Troubleshooting

The problems and the possible causes listed are not definitive, but suggest some typical situations that may turn up during normal use of the welding system. For further information and assistance, contact your nearest Kemppi service workshop.

If you have received an error code, refer also to Error codes.

General:

The welding system does not power up

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Check that the mains cable is plugged in properly.

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Check that the mains switch of the power source is at the ON position.

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Check that the mains power distribution is on.

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Check the mains fuse and/or the circuit breaker.

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Check that the earth return cable is connected.

The welding system stops working

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The torch may have overheated. Wait for it to cool down.

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Check that none of the cables is loose.

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The power source may have overheated. Wait for it to cool down and see that the cooling fans work properly and the air flow is unobstructed.

Welding torch:

The torch overheats

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Make sure the torch body is properly connected.

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Make sure that the welding parameters are within the range of the welding torch. If different torch components have separate limits for the maximum current; the lower one of these is the maximum current that can be used.

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Make sure the coolant circulation is working normally (see the coolant circulation warning LED on the power source).

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Measure the coolant circulation speed: detach the coolant output hose from the cooler unit when the power source is on, and let the coolant run into a measurement cup. The circulation must be at least 0.5 l/min.

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Make sure you are using original Kemppi consumable and spare parts. Incorrect spare part materials may also cause overheating.

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Make sure the connectors are clean, undamaged and properly fastened.

Weld quality:

Dirty and/or poor weld quality

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Check that the shielding gas has not run out.

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Check that the shielding gas flow is unobstructed.

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Check that the gas type is correct for the application.

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Check the polarity of the torch/electrode.

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Check that the welding procedure is correct for the application.

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Check that the filler material is correct type/diameter for the application and clean

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Check that the electrode is correct size/type and correctly shaped for the application

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Check that the base material is clean

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Check that the groove type is correct for the application.

Tip: For checking the correct welding settings, you can also use Weld Assist.

Varying welding performance

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Check that the welding torch is physically intact and the nozzle is clear of any obstructions.

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Check that the welding torch is not overheating.

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Check that the earth return clamp is properly attached to a clean surface of the workpiece.