How to prevent "birds nesting"
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  1. #1
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    How to prevent "birds nesting"

    My boss and I have taken the advice from many of you welding webbers about running flux core wire. I've never used it before, and so far it's going ok besides the really annoying fact that it seems like every few minutes the wire gets all jammeed up inside and I have to take the welder apart and run it back through. Any tips on how to prevent this would be greatly appreciated. I have literally spent most of my day trying to fix the problem. Needless to say my boss is getting very frustrated with me as well as me frustrating myself.

  2. #2
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    Re: How to prevent "birds nesting"

    Is it unspooling or kinking up between drive rolls and gun?

  3. #3
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    Re: How to prevent "birds nesting"

    Using small rolls?



    PIA.
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  4. #4
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    Re: How to prevent "birds nesting"

    Quote Originally Posted by Bls repair View Post
    Is it unspooling or kinking up between drive rolls and gun?
    Yes, it is kinking up between the role of wire and the rollers that move it into the wire line. It hasn't come unspooled though.

  5. #5
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    Re: How to prevent "birds nesting"

    using correct drive rolls for flux core?
    Ed Conley
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  6. #6
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    Re: How to prevent "birds nesting"

    I am using an 11lb roll of flux core wire. That is the biggest size roll that will fit in the hobart 190 handler that I'm using.

  7. #7
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    Re: How to prevent "birds nesting"

    If you have the rollers too tight, it'll will bird nest easier. If your wire is coming out of the nozzel and has teeth marks, the rollers are too tight. Those ridges create more friction and can wear the liner prematurely. Another issue is if you get pushback when you fire up from the wire hitting the workpiece, the roller is still going to shove wire and if it kinks at the roller, that's where you get the birdnest. It needs to be tight enough to pull the wire without slipping, but loose enough that it can slip if there is a stoppage like the wire balling up on the contact tip or something.

    The machines usually have a chart for the tension setting, but outside of having those numbers, i would loosen the tension on the roller until i barely see teeth marks from the roller so that i can see them but not feel them.

    If you don't get results from adjusting the roller pressure, try swapping the contact tip to one size bigger, which i normally do anyway, and swapping out the liner for the whip if that doesn't help.

  8. #8
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    Re: How to prevent "birds nesting"

    Mess with the big black knob that says tighten if you haven't - wire coming of the top of the roll? or bottom? Take a pic with the hood open. And what BFA said above.
    Last edited by cloudman; 01-03-2017 at 07:02 PM.

  9. #9
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    Re: How to prevent "birds nesting"

    Quote Originally Posted by Broccoli1 View Post
    using correct drive rolls for flux core?
    I'm using the drive roll that says .030-.035. The wire is .035Name:  15871042_982054511939237_1860711220_n.jpg
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Size:  39.3 KB

  10. #10
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    Nov 2010
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    Re: How to prevent "birds nesting"

    Quote Originally Posted by aprilspence View Post
    Yes, it is kinking up between the role of wire and the rollers that move it into the wire line. It hasn't come unspooled though.
    EDIT to add that a few comments got in between when I read what you wrote and when I got done typing. I'm going to leave my reply as is although I realize you already answered at least one question I had below.

    I don't mean to put words in your mouth, but I think what you're trying to say is that it's kinking up between the drive rollers and where the wire enters the liner for the gun...in that little 3/4" or so gap. A birdsnest between the roll of wire and the drive rollers is something I've never seen unless the brake is loose and the roll unspools during travel or handling of the feeder....and it sounds like this isn't what's happening to you.

    So there are a few things that can cause flux-core feeding problems. First, be sure you're using V-knurled rollers which are for flux core. Regular V-groove or U-groove rollers can slip on the wire rather than feed it. Very annoying. Next, be sure your wire tension is set correctly. You shouldn't need to really crank down hard on the tension knob -- there should be just enough on it so the wire feeds reliably. Also, try to keep your gun's whip as straight as realistically possible. Tight turns or multiple curves can cause feeding problems. Blow your liner out with compressed air between rolls, and be sure it's sized properly for the wire so the wire can't build up a lot of 'spring' inside of it if it's too big, or bind if it's too small. Finally, if your tip is the wrong size or has burrs in it, it can be a bottleneck to good feeding. Even with flux-core, tips will last a good long while if properly cared for and not shorted out on the workpiece all the time.
    Applied Fabrications, LLC

    Mobile Welding / Mechanical Repair in VA's Piedmont & Shenandoah Valley

  11. #11
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    Oct 2006
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    Illinois
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    Re: How to prevent "birds nesting"

    I don't remember what machine you have but most have '' DEDICATED FLUX CORE '' rolls that normally '' DO NOT '' come with machine. It ay have a part number posted on the machine door or check with supplier or online.

