Smootharc 180 Multiprocess, Operating Manual

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11.2 MIG/MAG functions
Power source
Component Fault symptom Cause
Primary cable No or low welding output Poor or incorrect primary connection, lost phase
Earth cable and clamp Arc will not initiate Damaged, loose or undersized cables and clamps
Connectors and lugs Overheating of connectors and lugs Loose or poorly crimped connectors
Switches Erratic or no output control Switches damaged or incorrectly set for the application
Wire feeder
Component Fault symptom Cause
Gas solenoid valve No gas flow or gas flows continuously Gas valve faulty or sticking in open position
Wire feed rolls Wire slippage, wire deformation Incorrect feed roll size, incorrect tension adjustment,
misalignment
Inlet, outlet guides Wire shaving or snarling Incorrect wire guide sizes, misalignment
Torch connector Wire restriction, gas leaks, no trigger control Torch connector not correctly mounted or secured, incorrect size
of internal guide, bent contact pins
Wire feed speed control No control over wire feed speed, no amperage
control
Faulty wire speed feed potentiometer, machine in overload or
trip condition
Wire inch switch Wire live when feeding through cable and torch
before welding
Faulty wire inch switch, activitation of torch trigger switch
Spindle Wire spool drags or overruns Spindle brake set too tight or too loose, spool not properly
located on spindle
Welding torch
Component Fault symptom Cause
Type Welding torch overheats Welding torch underrated for welding application
Liners Erratic wire feed, wire snarls up at outlet guide Liner of incorrect type and size for wire in use, worn or dirty
liner, liner too long or too short
Gas distributor Inadequate gas flow, contaminated or porous weld Damaged or blocked distributor
Nozzle Inadequate gas cover, restricted joint accessibility Nozzle too large or too small, incorrect length or shape
Contact tip Erratic feeding, wire shudder, wire burnback,
unstable arc, spatter
Incorrect size of contact tip, incorrect contact tip to nozzle
distance for metal transfer mode, tip has worn out
Nozzle insulator Arcing between contact tip and nozzle and
between nozzle and workpiece
No nozzle insulator fitted, spatter build up has caused parts to
short out
Regulator / flowmeter
Component Fault symptom Cause
Inlet stem No gas flow, gas leaks at regulator body or
cylinder valve
Blocked inlet stem, leaking inlet stem to body thread, bullnose
not properly seated in cylinder valve
Gas hose and fitting Leaks at connections or in the hose, porosity in
the weld
Poorly fitted loose connections, damaged hose, air drawn into
gas stream
Welding wire
Component Fault symptom Cause
Wire basket and spool Erratic wire feeding or wire stoppages Damaged wire basket, loose spooling, random-wound wire
Wire Wire sticks in contact tip, erratic feeding Varying wire diameter, copper flaking, surface damage
Wire Weld has excessive amount of spatter Wrong polarity has been selected
48 BOC Smootharc 180 Multiprocess operating manual