The zone to be welded should be rid of rust and varnish. The burner is selected according to the type of material. It is
recommended to try the strength of current on a defective piece first.
Faults - Causes - Elimination
Fault
Cause
Elimination
Welding current drops
out
1.
– Protection against excessive temperature
fell out due to overload.
1.
Protection against excessive temperature will
perform automatic reset after cooling the transformer
(approx. after 10 minutes, take care of ED!)
Welding current not
available at all.
Protective power switch
or RCD fell out
1.
Mains fuse fell out
1.
Let the fuse checked
2.
Turn the protective output power switch on
3.
Turn the RCD on
Welding current is not
available .
1.
Bad contact between grounding clamp and
welded part
2.
Rupture in grounding cable or grounding line
3.
Rupture in burner line
1.
Clean and grind the welded area and surface of the
part.
2.
Repair or replace the grounding cable.
3.
Repair or replace the burner.
Wire feeding motor does
not operate, pilot lamp is
on.
1.
Fuse is burnt.
2.
Toothed rim is faulty or blocked.
3.
Motor is defective.
1.
Replace the 2 A-fuse.
2.
Replace the toothed rim.
3.
Replace the motor (contact customer service).
Wire feeding motor does
not work, Pulleys rotate.
1.
The pressure to the pulley is not adjusted
properly.
2.
There is dirt, dust etc. on the stream nozzle of
the burner.
3.
Gas nozzle is defective.
4.
The wire is warped.
5.
Inner tube of the wire guide is dirty or
damaged.
1.
Adjust the pressure to pulleys correctly.
2.
Clean the machine contact tube. Use an air
compressor to do so, in case of heavy contamination
replace the contact tube
3.
Replace the gas nozzle and check the tip.
4.
Check the pulley pressure and adjust it properly if
necessary,
5.
Clean with compressed air and let the hose replaced
if necessary.
Wire feeding is irregular.
1.
Dirt at the wire guide. Gas nozzle is worn-out
or defective.
2.
Gas nozzle is clogged.
3.
An obstacle restrains the wire feeding pulleys
guiding.
4.
Wire feeding pulleys guiding has deformed.
5.
Improper tension of the wire
1.
Clean the machine wire guide using an air
compressor.
2.
Replace the gas nozzle or contact tube.
3.
Clean or replace the gas nozzle.
4.
Clean the wire feeding pulleys.
5.
Replace the wire feeding pulleys.
6.
Adjust the wire tension properly.
Electric arc burns in
unstable way.
1.
Improper wire speed adjustment
2.
Dirt at the welded place.
3.
Gas nozzle is worn-out or defective.
1.
Adjust the wire speed according to recommended
systems.
2.
Clean or polish the welded surface.
3.
Replace the gas nozzle and check the tip.
Welded joint is porous.
1. No
gas
2.
Nozzle holder is blocked
3.
Material is rusty or damp
4.
Burner is too far or you hold it at incorrect
angle towards the point being welded.
1.
Open the gas and adjust the gas intake flow.
2.
Clean or replace the gas nozzle.
3.
Properly treat the place of welding or increase the
gas inflow.
4.
Clean or polish the material.
5.
Distance between the gas nozzle and processed
piece must be 8-10 mm and the hose should be held
at an angle of 30°.
6.
Check the rubber hose, connection and hose set
assembly. – Depress the gas nozzle into proper
position.
Welding wire stops in
proximity of stream
nozzles
1.
Stream nozzle is worn-out.
2.
Welding wire is warped.
3.
Wire feeding speed is too low.
1.
Replace the stream nozzle.
2.
Check the pulley tension pressure.
3.
Follow the instructions for wire feeding speed.
Welding pressure is
irregular
1.
Welding wire blocked on the coil
1.
Check the pressure of pulley tension and adjust if
necessary.
Too weak penetration
1.
Welding current too weak
2.
Electric arc too long
1.
Increase the welding current and wire feeding.
2.
The hose should be held near the piece being
processed.
Too strong penetration
1.
Welding current too high
2.
Wire feeding speed too slow
3.
Improper distance of the burner from piece
being processed
1.
Reduce the welding current and wire feeding.
2.
The burner should be moved calmly and uniformly.
3.
The distance of the nozzle from the piece being
processed must be 8-10 mm.
Inspection and maintenance
Maintenance of hose set
Regular maintenance must be performed to ensure faultless function of hoses.
Gas nozzle must be sprayed by protective spray for nozzles and remove sediments inside regularly.
For this case the following steps should be performed (see Fig. 26):
1. Remove the nozzle (1) by pulling it forward.
20
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