Sealey MiGHTYMiG250 Manual page 7

ProBleM
1. Power source stops
2. no weld current
3. no weld current
4. Feed motor not working, lamp is on
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
© Jack Sealey limited
PossiBle CaUse
overheating protection activated due to overload
Rectifier blown
Bad connection between clamp & workpiece
Break in earth lead
Break in torch lead
Gear damaged or worn
Motor defective
Pressure roller improperly adjusted
dirt, copper, dust, etc, has 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 improper
Incorrect 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
Faulty electrovalve
Worn or defective gas cup (nozzle)
electrode deformed
Wire speed too slow
Torch incorrectly held
Wire weaving in weld pool
Weld current too low
Weld speed too high
Weld current too high
Weld speed too low
Arc too long
Weld current too low
Arc too long
Weld current too high
Weld speed too slow
incorrect distance of torch to workpiece
Original Language Version
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 torch
Replace gears. (Contact service agent)
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. (Section 3.10)
Check roller tension and adjust it if necessary (Section 3.13)
Clean the liner from the machine forward. Use compressed air
Replace gas cup (nozzle) and/or tip. (Section 3.10)
Clean or replace gas cup (nozzle) (Section 3.10)
Clean feed roller. (Section 6.1).
Replace feed roller. (Section 3.13)
Adjust tension. (Section 3.10)
Check settings. (Section 4)
Clean and/or grind workpiece. (Section 4.1.1)
Replace gas cup (nozzle). (Section 3.10)
open gas cylinder, regulate gas flow
Clean or replace cup. (nozzle) (Section 3.10 & 6.5)
Screen off welding site or increase gas flow
Clean and/or grind workpiece. (Section 4.1.1)
The distance from gas cup to workpiece should be 8 to 10mm
Check hoses, connections and torch assembly. (Section 3.6.2). Press the gas cup
in correction position
Clean out or replace
Replace gas cup (nozzle). (Section 3.10)
Check roller tension. (Section 3.10)
See recommendations for wire speed
Use correct torch angle
Check roller tension and adjust as needed. (Section 3.10)
Increase power and wire speed. (Section 4)
Move torch slower and weave a little more
decrease power and wire speed. (Section 4)
Move torch faster and weave less
Bring torch closer to workpiece
Increase power and wire speed. ( Section 4 )
Bring torch closer to workpiece
decrease power and wire speed. ( Section 4 )
Move torch faster
Torch distance should be 8-10mm
MIGHTYMIG250 Issue 2 (HF) 15/05/18