Welding Fume Extraction Not Working? Troubleshooting Guide

Welding, a critical process in many manufacturing and construction projects, generates harmful fumes that pose significant health risks. Effective fume extraction is not just a matter of compliance but also an essential aspect of workplace safety and efficiency. However, even the best fume extraction systems can encounter problems.

This troubleshooting guide is designed to help you identify and resolve common issues with welding fume extraction systems. We’ll start with simple checks that you can perform yourself and then move on to more complex issues that may require professional assistance.

Whether you’re a seasoned welder or responsible for maintenance, this guide aims to ensure your fume extraction system functions optimally, safeguarding both your health and your work environment.

What You Could Check Yourself

Before diving into troubleshooting, remember that safety is paramount. Ensure the welding equipment and fume extractor are turned off and unplugged before inspecting or performing maintenance. Wear appropriate protective gear, and if you’re ever in doubt, it’s best to consult a professional.

1.1 Extractor/Hood Positioning

This is not an issue for fume extraction MIG guns. Extraction arms should be no more than 12 to 18 inches away from the weld pool, ideally above it. Extraction nozzles should be a few inches away for optimal fume capture. Extraction hoods should cover the whole welding area. A poorly placed extractor will significantly reduce its effectiveness.

1.2 Clogged Flexible Hose, Duct, Extractor, or Dust Collector

Regularly inspect extractors, hoses and ducts for clogs. If you find any blockages, carefully clean them out. Remember that accumulated welding fumes can be hazardous, so wear a mask during cleaning.

1.3 Crushed Flexible Hose or Duct

Look for any crushed or bent sections in the flexible hose or ductwork. These can impede airflow and reduce extraction efficiency. If damage is found, the affected part may need to be replaced.

1.4 Air Leak in the Ventilation Network

Go through the whole fume extraction network. Listen for any hissing sounds or feel for air entering through joints and connections in the ventilation network (there is negative pressure in the ducts). Sealing these leaks can dramatically improve the performance of your extraction system. During inspections, we’ve seen things as bad as a whole duct open on one end.

1.5 Vacuum Unit Running Backwards

Some vacuum units, like our high-performance turbines, are directional. If wired backwards, they will not function correctly. Check the manufacturer’s instructions to ensure that your unit is running in the correct direction.

1.6 Filters Need to Be Changed

Most systems have indicators or manometers to signal when filters need changing. Don’t ignore these signs, as a clogged filter can drastically reduce the efficiency of your extraction system. If your system’s efficiency has diminished slowly over time, it is likely the cause. Even with an automatic cleaning system, filters will eventually need to be changed.

We invite you to read our short guide if you want to ensure you have the appropriate filters for welding fume extraction.

1.7 Faulty or Worn-Out Fan Motors

One motor may stop working in portable units with multiple motors without apparent signs, except for lower performance. Check and replace brushes on brush motors every 500 to 1500 hours of operation to maintain optimal performance.

On a stationary industrial vacuum unit, a faulty motor will be very obvious as the whole system will stop working.

1.8 Too Much Air Circulation in the Shop

Be aware of how air circulation in your shop, like drafts or strong winds, can affect extraction. Keeping the garage doors shut or altering the layout can help mitigate these effects.

1.9 User Error / Misusing of the System

Ensure all users are trained on the correct usage of the extraction system. Misuse, whether intentional or not, can lead to poor performance and increased risk.

1.10 Compatibility with Welding Processes

Verify that your fume extraction system is compatible with the welding you perform. Different processes produce different types and amounts of fumes, and your extraction solution should be able to handle them effectively.

• Fume extraction MIG guns are the best for MIG welding; flexible arms come second.
• For TIG welding, flexible arms are the best; nozzles come second.
• Fume extraction MIG guns are the best for Fuxed-cored welding; flexible arms come second.
• For Stick welding, flexible arms are the best; nozzles come second.
• For Robotic welding, an extraction hood is the best.

Any questions? Ask them directly in the chat at the bottom right of your screen or during one of our webinars.

When You Need a Professional

Sometimes, issues with welding fume extraction systems are beyond the scope of routine maintenance and require professional expertise. It’s important to recognize when to seek help from a qualified technician to ensure your system operates safely and effectively.

2.1 Poorly Designed Systems

The root cause of a failing fume extraction system can lie in its initial design. Systems not designed to provide the necessary operating airflow can be inadequate for the extractors to work correctly.

Our team can assist in determining the required airflow for your specific application and type of extractor. Right away, you will be able to determine whether your system will ever be able to suit your needs based on the manufacturer’s specs, especially the targeted airflow at the extractors.

2.2 Duct or Hose Too Small

If the ducts or hose are too narrow, it can create significant pressure drops, reducing the efficiency of the extraction system. A professional can assess your setup and recommend appropriate sizing based on your specific needs and the layout of your workspace. We will gladly help you with that.

2.3 Vacuum Unit Not Powerful Enough

The maximum performance of a vacuum unit can be misleading. The operating performance matters, considering the required airflow at each extractor and the pressure drops in the system. A professional can evaluate your system’s capacity and suggest upgrades if necessary to meet the demands of your welding processes. We can also review that with you even on the phone.

2.4 Electrical Problems

Electrical issues in fume extraction systems can be complex and dangerous. Problems like tripped circuit breakers, faulty wiring, or inconsistent power supply, require a skilled technician. Fixing these issues without proper knowledge can lead to further damage or pose serious safety risks.

2.5 Fume Extractor System Requires Maintenance

Finally, it is possible that something not obvious broke in your welding fume extraction system, which would require the care of a technician from the manufacturer.

Conclusion

Recognizing the limits of do-it-yourself maintenance is crucial for the longevity and effectiveness of your welding fume extraction system. If you still face issues after going through the self-checks in the first section, it’s time to call in a professional.

Regular professional inspections and maintenance can preempt many of the problems outlined in this guide, ensuring your system operates at its best. Remember, an efficient fume extraction system is not just about compliance; it’s a cornerstone of a safe and healthy work environment. Trusting a qualified technician with your system’s more complex needs is an investment in safety and productivity.