Welding Troubleshooting Guide
 

 

PROBLEM

POSSIBLE CAUSE

POSSIBLE SOLUTION

 Electrode does not feed

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 switch.

 

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 - be sure to

 

 

 

 

   measure accurately before cutting.

 

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 gun.

 

 

 

 

   b.  Decrease parameters to within gun

 

 

 

 

        rating.

 

2.

   Loose or poor power

2.

   a.  Clean, tighten or replace cable

 

 

   connection.

 

        grounding connection.

 

 

 

 

   b.  Tighten gun & cable connections to

 

 

 

 

        specified torque.

 

 

 

 

 

 Porosity in weld.

1.

   Insulator worn.

1.

   Replace nozzle / insulator.

 

2.

   Retaining head damaged.

2.

   Replace retaining head / diffuser.

 

3.

   Extreme heat or duty cycle.

3.

   Replace with heavier 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 / diffuser.

1.

   Replace tip and/or diffuser.

 retaining head.

2.

   Improper tip installation.

2.

   Install as per your productSpec Sheet

 

 

 

 

   or Operations Manual.

 

3.

   Extreme heat or duty cycle.

3.

   Replace with heavy duty

 

 

 

 

   consumables.

 

 

 

 

 

 Erratic arc.

1.

   Worn contact tip.

1.

   Replace contact tip.

 

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.

 

 .

  
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