, a nozzle is not necessary unless it is gas-shielded fluxcore.  If there is a burr in the tip, then you can take a tip cleaner and clean out the tip.  Make sure that you have the proper tension of your drive rolls.
Reply:the liner could be dirty
Reply:Re: wire coming off the spoolPut extra tension on the adjuster on the spool axle when loading the wire.  And don't take the wire loose from the spool until you have it mounted on the axle.You can go back to your normal tension setting after you've threaded the wire.And yes, it can get out of hand once in a while"Any day above ground is a good day"http://www.farmersamm.com/
Reply:I am having the same issue with my Hobart 187 and Hobart wire.I am using flux core.  So when using flux core you don't use a tip.... just the flux core nozzle correct??My nozzle just fries in short order.  Wonder why they do not make a nozzle that does not melt for flux core??
Reply:I ran some flux core on a 210 millermatic. I ran .030 wire with a .035 tip. Watch wire where I didn't put wire drive roller to tight. It did a good job set like this.
Reply:So Laman.... you just use the gas tips instead of the Flux Core nozzle?If you were to use the Flux Core nozzle... would you keep the tips on under the nozzle or just run with the nozzle?
Reply:Originally Posted by cybordolphinSo Laman.... you just use the gas tips instead of the Flux Core nozzle?If you were to use the Flux Core nozzle... would you keep the tips on under the nozzle or just run with the nozzle?
Reply:I had this happen when I first started. I was over tightening the drive tension crushing the flux core and getting teeth marks down the wire from the knurled drive roll. loosened up and all was well. Might be the problem.
Reply:I'll recheck to make sure I have the proper drives, and tension.
Reply:Originally Posted by cybordolphinSo Laman.... you just use the gas tips instead of the Flux Core nozzle?If you were to use the Flux Core nozzle... would you keep the tips on under the nozzle or just run with the nozzle?
Reply:Originally Posted by jag8243I had this happen when I first started. I was over tightening the drive tension crushing the flux core and getting teeth marks down the wire from the knurled drive roll. loosened up and all was well. Might be the problem.