TROUBLE SHOOTING GUIDE
FAULT REASON REMEDY
Excessive
Wire
Consumption
Inadequate / excessive gas
flow
Test for correct gas flow, use the gas
flow charts as a reference.
Excessive heating of torch Check for proper contact.
Wire oxidation during
cooling
Depending on the welding application,
keep the gas flowing for 5 to 15 sec-
onds after stopping the arc.
Using shield gas containing
excessive oxygen or mois-
ture
Change to the proper purity of the gas
required.
Contami-
nated Wire
Base metal is dirty or
greasy
For surface cleanliness use the appro-
priate chemical cleaners e.g. alcohol,
wire brush or abrasive.
Contaminant elements that
out gas may exist within
the base material itself
If possible, improve the base material
or modify the welding parameters to
accommodate out gassing effect.
Check for wire
contamination
Remove the contaminated portion of
the wire.
Cable Layout In so far as possible, try to
layout cables from power
supply to welding torch as
straight as possible
Occasionally, cables are coiled like a
garden hose. The coil becomes a giant
inductor causing resistance that re-
duces starting energy. Inductance ef-
fects can also be caused by having
welding power cables very close to
grounded steel plates.
Grounding
Problems
Make sure clamps and
clamp inserts are clean of
oxidation. Make sure
ground clamp is not worn.
Oxidation and/ or worn equipment can
cause poor ground between part and
clam/ inserts which may hinder arc
starting, wander and other inconsisten-
cies.
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