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MAINTENANCE AND TROUBLESHOOTING

4 Welding trouble shooting

4.1 MIG welding trouble shooting

The following chart addresses some of the common problems of MIG welding. In all cases of
equipment malfunction, the manufacturer’s recommendations should be strictly adhered to and
followed.

NO.

Problem

Possible Reason

Suggested Remedy

Excessive

Spatter

Wire feed speed set too high

Select lower wire feed speed

Voltage too high

Select a lower voltage setting

Wrong polarity set

select the correct polarity for the

wire being used - see machine

setup guide

Stick out too long

Bring the torch closer to the work

Contaminated base metal

Remove materials like paint,

grease, oil, and dirt, including

mill scale from base metal

Contaminated mig wire

Use clean dry rust free wire. Do

not lubricate the wire with oil,

grease etc

Inadequate gas flow or too much

gas flow

Check the gas is connected, check

hoses, gas valve and torch are not

restricted. Set the gas flow

between 6-12 l/min flow rate.

Check hoses and fittings for

holes, leaks Protect the welding

zone from wind and drafts

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ADVANCEMIG 255C

Содержание ADVANCEMIG 255C

Страница 1: ...GBT INVERTER TECHNOLOGY DIRECT CURRENT OUTPUT CONSTANT CURRENT VOLTAGE LIFT TIG OPTIONAL TORCH SPOOL GUN CAPABLE POWER FACTOR CORRECTION SPIKE GENERATOR SAFE LCD SCREEN VOLTAGE REDUCTION DEVICE INTELL...

Страница 2: ...ng method 15 3 1 3 Operation of the MIG MAG Manual welding method 17 3 1 4 Wire Feed Roller Selection 18 3 1 5 Wire Installation and Set Up Guide 19 3 1 6 MIG Torch Liner Installation 22 3 1 7 MIG Tor...

Страница 3: ...3 3 7 Tig Gun switch control 56 3 4 Operation environment 57 3 5 Operation Notices 57 4 Welding trouble shooting 58 4 1 MIG weldi ng trouble shooting 58 4 2 MIG wire feed trouble shooting 60 4 3 DC T...

Страница 4: ...epair For more industrial welding solutions check out the full Strata Range from Euroquip at www strata co nz Euroquip is a market leading provider of innovative power equipment solutions to a wide ra...

Страница 5: ...peration with parameter save recall an intuitive simple setting of controls for consistent welding results Remote control spool gun connection gives effective results welding with soft wires such as a...

Страница 6: ...SW17833 Drive Roller 0 8 0 9mm knurled x 2 SW17839 Drive Roller 1 0 1 2mm ux cored x2 MSL1549 Steel liner 0 6 0 9mm 4m MSL2442 Steel liner 1 0 1 2mm x 4m 31535 Liner for Aluminium please State the le...

Страница 7: ...y Change Power Connection 5 Remote connection plug 6 Negative welding power output connection socket 7 Gas inlet connector 8 Power switch 9 Input power cable Welding machine internal view 10 Wire feed...

Страница 8: ...omatic protection functions to protect the machines from over voltage over current and over heat If any one of the above problems happens the LCD on the front panel will be display error code and outp...

Страница 9: ...the portion of the time a welding machine can weld continuously with it s rated output current within a certain time cycle 10 minutes The relation between the duty cycle X and the output welding curr...

Страница 10: ...ng current parameter can be adjusted continuously and infinitely to meet with the requirements of welding craft Rectifier Inverter Transformer Rectifier Hall Current Feedback control Single phase AC D...

Страница 11: ...ter setting interface a welding parameter and its corresponding value may be selected and set by rotating L Knob and R Knob in the interface 4 System setting interface a system parameter and its corre...

Страница 12: ...thod is selected 8 Multifunction display interface an interface displaying the contents corresponding to those selected by users such as icons of welding method welding mode and parameter parameter va...

Страница 13: ...se connection can result in the connector arcing and damaging the machine and gun connector 3 Connect the MIG power connection lead to the positive welding power output socket Note if this connection...

