TROUBLE SHOOTING ARC WELDING EQUIPMENT

TROUBLE SHOOTING ARC WELDING EQUIPMENT

Date 06/05/2019

 

TROUBLE SHOOTING ARC WELDING EQUIPMENT

  Problem  Cause Remedy  
   Welder will not start (Starter not operating)   Power circuit dead  Check voltage
     Broken power lead  Repair
     Wrong supply voltage   Check nameplate against supply
     Open power switches   Close
     Blown fuses  Replace
    Overload relay tripped  Let set cool. Remove cause of overloading.
     Open circuit to starter button  Repair
     Defective operating coil  Replace
     Mechanical obstruction in contactor  Remove
   Welder will not start (Starter operating)  Wrong motor connections  Check connection diagram
     Wrong supply voltage  Check nameplate against supply
     Rotor stuck  Try turning by hand
     Power circuit single-phased  Replace fuse; repair open line
     Starter single-phased  Check contact of starter tips
     Poor motor connection  Tighten
     Open circuit in windings  Repair
   Starter operates and blows fuse  Fuse too small  Should be two to three times rated motor
 current
     Short circuit in motor connections  Check starter and motor leads for insulation
from around and from each other
   Welder runs but soon stops  Wrong relay heaters  Renewal part recommendations
     Welder overloaded  Considerable overlaod can be carried only for
a short time
     Duty cycle too high  Do not operate continually at overload currents
     Leads too long or too narrow in cross section  Should be large enough to carry welding current
without excessive voltage drop
     Power circuit single-phased  Check for one dead fuse or line
     Ambient temperature too high  Operate at reduced loads where temperature
 exceeds 100° F
     Ventilation blocked   Check air inlet and exhaust openings
   Welding arc is loud and spatters excessively  Current setting too high  Check setting and output with ammeter
     Polarity wrong  Check polarity, try reversing, or an electrode of
 opposite polarity
   Welding arc sluggish  Current too low  Check output, and current recommended for
electrode being used
     Poor connections  Check all electrode-holder, cable and groundcable
connections. Strap iron is poor ground return
     Cable long or too small  Check cable voltage drop and change cable
   Touching set gives shock  Frame not grounded  Ground solidly
    Generator control fails to vary current  Any part of field circuit may be short circuited
or open circuited
 Find faulty contact and repair
   Welder starts but will not deliver welding current  Wrong direction of rotation  See INITIAL STARTING
     Brushes worn or missing  Check that all brushes bear on commutator with
sufficient tension
     Brush connections loose  Tighten
     Open field circuit  Check connection to rheostat, resistor, and
auxiliary brush studs
     Series field and armature circuit open  Check with test lamp or bell ringer
     Wrong driving speed  Check name plate against speed of motor or
belt drive
     Dirt, grounding field coils  Clean and reinsulate
     Welding terminal shorted  Electrode holder or cable grounded
     Welder generating but current falls off when welding  Electrode or ground connection loose
    Clean and tighten all connections  Poor ground  Check ground-return circuit
    Brushes worn worn off  Replace with recommended grade. Sand to fit.
Blow out carbon dust.
      Weak brush spring pressure  Replace or readjust brush springs
     Brush not properly fitted  Sand brushes to fit
     Brushes in backwards   Reverse
     Wrong brushes used  Renewal part recommendations
     Brush pigtails damaged  Replace brushes
     Rough or dirty commutator  Turn down or clean commutator
     Motor connection single-phased  Check all connections
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