I. Power System Troubleshooting
1. Failure to Start
Check the input voltage (three-phase 380V ±10% or single-phase 220V).
If the fuse is blown, replace it with a fast-acting fuse of the same specification (do not use copper wire as a substitute).
If the main transformer coil is short-circuited, replace it completely.
2. Overheating Protection
Check whether the cooling fan is operating properly.
Measure the resistance of the temperature relay (normally it should be 0Ω).
Avoid excessive duty cycle operation (recommended ≤80%).
II. Welding Process Troubleshooting
1. Failure to Start the Arc/Poor Welding
Check the output cable resistance (should be <0.5Ω) and the grounding wire contact surface.
Grind the workpiece contact surface to the original metal color and ensure the grounding clamp is secure.
Check the gas flow rate for gas shielded welding (20-25L/min for CO2 welding).
2. Welding Seam Defects
Porosity: Check gas purity (CO2 purity ≥ 99.5%) and pipeline tightness.
Miss-fusion: Adjust heating time (7-10 seconds for 40-63mm PPR pipe).
III. Mechanical Component Failures
1. Abnormal Wire Feeding
Adjust the wire feed roll tension (too tight results in difficult wire feeding, too loose results in slippage).
Check contact tip wear (recommended wire extension of 8-12mm).
2. Die/Gun Problems
Ultrasonic die heating exceeding 50-70°C (no-load) requires replacement.
A damaged torch switch or poor control line contact requires repair.
IV. Special Troubleshooting
Current Imbalance: Check the 6-core control cable and remote control box potentiometer.
Arc Unstable: Reduce wire extension or replace clogged wire feed hose.
Wire Sticking: Severe contact tip wear requires replacement (recommended inspection every 8 hours).
