Tig Welding Troubleshooting - Pro-Tec Welding PRO-TEC 215 MP Operating Manual

6.3 TIG Welding Troubleshooting

NOTE 22: Weld quality is dependent on the correct consumables, proper welding
Description
1. Excessive bead buildup or poor penetra-
tion/fusion at weld edges.
2. Weld bead too wide or undercut at weld
edges or arc burning thru workpiece.
3. Weld bead too small or insufficient pene-
tration or ripples in bead are widely spaced
apart.
4. Weld bead too wide or excessive bead
build up or excessive penetration in butt
joint.
5. Uneven leg length in fillet joint.
6. Electrode melts when arc is struck.
7. Dirty weld pool.
8. Poor weld finish.
9. Arc flutters during TIG welding.
10. Welding arc cannot be established.
11. Electrode melts or oxidizes when an arc is
struck.
12. Arc start is not smooth.
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TROUBLESHOOTING and MAINTENANCE
Possible Cause
Welding Amperage is too low
Welding Amperage is too high.
Travel speed too fast.
Travel speed is too slow.
Wrong placement of filler rod.
Electrode is connected to the "+" Positive
Output Terminal.
A Electrode contaminated through contact
with work piece or filler rod material.
B Gas contaminated with air.
Inadequate shielding gas.
Tungsten electrode is too large for the Welding
Amperage.
A Work clamp is not connected to work piece
or ground/torch leads are not connected to
the correct welding terminals.
B Torch lead is disconnected.
C Gas flow incorrectly set, cylinder empty or
the torch valve is off.
A No gas is flowing to weld zone.
B Torch is clogged with dust.
C Gas hose is cut.
D Gas hose contains impurities.
E Gas regulator turned off.
F Torch valve is turned off (160S only).
G The electrode is too small for the Welding
Amperage.
A Tungsten electrode is too large for the
Welding Amperage.
B The wrong tungsten type is being used for
the welding job.
C Gas flow rate is too high.
D Incorrect shield gas is being used.
E Poor work clamp connection to work piece.
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technique and equipment maintenance.
Remedy
Increase weld amperage and/or change joint
preparation.
Decrease Welding Amperage.
Reduce travel speed.
Increase travel speed.
Re-position filler rod.
Connect the electrode to the Negative Output
Terminal.
A Clean the electrode by grinding contami-
nates off.
B Check gas lines for cuts and loose fitting
or change gas cylinder.
Increase gas flow or check gas line for prob-
lems
Select the right size electrode.
0.040 in. (1.0 mm) = 5 to 30 Amps
1/16 in. (1.6 mm) = 10 to 70 Amps
3/32 in. (2.4 mm) = 15 to 150 Amps
1/8 in. (3.2 mm) = 20 to 230 Amps
A Connect the work clamp to the work
piece or connect the work/torch leads to
the correct welding terminals.
B Connect it to the "-" Negative Output
Terminal.
C Set gas flow rate to 5 – 12 CFH, change
cylinder or turn torch valve on.
0.040 in. Tungsten @ 5 – 30 Amps = 5 – 10 CFH
1/16 in. Tungsten @ 10 – 70 Amps = 7 – 12 CFH
3/32 in. Tungsten @ 15 – 150 Amps = 10 – 15 CFH
1/8 in. Tungsten @ 20 – 230 Amps = 10 – 18 CFH
A Check the gas lines for kinks or breaks or
cylinder contains gas.
B Clean torch.
C Replace gas hose.
D Raise gas pressure to blow out impuri-
ties.
E Turn on.
F Turn on.
G Increase electrode diameter or reduce the
Welding Amperage.
A Use smaller diameter tungsten.
B Use tungsten suitable for DC.
C Use a flow rate of 5 – 18 CFH for the TIG
welding job.
D Use 100% argon for TIG welding.
E Improve connection to work piece.
Operating Manual No: PWOM-215/250MP-001