Troubleshooting - Welding Industries Malaysia MIG210S Instruction Manual

8-0 TROUBLESHOOTING

Table 1: Common Faults
No. FAULT
1 Too little welding effect.
The welding seam
forms a bead.
2 The wire feed is
blocking.
3 Spatter
4 Porous weld. A cone is
formed when spot
welding
5 The arc does not look
normal, and there is a
lot of spatter.
6 The wire keeps sticking
in the contact tip and is
very slow.
7 No welding voltage
Table 2: Troubleshooting for MIG S SERIES P.C. Assembly Board
No. Trouble
1 Motor automatic work
2 Motor does not work
3 Spot & stitch time is short
4 Motor can not stop
5 Motor speed is slow
6 Contactor's malfunction
7 Contactor does not work
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V1.1.07
PROBABLE CAUSE AND REMEDY
1) One of the three fuses in the main switch is not working
(one phase is missing).
2) The welding voltage is too low.
Switch one setting higher.
1) The inlet nozzle and the wire are not in alignment with
each other.
2) The reel of wire is too taut; the wire must come off the
reel evenly.
3) The inlet or contact tip is worn out or is blocked up.
4) The welding wire is not clean or it is rusty. It could
also be of an inferior quality.
5) The pressure roller has to be tightened.
1) The wire feed is too fast for the voltage setting.
2) Worn out contact tip.
1) Insufficient gas-not enough pressure or the cylinder is
empty.
2) Contact tip is blocked up.
3) Leakage-air is pumped in and dilutes the shielding gas.
1) The material is dirty, under sealed or paint.
1) The wire can be malformed. The damage wire should be
cut off, pulled out and replaced. The pressure on the
wire feed roller should be checked.
2) Worn out contact tip.
1)Working voltage interrupted due to overloading of the
transformer. Automatic switch on after cooling (15-30 min.)
PROBABLE CAUSE
a) Transistor 2SA1215 (MOSFETS)
a) VR2 (B10K) Damage (Open circuit, short
circuit or broken pin).
b) Transistor BC557 (Q5) open circuit.
c) Transistor 2SA1215(MOSFETS)
d) Selector switch damage.
e) Resistor 10W 0.68 Ohm open circuit.
a) VR1 (B250K) damage (Open circuit, short
circuit or broken pin).
a) Resistor 5W 0.68-Ohm (R3) open circuit.
a) Transistor 2SA1215(MOSFETS)
b) VR2 (B10K) leaking.
a) Zener diode 24V 1/2W (ZD4) open circuit.
b) Transistor BC547 (Q11) short circuit.
a) TRIACS BTA10 600C (T1) open circuit.
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