Wire Spool Binding

Ok I hope this makes since. I have an I-MIG 200 and lately I've been having issues with the wire spool binding on the shaft that it turns on. It still turns and welds fine but it makes this terrible noise like a tupperware burp (farting). I'm using a 10 pound spool of wire. I put a little oil on it with my finger and it stopped for about a day but now it's doing it again. Am I the only one having this issue? I don't like how the spool rides on the washer rather than the shaft. Is there some sort of adapter I could get to increase the size of the shaft hahaha? No but really. I hope you get what I'm talking about. I'm sure this binding will eventually cause a problem with the wire feed motor so I want to take care of the problem ASAP.

I just looked at a IMIG200, no spool in it of course at the moment (4043 and spool gun).

Make sure the wingnut is not too tight. I will add a spool later (when I open up everything) and see what I find. I know the wire feeder rollers pull the wire and turn the spool, the back does not turns. The spool just rides on it. We have ran many 10lbs spool in them and no noise. So something is up.

Can you tell if the sound is from the roller area or the backshaft that holds the spool. Maybe some wax on the inside of the washers edge, but you might have the wingnut too tight.

Remove the wire from the machine and check the plastic spool for cracks at the edge of the hub. If it's cracked the wire can pull down into the side of the spool as it rotates causing it to bind. Attachment 9455

I'll check the spool again for damage later today when I get home. The binding is on the outer edge where the spool comes in contact with the outside washer. That's where I put the oil and the noise stopped for the day. I like the adapter option allot. I don't like the current design. I'd rather have the welder not accept the smaller spools of wire (I have no need for them) than to keep this current setup. I might be alone in the thought though. The wing nut isn't too tight. If I loosen the wing nut the spool won't sit properly.

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Originally Posted by everlastsupport

the back does not turns. The spool just rides on it.

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Should the front outside washer turn? Mine doesn't.

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Originally Posted by Rafael

Should the front outside washer turn? Mine doesn't.

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No, it's keyed on the shaft.

Yea, check for burrs on the spool too. Do you have any wax? Candles? You can see if they helps. Be careful with any sprays, or take it off, spray and put back on so nothing gets on the wire. Make sure no cracks like mentioned (check on the inside too, could be there).

They do get bounced around in shipping and 10-12lbs all on top of each other. Also make sure the end of the wire is not sticking out and making the noise.

If you have the wire spool too tight it will make those noises. It probably feels as if it is struggling to weld, when you loosen the nut it will weld 10x smoother.

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Originally Posted by SeanMurphy265

If you have the wire spool too tight it will make those noises. It probably feels as if it is struggling to weld, when you loosen the nut it will weld 10x smoother.

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That's still my thought.

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Originally Posted by SeanMurphy265

If you have the wire spool too tight it will make those noises. It probably feels as if it is struggling to weld, when you loosen the nut it will weld 10x smoother.

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That's what I was thinking too. If you loop the loose (stinger end) of the wire into the spool housing so the spool doesn't unravel, can you spin the spool on the shaft easily by hand? Any strange noises while doing this (with the machine off)? Does the keyed washer have a sharp burr on the edge leftover from the stamping process? As Mike suggested, look at the "dead end" of the wire on the spool to see if it's sticking out too far and dragging on the inside of the machine as it spins.

Other than that, I can't think of anything else in that area that would cause problems.

Don't see anything that could be causing it. I even loosened the nut to the point where it's barely holding the spool up. I just rubbed some more oil on the washer with my finger and I'll wait until this spool is gone. If it does it with the new spool I'll let you know.

The way I was taught to adjust the wire spool tension is to angle the gun and hold it against a slick surface (against the welder). Pull the trigger and the wire should curl. If the wire pushes on the gun and does not curl then you have too much tension. You want the spool to spin with ease, but you don't want the spool to spin freely. In other words when you let off the trigger the spool stops and does NOT continue to spin.

Also how do you have wing nut, spring, and washer in place? I put on the spool with the plate that goes in the center and align. Put the spring on the shaft it will go against the metal plate. Put the washer against the (outside) spring, and tighten the wing against the washer. I've played with it but this works the best.

What is the brand name wire?

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Originally Posted by SeanMurphy265

The way I was taught to adjust the wire spool tension is to angle the gun and hold it against a slick surface (against the welder). Pull the trigger and the wire should curl. If the wire pushes on the gun and does not curl then you have too much tension. You want the spool to spin with ease, but you don't want the spool to spin freely. In other words when you let off the trigger the spool stops and does NOT continue to spin.

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That's the way to adjust the drive roller tension Attachment 9500 The spool tension should only be tight enough to prevent backlash when you release the trigger.

Could it be something as simple as having the spool on backwards,,the wire should feed in from the bottom of the spool...spool tension on a new 10 lb spool should be almost non existent as if turns slowly when it is new..

So here is an update. I didn't change a thing just let the spool of wire run out and swapped put in a new spool. No more noise. I think it may have had something to do with old sticker gunk on the spool. I went with a MUCH CHEAPER MIG wire from www.usaweld.com this time and love it. Two spools for the price I was paying for one Hobart spool.

Maybe the spool was not wound well? The one that made the noise. Or at the end of it unwound. Either what glad it is all worked out.