Razorweld KUMJRRW160, Operating Manual

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1: Tungsten burning away quickly
Possible Reason Suggested Remedy
Incorrect Gas Check that pure Argon is being used
No gas Check the gas cylinder contains gas and is connected
Inadequate gas flow Check the gas is connected, check hoses, gas valve and torch are not restricted. Set
the gas flow between 20 - 35 CFH flow rate
Back cap not fitted correctly Make sure the torch back cap is fitted so that the o-ring is inside the torch body
Torch connected to DC + Connect the torch to the DC- output terminal
Incorrect tungsten being used Check and change the tungsten type if necessary
Tungsten being oxidised after weld
is finished
Keep shielding gas flowing 10–15 seconds after arc stoppage. 1 second for each 10
amps of weld current.
Tungsten melting back into the
nozzle on AC welding
Check that correct type of tungsten is being used. Check the balance control is not set
too high on the balance - reduce to a lower setting
2: Contaminated tungsten
Possible Reason Suggested Remedy
Touching tungsten into the weld
pool
Keep tungsten from contacting weld puddle. Raise the torch so that the tungsten is off of
the work piece 5/64” - 13/64”
Touching the filler wire to the tung-
sten
Keep the filler wire from touching the tungsten during welding, feed the filler wire into the
leading edge of the weld pool in front of the tungsten
Tungsten melting into the weld pool Check that correct type of tungsten is being used. Too much current for the tungsten
size so reduce the amps or change to a larger tungsten
3: Porosity - poor weld appearance and colour
Possible Reason Suggested Remedy
Incorrect Gas Check that pure Argon is being used
Inadequate gas flow / gas leaks Check the gas is connected, check hoses, gas valve and torch are not restricted. Set the
gas flow between 20 - 35 CFH flow rate. Check hoses and fittings for holes, leaks etc.,
Moisture on the base metal Remove all moisture from base metal before welding
Contaminated base metal Remove materials like paint, grease, oil, and dirt, including mill scale from base metal
Contaminated filler wire Remove all grease, oil, or moisture from filler metal.
Incorrect filler wire Check the filler wire and change if necessary
4: Yellowish residue / smoke on the alumina nozzle & discoloured tungsten
Possible Reason Suggested Remedy
Incorrect Gas Use pure Argon gas
Inadequate gas flow
Set the gas flow between 20 - 35 CFH flow rate
Inadequate post flow gas Increase the post flow gas time
Alumina gas nozzle too small for size
of tungsten being used
Increase the size of the alumina gas nozzle
5: Unstable Arc during DC welding
Possible Reason Suggested Remedy
Torch connected to DC + Connect the torch to the DC- output terminal
Contaminated base metal Remove materials like paint, grease, oil, and dirt, including mill scale from base metal.
Tungsten is contaminated Remove 10mm of contaminated tungsten and re grind the tungsten
Arc length too long Lower torch so that the tungsten is off of the work piece 5/64” - 13/64”
The following chart addresses some of the common problems of TIG welding. In all cases of equipment malfunction,
the manufacturer’s recommendations should be strictly adhered to and followed.
TIG WELDING TROUBLE SHOOTING
6: HF present but no welding power
Possible Reason Suggested Remedy
Incomplete welding circuit Check earth lead is connected. Check all cable connections. If using a water cooled
torch check that the power cable is not separated.
No gas Check the gas is connected and cylinder valve open, check hoses, gas valve and torch
are not restricted. Set the gas flow between 20 - 35 CFH flow rate
Tungsten melting into the weld pool Check that correct type of tungsten is being used. Too much current for the tungsten
size so reduce the amps or change to a larger tungsten