MIGATRONIC 54110324 Feed Rollers for MIG and MAG Welding Instruction Manual

54110324 Feed Rollers for MIG and MAG Welding

Specifications

• Product Name: Feed rollers for MIG/MAG welding

• Roller Types: V groove, U groove, U groove cerated, Needle
  bearing

• Wire Types: Aluminium, Copper wire, Stainless steel, Flux-cored
  wire, Solid wires

• Wire Pressure Range: 1.5-3.5 (varying based on wire type)

Product Usage Instructions

1. Understanding Feed Roller Types

Feed rollers play a crucial role in wire feeding during welding.
Different types of feed rollers are suitable for different wire
materials:

• V groove: Suitable for solid and flux-cored
  wires with stiff surfaces.

• U groove: Ideal for soft metals like aluminium
  and magnesium to prevent wire damage.

• U groove cerated: Specifically designed for
  flux-cored wires with a graphited surface.

• Needle bearing: Recommended for heavy-duty
  applications and prolonged welding.

2. Adjusting Wire Roll Pressure

Proper wire roll pressure is essential for smooth wire feeding.
Adjust the pressure according to the wire type using the
thumbscrew:

• Aluminium: 1.5-2.5
• Copper wire: 2.0-3.0
• Stainless steel: 2.5-3.5

3. Best Practices for Feed Rollers

Follow these best practices to ensure optimal performance:

• Ensure feed rollers match wire diameters and are color-coded
  for easy identification.

• Avoid over-tightening feed rollers to prevent wire
  deformation.

• Clean feed rollers regularly using a stainless steel brush or
  suitable solvent.

• Inspect and replace damaged or worn feed rollers promptly.

4. Checking Symbols and Maintenance

Check symbols for wire roll groove and ensure capillary tubes
and guide tubes match feed roller colors.

If U-grooves or V-grooves contain metal residue, clean them
mechanically to maintain smooth wire feeding.

Frequently Asked Questions (FAQ)

Q: How do I know which feed roller type to use for a specific

wire?

A: Refer to the guidelines provided in the manual. Choose V
groove for solid and flux-cored wires, U groove for soft metals, U
groove cerated for flux-cored wires, and Needle bearing for
heavy-duty applications.

Q: What should I do if the feed rollers are damaged?

A: If the feed rollers are damaged, worn, or cannot be cleaned
effectively, it is recommended to replace them to maintain optimal
performance during welding.

Trådtrisser til MIG/MAG-svejsning

Valg af de rigtige trådtrisser til den aktuelle tråd er nøglen til jævn og problemfri trådtilførsel. Når de rigtige trådtrisser bruges, kan produktivitet, effektivitet og svejsekvalitet øges og samtidig kan der spares penge på fejlfinding og vedligeholdelse.
Ujævn trådtilførsel eller tilstopning af liner og kontaktdyse kan skyldes forkert valg af trådtrisser ­ og er ofte skyld i svejsefejl og dyre driftsstop.

Trådtrissetyper

V-spor: Bruges typisk til massive tråde og pulverfyldte rørtråde, der er forholdsvis lette at skubbe gennem lineren, da de er stive og hårde i overfladen.
U-spor: Bruges typisk til aluminium, magnesium og andre bløde metaller. Den bløde overflade kan nemt beskadiges og blive oval-formet af trisserne, og dette kan påvirke trådfremføringen negativt.

Rouletterede U-spor: Bruges typisk til de gasløse rørtråde (Innershield) i større diametre, da de kan være bløde på grund af det rørformede design og flux-fyldning. Grafitlaget på overfladen gør det vanskeligt at skubbe tråden frem med en almindelig glat V-spors-trisse. Den rouletterede U-spors-trisse har tænder, der graver sig ned i overfladen og tvinger tråden frem. Start altid først med at bruge den glatte U-spors-trisse, da de rouletterede trisser laver grater på tråden og forårsager, at liner og kontaktdyse hurtigt stopper til.

Glatte trisser: Bruges i kombinationen glat overtrisse og V-spors undertrisse til ø0,6mm Fe, Fe Flux og CrNi tråde. Det giver den bedste fremføring af så tynd en tråd.

Trisser med lejer: Bruges ved meget lang lysbuetid og hårdt brug/slid på trådfremføringen (mange meter tråd i lang tid). Fordele: trisse og stålaksel bliver ikke opvarmet (friktionsopvarmning), nav på plasttrisse smelter ikke fast til stålaksel.

