Can gap too big or inconstant!

Possible causes:

  • blank cutting (especially development) not within tolerance
  • inconstant overlap – Z-bar worn (—> for “overlap variation“ see also here )
  • wire tension not correct
  • calibration crown inconstant (for example due to worn bearing)
  • wrong adjustment of „overtravel“ of final pusher system (see instruction manual of your welder)
  • „backlash“ in final pusher system due to worn bearing or linear guides
  • copper wire profile not correct