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Lincoln welder wire burn back

[memphis]

Web wheeler
Joined
Jun 6, 2020
Member Number
1867
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751
I have a Licoln Mig Pak 15 (tapped 240v machine)

I have only ran this machine on fluxcore for the last 15 years, probably 20-25 spools through it.

Changed my spool out and I am having all sorts of burn back issues?!

It’s burning like 1.5” inside the tip.
It looks like it’s shorting the liner to the tip. I trimmed off about 3/4” to see if that helped and it sort of did for a bit but I am still having issues.

It ran flawless until the roll change… I can’t see it being the new roll of fluxcore causing this but it’s something I haven’t changed?

Anyone ran into this before? It is NOT arcing out on the drive wheel.
 

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And you said old roll was flux core AND new roll was flux core?

Flux and solid use different polarities. If you didnt swap the wires maybe you hit a switch on the face.
 
Ever changed the liner in the gun? New tip?

Cheap garb brand of flux Core wire?
 
total newb said:
And you said old roll was flux core AND new roll was flux core?

Flux and solid use different polarities. If you didnt swap the wires maybe you hit a switch on the face.
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Correct I have never run gas in this unit or switched the polarity.
 
Winchested said:
Ever changed the liner in the gun? New tip?

Cheap garb brand of flux Core wire?
Click to expand...
Never changed the liner in 15 years. Not even sure how to 😆

Forney flux from CQ. I’ve run a handful of these spools in it over the years without issue but I am starting to wonder.

New Lincoln gun is $360 CAD. Looks like there are some knock offs on Amazon? Not sure if those are a bad idea
 
[memphis] said:
Never changed the liner in 15 years. Not even sure how to 😆

Forney flux from CQ. I’ve run a handful of these spools in it over the years without issue but I am starting to wonder.

New Lincoln gun is $360 CAD. Looks like there are some knock offs on Amazon? Not sure if those are a bad idea
Click to expand...
Change the liner. It’s a $20 fix. Increase tension on drive roll. You may need to swap polarity going from straight flux to shielded.
 
Need to swap polarity. This is the setup your running. Reverse these steps.

DE08EF6B-AECA-4607-9AEE-AD2B490D1882.png
 
Did you accidentaly turn the wire speed down to nothing?

Forget to flip down the pressure roll?

You change the liner by removing the lead from the machine and pulling on the lil brass end
 
not familiar with that welder.

if your arcing in the liner and not the tip, you have a problem with the tip. and you need a new liner, if you trimmed it 3/4" your asking for more problems you want them to fit tight, most people trim liners too short. make sure the whip is completely straight when checking fit, even then i cut 1/2" at least more than i think i should on a 15' whip. and touch up the end after cutting.

there can be current in the liner but should ultimatly transfer at the copper tip, if burn back doesn't melt the tip thats got to be hot dog in a hall way loose. either way tips over used or the wrong size.

flux core fed with the grooved wheels is dirty, will fuck liners up often, between every roll i blow compressed air thru and change tips. everytime. when in doubt change the liner. cheap insurance.
 
The wiring on the machine is correct. I did notice the line was not feeding in the drive roller groove. Not sure how it walked out of that but it did. So I reset the wheel and will order the liner. This machine owes me nothing… it’s the least I could do for it.
 
if it is arcing in the liner you've got problems in the gun/whip lead thingiemabob
take it apart and make sure the copper wire that should be conducting the weld current is still connected to the bit that the diffuser screws into (the diffuser is the bit that the copper contact tip screws into and the gas nozzle fits over)
also give the copper wire a good tug to see if it has come loose at the machine end of the gun whip
 
[memphis] said:
The wiring on the machine is correct. I did notice the line was not feeding in the drive roller groove. Not sure how it walked out of that but it did. So I reset the wheel and will order the liner. This machine owes me nothing… it’s the least I could do for it.
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Same with my 140. Bought it in 08 and have prob 40 10lb spools through it. It live in my work truck for 4 years and now at the mill for the last 2.
 
While you are messing with stuff, are the drive rolls set for the solid wire? Flux core groove is usually knurled while the solid wire one is smooth grooved.
 
Brad said:
While you are messing with stuff, are the drive rolls set for the solid wire? Flux core groove is usually knurled while the solid wire one is smooth grooved.
Click to expand...
Lincoln usually just comes with solid groove, but has adjustable pressure design.
 
Winchested said:
Lincoln usually just comes with solid groove, but has adjustable pressure design.
Click to expand...
This is correct, single groove for .030 and .035. It does have a .025 groove on the opposite side. But the machine itself is very basic.

I should try welding again now with the roller adjusted correctly. I can’t see that fixing the issue but stranger things have happened
 
I had a similar issue recently with my Lincoln. 180. I had the settings for volts between d and e. There is no setting between d and e. Mess with the volt knob while welding.
 
NOODLES said:
I had a similar issue recently with my Lincoln. 180. I had the settings for volts between d and e. There is no setting between d and e. Mess with the volt knob while welding.
Click to expand...
I was burning 1/4” plate on E when this was happening
 
I was drunk when it happened to me. Next day, checked my power cord ends,like actually took them apart. Slapped them back together, then I realized my issue when I adjusted the setting to weld thinner for a test run. I had it between settings. :laughing:
 
Winchested said:
Lincoln usually just comes with solid groove, but has adjustable pressure design.
Click to expand...
My buddies 150 has a reversible drive roll. We went to look at it before he bought it. Guy said it wasn’t feeding right. I saw he had the solid wire on the flux core side. Told buddy tok talk him down and buy it. He did, 220v Lincoln 150. This was back when they were actually more like a 175
 
Brad said:
My buddies 150 has a reversible drive roll. We went to look at it before he bought it. Guy said it wasn’t feeding right. I saw he had the solid wire on the flux core side. Told buddy tok talk him down and buy it. He did, 220v Lincoln 150. This was back when they were actually more like a 175
Click to expand...
Mines reversible too but for 25 wire on one side and 35 on the other.
 
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