Problem with Imig 205

I got this welder a little over a year ago but didn't have power set up for it until early this year. It welds somewhat ok, but it pulses a lot in the higher amp settings. I'm running 0.045 flux core wire. The power supply seems fine and I run a power plasma 80 on the same circuit just fine at 45 amps output. That thing is awesome. The length of wire stickout varies a lot, several times per second and it's really hard to get a good weld out of it. It's just as if someone is turning the wire feed speed up and down really fast while I'm welding. I've noticed the wire feed speed readout and the volt output numbers also vary in the same way during welding. Anyone have any thoughts? Any help is greatly appreciated.

Be sure you have a solid ground directly to the piece you're welding.
Do you have .045 flux core rollers in it ?
In my experience, you need to run one size larger contact tip than normal for flux core to make it feed smoothly and stop the wire from eventually jamming in the tip.
You also need the machine setup DC negative for flux core.

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Originally Posted by zoama

Do you have .045 flux core rollers in it ?

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...and is the drive roller tension properly adjusted?

Welcome to the forums, Chris!

And are you sure the correct size has been chosen? And is the wire properly centered and not overtightened on the spool holder? Sounds like a classic feeding problem, which is usually easily resolved.

Running wire out of the gun with the cover open will help spot feeding problems. Sometimes the wire can bind coming off the spool if the wire is overlapped or pinching in the sides of the spool, which can happen to 8 inch and larger spools if they get bent or the plastic sides crack from being dropped. I have a full 44lb spool with the plastic side split half way around in the hub making it useless. Every time the wire is pulled from that edge of the roll, it's pulled down into the side of the spool and binds enough to make the wire come out jerky. I found the problem by running off wire with the cover open.

Does the spool turn by hand with a small amount of drag. I have had a gun that the rubber the spool turns on we a hair too big. Remove and put a new smaller OD one in and that fixed it.

Thanks for all the replies. The wire seems to feed smooth as glass until the arc starts. I'll go look for some of the things suggested tomorrow. I don't have flux core rollers. Maybe that's the problem?

I think I found the problem. My wire stick out was too long because the tip is recessed too far into the gas shield (if that's what the metal tube is called anyway). I tried taking that shield off and weld without it since I'm using flux core. Any time the wire stick out got longer than 1/8 to 1/4 inch it started that pulsing again. It welded perfectly with a very short stick out at high power. Awesome! Now if I could get the welds to stop being porous I'd be all set. Maybe I just need to break down and get gas on it.

Usually that is a sign of mismatched voltage and wire speed. Some guns have a cover to replace the nozzle for FC. If yours has threads, make sure you protect them from spatter. MIG is so much nicer than FC. Unless you need it for windy conditions or something, go for solid wire. You'll be much happier.

Flux core really costs more in the long run to weld with. People think it's a cheaper way to go...and it is for the first roll. But when you average the costs out over 3 or 4 rolls the savings start coming back really fast.

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Originally Posted by Rambozo

Usually that is a sign of mismatched voltage and wire speed. Some guns have a cover to replace the nozzle for FC. If yours has threads, make sure you protect them from spatter. MIG is so much nicer than FC. Unless you need it for windy conditions or something, go for solid wire. You'll be much happier.

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I agree with Ram and Mark.

The FC will cause a bit more spatter. Get some anti-spatter spray or original PAM (even without the nozzle it's easier to cleanup and it helps to protect the tip/nozzle). And when you see/use MIG (with CO2 and Argon like C25) over FC you will pat yourself on the back. MIG is less money in the long. Only time we use Flux Core is outside remote (mobile) and we are going to try C25 soon, only deal is the tank must be vertical (due to CO2). Argon can run with the tank laying on it's side, you would need that to due aluminum with the IMIG-200. Do it all the time.

How much does a gas cylinder cost on average and how much does it cost to fill one? I have no interest in renting a gas cylinder, so if that's the only way, then I definitely don't want one. I'd want a big one because I live in a remote place and getting it refilled often would be inconvenient. How many pounds of wire is a cylinder good for on average?

Shielding gas prices and cylinder rental details vary a LOT by region and by provider, so there really is no good answer to that question. (I don't mean to be vague, sorry.)

Since Chris is using .045 wire (suggesting thicker weld pieces), and since price and refill convenience are a concern, could he use pure co2 for shielding? I've been looking for a co2 bottle so I can try it for myself.

ChrisA,

Like Dave said it will vary a lot. But I live in an area where there's not a lot of welding. And picked up 3 of my 4 on Craigslist. Look for not just a tank, but a welding setup. Buy it and sell the welder off. If a RED or BLUE you will get your money back and be on your way.

A 150cf here is about $300 and $34 to fill. Got all my big tanks on craigslist many years ago. But a 350+ tank is $24 to fill here.