TROUBLESHOOTING
May 25, 2022
Page 38
User Manual No: OM-10
4
A EN
Description
Possible Cause
Corrective Action
5.
Welding wire feeding prob-
lems.
A
The MIG/MAG equipment is not compatible
with the SPOOL Torch / PUSH-PULL Torch.
B
Contact tip is worn.
C
Torch Liner and/or Swan Neck Liner is worn /
dirty.
D
Consumables used are not suitable for the
welding wire diameter or material.
E
MIG/MAG equipment not set-up properly.
F
Welding wire is contaminated.
G
SPOOL Torch / PUSH-PULL Torch Drive Roll
groove size is a different size to the Welding
Wire diameter.
H
SPOOL Torch / PUSH-PULL Torch control
Multi-Pin Connector is not connected to the
MIG/MAG equipment.
A
Ask an Authorized Distributor if a SPOOL Torch /
PUSH-PULL Torch Interface Kit is available for
your MIG/MAG equipment
B
Replace contact tip.
C
Check the Liner; blow it out with clean, dry com-
pressed air. If needed replace it.
D
Use recommended consumables for the welding
wire diameter/material used.
E
Check the feed rolls, feed roll pressure and the
spool brake are adjusted as stated by the
MIG/MAG equipment
’s manual.
F
Use a cleaning felt to clean welding wire in the
MIG/MAG equipment.
G
Change the SPOOL Torch / PUSH-PULL Torch
Drive Roll groove size to suit the Welding Wire
diameter or change the Welding Wire diameter to
suit the SPOOL Torch / PUSH-PULL Torch Drive
Roll groove size.
H
Connect the Multi-Pin to the MIG/MAG equip-
ment.
6.
Wire feed stops during
welding.
A
Welding Wire blockage in contact tip.
B
Wire burns back into contact tip.
C
Groove worn in contact tip by welding wire.
A
Check for contamination/clogging, clean or re-
place contact tip.
B
Move the contact tip further away from the arc.
C
Replace contact tip.
7.
Porosity in the weld metal. A
Turbulent shielding gas flowing to weld zone
caused by spatter build up inside nozzle or on
gas diffuser.
B
Too low or extremely high shielding gas flow in
the Torch.
C
Shielding gas supply contaminated or incorrect
shielding gas used.
D
Moisture or contamination on the welding wire
or on the work piece
A
Clean the Torch consumables and use nozzle /
gas diffuser anti-spatter spray.
B
Check flow using a gas flow meter then adjust
gas flow rate from 10 LPM (indoors, no drafts)
up to 20 LPM (welding in drafts or outdoors).
C
Check for gas leakages using soapy water or
check for correct shielding gas to the Welding
System.
D
Check the wire and the work piece, use less or
different anti-spatter spray.
8.
Welding arc:
- always varies length
- is unstable
- is erratic
A
Contact tip is worn.
B
Wrong welding parameters.
C
Poor electrical connections in the welding cir-
cuit.
A
Change contact tip.
B
Check the MIG/MAG equipment setup parame-
ters then change parameters.
C
Check / tighten all electrical connections of the
MIG/MAG equipment, Torch, and ground cable to
work piece.
9. Welding wire burns back
to contact tip
A
Incorrect arc voltage/ wire feed speed weld pa-
rameters for the welding wire wire/mate-
rial/Torch position.
B
Erratic / unstable welding arc.
C
Incorrect contact tip stick-out length for re-
quired weld.
D
Incorrect welding wire stick-out length for re-
quired weld.
E
Ground cable to work piece fault.
A
Adjust arc voltage and/or wire feed speed param-
eters.
B
Refer to
6. Wire feed stops during welding.
on
page 38.
C
Adjust nozzle / tip relationship.
D
Adjust wire stick-out.
E
Replace ground cables and/or connections.
10. Short contact tip life
A
Contact tip size.
B
Welding wire eroding contact tip due to feed
rolls scoring wire.
C
Exceeding Torch duty cycle.
A
Replace with correct contact tip size.
B
Change feed rolls.
C
Replace with higher rated Torch.
11. Extreme spatter
A
Incorrect arc voltage/ wire feed speed weld pa-
rameters for the welding wire / material / Torch
position.
B
Inadequate shielding gas coverage.
C
Contaminated wire or work piece.
A
Adjust arc voltage and/or wire feed speed param-
eters.
B
Verify shielding gas coverage or gas mixture.
C
Use a cleaning felt to clean welding wire in the
MIG/MAG equipment and work piece.
