TROUBLESHOOTING GUIDE
Have a technical support question concerning a Magnatech product? Reading our troubleshooting FAQ is the best place to start! If you do not see a question that relates to the problem you are experiencing, or if any of the recommended checks fail to correct the problem, please contact Technical Support for assistance.
 

weld Heads:
C-Series GTAW Tube weld Head
Redhead Series GTAW Tube/Pipe weld Head
E-Series GTAW Pipe weld Head
D-Series GTAW Pipe weld Head
Pipeliner II GMAW/FCAW Pipe weld Head

Power Supplies:
Tubemaster GTAW Power Source/Controller
Pipemaster GTAW Power Source/Controller
 

C-Series GTAW Tube weld Head
Q: Where can I purchase tungsten for my C-Head?
A: Tungsten can be purchased directly from Magnatech. Magnatech strongly recommends the use of Sylvania 2% Ceriated tungsten.

Q: What should the angle and length of the tungsten be for my C-Head?
A: You can calculate a part number using a Tungsten Length Calculator. The part number for tungsten includes very important information to assure that you are provided with the best tungsten for your weld head. An example of the part number reads as follows for a C-25 Weld Head Model 821, welding on 1" OD tubing with an .065" wall thickness:

TICB20-1.176-2S
T = Tungsten
I = Inches
C = 2% Ceriated
B = 1.6mm (.062") tungsten diameter
20 = 20% Included Angle
1.176 = cut length of tungsten in inches for this specific OD
2 = Tip Diameter
S = Sylvania 2% Ceriated Tungsten

Q: Why do I notice imperfections in the same place on the work pieces every time I weld?
A: Open the Cartridge. Slowly rotate the weld head's Horseshoe Gear and listen for a stutter in the gears. Also, look for weld spatter on the gear itself. If you see weld spatter on the gear, carefully remove it.

Q: The tungsten is melting on my weld head. What should I do?
A: Check the Positive(+) & Negative(-) connections on the controller. Each cable is properly labeled.  back to top

Redhead Series GTAW Tube/Pipe weld Head
Q: What can I do if the Torch Cable on my Redhead gets in the way of performing the weld?
A: Make sure the Torch Cable is coiled properly. If not wrapped around enough, the cable can touch the work piece and become burned which causes failure.

Q: Why is my Redhead not rotating around my work piece?
A: Check to make sure the clutch is engaged. It is located on the top front center of the weld head. If the clutch is engaged, next check to make sure the Rotation circuit breaker has failed. If it has, reset the circuit breaker.

Q: My Redhead welds, but does not finish the weld. What should I do?
A: Check your level times and make sure all six (6) levels added together equal or exceed the Total Weld time.

Q: When my Redhead is welding between the 9 o'clock and 3 o'clock positions, the arc is falling away from the work piece. How can I prevent or fix this?
A: Check the set screw on the Tensioner which is located behind the Pivot Arm which is mounted on the Torch Block to make sure it is tightened. If the set screw is tightened, check the clamping of the weld head. Look at the pipe clamp from the backside of the weld head and check the scribed line to make sure it is parallel with the main body of the weld head. If not, use fine adjustment to center it.  back to top

E-Series GTAW Pipe weld Head
Q: Why is my E-Head not feeding wire or experiencing poor wire feed?
A: First, check the Tensioner Assembly on the wire drive for adequate tension. Next, make sure the Wire Spool Nut is not overtightened on the Wire Spool Mount. Finally, check the Wire circuit breaker located on the front of the controller to see if it has failed. If it has, reset the circuit breaker.

Q: What should I do if the wire on my E-Head will not stay between the Drum & Rim Assembly?
A: Check to make sure the Wire Conduit Inlet Guide is properly lined up to feed into the rollers correctly.

Q: My E-Head stops during welding. What should I do?
A: Check to make sure the cable is not wrapped around the work piece tighly, causing the weld head to pinch the gas and/or coolant lines. This can result in an interruption of gas and/or coolant which will shut the system down.  back to top

D-Series GTAW Pipe weld Head
Q: While welding, why does my Travel, Oscillation, Wire, or AGC motor fail?
A: Check the circuit breakers for each, located above the Pendant Cable connector. Reset the circuit breakers in case one of them has failed.

Q: If my AGC compensation is fluctuating too excessively to make/perform a weld, what should I do?
A: Check the AGC sensitivity setting on the Pipemaster controller. The standard factory setting is 20. Increasing this number will increase sensitivity and cause over compensation thus resulting in excessive fluctuating.

