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Idle Roll Pressure Setting
The idle roll pressure is set at the factory, backed out
three turns from full pressure on 4-roll feeders. This is
an approximate setting. For small wire sizes and
aluminum wire up to 9 or 10 turns out may be required
to minimize “birdnesting”. The optimum idle roll
pressure varies with type of wire, surface condition,
lubrication, and hardness. The optimum idle roll
setting can be determined as follows:
1) Release the incoming idle roll pressure arm, then
press end of gun against a solid object that is
electrically isolated from the welder output and
press the gun trigger for several seconds.
2) If the wire “birdnests”, jams, or breaks at the drive
roll, the idle roll pressure is too great. Back the
pressure setting out 1/2 turn, run new wire through
gun, and repeat above steps.
3) If the only result is drive roll slippage, disengage
the gun locking nut, and pull the gun cable forward
about 6” (150mm). There should be a slight
waviness in the exposed wire. If there is no
waviness, the pressure is too low. Increase the
pressure setting 1/4 turn, reconnect the gun,
tighten the locking nut, and repeat the above
steps.
4) After the outgoing pressure is set, determine how
many turns away from full pressure the setting is.
Set both idle roll tensions to this setting. Engage
both idle rolls before welding. In most applications,
best wire feeding will occur when both idle roll
pressures are set the same.
Gas Guard Regulator Setting (Optional
K659-1)
1) With the gas supply shut off, the Gas Guard
regulator flow adjusting key should be set to
maximum (full clockwise) which is rated to be 60
SCFH (28 lts/ min).
2) Adjust gas supply flow rate for a level higher than
will be required, then adjust Gas Guard flow
adjusting key counterclockwise to the desired gas
flow rate.
Wire Loading of 13-14lb (6kg) Innershield
Coils
Requires use of K162H Spindle Kit and K435 14 Lb.
Coil Adapter.