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6.3.
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 metallic dust deposits. Whilst the feed roller is
removed blow compressed air through the wire path to remove any debris.
6.4.
Changing Wire Feed Roller IMPORTANT: (Refer to section 3.21) Make sure that the wire feed rollers, the wire guide hose and the contact tip of
the torch match the diameter and type of wire to be used and ensure that these parts are fitted correctly.
6.5.
Contact Tip. 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.
6.6.
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.
7. TROUBLESHOOTING
PROBLEM
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 bead.
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 gun but there is no
welding current.
POSSIBLE CAUSE
Overheating protection activated due to overload.
Rectifier blown.
Bad connection between clamp & workpiece.
Break in earth lead.
Break in gun lead.
Fuse blown.
Gear damaged or worn.
Motor defective.
Pressure roller incorrectly adjusted.
Dirt, copper, dust, etc, have collected in gun liner.
Gas cup (nozzle) or tip defective.
Deformed wire.
Dirt, etc, guide hose/swan neck.
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.
Weld speed too low.
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.
REMEDY
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 gun, lead.
Replace fuse.
Replace gears.
Replace motor (contact service agent).
Adjust tension.
Clean the liner using compressed air. If too much dirt, replace the swan neck.
Replace gas cup (nozzle) and/or tip.
Check roller tension and adjust it if necessary.
Clean the guide hose/swan neck using 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.
Check hoses, connections and torch assembly.
Clean.
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 gun slower and weave a little more.
Decrease power and wire speed.
Move gun faster and weave less.
Bring gun closer to workpiece.
Increase power and wire speed.
Bring gun closer to workpiece.
Decrease power and wire speed.
Move gun faster.
Torch distance should be 8-10mm.
Release tension (see Section 3).
Clean gas cup and contact tip (see Section 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.
MIG/SGT15.V2 & MIG/SGT15/12.V2 - 1 - 21/12/07
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