1. Power source stops
2. No weld current, fuses blowing.
3. No weld current
4. Feed motor not working.
5. Wire does not feed, feed roller rotates
6. Wire feeds unevenly.
7. Unstable arc.
8. Porous weld
9. electrode sticking in gas cup (nozzle)
10. Irregular weld head
11. Weld bead too narrow and raised
12. Weld bead too wide
13. Poor penetration
14. excessive penetration
15. Fuse blowing
16. Coils of wire on reel overlap, or wire is
oxidised. Coils break or fall under wheel.
17. Wire runs through torch but there is no
welding current.
Overheating protection activated due to overload
Rectifier blown
Bad connection between clamp & workpiece
Break in earth lead
Break in torch lead
Fuse blown
Gear damaged or worn
Motor defective
Pressure roller incorrectly adjusted
dirt, copper, dust, etc, have collected in torch liner
Gas cup (Nozzle) or tip defective.
deformed wire
dirt, etc, in liner
Gas cup (Nozzle) or Tip defective
Gas cup (Nozzle) spattered
Feed roller groove clogged
Feed roller groove deformed
Pressure roller tension too slight.
Incompatible settings
Impurities in weld area
Worn or defective gas cup (nozzle)
No gas
Gas cup clogged
draft blowing away shielding gas
Rusty or dirty joints
Torch too far from or at wrong angle to work
Gas leak
dirty Workpiece
Worn or defective gas cup (nozzle)
electrode deformed
Wire speed too slow
Torch incorrectly held
Wire weaving in weld pool
Weld current too high
Weld speed too low
Weld current too high
Weld speed too low
Arc too long
Weld current too high
Arc too long
Weld current too high
weld speed too slow
incorrect distance of torch to workpiece
Tension too great
Gas cup contact tip clogged
Tension to loose or tight. Coil damaged or wire twisted.
defective contactor.
Worn contacts of contactor regulator.
Regulation switch problem
Faulty rectifier.
Fault on electronic circuit of contactor.
Work cable not connected correctly.
PROBleM
POSSIBle CAUSe
ReMedY
(Numbers refer to chapter and item heading)
11. TROUBLESHOOTING
Protection automatically resets when transformer has cooled (about 15 min).
Replace rectifier.
Clean or grind contact surface and weld area.
Repair or replace earth lead.
Repair or replace torch, lead.
Replace fuse.
Replace gears.
Replace motor (Contact service agent).
Adjust tension.
Clean the liner from the machine forward. Use compressed air. If too much
dirt, replace the liner.
Replace gas cup (nozzle) and/or tip. .
Check roller tension and adjust it if necessary.
Clean the liner from the machine forward. Use compressed air.
Replace gas cup (nozzle) and/or tip.
Clean or replace gas cup (nozzle).
Clean feed roller.
Replace feed roller.
Adjust tension.
Check settings.
Clean and/or grind workpiece.
Replace gas cup (nozzle).
Open gas cylinder, regulate gas flow.
Clean or replace cup.
Screen off welding site or increase gas flow.
Clean or grind the workpiece.
The distance from gas cup to workpiece should be 8-10mm
See chapter 4 for angle. Check contact tip and nozzle.
Check hoses, connections and torch assembly..
Press the gas cup into correct position.
Replace gas cup (nozzle).
Check roller tension..
See recommendations for wire speed.
Use correct torch angle.
Check roller tension and adjust as needed.
Increase power and wire speed.
Move torch slower and weave a little more.
decrease power and wire speed.
Move torch faster and weave less.
Bring torch closer to workpiece.
Increase power and wire speed.
Bring torch closer to workpiece.
decrease power and wire speed.
Move torch faster.
Torch distance should be 8-10mm.
Release tension. (Chapter 3).
Clean gas cup and contact tip. (Chapter 5).
Reset tension. Change wire reel.
Check coil ends, change coil if necessary.
Check, clean contacts, change if oxidation is present.
Check secondary voltage for each switch setting.
disconnect rectifier from secondary, check each diode goes one way only.
If not change rectifier.
Change control module.
Connect work clamp directly to workpiece. Check wire is in good condition
and making good contact with clamp.
10.8. Gas Cup.
The gas cup must also be kept clean and free from spatter. Build up of spatter inside the gas cup can cause a short circuit at the contact tip
which will result in either the fuse blowing on the printed circuit card, or expensive machine repairs. To keep the contact tip free from spatter, we
recommend the use of Sealey anti-spatter spray (MIG/722307) available from your Sealey dealer.
10.9. Changing Fuses.
The fuse is located on the auxiliary transformer and is mainly blown for the following reasons:
Spatter collecting in the gas cup, causing contact tip to short circuit.
Wire tension is too great.
A sudden surge of current.
NOTE: It is our policy to continually improve products and as such we reserve the right to alter data, specifications and component parts without prior notice.
IMPORTANT:
No liability is accepted for incorrect use of this product.
WARRANTY:
Guarantee is 12 months from purchase date, proof of which will be required for any claim.
INFORMATION:
For a copy of our latest catalogue and promotions call us on 01284 757525 and leave your full name and address, including postcode.
01284 757500
01284 703534
Sole UK Distributor, Sealey Group,
Kempson Way, Suffolk Business Park
,
Bury St. edmunds, Suffolk,
IP32 7AR
www.sealey.co.uk
Web
Original Language Version
eleCTROMIG195.V3 Issue: 3 - 08/03/10
