Basic Troubleshooting; Tig Welding Problems - Thermal Arc ARCMASTER 200 TS Service Manual

8

BASIC TROUBLESHOOTING

WARNING
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 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

TIG Welding Problems

Weld quality is dependent on the selection of the correct consumables, maintenance of equipment and
proper welding technique.
Description
1 Excessive beard 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.
BASIC TROUBLESHOOTING
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.
WAVE BALANCE is greater than 50%.
B
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%.
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.
Reduced WAVE BALANCE to below
B
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.
8 – 1
Remedy