An experienced welder is using FCAW-G to weld a critical component with an E71T-1 electrode. The welding machine consistently triggers the overcurrent protection (trip). The wire feed speed is set to 10 m/min (390 ipm) and the voltage to 28V, and the contact tip is new, but the power cable is noticeably warm. What is the most probable cause of the tripping?

Question: An experienced welder is using FCAW-G to weld a critical component with an E71T-1 electrode. The welding machine consistently triggers the overcurrent protection (trip). The wire feed speed is set to 10 m/min (390 ipm) and the voltage to 28V, and the contact tip is new, but the power cable is noticeably warm. What is the most probable cause of the tripping?

Answer options:

• The shielding gas flow rate is set too low, causing excessive heat.
• The electrode wire diameter is too small for the set parameters. ✅ The duty cycle of the welding machine is being exceeded.
• The polarity is incorrectly set to DCEN (Direct Current Electrode Negative).

Correct answer: The duty cycle of the welding machine is being exceeded.

Explanation: An overcurrent trip, especially with a warm power cable, strongly indicates that the welding machine's duty cycle is being exceeded. The machine is being operated at an output current or for a duration that is too high relative to its rated capacity, leading to overheating and thermal protection activation. While incorrect wire diameter or low gas could cause issues, they are less likely to directly cause an overcurrent trip compared to exceeding duty cycle.