Страница 14: ...feed through about 150mm into the torch receptacle Check that the drive roller size is compatible with the wire diameter replace the roller if necessary 9 Align the wire into the groove of the drive r...

Страница 15: ...open the gas cylinder valve and set the required gas flow rate 13 Fit the gas nozzle to the torch head 3 1 2 Operation of MIG MAG Synergic welding method 1 Selection of the welding method 1 In the ma...

Страница 16: ...welding parameter setting interface 2 In the welding parameter setting interface rotate L Knob to select the parameter as required and rotate R Knob to set a value for the parameter Press L Knob or R...

Страница 17: ...nterface press the MENU key to enter the function selection interface 2 In the function selection interface rotate L Knob to select the MIG MAG Manual welding method and press down it for confirmation...

Страница 18: ...w much pressure can be applied and what type of drive roller is best suited to obtain optimum wire feed Solid Hard Wire like Steel Stainless Steel require a drive roller with a V shape groove for opti...

Страница 19: ...clogging in the liner and added friction that will lead to welding wire feed problems A U groove wire can also be used for flux core wire without the wire particles coming of the wire surface However...

Страница 20: ...e wire through the drive roller 6 Lock down the top pressure roller and apply and into the outlet guide tube of the wire a medium amount of pressure us ing the tension feeder adjustment knob 7 Check t...

Страница 21: ...ping and slipping at the drive rollers increase the tension if it slips 9 The weight and speed of the wire spool turning creates an inertia that can cause the spool to run on and the wire loop over th...

Страница 22: ...liner if you kink the liner it will make it no good and will require replacement 5 Carefully and slowly feed the liner in short forward movements down the cable assembly all the way through and out t...

Страница 23: ...e liner with good rigidity and flexibility and allows it to guide the welding wire smoothly through the welding cable as it bends and flex during operational use Steel liners are primarily 9 Screw dow...

Страница 24: ...r strength but it is important to make sure the liner has enough internal diameter clearance Most manufacturers will produce liners sized to match wire diameters and length of welding torch cable and...

Страница 25: ...e electrical conductivity of the welding power transfer to the wire 3 1 8 Torch Wire Feed Set Up for Aluminium Wire Blue 0 6mm 0 8mm Red 0 9mm 1 2mm Yellow 1 6mm Teflon Liners PA Liner Black 1 0mm 1 6...

Страница 26: ...Avoid kinking the liner kinking the liner will ruin it and require replacement 7 Leave the liner extending out the end of the torch neck end by 3mm 8 Place the tip holder over the end of the liner and...

Страница 27: ...euro connection 10 Install a U groove drive roller of the correct size to match the wire diameter being used 31 3 1 9 Set up installation for Spool Gun 11 Place aluminium wire onto spool holder Feed t...

Страница 28: ...3 Connect the Spool Gun control cable to the multipin receptacle on the front panel 4 Connect the MIG power connection lead to the positive welding power output socket 5 Connect the gas regulator to...

Страница 29: ...ller into the inlet guide tube Swing back and clip down the wire tension swing arm 12 Pull the trigger to drive the wire through the neck until it exits the contact tip holder 13 Close the wire feed h...

Страница 30: ...ions Clean the wire guide in the following manner Remove the welding gun s gas nozzle contact tip and contact tip s adapter With a pneumatic pistol below compressed air through the wire guide Blow the...

Страница 31: ...gun Push a new wire guide in to the gun Make sure that the wire guide enters all the way into the contact tip s adapter and that there is an O ring at the machine end of the guide Tighten the wire gu...

Страница 32: ...ur primary methods of metal transfer in MIG welding called short circuit also known as dip transfer globular transfer spray transfer and pulsed spray each of which has distinct properties and correspo...

Страница 33: ...o and exiting the contact tip The wire touches the work piece and causes a short circuit the wire heats up and begins to form a molten bead the bead separates from the end of the wire and forms a drop...

Страница 34: ...ss of base metal wire feed speed and arc voltage To follow are some basic guides to assist with your setup Gun Position Travel Direction Work Angle Gun position or technique usually refers to how the...

Страница 35: ...welds are wider and flatter allowing for minimal clean up grinding time Perpendicular Technique The wire is fed directly into the weld this technique is used primarly for automated situations or when...

