Section 6 - Troubleshooting And Maintenance; Mig/Fcaw (Gmaw) Welding Troubleshooting - Pro-Tec Welding PRO-TEC 215 MP Operating Manual

TROUBLESHOOTING and MAINTENANCE
SECTION 6 – TROUBLESHOOTING and MAINTENANCE

6.1 MIG/FCAW (GMAW) Welding Troubleshooting

NOTE 20: Weld quality is dependent on the correct consumables, proper welding technique and equipment maintenance
Description
1. Porosity: gas pockets or holes in weld
metal.
2. Excessive Penetration: weld metal melt-
ing through base metal.
3. Burn Through: weld metal burns through
base metal producing holes.
4. Lack of Penetration: no melting between
weld metal and base metal.
5. Excessive Spatter: molten metal particles
solidify onto base metal.
6. Wire feeds out of MIG Gun but no shield-
ing gas flows.
7. Drive Roll rotates but welding weld does
not feed out of the MIG Gun.
Operating Manual No: PWOM-215/250MP-001
Possible Cause
A Surface impurities such as oil, grease,
paint, etc.
B Insufficient shielding gas coverage.
C Wrong shielding gas.
D Dirty welding wire.
E Welding wire extends too far out of noz-
zle.
F Incorrect distance between the MIG Gun
nozzle and the work piece.
A Amperage and/or Voltage too high.
B MIG Gun travel speed is too slow.
A Amperage and/or Voltage too high.
B MIG Gun travel speed is too slow.
A Improper joint preparation or material
too thick.
B Improper weld technique.
C Insufficient heat input into weld puddle.
A Wirefeed Speed too high.
B Voltage too high.
C Welding wire Stick-Out too long.
D Work piece dirty.
E Insufficient shielding gas at welding arc.
F Dirty welding wire.
A Gas cylinder empty.
B Gas regulator closed.
C Faulty solenoid or electronics.
D Restriction in MIG Gun cable.
A Insufficient Drive Roll pressure.
B Incorrect Drive Roll size.
C Excessive wire spool brake tension.
D Wrong Liner or blocked Liner.
E Welding Wire bird nest in the wire feed
system.
F Welding wire has fused (burnt back) onto
the contact tip.
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Remedy
A Clean joint before welding.
B Check for shielding gas flow of 15-45 CFH.
Remove spatter from gun nozzle.
Check gas hoses for leaks.
Stop air drafts near welding arc.
C Check that you have welding grade correct
shielding gas.
D Use clean, dry welding wire. Eliminate pickup
of oil or lubricant on welding wire from liner.
E Be sure welding wire extends not more than
13 mm beyond nozzle.
F Distance between MIG Gun nozzle and the
work piece (Stick-Out length) to 3/8"-1/2".
A Reduce Wirefeed Speed or lower Voltage.
B Increase MIG Gun travel speed.
A Reduce Wirefeed Speed or lower Voltage.
B Increase MIG Gun travel speed.
A Joint design must allow access to the bottom
of joint with a welding wire stick-out length of
3/8"-1/2".
B Requires a MIG Gun angle of 0-15° for maxi-
mum penetration. Keep arc on leading edge of
weld puddle.
C Set higher Wirefeed Speed and/or higher
Voltage or reduce MIG Gun travel speed.
A Reduce Wirefeed Speed.
B Reduce Voltage.
C Reduce Stick-Out length to 3/8"-1/2".
D Remove all grease, oil, moisture, rust, paint,
undercoating or dirt from work surface before
welding.
E Increase shielding flow to 15-45 CFH.
F Use clean, dry welding wire. Eliminate pickup
of oil or lubricant on welding wire from liner.
A Change to a full gas cylinder.
B Open gas regulator.
C Have an approved Service Provider repair the
connection. Refer to SECTION 7 – PRO-TEC
WARRANTY POLICY.
D Straighten out MIG Gun cable.
A Increase pressure on the Drive Roll by turning
Pressure Device clockwise.
B Fit a suit size and type of Drive Roll that suits
the welding wire.
C Reduce wire spool brake tension by turning
the Tension Screw counterclockwise.
D Replace the Liner to suit the Welding Wire.
E See No. 8 Welding Wire bird nest.
F See No. 9 Burnt Back onto the contact tip.
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