Welding Troubleshooting Guide

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

  Back to top