Common Cutting Issues - ESAB ESP-101 Instruction Manual

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Common Cutting Issues

Listed below are common cutting problems followed by the probable cause of each. If problems are determined to be caused
by the ESP-101, refer to the maintenance and troubleshooting sections of this manual. If the problem is not corrected after
referring to the maintenance and troubleshooting sections, contact your ESAB distributor.
a. Insufficient Penetration.
1. Current too low.
2. Cutting speed too fast.
3. Damaged cutting nozzle.
4. Improper air pressure.
5. Low air flow rate.
6. Standoff too high - Nozzle to plate distance.
B. Main arc Extinguishes.
1. Cutting speed too slow.
2. Worn electrode.
3. Standoff too high - Nozzle to plate distance.
C. Dross formation. (In some materials and thicknesses, it may be impossible to get dross-free cuts.)
1. Current too low.
2. Cutting speed too fast or too slow.
3. Improper air pressure.
4. Faulty nozzle or electrode.
5. Low air flow rate.
D. Double arcing. (Damaged Nozzle orifice.)
1. Low air pressure.
2. Damaged cutting nozzle.
3. Loose cutting nozzle.
4. Heavy spatter accumulation on nozzle.
5. Nozzle contact with workpiece during starting or cutting operation.
E. uneven arc.
1. Damaged cutting nozzle or worn electrode.
2. Heavy spatter accumalation on nozzle or torch heat shield.
f. unstable Cutting Conditions.
1. Incorrect cutting speed.
2. Loose cable or hose connections.
3. Electrode and/or cutting nozzle in poor condition.
g. Main arc Does Not Strike.
1. Worn electrode.
2. Loose connections.
3. Work cable not attached.
h. Poor Consumable life.
1. Improper air pressure.
2. Contaminated air supply.
3. Low air flow rate.
4. Incorrect current setting for consumable set installed in torch.
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