Sealey POWERMIG6025S User Manual download pdf (Page 10)

11. TROUBLESHOOTING

PROBLEM POSSIBLE CAUSE

REMEDY

(Numbers refer to chapter and item heading)

1. Power source stops Overheating protection activated due to overload Protection automatically resets when transformer has cooled (about 15 min).

2. No weld current Rectifier blown Replace rectifier.

3. No weld current

Bad connection between clamp & workpiece

Break in earth lead

Break in torch lead

Clean or grind contact surface and weld area.

Repair or replace earth lead.

Repair or replace torch, lead.

4. Feed motor not working, lamp is on

Fuse blown

Gear damaged or worn

Motor defective

Replace fuse 1.5 amp.

Contact service agent.

Replace motor (Contact service agent).

5. Wire does not feed, feed roller rotates

Pressure roller improperly adjusted

Dirt, copper, dust, etc, have collected in torch liner

Gas cup (Nozzle) or tip defective.

Faulty speed control / Deformed wire

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. (See section 5.7).

Check roller tension and adjust it if necessary (See section 6.8)

6. Wire feeds unevenly.

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

Clean the liner from the machine forward. Use compressed air.

Replace gas cup (nozzle) and/or tip. (See fig.16).

Clean or replace gas cup (nozzle) (See fig.16).

Clean feed roller. (See section 6.4).

Replace feed roller. (See section 6.4).

Adjust tension. (See section 6.6).

7. Unstable arc.

Incorrect settings

Impurities in weld area

Worn or defective gas cup (nozzle)

Check settings. (See section 9.4).

Clean and/or grind workpiece. (See section 9.2.1).

Replace gas cup (nozzle). (See fig.16).

8. Porous weld

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

Open gas cylinder, regulate gas flow.

Clean or replace cup. (See fig.16).

Screen off welding site or increase gas flow.

Clean or grind the workpiece (See section 9.2.1).

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. (See sections 5.5 & 5.6).

Press the gas cup into correct position.

9. Electrode sticking in gas cup (nozzle)

Worn or defective gas cup (nozzle)

Electrode deformed

Wire speed too slow

Replace gas cup (nozzle). (See fig.16).

Check roller tension. (See section 6.6 ).

Adjust wire feed rate control. (See section 8.2 ).

10. Irregular weld bead

Torch incorrectly held

Wire weaving in weld pool

Use correct torch angle.

Check roller tension and adjust as needed. (See section 6.6).

11. Weld bead too narrow and raised

Weld current too high

Weld speed too low

Increase power and wire speed.

Move torch slower and weave a little more.

12. Weld bead too wide

Weld current too high

Weld speed too low

Arc too long

Decrease power and wire speed.

Move torch faster and weave less.

Bring torch closer to workpiece.

13. Poor penetration

Weld current too high

Arc too long

Increase power and wire speed.

Bring torch closer to workpiece.

14. Excessive penetration

Weld current too high

weld speed too slow

incorrect distance of torch to workpiece

Decrease power and wire speed.

Move torch faster.

Torch distance should be 8-10mm.

15. Fuse blowing

Tension too great

Gas cup contact tip clogged

Release tension. (See section 6.6).

Clean gas cup and contact tip (See fig.16).

16. Coils of wire on reel overlap, or wire is

oxidised. Coils break or fall under wheel.

Tension to loose or tight. Coil damaged or wire twisted. Reset tension. Change wire reel.

17. Wire runs through torch but there is no

welding current.

Defective contactor.

Worn contacts of contactor regulator.

Regulation switch problem

Faulty rectifier.

Fault on electronic circuit of contactor.

Work cable not connected correctly.

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.

Original Language Version

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

sales@sealey.co.uk

Sole UK Distributor, Sealey Group,

Kempson Way, Suffolk Business Park,

Bury St. Edmunds, Suffolk,

IP32 7AR

www.sealey.co.uk

Web

Parts support is available for this product. To obtain a parts listing and/or diagram, please log on to

www.sealey.co.uk, email sales@sealey.co.uk or phone 01284 757500.

POWERMIG6025S, POWERMIG6035S Issue: 2(L) -06/03/14

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Sealey POWERMIG6025S User Manual Page 10

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