Helvi TP 195 Operating Manual

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TP 195

OPERATING MANUAL

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1.0 SAFETY INFORMATION

1.1 INTRODUCTION

Make sure this manual is carefully read and understood by the welder, and by the maintenance and technical workers.

1.2 PERSONAL PROTECTION

Welding processes of any kind can be dangerous not only to the operator but to any person situated near the equipment, if safety and operating rules are not strictly observed.

Arc rays can injure your eyes and burn your skin. The welding arc produces very bright ultra violet and infra red light. These arc rays will damage your eyes and burn your skin if you are not properly protected.

• Wear closed, non-flammable protective clothing, without pockets or turned up trousers, gloves and shoes with insulating sole and steel toe. Avoid oily greasy clothing.

• Wear a non-flammable welding helmet with appropriate filter lenses designed so as to shield the neck and the face, also on the sides. Keep protective lens clean and replace them when broken, cracked or spattered. Position a transparent glass between lens and welding area.

• Weld in a closed area that does not open into other working areas.

• Never look at the arc without correct protection to the eyes. Wear safety glasses with the side shields to protect from flying particles.

Gases and fumes produced during the welding process can be dangerous and hazardous to your health.

• Adequate local exhaust ventilation must be used in the area. It should be provided through a mobile hood or through a built-in system on the workbench that provides exhaust ventilation from the sides, the front and below, but not from above the bench so as to avoid raising dust and fumes. Local exhaust ventilation must be provided together with adequate general ventilation and air circulation, particularly when work is done in a confined space.

• Welding process must be performed on metal surfaces thoroughly cleaned from rust or paint, to avoid production of harmful fumes. The parts degreased with a solvent must be dried before welding.

• Be very carefull when welding any metals which may contain one or more of the follwing: Antimony Beryllium Cobalt Manganese Selenium Arsenic Cadmium Copper Mercury Silver Barium Chromium Lead Nickel Vanadium

• Remove all chlorinated solvents from the welding area before welding. Certain chlorinated solvents decompose when exposed to ultraviolet radiation to form phosgene gas (nerve gas).

1.3 FIRE PREVENTION

Fire and explosion can be caused by hot slag, sparks or the welding arc.

• Keep an approved fire extinguisher of the proper size and type in the working area. Inspect it regularly to ensure that it is in proper working order;

• Remove all combustible materials from the working area. If you can not remove them, protect them with fire-proof covers;

• Ventilate welding work areas adequately. Maintain sufficient air flow to prevent accumulation of explosive or toxic concentrations of gases;

• Do not weld on containers that may have held combustibles;

• Always check welding area to make sure it is free of sparks, slag or glowing metal and flames;

• The work area must have a fireproof floor;

1.4 ELECTRIC SHOCK

WARNING: ELECTRIC SHOCK CAN KILL!

• A person qualified in First Aid techniques should always be present in the working area; If a person is found unconscious and electric shock is suspected, do not touch the person if she or he is in contact with cable or electric wires. Disconnect power from the machine, then use First Aid. Use

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dry wood or other insulating materials to move cables, if necessary away from the person.

• Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit.

• Make sure the main line is properly grounded.

• Do not coil the torch or the ground cables around your body.

• Never touch or come in physical contact with any part of the input current circuit and welding

current circuit.

Electric warning:

• Repair or replace all worn or damaged parts.

• Extra care must be taken when working in moist or damp areas.

• Install and maintain equipment according to local regulations.

• Disconnect power supply before performing any service or repair.

• Should you feel the slightest electrical shock, stop any welding immediately and do not use the

welder until the fault has been found and corrected.

1.5 NOISE

Noise can cause permanent hearing loss. Welding processes can cause noise levels that exceed safe limits. You must protect your ears from loud noise to prevent permanent loss of hearing.

• To protect your hearing from loud noise, wear protective ear plugs and/or ear muffs.

• Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.

1.6 ELECTROMAGNETIC COMPATIBILITY

Before installing your welder, carry out an inspection of the surrounding area, observing the following guidelines:

• Make sure that there are no other power supply cables, control lines, telephone leads or other

equipment near the unit.

• Make sure that there are no radio receivers, television appliances, computers or other control

systems near the unit.

• People with pace-maker or hearing-prosthesis should keep far from the power source.

! In particular cases special protection measures may be required.

Interference can be reduced by following these suggestions:

• If there is interference in the power source line, an E.M.T. filter can be mounted between the power

supply and the power source;

• The output cables of the power source should be not too much long, kept together and connected

to ground;

• After the maintenance all the panels of the power source must be securely fastened in place.

