Mig Welding 0.25 Wire Early Burn question

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Guys I'm using a Lincoln Weld Pack 100 and using a .025 with the 75/25 gas mixtures. I'm welding some angle iron (pretty thick) and have it cranked all the way up (d setting an 10 wire speed). I can weld for a few minutes then all of a sudden the wire starts melting before it hits the metal. Now my gas gauges took a thumping but I did verify that gas was making it to th nozzle. have cleaned the nozzle and put in a new wire tip but all of a sudden the wire starts melting before it hits the metal I'm  welding. I checked the clamp. But I have no clue what's causing this. Can anyone offer some experience on this.MPWeld-Pak 100 Mig. New to welding and melting anything metal
Reply:That sounds very odd. Your speed should be from 4-5.5 for that application. You need to check your connections, your ground lead, and you need to check how the gun hose/ sleeve is making its' connection, both at the tip of the gun, and back at the machine. When the gun is dissassembled, the sleeve should come all the way up to the inner threads, so there is no gap when the gas diffuser is screwed on. Other than that, reduce your speed and see how that helps.And then, after so much work...... you have it in your hand, and you look over to your side...... and the runner has run off. Leaving you holding the prize, wondering when the runner will return.
Reply:Hey satex,What's the wire ipm at max setting? Sometimes it is kinda tuff to get consistant feed rates with .025 at high feed rates and an generic 'fit all' liner. Unless everything is running great you'll get this surging thing going on.I can weld for a few minutes then all of a sudden the wire starts melting before it hits the metal.
Reply:What is the duty cycle of a weld pac 100?  20% ?  If you are welding with the wire speed turned all the way up, it may be getting ready to shut down.  IF its 20% duty cycle, then it will or should weld 2 minutes out of 10.Is there a chart to show max settings with .023 wire?DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Originally Posted by David RWhat is the duty cycle of a weld pac 100?  20% ?  If you are welding with the wire speed turned all the way up, it may be getting ready to shut down.  IF its 20% duty cycle, then it will or should weld 2 minutes out of 10.Is there a chart to show max settings with .023 wire?David
Reply:Check your Current, it should be DCEP, if DCEN the wire is hot and will burn back.  JohnSMAW,GMAW,FCAW,GTAW,SAW,PAC/PAW/OFCand Shielding Gases.  There all here. :
Reply:I'm going to try turning the speed down and crack a few lines and see how it looks if that does not get it then I'll back the setting down to say a b or c with the wire speed down and see how it looks. If that does not work then I'll make sure my wire tension is not to high then retry. If that does not work then I'm going to check  sleeve to make sure its on right. But thank you all for you advice. I'll let you know.Weld-Pak 100 Mig. New to welding and melting anything metal