PROBLEMS
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| PROBLEM |
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| POSSIBLE CAUSE |
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| WHAT TO DO |
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| 1. Rough wire feeding or wire not |
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| a. Gun cable kinked and/or twisted. |
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| a. Inspect gun cable and replace if |
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| feeding but drive rolls turning. |
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| necessary. |
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| b. Wire jammed in gun and cable. |
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| b. Remove wire from gun and cable |
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| feed in new wire. Note any |
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| obstructions in gun and cable. |
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| Replace gun and cable if |
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| necessary. |
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| c. Incorrect position of drive rolls |
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| c. See Wire Feed Drive Roll and |
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| with grooves. |
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| Guide Tubs Kits section for |
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| proper installation of drive roll. |
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| d. Drive rolls loose. |
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| d. Remove, clean, install and |
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| tighten. |
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| e. Gun cable dirty. |
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| e. Clean cable or replace liner. |
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| f. Worn drive roll. |
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| f. Replace. |
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| g. Electrode rusty and/or dirty. |
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| g. Replace. |
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| h. Worn nozzle or cable liner. |
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| h. Replace. |
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| i. Partially flashed or melted |
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| i. Replace contact tip. |
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| contact tip. |
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| j. Incorrect idle roll pressure. |
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| j. Set idle roll pressure per section |
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| on Idle Roll Pressure Setting. |
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| k. Improper liner, tip or guide tube. |
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| k. Install proper equipment. |
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| 2. Variable or “hunting” arc. |
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| a. Wrong size, worn and/or melted |
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| a. Replace tip - remove any spatter |
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| contact tip. |
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| on end of tip. |
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| b. Worn work cable or poor work |
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| b. Inspect - Repair or replace as |
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| connection. |
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| necessary. |
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| c. Loose electrode connections. |
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| c. Be sure electrode lead is tight in |
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| wire feeder contact block, gun |
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| nozzle and gun tip tight. |
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| d. Wrong polarity. |
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| d. Check connection at output studs |
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| for polarity required by welding |
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| process. |
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| e. Problem with serial |
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| e. Make sure control cable connections are |
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| communications in control cable. |
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| tight. Check for consistent WFS. Make sure |
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| parameters on Power Source display, such |
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| as WFS, match those on wire feeder |
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| display, if not, try changing Synergic 7F |
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| control board. If problem persists refer to |
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| Power Source trouble shooting information. |
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– 29 –
