MAGNATECH Pipeliner II 609A, Operating And Maintenance Instruction Manual

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Irregular wire feed, burnback. 1. Check drive roll pressure.
2. Check, adjust wire feed speed.
3. Clean or replace contact tip.
4. Check input line voltage for fluctuations.
5. Remove kinked electrode wire; replace wire spool.
6. Lubricate or replace conduit liner.
Overheating welding cables. 1. Use larger cables.
2. Check, tighten cable connections.
3. Use shorter cables.
Unstable arc. 1. Check, tighten cable connections.
2. Clean weld joint areas.
3. Change contact tip.
4. Correct contact tip-to-workpiece distance.
5. Correct ARC TRIM CONTROL setting.
6. Replace low pressure Gas cylinder. Gas mixtures may
vary at low bottle pressures.
Incomplete fusion. 1. Check joint geometry preparation.
2. Shorten arc length.
3. Clean weld joint area.
4. Reduce electrode (wire) stick-out.
5. Increase oscillation width and dwell
6. Reduce travel speed.
Dirty welds. 1. Maintain gas nozzle closer to weld puddle.
2. Increase gas flow.
3. Decrease torch angle.
4. Check torch cables for gas leaks.
5. Shield arc from drafts.
6. Check gas diffuser for damage; replace.
7. Keep unused electrode wire in sealed shipping
containers.
8. Clean weld joint area.
Arc blow. 1. Rearrange or split ground connection.
2. Demagnetize workpiece.
Excessively wide bead. 1. Reduce power.
2. Increase welding speed.
3. Shorten arc length.
Porosity in welds. 1. Keep unused electrode wire in sealed shipping
containers.
2. Clean weld joint areas.
3. Hold gas cup closer to work.
4. Increase gas flow.
5. Decrease torch angle.
6. Check torch and cables for air, water leaks.
7. Shield arc from drafts.
8. Check gas cup for damage; replace.