How to properly thread wire into the feed roller?

What the article is about:

How to cook with semi-automatic and wire

Before starting welding, it is necessary to properly prepare the semi-automatic machine. First of all, you need to place the spool of welding wire on the brake drum pin, and then adjust the clamping screw.

The pressure screw must be adjusted in such a way as to completely eliminate inertia and radial play during rotation. Then you need to adjust the guide roller to the diameter of the welding wire used.

Do not forget that the wire feed mechanism must be clean. Therefore, before starting welding with a semi-automatic machine, you need to wipe it with a piece of clean cloth. After this, you can lower the pressure roller. In this case, the welding wire should not slip excessively or be pressed too hard.

What is a feed roller?

The feed roller is a replaceable element of the feed mechanism of a semi-automatic MIG/MAG welding machine, which is selected in accordance with the type of welding wire, its diameter, overall dimensions of the rollers and the machine itself.

The feed rollers are made of alloy steel. The most commonly used are solid ( 1 ) rollers with knurling and conical smooth grooves. The second type is compound ( 2 ), which consist of two feed rollers with chamfers and knurling along the chamfer.

Preparing the transformer

The transformer consists of a pair of coils with a winding of insulated wire, one winding is primary, the other is secondary.
To remake an inverter device, only the secondary coil is changed . It needs to be redone to reduce the voltage and increase the current. To do this, the existing wrap is removed and a new one is wound from the insulated cable.

Dismantling is done as carefully as possible so as not to damage the desired winding; the turns should lie closely.

The number and thickness of turns can be determined using specialized online services.

Upon completion of laying the wires, the windings are covered with insulating material.

What kind of videos are there?

There are 3 types of feed rollers for semi-automatic welding machines and this difference lies in the wire that is used in the work.

Rollers for steel wire are marked with the letter “V”, which characterizes the shape of the groove. The steel wire feed rollers have two V-shaped guide grooves.

Rollers for aluminum wire have the letter “U”, which characterizes the shape of the guide grooves. The grooves of the roller ensure tight contact with the wire, as a result of which it does not slip or break.

Rollers for cored wire are designated with the letter “K”.

Flux cored wire is a tubular wire filled with flux and metal powder that protects the molten metal from exposure to air during welding.

Classification

It will be easier to choose a hose for gas welding if you know in advance what types exist. There are only three types, each corresponding to its own class:

To make the hoses easy to distinguish from each other, they are painted in different colors. First class is always red, second is yellow, and third is blue. There is also a fourth, universal type, it is designated black or any other color other than the three basic ones.

The temperature capabilities of welding hoses may vary depending on their manufacturer.

How to choose the right video?

When choosing a video, you need to consider the following points:

• A type of wire falling mechanism that is installed in a welding machine. There are 2-roller and 4-roller wire feed mechanisms.
• Overall dimensions of the roller. There are 2 ways to choose the right video size:

Method 1 is the easiest - just know what size roller is in your welding machine.

Method 2 is to measure the video yourself. You need to measure the overall width of the roller (this will be the first number in the dimensions), then you need to measure the mounting thread/hole (this will be the second number in the dimensions), and then measure the width of the end part of the roller (this is the third number in the dimensions). The resulting numbers, for example, 30x10x12, are the overall dimensions of the roller.

Cooling system

During prolonged continuous operation, the semi-automatic device is subject to severe overheating, which leads to malfunctions and the need to repair the device.
Therefore, it must be equipped with a cooling system, consisting of a temperature sensor that determines the threshold of the temperature permissible for operation, and coolers. To create a cooling system, you can purchase an optocoupler pair that connects to the device control unit. If the set limit is exceeded, a signal will be sent from the sensor to the executive relay, turning off the power supply until the welder cools down.

The simplest option is to use fans , which should be attached on both sides of the housing in front of the transformer device. The fans are fixed so that they rotate not for air supply, but for exhaust.

device can be used as a cooling system . To ensure the removal and supply of oxygen inside, 20-30 holes with a size of 5 mm should be drilled on the sides.

