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   17

Power source

Component

Fault symptom

Cause

Primary cable

No or low welding output

Bad 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 badly 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

Universal adaptor

Wire restriction, gas leaks, no 
trigger control

Universal adaptor 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, wire feed motor in 
overload or trip condition

Wire inch switch

Wire live when feeding through 
cable and gun before welding

Faulty wire inch switch, 
inappropriate use of gun trigger 
switch

Spindle

Wire spool drags or overruns

Spindle brake set too tight or too 
loose, spool not properly located 
on spindle

5.0  Troubleshooting and Fault Finding

Содержание 180P

Страница 1: ...180P O P E R AT I N G M A N U A L...

Страница 2: ...omission which may become apparent after the document has been issued Neither BOC nor any of its agents has independently verified the accuracy of the information contained in this document The infor...

Страница 3: ...elding MCAW 8 2 4 Fundamentals of MIG FCAW and MCAW 12 3 0 General Welding Information 14 3 1 Recommended Welding Parameters 14 4 0 Correct ApplicationTechniques 15 5 0 Troubleshooting and Fault Findi...

Страница 4: ...es Be alert to this at all times Keep your head out of the fumes rising from the arc Fumes from the welding of some metals could have an adverse effect on your health Don t breathe them in If you are...

Страница 5: ...ian and operator and will void your warranty Only qualified personnel approved by BOC should perform repairs Always disconnect mains power before investigating equipment malfunctions Parts that are br...

Страница 6: ...l of manual welding The process is also suitable for mechanised set ups and its use in this respect is increasing MIG welding can be carried out using solid wire flux cored or a copper coated solid wi...

Страница 7: ...ed to as gas shielded Using an auxiliary gas shield enables the wire designer to concentrate on the performance characteristics process tolerance positional capabilities and mechanical properties of t...

Страница 8: ...ves less scope to address performance arc stabilisation and process tolerance so these tend to suffer when compared with gas shielded types Wire efficiencies are also lower at about 65 in this mode of...

Страница 9: ...tes the shielding gas evenly around a shroud which then allows the gas to flow over the weld area The position of the contact tip relative to the gas shroud may be adjusted to limit the minimum electr...

Страница 10: ...with these types of wire GlobularTransfer Metal transfer is controlled by slow ejection resulting in large irregularly shaped globs falling into the weld pool under the action of gravity Carbon dioxid...

Страница 11: ...o the weld In spray transfer as the current density increases an arc is formed at the end of the filler wire producing a stream of small metal droplets In solid wire MIG this transfer mode occurs at h...

Страница 12: ...roperties or level of residual hydrogen in the weldmetal Solid MIG wires are all considered to be of the low Hydrogen type consumables The following table gives a general overview of the selection of...

Страница 13: ...al rule all solid and metal cored wires are welded on electrode positive Work return lead fitted to the negative connector Some grades of self shielded flux cored wires i e E71T 11 E71T GS etc needs t...

Страница 14: ...14 16 16 17 16 18 16 18 23 25 Wire feed speed m min 3 5 5 0 4 0 7 0 4 0 7 0 4 0 7 0 7 5 9 0 Gas rate flow L min 15 15 15 15 15 Travel speed mm min 350 500 350 500 320 500 280 450 800 1000 Stainshield...

Страница 15: ...rcement Flux cored welding with cored wires takes place normally with the drag technique when there is slag in your drag The welding gun is tilted at an angle of 10 away from the direction of welding...

Страница 16: ...the melt off rate of the wire that will have an influence on the weldbead profile Short Normal Long Normal Long Short Normal Long Influence of the change in electrical stickout length on the weldbead...

Страница 17: ...deformation Incorrect feed roll size incorrect tension adjustment misalignment Inlet outlet guides Wire shaving or snarling Incorrect wire guide sizes misalignment Universal adaptor Wire restriction...

Страница 18: ...workpiece No nozzle insulator fitted 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 bo...

Страница 19: ...tput voltage adjustment V 14 26 Duty Cycle 60 Power Factor 0 73 Efficiency 80 Type of wirefeeder machine Compact Wire speed m min 2 15 Post flow s 1 Maximum spool size mm 200 Wire diameter mm 0 6 0 8...

Страница 20: ...that the wire feed speed is not excessive Adjust the pressure adjusting knob to ensure 4 that the wire is fed evenly Over tightening the adjusting knob will cause undue strain on the wire feed motor S...

Страница 21: ...achine and its consumables 8 1 Power Source Check electrical connections of unit at least twice a year Clean oxidised connections and tighten Inner parts of machine should be cleaned with a vacuum cle...

Страница 22: ...o daily allowances or accommodation and travelling costs Note Under the terms of warranty welding guns and their consumables feed drive rollers and feeder guide tubes are not covered Direct or indirec...

Страница 23: ...inder Never use oxygen for venting containers 10 0Recommended Safety Guidelines Diagram and safety explanation Electrical safety alert Welding electrode causing electric shock Fumes and gases coming f...

Страница 24: ...believed to be correct at the time of printing Whilst proper care has been taken in the preparation no liability for injury or damage resulting from its improper use can be accepted BOC Limited 970 98...

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