Causes for too big or inconstant wire gap
Causes:
- blank cutting (especially development) not within tolerance
- inconstant overlap – Z-bar worn (—> for “constant overlap“ see related article)
- wire tension not correct (Check wire chopper settings and condition of wire transport wheel)
- calibration crown inconstant (for example due to worn bearing)
- wrong adjustment of „overtravel“ of final pusher system (see instruction
manual of your welder) - „backlash“ in final pusher system due to worn bearing or linear guides
- copper wire profile not correct