Power vs feed

[rodroy]

I exchanged a Clarke 100EN for a 90EN to get the lower 24 amp setting to weld 0.85mm mild steel using gasless wire. I'm using the Clarke 0.8mm gasless wire supplied and seem to suffer from endless spatter rather than the healthy 'sizzling bacon' sound for both settings MIN1 & MIN2. I can see the advantage of independent amps and wire speed.
If I back off the feed to 4 I can run a weld of sorts without blowing holes but deposition of wire is poor. If I use the recommended 5 or even 6 the feed is too fast and doesn't melt quickly enough leaving too much wire protruding from the nozzle. Can't seem to synchronise.
Am I at the lower limits of the Clarke 90EN?

 

[shenion]

I think you are at the lower limits of gasless wire.

My 130 ran wire speed of 2-3 on lower settings.

 

[keith19]

Couple of suggestions.

Have you tried switching the polarity around? Sometimes works.

Try some of this good quality Lincoln gasless wire instead of the Clarke gasless?
http://www.rapidwelding.com/dynamic/DisplayItem.aspx?c=ED031448&zl=3

Just thought, you are using the TMT - Thin Metal Technique, aren't you? Essential with gasless wire on thin metal.

 

[fuff66uk]

I can vouch for that lincoln wire it's superb stuff,improved my welds a hell of a lot

 

[l4urence]

Hiya - change the wire liner in the welder. The cheaper machines seem to come with nylon liner and a metal one has far less drag, costs a fiver and takes 20 mins to change. On the lower speed the drag of the wire is much more - this simple change transformed mine.

Keith19's point about polarity is important - check it and gas less is the opposite to gas.