Routine Service And Calibration Requirements - Thermal Arc Fabricator 211i Service Manual

FABRICATOR 211i
6 The wirefeed motor does
not operate when the
torch trigger switch is
depressed
7 The wirefeed motor
operates at maximum
speed and cannot be
adjusted.
8 Wirefeed motor operates
when the torch trigger
switch is depressed but
the gas valve does not
operate.
9 A welding arc can be
established but the weld
is erratic or inconsistent

5.02 Routine Service and Calibration Requirements

There are extremely dangerous voltage and power levels present inside this Inverter Power Source. Do
not attempt to open or repair unless you are an accredited Thermal Arc Service Provider. Disconnect the
Welding Power Source from the Mains Supply Voltage before disassembling.
Routine Inspection, Testing & Maintenance
The inspection and testing of the power source and associated accessories shall be carried out by a licensed electri-
cian. This includes an insulation resistance test and an earthing test to ensure the integrity of the unit is compliant
with Thermal Arc's original specifications.
A. Testing Schedule
1. For transportable equipment, at least once every 3 months; and
TROUBLESHOOTING
A Power Source set to TIG or STICK
mode
B Wirefeeder motor wiring has
become loose
C Trigger wires or torch switch faulty
D Faulty Power PCB
A Faulty Power PCB
B Faulty Display PCB
A Internal wiring fault
B Faulty Solenoid
C Debris in gas system causing
solenoid to stay open or closed
D Faulty Power PCB
E Faulty Control PCB
A Work Lead cable too small
B Loose welding connections
C Loose work clamp
D Incorrect weld polarity selected
E No shielding gas
F Wind blows shielding gas away
G Incorrect TIG tungsten electrode
H Poorly prepared or worn TIG
tungsten
Table 5-1 Power Source Faults
5-2
A Set power Source to MIG mode
Check motor wiring
B Check & Repair
C Replace trigger switch/wire
D
Replace Power PCB
A Replace Power PCB
B Replace Display PCB
A Check solenoid wiring header is
plugged securely into Control
PCB. Check solenoid wiring is not
damaged
B
Replace Solenoid
Clean out gas system. Disassemble
C
solenoid & clean out debris
D
Replace Power PCB
Replace Control PCB
E
A
Use correct weld cable size
Tighten welding connections
B
Tighten work clamp
C
D
Correct weld polarity. Refer to
weld consumable manufacturers
recommended polarity
E
Connect shielding gas
F Shield welding area from drafts
G
Use correct tungsten type
H
Regrind tungsten to correct shape
WARNING
TROUBLESHOOTING
Manual 0-5158