Thermal Arc ULTRA FLEX 350 Owner'S Manual Download Page 38

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5. Troubleshooting Hints.

Carefully note all operating conditions and prob-

lem symptoms for effective troubleshooting diagno-
sis. During problem analysis, bear in mind that the
total welding system includes not only the power
source but may also include a wire feeder, control
cables, welding gun or torch, gun liner, gun contact
tip, gun trigger, remote controls, water coolers,
ground cables and connections, electrode cables
and connections, electrodes, shielding gas type and
flow, weld plate quality and composition, weld proc-
ess, control settings, chassis grounding, input ca-
bles and connections, input fuses or breakers, input
voltage, and effects of nearby equipment.

Troubleshooting should begin with an assessment

of the welding process and control settings being
used. Are they appropriate for the weldment? Is
the correct electrode and gas being used? Is the
optimal technique being used?

Next, an examination of the welding system should

be made to determine that all equipment is compat-
ible and connected correctly. Determine that all
input fuses are intact and that the input power is
correct. Examine cables and connections for pos-
sible faults.

Examine and eliminate external equipment as the

problem source.

Are the wire feeder drive rolls

tight? Is the gun liner worn or plugged? Does the
gun trigger work? Are the control cables connected
correctly and in good condition?

Disconnect as

much external equipment as possible to determine
its’ impact on the problem.

Examine the power source externally and inter-

nally for signs of possible damage.

Inspect the

wiring and connections.

Lastly, begin diagnosis of the machine and it’s

sub-systems.

An effective troubleshooting approach is often to

eliminate symptoms or possible causes by deter-
mining what is working correctly.

A few typical questions whose answers might be

of benefit in troubleshooting are:

Is the input voltage correct?

Are fuses

blown?

Does the machine have the proper input
voltage for what the machine is configured
for, or vice versa?

Are accessories connected properly?

Are accessories compatible with the power
source?

Are the power source’s accessory circuit
breakers tripped?

Are accessories in good condition and
properly set? Is the wire feed speed cor-
rect? Does the wire feed smoothly? Is the
contact tip or gun liner worn? Are the drive
rolls properly tensioned? While welding, is
the gun cable kinked?

Are the ground cables and connections in
good condition and of the correct size?

Are the electrode cables and connections
in good condition and of the correct size?

Is the welding procedure being used within
the capabilities of the machine? Does the
welding duty cycle match the power
source’s duty cycle?

Will adjustments in the control settings
eliminate the problem?

Will adjustments in torch or electrode stick-
out, angle, or movement eliminate the prob-
lem?

Does the problem exist in all operating
modes?

If appropriate, does the problem persist
with wire feeders and other equipment dis-
connected from the machine?

Which indicators are on and which are off
as a result of this problem?

What are all of the control panel settings
during the problem?

How often and in what manner is the ma-
chine serviced or maintained?

Is the machine clean and dry? Does mois-
ture condense in or on the machine during
operation or during idle?

Is air flow in and around the machine unob-
structed?