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Troubleshooting table
Problem Cause Remedy
The line fuses burn out and
close the line circuit breaker
• Wrong connection • Check and follow the instructions for connection
• Short circuit on fan motor • Repair or replace the motor
The line fuses burn out when
the torch button is pressed
• Short circuit on rectifier • Replace rectifier
• Short circuit on main transformer winding • Replace transformer
The line fuses burn out after
working for some time
• Fuses not high enough capacity • Use fuses of adequate capacity
for the line absorption
The welder does not emit current • Wrong connection • Check and follow the instructions for connection
• Line fuses burnt out • Find the cause and replace
• Circuit open on welding cables • Check the welding cables for breakage
Welding current unsteady • Variations of voltage on the line • Check the line voltage with a voltmeter
• Section of connecting cables too small • Replace with cables of adequate section
• Loose connections • Check connections to the power mains and
welding circuit and tighten if necessary
Welding defects
Problem Cause Remedy
Porosity (external or internal) • Defective wire • Change wire
• Insufficient gas flow • Adjust flow
• Defective solenoid • Check
• Wire guide nozzle clogged • Clean nozzle
• Gas flow holes clogged • Clean with jets of air
• Drafts of air • Screen the workplace
Withdrawal cracks • Wire or piece dirty or rusty • Replace wire or clean piece
• Bead too small • Increase current
• Bead too concave • Reduce voltage
• Bead too penetrating • Reduce voltage and current
Lateral incisions • Pass speed too high • Slow down
• Current too low and voltage too high • Increase wire speed and reduce voltage
Excessive splashing • Voltage too high • Adjust voltage
• Wire guide nozzle clogged • Clean nozzle
• Torch tilted too much • Tilt correctly
ponents. Check, that the gas circuit is completely free from im-
purities and that the connections are tight and that there are
no leaks. Carefully check that the electric valve does not leak.
Check the wire feeder rolls periodically and replace them when
wear impairs the regular flow of the wire (slipping etc).
TORCH
The torch is subjected to high temperatures and is also stressed
by traction and torsion. We recommend not to twist the wire and
not to use the torch to pull the welder. As a result of the above
the torch will require frequent maintenance such as:
• Cleaning welding splashes from the gas diffuser so that the
gas flows freely.
• Substitution of the contact point when the hole is deformed.
•
Cleaning of the wire guide liner using trichloroethylene or
specific solvents.
• Check of the insulation and connections of the power cable;
the connections must be in good electrical and mechanical
condition.
REPLACEMENT OF THE ELECTRONIC PCB
Proceed as follows:
•
Open the moving part of the cover on the right-hand side us-
ing the relative bolts.
•
Remove the black fibre board cover by unscrewing the 3
screws with a suitable screwdriver (Fig. I).
• Remove the circuit board connectors.
•
Take the plugs off the handles located on the front rack panel
and then remove them with a suitable box wrench.
• The circuit board can now be removed and replaced.
• Reverse the procedure to fit the new card.
Possible problems and remedies
The detection of eventual problems and their solution. The pow-
er supply line is the major source of problems. In the event of
a fault proceed as follows:
1) Check the voltage of the supply.
2) Check the state of the line connection at the plug and the
main switch.
3) Check that the main fuses are not burnt out or loose.
4) Check the following for defects:
• The switch and wall outlet that power the machine
• The plug and mains cable
• The welder switch
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