1.7 PROTECTIVE WELDING GASES

Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Treat them carefully.

• These welders use only inert or non-flammable gases for welding arc protection. It is important to

choose the appropriate gas for the type of welding being performed;

• Do not use gas from unidentified cylinders or damaged cylinders;

• Do not connnect the cylinder directly to the welder, use a pressure regulator;

• Make sure the pressure regulator and the gauges function properly;

• Do not lubricate the regulator with oil or grease;

• Each regulator is designed for use with a specific gas. Make sure the regulator is designed for the

protective gas being used;

• Make sure that the cylinder is safely secured tightly to the welder with the chain provided.

• Never expose cylinders to excessive heat, sparks, slag or flame;

• Make sure that the gas hose is in good condition;

• Keep the gas hose away from the working area.

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2.0 INSTALLATION

2.3 LOCATION

Be sure to locate the welder according to the following guidelines:

• In areas, free from moisture and dust;

• Ambient temperature between 0° to 40°C;

• In areas, free from oil, steam and corrosive gases;

• In areas, not subjected to abnormal vibration or shock;

• In areas, not exposed to direct sunlight or rain;

• Place at a distance of 300mm or more from walls or similar that could restrict natural air flow for cooling.

2.4 VENTILATION

Since the inhalation of welding fumes can be harmful, ensure that the welding area is effectively ventilated.

2.5 MAIN SUPPLY VOLTAGE REQUIREMENTS

Before you make any electrical connection, check that supply voltage and frequency available at site are those stated in the ratings label of your generator. The main supply voltage should be within ±10% of the rated main supply voltage. Too low a voltage may cause poor welding performance. Too high a supply voltage will cause components to overheat and possibly fail. The welder Power Source must be:

• Correctly installed, if necessary, by a qualified electrician;

• Correctly grounded (electrically) in accordance with local regulations;

• Connected to the correct size electric circuit. In case the supply cable is not fitted with a plug, connect a standardized plug (2P+T) to the supply cable

(in some models the supply cable is supplied with plug). To connect the plug to the supply cable, follow these instructions:

• the brown (phase) wire must be connected to the terminal identified by the letter L

• the blue (neutral) wire must be connected to the terminal identified by the letter N

• the yellow/green (ground) wire must be connected to the terminal identified by the letter PE or by the symbol .

In any case, the connection of the yellow/green wire to the PE terminal must be done in order that in the event of tearing of the power supply cable from the plug, the yellow/green wire should be the last one to be disconnected.

The outlet should be protected by the proper protection fuses or automatic switches.

Notes:

• Periodically inspect supply cable for any cracks or exposed wires. If it is not in good conditions, have it repaired by a Service Centre.

• Do not pull violently the input power cable to disconnect it from supply.

• Do not squash the supply cable with other machines, it could be damaged and cause electric shock.

• Keep the supply cable away from heat sorces, oils, solvents or sharp edges.

• In case you are using an extension cord, try to keep it well straight and avoid its heating up.

2.1 HANDLE AND WHEELS ASSEMBLY

• Unpack the welder;

• Screw the two casters (A) to the machine;

• Insert the axle (B) through the holes at the rear of the welder and slide a wheel (C) on to each end followed by the retaining washers (D);

• Assemble the plastic handle (E) using the screws provided;

2.2

TORCH LEAD ASSEMBLY – EURO CONNECTION

• Plug the torch hose into the socket on the front of the welder and secure by hand screwing in the threaded connection.

B D

Figure 1

Figure 2

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2.6 SAFETY INSTRUCTIONS

For your safety, before connecting the power source to the line, closely follow these instructions:

• An adequate two-pole switch must be inserted before the main outlet; this switch must be equipped with time-delay fuses;

• The connection with ground must be made with a two-pole plug compatible with the above mentioned socket;

• When working in a confined space, the power source must be kept outside the welding area and the ground cable should be fixed to the workpiece. Never work in a damp or wet area, in these conditions.

• Do not use damaged input or welding cables

• The welding torch should never be pointed at the operator’s or at other persons’ body;

• The power source must never be operated without its panels; this could cause serious injury to the operator and could damage the equipment.

3.0 INTRODUCTION

MATERIAL TO WELD

GAS CYLINDER WIRE

Mild steel

Argon + CO2 cylinder or

CO2 cylinder

Copper coated mild steel wire spool.