Type and diameter of welding wire

The diameter of the roller groove is selected depending on the diameter and type of welding wire. The diameter and type of wire is written on the product itself - this is an alphanumeric engraving. When changing the wire section, you simply turn the roller over to the desired side and continue to use it further. Please note that the welding wire diameter marking indicates the groove that is closest to the marking.

On the PTK website, in the section about feed rollers, in the configured filters, you can easily select the desired roller by size, type and diameter of welding wire.

Principle of operation

The semi-automatic welding production process consists of:

• moving and adjusting the burner;
• controlling the welding process.

The main function of an inverter semiautomatic device is the transformation of alternating current received from the network into direct current . The length and quality of the arc depends on the voltage, and the rate of addition of the additive is determined by the welding current.

The operating principle of any self-made semi-automatic device is as follows:

• purge to remove blockages that impede a stable gas supply;
• turning on the power supply;
• additive supply;
• operation of the inverter at a given pace;
• covering the seam and welding the formed crater.

At the final stage, if necessary, manual cleaning of the joint or surfacing is performed , the seam is protected and the crater is sealed.

How to properly thread the wire into the roller?

Correctly threading the welding wire into the feed roller is a guarantee of success when carrying out welding work; it also increases the productivity of semi-automatic welding machines and their service life.

Schematically in the figure we have shown the correct threading of the wire and possible errors that you may encounter.

1. Normal clamping force.
2. Excessive clamping force.
3. Wire diameter too large.
4. Wire diameter too small.

When threading the rollers with wire, take into account the recommendations for choosing the clamping force, which is adjusted using the adjusting screw on the feed mechanism of the welding machine.

The range of PTK branded products includes a wide selection of feed rollers and related products; you can learn more about the technical characteristics, descriptions and photographs in the product cards. All products are available for order from sales managers and official dealers.

Pros and cons of MIG welding of stainless steel

If we compare semi-automatic welding of stainless steel with manual arc (MMA) and non-consumable electrode in a gas environment (TIG), then MIG welding has the following advantages:

• low amount of smoke;
• fast stitching;
• the ability to weld thin and thick parts;
• no need to stop to replace consumables (change the coated electrode or sharpen the tungsten needle);
• ease of operation in all spatial positions.

The method also has disadvantages,

but argon welding has the same disadvantages:

• a gas cylinder is required, which makes transportation more difficult;
• when working in the wind, the protective gas is blown away and pores appear in the seam;
• high cost of consumables.

The main disadvantage of MIG welding of stainless steel is the strong splashing of the filler metal. Therefore, the burner nozzle and heat-affected zone should be protected from scale using welding chemicals (sprays and pastes).

If you need to frequently move welding equipment around a large workshop, it is practical to buy a gas cylinder cart. It can combine a semi-automatic platform to transport everything at once. When you regularly plan to cook stainless steel with a semi-automatic machine on-site (repair work on call, etc.), buy a 5-liter argon cylinder that weighs 8.5 kg. It is more convenient to load it into a car and carry it to the place of work.

Feed rollers for steel wire

Article: 005.040.120 Feed roller 30x22x10 V 0.6–0.8

Feed roller for steel wire with a diameter of 0.6–0.8 mm. V-shaped groove. The dimensions of the roller are 30x22x10. Suitable for PROFI semi-automatic welding machines MIG 200, MIG 250, MIG 300, MIG 350-1, MIG 350, MIG 500 from the HISTER factory and RILON PTK MIG 250 GS, MIG 250 GDM, MIG 300 Y, MIG 200 GW, MIG 300 GW , MIG 300 GDL.

Price: 431 RUR

Article: 005.040.127 Feed roller 40x32x10 V 1.0–1.2

Feed roller for steel wire with a diameter of 1.0–1.2 mm. V-shaped groove. The dimensions of the roller are 40x32x10. Suitable for semi-automatic welding machines PTC RILON MIG 350 GF, MIG 500 GF, MIG 500 I, MIG 500 F, MIG 500 FW.

Price: 520 RUR

Article: 005.040.109 Feed roller 40x32x10 V 1.2–1.6

Feed roller for steel wire with a diameter of 1.2–1.6 mm. V-shaped groove. The dimensions of the roller are 40x32x10. Suitable for semi-automatic welding machines PTC RILON MIG 350 GF, MIG 500 GF, MIG 500 I, MIG 500 F, MIG 500 FW.

