Maintenance - Sealey POWERMIG3525 Instructions Manual

10. MAINTENANCE

 WARNING! Ensure the unit is disconnected from the mains
power supply before performing any maintenance or service.
10.1 Regularly check all welding cables and secondary terminals to ensure
they are in good order and connected correctly, also check during
welding to ensure they are not overheating.
10.2 Check that the gas hose connections are tight and that there are no
gas leaks.
10.3 Wire feed unit.
Check the wire feed unit at regular intervals. The feed roller wire guide
plays an important part in obtaining consistent results. Poor wire
feeding affects welding. Clean the rollers weekly, especially the feed
roller groove, removing all dust deposits from the feeder area.
10.4 Changing Feed Roller / Rollers IMPORTANT: Set up the feed rollers
according to the wire size required for the job in hand. Refer to section 6.
10.5 Torch
Protect torch cable assembly from mechanical wear. Also do not allow
the torch or its cable to come into contact with hot surfaces, especially
a hot workpiece as this would cause the insulating materials to melt,
making the torch unsafe and unusable.
- Make regular checks on the gas pipe and connector seals;
- Every time the wire reel is changed, blow out the wire-guide hose
using dry compressed air (max. 5 bar) to make sure it is not damaged;
- Before using the welding machine, always check the torch terminal
parts for wear and make sure they are assembled correctly: nozzle,
contact pipe, gas diffuser.
10.6 Contact Tip (to remove the tip refer to section 6.3 and fig.16).
The contact tip is a consumable item and must be replaced when the
hole becomes enlarged or oval. The contact tip MUsT be kept free
from spatter to ensure an unimpeded flow of gas.
10.7 Gas Cup (to remove the tip refer to section 6.3 and fig.16).
The gas cup must also be kept clean and free from spatter. Build up
Environmental Protection.
Recycle unwanted materials instead of disposing of them as waste. All tools, accessories and packaging
should be sorted, taken to a recycle centre and disposed of in a manner which is compatible with the
environment.
WEEE REGULATIONS. Dispose of this product at the end of its working life in compliance with the EU
Directive on Waste Electrical and Electronic Equipment. When the product is no longer required, it must be
disposed of in an environmentally protective way.
© Jack Sealey Limited
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.
10.8 Changing Fuses
The fuses are located on the back panel of the main welding unit and
are 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.
10.9 INTERNAL MAINTENANCE / INSPECTION
INTERNAL INSPECTION AND MAINTENANCE OPERATIONS
SHOULD BE CARRIED OUT ONLY AND EXCLUSIVLY BY SKILLED
OR AUTHORISED ELECTRICAL/MECHANICAL TECHNICIANS.
WARNING BEFORE REMOVING THE WELDING MACHINE PANELS
AND WORKING INSIDE THE MACHINE MAKE SURE THE
WELDING MACHINE IS SWITCHED OFF AND DISCONNECTED
FROM THE MAIN POWER SUPPLY OUTLET.
If checks are made inside the welding machine while it is live, this
may cause serious electric shock due to direct contact with live parts
and/or injury due to direct contact with moving parts.
- Inspect the welding machine regularly, with a frequency depending
on use and the dustiness of the environment, and remove the dust
deposited on the transformer, reactance and rectifier using a jet of dry
compressed air (max. 10 bar).
- Do not direct the jet of compressed air on the electronic boards;
these can be cleaned with a very soft brush or suitable solvents.
- At the same time make sure the electrical connections are tight and
check the wiring for damage to the insulation.
- At the end of these operations re-assemble the panels of the welding
machine and screw the fastening screws right down.
- Never, ever carry out welding operations while the welding machine
is open.
Original Language Version
POWERMIG3525, POWERMIG3530 Issue: 3 (SP) -18/07/13