Welding problems

[Wilfred]

Millermatic 211 is shorting out. The wire keeps grounding (welding) out to the opening of the wire liner INSIDE the welding unit where the wire feeds into the liner. I am going to replace the ground clamp and wire liner? Anyone have this happen or know the problem and if my new items will fix the issue?

 

[wanderinthru]

You mean inside the case? Under the flap/door where the wire roll is?

 

[Wilfred]

Yes right where it feeds into the weld wire sleeve it balls up into a tiny welded bend/ball that stops the wire from feeding through the sleeve.

 

[Scotty D]

Sounds like the liner is shorting out to me

 

[Wilfred]

right so new liner....?
I've already got one coming.

 

[wanderinthru]

Yup. sounds like the liner is wore out, then shortin out after it all balls up. Assume your tip is clean and the right size?

 

[Wilfred]

Yep thanks

 

[Wilfred]

So, replaced the liner and the ground and she is still shorting in the same location WTF is wrong with my welder?!?!?!?

 

[75Monza]

Might check your nozzle and make sure the Teflon liner is still good. Also, want to lay cable out straight and try to feed wire through to gun by hand with tip off, there should be little to no resistance.

 

[Wilfred]

It was the contact at the unit. The 4 or 5 square inches of contact area at the unit was corroded enough to stop current flowing down the line and making it try and go up the wire.

 

[shiftpro]

It's bird nesting right after the last roller?

 

[wanderinthru]

It was the contact at the unit. The 4 or 5 square inches of contact area at the unit was corroded enough to stop current flowing down the line and making it try and go up the wire.

So? You got it sorted out?

 

[dvdswan]

Good to know. I've got the same welder, I'll have to look at it.

 

[Wilfred]

Yes she is hot now. Took a red scrubber to it and a little di-electric grease and away we go!