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Monitor Troubleshooting Guide

Your guide to correcting the most common resistance welding issues

Resistance welding can be a challenging process to master, and even experienced welders run into issues from time to time. Nothing can be more frustrating than an inconsistent or faulty weld, which can cause costly production downtime. Knowing the root cause and how to fix it can be even more difficult. That’s where the “Resistance Welding Troubleshooting Guide” comes in. This guide is a comprehensive resource that will help you diagnose and solve issues you may be having with projection or spot welding. It covers everything from common conditions you might encounter to possible causes and the corrective actions you should take to improve your welding. Whether you’re a seasoned pro or a novice in the field, this guide is an essential tool to have in your arsenal.

PROJECTION & SPOT WELDS

Screen

Condition/Diagnosis

Possible Causes

Corrective Action

Thickness

Exceeds (HL)

Fit-up problem

identify and correct

Electrodes damaged

Dress or replace as needed

Exceeds (LL)

Workpiece damaged or missing

Identify and correct

Electrodes worn


Replace electrodes and/or rezero linear transducer

Force


Exceeds HL

Force is too high

Check head for binding; decrease pressure

Exceeds LL

Force is too low

Check head for binding; increase pressure

Varies widely

Friction in head

Clean/repair/lubricate as required

Current

Exceeds HL

Problem with machine connections or control regulation

Check machine connections/tune control settings/widen limits as required

Exceeds LL

Voltage

Exceeds HL

Current set too high

Decrease Current setting

Force is too low

Check head for binding; increase pressure

Secondary resistance high

Clean connections; replace cables, tips

Exceeds LL

Current set too low

Increase Current setting

Force is too high

Check head for binding; decrease pressure

Conductance

Exceeds HL

Force is too high

Check head for binding; decrease pressure

Secondary shorted

Check connections, cables, shunts, etc.

Exceeds LL

Fit-up problem

Identify and correct

Force is too low

Check head for binding; increase pressure

Secondary resistance high

Clean connections; replace cables, tips

Power

Exceeds HL

Current set too high

Decrease Current setting

Force is too low

Check head for binding; increase pressure

Exceeds LL

Current set too low

Increase Current setting

Force is too high

Check head for binding; decrease pressure

PROJECTION WELDS

DISPLACEMENT

SPOT WELDS

Condition/Diagnosis

Possible Causes

Corrective Action

Possible Causes

Condition/Diagnosis

Expulsion

Weld is too hot

Force is too low

Check head for binding; increase pressure

Force is too low

Expulsion

Weld is too hot

Current set too high

Decrease Current setting

Current set too high

Electrodes damaged

Dress or replace as needed

Electrodes damaged

Exceeds LL Weld may still be acceptable

Several

Lower LL / Raise HL or take no action

Several

Exceeds LL Weld may still be acceptable

No resistance welding challenge is too complex for our experts to help you with. Speak to our team in a FREE consultation to see what WeldComputer can do for you.

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