Troubleshooting; Basic Troubleshooting-Power Source Faults - Thermal Arc 181i Fabricator Service Manual

TROUBLESHOOTING

6.01 Basic Troubleshooting-Power Source Faults

The following table is a guide for analysing problems and making repairs to the Power Source.
FAULT
1 Electricity Supply is ON,
power indicator is illumi-
nated however the Power
Source will not commence
welding.
2 Fault Indicator is illuminat-
ed and the Power Source
will not commence welding.
3 The Power Source will not
feed wire in MIG mode.
4 Welding wire continues to
feed when torch trigger is
released.
5 Welding arc cannot be
established in MIG mode.
6 Inconsistent wire feed.
7 No gas flow in MIG mode.
Manual 0-5192
SECTION 6:
TROUBLESHOOTING
CAUSE
A Power Source is not in the cor-
rect mode of operation.
B Faulty torch trigger.
Duty cycle of Power Source has
been exceeded.
A Electrode wire stuck in conduit
liner or contact tip (burn-back
jam).
B MIG GUN/SPOOL GUN switch
is switched to SPOOL GUN.
A Trigger mode selection switch
is in 4T latch mode.
B Torch trigger leads shorted.
A MIG Gun polarity lead is not
connected into a welding out-
put terminal.
B Poor or no work lead contact.
A Worn or dirty contact tip.
B Worn feed roll.
C Excessive brake tension on wire
reel hub.
D Worn, kinked or dirty conduit
liner
A Gas hose is damaged.
B Gas passage contains impuri-
ties.
C Gas regulator turned off.
D Empty gas cylinder.
6-1
FABRICATOR 181i
REMEDY
A Set the Power Source to the correct
mode of operation with the process
selection switch.
B Repair or replace torch trigger
switch/lead.
Leave the Power Source switched
ON and allow it to cool. Note that
fault indicator must be extinguished
prior to commencement of welding.
A Check for clogged / kinked MIG Gun
conduit liner or worn contact tip.
Replace faulty components.
B Switch the MIG GUN/SPOOL GUN
switch to MIG GUN.
A Change the trigger mode selection
switch from 4T latch mode to 2T
normal mode.
B Repair or replace torch trigger
switch/lead.
A Connect the MIG Gun polarity lead
to either the positive welding output
terminal or the negative welding
output terminal as required.
B Clean work clamp area and ensure
good electrical contact.
A Replace if necessary.
B Replace.
C Reduce brake tension on spool hub
D Clean or replace conduit liner
A Replace or repair.
B Disconnect gas hose from the rear
of Power Source and blow out
impurities.
C Turn on regulator.
D Replace gas cylinder.
Troubleshooting