Tweco 500SP PowerMaster Automation - Manual (Page 71)

POWERMASTER 400SP, 500SP AUTOMATION
March 16, 2007 7-3
7.03 Welding Process Troubleshooting Guide
Symptom Cause Remedy
Gas mixture in the cylinder has separated due to lack
of use Place protective cap used for storage and
transport on cylinder then carefully disconnect
the cylinder from the welder and lay it down on
the floor. Carefully roll it back and forth to re-
mix the gas
Wire is contaminated with oil or the wire quality is
uncertain Contact wire manuafacturer / supplier.
Keep the wire covered
Work piece is contaminated with grease or oil Degrease with mineral spirits, etc to remove
contaminates
Poor current transfer to the wire at the contact tip Use a copper or brass jump liner in the
conductor tube to improve current transfer to
the wire
Stanless steel weld has
a dark burnt finish Arc length control (58) has been adjusted too high Reduce arc length, control (58)
Inadequate gas coverage Increase gas flow by 10% and check again.
Shield arc from drafts.
Hold nozzle closer to the work.
Replace the damaged nozzle to center contact
tip in nozzle
Wire is contaminated with oil Contact wire manuafacturer / supplier.
Keep the wire covered
Work piece is contaminated with grease or oil Degrease with mineral spirits, etc to remove
contaminates
Poor current transfer to the wire at the contact tip Use a copper or brass jump liner in the
conductor tube to improve current transfer to
the wire
Weld performance is
very poor or high
spatter levels Incorrect wire / gas combination selected Set the correct gas / wire combination
Improper work lead connection Reconnect work lead
Contact tip is worn with an oval shape hole or
contact tip is black Replace contact tip
Contact tip is loose Tighten contact tip
Material build-up in torch liner Replace torch liner
Contact tip is worn or damaged Replace contact tip
Varying arc length
when welding
Poor edge wetting on
stainless steel welds
Dirty aluminum welds
Poor weld starts