Price: 520 RUR

Article: 005.040.108 Feeding roller 40x32x10 V 0.8-1.0

Feed roller for steel wire with a diameter of 0.8–1.0 mm. V-shaped groove. The dimensions of the roller are 40x32x10. Suitable for semi-automatic welding machines PTC RILON MIG 350 GF, MIG 500 GF, MIG 500 I, MIG 500 F, MIG 500 FW.

Price: 520 RUR

Article: 005.040.107 Feed roller 30x22x10 V 1.2–1.6

Feed roller for steel wire with a diameter of 1.2–1.6 mm. V-shaped groove. The dimensions of the roller are 30x22x10. Suitable for semi-automatic welding machines PROFI MIG 350-1, MIG 350, MIG 500 from the HISTER factory.

Price: 431 RUR

Article: 005.040.105 Feed roller 30x22x10 V 1.0–1.2

Feed roller for steel wire with a diameter of 1.0–1.2 mm. V-shaped groove. The dimensions of the roller are 30x22x10. Suitable for PROFI semi-automatic welding machines MIG 200, MIG 250, MIG 300, MIG 350-1, MIG 350, MIG 500 from the HISTER factory and RILON PTK MIG 250 GDM, MIG 300 Y, MIG 250 GW, MIG 300 GW, MIG 300 GDL .

Price: 431 RUR

Article: 005.040.106 Feed roller 30x22x10 V 0.8–1.0

Feed roller for steel wire with a diameter of 0.8–1.0 mm. V-shaped groove. The dimensions of the roller are 30x22x10. Suitable for PROFI semi-automatic welding machines MIG 200, MIG 250, MIG 300, MIG 350-1, MIG 350, MIG 500 from the HISTER factory and RILON PTK MIG 250 GS, MIG 250 GDM, MIG 300 Y, MIG 200 GW, MIG 250 GW , MIG 300 GW, MIG 300 GDL.

Price: 431 RUR

Article: 005.040.101 Feed roller 30x10x12 V 0.8–1.0

Feed roller for steel wire with a diameter of 0.8–1.0 mm. V-shaped groove. The dimensions of the roller are 30x10x12. Suitable for semi-automatic welding machines PROFI MIG 350, MIG 500 and PTK RILON MIG 250 P GDM, MIG 300 P GDL, MIG 300 GN, MIG 300 GD.

Price: 431 RUR

Article: 005.040.102 Feed roller 30x10x12 V 1.0–1.2

Feed roller for steel wire with a diameter of 1.0–1.2 mm. V-shaped groove. The dimensions of the roller are 30x10x12. Suitable for semi-automatic welding machines PROFI MIG 350, MIG 500 and PTK RILON MIG 250 P GDM, MIG 300 P GDL, MIG 300 GN, MIG 300 GD.

Price: 431 RUR

Article: 005.040.103 Feed roller 30x10x12 V 1.2–1.6

Feed roller for steel wire with a diameter of 1.2–1.6 mm. V-shaped groove. The dimensions of the roller are 30x10x12. Suitable for PROFI semi-automatic welding machines MIG 350, MIG 500.

Price: 431 RUR

Article: 005.040.113 Feed roller 35x25x8 V 1.0–1.2

Feed roller for steel wire with a diameter of 1.0–1.2 mm. V-shaped groove. The dimensions of the roller are 35x25x8. Suitable for semi-automatic welding machines PROFI MIG 200, MIG 250.

Price: 451 RUR

Article: 005.040.112 Feed roller 35x25x8 V 0.8–1.0

Feed roller for steel wire with a diameter of 0.8–1.0 mm. V-shaped groove. The dimensions of the roller are 35x25x8. Suitable for semi-automatic welding machines PROFI MIG 200, MIG 250.

Price: 451 RUR

Article: 005.020.102 Feed roller 30x10x10 V 0.6–0.8

Feed roller for steel wire with a diameter of 0.6–0.8 mm. V-shaped groove. The dimensions of the roller are 30x10x10. Suitable for semi-automatic welding machines of the PTK MASTER MIG S, MASTER MIG F, MASTER MIG SYNERGY D and PTK RILON MIG GDM series.

