Feeder And Wire-Path Matrix

This annex is for MIG and multiprocess complaints where the machine is blamed for what is really a wire-path problem.

Use it with MIG and multiprocess guides in this repository across:

Core rule

If the machine powers up and the complaint centers on feed, start with the wire path before the power section.

The wire path should be checked in this order:

Symptom	Most likely wire-path branch	High-value first move
Birdsnesting at feeder	too much tension, wrong groove, liner drag, bad tip	remove tip and test bare-wire feed
Feed slips or surges	wrong groove, low/high tension, rusty wire, spool drag	inspect groove, tension, and wire condition
Good motor sound, poor arc start	tip restriction, burnback, current-path issue	replace tip and retest feed and start
One wire size feeds badly, another is fine	guide alignment or roll mismatch	inspect roll and guide geometry for that wire size

Remove the contact tip and test bare-wire feed.
If feed improves, stay in the front-end branch.
If feed remains poor, move upstream into liner, rolls, guides, and spool drag.
Only after the wire path is normalized should the feeder motor or control board be suspected.

Handler 140, Handler 140EZ, Rogue EM 125/140, and similar machines are especially sensitive to wrong drive-roll choice, rusty wire, and spool drag.
Do not treat weak garage power and feed drag as the same problem.

POWER MIG 211i, Millermatic 211 PRO, Handler 210MVP, and similar units combine wire-path faults with branch-voltage issues.
Prove feed quality first, then prove the supply.

POWER MIG 210 MP, POWER MIG 215 MPi, Multimatic family, Rebel family, and similar platforms can be mis-set after process changes.
Keep process-change drift and wire-path drag in the same first diagnostic pass.

"drive motor is weak" when the tip is restricted
"machine has no power" when the wire path is dragging and branch power is also marginal
"software fault" when stored settings changed but the real issue is still liner and tip wear

bare-wire feed remains poor after liner, rolls, guides, and spool drag are normalized
feed problems appear across multiple guns or feeders on the same base machine
control behavior changes independent of actual wire-path condition

This annex is synthesized from MIG and multiprocess model guides in this repository.
Exact roll selection, tension values, and gun service procedures should still be verified in the affected machine's manual.