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10.0 BASIC TROUBLESHOOTING
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
Accredited Thermal Arc Service Agent for repair.
The basic level of troubleshooting is that which can be performed without special equipment or
knowledge.
10.01 TIG Welding Problems
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 penetra-
tion in butt joint
5 Uneven leg length
in fillet joint
43
WARNING 9
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
PRO-LITE 250S
Remedy
Increase weld current and/or
faulty joint preparation
Decrease weld current
Reduce travel speed
Increase travel speed
Re-position filler rod
June 29, 2005
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