Troubleshooting Guide

 


Electrode does not feed / erratic wire feeding.

Possible Causes

Possible Solution

1.

Feeder relay / malfunction.

1.

 

Consult feeder manufacturer.

2.

Broken control lead.

2.

a.

Test and connect spare control lead.

 

 

 

b.

Install new cable.

3.

Poor adaptor connection.

3.

 

Test and 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 relationship

11.

a.

Adjust / replace guide as close to drive rolls as possible.

 

 

 

b.

Eliminate all gaps in elecgtrode 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 and replace.

       


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Short contact tip life.

Possible Cause

Possible Solution

1.

Improper voltage and/or wire feed speed.

1.

 

Set parameters.

2.

Erratic wire feeding.

2.

 

See 'Erratic 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 and connections.

       


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Torch running hot.

Possible Cause

Possible Solution

1.

Exceeding duty cycle.

1.

a.

Replace with properly rated Tregaskiss torch.

 

 

 

b. 

Decrease parameters to within torch rating.

2.

Loose or poor power connection.

2.

a. 

Clean, tighten or replace cable grounding connection.

 

 

 

b. 

Tighten torch and cable connections to specified torque.

       


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Porosity in weld.

Possible Cause

Possible Solution

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 and cable connections to specified torque.

       


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Contact tip burn back.

Possible Cause

Possible Solution

1.

Improper voltage and/or wire feed speed.

1.

 

Set parameters.

2. 

Erratic wire feeding.

2. 

 

See 'Erratic 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 and connectors.

       


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Tip disengages from retaining head.

Possible Cause

Possible Solution

1.

Worn retaining head.

1.

 

Replace tip and/or 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.

       


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Erratic arc.

Possible Cause

Possible Solution

1.

Worn contact tip.

1.

 

Replace.

2. 

Buildup inside of liner.

2. 

 

Replace liner, check condition of electrode.

3.

Wrong tip size.

3.

 

Replace with correct tip size.

4. 

Not enough bend in neck.

4. 

 

Replace with 45° or 60° neck.

       


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Extreme spatter.

Possible Cause

Possible Solution

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 piece.

5.

 

Clean wire and work piece.

       


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Liner is discolored full length.

Possible Cause

Possible Solution

1.

Short circuit to electrode.

1.

 

Isolate electrode reel from feeder and drive block. Consult manufacturer's manual.

2. 

Broken copper stranding in power cable.

2. 

 

Replace gun.

       


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Have a Question?

Please contact our Technical Services department by email or click here to Ask The Experts. Our Technical Services department can also be reached by phone at 1-855-MIGWELD (644-9353). Assistance is available Monday through Friday from 8:00 a.m. to 5:00 p.m. EST.


All questions are answered to the best of our ability with the information supplied to us. Other factors not disclosed in electronic inquiries we receive may alter the best welding advice and procedures we recommend. 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.