I have changed a part from Manual weld to robotic. It is 514 T-1 plate to T-1. I allow the use of Lincoln LA-100 ( ER 100S-G ) or MC1100 (E-110C-G ). I use the MC1100 robotically. Everytime The robot starts a new weld, I get an "arc failure" and find the wire is stuck inside the TIP. I am using .045" wire and making .25" welds. Abicor Binzel WH-450 torches and Abicor .045" Tips. Lincoln Powerwave 450 and 90/10 Ar/Co2 shield.
I have verified a postweld stickout of 1/2-5/8" and there is NO burnback schedules set on the system.

I never have this problem robotically with Hard Wire.

Anyone else ever have this issue???