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Hello,
I have a Hobart 210 set up with a spool gun. The set up has been working fine for years (although used very intermittently.) In the middle of a project something seems to have gone wrong with either the spool gun or welder. It immediately burns back/melts contact tip when used at settings that previously worked. I am using 100% argon and 4043 filler wire. I'm holding ~3/4" stickout. I can max out wire speed and it still burns back and melts the contact tip almost instantly at setting of 5 and 6 on the machine. Here is what I have tried so far with no luck:
I have a Hobart 210 set up with a spool gun. The set up has been working fine for years (although used very intermittently.) In the middle of a project something seems to have gone wrong with either the spool gun or welder. It immediately burns back/melts contact tip when used at settings that previously worked. I am using 100% argon and 4043 filler wire. I'm holding ~3/4" stickout. I can max out wire speed and it still burns back and melts the contact tip almost instantly at setting of 5 and 6 on the machine. Here is what I have tried so far with no luck:
- Checked input voltage at machine (244 volts)
- fresh spool of filler wire (tried both .030" and .035")
- varying gas rates
- tried various pieces of scrap (1/8" and 3/16") all wire brushed clean
- changed o rings on welding lead
- added scotch brite pad to diffuser in gun
- triple checked that polarity is set correctly
- tried lower voltage settings (i can get it to not burn back at lower settings, but it doesn't weld, just makes a mess of melted drops of filler wire)
- swapped machine back to conventional MIG and welded steel with flux core - no issues, although at lower voltage than aluminum requires
- measured wire speed exiting gun (240-250 in/min) with a full spool of .035"
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