MK Products Copperhead Weldhead - Manual (Page 22)

CopperHead ® Owner’s Manual - Page 14
Section E Troubleshooting
Arc Start Troubleshooting
If you experience intermittent arc start problems or strikes to the Collet or
Side Plate Clamp instead of the part to be welded, check for the following:
1. Proper arc gap is an important part of the proper use of your MK Orbital
equipment. An improper arc gap can cause errant arc strikes to occur to
other places within the weldhead.
2. Be sure that the tungsten is ground properly, (18° included angle
and a .015” - .017” flat at the end of the tip). Sharpening should be
accomplished with the grind marks parallel to the longitudinal axis of the
tungsten, not around the tungsten.
3. Parts must be clean with no oxidation, oils or other insulating surface
contaminant.
4. If the tungsten is contaminated at any time, it should be replaced. Dirty
tungsten can cause poor arc starts and tungsten inclusions.
5. Make sure that the part to be welded is tight in the Collets, or a loose
ground will result. If the part to be welded can be turned in a latched
Collet, adjust the Collet plungers accordingly.
6. When using tungsten extenders and holders, be sure that the gap
between either of these parts and the Collets is greater than the gap
between the tungsten and the tube.
7. Avoid any tooling that might have sharp edges or points or this will cause
an arc strike to the Collets or the Side Plate Clamp.
8. To insure reliable arc starting and extended tungsten life, the pre-purge
settings should be determined by the size of the tube and weldhead size:
the smaller the tube in a given size weldhead; the longer the pre-purge
time.
9. If an arc strike occurs to the Collet or Side Plate Clamp, the resulting arc
spot may induce future arc strikes. Be sure to smooth out any arc spots
with a fine abrasive pad or cover it with appropriate insulating tape.
10. Be sure that there is a tube in the weldhead before trying to make a
weld.
11. Insufficient or unstable input-power line-voltage can affect the intensity
of the arc start as well as reduce the quality of the weld. When using
extension cords with your orbital power supply, use the guidelines from
the Maximum Allowable Extension Cord Length chart found in Appendix.
12. The use of a generator as input-power for the orbital welding power
supply is generally not recommended. However, if a generator must
be utilied, be certain the Volt-Ampere performance is sufficient and that
its output operating frequency does not interfere with the orbital power
supply digital controller.
Operational Troubleshooting
At times, certain pieces of equipment may need to be serviced. Many times
the components in question are not easily accessible and necessitate some
sort of product disassembly.
Refer to the Weldhead Disassembly section or contact MK Technical
Customer Service Department for further troubleshooting and/or instruction.