The difference between CO2 gas shielded welding wire and other welding machines is that it is an integrated device of machine, electricity, and gas. Problems that arise during use should be understood, analyzed, and solved from these three elements. Generally speaking, inability to weld indicates a circuit fault, difficulty in welding indicates a mechanical fault, and inability to weld can be due to process issues, impure shielding gas, gas channel problems, and other reasons. Let's analyze and solve common faults of CO2.Gas shielded welding wireCommon faults!

Are the entry, middle, and exit of the mechanical problem concentric on a straight line? When they are not aligned, the feeding resistance increases, making the feeding unstable.

Is the feeding trolley slipping? Wipe off rust-proof grease on the first test machine, regularly clean the wheel cover, and be careful to use soft materials for wiping. Check if the wheel groove is severely worn: usually expose 1/3 of the steel wire on the groove surface; otherwise, replace it with a corresponding diameter feeding wheel. The wheel groove must be installed with the positive electrode according to the wire diameter.

The retaining ring of the feeding trolley can only prevent excessive movement such as falling off or escaping during feeding; it should not be tightened too much. If not tightened too much, embedded screws may easily fall off or loosen.

Since the feeding hose (guide wire tube) is used for a long time, it can fill with dust and iron powder; sometimes the feeding resistance increases, so please clean it carefully. Although the guide wire has worked for some time, if it is still new, just blow it clean with compressed air (nylon tubes can only be cleaned this way); when the guide wire ages, please clean it with organic solvents like kerosene, gasoline, or alcohol. When replacing the guide wire tube, choose a suitable hose based on the diameter of the metal wire and cut it according to the actual length of the gun; be sure to remove burrs from the spiral metal nozzle. Additionally, in low-speed welding situations, a guide wire tube for a higher grade welding wire diameter can be used; however, thick welding wires are not allowed to use guide tubes for thinner wires. For example, a 1.2mm wire can use a 1.6mm guide tube but not vice versa. In high-speed welding situations, the feeding tube must strictly match the diameter of the welding wire.

When the conductive nozzle is larger than necessary due to excessive gap, there may be issues with poor conductivity leading to unstable welding processes and insufficient output current; therefore, please replace it promptly. Using anti-spatter agents during welding can extend the life of conductive nozzles while ensuring timely cleaning of spatter inside the torch sleeve during welding. The aperture of conductive nozzles for steel wires should be 0.1-0.2mm larger than the diameter of the steel wire and about 20-30mm in length. For aluminum welding wires, to reduce feeding resistance and ensure reliable conductivity, appropriately increase the aperture of conductive nozzles (0.2-0.3mm larger than wire diameter) and length so that nozzles for aluminum with the same diameter have larger apertures than those for steel.

　　Gas shielded welding wireSelect standard 3m guns based on meeting working radius conditions. The welding gun cable should not be bent during use. Special attention should be paid to areas adjacent to the handle and cable of the gun to ensure smooth feeding.

The selection of pressure must be appropriate. Generally, just tighten the pressure adjustment handle at scale 2-4 to avoid deformation of welding wire which increases feeding resistance and accelerates wear on wheel grooves; since the supporting shaft of the feeding disc is made of magnesium-aluminum alloy, it must endure long-term wear against plastic holes during use; regularly clean its surface and apply grease.

The rotation direction of gas shielded welding wire should be clockwise, not counterclockwise.

Is there a correct connection for aviation plugs, sockets, secondary cables, and grounding wires?

1) Correct connection method for air plugs

When inserting an aviation plug, please align it correctly with the positioning slot of the socket (corresponding width), then rotate right to lock it in place. At this point, the positioning lock of the socket enters into that of the plug perfectly. After removing the plug, please handle it carefully to avoid hardening or damage.

2) Phenomena occurring during virtual connection of aviation plugs

a. No action response when pressing the gun (no response from solenoid valve or motor).

b. The normal display range on power panel is voltage 15-48V and current preset digital scale 30-280; abnormal display shows voltage at 60-70V and current preset scale around 400; specific values depend on grid voltage.

c. Current and voltage cannot be adjusted.

3) Correct connection method for secondary cables

For connecting secondary cable quick connectors: just align them with grooves in secondary output socket on power front panel and push forward while turning right about 90 degrees.

4) Phenomena occurring during virtual connection of secondary cables and grounding wires

a. Severe heating at joint parts or even sticking together;

b. During high current welding, corresponding welding voltage exceeds normal matching range;

c. During low current welding process is unstable;

d. Trunk elongation adaptability decreases (short).

The above introduces common faults analysis and solutions for CO2 gas shielded welding wire; feel free to contact us for more information!