Страница 36: ...or quality finished weld Stick Out Stick out is the length of the unmelted wire protruding from the end of the contact tip A constant even stick out of 5 10mm will produce a stable arc and an even cur...

Страница 37: ...t travel speed produces too little heat per mm of travel resulting in less penetration and reduced weld fusion the weld bead solidifies very quickly trapping gases inside the weld metal causing porosi...

Страница 38: ...and wetting out of the weld pool producing a weld deposit of good quality Wire types and sizes Use the correct wire type for the base metal being welded Use stainless steel wire for stainless steel al...

Страница 39: ...osity lack of fusion and slag inclusions Additionally some of the gas becomes ionised electrically charged and helps the current flow smoothly The correct gas flow is also very important in protecting...

Страница 40: ...work piece is connected to the negative socket this is known as DCEP However various electrodes require a different polarity for optimum results and careful attention should be paid to the polarity r...

Страница 41: ...ng parameter setting interface 2 In the welding parameter setting interface rotate L Knob to select the parameter as required and rotate R Knob to set a value for the parameter afterwards press L Knob...

Страница 42: ...atmospheric contamination The electrode core itself acts as filler material the residue from the flux that forms slag covering over the weld metal must be chipped away after welding The arc is initiat...

Страница 43: ...fluxing elements and deoxidizer creating a protective slag coating over the weld as it cools establishing arc characteristics adding alloying elements Covered electrodes serve many purposes in additio...

Страница 44: ...considered as the maximum which can be used without burning through the work over heating the electrode or producing a rough spattered surface The table shows current ranges generally recommended for...

Страница 45: ...d free of any moisture paint oil grease mill scale rust or any other material that will hinder the arc and contaminate the weld material Joint preparation will depend on the method used include sawing...

Страница 46: ...3 2 Operation of the TIG Lift welding method 1 Selection of the welding method 1 In the main interface press the MENU key to enter the function selection interface 2 In the function selection interfa...

Страница 47: ...tating L Knob Welding parameters available by rotating R Knob Two four Stroke 2T 4T Pre flow 0 2 S Down Slope 0 10 S Post Flow 0 10 S 3 Setting of welding current 1 Press the ENTER key to enter the we...

Страница 48: ...ward so that the Tungsten Electrode touches the work piece 7 Now rotate the Gas Cup in the reverse direction to lift the Tungsten electrode from the work piece to create the arc 8 Release the trigger...

Страница 49: ...nert gas flow to prevent contamination of the tungsten molten pool and weld area When the TIG arc is struck the inert gas is ionized and superheated changing it s molecular structure which converts it...

Страница 50: ...must maintain a short arc length great care and skill are required to prevent contact between the electrode and the work piece Similar to Oxygen Acetylene torch welding Tig welding normally requires t...

Страница 51: ...a weld pool of the desired size Once the weld pool is established tilt the torch at about a 75 angle and move smoothly and evenly along the joint The filler metal is introduced to the leading edge of...

Страница 52: ...tungsten should not get in contact with open cuts or wounds The more significant danger to welders can occur when thorium oxide gets into the lungs This can happen from the exposure to vapours during...

Страница 53: ...n a minimum of 97 80 percent tungsten and 1 30percent to 1 70 percent lanthanum and are known as 1 5 percent lanthanated These electrodes have excellent arc starting a low burn off rate good arc stabi...

Страница 54: ...out diamond wheels such as aluminium oxide wheels can lead to jagged edges imperfections or poor surface finishes not visible to the eye that will contribute to weld inconsistency and weld defects Alw...

Страница 55: ...ibility of the point falling off into the weld pool Electrode Included Angle Taper DC Welding Tungsten electrodes for DC welding should be ground longitudinally and concentrically with diamond wheels...

Страница 56: ...mm 500 25 08 50 05 100 1 6mm 800 30 10 70 10 140 2 4mm 800 35 12 90 12 180 2 4mm 1 100 45 15 150 15 250 3 2mm 1 100 60 20 200 20 300 3 2mm 1 500 90 25 250 25 350 3 3 7 Tig Gun switch control Gun switc...

