Can't get a consistent arc???.... HELP!!!

[Slurpee]

Hello everyone.
I'm a rookie welder and new to this site and I am having an issue with my Miller Cricket, currently set up with Blueshield gas
Ever since I have gotten it (used) I have had an impossible time getting a nice consistent arc or connection with my welding surface. Both with flux core and now with gas.
Once I set up and pull the trigger I get an arc for about a second and then it's as if the wire stops moving for only a fraction of a second and then starts again creating a bit of a "chugging" wire for lack of a better word. I am also getting a big bubble of molten wire attached to my wire after every weld.
-I have tried adjusting everything I can. High speed low speed, high voltage low voltage and any combination in between. Some mixes get me better results but ultimately the same thing is happening.
-I have tried playing with the wire feed tensioner and wheel as well. If it's too loose it doesn't push but if it's too tight it folds the wire up in the spool box. I have tried both sides of the one wheel that came with the unit. A smooth track on one side and a grooved track on the other.
-I have cleaned and replaced the tip.
-I have tried new and old metal.
-I just need some advice. I am currently working on a 16g gas tank project and need this thing to work properly now!!!!

Thanks

(I just went out and checked my wire to give more details on the size and IDIOTICALLY discovered that both my rolls are flux cored. I thought the one I had just been using with the gas was non flux.... hopefully that will make a HUGE difference when replaced! Either way please pass on advice that may come to mind)

 

[shenion]

Welcome to the forum

Could be your liner is worn or plugged up. If you are getting birdsnesting (wire folds up) there is a restriction somewhere. Could be the liner was kinked or you had used rusty wire.

Also could be the wrong size tip or a worn tip. Most gasless wire is 0.035"/0.9mm.

Also a too short torch/work gap will cause the wire to stick to the tip.

 

[Slurpee]

Awesome thanks. I'll try blowing out my liner and getting new tips.
What side of the wheel should I use with the .035 wire? Smooth or grooved?

 

[keith19]

Grooved with gasless flux-cored wire.

 

[Slurpee]

OK, I just got my new spool of 0.035 solid wire and matching tips. I blew out the liner and a lot of dust came out. I got everything set up and .... still no good really.
It's a little better, and with the voltage and speed cranked I can sometimes get a half decent puddle going. But mostly the wire is still pulsing out and causing the connection to be lost.
I did notice tonight that it is set up on reverse polarity and has a sticker that says for solid wire and aluminium that's the way it should be... Is that right?

The wire seems to slide through the liner easy enough. I can push it and pull it by hand. What side of my drive wheel should I be using with this wire, grooved or smooth?

Any other ideas please help?

 

[Sparkey]

Smooth is for solid wire so that's the side of the roller you should be using!
For solid wire your torch will be positive and the earth lead negative, but it will be indicated on your welder!

Does the drive wheel match your wiresize? again the size should be stamped into the side of it...

 

[shenion]

So the wire speed is not consistent?

Watch it without welding anything. Just see how it moves and see if the feed roller is turning consistently (and the pinch roller). Also make sure the reel is turning smoothly.

If the wire is slipping, you should be able to see it at the roller. If it is consistent, then it sounds like it is too slow.

 

[keith19]

Just a thought. If it's an oldish machine check the earth clamp is not corroded at all, either at the jaws or at the cable connection. Reason being that a poorish connection may offer resistance which takes a fraction of time for the current to overcome, then it may strike an arc, then cut out again as power drops momentarily, then pick up and arc again.
Your problem might not be this at all, but it's worth checking it out.

 

[scarecrow]

this problem sounds similar to this tread

 

[Slurpee]

So the wire speed is not consistent?

Watch it without welding anything. Just see how it moves and see if the feed roller is turning consistently (and the pinch roller). Also make sure the reel is turning smoothly.

If the wire is slipping, you should be able to see it at the roller. If it is consistent, then it sounds like it is too slow.

I've done that. The wire moves fine when there is no resistance to it. BUT if you put your finger in front of the wire it starts slipping at the drive wheel right away.... This is what I seem to think causes the problem as the wire is constantly touching the welding surface then hesitating for a second before being shot back down again... but I know next to nothing about welding. What should I check next?

 

[shenion]

Sounds like a problem with the feed roller tension or the wrong size feed roller.

Is the feed roller marked for the the same size as the wire?

Edit: Looking at the manual, it looks to have one roller for 0.023 to 0.045 wire. Seems odd as near every other model they uses different rollers.

You might try the knurled side of the roller. The wire should only slip when it hits something hard.

Could be the pressure roller is worn or misaligned.

 

[Ed.]

If I understand you correctly, it appears that you have one roller to do wire sizes from 0.023 to 0.045 wire. That to me seems very wrong. On all the Migs I have ever used in 40 odd years I always had a roller set to suit the wire size, so 0.6mm wire had .6mm rollers and 1.2mm wire had 1.2mm rollers etc.

My latest miller wirefeeder that I have has a couple of rollers which are dual size in that one of the grooves on one side fits 0.9mm wire and the other groove on the other side fits 1.1mm and you just flip both of them them around to suit the correct wire that you are using, but I have never come across a roller where one roller groove suits all the wire sizes from 0.023 to 0.045 wire. If that is the case then I think that is where your problem lies.

I can't see how the rollers can get the right friction on the wire for the size groove that the roller has. Just my 2 cents worth.

 

[Subsonicnat]

wire feed

Hi Guys, Right did have the same trouble last week as a matter of fact!!!!!!!!.
Mine was plain and simple, when I had sussed it.lol.
The wire was 0.06, BUT the copper TIP was for a 0.08, Now that is not good because it is NOT making Contact with the tip all the time, So you get intermitent contact, I tapped the end with a small hammer till it felt just right and it ran a Treat, worth a shot anyway mate, Just Check..
Colin:UK.
PS: Bought about 400 of them from a car boot for a couple of quid some years back forgot the size and just used them, caused me a head ache for while.l

 

[R Kraft]

Crickets are good little welders.
A Cricket is a fairly old machine,and may have some wear on it, check to see that there is enough tension on the feed roller spring.
If the rollers have enough tension,check to see if the groove on the drive wheel the wire runs in, has worn too deep.
The owners manual is here.:http://www.millerwelds.com/om/o1307b_mil.pdf