Turned out the gun liner was too long and needed to have 3/8" trimmed off so it would not obstruct the gas flow. I also cleaned and tightened the ground (don't think that was the problem) welded great on flux wire but bad on non-flux wire. Now it works great on both. Just tested out the Hobart on the 220v side today, all I can say is WOW! with this much power welding some thick steel.What was the fix?
For me it was running a dedicated line for power, mines a 110v.