Chapter 5. Anomalies. Probable Causes. Possible Solutions - gala gar GAR CONTINUOS 450 Manuel Technique D'instructions

CHAPTER 5. ANOMALIES. PROBABLE CAUSES. POSSIBLE SOLUTIONS.

SYMPTOM. ANOMALY
GENERAL PROBLEM
NOTHING WORKS
.
LIMITER TRIPS
ALTHOUGH THE MACHINE IS
CONNECTED AND WITH
PILOT ILLUMINATED, THE
MACHINE DOES NOT WELD
THE WELDING IS AT LOW
VOLTAGE
NOISES OCCUR
ELECTRODE BURNS IN T.I.G.
WELDING
THE ARC IS INTERRUPTED IN
THE AIR CUTTING PROCESS
THE ARC IS INTERRUPTED IN
THE MMA WELDING PROCESS
SLAG INCLUSIONS
UNSTABLE ARC
VERY HIGH IGNITION
VERY LOW IGNITION
OVERLY SENSITIVE
REMOTE CONTROL
BOTH AT THE BEGINNING AND END OF A REPAIR CHECK THE EQUIPMENT INSULATION LEVELS. DISCONNECT THE ELECTRONIC
BOARDS WHEN MEASURING THE INSULATION. BLOW THE INSIDE OF THE EQUIPMENT WITH COMPRESSED AIR.
The insulation-measuring device will have 500 V D.C. and will be applied to the following points of the circuit:
- Power supply- Earth: Ra>50 Mohms
GAR CONTINUOS. Instructions Manual.
PROBABLE CAUSE
The machine has no voltage in one or all
its vital elements.
Magnetothermal switch has low gauge for
the case. There may be a short circuit,
which is what causes the limiter to trip.
(Primary or secondary) coiling burnt out.
Someone has tried to connect at 220V
when the supply voltage was 380 V.
Someone has tried to weld with remote
control mode without connecting the
remote control.
Faulty control system.
Defect in electrical diagram.
The electricity supply is not correct.
Supply cables broken or badly connected.
Faulty switch.
Connection loose or slack.
Burnt coiling.
Phase missing.
Faulty thyristorised rectifier.
Faulty control system.
Loose metal casing.
Loose loops in one of the coilings.
Lack of shielding gas.
Excessive welding intensity for a certain
electrode.
Use of reverse polarity.
Very hot graphite electrode.
Very low arc voltage.
Excessive air pressure.
Inappropriate length between clamp and
graphic electrode tip.
Inappropriate graphite electrodes.
Inappropriate advance process.
Use of reverse polarity.
Wet electrodes
Defective contact
Dirt in the metal base
Very low intensity
Lack of cleanliness
Travel speed too high
Defective contact terminal voltage
High Hot Start
Low Hot Start
High sensitivity potentiometer control
SPECIALIZED PERSONNEL MUST CARRY OUT ANY WORK ON THE EQUIPMENT.
- Welding-Earth: Ra>50 Mohms
POSSIBLE SOLUTION
Make sure there is voltage at the entry to the machine, if not the
tapping must be changed or the supply hose repaired. It is
advisable to see if any magnetothermal has "blown".
The machine panels must be removed testing the logical points
of the electrical diagram.
Change the magnetothermal for another larger gauge one. It is
important for the magnetothermal
CHARACTERISTIC SLOW TYPE CURVE.
magnetothermal switch to have a characteristic slow type curve. In
the event that the electrical installation has limited power the
welding work must be tested at lower current levels.
Change coil.
Change the position of the terminal plate bridges.
Change to LOCAL mode or connect the remote control.
Replace control system, mark 70 of the general parts explosion.
Test internal connections. Test switch points, check rectifier input
voltage (approximately 44V).
secondary card voltages. (Mark 37 of general parts explosion).
Change supply tap.
Repair connection.
Change switch.
Repair connection.
Change coiling.
Repair electrical connection.
Change rectifier.
Replace control system, mark 70 of the general parts explosion.
Review and screw casing.
Change or varnish the coiling.
Regulate at an appropriate flow.
Decrease welding current or change electrode for one with larger
diameter.
Place electrode to negative pole.
Leave electrode to cool down.
Increase adjustment power.
change to TIG working mode with adjustment set at maximum.
Lower the pressure.
Keep a distance of between 100 and 150 mm.
Use graphite electrodes for direct current.
Use one forward advance direction in the process.
inclination between the electrode and the part of up to 45º.
Place electrode to positive polarity.
Dry electrodes in heating stoves.
Review internal and external connections.
Degrease and clean the parts befote welding
Increase intensity.
Maximize clearing completely removing the slag to the next
weld bead.
Reduce speed to favor the slow cooling weld helping the
output of slag.
Adjusting connections and verify phases.
Adjust adjustment potentiometer.
Adjust adjustment potentiometer.
Replace remote control for MD-2 or multiturn.
- Power supply-Welding: Ra>50 Mohms
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switch to have
It is important for the
Check transformer auxiliary
If at maximum in ARC-AIR MODE
Keep an
a