Troubleshooting Guide

 
Download TROUBLESHOOTING GUIDE in PDF format

 

 PROBLEM
 
  POSSIBLE CAUSE
 
  POSSIBLE SOLUTION
 
1.    Feeder relay/malfunction. 1.    Consult feeder manufacturer.
 or erratic wire feeding. 2.    Broken control lead. 2.    a.  Test & connect spare control lead.
           b.  Install new cable.
  3.    Poor adaptor connection. 3.    Test & replace leads and/or contact pins.
  4.    Worn or broken switch. 4.    Replace.
  5.    Improper drive roll size. 5.    Replace with proper size.
  6.    Drive roll tension misadjusted. 6.    Adjust tension at feeder. 
  7.    Burn back to contact tip. 7.    See 'Contact Tip Burn Back'. 
  8.    Wrong size liner.  8.    Replace with correct size.
  9.    Buildup inside of liner. 9.    Replace liner, check condition of
           electrode.
  10.    Worn drive roll. 10.    a.  Replace with new drive roll.
           b.  Stone edge of groove on drive roll.
  11.    Improper guide tube 11.    a.  Adjust/replace guide as close to drive
       relationship.           rolls as possible.
           b.  Eliminate all gaps in electrode path.
  12.    Improper wire guide diameter. 12.    Replace with proper guide diameter.
  13.    Gaps at liner junctions. 13.    Replace with new liner using the
           Tregaskiss Liner Gauge.
  14.    Contact tip. 14.    Inspect & replace.
         
 Short contact tip life. 1.    Improper voltage and/or wire 1.    Set parameters.
       feed speed.    
  2.    Erratic wire feeding. 2.    See 'Erratic Wire Feeding'.
  3.    Improper tip stickout. 3.    Adjust nozzle/tip relationship.
  4.    Improper electrode stickouot. 4.    Adjust torch to base metal relationship.
  5.    Faulty ground. 5.    Repair all cables & connections.
         
 Torch running hot. 1.    Exceeding duty cycle. 1.    a.  Replace with properly rated
                Tregaskiss torch.
           b.  Decrease parameters to within torch
                rating.
  2.    Loose or poor power 2.    a.  Clean, tighten or replace cable
       connection.           grounding connection.
           b.  Tighten torch & cable connections to
                specified torque.
         
 Porosity in weld. 1.    Insulator worn. 1.    Replace nozzle/insulator.
  2.    Retaining head damaged. 2.    Replace retaining head.
  3.    Extreme heat or duty cycle. 3.    Replace with heavy duty consumables.
  4.    Solenoid faulty. 4.    Replace solenoid.
  5.    No gas. 5.    a.  Install full tanks.
           b.  Check supply.
           c.  Check for hose leaks.
  6.    Flow improperly set. 6.    Adjust.
  7.    Gas ports plugged. 7.    a.  Clean or replace gas
                diffuser/retaining head.
           b.  Clean nozzle.
  8.    Ruptured gas hose. 8.    Repair or replace cable or line.
  9.    Control circuit loss. 9.    See 'Electrode Does Not Feed'.
  10.    Worn, cut or missing o-rings. 10.    Replace o-rings.
  11.    Loose fittings. 11.    Tighten torch & cable connections to
           specified torque.
         
 Contact tip burn back. 1.    Improper voltage and/or wire 1.    Set parameters.
       feed speed.    
  2.    Erratic wire feeding. 2.    See 'Erractic Wire Feeding'.
  3.    Improper tip stickout. 3.    Adjust nozzle/tip relationship.
  4.    Improper electrode stickout. 4.    Adjust torch to base metal
           relationship.
  5.    Faulty ground. 5.    Repair all cables & connectors.
         
 Tip disengages from 1.    Worn retaining head. 1.    Replace tip and/or retaining head.
 retaining head. 2.    Improper tip installation. 2.    Install as per your Tregaskiss product
           Technical Guide.
  3.    Extreme heat or duty cycle. 3.    Replace with heavy duty
           consumables.
         
 Erratic arc. 1.    Worn contact tip. 1.    Replace.
  2.    Buildup inside of liner. 2.    Replace liner, check condition of
  3.    Wrong tip size.      electrode.
  4.    Not enough bend in 3.    Replace with correct tip size.
       gooseneck. 4.    Replace with 45° or 60° gooseneck.
         
 Extreme Spatter. 1.    Improper machine parameters. 1.    Adjust parameters.
  2.    Improper tip installation. 2.    Adjust nozzle/tip relationship.
  3.    Improper shielding. 3.    a.  Verify shielding gas coverage.
           b.  Verify gas mixture.
  4.    Contaminated wire or work 4.    Clean wire and work piece.
       piece.    
         
 Liner is discolored full 1.    Short circuit to electrode. 1.    Isolate electrode reel from feeder and
 length.          drive block. Consult feeder
           manufacturer's manual.
  2.    Broken copper stranding in 2.    Replace gun.
       power cable.    Back to top .
         

 

Have a question?
Please contact our Technical Services Department by email or click here Ask The Experts. Our Technical Services Department can also be reach by phone at 1-877-737-3111. Assistance is available Monday to Friday from 8:00 AM to 5:00 PM EST. 
 
All questions are answered to the best of our ability with the information given. Other factors not disclosed in the question may alter the best welding advice and procedures. We will respond to your question as soon as possible. Depending on the complexity of your question, it could take up to 1-2 business days to respond if you contact us electronically.