Welding Problems - Firepower FP 95 Operating Manual

FIREPOWER FP 95 FC

5.04 Welding Problems

FAULT
1 Undercut.
2 Lack of penetration.
3 Lack of fusion.
4 Excessive spatter.
5 Irregular weld shape.
6 Weld cracking
7 Cold weld puddle
Manual 0-5122
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
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 Insufficient or excessive
heat input
A Weld beads too small
B Weld penetration narrow
and deep
C Excessive weld stresses
D Excessive voltage
E Cooling rate too fast
A Faulty rectifier unit
B Loose welding cable con-
nection.
C Low Primary Voltage
Table 5-1: 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 weld-
ing 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
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
D Adjust the wirespeed control or the voltage selec-
tion switch
A Decrease travel speed
B Reduce current and voltage and increase MIG torch
travel speed or select a lower penetration shielding
gas.
C Increase weld metal strength or revise design.
D Decrease voltage by reducing the voltage selection
switch.
E Slow the cooling rate by preheating part to be
welded or cool slowly.
A Have an Accredited ESAB Service Agent to test then
replace the faulty component.
B Check all welding cable connections.
C Contact supply authority.
SERVICE
Service