www.parweld.com
13
Problem
Cause/Corrective Action
Excessive Spatter -
scattering of
Molten metal particles
that cool to solid form
near weld bead.
Wire feed speed too
high. Select lower wire
feed speed.
Voltage too high. Select
lower voltage range.
Electrode extension
(stick out) too long.
Use shorter electrode
extension (sick out).
Work piece dirty.
Remove all grease, oil,
moisture, rust, paint,
undercoating, and dirt
from work surface
before welding.
Insufficient shielding gas
at welding arc. Increase
flow of shielding gas at
regulator/flow meter
and/or prevent drafts
near welding arc.
Dirty welding wire. Use
clean, dry welding wire.
Eliminate pickup of oil
or lubricant on welding
wire from feeder or
liner.
Wire feed unit operates
but no gas flow .
Gas cylinder empty
Gas regulator closed
Faulty solenoid
Restriction in torch
cables
Wire feed unit operates,
but does not feed
Insufficient drive roll
pressure
Incorrect drive rolls
Excessive wire spool
brake tension
Incorrect liner
Blocked liner
Bird nesting
Burn back
Bird nesting
Excessive feed roll
pressure
Incorrect or blocked
liner
Incorrect contact tip size
Contact tip overheating
Restriction in torch
cable
Misaligned drive rolls or
wire guides
Excessive cable kinkage
Problem
Cause/Corrective Action
Burn back
Improper voltage setting
Improper stick out
Erratic wire feed
Incorrect or blocked
liner
Contact tip overheating
Excessive cable kinking
Adjust the burn back
control correctly
Erratic Wire Feeding or
Arc
Improper drive roll
tension
Improper drive roll size
Worn drive rolls
Incorrect or blocked
liner
Incorrect wire guide size
Misaligned drive rolls or
wire guide
Gaps at liner or wire
guide junctions
Incorrect contact tip size
Contact Tip overheating
Spatter adhesion on exit
geometry of tip bore
Excessive cable kinkage
Poor earth or cable
connections
Weld joint area dirty
Yellow temperature light
illuminates
Power source has
over heated leave the
machine running to
allow it to cool down.
Ensure entry and exit
vents on machine are
clear and machine has a
good supply of cooling
air.
Reduce operating duty
cycle and or amperage.
