Polarity And Process-Mismatch Matrix

This annex is for faults caused by wrong polarity, wrong process state, or incomplete process changeover.

Use it with:

MIG and flux-cored machines
multiprocess platforms
stick/TIG-capable platforms

Core rule

If one process works and another does not, verify process state and polarity before suspecting hardware.

Symptom matrix

Symptom	Most likely mismatch	High-value first move
Solid-wire MIG has heavy spatter and poor penetration	wrong polarity or gas/process mismatch	confirm DCEP and gas setup
Flux-cored welds poorly after solid wire use	polarity not changed back	confirm DCEN or correct process polarity
Stick or TIG no output after MIG use	leads not moved, wrong process selected	return to process baseline and move leads correctly
TIG poor after process switch	wrong mode, remote mismatch, gas path not established	verify TIG mode, remote method, and gas path

By process

MIG and flux-cored

Solid wire and self-shielded flux-cored do not share the same polarity assumptions.
After changing wire type, verify polarity before touching wire speed or voltage settings.

Multiprocess

Multimatic, POWER MIG 210 MP, POWER MIG 215 MPi, Rebel, and similar units often get misdiagnosed after process changes.
Verify active process, accessory branch, output-lead placement, and polarity as one group.

Stick and TIG

If MIG works and stick or TIG do not, the machine may be fine and the process path may simply be wrong.
A good baseline test in one process is more valuable than guessing across all processes.

Common false diagnoses

"machine is weak" when MIG polarity is wrong
"TIG start circuit is bad" when the machine is still effectively set up for another process
"multiple-process failure" when the process change was incomplete

Escalate sooner when

the machine remains abnormal after full process and polarity normalization
multiple process branches fail on a clean baseline
control behavior remains abnormal independent of process setup

Source posture

This annex is synthesized from MIG, TIG, stick, and multiprocess guides in this repository.
Exact polarity and lead-placement requirements should still be confirmed in the affected machine's manual.