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