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Wire bunching up

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  • Wire bunching up

    I recieved a millermatic 200 from my father and I changed the wire from .035 to .023. I am having problems with the wire bunching up as soon as it comes out of the roller and before it goes into the wire housing. I did change the rollers and the tip to .023. I didnt change the wire housing but it seems several people on here say that changing the wire housing to .023 isnt necessary. I have kept the wire sraight while welding but it still bunches up. Does anyone have any suggestions on how to correct the problem? Additionally, how do I know if I have the correct tension on the rollers and the roll of wire? Thanks in advance.

  • #2
    I adjust the rollers tension by loosening it where it won't pull any wire and then tighten till it just starts to take it then a smidge more. I would also take the tip off and take a fresh cut piece of wire and see if you can slide it through the tip with no resistance not all wire and tips are exactly the same. I would also see if you can draw the wire through the liner easly if there is resistance the other could be something inside like dirt or grime you might be able to blow it out. Worst case is there might be a small kink or the liner has gone bad and needs replaced.
    Is the wire you are using new?
    Also make sure your drive roller is correct for the size wire.
    Last edited by DATEC; 07-01-2015, 06:17 PM.

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    • #3
      2346 welcome to the forum.
      Lincoln A/C 225
      Everlast PA200

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      • #4
        A .023 liner might be your friend on this one. It fixed my same issue on my MM251. Obnoxious to do but relieves frustration.

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        • #5
          this may help, https://www.youtube.com/watch?v=ahf2oggp8qY

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          • #6
            Incorrect drive roll size, incorrect drive roll tension, bad liner, bad/wrong size contact tip, bad ground clamp/incorrect WFS.
            Miller Trailblazer's ( 2 )...MillerBobcat 250...Millermatic 251's ( 2 )...Miller Syncrowave 200...Miller Syncrowave 180SD...Miller 12VS Suitcases ( 2 )... Hobart Hefty CC/CV Suitcases ( 2 )...Miller 30A Spool Guns ( 2 )...Miller WC 15A Control boxes ( 2 )...Thermo Dynamics Cutmaster 50 Plasma Cutters ( 2 )...Thermo Arc Hi Freq Units ( 2 )...Smith / Victor O/A Sets...DeWalt Power Tools...Craftsman / Snap On Hand Tools... Two Dodge Mobile Rigs

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            • #7
              Gun length & liner size. Run an .023 liner & hopefully you have a 10' gun. The longer the gun the more difficult it is to feed .023 wire.
              MM250
              Trailblazer 250g
              22a feeder
              Lincoln ac/dc 225
              Victor O/A
              MM200 black face
              Whitney 30 ton hydraulic punch
              Lown 1/8x 36" power roller
              Arco roto-phase model M
              Vectrax 7x12 band saw
              Miller spectrum 875
              30a spoolgun w/wc-24
              Syncrowave 250
              RCCS-14

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              • #8
                Thanks for the suggestions I will start with the simple ones and go from there.

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