For no gas welding use flux-cored wire spool

Stainless steel Argon cylinder Stainless steel wire spool.

Aluminum Argon cylinder Aluminum wire spool

This manual was edited to give some indications on the operation of the welder and was thought to offer information for its practical and safe use. Its purpose is not to teach welding techniques. All suggestions are indicative and intended to be only guide lines.

To ensure that your welder is in good condition, inspect it carefully when you remove it from its packing taking care to ascertain that the cabinet or the stocked accessories are not damaged.

Your welder is capable of daily activity metal fabrication and maintenance. Its simplicity and versatility and its excellent welding characteristic are the product of the most up to date inverter technology. This welding inverter offers the welder the ability to create precise arc characteristics and at the same time reduce consumption of energy with respect to the welders based on a traditional transformer.

Respect the duty cycle of the welder making reference to the technical data label on the welder’s back. Duty cycle is given as percentage on a 10 minute time. During this period of time the unit can be used at the rated duty cycle. Exceeding the rated duty cycle may cause overheating or welder damage.

Welder’s basic specifications (Figure 3)

Welding Wire Selection:

This welder can work with Aluminum wire 0,8÷1,0 diameter, solid steel wire 0,6÷1,0 diameter and stainless steel wire 0,8÷1,0 diameter (Gas Welding) and with flux core wires 0,8÷1,0 diameter (No Gas Welding).

Feed Rolls:

groove 0,6-0,8mm for wires 0,6÷0,8mm groove 1,0-1,2mm for wires 1,0mm Feed rolls for Aluminum, U-groove 0,8-1,0mm for wires 0,8mm

Gas Selection

According to the material to be welded and to the wire you are going to use, select the shielding gas. The table below can give you some useful indications:

Figure 3

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4.0 KNOW YOUR WELDER

QUICK START

Your new single phase inverter multi-function welder offers THREE WELDING FUNCTIONS in the same power source. These functions can be selected with knob (6) on the front panel of the unit:

MIG (GMAW and FCAW) Welding with Gas and without Gas

This welder offers the choice to weld in manual or synergic mode.

1. Manual Mode: The operator is required to set both the wire speed (Left Knob - 8- ) and the welding

voltage (Right Knob - 7 -).

2. Synergic Mode: the operator is required to simply set the thickness of the material to be welded (Right Knob -7-). Once this parameter is set, the synergic function automatically adjusts the welding voltage and the wire speed allowing the operator to balance this last value simply adjusting the Left

Knob (8).

Stick Welding (SMAW)

Both rutile and basic electrodes can be welded. Welding current is adjusted using the Left Knob (8).

TIG welding (GTAW)

In the TIG position, a TIG torch with a gas valve in the handle is required. The gas valve must be opened manually before welding and closed manually when welding is completed. The arc is activated by scratching the tip of the electrode. Using the Left Knob (8) welding current can adjusted.

CONTROLS AND OPERATIONAL FEATURES

8 76

Figure 4

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1. Power switch indicator: This green LED lights when the welding machine is ON and is ready to work. In the event of an overvoltage supply the green LED blinks and the red LED (3) is ON.

2. Thermal overload indicator: If the yellow LED is ON it indicates that the welder has overheated and the machine has automatically shut down. This may be a result of having exceeded the welders duty cycle or that normal cooling air flow has been interrupted. Check to confirm that the cooling fan is running and that air flow is not blocked. Do not turn off the welder as this will stop the cooling fan. When the welder has cooled sufficiently the yellow LED will go out and the welder is ready to weld.

3. Alarm indicator: This red LED lights when there is a working abnormality such as an over voltage supply.

4. Left Display: During welding it displays the actual value of the output current (AMP). When the machine is not welding, (no load), the display shows the value of the parameter selected with the Left Knob (8): a. In STICK and TIG mode it shows the selected current value. b. In MIG MANUAL mode the display shows the selected wire speed in m/min. c. In MIG SYNERGIC mode the display shows wire speed balance; possible variation is +/-40% on the base value adjusted by default ( “0” on the display, central position).

5. Right Display: during welding it displays the actual arc voltage. When the machine is not welding (no load) it displays the value of the parameter adjusted with the Right Knob (7): a. in STICK mode it displays the Hot Start over-current value expressed as a percentage of the base welding current selected with the left knob (8). The over current value is variable from 0 to 50% of the base current. Maximum Hot start value of 50% can be adjusted up to 120Amp of welding current. On the display the value of Hot Start is shown as “H” and the value of the over current in %. b. In TIG Mode the display is not active. c. In MIG MANUAL it displays the selected arc voltage from 12V to 26V. d. In MIG SYNERGIC it displays the thickness of the material to be welded expressed in mm.

