ESAB CIGWELD XF190 Operating Manual page 47

BASIC MIG (GMAW) WELDING TROUBLESHOOTING
FAULT CAUSE
1 Undercut A Welding arc voltage too high
B Incorrect gun angle
C Excessive heat input
2 Lack of penetration A Welding current too low
B Joint preparation too narrow or gap
C Incorrect shielding gas
3 Lack of fusion
4 Excessive spatter A Voltage too high
B Voltage too low
5 Irregular weld shape A Incorrect voltage and current settings.
B Wire is wandering.
C Incorrect shielding gas
D Insufficient or excessive heat input
6 Weld cracking A Weld beads too small
B Weld penetration narrow and deep
C Excessive weld stresses
D Excessive voltage
E Cooling rate too fast
7 Cold weld puddle A Loose welding cable connection.
B Low primary voltage
C Fault in power source
8 Arc does not have a
crisp sound that short
arc exhibits when the
Wire Feed Speed and
voltage are adjusted
correctly.
too tight
Voltage too low
Convex, voltage too low. Concave,
voltage too high.
The MIG Gun has been connected to
the wrong voltage polarity on the front
panel.
OPERATING MANUAL
REMEDY
A Decrease voltage or increase the Wire Feed Speed.
B Adjust angle.
C Increase the gun travel speed and/or decrease welding
current by decreasing the voltage or decreasing the Wire
Feed Speed.
A Increase welding current by increasing Wire Feed
Speed and increasing voltage.
B Increase joint angle or gap.
C Change to a gas which gives higher penetration.
Increase voltage.
A Decrease voltage or increase the Wire Feed Speed
control.
B Increase the voltage or decrease Wire Feed Speed.
A Adjust voltage and current by adjusting the voltage
control and the Wire Feed Speed control.
B Replace contact tip.
C Check shielding gas.
D Adjust the Wire Feed Speed control or the
voltage control.
A Decrease travel speed.
B Reduce current and voltage and increase MIG Gun trav-
el speed or select a lower penetration shielding gas.
C Increase weld metal strength or revise design
D Decrease voltage.
E Slow the cooling rate by preheating part to be welded
or cool slowly.
A Check all welding cable connections.
B Contact supply authority.
C Have an Accredited CIGWELD Service Provider to test
then replace the faulty component.
Connect the MIG Gun to the positive (+) welding terminal
for most solid wires and gas shielded flux cored wires.
Connect MIG Gun to the negative (-) welding terminal
for most Gasless Wires. Refer to the electrode wire
manufacturer for the correct polarity.
BLUEVENOM XF190
CIGWELD.COM.AU | 47