MTS250S Code 802 ??

[Kempy]

Code 802.
I keep getting code 802.
Start machine get 25.9V in Syn. Spool wire set to .035.
Start welding for about two seconds then the spool gun stops.
Machine has code 802 shut off machine restart volts 25.9V or 26.0V weld two or three seconds then it stops again.
Restart machine get 25.9V use selector go through everything back to Syn. Spool now volts is at 23.6V welder work and does not shut off.
Restart machine get 25.9V start welding for about two to five seconds then machine quits welding and code 802.
Restart welder get 25.9V use selector go through everything back to Syn. Spool now volts is at 23.6V change to 25.9 it welds O.K. select any wire size everything work. Shut of welder restart 25.9V any wire size machine welds two or so seconds then quits then I get code 802.

[performance]

Overcurrent. Check your exact input voltage. If it's a little low it can create a higher amp draw at higher voltages. Also can happen at higher volts/lower volts if your wire is on the metal when you pull the trigger.

[Kempy]

Overcurrent. Check your exact input voltage. If it's a little low it can create a higher amp draw at higher voltages. Also can happen at higher volts/lower volts if your wire is on the metal when you pull the trigger.

My in Voltage is 242V to 243V. Also just remembered it spray welded before and now it will not do it when it was spray welding it was very quite and no splatter now it has fine splatter spray. I will test Voltage will I weld to see if it changes that the input.

[Kempy]

Well I test on alum. with old settings and it welds then quits and melts the tips off.

problem welding tips melting

old weld no problems

tips

[Kempy]

Test with new tip .045 wire alum. 4043 .035 in standard Spool gun weld OK.

[Rambozo]

What is the 802 error code? I don't see any codes listed in the manual. On-board diagnostics are great, but only if you have the key.

Just overcurrent of the input or something more specific? Is there a list of codes somewhere?

[Kempy]

What is the 802 error code? I don't see any codes listed in the manual. On-board diagnostics are great, but only if you have the key.

Just overcurrent of the input or something more specific? Is there a list of codes somewhere?

Good question we need a list of error codes for all the machines.

Figured out one problem it seem to be the Spool gun why I do not know. Change to the Mig gun and see pics.

Spray weld OK with Mig gun no splatter runs quite

Setting on MTS250S in SYN MIG Mode

Will need tech to figure out what went wrong with the Spool Gun when it is plug in and the machine is turned on it goes to 25.9V or 26.0V every time but in other setting they stay the same.

[zoama]

I've never tried spray arc before but it seems like low wire speed would cause the melted tips.

[Rambozo]

As a test to help narrow down things, does the spoolgun work in the non-syn mode?
And how does the wirespeed control on the gun work?
I'm thinking that if the pot for wirespeed on the gun is bad, then in the SYN mode, the welder will get bad data and make changes in voltage to try to keep things in sync.
But that still doesn't explain your error code.

[Kempy]

As a test to help narrow down things, does the spoolgun work in the non-syn mode?
And how does the wirespeed control on the gun work?
I'm thinking that if the pot for wirespeed on the gun is bad, then in the SYN mode, the welder will get bad data and make changes in voltage to try to keep things in sync.
But that still doesn't explain your error code.

The wire speed controller work you can change the speed will it is running for a short time then it stops.
It works in none SYN mode but can not get it to spray just weld with fine splatter for a little longer then in SYN mode then it burns the tip also the wire speed is at full can not go any faster.

[performance]

What wire diameter and what wire tip size are you using?

[Kempy]

Just welded a truck crack in a truck frame and when I moved the spool gun sideways to weld around the frame support the gun cooling rings touched the frame and arced, I did not know that the neck was live also.

[Rambozo]

Just welded a truck crack in a truck frame and when I moved the spool gun sideways to weld around the frame support the gun cooling rings touched the frame and arced, I did not know that the neck was live also.

That seems odd. Doesn't that make the nozzle live, too?

[Kempy]

That seems odd. Doesn't that make the nozzle live, too?

Yes it is also live the nozzle is not insolated like the Mig gun. If the splatter builds up it sometimes arcs and sticks to the wire and goes in to the weld so I have to keep it clean or keep putting Rocol spatter release spray on the nozzle.

[zoama]

The neck/nozzle was like that on the regular mig gun that came with my 250p... first time the nozzle touched in a corner it burned the edge off it.
The spatter bonded to the nozzle like mad as well. It just would not release like on a bare copper one so I replaced it with the 20' profax. I want to purchase a spool gun for my machine but I don't want a live nozzle.

[Kempy]

Test with new tip .045 wire .035 in SYN Spool same settings 23.5V to 23.6V wire speed the same full speed as with standard setting in spool gun still melding down tips.

Conclusion testing in SYN Spool mode steel or alum. takes time and uses up a lot of tips and wire.

[Kempy]

More testing on the MTS250S.
Turn on MTS250S use Spool gun using Aluminum 4043 wire .035 tip .040 SYN mode burns up tip in two seconds or shuts down 802.
Turn on MTS250S use Spool gun using Steel S-6 wire .035 tip .035 SYN mode burns up tip in four or five seconds or shuts down 802.
Turn on MTS250S go thru all settings and then use Spool gun using Aluminum 4043 wire .035 tip .040 SYN mode burns up tip in 10 to 15 seconds.
Turn on MTS250S go thru all settings and then use Spool gun using Steel S-6 wire .035 tip .035 SYN mode burns up tip in 30 to 40 seconds.
Turn on MTS250S go thru all settings and use Spool gun using Steel S-6 wire .035 tip .035 in none SYN mode get nice weld.
Turn on MTS250S go thru all settings and use Spool gun using Aluminum 4043 wire .035 tip .040 in none SYN mode get nice weld for 10 seconds OUT OF WIRE cannot keep testing.
My conclusion right or wrong are.
Conclusion #1 Spool gun is OK but not in SYN mode. Synergic mode not working with Spool gun when selected SYN SPOOL mode.
Conclusion #2 Spool gun work very well in Spool mode.
Conclusion #3 Mig gun work very well in SYN MIG mode.
Conclusion #4 Mig gun work very well in MIG mode.

[Rambozo]

Sounds like it's in the spool gun for sure. I would still say that there is an intermittent open or short that is giving the SYN mode fits, and causing it to crank the current through the roof to try to compensate. Maybe something as simple as a bad wiper in the pot for wirespeed. In non SYN mode you might not notice the wire speed changing if it was only a few milliseconds, but the SYN mode would react to it.
Too bad your other spoolgun isn't the same, that would let you verify things easy.

[performance]

Have you turned your burn back OFF for aluminum? Also have you fine tuned any in synergic mode with the spool gun? You likely will need to retune some, depending upon a number of factors. But honestly, I'd go to a .045 for the .035 aluminum.

Rambozo, synergic doesn't work by reacting.

[performance]

Are you using pure argon or argon/helium on aluminum?