TROUBLESHOOTING
MOTOMAN 5-5 Spot Welding Manual for Medar
5.4 Tips for Producing Quality Welds
Follow these tips to avoid weld problems and produce consistent, high-quality
welds:
• Make sure the electrodes you are using are suitable for the job. Select an
electrode tip suitable for the thickness of the stock you are welding. Do not
use a small tip for welding heavy gauge materials or a large tip on thin
materials.
• Use standard electrodes whenever possible. Avoid using special purpose or
offset tips if the job can be handled with a standard straight tip.
• Do not weld using unidentified electrodes or electrode materials.
• Use flow indicators to assure that the proper amount of cooling water flows
through the electrodes (typically 1.5 gallons per minute). Always adjust the
cooling water to the appropriate pressure before beginning to weld.
• To avoid leaks and loss of water pressure, make sure the water hose firmly
fits the water connection nipples. Before welding, check for leaky, broken,
or clogged water connections.
• Make sure the holder’s internal water cooling tube projects into the tip water
hole to within one-fourth inch of the bottom of the tip hole.
• Always use electrode holders with adjustable internal water cooling tubes.
When switching to a different tip length, adjust the holder’s internal water
cooling tube to the appropriate height.
• Do not use holders that have leaky or deformed tapers.
Cracked or poor weld nugget Weld force too low.
Material is dirty or unsuitable for welding.
Follow up is poor.
Hold time is too short.
Discolored weld nugget Weld force too low, weld current too high, or weld time too long.
Electrode face too small.
Fit up is poor.
Material is dirty.
Follow up is poor.
No weld Weld force is too high.
Weld current is too low.
Weld time is too short.
Electrode face is too large.
Weld spacing is too close.
Material is dirty or unsuitable for welding.
Transformer tap set to OFF.
“No Weld” switch is set to NO WELD.
Pressure switch is OPEN.
Temperature limit switch is OPEN.
Electrodes are not contacting work.
Electrodes/holders are insulated.
Shunt path is in secondary.
Excess ferrous material in throat.
Emergency Stop switch OPEN.
Table 5-3 Welding Troubleshooting Chart - continued
Problem Probable Causes
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