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6.01 Basic Troubleshooting-Power Source Faults
The following table is a guide for analysing problems and making repairs to the Power Source.
FAULT
1
Electricity Supply is
ON, power indicator is
illuminated however the
Power Source will not
commence welding.
2
Fault Indicator is
illuminated and the Power
Source will not commence
welding.
3
The Power Source will not
feed wire in MIG mode.
4
Welding wire continues to
feed when torch trigger is
released.
5
Welding arc cannot be
established in MIG mode.
6
Inconsistent wire feed.
7
No gas flow in MIG mode. A Gas hose is damaged.
Manual 0-5449
SECTION 6:
TROUBLESHOOTING
CAUSE
A Power Source is not in the
correct mode of operation.
B Faulty torch trigger.
Duty cycle of Power Source
has been exceeded.
A Electrode wire stuck in conduit
liner or contact tip (burn-back
jam).
B MIG GUN/SPOOL GUN switch
is switched to SPOOL GUN.
A Trigger mode selection switch
is in 4T latch mode.
B Torch trigger leads shorted.
A MIG Gun polarity lead is not
connected into a welding
output terminal.
B Poor or no work lead contact.
A Worn or dirty contact tip.
B Worn feed roll.
C Excessive brake tension on
wire reel hub.
D Worn, kinked or dirty conduit
liner
B Gas passage contains
impurities.
C Gas regulator turned off.
D Empty gas cylinder.
6-1
ESAB FABRICATOR 181i
REMEDY
A
Set the Power Source to the
correct mode of operation with the
process selection switch.
B
Repair or replace torch trigger
switch/lead.
Leave the Power Source
switched ON and allow it to
cool. Note that fault indicator
must be extinguished prior to
commencement of welding.
A
Check for clogged / kinked MIG
Gun conduit liner or worn contact
tip. Replace faulty components.
B
Switch the MIG GUN/SPOOL GUN
switch to MIG GUN.
A
Change the trigger mode selection
switch from 4T latch mode to 2T
normal mode.
B
Repair or replace torch trigger
switch/lead.
A
Connect the MIG Gun polarity
lead to either the positive welding
output terminal or the negative
welding output terminal as
required.
B
Clean work clamp area and ensure
good electrical contact.
A
Replace if necessary.
B
Replace.
C
Reduce brake tension on spool
hub
D Clean or replace conduit liner
A
Replace or repair.
B
Disconnect gas hose from the rear
of Power Source and blow out
impurities.
C
Turn on regulator.
D Replace gas cylinder.
TROUBLESHOOTING
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Table of Contents
Troubleshooting
