wire melting near drive wheel????

[sharky8js]

Hi I just got a used Millermatic 135,
When using flux core wire; if the tip bumps the metal, the wire on the spool will melt and lock up near the drive wheel........
What causes this?
How can I stop it?
Will this only happen with flux core?

I have only used a flux core mig once before - hate it!!
I will be getting a tank of gas and regular wire in the next couple weeks.
Thanks, Josh

[jessehornberger]

your problem

solve the problem at the source...dont touch the tip to the workpiece...
but it sounds like your wip is not properaly installed in the machine, so your ground is tracing back to where there would be an "arc gap" and heating up and melting at that point. check the set screw and connections between the wip and the machine.

[jpence38]

When you pull the trigger your contact tip is "hot". This happens on all mig guns, but in your case, you are using a gassless wire with the tip unprotected by a nozzle. you should be maintaining a min. 1/2" stick-out and you wouldn't bump your tip on the workpiece. This machine should have tip saver/short circuit protection built in which extends contact tip life and protects internal components from damage. If contact tip is shorted to workpiece, the unit shuts down the welding output then you have to release gun trigger to reset unit.

[sharky8js]

Thanks for the tip Jesse!!! "dont touch the tip to the workpiece..." LOL!!!

Ok 1st off I'm new to Flux core welding - I mig welded with Gas for for 11 years using a L-tec 225 + Miller 250.

I got this used so yes the WIP could be hooked up wrong -- whats a Wip?

Whats the tip protector look like?? it might be missing.

[go2building]

WIP is your stinger and tip protector looks like a nozzle cup

[jpence38]

I mig welded with Gas for for 11 years using a L-tec 225 + Miller 250.

I got this used so yes the WIP could be hooked up wrong -- whats a Wip?

Whats the tip protector look like?? it might be missing.

I'm sorry, but if you have mig welded for 11 years and don't know what a wip and nozzle are, well..........

Wip = mig gun and attached cable that connects to welder
Nozzle = Brass or Copper cover over contact tip for distributing shielding gas

just sayin'.........

[aametalmaster]

I'm sorry, but if you have mig welded for 11 years and don't know what a wip and nozzle are, well..........

just sayin'.........

Thats funny...Bob

[turbo38t]

Wouldn't it be whip? I know the term, never thought it was spelled different though. Assumed is was called a WHIP because it looks like a WHIP. The guy came on here to answer a question. He didn't say he was a welder by trade, just that he has used solid wire mig for 11 years. That's all some people use and some people didn't have internet until recently. I'd say, before you even follow the instructions mentioned in the first couple posts that you should make sure the machine is hooked up electrode negative (ground positive). Then, make sure the gun is inserted all the way into the drive area(loosen the finger screw and make sure it is pushed in all the way). That's a great little machine......for the most part leave the voltage cranked at 10.....run .023 wire and gas and it's a dream. However it does run flux core as good as it can be run too.....Dave

Thanks for the tip Jesse!!! "dont touch the tip to the workpiece..." LOL!!!

Ok 1st off I'm new to Flux core welding - I mig welded with Gas for for 11 years using a L-tec 225 + Miller 250.

I got this used so yes the WIP could be hooked up wrong -- whats a Wip?

Whats the tip protector look like?? it might be missing.

[sharky8js]

I'm sorry I never heard the terminlogy "WIP" before! I just called it the gun assembly.
Yes I know what a nozzle is, but never called it a "tip protector" - I wasn't sure if it was the same thing.
Like I said; I'm new to flux core welding.
No I did not go to school for welding, and yes it was part of my job. I was also a machinest, electrican, plumber, and carpenter.
I learned brazing and stick in body shop class in high school.
I built floating fountains out of stainless angle using mig for 11 years 95-06
and in 2008 I learned how to tig weld - did it for about 6months untill I was laid off

I just downloaded a owners manual - I'll double check the polarity.

Other than that, I'm just going to scrap the flux core wire, and hook up gas and use regular wire.

[jpence38]

Sharky,
I apologize if I offended you. Was just bustin' balls that's all.
Gasless flux-cored wire does not need a nozzle around the tip to distribute shielding gas. It has a black cover that goes over the gas diffuser to protect it but leaves the contact tip exposed. Which, as you have experienced, will short out when it touches the work piece. Also, gasless flux-cored wire is supposed to be run Electrode Negative. Gas-shielded flux-core and solid wire are supposed to be run Electrode Positive. I would say that you are on the right track with switching to solid wire.