This is a tip for loading aluminum wire correctly and is very important for loading aluminum wire and avoiding soldering failures. Hold the spool of wire firmly in one hand to make sure it doesn't come loose, but once the cellophane wrapping is opened, hold the loose end of the wire with the other hand-don't let go until you put it into the drive rollers. Inexperienced people usually don't hold the loose end tightly, which can cause the whole bundle of wires to start coming loose and falling apart.

Setting the Tightness of the Wire Brake

The looseness should only be enough to ensure that the wire will not come loose, but not so tight that it will cause the wire to pull. To set it correctly, first set the looseness to minimum, then install the wire and let it pass through the drive roll. If any part other than the wire roll stops, it is not tight enough. Care should be taken when operating as too much tightness can cause excessive force on the welding wire.

Setting the Drive Roller Tightness

Probably the most important step in the setup process. Experts recommend that the wire head should be at a small angle of 1 inch from the surface of the insulation. Then, set the roller slack to almost minimum. Press the switch on the flashlight and watch it work - the wire should slide as it touches the surface of the insulation. From that point, tighten until the wire stops sliding. Again, it is important to note that over-tightening can cause the wire to break. This means that the wire stays in the torch while the wire drive rollers are still rotating. The end result is that the wire breaks when the rollers are used up, or the accumulated portion falls backward, resulting in a mess of wire, including guide bushings, torch bushings, and so on. Keep in mind that when you are setting the tightness of the rollers as described above, the torch switch is depressed and the wire is hot, so be sure to wear good quality welding gloves.