Weldmatic 215Operators Manual
Model No. CP111-0, Iss A 02/05 13
Quality, Reliability, Performance
9 External Trouble Shooting
Unsatisfactory Welding Performance and
Results
Erratic arc characteristics caused by poor
wirefeed
Erratic wirefeed is the MOST LIKELY cause of
failure in all Gas Metal Arc Welding. It should
therefore be the first point checked when
problems occur.
1 Refer to the points in ‘Wirefeed’ in
Section 8
2 Check if the consumable wire is slipping in
the drive rolls. Replace the feed roll if it is
the incorrect size or is worn
3 Check that gun cable liner is not too short
and is fitted correctly. Refer to page 19 for
fitting instructions.
Constant poor arc characteristics
Check that the:
1 Correct polarity has been selected for work
and weld cables (refer page 8)
2 Shielding gas is correct for the consumable
wire in use (refer page 10)
3 Welding circuit is making good electrical
connection. Ensure that the work clamp is
securely tightened onto the work piece so
that good electrical contact is achieved
4 All connections in the external welding
circuit are clean and tight. Problems may
show as hot spots
5 Work piece surface is not contaminated.
Water, oil, grease, galvanising, paint,
or oxide layers can severely disturb the
welding arc and result in a poor weld.
Porosity in weld caused by lack of shielding gas
1 Check that the correct gas flow rate has
been set (refer page 10)
2 Check for leaks in the gas hose. Replace if
leaking
3 Check for leaks in gun/cable assembly, eg.
fractured gas hose, broken or missing ‘O’
rings. Replace as required
4 Check the gun nozzle is free from spatter
and is firmly attached to the welding gun to
ensure that no air is being drawn into the
shielded area.
If the following checks do not identify the
fault condition, the equipment should be
returned to a WIA Service agent. Phone
1300 300 884 for details of your nearest
service agent.
Power source has no output and no
wirefeed when gun switch is closed :
Power light is off and fan is not running
1 Check equipment is connected to a
functional mains power outlet. Test outlet
using a known working appliance
2 Check the equipment is switched on, ie
‘Coarse’ switch is in position 1,2 or 3.
Fan is running but power light is off
1 Call your WIA service agent.
Fan is running, power light is on and overload
light is on
1 Power source has overheated.
The Weldmatic 215 welding power source
incorporates an in-built over-temperature
thermostat which will trip if the welding
load exceeds the operating duty cycle. The
thermostat will reset automatically - do not
switch the equipment off as the cooling fan
will assist the resetting of the thermostat
2 If problem persists after the cool down
period, call your WIA service agent.
Fan is running, power light is on and overload
light is off
The gun switch circuit is incomplete.
1 Check the gun switch for continuity with
an ohm meter when the switch is pressed.
Replace if faulty
2 Check the 2 pin receptacles in Euro adaptor
are making contact with the mating pins
from the gun Euro end.
Power source has low weld output
1 Check all electrical connections in the
welding current circuit, including weld
cable, work clamp and gun/cable assembly.
Circuit breaker trips instantly when mains
voltage is applied
1 Check the rating of the mains supply circuit
breaker. The Weldmatic 215 should be
supplied from a 20 Amp or larger circuit
breaker.
To Next Page
Loading...
