Basic Troubleshooting; Solving Problems Beyond The Welding Terminals - Thermal Arc 210 Fabricator Operating Manual

5.02 Basic Troubleshooting

The basic level of troubleshooting is that which can be performed without special equipment or knowledge, and
without removing the covers from the Power Supply.
If major components are faulty, then the Power Supply should be returned to an Accredited Thermal Arc Service Agent
for repair.

5.03 Solving Problems Beyond the Welding Terminals

The general approach to fix GMAW/FCAW problems is to start at the wire spool then work through to the MIG torch.
There are two main areas where problems occur:
Porosity
When there is a gas problem the result is usually porosity within the weld metal. Porosity always stems from
some contaminant within the molten weld pool which is in the process of escaping during solidification of the
molten metal.
Contaminants range from no gas around the welding arc to dirt on the work piece surface. Porosity can be
reduced by checking the following points:
FAULT
Porosity
Manual No. 0-4855
CAUSE
1. Gas cylinder a. Ensure that the gas cylinder is not empty
contents and flow
meter
a. Check for gas leaks between the
2. Gas leaks
a. The hose from the solenoid valve to the
3. Internal gas hose in
the power supply
4. Welding in a windy a. Shield the weld area from the wind or
environment
5. Welding dirty, oily,
painted, oxidized or a. Clean contaminates off the plate
greasy plate.
6. Distance between the
a. Keep the distance between the MIG torch
MIG torch nozzle and
the work piece.
a. Ensure that the gas holes are not blocked
7. Maintain the MIG
b. Do not restrict gas flow by allowing
torch in good
working order.
C. Check that the MIG gun O-rings are not
Table 5-1: Porosity Problems
5-3
REMEDY
and the flow meter is correctly adjusted to
25CFM (15 litres per minute)
regulator/flow meter connection and in
the gas hose to the power supply
MIG torch adaptor may be fractured or
disconnected from the MIG torch adaptor.
Return to an Accredited Thermal Arc
Service Agent for repair.
increase the gas flow
nozzle and the work piece to a minimum.
and gas is exiting out of the torch nozzle.
Refer to WARNING below
spatter to build up inside the MIG
torch nozzle.
damaged.
FABRICATOR 210
SERVICE