Maintenance / Trouble Shooting - Migatronic Rally MIG 160 Manuel D'instruction

MAINTENANCE
Insufficient maintenance may result in reduced
operational reliability and in lapse of guarantee.
Wire feed unit
This unit must be cleaned with dry, clean, com-
pressed air and maintained regularly at the wire feed
roll and the capillary tubes, as it is of great
importance for a satisfactory welding result and a
minimum of wear and tear that the wire passes
through the wire drive system without any de-
formations of the wire or the wire feed roll. The
contact tips must be checked often and changed if
the copper plating of the wire is damaged on its way
through the tips. Copper dust may prevent free
passage of wire through the torch liner. Check and
cleaning of the capillary tubes and the wire drive
rolls is recommended when necessary.
Welding hose
Great care should be taken to ensure that the
welding hose is not overloaded. It should not be
pulled over sharp edges, and heavy machines
should not run over it as this may damage the torch
liner.
The torch hose assembly should be dismantled
when necessary and blown out with clean, dry com-
pressed air. The torch must be disconnected from
the machine during this process.
Welding torch
There are many parts in the welding torch that have
to be cleaned regularly. The main ones are the
contact tips and the gas shroud.
During the welding process, these parts are bom-
barded with spatter that sticks to the shroud. This
may disturb the shielding gas flowing from the gas
shroud down to the molten pool, and must be
removed regularly. The use of MIGATRONIC MIG
SPRAY loosens spatter.
During the cleaning process, the gas shroud should
be removed. Do not clean by banging or hitting the
torch.
Power source
The rectifier and transformer should be blown out
with dry air occasionally, otherwise the air cir-
culation will be affected by the dust.
Important!
Make sure that the machine is disconnected from
the mains supply when the power source needs to
be opened for e.g. replacement of control unit.
TROUBLE SHOOTING
Too little welding effect.
The welding seam forms a bead standing proud
of the plate.
1. One of the three fuses in the main switch is not
working. (This applies to three-phase machines
only).
2. The welding voltage is too low.
Switch one setting higher.
The wire feed is blocking.
1. The inlet nozzle and the wire are not in align-
ment with each other.
2. The reel of wire is too taut, the wire must come
off the reel evenly.
3. The inlet or contact tip has worn out or is
blocked up.
4. The welding wire is not clean or it is rusty. It
could also be of an inferior quality.
5. The pressure roller has to be tightened.
Spatter.
1. The wire feed is too fast for the voltage setting.
2. Worn out contact tip.
Porous weld. A cone is formed when spot wel-
ding.
1. Insufficient gas - too little pressure or the bottle
is empty.
2. Contact tip is blocked up.
3. Leakage air is pumped in and mixes with the
shielding gas.
The wire keeps sticking in the contact tip and
feeds at slow speed.
1. The damaged wire should be cut off, pulled out
and replaced. The pressure on the wire feed
roller should be checked and adjusted if neces-
sary.
2. Worn out contact tip.
3. Wire feed speed may need increasing.
If any problems arise that cannot immediately be
remedied on basis of the above section on Trouble
Shooting, the machine should be taken to an
authorised Migatronic distributor for repair.
9