Desperate help needed

[inverted_577]

ok so i bought a brand new mig welder so i could restore and repair my mini but i dont kno if its me or the welder but it just keeps snagging and bundling up in the rollers no matter what i do nothing changes if i loosen off the tention or adjust the wire speed it does the same i can normally weld about 4 inches before it does it also the wire reel doesnt sit great on the holder theres loads of room and it judders round theres nothing tentioning it, the welder is a varmig 1600 i bout it off gasman on here but just wondered if it was something im doing wrong, if not ill contact him, here is some pictures of it

 

[wyn]

That looks like a pretty sharp bend where the wire liner comes out of the casing.

It somehow looks like it could do with a bit of support to keep it straighter until it exits the casing.

Are the tips the right size ? If they are too tight, after 4" of welding it might have heated up enough to jam the wire.

 

[inverted_577]

yea the tips are the right size, should there not be some kind of tentioner on the reel?

 

[shenion]

Usually when the reels lie flat, there is no tensioner.

 

[malcolm]

I'm guessing the wire is birds nesting directly after the rollers. The wire liner in the torch should extend right up to the rollers, and your photos suggest a gap.

You'll probably be able to unscrew the cover on the right of the rollers and move the liner closer to the rollers, but I'd be inclined to contact the seller so he's aware of the issue and can alert the factory or tell the shippers off, and also advise you about any warranty issues that might occur if you fiddle with the welder.

Looks like the torch has had a pull - I'd imagine the rubber support ought to engage with the hole in the front of the welder to help avoid wild bends.

 

[inverted_577]

ok thanks for the help guys ill have a go and see what happens , so it will be ok then with the reel running loose with nothing holding it tightly

 

[inverted_577]

ok i've now found the problem its the liner, when you pull the trigger and apply a bit of pressure to the wire it pushes the liner forward causing a gap between the roller and the liner which then causes the birds nest, so my question is how do i keep the liner from moving?

 

[guzziguy]

where the reel off wire is sitting in the machine there is normally a plastic cap which you twist which stops the reel from coming off as you weld,also another thing that may cause the wire snagging is if it is either randomly wound wire or robotically wound wire,but definately agree with malcolm and the rubber support that appears to be missin near where torch comes out of machine

 

[shenion]

the 3 screws on the front end of the feeder should tighten down on the liner. One is near the rollers, 2 where the liner connects.

If the liner was pulled out hard enough, it may have stripped the clamp.

As I have said, ther is no need for any clamp on the reel. Most are done that way in that type of setup.

 

[guzziguy]

if the liner is moving as you press trigger then id say the liner has been cut 2 short,if thats the case you need a new liner and need to leave it longer than the current one

 

[inverted_577]

aww what, that sucks as its only a couple of months old, where can i get a liner from? also where the liner meets the rollers there nothing holding the liner like a nut or anything, its just the liner

 

[Rusty]

Have you been pulling the welder around by the torch ? We've probably all done it looks like the rubber torch surround has pulled out of the case and the liner has followed

 

[malcolm]

Looks like it has come out. I'd try to reinsert the rubber bung into the front of the welder myself. Maybe add a cable tie to try to stop it from coming out again. Then the liner will be the right length again.

It's possible as others have said that whatever caused the liner to yank out has damaged it's fixings. If so some imagination might be required. I keep a stock of old car inner tube to improve grip on liners whenever I need imagination.

 

[inverted_577]

no i haven't thats whats puzzling me and i haven't wrapped the torch up to tight either, this is the first time i've really used it for more than 2 minutes, so now im finding the problem

 

[rtbcomp]

My Sip has the reel lying flat and is equipped with a tensioner to prevent running on.

I don't see what difference the orientation of the reel makes, however it lies momentum will cause it to carry on rotating once the wire has stopped.

 

[KTMMICK]

Are you sure that the adjuster (the black knob by the rollers) is not to tight.
It is a common misconception they need to be tight. The wire should stop when gripped between a gloved hand.......this may not solve your problem but may save you a fortune in birds nested wire.
Are you using the right size wire for the rollers?
Try pulling the trigger with no tip and see what happens, is the roll of wire positioned on the locating pin?

Once you have tried these come back with your findings and we will think of other options if these have not worked.

One last thing have you dropped anything on the cable?