Troubleshooting Guide - Everlast PowerMTS 251Si Operator's Manual

Section 4
NO. Trouble
Unit is switched on, but the power
1
light isn't on
After welding machine is over-
2
heating and the fan does not work
When torch switch is pressed, no
3
gas Flows
Wire-feeder does
4
not work
5 No arc, or no output voltage
Welding stops and warning light is
6
on, Wire continues feeding but no
arc is present.
Welding Voltage/Current is uncon-
7
trollable
9 Intermittent Arc/ Wandering arc
10 Excessive spatter
11 Weld sooty or oxidized looking
Bird nesting of the wire around the
12
drive roll
13 Wire feeds irregularly
14 Wire burns back and seizes in tip
15 Nozzle arcs to work piece welding
16 In Stick mode will not arc
17 In Stick mode, the rod sticks
Possible Cause
Switch damaged.
Unit Fuse damaged.
Power breaker tripped.
Fan damaged.
Fan power connector is loose.
No gas in the gas cylinder.
Gas pipe leaks gas.
Gas solenoid valve damaged.
Torch switch damaged.
Control board damaged.
Motor damaged/Fuse blown.
Wire reel
does not turn
Control circuit damaged.
The tensioner is loose or wire slips
on rollers. Wrong size drive roll.
Wire is not mated in drive groove.
The drive roller doesn't fit the
diameter of weld wire.
Wire reel
turns
Wire Spool is damaged.
Gun liner is jammed.
Contact Tip is jammed because of
slag or burn back.
Work clamp engaged in wrong
connector.
Control circuit damaged.
Self-protection has engaged.
Potentiometer damaged.
Control board damaged.
Work Clamp is not secure or it is
damaged. Too windy/breezy.
Voltage too high too high arc force/
Too high wire speed. Too much
torch angle. Wrong size nozzle
Poor metal prep, poor gas flow, too
much torch angle, wrong gas type,
windy or breezy. Plugged nozzle
Jammed gun liner, wire too soft
(aluminum), gun hose is kinked or
coiled too tightly. Too much ten-
sion / pressure on wire feeder .
Wrong drive roller or wrong size
drive roller, too little tension on
wire, wire in wrong groove.
Wrong contact Tip size or too much
burn back time set.
Nozzle plugged with spatter
Cables not connected, inverter issue
Arc force/Hot Start is set too low,
arc striking method is poor, wrong
polarity, too low of amperage. Wet
welding rods or wrong kind.

Troubleshooting Guide

Solution
Replace.
Replace.
Reset.
Check fan housing and fan. Replace if necessary.
Tighten wires, check for dislodged connectors.
Replace.
Resolve .
Check and clean/replace.
Repair or Replace.
Inspect the circuit.
Check and Replace.
Check the board.
Increase tension. Check for proper drive roll size/type.
Make sure wire is in groove not riding on top of the
drive roller shoulder.
Change roller or wire size to match.
Change out wire spool.
Repair or change it, clear wire from liner/clean liner
with compressed air.
Clean or replace. If with Aluminum, increase tip size to
next size.
Change polarity.
Check the circuit.
Check over-voltage, over-current, over-temperature,
lower-voltage and over-temperature. Allow unit to cool
if over heated. If an OC, use a shorter wire stick out or
smaller diameter wire or reduce power settings with
large diameter wires. Check power plug for problems.
If easily tripped the Resistor value too low. (Contact
Everlast if OC is tripping regularly with normal settings.)
Repair or Replace it.
Check the circuit.
Check and/or Work Clamp, change position of clamp
and attach direct to the work. Move out of wind.
Lower voltage or increase wire speed. Check torch
angle for less than 15° push or pull. Change arc force
settings to reduce spatter. Change nozzle size.
Thoroughly clean metal, check gas flow and reposition
gun so gas flow is not creating turbulence. Move in-
doors if necessary. Reposition the welder so its fan will
not blow on the weld area. Clean nozzle.
Reduce wire feed tension so that drive will slip if it
encounters too much resistance Check Gun and liner
and replace if necessary. Straighten cable.
Check and match wire size to groove size, increase
tension on drive rollers. Check to make sure the wire is
not riding on the shoulder of the drive roller.
Match tip size for wire diameter. Reduce burn back
time. If using with aluminum, use tip designed for
aluminum or use one size larger tip than the wire.
Check/clean nozzle and use a nozzle dip.
Check connections.
Check polarity. Check Hot Start settings. Increase arc
force control/Hot Start. Change arc striking method.
Increase amperage. Use fresh welding rods when
possible.
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