Price: 484 RUR

Article: 005.020.103 Feed roller 30x10x10 V 0.8–1.0

Feed roller for steel wire with a diameter of 0.8–1.0 mm. V-shaped groove. The dimensions of the roller are 30x10x10. Suitable for semi-automatic welding machines of the PTK MASTER MIG S, MASTER MIG F, MASTER MIG SYNERGY D and PTK RILON MIG GDM series.

Price: 484 RUR

Feed rollers for aluminum wire

Article: 005.040.116 Feed roller 30x10x12 U 1.0–1.2

Feed roller for aluminum wire with a diameter of 1.0–1.2 mm. U-shaped groove. The dimensions of the roller are 30x10x12. Suitable for semi-automatic welding machines PTC RILON MIG 250 P GDM, MIG 300 P GDL.

Price: 431 RUR

Article: 005.040.111 Feed roller 40x32x10 U 1.0–1.2

Feed roller for aluminum wire with a diameter of 1.0–1.2 mm. U-shaped groove. The dimensions of the roller are 40x32x10. Suitable for semi-automatic welding machines PTC RILON MIG 350 GF, MIG 500 GF, MIG 500 I, MIG 500 F, MIG 500 FW.

Price: 520 RUR

Article: 005.040.130 Feed roller 40x32x10 U 1.2–1.6

Feed roller for aluminum wire with a diameter of 1.2–1.6 mm. U-shaped groove. The dimensions of the roller are 40x32x10. Suitable for semi-automatic welding machines PTC RILON MIG 350 GF, MIG 500 GF, MIG 500 I, MIG 500 F, MIG 500 FW.

Price: 520 RUR

Article: 005.040.123 Feed roller 30x22x10 U 1.0–1.2

Feed roller for aluminum wire with a diameter of 1.0–1.2 mm. U-shaped groove. The dimensions of the roller are 30x22x10. Suitable for semi-automatic welding machines PTC RILON MIG 250 GDM, MIG 300 GDL.

Price: 431 RUR

Article: 005.040.121 Feed roller 30x22x10 U 0.6–0.8

Feed roller for aluminum wire with a diameter of 0.6–0.8 mm. U-shaped groove. The dimensions of the roller are 30x22x10.

Article: 005.040.115 Feed roller 30x10x12 U 0.8–1.0

Feed roller for aluminum wire with a diameter of 0.8–1.0 mm. U-shaped groove. The dimensions of the roller are 30x10x12. Suitable for semi-automatic welding machines PTK RILON MIG 300 GD.

Price: 431 RUR

Article: 005.020.101 Feed roller 30x10x10 U 0.8–1.0

Feed roller for aluminum wire with a diameter of 0.8–1.0 mm. U-shaped groove. The dimensions of the roller are 30x10x10. Suitable for semi-automatic welding machines of the PTK MASTER MIG S and PTK RILON MIG GDM series.

Price: 484 RUR

Feed rollers for cored wire

Article: 005.020.107 Feed roller 30x10x10 K 1.0–1.2

Feed roller for cored wire with a diameter of 1.0–1.2 mm. K-shaped groove. The dimensions of the roller are 30x10x10. Suitable for semi-automatic welding machines of the PTK MASTER MIG S, MASTER MIG F, MASTER MIG SYNERGY D and PTK RILON MIG GDM series.

Price: 484 RUR

Article: 005.040.124 Feed roller 30x22x10 K 0.8–0.9

Feed roller for cored wire with a diameter of 0.8–0.9 mm. K-shaped groove. The dimensions of the roller are 30x22x10. Suitable for PROFI semi-automatic welding machines MIG 300, MIG 350-1, MIG 350, MIG 500 from the HISTER factory and RILON MIG 250 GS, MIG 250 GDM, MIG 300 GDL, MIG 200 GW.

Price: 431 RUR

Article: 005.040.131 Feed roller 40x32x10 K 0.8–0.9

Feed roller for cored wire with a diameter of 0.8–0.9 mm. K-shaped groove. The dimensions of the roller are 40x32x10. Suitable for semi-automatic welding machines PTC RILON MIG 350 GF, MIG 500 GF, MIG 500 I, MIG 500 F, MIG 500 FW.

