Clarke welder, uneven wfs

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Clarke Turbo Weld 150EN.025 Lincoln SuperArc L56/ER70S-6Lincoln .025 tipsmax voltage80-100% wfsC25 @ 20CFH1/4" mild steel plateOn lower settings with thinner metal it runs fine but on 1/4" plate I was getting very uneven wfs. I could hear the wire feed motor surging a couple times a second making arc length go from normal short circuit appearance to upwards of 1/4" - back and forth a couple times a second.I tried playing with spool tension, feed roll tension, changed tip, straightened cable/liner - nothing helped at all.Is this because I'm running .025 wire on max settings welding 1/4"(spool says 12g max material)?Before anyone asks, 1/4" is all I had to practice with today and I didn't want to let that stop me.Miller Syncrowave 250 w/ PC-300 pulserLincoln AC/DC 225/125Clarke TurboWeld 150ENJackson Halo w/ gold lensHuntsman w/ blue lensDoing sanitary stainless tig
Reply:This couldn't have stumped you guys. Did I answer my own question? Would be nice to hear some confirmation or correction.....Or is it more likeMiller Syncrowave 250 w/ PC-300 pulserLincoln AC/DC 225/125Clarke TurboWeld 150ENJackson Halo w/ gold lensHuntsman w/ blue lensDoing sanitary stainless tig
Reply:My Clarke 160EN really hates running the .023 wire, even when flipping the feed roller to the smaller groove. I have also notice when running .030 wire that it struggles keeping a constant feed rate when my tip gets a little use on it. Changing the tip or cleaning it out with a file restores the smooth feeding.I guess maybe these Clarke's have a somewhat weak feed motor.
Reply:I'd say you were undersized on the wire. 1/4 inch will be pushing the top end of a 150 amp class machine. At the very least, you should be running 100 percent wire feed and note that your duty cycle will be pretty short at the top end. Be sure to let the machine cool off or you might get erratic behavior before it trips the thermal shut down.PapaLincoln Idealarc 250 (circa 1962)Lincoln Weldpak 155 w/Mig KitLincoln Squarewave TIG 175
Reply:Originally Posted by SampleMy Clarke 160EN really hates running the .023 wire, even when flipping the feed roller to the smaller groove. I have also notice when running .030 wire that it struggles keeping a constant feed rate when my tip gets a little use on it. Changing the tip or cleaning it out with a file restores the smooth feeding.I guess maybe these Clarke's have a somewhat weak feed motor.
Reply:Originally Posted by papaharley03I'd say you were undersized on the wire. 1/4 inch will be pushing the top end of a 150 amp class machine. At the very least, you should be running 100 percent wire feed and note that your duty cycle will be pretty short at the top end. Be sure to let the machine cool off or you might get erratic behavior before it trips the thermal shut down.Papa