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MIG 250GS Operating manual
9.0 Troubleshooting and Fault Finding
Power source
Component
Primary cable
Earth cable and clamp
Connectors and lugs
Switches
Wire feeder (as part of the powersource unit)
Component
Gas solenoid valve
Wire feed rolls
Inlet, outlet guides
Universal adaptor
Wire feed speed control
Wire inch switch
Spindle
Welding torch
Component
Type
Liners
Gas distributor
Nozzle
Contact tip
Nozzle insulator
Regulator / flowmeter
Component
Inlet stem
Gas hose and fitting
Shielding gas
Component
Cylinder, MCPs
Bulk
Welding wire
Component
Wire basket and spool
Wire
Wire
Fault symptom
No or low welding output
Arc will not initiate
Overheating of connectors and lugs
Erratic or no output control
Fault symptom
No gas flow or gas flows continuously
Wire slippage, wire deformation
Wire shaving or snarling
Wire restriction, gas leaks, no trigger control
No control over wire feed speed, no amperage
control
Wire live when feeding through cable and torch
before welding
Wire spool drags or overruns
Fault symptom
Welding torch overheats
Erratic wire feed, wire snarls up at outlet guide
Inadequate gas flow, contaminated or porous
weld
Inadequate gas cover, restricted joint
accessibility
Erratic feeding, wire shudder, wire burnback,
unstable arc, spatter
Arcing between contact tip and nozzle and
between nozzle and workpiece
Fault symptom
No gas flow, gas leaks at regulator body or
cylinder valve
Leaks at connections or in the hose, porosity in
the weld
Fault symptom
No gas flow, porosity in the weld
No gas flow, change in welding conditions
Fault symptom
Erratic wire feeding or wire stoppages
Wire sticks in contact tip, erratic feeding
Weld has excessive amount of spatter
Cause
Bad or incorrect primary connection, lost phase
Damaged, loose or undersized cables and clamps
Loose or badly crimped connectors
Switches damaged or incorrectly set for the application
Cause
Gas valve faulty or sticking in open position
Incorrect feed roll size, incorrect tension adjustment,
misalignment
Incorrect wire guide sizes, misalignment
Universal adaptor not correctly mounted or secured,
incorrect size of internal guide, bent contact pins
Faulty wire speed feed potentiometer, wire feed motor in
overload or trip condition
Faulty wire inch switch, inappropriate use of torch trigger
switch
Spindle brake set too tight or too loose, spool not properly
located on spindle
Cause
Welding torch underrated for welding application
Liner of incorrect type and size for wire in use, worn or
dirty liner, liner too long or too short
Damaged or blocked distributor
Nozzle too large or too small, incorrect length or shape
Incorrect size of contact tip, incorrect contact tip to nozzle
distance for metal transfer mode, inferior contact tip
material
No nozzle insulator fitted
Cause
Blocked inlet stem, leaking inlet stem to body thread,
bullnose not properly seated in cylinder case
Poorly fitted 'o' clips, damaged hose, air drawn into gas
stream
Cause
Gas cylinder closed or empty, faulty cylinder valves
Bulk tank empty, incorrectly set mixing panel
Cause
Damaged wire basket, loose spooling, random-wound
wire
Varying wire diameter, copper flaking, surface damage
Wrong polarity has been selected
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