Troubleshooting
SECTION 6: SERVICE
Review the troubleshooting and procedures in this section to fix or adjust your machine if a problem devel- ops. If you need replacement parts or you are unsure of your repair skills, then feel free to call our Technical Support at (570)
Troubleshooting
Symptom |
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Welder | does | not | 1. | Plug/receptacle is at fault or wired incor- | 1. | Test for good contacts; correct the wiring. | |
power | up | or | the |
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breaker trips. |
| 2. | Wiring is open/has high resistance. | 2. | Check for broken wires or disconnected/corroded | ||
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| connections, and repair/replace as necessary. |
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| 3. | ON/OFF switch is at fault. | 3. | Replace faulty ON/OFF switch. |
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| 4. | Duty cycle has been exceeded. | 4. | Let the fan cool the welder. |
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Porosity (small cavi- | 1. | Arc length is too long. | 1. | Reduce length of arc. | |||
ties or holes caused | 2. | Workpiece is dirty or damp. | 2. | Remove all grease, oil, moisture, coatings, rust, and | |||
from gas | pockets |
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| dirt from workpiece before welding; blow out all air | ||
in weld); poor weld |
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| and moisture from gas lines. | ||||
bead color. |
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| 3. | Damp electrodes. | 3. | Use dry electrodes. | ||
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| 4. | Inadequate gas flow (TIG). | 4. | Adjust gas flow rate as necessary. |
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| 5. | Incorrect electrode/filler metal used. | 5. | Use correct type and size of electrode/filler metal. |
6.Loose fittings in torch/gas hoses (TIG). 6. Tighten torch/gas hose fittings; check gas hoses and connections for leaks; replace if necessary.
Excessive spatter. | 1. | Amperage too high for electrode. | 1. | Select large electrode or decrease amperage. |
| 2. | Voltage too high; arc length too long. | 2. | Reduce voltage or arc length. |
| 3. | Incorrect electrode/tungsten rod used. | 3. | Use correct type and size of electrode/tungsten rod. |
4.Incorrect gas or gas settings (TIG). 4. Use the correct gas for the welding operation; adjust the gas flow as necessary.
Distortion of base | 1. | Excessive heat applied to base metal. | 1. | Make tack welds along joint before starting opera- |
metal. |
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| tion; select lower amperage for electrode; increase |
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| travel speed; weld in small segments and allow cool- |
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| ing between welds. |
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Burn through or | 1. | Excessive heat applied to base metal. | 1. | Select lower amperage; use smaller electrode; |
excessive penetra- |
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| increase and/or maintain steady travel speed. |
tion of base metal. |
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Lack of penetration. | 1. | Improper joint preparation. | 1. | Material too thick; joint preparation must provide |
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| access to bottom of groove. |
| 2. | Improper weld technique. | 2. | Keep arc on leading edge of weld puddle; reduce |
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| travel speed. |
| 3. | Insufficient heat applied to weld. | 3. | Increase amperage; select larger electrode. |
4.Incorrect gas or gas settings (TIG). 4. Use the correct gas for the welding operation; adjust the gas flow as necessary.
H8154 AC/DC Stick/TIG Welder |