Telwin MIG-MAG Manual De Instrucciones página 27

7. MAINTENANCE
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WARNING! BEFORE CARRYING OUT MAINTENANCE OPERATIONS MAKE
SURE THE WELDING MACHINE IS SWITCHED OFF AND DISCONNECTED FROM
THE MAIN POWER SUPPLY.
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7.1 ROUTINE MAINTENANCE
ROUTINE MAINTENANCE OPERATIONS CAN BE CARRIED OUT BY THE
OPERATOR.
7.1.1.Torch
- Do not put the torch or its cable on hot pieces; this would cause the insulating
materials to melt, making the torch unusable after a very short time.
- 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. 5bar) to make sure it is not damaged.
- At least once a day, check the wear and correct assembly of the parts at the end of
the torch: nozzle, contact tip, gas diffuser.
7.1.2 Wire feeder
- Make frequent checks on the state of wear of the wire feeder rollers, regularly remove
the metal dust deposited in the feeder area (rollers and wire-guide infeed and
outfeed).
7.2 EXTRAORDINARY MAINTENANCE
EXTRAORDINARY MAINTENANCE OPERATIONS SHOULD BE CARRIED OUT
ONLY AND EXCLUSIVEL Y BY SKILLED OR AUTHORISED ELECTRICAL-
MECHANICAL TECHNICIANS.
TAB. 6
FAULT POSSIBLE CAUSES
1- Pressure of wire feeder rollers.
UNEVEN
WIRE FEED
2- Wire guides are not aligned with groove on small rollers.
3- Feed rollers or wire guide tip unsuitable for wire.
4- Wire guide hose blocked.
5- Coils overlapping on reels.
6- Oxidised or poor quality wire.
7- Excessive reel braking.
8- Coils fallen under the reel .
1- Gas supply connected incorrectly.
POROUS WELD
2- Gas bottle empty valve closed.
3- Solenoid valve not working with torch button "on".
4- Faulty pressure reducing valve.
5- Torch diffuser holes blocked.
6- Draughts in the welding area.
7- Gas leaks.
8- Wire guide tip too far in.
9- Pieces to be welded of poor quality.
10-Poor gas or wire quality.
1- Faulty torch button.
WIRE DOES
2- Overload thermostat triggered.
NOT FEED
3- Control circuit fuses.
4- Gear motor failure.
5- Fault in electronic circuits for feed rate control.
6- Spot welding timer on.
1- Faulty contactor.
NO WELDING
2- Worn contactor contacts.
CURRENT
3- Adjustment switch.
4- Faulty rectifier.
5- Faulty electronic control circuit for contactor.
6- Earth cable prepared incorrectly.
INAPPROPRIATE 1- Error in feed rate control system adjustment.
MAXIMUM AND
MINIMUM WIRE
FEED RATE
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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.
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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. 10bar).
- 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.
8. TROUBLESHOOTING
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WARNING! CARRYING OUT CERTAIN CHECKS IMPLIES THE RISK OF
CONTACT WITH LIVE AND/OR MOVING PARTS.
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Before carrying out any operation on the wire feeder or inside the welding machine it is
absolutely necessary to refer to section 7 " MAINTENANCE".
FAULTS, CAUSES AND REMEDIES
CHECKS AND REMEDIES
1- Make sure the rollers allow the wire to slide and adjust the pressure
2- Make sure the wire is not bent and align as necessary.
3- Check and replace if necessary.
4- Remove the hose, blow compressed air through it or replace it.
5- Check and replace the reel if necessary.
6- Cut any oxidised coils or replace the reels.
7- Adjust braking lock.
8- Adjust reel braking.
1- Check.
2- Open the taps and detach the rubber pipe to check whether gas output is
3- Check for the presence of voltage at the ends of the reel: if positive, replace
4- Check.
5- Remove the diffuser and unblock the holes. To prevent clogging spray the
6- Protect the arc area with suitable shields.
7- Check the gas pipe clips are tightened properly and tighten further if
8- Check.
9- Make sure the pieces are not wet or dirty and are not rusty.
10-Replace the wire reel or the gas bottle: note that the gas should be dry and
1- Check and replace.
2- Wait a few minutes to allow the machine to cool.
3- Check and replace.
4- Check and replace.
5- Check and replace the board.
6- Switch off: position "OFF".
1- Make sure 24V arrive at the ends of the reel; if so replace the reel.
2- Check the state of the contacts and clean them or replace them if they are
3- Check the secondary voltage for every switch position.
4- Disconnect the secondary rectifier and make sure each diode conducts in
5- Replace the electronic board.
6- Connect the earth clamp directly to the piece being welded; make sure the
1- Go to the electronic board and calibrate by adjusting the appropriate timers.
- 27 -
(TAB.6)
accordingly.
normal.
the solenoid valve.
diffuser with silicon-free spray.
necessary.
not damp.
very oxidised.
one direction only; otherwise replace the rectifier.
cable is undamaged and locked tightly to the earth clamp.