ESAB ESAB Welding Equipment Error Code ES011

ESAB Welding Major Arc

Model: ESAB Welding Equipment | Code: ES011

Applicable Systems

ESAB Welding Equipment

Symptoms

The welding arc is unstable, producing excessive spatter. The weld bead is irregular and the welder displays an arc stability fault.

Step 1: Check and clean all cable connections at the torch, feeder, and work clamp
Tighten to the specified torque; look for overheating discoloration
Step 2: Inspect the drive rolls for wear and verify the groove matches the wire size
Replace worn rolls and set the correct tension per the manual
Step 3: Verify the shielding gas flow rate (typically 15-25 CFM for MIG)
Check for gas leaks at all fittings using soap solution
Step 4: Measure the contact tip bore and compare to the wire diameter
Replace if bore is more than 0.5mm larger than the wire diameter

Reset: The fault clears after the root cause is corrected. Restart the welder and verify arc stability on a test coupon.

Contact tip: M6 or M8, match wire size (Replace every 8-12 hours of welding)
Drive roll: V-groove or knurled, match wire type (Replace when wire slip is detected)
Shielding gas: 75/25 Ar/CO2 for mild steel (Verify gas type for the application)

Q: How often should I replace the contact tip?
Every 8-12 hours of welding or when arc instability is noticed. Use only OEM tips to ensure bore precision.
Q: What gas flow rate should I use?
15-25 CFM for MIG, 15-20 CFM for TIG. Too high causes turbulence and air entrainment; too low gives poor coverage.
Q: What causes wire feed problems?
Worn drive rolls, incorrect tension, kinked liner, or oversized contact tip. Inspect the entire feed path.