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TYPE OF FAULT
Irregular wire feed.
Reduced welding power.
Porous or spongy welds.
Presslng torch trigger
produces no result.
9.0 TYPES OF MALFUNCTIONING/WELDING FAULTS - CAUSES - REMEDIES
TYPES OF MALFUNCTIONING
WELDING FAULTS
The generator does not weld: the digital switch is
not lit.
During welding suddenly the outgoing current is
interrupted, the the orange led goes on.
Welding power reduced.
Excessive jets.
Craters.
Inclusions.
Inadequate penetration.
Sticking.
Blowing and porosity.
Jacks.
The electrode fuses in TIG.
TYPES OF MALFUNCTIONING/WELDING FAULTS - CAUSES - REMEDIES
POSSIBLE CAUSES
Insufficient spring pressure.
Wire-guide sheath blocked.
Wrong race - unsuitable for wire, or
excessively worn.
Braking on coil excessive.
Oxidized, poorly wound,
poor quality wire, with
tangled or overlapping coils, etc.
Earth cable not connected.
No gas.
Draughts in welding area.
Ciogged holes in diffuser.
Gas leakage due to rupture
in supply hoses.
Solenoid valve blocked.
Faulty pressure regulator.
Poor quality gas or wire.
Faulty torch trigger, disconnected or bro-
ken control cables.
Faulty power switch.
Faulty electronic circuit.
POSSIBLE CAUSES
A) The main switch is off.
B) The power lead is interrupted (lack of one or
two phases).
C) Other.
Overheating has occurred and the automatic
protection has come on. (See work cycles).
Outgoing wires are not correctly attached.
A phase is missing.
Welding arch too long.
Welding current too high.
Fast removal of the electrodes.
Inadequate cleaning and bad distribution of coating.
Faulty movement of the electrodes.
Forward speed too high. Welding current too low.
Welding arch too short.
Current too low.
Damp electrodes. Arch too long. Wrong torch polarity.
Currents too high. Dirty materials.
Wrong torch polarity. Type of gas not suitable.
CHECKS AND REMEDIES
Try tightening regulating knob.
Renew.
Turn roller over or change it.
Loosen brake using adjusting screw.
Remedy by removing defective coils. If problem persists, change the
wire reel.
Check that the power cord is in good condition and make sure that
the ground clamps are flrmly fixed to the works piece, which must be
free of rust, grease and paint.
Check presence of gas and gas supply pressure.
Use a suitable screen. Increase gas delivery pressure if necessary.
Clear clogged holes using compressed air.
Check and renew faulty component.
Check solenoid operation an electrical connection.
Check operation by removing the hose connecting the pressure reg-
ulator to the power source.
Gas must be extra-dry; change the cylinder or use a different type
wire.
Remove the torch connection plug and short-circuit the poles; if the
machine operates properly, check the cables and the torch trigger.
Clean with compressed air. Ensure that wires are tightly secured;
renew switch if necessary.
Contact our services department for maintenance.
A) Switch on mains.
B) Verify and repair.
C) Ask for the intervention of the Assistance Centre.
Keep generator switched on and wait till temperature
has dropped again (10-15 minutes) to the point where
the orange switch goes off again.
Check that wires are intact, that the pliers are sufficient
and that they are applied to welding surface clean from
rust, paint or oils.
Wrong torch polarity, lower the current values.
Increase current values.
(GB) 11
CONTROLS AND REMEDIES
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