Welding Defects; Maintaining The System - Elettro CF synergic mig 245 Manual De Instrucciones

S – Gas fitting SIDE B
U – Gas fitting SIDE A
Adjust the welding tension.
4 WELDING
4.1 INSTALLATION
Make sure that the wire diameter corresponds to the diameter
indicated on the wire feeder roller, and that the selected
program is compatible with the material and type of gas. Use
wire feeder rollers with a "U"-shaped groove for aluminium
wires, and with a "V"-shaped groove for other wires.
4.2 THE MACHINE IS READY TO WELD
When using the torch P3KP, follow the instructions
enclosed.
• Connect the torch to the central connection P on side B.
• Connect the earth clamp to the workpiece.
• Set the switch J in position B.
• Set the switch Q to 1.
• Connect the gas cylinder to the fitting S.
• Remove the gas nozzle.
• Unscrew the contact tip.
• Insert the wire in the wire liner of the torch, making sure that
it is inside the roller groove and that the roller is in the correct
position.
• Press the torch trigger to move the wire forward until it
comes out of the torch.
• Caution: keep your face away from the gun tube
assembly while the wire is coming out.
• Screw the contact tip back on, making sure that the hole
diameter is the same as that of the wire used.
• Assemble the gas nozzle.
4.3 WELDING CARBON
PROTECTION.
In order to weld these materials you have to:
• Use a welding gas with a binary composition, usually
ARGON + CO2 with percentages of Argon ranging from 75%
up. With this blend, the welding bead will be well jointed and
attractive. Using pure CO2 as a protection gas will produce
narrow beads, with greater penetration but a considerably
increase in splatters.
• Use a welding wire of the same quality as the steel to be
welded. It is best to always use good quality wires, avoiding
welding with rusted wires that could cause welding defects.
• Avoid welding rusted parts, or those with oil or grease
stains.
4.4 WELDING STAINLESS STEEL
Series 300 stainless steels must be welded using a protection
gas with a high Argon content, containing a small percentage
of O2 or carbon dioxide CO2 (approximately 2%) to stabilize
the arc.
Do not touch the wire with your hands. It is important to keep
the welding area clean at all times, to avoid contaminating the
joint to be welded.
4.5 WELDING ALUMINIUM
In order to weld aluminium you have to use:
• Pure Argon as protection gas.
STEELS WITH GAS
• A welding wire with a composition suitable for the base
material to be welded.
• Use mills and brushing machines specifically designed for
aluminium, and never use them for other materials.
• In order to weld aluminium you have to use the torch P3KP.

5 WELDING DEFECTS

1 DEFECT- Porosity (within or outside the bead)
CAUSES • Electrode defective (rusted surface)
• Missing shielding gas due to:
- low gas flow
- flow gauge defective
- regulator frosted due to no preheating of the
CO2 protection gas
- defective solenoid valve
- contact tip clogged with spatter
- gas outlet holes clogged
- air drafts in welding area.
2 DEFECT - Shrinkage cracks
CAUSES • Wire or workpiece dirty or rusted.
• Bead too small.
• Bead too concave.
• Bead too deeply penetrated.
3 DEFECT - Side cuts
CAUSES • Welding pass done too quickly
• Low current and high arc voltages.
4 DEFECT - Excessive spraying
CAUSES • Voltage too high.
• Insufficient inductance.
• No preheating of the CO2 protection gas

6 MAINTAINING THE SYSTEM

• Shielding gas nozzle
This nozzle must be periodically cleaned to remove weld
spatter. Replace if distorted or squashed.
• Contact tip.
Only a good contact between this contact tip and the wire can
ensure a stable arc and optimum current output; you must
therefore observe the following precautions:
A) The contact tip hole must be kept free of grime and
oxidation (rust).
B) Weld spatter sticks more easily after long welding
sessions, blocking the wire flow.
The tip must therefore be cleaned more often, and replaced if
necessary.
C) The contact tip must always be firmly screwed onto the
torch body. The thermal cycles to which the torch is subjected
can cause it to loosen, thus heating the torch body and tip
and causing the wire to advance unevenly.
• Wire liner.
This is an important part that must be checked often,
because the wire may deposit copper dust or tiny shavings.
Clean it periodically along with the gas lines, using dry
compressed air.
The liners are subjected to constant wear and tear, and
therefore must be replaced after a certain amount of time.
• Gearmotor group.
Periodically clean the set of feeder rollers, to remove any rust
or metal residue left by the coils. You must periodically check
the entire wire feeder group: hasp, wire guide rollers, liner
and contact tip.
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