A Si C Tr O U B Lesh O O Ti N G; Tig Welding Problems - Thermal Arc ARCMASTER 300S Service Manual

8
B A SI C TR O U B LESH O O TI N G
W A R N I N G
Ther e ar e ext r em el y danger ous vol t ages and pow er l evel s pr esent i nsi de t hi s pr oduct . D o not at t em pt t o
open or r epai r unl ess you ar e an Accr edi t ed Ther m al Ar c Ser vi ce Agent and you have had t r ai ni ng i n pow er
m easur em ent s and t r oubl eshoot i ng t echni ques.
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
TI G W el di ng Probl em s
Weld quality is dependent on the selection of the correct consumables, maintenance of equipment and
proper welding technique.
Description
1. Excessive bead build-up or poor
penetration or poor fusion at edges
of weld.
2. Weld bead too wide and flat or
undercut at edges of weld or
excessive burn through.
3. Weld bead too small or insufficient
penetration or ripples in bead are
widely spaced apart.
4. Weld bead too wide or excessive
bead build up or excessive
penetration in butt joint.
5. Uneven leg length in fillet joint.
6. Electrode melts when arc is struck.
7. Dirty weld pool.
8. Electrode melts or oxidizes when an
arc is struck.
B A SI C TR O U B LESH O O TI N G
Possible Cause
Welding current is too low.
Welding current is too high.
Travel speed too fast.
Travel speed too slow.
Wrong placement of filler rod.
A. Electrode is connected to the '+'
terminal.
B. WAVE BALANCE is greater than
50%.
A. Electrode contaminated through
contact with work piece or filler
rod material.
B. Gas contaminated with air.
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%.
8 – 1
Remedy
Increase weld current and/or faulty joint
preparation.
Decrease weld current.
Reduce travel speed.
Increase travel speed.
Re-position filler rod.
A. Connect the electrode to the '–'
terminal.
B. Reduced WAVE BALANCE to below
50% or increase the electrode size.
A. Clean the electrode by grinding off
the contaminates.
B. Check gas lines for cuts and loose
fitting or change gas cylinder.
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.