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  • Spoolmatic problems

    I have a spoolmatic 30a hooked to a miller matic 250 that is used for aluminun and am having some problems with it. We use either .035 or .025 wire and have the drive rolls to match, two things are happening, it's either burning off inside the tip, or it acts like it's pulsing while your welding and I don't have a pulser. We have to tighten the tension on it with pliers to get it tight enough to weld but then the wire spirals outta the tip and it leaves grooves in the wire from being so tight. The machine is set at 19 to 21 and the wire speed on the gun is 5 to 8, the machine welds great sometimes and sometimes I wanna throw it out the window. Straight argon is used and I still get a lot of black around the welds even after cleaning with a tiger disc and a ss wire wheel. I also have a Dialarc 250 A/C-D/C machine and want to know if Miller makes a machine that will hook up to it to give it high frequency, pulse, etc. I appreciate ya'lls help,,, Outlaw

  • #2
    Originally posted by outlaw
    I have a spoolmatic 30a hooked to a miller matic 250 that is used for aluminun and am having some problems with it. We use either .035 or .025 wire and have the drive rolls to match, two things are happening, it's either burning off inside the tip, or it acts like it's pulsing while your welding and I don't have a pulser. We have to tighten the tension on it with pliers to get it tight enough to weld but then the wire spirals outta the tip and it leaves grooves in the wire from being so tight. The machine is set at 19 to 21 and the wire speed on the gun is 5 to 8, the machine welds great sometimes and sometimes I wanna throw it out the window. Straight argon is used and I still get a lot of black around the welds even after cleaning with a tiger disc and a ss wire wheel. I also have a Dialarc 250 A/C-D/C machine and want to know if Miller makes a machine that will hook up to it to give it high frequency, pulse, etc. I appreciate ya'lls help,,, Outlaw
    You should ck. the spool tensioner & the plastic wire guides that lead into the contact tip. How about the tip itself has it arced on the inside or plugged up with dirt ? If you have to tighten the tension that much to push the wire a few inches the problem should be pretty easy to spot.

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    • #3
      Is the tension on the spool spindle too tight?? There's a nut, tightens up and forces out the rubber spindle to create more drag. Too much, you're trying to pull against it and get erratic feeding.

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      • #4
        As said previously check spool tensioner first. Then check the drive roll. Sometimes they get clogged up with aluminum & need to get replaced because they don't grip the wire correctly so you wind up over tightening them to get it to feed. I'm assuming you already replaced the tip. Try pushing the gun to aleviate black soot. ---MMW---
        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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        • #5
          .035 aluminum wire needs a larger tip than .035. I would have to go into the shop but if my memory serves me right I think it is .041, I will check and post back in a minute.

          Do you have a newer gun or one with the quick tip (older)?

          Are you pre flowing your gas & what amount of gas are you using?

          I think your liner might have also went south, there should not be that much tension on the feed roll to push that wire like that.

          The unit is pretty easy to service, check your tube and tip, mine does put little teeth marks in the wire but not much.

          One last thing to try. remove your tip and loosen the feed down on booth the spool and the feed and see how the wire runs. If it feeds well, its in the tip.
          I can actually just finger my tension and the wire runs well.

          Let us know what you find.
          Out to the shop it see the size.

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          • #6
            Make sure the spool is turning on the spindle. So many times mine has given me fits and that is the problem. It gets bits of something in there and locks it up. Every new roll i put on gets a 5/8" bit run thru it just to be sure....Bob
            Bob Wright

            Spool Gun conversion. How To Do It. Below.
            http://www.millerwelds.com/resources...php?albumid=48

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            • #7
              Correct Fastip for .035 aluminum is the .035/.052 tip, not the .030/.035.
              Just the heads up....

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              • #8
                .035 aluminum wire needs a larger tip than .035.
                That's for sure The instruction book for my 30A (about a year old) specs a .047 Fastip #206 187, used with drive roll #136 135. Those would be the first areas to look at.

                The 30A has a 2-stage trigger which includes gas preflow. There are two things I do when aluminum welding. First, as soon as the Argon tank valve is opened, pull the trigger halfway (so the wire does not feed). Count to ten or fifteen to allow the Argon to fill the line from the tank to the gun. Then, on every arc start, pull the trigger halfway for one or two seconds to get shield gas coverage before starting the arc.
                Barry Milton
                ____________________

                HTP Invertig 201
                HTP MIG2400

                Miller Trailblazer 302, Spoolmatic 30A, Suitcase 12RC
                Clarke Hotshot

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                • #9
                  Hey, thanks for the information,,, been messing with most of the stuff yall suggested except for the larger tips. Do yall run enough tension on your spools to keep it from backlashing? I'll get some bigger tips and change the liner when I open up tomorrow. The rig is probably about 5 years old and really can't complain about it, usually run about 35 on my flow meters and will start paying more attention to pre and post flow. Appreciate it, will keep yall posted, later ,,, outlaw

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                  • #10
                    I have looked at tips for about 2 years, and worked with a few tip companys engineers to iron out some problems. Most .035 tips are .010-.014 thou bigger so they should work with no problem so they are already .045-.049. But some tips are just as they say .035 and .035 wire just squeeks thru, then you add the little knurl from the drive rolls and the wire is too big now to fit. I was drilling some out to get the fit i wanted and they worked fine. My spoolgun with the proper .035 tips just would not work well, and they were the biggest i coud buy. So i redesigned the gun to take different tips. It worked so well i am going to switch my other gun over also. Now i can run .035 marked tips with zero problems with .035 wire. So all tips are not created equal no matter whose name is on the package, check them out with some small wires and a mic and you will see, i used the smooth end of the tip cleaners for a torch for the gage wires....Bob
                    Bob Wright

                    Spool Gun conversion. How To Do It. Below.
                    http://www.millerwelds.com/resources...php?albumid=48

                    Comment


                    • #11
                      usually run about 35 on my flow meters and will start paying more attention to pre and post flow
                      My settings on the gas in shop are 20 to 25 with no circulation fan running, with fan running 25 to 30 and I have had very good luck.

                      It has been discussed that over gassing can cause turbulance and bring in contamination, just something else to consider try dropping down a little and see if that also helps.

                      Just food for thought my Python likes 18 to 20 on the gas, but that is a different animal all togeter....

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                      • #12
                        My settings on the gas in shop are 20 to 25 with no circulation fan running, with fan running 25 to 30 and I have had very good luck.
                        Exactly the settings I use.

                        Funny how great minds think alike
                        Barry Milton
                        ____________________

                        HTP Invertig 201
                        HTP MIG2400

                        Miller Trailblazer 302, Spoolmatic 30A, Suitcase 12RC
                        Clarke Hotshot

                        Comment


                        • #13
                          I've run .035 wire with mine but find it to be finicky, I find I have alot less trouble running the 3/64.
                          So if you are welding on thick enouph material I would recommend switching to the larger wire.
                          As far as tig welding off your arc welder you should be able to buy an HF-251 high freq. box, a foot pedal and a water cooler with a tig torch.
                          I dont recomend trying to run tig aluminum without a water cooled torch.
                          This set up should run you about $ 1,750.00
                          However I just sold my 1992 250 amp synchrowave with a cart and everything but the plug for $ 2,000.00 to make room for my new
                          Dynasty 300 DX
                          So I would recommend looking for a good used tig.

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