Product Manual

FIREPOWER FP 95 FC SERVICE
Manual 0-5122 5-2 Service
5.04 Welding Problems
FAULT CAUSE REMEDY
1
Undercut. A Welding arc voltage too
high.
A Reduce voltage by reducing the voltage selection
switch position or increase the wire feed speed.
B Incorrect torch angle B Adjust angle
C Excessive heat input C Increase the torch travel speed and/or reduce weld-
ing current by reducing the voltage selection switch
position or reducing the wire feed speed.
2
Lack of penetration. A Welding current too low A Increase welding current by increasing wire feed
speed and increasing voltage selection switch posi-
tion.
B Joint preparation too nar-
row or gap too tight
B Increase joint angle or gap
3
Lack of fusion. Voltage too low Increase voltage by increasing voltage selection
switch position.
4
Excessive spatter. A Voltage too high A Lower voltage by reducing the voltage selection
switch or increase wirespeed control.
B Voltage too low B Raise voltage by increasing the voltage selection
switch or reduce wirespeed control.
5
Irregular weld shape. A Incorrect voltage and
current settings. Convex =
voltage too low. Concave
= voltage too high.
A Adjust voltage and current by adjusting the voltage
selection switch and the wirespeed control.
B Wire is wandering B Replace contact tip
C Insufficient or excessive
heat input
D Adjust the wirespeed control or the voltage selec-
tion switch
6
Weld cracking A Weld beads too small A Decrease travel speed
B Weld penetration narrow
and deep
B Reduce current and voltage and increase MIG torch
travel speed or select a lower penetration shielding
gas.
C Excessive weld stresses C Increase weld metal strength or revise design.
D Excessive voltage D Decrease voltage by reducing the voltage selection
switch.
E Cooling rate too fast E Slow the cooling rate by preheating part to be
welded or cool slowly.
7 Cold weld puddle A Faulty rectifier unit A Have an Accredited ESAB Service Agent to test then
replace the faulty component.
B Loose welding cable con-
nection.
B Check all welding cable connections.
C Low Primary Voltage C Contact supply authority.
Table 5-1: Welding Problems