Flux_Cored_Wire_Runs_Erratic

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A couple of problems have developed on my Miller 130 MIG Welder:1) The wire feed is erratic, doesn't always feed: The gun liner has been replaced and I've tried to adjust and re-adjust the feed roller tension (don't know how tight or loose it should be). I turned the wire drive wheel around so the knurled part contacts the wire (as the manual says to) Have not yet checked the tension on the wire spool (just thought of it tonight)2) I'm running the wire speed as slow as it will go, but the machine does not produce the nice sounding buzz it gets with gas and solid wire.  BTW: the machine is set up for reverse polarlity (just as manual says).  The wire brand is American Forge, I use their stick electrodes and they work well, so am assuming their wire is OK.Comments and suggestions would be appreciated.........tks........no_arc
Reply:To clarify, the off the shelf flux core should be DCEN/straight polarity.
Reply:Oops!! Sounds like I got my words mixed up.  I reversed the machine polarity from what it uses for solid wire and gas shielding (per manual instructions).....will check the manual tomorrow..........no_arc
Reply:Originally Posted by no_arcOops!! Sounds like I got my words mixed up.  I reversed the machine polarity from what it uses for solid wire and gas shielding (per manual instructions).....will check the manual tomorrow..........no_arc
Reply:Originally Posted by no_arcA couple of problems have developed on my Miller 130 MIG Welder:1) The wire feed is erratic, doesn't always feed: The gun liner has been replaced and I've tried to adjust and re-adjust the feed roller tension (don't know how tight or loose it should be). I turned the wire drive wheel around so the knurled part contacts the wire (as the manual says to) Have not yet checked the tension on the wire spool (just thought of it tonight)2) I'm running the wire speed as slow as it will go, but the machine does not produce the nice sounding buzz it gets with gas and solid wire.  BTW: the machine is set up for reverse polarlity (just as manual says).  The wire brand is American Forge, I use their stick electrodes and they work well, so am assuming their wire is OK.Comments and suggestions would be appreciated.........tks........no_arc
Reply:Does it do it straight off the start? Or after you have been burning for awhile? Make sure you have the right contact tip in the gun. I use .030 copper clad for mig and .035 fluxcore. the flux core will go through the 030 contact tip but as soon as it gets a little heat in it then it gets flaky. DSoes exactly what you are desribing. Had a bout of it today when I switched the wire and forgot to switch the tip.The difference between art and craft is the quality of the workmanship. I am an artist.
Reply:Make sure the inlet and outlet guides into and out of the feed rolls are in line, that can cause some problems.  I have always used an over sized liner and tip for flux cored wire.  There is a long explanation for this.  for .035 wire use a .045 tip and liner.   JohnSMAW,GMAW,FCAW,GTAW,SAW,PAC/PAW/OFCand Shielding Gases.  There all here. :
Reply:First figure out where the drag is coming from. Remove the top roller and check liner drag by moving the wire in and out of the liner by hand, if it seems to move fairly easily it could be because you are either using a worn out contact tip (wrong size orifice) or the tension on the roll of wire is excessive. If it doesn't move easy then you probably have a dirty liner.
Reply:While I agree with Weldgault about using an oversized liner I recommend sticking with the proper sized contact tip for the wire.