Thermal Arc POWERMASTER 400SP, Service Manual

Page: 69 / 110

POWERMASTER 400SP, 500SP AUTOMATION
Octobe r 30, 2008 7-3
7.03 Welding Process Troubleshooting Guide
Symptom Cause Remedy
Gas mixtu r e in the cylinde r has sepa r ated due to lack
of use
Place p r otective cap used fo r sto r age and
t r anspo r t on cylinde r then ca r efully disconnect
the cylinde r f r om the welde r and lay it down on
the floo r . Ca r efully r oll it back and fo r th to r e-
mix the gas
Wi r e is contaminated with oil o r the wi r e quality is
unce r tain
Contact wi r e manuafactu r e r / supplie r .
Keep the wi r e cove r ed
Wo r k piece is contaminated with g r ease o r oil Deg r ease with mine r al spi r its, etc to r emove
contaminates
Poo r cu rr ent t r ansfe r to the wi r e at the contact tip Use a coppe r o r b r ass jump line r in the
conducto r tube to imp r ove cu rr ent t r ansfe r to
the wi r e
Stanless steel weld has
a da
r k bu r nt finish
A r c length cont r ol (58) has been adjusted too high Reduce a r c length, cont r ol (58)
Inadequate gas cove r age Inc r ease gas flow by 10% and check again.
Shield a r c f r om d r afts.
Hold nozzle close r to the wo r k.
Replace the damaged nozzle to cente r contact
tip in nozzle
Wi r e is contaminated with oil Contact wi r e manuafactu r e r / supplie r .
Keep the wi r e cove r ed
Wo r k piece is contaminated with g r ease o r oil Deg r ease with mine r al spi r its, etc to r emove
contaminates
Poo r cu rr ent t r ansfe r to the wi r e at the contact tip Use a coppe r o r b r ass jump line r in the
conducto r tube to imp r ove cu rr ent t r ansfe r to
the wi r e
Weld pe r fo r mance is
ve r y poo r o r high
spatte r levels
Inco rr ect wi r e / gas combination selected Set the co rr ect gas / wi r e combination
Imp r ope r wo r k lead connection Reconnect wo r k lead
Contact tip is wo r n with an oval shape hole o r
contact tip is black
Replace contact tip
Contact tip is loose Tighten contact tip
Mate r ial build-up in to r ch line r Replace to r ch line r
Contact tip is wo r n o r damaged Replace contact tip
Va r ying a r c length
when welding
Poo r edge wetting on
stainless steel welds
Di r ty aluminum welds
Poo r weld sta r ts