6. Selector switch for the Welding Modes Selection: MMA, TIG, MIG manual, MIG Syn.

7. Right Knob: it is used to adjust the following welding parameters. a. in STICK Mode it adjusts the over-current value of the electric arc (Hot Start), variable from 0 to 50% on the current value adjusted with the Left Knob (8). b. In TIG Mode is not active. c. In MIG manual it adjusts arc voltage value (no load) from 12V to 26V. d. In MIG Synergic it selects the thickness of the material to be welded.

8. Left Knob: it is used to adjust the following welding parameters. a. In STICK Mode it adjusts the current value from a minimum of 20Amp to a maximum of 170Amp. b. In TIG Mode, it adjusts the current value from a minimum of 5 Amp to a maximum of 170Amp. . c. In MIG manual it adjusts the wire speed. d. In MIG Syn it adjusts the wire speed; possible variation is +/-40% on the base value adjusted by default ( “0” on the display).

9. Negative Dinse socket: a. in STICK welding for the connection of the ground cable connector (check for correct polarity for the electrode you are going to use, refer to the information on its box); b. in TIG Welding for the TIG torch cable connection; c. in MIG welding (with gas) for the connection of the ground cable connector.

10. Positive Dinse socket: a. in STICK welding, for the connection of the working cable connector (check for correct polarity for the electrode you are going to use, refer to the information on its box); b. in TIG Welding for the connection of the ground cable connector; c. in MIG Flux Core Welding (FCAW), for the connection of the ground cable connector

11. Euro connect for attaching the MIG torch cable. In MIG Flux Core welding (FCAW), change the polarity of the Euro socket using the terminals on the polarity change board located inside the wire spool compartment above the wire feeder -18-.

12. Input power cable (back panel)

13. ON/OFF Switch

14. Gas Hose connector (back panel)

15. 2 roll Aluminum wire feeder

16. Slope up Time regulation potentiometer

17. Burn Back Time Regulation Potentiometer (B.B.T.)

18. Polarity Change Terminals for the Euro Socket: a. positive polarity for MIG/MAG Welding; b. negative polarity for No Gas Welding.

19. Spool holder

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5.0 STICK ELECTRODE WELDING (SMAW)

5.1 GETTING READY FOR STICK ELECTRODE WELDING (SMAW).

• Select the Stick function (SMAW) with the Selector Switch (6) on the front panel.

• Check the electrode packaging to determine the recommended polarity and connect the Electrode holder and ground clamp to the plus and minus Dinse sockets accordingly.

• Switch the unit ON thru the ON/OFF switch (13).

• Set the welding current with the Left Knob (8) on the front panel and the strike over-current value of the electric arc (Hot Start) with the Right Knob (7).

6.1 SETTING UP THE EQUIPMENT FOR TIG WELDING

• Select the TIG function on the control panel with knob (6).

• Connect the TIG torch cable to the negative dinse socket (9) of the welder.

• Connect the ground cable connector to the positive dinse socket (10) of the welder.

• Connect the TIG torch gas line to the gas regulator, ARGON GAS ONLY

The gas flow is manually controlled with the knob on the TIG torch. Use inert gas (argon ) only.

6.2 CLOSE THE GAS VALVE ON THE TORCH HANDLE. Turn on gas at the gas regulator, then open the valve on the torch handle and check for gas flow.

6.3 STARTING THE ARC BY SCRATCH

• Fix the tungsten electrode so that it protrudes approximately 4-5mm from the torch nozzle.

• Position the torch so that the tungsten electrode is in contact with the work piece at a 45 degree angle.

• Scratch the tip of the electrode until an arc develops, quickly withdraw the electrode and maintaning a gap of approx. 3-4 mm proceed to weld. To stop welding, simply remove the torch from the work piece.

REMEMBER to turn OFF the gas immediately after you finish welding.

6.0 TIG WELDING WITH LIFT START (GTAW)

7.0 MIG/MAG (GMAW) & FLUX CORE (FCAW) WELDING

7.1.1 TORCH CONNECTION

• Plug the torch hose into the socket (9) on the front of the welder having care to not damage the contacts and secure by hand screwing in the threaded connection.