Anbefalet trissetryk i forhold til trådtype

Trådtype

Trissetryk (3)

1

2

Aluminium (Al)

Trissetype
U

1,5-2,5
P

2,0-3,0

2,5-3,5

Vær opmærksom på, at fremføringen påvirkes af flere faktorer, der kan have indflydelse på trissetrykket. Eks:

Kobbertråd (Cu)

U

blød Rustfrit stål (CrNi)

U

1

2 3 4

Rørtråd (Fe flux)

V

5

hård Massiv tråd (Fe)

V

P P
P P

· Svejseslangens længde (3-4m er det optimale, da modstanden i trådlineren øges ved længere slanger)
· Trådliner (1) skal passe til trådtype. · Trissespor (4) skal passe til trådtype. · Trådfører (2) og kapillarrør (1) skal passe til trisse.

Fingerskruens (3) tryk indstilles, således at trådtrisserne netop glider på tråden, når denne bremses ved kontaktdysen.

Tjek symbol for trissespor

Best practice

Størrelsen på trådtrisser skal altid passe sammen med tråddiametre. For at gøre det nemt at se forskel på trådtrisserne er de farvekodede efter størrelse, og formen på trådtrisserne er markeret med V eller U.
Spænd ikke trådtrisserne så meget, at de deformerer tråden. Det skal være muligt at skubbe tråden jævnt gennem liner og ud i kontaktdysen.

54110324

Sørg for, at kapillarrør og førerrør mellem trådtrisser er intakte og har samme farvekode som trisser.
Rengør trådtrisser regelmæssigt. Hvis de er beskadigede eller slidte eller ikke kan rengøres tilstrækkeligt skal de kasseres. Trisser kan rengøres mekanisk med en børste i rustfrit stål eller renses i en egnet rensevæske. Sidder der metalrester i U- eller V-spor, skal de renses mekanisk.

Feed rollers for MIG/MAG welding

Choosing the right type of feed rollers for a given wire is the key to smooth and trouble-free wire feeding. You can improve productivity, efficiency and welding quality and at the same time save money on troubleshooting and maintenance.
Choosing the wrong type of feed rollers can cause irregular wire feeding or blocking of liner and contact tips and often result in welding defects and expensive breakdowns.

Feed roller types

V groove: Typically used for solid and flux-cored wires, which are relatively easy to push through the liner owing to their stiff and hard surfaces.
U groove: Typically used for aluminium, magnesium and other soft metals. The surface of soft wires can easily be damaged and oval-shaped by feed rollers, which may negatively affect wire feeding.

U groove cerated: Typically used for flux-cored wires (Innershield) in large diameters because their tubular shape and flux can make them soft. Their graphited surface makes it difficult to feed the wire using a smooth V groove feed roller. U groove cerated feed rollers have teeth that dig into the surface and force the wire up. Always start with the smooth U groove feed roller because cerated feed rollers make burrs on the wire and cause blocking of liner and contact tip.

Smooth surface: Typical use: smooth upper feed roller combined with V groove lower feed roller for ø 0.6mm Fe, Fe Flux and CrNi wires. This give optimal feeding of such a thin wire.

Needle bearing: For very long arc time and heavy-duty applications (many meters of wire for a long time). Advantages: No heating (friction heating) of feed roller and steel axle, and hub on plastic feed roller does not melt and stick to the steel axle.

Recommended wire roll pressure according to wire type

Wire type

wire pressure (3)

1

2

Aluminium (Al)

Copper wire (Cu)

Wire roll type
U
U

1,5-2,5
P

2,0-3,0
P

2,5-3,5

Be aware that the wire feed is affected by several factors that can influence the wire roll pressure. Eg. · The length of the welding hose (3-4m is optimal
as the resistance in the wire liner increases with

soft Stainless steel (CrNi)

U

1

2 3 4

Flux-cored wire (Fe flux) V

5

hard Solid wires (Fe)

V

P

longer hoses). · Wire liner (1) must match the wire type.

P

· Wire roll groove (4) must match thread type.

· Wire guide (2) and capillary tube (1) must fit wire

P

roll.

Adjust the pressure of the thumbscrew (3) so that the wire feed rolls run smoothly on the wire when it is stopped at the contact tip

Check symbol for wire roll groove

Best practice

The size of feed rollers must fit together with wire diameters. To make it easy to distinguish between feed rollers, they are colour-coded according to size, and the shape of the feed rollers is marked V or U.
Do not tighten feed rollers so much that they deform the wire. It must be possible to push the wire evenly through the liner and into the contact tip.

Make sure that capillary tubes and guide tubes are intact and have the same colour code as feed rollers.
Clean feed rollers regularly. If they are damaged or worn or cannot be sufficiently cleaned, reject them. You can clean the feed rollers mechanically using a stainless steel brush or cleanse them using a suitable cleaning solvent. If U-grooves or V-grooves contain metal residue, they must be cleaned mechanically.

Read User Manual Online (PDF format)

Read User Manual Online (PDF format)  >>

Download This Manual (PDF format)

Download this manual  >>