Sealey Wire feed problem? (video included)

[SteveNI]

Im having serious problems with my wire feed (Supermig 150) There is no tension on the spool of wire & no kinks in the wire either, can anyone see what the problem might be?

http://www.youtube.com/watch?v=nj5TzIuUDns

 

[Tiggy_dorset]

Im having serious problems with my wire feed (Supermig 150) There is no tension on the spool of wire & no kinks in the wire either, can anyone see what the problem might be?

http://www.youtube.com/watch?v=nj5TzIuUDns

Does the top roller move or is it seized. Wire sat in the roller groove correctly?

 

[SteveNI]

I'll go check the top roller but the wire is definately in the groove. When i turn the wire reel by hand there's no problem

 

[SteveNI]

Top roller is as free as a bird, the wire is in the correct groove (0.8mm) & the groove is nearest the side flap.

 

[SteveNI]

Just for a laugh, here is my 1st attempt at welding. 2mm sheet steel.

I used the calculator on here for the power & wire speed settings & it seemed to be pretty much bang on. I turned it up to full power & blew a couple of holes just to see how easy it was to do it.

 

[CKJDJK]

Take the tip off the torch and retry. The wire may be fouling the edge of the tip. Once the wire is through the liner, clean and refit the tip. If that does not work, remove wire and check end is not burred. Failing that check the liner and replace if required.

 

[jweaver]

Edit: Re-writen as my original post made no sense.

Are you using 0.6mm wire? Do you have the roller the right way around, so you are using the 0.6mm side? (Bearing in mind the numbers of the roller might be the wrong way around)

If you are using the 0.8mm side of the roller, and 0.6mm wire, the wire sits flush, and since its not proud, the top roller can't put any pressure on it.

On my welder, the numbering on the roller, is back to front.. The 'active' grove is the one at the back, but the number at the front (facing you) is the size of the grove at the back..

When I got my new GYS, I looked at the roller and assumed it was round the wrong way.. So I turned it round so that the grove on the 0.6 side was loaded (and 0.8 was visible at the front) and had exactly the same problem as you.

The wire would feed, but the rollers kept slipping no matter how tight I set it.. In the end I realised that I had the 0.8mm grove in place and it wasn't feeding.

Could this explain it?

Jon

 

[SteveNI]

0.8mm wire on the thicker slot which says 0.8mm

I removed the tip to check for fouling or obstruction, there was none at all & it still wouldn't feed correctly.

I left it a while & went back later, it was working as it usually did but im still not impressed. It seems to grip & feed, then slip, then grip & feed.......incredibly frustrating when welding as you get wire, then no wire, then wire!!!!

 

[jweaver]

0.8mm wire on the thicker slot which says 0.8mm

I removed the tip to check for fouling or obstruction, there was none at all & it still wouldn't feed correctly.

I left it a while & went back later, it was working as it usually did but im still not impressed. It seems to grip & feed, then slip, then grip & feed.......incredibly frustrating when welding as you get wire, then no wire, then wire!!!!

If you lift the top roller and put the wire in the grove, does it stand proud?

Could it be that the roller is worn.

As I said, mine did EXACTLY the same as this, and it was because 0.6mm wire sits in the 0.8mm grove perfectly flush.. So whilst this isn't the cause on yours, perhaps the 0.8mm grove is worn.

Also, push the top roller down onto the wire by hand.. Does this make it better.. This will prove whether its the tension of the roller, the roller itself or the torque of the motor.

Jon

 

[SteveNI]

Cheers Jon. I'll take a look tonight. The wire roller shouldn't be worn as 0.8mm wire was never used on it before, the previous owner just used 0.6mm, i havent tried the 0.6mm for feed problems.

Would it do any harm to use the 0.8mm wire on the 0.6 groove?

 

[jweaver]

Cheers Jon. I'll take a look tonight. The wire roller shouldn't be worn as 0.8mm wire was never used on it before, the previous owner just used 0.6mm, i havent tried the 0.6mm for feed problems.

Would it do any harm to use the 0.8mm wire on the 0.6 groove?

I wouldn't imagine so.. As long as it feeds, but more importantly stops/slips when you get a jam, thats fine.

I don't want to teach you to suck eggs, so if you know this already, apologies. You need the wire to push with enough force to get it to feed, but the rollers loose enough so that they will slip if there is some kind of jam/blockage.

If you use the 0.6mm groove, you might find that if you get a jam and the rollers biting so hard on the wire, they don't slip and this could damage the motor... So you need the rollers to push the wire firmly, but still slip if there is any kind of resistance.

Before going down that route, I would try a few things (Assuming you havn't already):

1. Push a length of wire through the torch and out through the tip, just to see if its completely free. There should be very little resistance.

2. As suggested, push down on the roller with your thumb/hand, just to increase the pressure and see if that works.. if it does, then there is something wrong with the tensioner.. If the motor stalls, then there is either a blockage, or the motor is faulty..

3. Check that the wire is standing proud of the groove, so that the top roller can actually push the wire into the groove.

4. Have a look at the groove.. Make sure that its not smooth (it should be rough, so that it grips the wire)... I wonder if its worth degreasing it, just incase there is any lube in it?

This should help determine exactly where the problem is.. I guess I should have asked.. Is this welder new to you? Have you see it working OK?

Jon

 

[SteveNI]

I'll go check all those things now Jon, i appreciate any pointers as im an absolute NOOB!

The welder came with 0.6mm wire loaded so i loaded the 0.8mm stuff in so i know there is no obstruction. The wire is also definately proud of the groove.

I'll go degrease the wheel here & put more pressure on the roller to see how that goes, i'll report back

 

[SteveNI]

Well ok! That was a cheap fix!! Thank you for helping!

I degreased the roller but it still slipped, i put more tension on the roller & it fed well. I removed the tensioner screw mechanism & slid an M6 washer down the shaft, replaced the tensioner screw & it now feeds well!!

Thank you again!

 

[shenion]

I think you are missing a spring that is supposed to go under the tensioner knob. That allows the idler to move a bit to keep constant pressure.

 

[SteveNI]

Hmmmmmm, there was a spring. It was under the adjuster knob & a kinda cup thing was holding it so you couldnt see it from the outside looking in.

 

[norsa]

Just out of interest. Years ago I had a roll of wire that was stored inside but in slightly damp environment. Said wire acquired some minute rust spots that you could feel but not see. Same problem. New wire stored in drier place. Never had a problem since.
Nick.