CEA MAXI 405 - Troubleshooting Guide; Problem Resolution Table; Welding Defect Analysis

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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
• Short circuit on auxiliary
transformer winding
• Check and, if necessary,
replace the transformer
The line fuses burn out when
the torch button is pressed
• Wrong connection of the
voltage change connector
• Check and follow the
instructions for connection
• 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 • Defective circuit • Replace circuit
• Wrong connection • Check and follow the
instructions for connection
• Line fuses burnt out • Find the cause and replace
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
• Section of welding cables too
small or cables too long
• Replace with cables of
adequate section or length
• Loose connections • Check connections to the
power mains and welding circuit
and tighten if necessary
Welding current insufficient • Missing power supply phase • Check the power mains
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