Troubleshooting - Prima MIG 210 SYNERGIC Operating Instructions Manual

17.0 TROUBLE SHOOTING
This chart will assist you in resolving common problems you may encounter. These are not all the possible solutions.
PROBLEM
No "life" from welder
Fan operates normally, but when
gun trigger pulled, there is no wire
feed
Feed motor operates but wire will
not feed
Lack of penetration
Wire is birdnesting at the drive
roller
Wire burns back to contact tip
Workpiece clamp and/or cable
gets hot.
Gun nozzle arcs to work surface.
Wire pushes torch back from the
workpiece
Poor quality welds
Weld deposit "stringy" and incom-
plete
Weld deposit too thick
24
POSSIBLE CAUSE
Input cable or plug malfunction.
Wrong size fuse.
Faulty trigger on gun
Thermostat intervention
Faulty wire feeding motor (rare)
Insuffi cient feed roller pressure
Burr on end of wire
Liner blocked or damaged
Voltage or wire feed speed too low.
Loose connection inside the machine (rare).
Worn or wrong size contact tip.
Loose gun connection or faulty gun assembly
Wrong size wire.
Torch moved too fast.
Eccessive pressure on drive roller
Gun liner worn or damaged
Contact tip clogged or damaged
Liner stretched or too long
Contact tip clogged or damaged
Wire feed speed too slow
Wrong size contact tip
Bad connection from cable to clamp
Slag buildup inside nozzle or nozzle is shorted.
Wire feed speed too fast
Nozzle clogged
Torch held too far from the workpiece
Insuffi cient gas at weld area
Rusty, painted, damp, oil or greasy workpiece
Rusty or dirty wire
Poor ground contact
Incorrect gas / wire combination
Torch moved over workpiece too quickly
Gas mixture incorrect
Torch moved over workpiece too slowly
Welding voltage too low
POSSIBLE SOLUTION
Check for proper input cable connection
Check fuse and replace as necessary
Replace torch trigger
Allow welder to cool. The extinguishing of the
pilot lamp / switch on the front panel indicates
the thermostat has closed.
Replace wire feeding motor
Increase roller pressure
Re-cut wire square with no burr
Clear with compressed air or replace liner
Re-adjust the welding parameters.
Clear with compressed air and tighten all con-
nections.
Replace the contact tip.
Tighten or replace torch.
Use correct size welding wire.
Move the gun smoothly and not too fast.
Adjust pressure on drive roller.
Replace wire liner
Replace contact tip
Cut wire liner at the right lenght
Replace the contact tip
Increase wire speed before operating again.
(only manual mode)
Use correct size contact tip.
Tighten connection or replace cable.
Clean or replace nozzle.
Decrease wire feed speed
(only manual mode)
Clean or replace nozzle
Hold the torch at the right distance
Check that the gas is not being blown away by
drafts and if so move to more sheltered weld area.
If not check gas cylinder contents gauge, regulator
setting and operation of gas valve.
Ensure workpiece is clean and dry.
Ensure wire is clean and dry.
Check ground clamp/workpiece connection
Check on the manual for the correct combina-
tion
Move the torch slower
See shielding gas table
Move the torch faster
Increase welding voltage