8 BASIC TROUBLESHOOTING
8 – 1
BASIC TROUBLESHOOTING
WARNING
There are extremely dangerous voltages and power levels present inside this product. Do not attempt to
open or repair unless you are an Accredited Thermal Arc Service Agent and you have had training in power
measurements and troubleshooting techniques.
If major complex subassemblies are faulty, then the Welding Power Source must be returned to an Accred-
ited Thermal Arc Service Agent for repair.
The basic level of troubleshooting is that which can be performed without special equipment or knowledge.
1
TIG Welding Problems
Weld quality is dependent on the selection of the correct consumables, maintenance of equipment and
proper welding technique.
Description Possible Cause Remedy
1. Excessive bead build-up or poor
penetration or poor fusion at edges
of weld.
Welding current is too low. Increase weld current and/or faulty joint
preparation.
2. Weld bead too wide and flat or
undercut at edges of weld or
excessive burn through.
Welding current is too high. Decrease weld current.
3. Weld bead too small or insufficient
penetration or ripples in bead are
widely spaced apart.
Travel speed too fast. Reduce travel speed.
4. Weld bead too wide or excessive
bead build up or excessive
penetration in butt joint.
Travel speed too slow. Increase travel speed.
5. Uneven leg length in fillet joint. Wrong placement of filler rod. Re-position filler rod.
6. Electrode melts when arc is struck. A. Electrode is connected to the '+'
terminal.
B. WAVE BALANCE is greater than
50%.
A. Connect the electrode to the '–'
terminal.
B. Reduced WAVE BALANCE to below
50% or increase the electrode size.
7. Dirty weld pool. A. Electrode contaminated through
contact with work piece or filler
rod material.
B. Gas contaminated with air.
A. Clean the electrode by grinding off
the contaminates.
B. Check gas lines for cuts and loose
fitting or change gas cylinder.
8. Electrode melts or oxidizes when an
arc is struck.
A. No gas flowing to welding region.
B. Torch is clogged with dust.
C. Gas hose is cut.
D. Gas passage contains impurities.
E. Gas regulator turned off.
F. Torch valve is turned off.
G. The electrode is too small for the
welding current.
H. WAVE BALANCE is set above
50%.
A. Check the gas lines for kinks or
breaks and gas cylinder contents.
B. Clean torch.
C. Replace gas hose.
D. Disconnect gas hose from torch then
raise gas pressure and blow out
impurities.
E. Turn on.
F. Turn on.
G. Increase electrode diameter or
reduce the welding current.
H. Reduced WAVE BALANCE to below
50% or increase the electrode size.
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