8

Trouble Shooting

 

Fault

 

 

 

Cause

Remedy

Irregular wire feed

 

 

Incorrect tension of tension roller

Adjust tension

 

 

 

 

 

 

Pilot groove of feed roller and intake nozzle not

Align

 

 

 

 

 

 

aligned

 

 

 

 

 

 

 

Liner clogged or not correct size for wire

Check and/or change

 

 

 

 

 

 

Wire spooled irregularly, rusty or of inferior quality

Clean or change liner

 

 

 

 

 

 

Wire spool carrier to tight

Change spool

 

 

 

 

 

 

Feed rollers dirty of worn, groove not matching

Loosen

 

 

 

 

 

 

wire size

Clean or replace

 

 

 

 

Brittle

or porous welding

Gas line fittings not tight

Check fittings

seam

 

 

 

 

Gas cylinder empty

Replace cylinder

 

 

 

 

 

 

Gas cylinder valve closed

Open valve

 

 

 

 

 

 

Pressure regulator not working

Check

 

 

 

 

 

 

Solenoid valve not working

Check power at solenoid

 

 

 

 

 

 

Gas shroud or line in lead ass'y clooged

Clean shroud and spray, blow out gas line

 

 

 

 

 

 

Air draft at weld seam

Protect from draft or increase gas flow

 

 

 

 

 

 

Workpiece not clean

Remove rust, grease, paint

 

 

 

 

 

 

Wire of inferior quality or unsuitable gas

Change wire, use suitable gas

 

 

 

 

 

Constant gas flow

 

 

Solenoid valve defective or dirty

Check, clean or replace

 

 

 

 

 

 

No wire feed

 

 

 

Trigger switch or leads in lead ass'y defective

Check, replace if necessary

 

 

 

 

 

 

PCB defective

Replace

 

 

 

 

 

 

Fine wire fuse on PCB defective

Replace (2 amp time-lag)

 

 

 

 

 

 

Wire

feed

speed

not

PCB defective

Replace

adjustable

 

 

 

 

 

 

 

 

 

 

 

Not

welding

current

with

Contactor faulty

Replace

normal working wire feed

Step with faulty

Replace

 

 

 

 

 

 

Earth cable not conducting

Correct

 

 

 

 

 

 

Arcing

when

gas

shroud

Short-circuit between contact tip and gas shroud

Clean shroud, treat with anti-clogging spray or

touches workpiece

 

 

 

nozzle dip (see footnote below).

 

 

 

 

 

Torch

becomes

exces-

Contact tip loose or too large for wire diameter

Tighten tip; replace with correct size tip

sively hot

 

 

 

 

 

 

 

 

No function of machine

Mains fuse/circuit breaker tripped

Reset or replace

 

 

 

Torch under current when

Contactor sticky or contacts burned

Check and replace

machine is switched OFF

 

 

 

 

 

 

3-phase

machine:

One phase missing

Check contactor for proper function

excessive spattering with

 

Check mains fuses, check power at contactor

all welding step setting

 

terminals (all 3 phases)

 

 

 

 

 

 

 

 

3-phase machine: excessive spattering at a particular welding step

Step switch defective

Check and replace

Cables between step switch and transformer

Check and replace

loose or broken

 

Important! The capacitors of the 1-phase machines need 40 seconds to discharge completely after the machine is switched off. If the electrode wire makes contact with the workpiece during this period, a short discharge spark is generated.