MICRO PRODUCTS GP0, Service Manual

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9.0 DIAGNOSTIC CHART FOR TROUBLE-SHOOTING WELDERS
WELDING ACTION CAUSE REMEDY
Molten metal is blown out
and ends not joined Weld heat too high
Stock is too small
Low upset pressure Lower heat settings
Check size rating of welder
Adjust upset
Weld is complete but is dry
and breaks off below surface
of wire Upset pressure too great
Lower upset pressure
Weld good but poorly aligned Welding dies & clamp fingers
Starting space
Loose shafts
Replace worn dies and clamp
fingers
Decrease starting space
Return heads to factory
Ends of wire buckle and may
not weld Upset pressure too great
Low weld heat Decrease starting space
Increase weld heat
Varying weld results Stock slipping
Varying weld voltages
Wire condition variations
Dies
Flashings Check Clamp finger pressure
Check electric lines
Clean and tighten
transformer connections to
heads
Clean wire where clamped in
dies
Replace dies
Clean build-up of flash
materials
9.1 ELECTRICAL TROUBLE-SHOOTING OF WELDER
(CAUTION! Extreme care should be exercised when making
these tests. Dangerous voltages are present in the welder.
Only persons familiar with electrical safety precautions
should perform these tests.)
9.1.1 TROUBLE-SHOOTING TABLE
(See section 9.1.3)
This electrical trouble-shooting table is furnished as a
suggested method of trouble-shooting the welder. The
individual steps of the table should be performed in the
order given, to make the tests valid. The electrical
schematic (section 10) furnished for these tests show the
table test points. The table may be used for welders with
a different but closely related wiring by using
corresponding test points. (During all tests, line voltage
should be connected to L1 & L2 of the welder. The heat
switch should be set to the #1 position.
9.1.2 FINAL ELECTRICAL CHECKS
Set the heat switch to the number 1 position, connect the
voltmeter across the welding dies. Press the operating
switch. The meter reading will typically be less than 10
VAC. Consult the weld specification sheet for this value.
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