43
Troubleshooting
Common Welding Issues
NO.
Trouble
Possible Cause
Solution
1.
Unit is switched on, but the power light isn
’
t on.
Switch damaged.
Service Breaker/ Input Line Damaged
Check.
Replace.
2.
After welding machine is overheating and the fan
does not work.
Fan damaged.
Fan connector plus is loose
Replace.
Check. Reinstall.
3.
When switch/pedal is pressed, no gas flows.
Empty Cylinder/ Closed Valve.
Regulator Faulty/shut off.
Solenoid Dirty/Stuck Shut
Damaged PCB
Check. Replace/Open
Check, Open
Check. Clean or Replace. (Contact Everlast Technical Support)
Contact Everlast Technical Support
4.
Intermittent, wandering arc.
Work Clamp not connected directly to part being
welded.
Work Clamp worn/damaged
Torch height too high.
Reconnect.
Replace.
Reduce TIG torch height to under
1/8”.
Drag Welding Rod (Stick)
5.
Arc will not start unless lift started.
Points misadjusted, worn or dirty.
HF not selected
Check HF point gap. Clean and set to
.035”
Contact Technical Support for
details. Make sure unit is set to HF
6.
Tungsten is rapidly consumed.
Inadequate gas flow. Too small of tungsten.
Wrong shielding gas. Using green tungsten.
Wrong polarity. Possible contamination of shield-
ing gas from gas supplier.
Check gas flow.
Check for Leaks thoughout system/regulator/tank.
Check for 100% Argon.
Use Lanthanated 2% or any other type besides Green (Pure) or Zirconiated.
Put torch in Negative.
7.
Tungsten is contaminated, arc changes to a
green color.
Tungsten is dipping into weld.
Too long of stick
-
out.
Tungsten is melting.
Check and adjust stick out to 1/8 inch.
Reduce stick
-
out to less than
1/4”.
Reduce amperage or increase tungsten size.
8.
Porosity of the Weld. Discolored weld color.
Tungsten is discolored.
Low flow rate of shielding gas. High flow rate of
shielding gas. Tungsten stick
-
out is too far. Too
short of post flow period. Wrong TIG cup size.
Possible gas leaks internally or externally due to
loose fittings. Base metal is contaminated with
dirt or grease.
Increase flow rate on regulator. Check for kinks in tubing. Increase post
-
flow
time. Reduce stick
-
out to less than
1/4”.
Increase cup size, or use gas lens.
Clean metal thoroughly with approved metal cleaner, or use acetone and a rag
to clean metal
9.
Weld quality is poor.
Weld is dirty/oxidized, or porous.
Drafty conditions. The welder is located on the
workpiece and is blowing gas off due to fan
activity. Solenoid is sticking. Too short of pre
-
flow or post
-
flow
Eliminate drafts. Move welder. Check if there is sufficient shielding gas left
in tank. Check gas flow. Adjust for higher flow of gas. Listen for audible click
of gas solenoid. If no click is heard, then contact Everlast Support. Clean
weld properly. Increase pre flow or post flow.
10.
Unstable Arc.
Poorly ground or shaped tungsten. Bad work
clamp connection. Metal is indirectly connected
through table or other item.
Regrind to proper point. Wrong polarity. Place torch in DC negative (
-
).
Connect work clamp directly to item being welded.
11.
AC TIG will not weld properly.
Wrong polarity.
Work clamp is not connected direct to work.
Balled Tungsten
AC Balance too high
AC Frequency too low
Contaminated Gas
Check and change immediately. TIG torch is always negative.
Put clamp direct to work.
Sharpen Tungsten. Do not use Ball
Set for approximately 30%
Increase to 50 Hz or higher
Source new cylinder or new supplier
12.
Other.
Contact Everlast
Summary of Contents for PowerPro 164Si
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