1: Inconsistent / interrupted wire feed
Possible Reason
Suggested Remedy
Wrong polarity selected
Select the correct polarity for the wire being used - see machine setup guide
Incorrect wire speed setting
Adjust SYNERGIC Control Knob
Voltage setting incorrect
Adjust SYNERGIC Control Knob
MIG torch lead kinked or too sharp angle
being held
Remove the kink, reduce the angle or bend
Contact tip worn, wrong size, wrong type
Replace the tip with correct size and type
Liner worn or clogged (the most common
causes of bad feeding)
Try to clear the liner by blowing out with compressed air as a temporary cure,
it is recommended to replace the liner
Wrong size liner
Install the correct size liner
Blocked or worn inlet guide tube
Clear or replace the inlet guide tube
Wire misaligned in drive roller groove
Locate the wire into the groove of the drive roller
Incorrect drive roller size
Fit the correct size drive roller e.g.; 0.8mm wire requires 0.8mm drive roller
Wrong type of drive roller selected
Fit the correct type roller (e.g. knurled rollers needed for flux cored wires)
Worn drive rollers
Replace the drive rollers
Drive roller pressure too high
Can flatten the wire electrode causing it to lodge in the contact tip - reduce the drive roller pressure
Too much tension on wire spool hub
Reduce the spool hub brake tension
Wire crossed over on the spool or tangled
Remove the spool untangle the wire or replace the wire
Contaminated MIG wire
Use clean dry rust free wire. Do not lubricate the wire with oil, grease etc
The following chart addresses some of the common WIRE FEED problems during MIG welding. In all cases of equipment malfunction, the manufacturer’s
recommendations should be strictly adhered to and followed.
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| VIPER 120 SYNERGIC MIG Welder Manual
MIG WIRE FEED TROUBLE SHOOTING
