ESAB Cigweld EasyWeld 160, Operating Manual

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Manual 0-5617 5-23 MIG (GMAW) WELDING
EasyWeld / HandyWeld 160
Basic MIG (GMAW) Welding Troubleshooting
FAULT CAUSE REMEDY
1 Undercut A Welding arc voltage too
high.
A Decrease voltage or increase the Wire Feed Speed.
B Incorrect gun angle B Adjust angle.
C Excessive heat input C Increase the gun travel speed and/or decrease
welding current by decreasing the voltage or
decreasing the Wire Feed Speed.
2 Lack of penetration A Welding current too low A Increase welding current by increasing Wire Feed
Speed and increasing voltage.
B Joint preparation too
narrow or gap too tight
B Increase joint angle or gap.
C Incorrect shielding gas C Change to a gas which gives higher penetration.
3 Lack of fusion Voltage too low Increase voltage.
4 Excessive spatter A Voltage too high A Decrease voltage or increase the Wire Feed Speed
control.
B Voltage too low B Increase the voltage or decrease Wire Feed Speed.
5 Irregular weld shape A Incorrect voltage
and current settings.
Convex, voltage too low.
Concave, voltage too
high.
A Adjust voltage and current by adjusting the voltage
control and the Wire Feed Speed control.
B Wire is wandering. B Replace contact tip.
C Incorrect shielding gas C Check shielding gas.
D Insufficient or excessive
heat input
D Adjust the Wire Feed Speed control or the voltage
control.
6 Weld cracking A Weld beads too small A Decrease travel speed.
B Weld penetration narrow
and deep
B Reduce current and voltage and increase MIG Gun
travel speed or select a lower penetration shielding
gas.
C Excessive weld stresses C Increase weld metal strength or revise design
D Excessive voltage D Decrease voltage.
E Cooling rate too fast E Slow the cooling rate by preheating part to be
welded or cool slowly.
7 Cold weld puddle A Loose welding cable
connection.
A Check all welding cable connections.
B Low primary voltage B Contact supply authority.
C Fault in power source C Have an Accredited CIGWELD Service Provider to
test then replace the faulty component.
8 Arc does not have
a crisp sound that
short arc exhibits
when the Wire
Feed Speed and
voltage are adjusted
correctly.
The MIG Gun has been
connected to the wrong
voltage polarity on the
front panel. Connect the MIG Gun to the positive (+) welding
terminal for most solid wires and gas shielded flux
cored wires. Connect MIG Gun to the negative (-)
welding terminal for most Gasless Wires. Refer
to the electrode wire manufacturer for the correct
polarity.
Table 5-4: MIG (GMAW) Welding Problems