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PROBLEM
Low output or non-penetrating
weld.
Ground clamp, ground cable, and/
or welding cable get hot.
Frequent circuit breaker trips.
Poor quality welds.
Difficult arc start.
Arc is wandering (TIG).
POSSIBLE CAUSE
Weld parameters too low.
Too long or improper extension cord.
Poor ground connection or torch/electrode
connection.
Input power too low.
Bad ground or loose ground connection.
Machine is drawing too much amperage
due to use of larger size electrode.
Machine is not the only piece of electrical
equipment on the circuit.
Circuit breaker is incorrect/insufficient for
use with this machine.
Insufficient gas at weld area.
Rusty, painted, oily or greasy workpiece.
Poor ground connection or torch/electrode
connection.
Amperage is too low.
Make sure base metal is clean.
Make sure electrode is not damaged.
Tungsten is too large.
Gas flow is too high.
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POSSIBLE SOLUTION
Adjust welding parameters
Use a proper extension cord (#12 AWG
wire or heavier, no longer than 25 ft.). See
"Extension Cords", page 11.
Reposition clamp and check cable to
clamp connection.
Check connection of ground cable, torch
or electrode holder
Have a qualified electrician verify the
voltage at your outlet. If the voltage is
appropriate, verify that the circuit wiring is
sufficient for the circuit breaker size.
Check connection of ground cable, torch or
electrode holder.
Check connection of the ground cable to the
ground clamp. Tighten cable connection to
ground clamp if needed.
Ensure the connection between the ground
clamp and workpiece is good and on clean,
bare (not painted or rusted) metal.
Make sure cable is not damaged.
Use a smaller electrode.
Make sure the welder is on a dedicated
circuit or is the only thing plugged into a
circuit.
Verify that the circuit breaker for the circuit
is a 20A time-delay (slow-blow) breaker
for 120V and a 50A for 230V. If it is not,
have a qualified electrician install the proper
breakers.
Check that the gas is not being blown
away by drafts and, if so, move to a more
sheltered weld area. If not, check gas
cylinder contents, gauge, regulator setting,
and operation of gas valve.
Ensure workpiece is clean and dry.
Check ground clamp/workpiece connection
and all connections to the machine.
Increase amperage setting.
Properly clean base metal.
Replace electrode if needed.
Use a smaller tungsten.
Reduce gas flow.
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