Welding Problems - Firepower FP 125 Operating Manual & Installation Manual

ESAB FIREPOWER FP-125,135,165
6. Incorrect or worn contact tip.
a. The contact tip transfers the weld current to the electrode wire. If the hole in the contact tip is too large, then arcing
may occur inside the contact tip resulting in the electrode wire jamming in there. When using soft electrode wire such
as aluminum, the wire may become jammed in the contact tip due to expansion of the wire when heated. A contact
tip designed for soft electrode wires should be used.
7. Poor work lead contact to work piece.
a. If the work lead has a poor electrical contact to the work piece, then the connection point will heat up and result in a
reduction of power at the arc.
8. Bent liner.
a. This will cause friction between the wire and the liner thus reducing wire feedability

5.05 Welding Problems

FAULT
1 Undercut.
2 Lack of penetration.
3 Lack of fusion.
4 Excessive spatter.
5 Irregular weld shape.
SERVICE
CAUSE
A Welding arc voltage too
high.
B Incorrect torch angle
C Excessive heat input
A Welding current too low
B Joint preparation too nar-
row or gap too tight
C Shielding gas incorrect
Voltage too low
A Voltage too high
B Voltage too low
A Incorrect voltage and
current settings. Convex =
voltage too low. Concave
= voltage too high.
B Wire is wandering
C Incorrect shielding gas
D Insufficient or excessive
heat input
Table 5-1a: Welding Problems
5-2
REMEDY
A Reduce voltage by reducing the voltage selection
switch position or increase the wire feed speed.
B Adjust angle
C Increase the torch travel speed and/or reduce
welding current by reducing the voltage selection
switch position or reducing the wire feed speed.
A Increase welding current by increasing wire feed
speed and increasing voltage selection switch posi-
tion.
B Increase joint angle or gap
C Change to a gas which gives higher penetration
Increase voltage by increasing voltage selection
switch position.
A Lower voltage by reducing the voltage selection
switch or increase wirespeed control.
B Raise voltage by increasing the voltage selection
switch or reduce wirespeed control.
A Adjust voltage and current by adjusting the voltage
selection switch and the wirespeed control.
B Replace contact tip
C Check shielding gas
D Adjust the wirespeed control or the voltage selec-
tion switch
Manual 0-5123