MTS250S Code 802 ??

[Rambozo]

So what does the processor use to adjust the weld voltage in sync with wirespeed? Does it measure the voltage or current going to the drive motor, to infer speed, or something else?

[Kempy]

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.

Burn back was off.
Yes I tuned the spool gun in synergic mode the volts do drop but will not weld right and for long.
I will get a .045 tip or drill out a .035 to .045.

[Kempy]

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

100% Argon

[Kempy]

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

[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]

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.

[Rambozo]

That would drive me up the wall. I always use the nozzle to push something into place to get a tack on it. There are a lot of times where I don't even have a helmet on, I just get things into position, prop the nozzle in place, and look away when I give it a quick blast.

[Kempy]

When I first got the machine end of April 2013 it work very well and held the settings in Aluminum SYN mode.

Conclusion for 802 code is with a lot of playing around and using up gas, wire, hydro and time, it only really happens in SYN spool mode on wire type Alum 4043/5356 mode and wire size Auto to .045. burn back off Mig Wave Form on or off gas used was 100% Argon.
Change gas to 25% Helium 75% Argon it works a little better and longer but melt down did happen and not as clean a weld as with 100% Argon.
Adjusting things and using Unibraze S-6 wire in SYN Spool, wire type M Steel and wire size 0.035 or 0.030 it works and will spray with Argon/Co2 mix but will not spray with Lincoln S-6 wire.
Adjusting again and using Unibraze 316 wire in SYN Spool, wire type SS 308/316 and wire size 0.035 it works and sprays using Argon/Helium/O2 mix.

CODES for MTS250S-2013
801 = Over-Voltage or Low- Voltage
802 = Over- Temperature
804 = Over-Current
805 = Torch switch always close

[sportbike]

I have never seen a GMAW nozzle that was energized during welding. I suppose if there was a buildup of spatter or wire from the tip to the nozzle it could happen, but to have it energized intentionally during welding is odd. seems that there is something wrong with grounding or design of the gun.

[zoama]

Wire size was auto to .40 for aluminum, correct ?

[Kempy]

Wire size was auto to .40 for aluminum, correct ?

Wire size can not be changed Auto to .045 only.

[zoama]

Wire size can not be changed Auto to .045 only.

Post #12 confused me. Have you tried 1.2mm wire ?

[Kempy]

I have never seen a GMAW nozzle that was energized during welding. I suppose if there was a buildup of spatter or wire from the tip to the nozzle it could happen, but to have it energized intentionally during welding is odd. seems that there is something wrong with grounding or design of the gun.

I have not seen a schematic or detail drawing of the parts of any for the Everlast Mig Guns when you go on the Everlast site and go to (Know more by using Guns and Torches manual) on any Spool guns all you get is ERGOCUP S-45 Technical Data on the Plasma gun.

[Kempy]

Post #12 confused me. Have you tried 1.2mm wire ?

The Spool Gun is not made to run .045 (1.2mm) wire. In SYN mode ether in Spool gun or Mig gun SYN mode going to wire type using Alum. 4043/5356 it goes automatically to wire size .045 you can not change it. The welder did work very well with .035 4043 wire when I first got the machine.

[performance]

According to the factory, the gun will run .045. By the way, there is a typo error in the codes you posted. 802 is an overcurrent.

[zoama]

I think .045 aluminum wire will solve the syn mode problem.

[Kempy]

According to the factory, the gun will run .045. By the way, there is a typo error in the codes you posted. 802 is an overcurrent.

This is the page out of the MTS250S book on codes and the cover of the spool gun.