Q: Why is my weld head having trouble feeding wire?
A: First, check to make sure you are using only level wound wire. If you are not, please contact Tech Support for availability and approved suppliers. Next, check the adjust of the Wire Tensioner, located next to the Drum & Rim Assembly. Loosen/tighten the two screws on the Wire Tensioner to adjust the pressure applied to the Drum & Rim Assembly. Lastly, check the Wire Spool Nut to make sure it is not too tight/loose.  back to top

Pipeliner II GMAW/FCAW Pipe weld Head
Q: Why won’t my Pipeliner II welding system strike an arc?
A: First, check to make sure you have proper gas flow. Next, check the Water Cooler to make sure it has enough coolant. If the screen on the MPS4000 Power Supply read [No H2O], there is air in the water lines. Remove the water line from the coupling marked with blue tape and let some coolant out of the system. This should purge out the air bubbles. Lastly, check all the connections in between the components (cooler to controller/controller to power supply, etc.)

Q: My Pipeliner II weld head is experiencing poor wire feed. How can I fix this?
A: First, check to make sure the Wire Drive Roll size matches the wire size being used. Next, check the tension on the Spool Mount located on the Wire Feeder (for Push-Pull configurations). For Wire on Head configurations, check the tension on the weld head. Then, make sure the Torch Cable is as straight as possible. This will help prevent friction (for Push-Pull configurations). You can also check the Contact Tip on the torch to make sure it is the same size as the diameter of the wire being used.  back to top

Tubemaster GTAW Power Source/Controller
Q: My Tubemaster controller will not strike an arc. What should I do?
A: First, press the Stop Weld button. Then, press the Manual Purge button and check to see if the Flow Switch Status green LED light is illuminated (located above the Pendant Cable connector). If the Flow Switch Status red LED light is illuminated, check:

Q: My Tubemaster controller won't strike an arc, but the Flow Switch Status green LED light is illuminated. What should I do?
A: First, make sure you are not in the Test Mode and the Test light is not on. Then determine if the Ignition Clip is installed. It attaches to the Gas Cup and is grounded (connected) to the weld head (Not applicable on C-Series weld heads).

Q: Why is my Water Cooler making a loud noise?
A: The filters could be clogged due to dirty torch coolant. This requires the filters to be changed. Please contact Tech Support for assistance. You can also check the voltage setting on the Water Cooler to see if it is set at 115V or 230V.

*Remember to only use torch coolant with a mixture of 75% Dionized Water and 25% Ethylene Glycol. This mixture is readily available at Magnatech.

Q: While welding, either my Wire, or Rotation (ROT) motor failed. What is the issue?
A: Check the circuit breakers for each, located above the Pendant Cable connector. Reset the circuit breakers in case one of them has failed.

Q: Why won’t my Tubemaster turn on?
A: Check to make sure the plug is wired properly and is secured in a working outlet.

Q: What can I do if my printer will not print out characters on the printer paper?
A: The printer ribbon could be bad on the printer. Please contact Tech Support for assistance.  back to top

Pipemaster GTAW Power Source/Controller
Q: Why won’t my Pipemaster controller strike an arc. What should I do?
A: First, press the Stop Weld button. Then, press the Manual Purge button and check to see if the Flow Switch Status green LED light is illuminated (located above the Pendant Cable connector). If the Flow Switch Status red LED light is illuminated, check:

Q: My Pipemaster controller won't strike an arc, but the Flow Switch Status green LED light is illuminated. What should I do?
A: First, make sure you are not in the Test Mode and the Test light is not on. Then determine if the Ignition Clip is installed. It attaches to the Gas Cup and is grounded (connected) to the weld head (Not applicable on C-Series weld heads).

Q: My Pipemaster controller strikes an arc, but then the arc stops immediately. What should I do?
A: Check to make sure the Volt Sense Lead is properly connected.

Q: Why is my Water Cooler making a loud noise?
A: The filters could be clogged due to dirty torch coolant. This requires the filters to be changed. Please contact Tech Support for assistance. You can also check the voltage setting on the Water Cooler to see if it is set at 115V or 230V.

*Remember to only use torch coolant with a mixture of 75% Deionized Water and 25% Ethylene Glycol. This mixture is readily available at Magnatech.

Q: What if my Pipemaster Pendant display goes blank during welding?
A: First, check to make sure the Pendant is connected properly. You can also verify that the Pendant is not touching the work piece. If the Pendant is touching the work piece, high frequency is being fed back to the computer and disrupting the signal to the Pendant.

Q: Why won’t my Pipemaster turn on?
First, check to make sure the plug is wired properly and is secured in a working outlet. Next, check the label next to the power cords on the controller to see what the voltage is set to. Please see the following possible settings:

Q: What can I do if my printer will not print out characters on the printer paper?
A: The printer ribbon could be bad on the printer. Please contact Tech Support for assistance.  back to top