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A Division of ITW Canada Inc.

Troubleshooting Guide from Tregaskiss

PROBLEM 1. Electrode does not feed or erratic wire feeding. POSSIBLE CAUSE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Feeder relay/malfunction. Broken control lead. Poor adaptor connection. Worn or broken switch. Improper drive roll size. Drive roll tension misadjusted. Burn back to contact tip. Wrong size liner. Buildup inside of liner. Worn drive roll. POSSIBLE SOLUTION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 1. 2. 3. 4. 5. 1. 2. Consult feeder manufacturer. a. Test & connect spare control lead. b. Install new cable. Test & replace leads and/or contact pins. Replace. Replace with proper size. Adjust tension at feeder. See Contact Tip Burn Back. Replace with correct size. Replace liner, check condition of electrode. a. Replace with new drive roll. b. Stone edge of groove on drive roll. a. Adjust/replace guide as close to drive rolls as possible. b. Eliminate all gaps in electrode path. Replace with proper guide diameter. Replace with new liner, using the Tregaskiss Liner Gauge. Inspect and replace. Set parameters. See Erratic Wire Feeding. Adjust nozzle/tip relationship. Adjust torch to base metal relationship. Repair all cables & connections. a. Replace with properly rated Tregaskiss torch. b. Decrease parameters to within torch rating. a. Clean, tighten or replace cable grounding connection. b. Tighten torch & cable connections to specified torque.

11. Improper guide tube relationship. 12. Improper wire guide diameter. 13. Gaps at liner junctions. 14. Contact tip. 2. Short contact tip life. 1. 2. 3. 4. 5. 1. 2. Improper voltage and/or wire feed speed. Erratic wire feeding. Improper tip stickout. Improper electrode stickout. Faulty ground. Exceeding duty cycle. Loose or poor power connection.

3.

Torch running hot.

CANADA: 2570 North Talbot Road, Windsor, Ontario N0R 1L0 U.S.A.: P.O. Box 1768, Troy, Michigan 48099-1768

CANADA & U.S.A.: Phone 1-877-737-3111 Fax 1-877-737-2111 INTERNATIONAL: Phone +1-519-737-3000 Fax +1-519-737-2111

www.tregaskiss.com
A Division of ITW Canada Inc.

Troubleshooting Guide from Tregaskiss

PROBLEM 4. Porosity in weld. POSSIBLE CAUSE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 5. Contact tip burn back. 1. 2. 3. 4. 5. 1. 2. 3. 7. Erratic arc. 1. 2. 3. 4. 1. 2. 3. 4. 9. Liner is discolored full length. 1. 2. Insulator worn. Retaining head damaged. Extreme heat or duty cycle. Solenoid faulty. No gas. Flow improperly set. Gas ports plugged. Ruptured gas hose. Control circuit loss. Worn, cut or missing o-rings. Loose fittings. Improper voltage and/or wire feed speed. Erratic wire feeding. Improper tip stickout. Improper electrode stickout. Faulty ground. Worn retaining head. Improper tip installation. Extreme heat or duty cycle. Worn contact tip. Buildup inside of liner. Wrong tip size. Not enough bend in gooseneck. Improper machine parameters. Improper tip installation. Improper shielding. Contaminated wire or work piece. Short circuit to electrode. Broken copper stranding in power cable. POSSIBLE SOLUTION 1. 2. 3. 4. 5. Replace nozzle/insulator. Replace retaining head. Replace with heavy duty consumables. Replace solenoid. a. Install full tanks. b. Check supply. c. Check for hose leaks. 6. Adjust. 7. a. Clean or replace gas diffuser/retaining head. b. Clean nozzle. 8. Repair or replace cable or line. 9. See Electrode does not feed. 10. Replace o-rings. 11. Tighten torch & cable connections to specified torque. Set parameters. See Erratic wire feeding. Adjust nozzle/tip relationship. Adjust torch to base metal relationship. Repair all cables & connectors. Replace tip and/or retaining head. Install as per your Tregaskiss product Technical Guide. Replace with heavy duty consumables. Replace. Replace liner, check condition of electrode. Replace with correct size tip. Replace with 45 or 60 gooseneck. Adjust parameters. Adjust nozzle/tip relationship. a. Verify shielding gas coverage. b. Verify gas mixture. Clean wire and work piece. Isolate electrode reel from feeder and drive block. Consult feeder manufacturers manual. Replace gun.

1. 2. 3. 4. 5. 1. 2. 3. 1. 2. 3. 4. 1. 2. 3. 4. 1. 2.

6.

Tip disengages from retaining head.

8.

Extreme spatter.

CANADA: 2570 North Talbot Road, Windsor, Ontario N0R 1L0 U.S.A.: P.O. Box 1768, Troy, Michigan 48099-1768

CANADA & U.S.A.: Phone 1-877-737-3111 Fax 1-877-737-2111 INTERNATIONAL: Phone +1-519-737-3000 Fax +1-519-737-2111