MigPro 90 Wire Breakage

[nay27uk]

Hello all I’m new to the forum and im having a problem with my mig pro 90 it seems to have done this since I bought the thing over 6 years ago and it is really annoying, to complete a job that should take 5 mins it takes over 3 hours because I have to keep stopping and re feeding the wire when it breaks at the feed.
I’ve looked into everything to try and stop this breaking the wire at the feed including, slowing down and speeding up the feed, turning up and down the max min, even took the feed motor off once and reconditioned it as I thought it sounded like it was struggling and still does. Please can anyone tell me how I stop this happening before I just bin the crap?
Thanks

 

[gavuk]

Could really do with some more info ,what size wire are u using ? where in the feed is it breaking ,can u take a photo showing where?,is the liner in good condition?is the tip in good condition is the feed roller in the correct way around and have you over tensioned the drive rollers?.....a picture showing where it breaks will most likely bring more replies,i'm trying to anticipate questions other members will ask ...Gav

 

[nay27uk]

Hi and thanks for the reply.

the wire always breaks right between the rollers and gets all bent up towards the bottom of the welder.

wire im using is 0.6 and roller is on the corect way round.

not sure about tentions as i have never realy known how to use them as the instructions never realy explained it, but having read this site i now know how to set them up properly.

I think The liner, after reading this site, could do with being changed so im going to put one of them in, Also a new reel i think as this one has been sitting in the welder in the garage for well over a year with no use.

Also the rollers themselves look slightly rusty.

And i have seen the metal strip mod for the rollers on this site, but it says its for sip welders will this mod also work on mine

 

[shenion]

The liner may be jammed up. If there is any rust on the wire, it will plug up the liner.

How big a clearance is there between the rollers and the liner? Should be as sclose as possible. It may have been pulled out some. On my 130, I ground the end of the liner to a V so it fit right up close between the rollers. Was near impossible for the wire to birdsnest.

Picts may help.

The newer Clarke's don't need the strip mod. I hear the older ones do.

 

[nay27uk]

thanks shenion the liner goes about 1-2 mm away from the rollers i think as i moved them closer because when i bought the welder they was about over an inch away. I will go and take some photos today for you all

 

[nay27uk]

ok some pictures for ya all

 

[chevyman_de]

Regardless of anything else: turn the wire spool around so the wire can enter the wire feed in a more convenient line.

 

[malcolm]

The reel looks like it has been wound by hand. It is likely it will snag and tangle every now and again which could cause inconsistant wire feed. When you say break does the wire actually break into two pieces?

The grup screw holding the bottom roller looks like it is sticking out. Could it be catching on something? They are normally recessed.

What is the distance from the right of the roller to the liner that goes to the torch? If the distance is too large it will cause a birds nest. I used to have my liner sticking out of the plastic clamp.

 

[chevyman_de]

The grub screw holding the bottom roller looks like it is sticking out. Could it be catching on something? They are normally recessed.

Now where you mention it...
Looks like it can't turn at all without hammerings against the front of the wire feed block. And the groove in the drive roll does not line up with the incoming wire.

 

[R Kraft]

The screw may have hit the liner and pushed it into the mount.
Robert

 

[wyn]

As chevy man says... the groove doesn't line up. When the rollers are tightened to give a bit of drive it could well be flatening the wire and causing problems in the liner.

Also as malcom mentioned... the screw holding the roller on may be hitting some of the plastic parts. So pulling the roller outwards a bit would line up the groove and also prevent the screw hiting anything. It should really be a recessed grub screw and not anything that sticks out.

Another thing to be aware of is that sometimes the writing on the roller that is facing outwards corresponds to the wire groove furthest away. Can't quite read the number in the pic, but it would probably need to be 0.6 stamped on the face you can see.

Edit : just noticed it's a clarke so 0.6 on the roller face you can see.

 

[nay27uk]

sorry folks im not sure what screw your talking about, if its the small thing to the left of the roller in the third picture you meen this is not a screw its actualy a plastic cross shaped thing that sticks out as in picture 1. The screw that holds the roller on is sunk / ressed into the roller and is actualy a alankey screw, someone mentioned that the wire is not level with the grove on the roller. it is leavel the front most grove is for 0.8mm wire, where you see the wire it is sitting directly in the 0.6mm wire grove, then the other bit right at the back that looks like a grove is infact not a grove but is the ende of the roller

 

[Jake SS]

If as in your first photo the drive roller is flush with the motor shaft, I assume thats where you have it set to normally, if so there is no way that the wire will line up in a horizontal plane with the inlet guide, roller groove, and outlet.

Also take the outlet cover off and check that liner is pushed back as close to the roller as possible