Страница 57: ...50 60Hz 110V 220V 10 Before operation none concerned people should not be around the working area and especially children Do not watch the arc in unprotected eyes Ensure good ventilation of the machi...

Страница 58: ...ing Wrong polarity set select the correct polarity for the wire being used see machine setup guide Stick out too long Bring the torch closer to the work Contaminated base metal Remove materials like p...

Страница 59: ...le Missing or damaged gas diffuser Replace the gas diffuser Mig torch euro connect o ring missing or damaged Check and replace the o ring 3 Wire stubbing during welding Holding the torch too far away...

Страница 60: ...ugh heat input Select a higher voltage range and or adjust the wire speed to suit Reduce travel speed Contaminated base metal Remove materials like paint grease oil and dirt including mill scale from...

Страница 61: ...ong size liner Install the correct size liner Blocked or worn inlet guide tube Clear or replace the inlet guide tube Wire misaligned in drive roller groove Locate the wire into the groove of the drive...

Страница 62: ...Raise the torch so that the tungsten is off of the work piece 2 5mm Touching the filler wire to the tungsten Keep the filler wire from touching the tungsten during welding feed the filler wire into th...

Страница 63: ...f the tungsten and re sharpen the tungsten Poorly prepared tungsten Grind marks should run lengthwise with tungsten not circular Use proper grinding method and wheel Contaminated base metal or filler...

Страница 64: ...xcessive Spatter Amperage too high Decrease the amperage or choose a larger electrode Arc length too long Shorten the arc length 4 Weld sits on top lack of fusion Insufficient heat input Increase the...

Страница 65: ...e Poor welding technique Use the correct welding technique or seek assistance for the correct technique Poor joint preparation and or joint design Check the joint design and fit up make sure the mater...

Страница 66: ...listen if the arc welding machine has shaking whistle calling or peculiar smell If there is one of the above problems find out the reason and clear it If you can t find out the reason please contact...

Страница 67: ...tion is thought to be damaged and need to change and need to change or strengthen insulation 5 2 Troubleshooting Before the welding machines are dispatched from the factory they have already been test...

Страница 68: ...Check the PCB Wire reel works The press wheel is loosen or weld wire skids Press it tightly again The wheel doesn t fit with the diameter of weld wire Change the wheel Wire reel damaged Change it Wire...

Страница 69: ...n E13 Under voltage Yellow lamp thermal protection always on E14 Over voltage Yellow lamp thermal protection always on E15 Over current Yellow lamp thermal protection always on E16 Wire feeder over lo...

Страница 70: ...MAINTENANCE AND TROUBLESHOOTING 5 4 Electrical schematic drawing 70 www strata co nz ADVANCEMIG 255C...

Страница 71: ...not wear wet or damaged gloves 6 Protect yourself from electric shock Do not use the welder outdoors Insulate yourself from the work piece and the ground Use non flammable dry insulating material if...

Страница 72: ...manual before installing oper ating or servicing this equipment Have all instal lation operation maintenance and repair work performed by qualified people If an operator does not strictly observe all...

Страница 73: ...ive electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electri cally live whenever the output is on The input power circuit and machine internal circuits are als...

Страница 74: ...not breathe the fumes 2 If inside ventilate the area and or use an exhaust at the arc to remove welding fumes and gases 3 If ventilation is poor use an approved air supplied respirator 4 Read the Saf...

Страница 75: ...he flying sparks and hot metal weld spatter work piece and hot equipment can cause fires and burns Accidental contact of electrode or welding wire to metal objects can cause sparks overheating or fire...

Страница 76: ...lify for full warranty support your product must be registered Product not registered with Euroquip is supported by a base 12 month warranty only Spare parts and technical support will not be availabl...

Страница 77: ...77 www strata co nz ADVANCEMIG 255C...

Страница 78: ...78 www strata co nz ADVANCEMIG 255C...

Страница 79: ...79 www strata co nz ADVANCEMIG 255C...

Страница 80: ...ve you as our customer and will strive to provide you with the best service and reliability in the industry This product is backed by our extensive warranty To locate your nearest distributor or servi...

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