A couple more things to check are:
Is the spool of wire on upside down?
That could cause undue tension on the rollers causing them to bind the wire as it tries to feed it. Basically, it should be a straight shot through the rollers off the spool. The spool is usually underslung.
The spool is underslung....
Also having the spool not mounted correctly will cause it to bind. It should roll smoothly.
It does indeed roll smoothly
What are your settings?
With the wellder turned off you can grab the wire and push it back into the gun, so the settings have nothing to do with what I am thinking is a problem.....
Too much voltage and not enough wire speed will cause a burn back condition.
Try turning the voltage down a bit and see what happens.
Too much wire speed and not enough voltage will cause the opposite of a burn back, which is ''stubbing'' of the wire while you weld.
I have tried welding with with low voltage/low wire speed, high voltage/low wire speed, low voltage/high wire speed and high voltage/high wire speed and the results are always the same, it wants to burn back into the tip. Which is why I am thinking the wire "back pedaling" into the gun is a problem.
If this doesn't do anything, then i bet it's a kinked liner.
Kinked and/or dirty liners will cause a lot of problems overall.
I hope this helps.
Tom.
Thanks for your input Tom, I am hoping it is just a kink in the liner.
