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| Models WF2150, WF2154, | |
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| WG2160 and WG2164 | |
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| For Information About This Product Call | |||
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| Troubleshooting Chart - Welder | ||
| Symptom | Possible Cause(s) | Corrective Action |
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| No output | 1. Duty cycle exceeded | 1. Allow welder to cool until lamp goes out | |
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| 2. Poor work clamp connection | 2. Be sure all connections are secure, and attaching surface | |
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| 3. Blown breaker or fuse | is clean | |
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| 3. Reduce circuit load, reset breaker or replace fuse | ||
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| Wire tangles at drive roller | 1. Wrong size contact tip | 1. Use proper size contact tip | |
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| 2. Torch liner clogged or | 2. Clean or replace wire liner | |
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| damaged |
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| 3. Contact tip clogged or | 3. Clean or replace contact tip | |
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| damaged |
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| 4. Drive roller worn | 4. Replace | |
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| 5. Not enough tension | 5. Tighten tension knob | |
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| Gun nozzle arcs to work | 1. Slag inside gun nozzle | 1. Clean slag from gun nozzle | |
| surface | 2. Insulation ring melted/expired | 2. Replace nozzle | |
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| Work clamp and/or cable | 1. Poor contact | 1. Be sure all connections are secure, and attaching surface | |
| gets hot | 2. Using an extension cord with | is clean | |
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| 2. Never use an extension cord longer than 20 ft | ||
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| excessive length |
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| Wire does not feed | 1. Wire jammed | 1. Reload wire | |
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| 2. Out of wire | 2. Replace wire spool | |
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| 3. Not enough tension | 3. Tighten tension knob if wire is slipping | |
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| 4. Wire liner worn | 4. Replace liner | |
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| 5. Wire disconnected internally | 5. Call | |
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| 6. Contact tip clogged | 6. Replace contact tip | |
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| (Aluminum) Wire burns back | 1. Wire speed too slow | 1. Run speed in 7 - 10 range | |
| into tip or (Aluminum) Metal | 2. Travel speed too slow or heat | 2. Increase the travel speed or reduce heat settings | |
| bubbles or burns through | is too high |
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| Weld pops and sputters | 1. Wire speed setting | 1. Tune in correct setting | |
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| 2. Contact tip size too large | 2. Replace contact tip | |
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| 3. Polarity set incorrectly | 3. Reverse polarity | |
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| 4. Drive roller slipping | 4. Increase tension | |
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| 5. Gas bottle empty | 5. Replace gas bottle | |
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| Bead is intermittently too | 1. Inconsistent travel speed | 1. Decrease and maintain constant travel speed | |
| thin | 2. Output heat setting too low | 2. Increase output heat setting | |
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| Bead is intermittently too | 1. Slow and/or inconsistent | 1. Increase and maintain travel speed | |
| thick | travel speed | 2. Reduce output heat setting | |
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| 2. Output heat setting too high | ||
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| Ragged depressions at | 1. Travel speed too fast | 1. Decrease travel speed | |
| edge of weld | 2. Wire speed too fast | 2. Decrease wire speed | |
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| 3. Output heat setting too high | 3. Reduce output heat setting | |
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| Weld bead does not | 1. Inconsistent travel speed | 1. Decrease and maintain constant travel speed | |
| penetrate base metal | 2. Output heat setting too low | 2. Increase output heat setting | |
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| 3. No or low shielding gas | 3. Use gas for MIG process or refill bottle | |
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| 4. Wrong shielding gas | 4. Use only 100% Argon gas | |
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| (aluminum) | 5. Never use an extension cord longer than 20 ft | |
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| 5. Extension cord is too long | ||
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| 6. (Aluminum) Possible oxide | 6. Clean surface thoroughly with a stainless steel brush only | |
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| Wire sputters and sticks | 1. Damp wire | 1. Use dry wire and store in dry location | |
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| 2. Wire speed too fast | 2. Reduce wire speed | |
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| 3. Wrong type of wire | 3. Use | |
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| 4. No or low shielding gas | 4. Use gas for MIG process or refill bottle |
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