FAULT FINDING
Sr.
No.
Fault
What to check
1
Machine is switched on but neither the
mains indicator glows nor the fan is
operating
1) Check for the proper three phase supply
2) Check the control fuse mounted on the control
transformer of the power source
2
The machine is Switched on but the
indicator on the feeder do not glow
and on operating the inching button
the wire feeder
1) Check the three core inter connecting cable
connection at both the machine end and feeder
end.
1) Check the glass fuse provided on the feeder
( the glass fuse is mounted on the panel between
the front panel of the feeder and the control box)
3
When the machine is started the wire
start to come out of the torch
automatically with out triggering the
switch on the torch
Check the NC element connected to the inching
switch of the feeder ( If the NC contact is faulty
the two wires connected to the this element can be
shorted for temporary relief)
4
When the torch trigger is pressed the
wire comes out of the torch but gas do
not flow and the voltage do not come
Check the three core inter connecting cable
connection at both the machine end and feeder
end.
5
When the torch trigger is pressed the
wires comes out of the torch , gas
starts flowing but welding do not takes
place
1)
Check for the proper three phase
connection
2)
Set the feeder knob to zero and set the
COARSE and FINE SWITCH to the
maximum and press the trigger on the
torch, then volt meter should show a
voltage of around 55 volts in WARMIG-
400and 39 Volts in WARMIG-250. If the
voltage is less than this check the3 phase
supply and for proper operation of the
contactor.
6
Welding is taking place but the current
tends to drop in between and the arc
goes up to the TIP of the torch
The feed rate set is low increase the feed rate till
you get proper and steady current
7
Welding is taking place but a jerk is
felt while welding and the torch is
pushed away from the job
The wire feed set is high. Reduce the wire feed
rate till you get a steady welding current
8
Each time welding is finished long
wire comes out of the torch
BURN-OFF time set is too high
Blue color preset is provided on the sequence card
(a card with two relays). Adjust this to set it right.
NOTE: this adjustment has to be done only if it of
utmost importance and it is causing high
inconvenience to the welder
6