  12. #12
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    May 2007
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    Re: How to prevent "birds nesting"

    Quote Originally Posted by cloudman View Post
    There should be a way to tension the roll of wire .
    theres your answer

  13. #13
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    Re: How to prevent "birds nesting"

    Quote Originally Posted by TheBFA View Post
    If you have the rollers too tight, it'll will bird nest easier. If your wire is coming out of the nozzel and has teeth marks, the rollers are too tight. Those ridges create more friction and can wear the liner prematurely. Another issue is if you get pushback when you fire up from the wire hitting the workpiece, the roller is still going to shove wire and if it kinks at the roller, that's where you get the birdnest. It needs to be tight enough to pull the wire without slipping, but loose enough that it can slip if there is a stoppage like the wire balling up on the contact tip or something.

    The machines usually have a chart for the tension setting, but outside of having those numbers, i would loosen the tension on the roller until i barely see teeth marks from the roller so that i can see them but not feel them.

    If you don't get results from adjusting the roller pressure, try swapping the contact tip to one size bigger, which i normally do anyway, and swapping out the liner for the whip if that doesn't help.
    Ok, thank you. I am using .035 wire and the tip says .035 on it but it does seem a little small. The next biggest size I have is .045. I will give that a try.
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  14. #14
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    Re: How to prevent "birds nesting"

    the stamping should read

    .030-.035 VK

    https://www.hobartwelders.com/om/6di...60273d_hob.pdf

    V is for solid wire and VK is for Fluxcore.


    The stamping is on the opposite side of the corresponding groove so you can read it from the outside- Make sense?
    Last edited by Broccoli1; 01-03-2017 at 07:08 PM.
    Ed Conley
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  15. #15
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    Re: How to prevent "birds nesting"

    the roll is upside down. wire needs to feed from under the roll

  16. #16
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    Re: How to prevent "birds nesting"

    Also make sure you can run the torch line is as straight as possible..
    Going around things..
    Twisted 30 times around ...
    Kinks of any kind don't do you any favors either....


    ...zap!


    I am not completely insane..
    Some parts are missing

    Professional Driver on a closed course....
    Do not attempt.

    Just because I'm a dumbass don't mean that you can be too.
    So DON'T try any of this **** l do at home.

  17. #17
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    Mar 2016
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    Minneapolis MN
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    Re: How to prevent "birds nesting"

    ya, wire should be coming off the bottom of the roll - and make sure the wire is in the .035 groove - it should say .035 as you see it in the front - flip them around if you see .030

  18. #18
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    richmond, va
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    Re: How to prevent "birds nesting"

    April,
    change the wire so it comes off the bottom of the roll to give a more straight shot into the rollers. Make sure that you have the correct rollers as was suggested above.
    Regards
    Dave

  19. #19
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    Re: How to prevent "birds nesting"

    Sounds to me like you need to tighten the mounting nut for the spool .Also check drive roll,make sure they are for fluxcore.
    What wire are you using?Photo of spoolwould help.

  20. #20
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    Re: How to prevent "birds nesting"

    take a look at the manual I posted up.

    It has the wire feed orientation and the description of the Drive Roll stamping for The HH190.
    Ed Conley
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  21. #21
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    Re: How to prevent "birds nesting"

    Quote Originally Posted by Bls repair View Post
    Sounds to me like you need to tighten the mounting nut for the spool .Also check drive roll,make sure they are for fluxcore.
    What wire are you using?Photo of spoolwould help.
    She posted up photos.

    Wire feed is incorrect for 1, 2- not sure on drive roll orientation- can't make out the stamping in her pic.
    Ed Conley
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  22. #22
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    Re: How to prevent "birds nesting"

    If she has been feeding solid wire this way, it may explain any other problems too.
    Ed Conley
    http://www.screamingbroccoli.com/
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  23. #23
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    Re: How to prevent "birds nesting"

    I type slow

  24. #24
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    Re: How to prevent "birds nesting"

    Looks like it is EP .If using self shielded flux cored,most are EN.

  25. #25
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    Re: How to prevent "birds nesting"

    The way I set the drive roll tension. Run out 6” or 8” of wire from the contact tip. With a gloved hand put some side tension on the wire. Pull the trigger, if the wire continues to bow, and not slip at the drive rolls, the drive roll tension if fine.
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