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Troubleshooting
Common Welding Issues
NO. Trouble Possible Cause Solution
1.
Unit is switched on, but the power light isn’t on. Switch damaged.
Service Breaker/ Input Line Damaged.
Check.
Replace.
2. After welding machine is overheating .
Duty Cycle Exceeded.
Fan damaged and not running.
Fan connector plus is loose.
Temp Sensor damaged
Unit is dirty
Do Not Turn off if fan is running. Set fan to run continuously. Allow to cool
while running and unit should automatically reset. Allow to continue to cool
for no less than 15 minutes after duty cycle is exceeded, even if the unit
resets before this time.
Replace.
Check. Reinstall.
Check operating temperature in background menu and check fan operation.
Check and clean.
3. When switch/pedal is pressed, no gas flows.
Empty Cylinder/ Closed Valve.
Regulator Faulty/shut off.
Solenoid Dirty/Stuck Shut.
Damaged PCB.
Check. Replace/Open Valve.
Check regulator and cylinder.
Check. Clean or replace. (Contact Everlast Technical Support).
Contact Everlast Technical Support.
4. When switch/pedal is released gas continues to
flow after Post-Flow cycle has timed out. May
happen irregularly, or when unit is turned on.
Solenoid Dirty/Stuck.
Excess moisture from Argon Cylinder.
Disassemble and clean, or replace. (Contact Everlast Technical Support).
Install a dryer inline to remove moisture. Solenoid may need to be cleaned or
replaced.
5. Intermittent, wandering arc.
Work Clamp not connected directly to part being
welded.
Work Clamp worn/damaged.
Torch height too high.
Wrong Polarity
Reconnect.
Replace.
Reduce TIG torch height to under 1/8”. Drag Welding Rod (Stick.
Torch should be in negative for all TIG work. Stick should be positive.
6.
Arc will not start unless lift started. HV/HF board is damaged or disconnected
HV/HF settings are incorrect
HF Start not selected.
Make sure unit is set to HF Start.
Adjust Settings
7.
Tungsten is rapidly consumed. Inadequate gas flow. Too small of tungsten.
Wrong shielding gas. Using green tungsten.
Wrong polarity. Possible contamination of shield-
ing gas from gas supplier.
Welder is too close to work.Fans are blowing gas.
Check gas flow.
Check for Leaks thoughout system/regulator/tank.
Check for 100% Argon.
Use Lanthanated 2% or any other type besides Green (Pure) or Zirconiated.
Put torch in Negative terminal.
Move unit 6 to 8 ft away.
8.
Tungsten is contaminated, arc changes to a
green color.
Tungsten is dipping into weld.
Too long of stick-out.
Tungsten is melting.
Check and adjust stick out to 1/8”.
Reduce stick-out to less than 1/4”.
Reduce amperage or increase tungsten size.
9.
Porosity of the Weld. Discolored weld color.
Tungsten is discolored.
Low flow rate of shielding gas. High flow rate of
shielding gas. Tungsten stick-out is too far. Too
short of post flow period. Wrong TIG cup size.
Possible gas leaks internally or externally due to
loose ttings. Base metal is contaminated with
dirt or grease.
Increase flow rate on regulator. Check for kinks in tubing. Increase post-flow
time. Reduce stick-out to less than 1/4”. Increase cup size, or use gas lens.
Clean metal thoroughly with approved metal cleaner, or use acetone and a rag
to clean metal.
10.
Weld quality is poor.
Weld is dirty/oxidized, or porous.
Drafty conditions. The welder is located on the
workpiece and is blowing gas off due to fan
activity. Solenoid is sticking. Too short of pre-
flow or post-flow.
Eliminate drafts. Move welder. Check if there is sufcient shielding gas left
in tank. Check gas flow. Adjust for higher flow of gas. Listen for audible click
of gas solenoid. If no click is heard, then contact Everlast Support. Clean
weld properly. Increase pre flow or post flow.
11.
Unstable Arc. Poorly ground or shaped tungsten. Bad work
clamp connection. Metal is indirectly connected
through table or other item.
Regrind to proper point. Wrong polarity. Place torch in DC negative (-).
Connect work clamp directly to item being welded.
12.
AC TIG will not weld properly. Wrong polarity.
Work clamp is not connected direct to work.
Balled Tungsten.
AC Balance too high.
AC Frequency too low.
Contaminated Gas.
Check and change immediately. TIG torch is always negative.
Put clamp direct to work.
Sharpen Tungsten. Do not use form ball.
Set for approximately 30%.
Increase to 50 Hz or higher.
Source new cylinder or new supplier.
13.
Other. Contact Everlast.
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