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STICK WELD TROUBLESHOOTING
PROBLEM
CAUSE
CORRECTION
Electrode
Sticking
Arc Too Short
While welding, keep the ignited end of the electrode further from the weld joint.
Current Too Low
Adjust the current on the front of the Welder to a higher current setting.
Holes in
Weld Bead
(Porosity)
Arc Too Long
While welding, keep the ignited end of the electrode closer to the weld joint.
Moisture in Electrode
Replace electrode with a new one.
Excessive
Spatter
Arc Too Long
While welding, keep the ignited end of the electrode closer to the weld joint,
Current Too High
Adjust the current on the front of the welder to a lower current setting.
Poor
Penetration
Poor Joint Preparation
Clean the weld joint of any dirt, grease, paint of other possible contaminates.
If the pieces being Welder are of a heavy gauge it may be necessary to bevel
the edges of the pieces.
Current Too Low
Adjust the current on the front of the welder to a higher current setting.
Travel Speed Too Fast
Slow down the travel speed of the electrode while welding.
Overload Light
On
Duty Cycle Exceeded
Allow the Welder to cool for a minimum of 15 minutes before attempting to use
again.
MIG WELD TROUBLESHOOTING
PROBLEM
CAUSE
CORRECTION
Burn Through
High Voltage
Adjust voltage output to lower setting.
Fast Wire Speed
Adjust wire speed to slower setting.
Slow Gun Travel
Increase your travel speed with the Welding Gun.
Lack of
Penetration
Low Voltage
Adjust voltage output to higher setting.
Slow Wire Speed
Adjust wire speed to faster setting.
Fast Gun Travel
Slow your travel speed of the Welding Gun making sure to pull or drag the molten
metal puddle.
Excessive Wire Protruding
Move the Contact Tip on the Welding Gun closer to the work piece to shorten the
length of exposed wire.
Material Too Thick
The MP200i is rated for a maximum thickness of 3/8”, exceeding this will result
in poor penetration.
Poor Material Prep
If welding heavy gauge metals, it may be necessary to increase the welding gap
between the two pieces and also bevel the edges on the weld side of the pieces.
Excessive
Penetration
High Voltage
Adjust voltage output to lower setting.
Fast Wire Speed
Adjust wire speed to slower setting.
Slow Gun Travel
Increase your travel speed with the Welding Gun.
Warping
Lack of Tack Welds
Tack weld the pieces in multiple areas to keep the pieces from pulling apart.
No Clamping
Use welding clamps to secure the pieces in the proper shape.
Poor Technique
To prevent warping, allow the workpiece to cool after welding small sections at
a time. Move your welding areas around by not completing all the welding in one
section all at once, rather, welding a small amount in one area and then move to
another section area to spread out the heat in the piece.
