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Thread: Millermatic 200 birds nesting

  1. #1
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    Millermatic 200 birds nesting

    I can't seem to stop the birds nesting on my millermatic 200 since I swapped to 023 wire.
    In order to swap sizes I changed the rollers with a new Miller set, and contact tip.
    Rollers appear to be lined up correctly but I've adjusted them in both directions to try to remedy this.
    When I couldn't stop the wire from wadding up I also replaced the liner.
    I've also tried adjusting roller tension.

    Basically I'm at my wits end here and any suggestions would be appreciated

    Sent from my SM-G965U using Tapatalk

  2. #2
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    Re: Millermatic 200 birds nesting

    Make sure your gun is as straight as possible and also check your spool of wire. Years ago I bought some .023" wire that was interwound with itself. Tried 4 different rolls and all the same thing. If possible raise the machine up and have the gun hanging down. Is there a tension adjustment for the wire spool? If so loosen it slightly. Need some tension on the spool though.

  3. #3
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    Re: Millermatic 200 birds nesting

    That size of wire has absolutely zero benefit over 030 anyways, even for very thin panels... just go back to a bigger wire?

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  5. #4
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    Re: Millermatic 200 birds nesting

    Quote Originally Posted by etik746 View Post
    I can't seem to stop the birds nesting on my millermatic 200 since I swapped to 023 wire.
    In order to swap sizes I changed the rollers with a new Miller set, and contact tip.
    Rollers appear to be lined up correctly but I've adjusted them in both directions to try to remedy this.
    When I couldn't stop the wire from wadding up I also replaced the liner.
    I've also tried adjusting roller tension.

    Basically I'm at my wits end here and any suggestions would be appreciated

    Sent from my SM-G965U using Tapatalk
    If you have a 15' gun it will be difficult to push 023 that far. Even with a new liner and feed rolls. I keep a 10' 023 gun just because of this.
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    Boxes and boxes of welding crap.

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  7. #5
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    Re: Millermatic 200 birds nesting

    Drive roll tension too high is usually what causes bird nesting, could also need a new liner.

    edit: I see you tried all the stuff I mentioned. Beats me. New tip?

  8. #6
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    Re: Millermatic 200 birds nesting

    munkul has it right. Either get a gun with an 8-10ft wip or go to .030 wire. also keep the drive rolls loose , then hit the trigger and start to tighten the rolls until the wire starts moving then stop tightening. Keep watching the rollers and only give the tentioner a tweek if the wire stops feeding . When the wire comes out of the tip of the gun you should not need to tweek the tension anymore.

  9. #7
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    Re: Millermatic 200 birds nesting

    I like to set the tension to where I can just get it to stop feeding by pinching the wire between my thumb and first finger.

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  11. #8
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    Re: Millermatic 200 birds nesting

    wire spool tension is the biggest reason if the drive rollers don't pull the wire off the spool with enough force, the spool will overrun just a bit and an accumulation of little bits will cause the birds nesting. second is when loading spool and you get one or 2 loops come off the roll and under another, will bird nest. take roll off and and make sure no wires are crossed. keep tension on wire when loading.

    been using .023-.025 for 30 years and had just one or 2 rolls bird nest because of above. and yes i found for thin metal .023 works best on thin like body panels!
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  12. #9
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    Re: Millermatic 200 birds nesting

    Couple questions.
    Is it solid wire or flux core?
    Are the drive roller type matched for the type of wire?
    Was the roll of wire installed upside down and feeding from the wrong side (top or bottom)?
    What size liner did you put into the gun? I usually install the largest size liner I can into my gun regardless of what size wire Iím running.
    Jason
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  14. #10
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    Re: Millermatic 200 birds nesting

    .023" doesn't come in flux-core and needs to have a .023" liner so the wire isn't snaking around in it. If you were running .035" or larger wire the liner size isn't as critical.

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  16. #11
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    Millermatic 200 birds nesting

    I run .035 cored wire through a 1/16 liner usually.
    Iíve also pushed a lot of 030 wire through a .045 liner. Iíve also pushed a lot of .045 cored wire through a 1/16 liner. Never had any issues with with those set ups.
    That small .023 wire is foreign to me. No reason to use it.
    I wonder about his rollers. V rollers, u rollers or
    Knurled rollers?
    Last edited by snoeproe; 04-22-2020 at 11:41 PM.
    Jason
    Lincoln Idealarc 250 stick/tig
    Thermal Dynamics Cutmaster 52
    Miller Bobcat 250
    Torchmate CNC table
    Thermal Arc Hefty 2
    Ironworkers Local 720

  17. #12
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    Re: Millermatic 200 birds nesting

    Look at the wire in the bird nest. see if it is all the same color or if some of it has blued.
    we have had trouble with a few Miller welders that bird nested because the wire got hot.
    Picked up weld current from the drive rolls and not the gun tip. Check the miggun power pin
    and make sure it is clean and bright brass. Then look inside the drive where the power pin goes.
    It will need to be cleaned if it is not bright silver. Buff clean and wash with contact cleaner.
    Mig wire must pick up the weld current at the gun tip. Picking up weld current from the drive rolls or gun liner.
    will heat the wire up and make it soft. Then it will ball up anywhere it wants.

  18. #13
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    Re: Millermatic 200 birds nesting

    I've run into wire that had weird bends in it too from manufacturing. Some pics. of the set up may help to solve the problem.

  19. #14
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    Re: Millermatic 200 birds nesting

    I swapped out the wire roll to a different roll of wire and that seems to have fixed things. Thanks for the help though guys. Must have been an abnormally soft roll

    Sent from my SM-G965U using Tapatalk

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