Now keep in mind this happens both with my spoolgun and my push pull gun, which makes me think the problem is xr related rather than gun related.
The spoolgun liner is fine/clean, the tip is a 3/64 aluminum as it should be. The wire feeds okay when I take the tensioner off and push. The spool seems okay, not binding. Same holds true for the push pull. i am using knurled drive rolls, but they are clean, no shavings in the liner etc.
Both spoolgun and push pull power cables run thru the voltage sensing switch and connect to the XR power block.