WELDSKILL 200AC/DC INVERTER
BASIC WELDING GUIDE 4-12 Manual 0-5207
4.02 Stick (MMAW) Welding Troubleshooting
FAULT CAUSE REMEDY
1 Welding current
varying
ARC FORCE control knob
is set at a value that
causes the welding current
to vary excessively with
the arc length.
Reduce the ARC FORCE control knob until weld-
ing current is reasonably constant while prohibit-
ing the electrode from sticking to the work piece
when you “dig” the electrode into the workpiece.
2 A gap is left by
failure of the weld
metal to fill the
root of the weld.
A Welding current too low A Increase welding current.
B Electrode too large for
joint.
B Use smaller diameter electrode.
C Insufficient gap. C Allow wider gap.
3 Non-metallic par-
ticles are trapped
in the weld metal.
A Non-metallic particles may
be trapped in undercut
from previous run.
A If a bad undercut is present clean slag bout and
cover with a run from a smaller gauge electrode.
B Joint preparation too
restricted.
B Allow for adequate penetration and room for
cleaning out the slag.
C Irregular deposits allow
slag to be trapped.
C If very bad, chip or grind out irregularities.
D Lack of penetration with
slag trapped beneath weld
bead.
D Use smaller electrode with sufficient current to
give adequate penetration. Use suitable tools to
remove all slag from comers.
E Rust or mill scale is pre-
venting full fusion.
E Clean joint before welding.
F Wrong electrode for posi-
tion in which welding is
done.
F Use electrodes designed for position in which
welding is done, otherwise proper control of slag
is difficult.
Figure 1-Example of insufficient gap or incorrect sequence
4 A groove has been
formed in the base
metal adjacent to
the toe of a weld
and has not been
filled by the weld
metal (undercut).
A Welding current is too
high.
A Reduce welding current.
B Welding arc is too long. B Reduce the length of the welding arc.
C Angle of the electrode is
incorrect.
C Electrode should not be inclined less than 45° to
the vertical face.
D Joint preparation does not
allow correct electrode
angle.
D Allow more room in joint for manipulation of the
electrode.
E Electrode too large for
joint.
E Use smaller gauge electrode.
F Insufficient deposit time at
edge of weave.
F Pause for a moment at edge of weave to allow
weld metal buildup.
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