Section 5 - Fault Finding And Maintenance; Mma Welding Problems; Tig Welding Problems; Maintenance - NewArc rt2500 Instruction Manual

SECTION 5 — FAULT FINDING AND MAINTAINANCE

5.1 MMA Welding Problems

Most problems with MMA welding are the result of not
setting the correct welding parameters for the weld-
ing rod being used.
All welding rod packets have information on them in
symbolic format , giving suitable current range, polar-
ity and type of weld (normally called 'position').
If you are in doubt about what these symbols mean,
ask your welding rod supplier to explain them.
Choose an initial current setting towards the middle
of the quoted range and if necessary practice on a
piece of scrap the same thickness as the job to be
welded.

5.2 TIG Welding problems

If problems with the RT2500s operation while TIG weld-
ing are experienced, first refer to the information in
paragraph 3.1 in the installation section and para-
graph 4.2.2 in the operation section.
The common problems with TIG welding are poor
striking, porosity and poor appearance of the weld. If
you are experiencing any problems with TIG welding
follow the check list below, this will cure most prob-
lems :-
• If the RT2500 is suffering from poor striking, check
that all power leads are connected properly, check
that there is sufficient gas flow and that the correct
gas is being used, check that the earth clamp is
making a good connection to the work-piece.
• If there is porosity in the weld or the final weld is of
poor appearance, check that there is sufficient gas
flow and that the correct gas is being used, check
the condition of the TIG torch, particularly the gas
hose. Make sure that the collet or gas lens in the
torch head is not blocked in anyway. Check all gas
connections are secure and that there are no leaks,
use a leak detecting spray on all connections if
necessary.
Any welding problems not covered above must be
brought to the attention of a qualified Welding Engi-
neer, if the problem still persists have the RT2500
checked by a trained maintenance person.

5.3 Maintenance

Note! All Electric shocks are potentially fatal, switch the
machine off and unplug from the mains supply before
carrying out any maintenance work.
It is very important that the RT2500 is regularly main-
tained. The amount of use and the working environ-
ment must be taken into account when scheduling the
maintenance periods.
Careful use and regular preventative maintenance will
prolong the life of the machine and ensure trouble free
operation.
Weekly
• Clean the exterior of the machine
• Inspect the machines exterior for obvious signs of
damage.
• Check the condition of the welding cable, earth
clamp and welding output connectors for damage
and any sign of over-heating.
• Check the condition of the mains cable an plug.
Three monthly
As per the weekly schedule, plus:-
• Remove the side panels from the machine and re-
move the build up of dust and debris from inside the
machine. Either use compressed air at low pressure
or an industrial type vacuum cleaner.
• Make a thorough visual inspection of the interior of
the machine, look particularly for pieces of welding
wire, or stubs of old welding rods that may have got
through the cooling air intakes.
• Check the condition of the mains input connector,
look for loose terminal block screws and make sure
the sheath of the mains cable is still clamped se-
curely to the chassis. Make sure the earth wire is still
securely fastened to the earth stud.
• Check the condition of the welding output connec-
tors, look for any signs of discoloration. This could be
an indication of overheating and can be a cause of
welding set failure.
Annually
As per the three monthly schedule, plus :_
Have the machines calibration checked, if necessary
have the machine re-calibrated by a Newarc trained
technician.
RT2500
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