Troubleshooting Guide - Fronius MagicWave 2600 Instructions De Service

TROUBLESHOOTING GUIDE

Warning! Machine may only be opened up by suitably qualified and skilled personnel!
FAULT
1. MACHINE DOES NOT WORK
Mains switch is ON, but relevant
operating status LED and digital
displays are not lit up
2. NO REACTION WHEN TORCH
TRIGGER IS ACTUATED
Mains switch is ON, relevant operating
status LED and digital displays are lit up,
,
but LED displays
when trigger is pulled back
3. NO WELDING CURRENT
Mains switch is ON, relevant operating
status LED and digital displays are lit up,
, ,
LED displays
when the trigger is pulled back.
HF and shielding gas are present
4. NO WELDING CURRENT
Mains switch is ON,
relevant operating status LED is lit up,
and
digital displays
ErrO_t
5. ARC SOMETIMES BREAKS
(in AC-TIG)
6. ARC SOMETIMES BREAKS
(in manual electrode)
7. NO SHIELDING GAS
all other functions are OK
8. NO GAS POST-FLOW
Tungsten electrode discolours after
end of welding
9. POOR ARC IGNITION
10. HF IS TOO WEAK
CAUSE
Break in mains lead,
Mains plug is not plugged in
Mains fuse is faulty
Mains power socket or plug is faulty
Torch control plug is not plugged in,
or the plug-in connection is faulty
Torch switch (micro-switch) or torch control
line is faulty
,
do not light up
The "Power ON" reset time after switch-on
(10 sec) has not yet elapsed
Earth cable is not connected
Earth cable is plugged into wrong current
socket
light up
Torch is faulty
UTC control unit AC (DC) is faulty
Short circuit in welding-current circuit in electrode
welding mode (longer than 1 sec)
Max. duty cycle has been exceeded or fan is
faulty
Cooling air-stream is insufficient
are showing
Primary module is very dirty
Tungsten electrode is underloaded
Arc-drop voltage of electrode is too high
Gas cylinder is empty
Pressure regulator is defective
Gas hose is not connected, or is faulty
Welding torch is faulty
UTC-AC (DC) control unit is defective
Gas solenoid valve is defective
Gas post-flow time is set too short
Gas pre-flow time is set too short
HF is too weak
DC: Tungsten electrode is alloyed up,
or pointed tip is damaged
AC: Tungsten electrode is alloyed up,
or domed tip is damaged
Incorrect needle diameter
Tungsten electrode is underloaded
Gas nozzle is dirty; HF jumps over the gas
nozzle onto the workpiece
Gas nozzle is too small for the diameter of
tungsten electrode used
Torch is damaged: torch body, protective
hose etc. are faulty
No shielding gas, or not enough
has been set
20
REMEDY
Check mains lead, and mains voltage
if necessary
Change the fuse
Replace any faulty parts
Plug in the control plug and secure it, check
connection, replace if necessary
Repair or replace torch
After switching on the mains switch, wait for
about 10 sec before starting to weld
Clamp the earth cable to the workpiece
Plug the earth cable into the
secure it
Change the torch
Change the UTC-AC (DC)
Eliminate the short circuit in the welding-current
circuit
Allow the machine to cool, do not switch off,
check working of fan
Ensure adequate supply of cooling air
Open up the machine and blast clean with dry
compressed air
Use a suitable diameter of electrode for the
amperage in question
Use an alternative electrode if possible
Change the gas cylinder
Change the regulator
Connect the gas hose, replace faulty hose
Replace the torch
Change the UTC-AC (DC) control unit
Call after-sales service
Using internal program parameters, increase
the gas post-flow time (depends on welding
amperage)
Increase gas pre-flow time
See Pt. 10 below
Sharpen tip of tungsten electrode
Shorten the tungsten electrode and form a
new dome at the tip
Set correct needle diameter
Use a suitable electrode for the amperage
(also start-arc amperage) in question
Use a new ceramic nozzle
Use a bigger gas nozzle
Replace the damaged parts or change the
torch
See Pt. 7 above
socket and