CIGWELD 255 - Common Welding Problems & Remedies

TRANSMIG 225, 255 MIG Power Source, 255 2R MIG Wirefeeder
28 Sep 16, 2008
14.04 Welding Problems
FAULT
CAUSE
REMEDY
1
Undercut
A
B
C
Welding arc voltage too high.
Incorrect torch angle
Excessive heat input
A
B
C
Reduce voltage by reducing the Voltage
Control switch positions or turn the
Wirespeed control knob anticlockwise.
Adjust angle
Increase the torch travel speed or
reduce welding current by reducing the
Voltage Control switch positions and turn
the Wirespeed control knob anti-
clockwise.
2
Lack of penetration
A
B
C
Welding current too low
Joint preparation too narrow or gap too
tight
Shielding gas incorrect
A
B
C
Increase welding current by increasing
the Wirespeed control knob clockwise
and increasing Voltage Control switch
positions.
Increase joint angle or gap
Change to a gas which gives higher
penetration
3
Lack of fusion
Arc voltage to low
Increase Arc voltage by increasing the
Voltage Control switch positions.
4
Excessive spatter
A
B
Arc voltage too high
Arc voltage too low
A
B
Lower voltage by reducing the Voltage
Control switch positions or turn the
Wirespeed control knob anti-clockwise.
Raise voltage by increasing the Voltage
Control switches or turn the Wirespeed
control knob clockwise.
5
Irregular weld shape
A
B
C
D
Incorrect voltage and current settings.
Convex, Arc voltage too low
Concave, voltage too high
Wire is wandering
Incorrect shielding gas
Insufficient or excessive heat input
A
B
C
D
Adjust voltage and current by adjusting
the Voltage Control switch positions and
the Wirespeed control knob.
Replace contact tip
Check gas selection
Adjust the Wirespeed control knob or the
Voltage Control switch.
6
Arc does not have a crisp
sound that short arc
exhibits when the
wirefeed speed and
voltage are adjusted
correctly
The MIG torch has been connected to
the wrong voltage polarity on the front
panel
Connect the MIG torch to the positive
welding terminal (+) for solid wires and
gas shielded flux cored wires.
7
Weld cracking
A
B
C
D
E
Weld beads too small
Weld penetration narrow and deep
Excessive weld stresses
Excessive voltage
Cooling rate too fast
A
B
C
D
E
Decrease torch travel speed
Reduce current and voltage and
increase the MIG Torch travel speed or
select a lower penetration shielding gas.
Increase weld metal strength or revise
design
Decrease voltage by reducing the
Voltage Control switches.
Slow the cooling rate by preheating part
to be welded or cool slowly.
8
Cold weld puddle
A
B
C
D
Faulty rectifier unit
Loss of a phase in the Mains supply
voltage.
Loose welding cable connection.
Low Mains supply voltage
A
B
C
D
Have an Accredited CIGWELD Service
Agent test then replace the faulty
component.
Check mains power
Check all welding cable connections.
Contact supply authority