Spot Welding; Troubleshooting - Prima MIG 204 Manual De Uso

12.0 SPOT WELDING

It is possible to spot weld two sheets of up to 0,8mm thickness mild steel by replacing the torch gas nozzle with a spot welding nozzle (not
supplied).Select the spot welding fuction by adjusting the timer (4). Place two sheets one upon another; place the nozzle on the upper sheet and then
push the torch ensuring that the sheets are in contact. Press the trigger to spot weld the first sheet to the second one. The spot welding will automatically
stop when the adjusted time has passed. For spot welding, the machine must be set at maximum current and maximum wire speed. It is advisable to use
0,8mmø wire.
13.0 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, weld output or gas flow
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
POSSIBLE CAUSE
Input cable or plug malfunction.
Wrong size fuse.
Faulty trigger on gun
Thermostat intervention
Faulty wire feeding motor (rare)
Insufficient 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 to 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
Insufficient gas at weld area
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
connections.
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.
Use correct size contact tip.
Tighten connection or replace cable.
Clean or replace nozzle.
Decrease wire feed speed
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.
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