Price: 574 RUR

Article: 005.040.118 Feed roller 30x10x12 K 0.8–0.9

Feed roller for cored wire with a diameter of 0.8–0.9 mm. K-shaped groove. The dimensions of the roller are 30x10x12. Suitable for semi-automatic welding machines PROFI MIG 350, MIG 500 and PTK RILON MIG 250 P GDM, MIG 300 P GDL, MIG 300 GN, MIG 300 GD.

Price: 431 RUR

Article: 005.020.105 Feed roller 30x10x10 K 0.8–0.9

Feed roller for cored wire with a diameter of 0.8–0.9 mm. K-shaped groove. The dimensions of the roller are 30x10x10. Suitable for semi-automatic welding machines of the PTK MASTER MIG S, MASTER MIG F, MASTER MIG SYNERGY D and PTK RILON MIG GDM series.

Price: 484 RUR

Wire feeders

Article number: 005.040.164 Wire feeder WZ-SSJ

4-roller metal wire feeder for semi-automatic welding PROFI MIG 350 and MIG 500 from the HISTER factory. Suitable for rollers with dimensions 30x22x10 when using solid metal or cored wire. The delivery set includes two feed rollers for steel wire with a diameter of 1.0–1.2 mm.

Price: RUB 10,585

Article: 005.040.163 Wire feeder 15SSJ-DA04

4-roller metal wire feeder for semi-automatic welding machines PROFI MIG 350-1 from the HISTER factory. Suitable for rollers with dimensions 30x22x10 when using solid metal or cored wire. The delivery set includes two feed rollers for steel wire with a diameter of 1.0–1.2 mm.

Price: RUB 9,938

Article: 005.040.162 Wire feeder 15SSJ-A

2-roller metal wire feeder for PROFI semi-automatic welding machines MIG 200, MIG 250 and MIG 300 from the HISTER factory. Suitable for rollers with dimensions 30x22x10 when using solid metal or cored wire. The delivery set includes one feed roller for steel wire with a diameter of 0.8–1.0 mm.

Price: RUB 6,441

Article number: 005.040.161 Wire feeder 45SSJ29-D

2-roller metal wire feeder for semi-automatic welding machines PTK MASTER series F and SYNERGY D. Suitable for rollers with dimensions 30x10x10 when using all-metal or flux-cored wire. The delivery set includes one feed roller for steel wire with a diameter of 0.8–1.0 mm.

Price: RUR 3,297

Article: 005.040.152 Wire feeder 63SSJ02R

2-roller metal wire feeder for semi-automatic welding machines. Suitable for rollers with dimensions 30x22x10 when using solid metal or cored wire. The engine is located on the right.

Price: RUR 6,525

Article: 005.040.155 Wire feeder 77SSJ05R

4-roller metal wire feeder for semi-automatic welding machines. Suitable for rollers with dimensions 40x32x10 when using solid metal or cored wire. The engine is located on the right.

Price: RUB 13,475

Article: 005.040.156 Wire feeder 77SSJ05L

4-roller metal wire feeder for semi-automatic welding machines. Suitable for rollers with dimensions 40x32x10 when using solid metal or cored wire. The engine is located on the left.

Price: RUB 13,475

Article: 005.040.153 Wire feeder 63SSJ02L

2-roller metal wire feeder for semi-automatic welding machines. Suitable for rollers with dimensions 30x22x10 when using solid metal or cored wire. The engine is located on the left.

Price: RUR 6,525

Article: 005.040.157 Wire feeder mechanism 48024040

2-roller wire feeder for semi-automatic welding machines with a plastic body. Suitable for rollers with dimensions 30x10x15 when using solid metal or cored wire.

Price: RUB 3,900

Article: 005.020.152 Wire feeder SG 4SSJ29

2-roller metal wire feeder for semi-automatic welding machines PTK MASTER S series. Suitable for rollers with dimensions 30x10x10 when using all-metal or flux-cored wire. The engine is located on the left.

Price: RUR 4,526