Figure 5

7.1.2 WIRE LOADING

Ensure the gas and electrical supplies are disconnected. Before proceeding, remove the nozzle and the contact tip from the torch.

• Loosen the nut (A) of the spool holder (position 1) (brake drum). In the case you are replacing the wire spool, extract it by pushing the snap tongue (D) (Fig 5). Remove the plastic protection from the spool. Place it on the spool holder. Tighten the lock nut (A) turning it to position 2. (Fig. 16).

The unit can also accept 100 mm diameter wire spools. For the mounting follow these instructions:

• Remove the wire spool (B) from the spool holder (C).

• Loosen the nut (A), remove the spring and the washer; remove the spool holder (C) from the pivot.

• Insert on the pivot the 100mm diameter wire spool; Mount the washer and the spring.

• Tighten the lock nut (A).

Tighten nut (A) to appropriate tightness. Excessive pressure strains the wire feeding motor. Too little pressure does not allow the immediate stop of the wire spool at the end of the welding.

• Loosen and lower the plastic knob (A) (Fig.6). Open the pressure arm (B) of the feeder. Extract the wire from the torch liner.

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• When the wire is disconnected, grasp it with pliers

so that it cannot exit from the spool. If necessary, straighten it before inserting it in the wire input guide (C). Insert the wire on the lower roll (D) and in the torch liner.

WARNING: keep the torch straight. When feeding a new wire through the liner, make sure

the wire is cut cleanly (no burrs or angles) and that at least 2 cm from the end is straight (no curves). Failure to follow these instructions could cause damage to the liner.

• Lower the pressure arm (B) and place the knob (A). Tighten slightly. If tightened too much, the wire gets locked and could cause motor damage. If not tighten enough, the rolls will not feed the wire.

WARNING: When changing the wire diameter being used, or replacing the wire feed roll, be sure that the correct groove for the wire diameter selected is inside, closest to the machine. The wire is driven by the inside groove. Feed rolls are marked on the side identifying the groove nearest that side.

• Close the side panel of the machine.

• Connect the power supply cable to the power output line. Turn on the switch. Press the torch switch. The wire fed by the wire feeding motor at variable speed must slide through the liner. When it exits from the torch neck, release the torch switch.

Note: after three seconds torch trigger is pressed wire feeding speed increases to allow a fast exit of the wire on the torch neck.

• Turn off the machine.

• Mount the contact tip and the nozzle.

When checking the correct exit of the wire from the torch do not bring your face near the torch, you may run the risk to be wounded by the outgoing wire. Do not bring your fingers close to the feeding mechanism when working! The rolls, when moving, may crush the fingers. Periodically, check the rolls. Replace them when they are worn and compromise the regular feeding of the wire.

7.1.3 REPLACING THE WIRE LINER

Ensure the gas and electrical supplies are disconnected.

• Disconnect the torch from the machine.

• Place it on a flat surface and carefully remove the brass nut (1).

• Pull the liner out of the hose.

• Install the new liner and mount the brass nut (1) again. In case you are replacing a Teflon wire liner, follow these instructions:

• Install the new liner followed by the collet (3).

• Insert the O ring (4) on the wire liner collet (4)and replace the brass nut (1).

• Cut the wire liner close to the brass nut

Warning: the length of the new wire liner must be the same of the liner you have just pulled out of the hose.

• Connect the torch to the machine and install the wire into the feeding system.

7.1.4 HOW TO CHOOSE THE WIRE LINER

Mainly we can have 2 types of wire liners: Steel wire liners and Teflon wire liners.

• The steel wire liners can be coated or not coated: the coated wire liners are used for air cooled torches;

the wire liners which are not coated are used for water cooled torches.

• The Teflon wire liners are suggested for the welding of Aluminium, as they allow a smooth feeding

of the wire.

Figure 6

Colour BLUE RED YELLOW

Diameter Ø 0,6-0,9 Ø 1,0-1,2 Ø 1,2-1,6

Figure 7

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7.1.5 GAS CYLINDER AND REGULATOR CONNECTION

WARNING: Cylinders are highly pressurized. Handle with care. Serious accidents can result from improper handling or misuse of compressed gas cylinders. Do not drop the cylinder, knock it over, expose it to excessive heat, flames or sparks. Do not strike it against other cylinders.

The gas cylinder (not supplied) should be located at the rear of the welder, in a well ventilated area and securely fixed to the work bench or to the wall to insure that it will not fall.For safety, and economy, ensure that the regulator is fully closed, (turned counter-clockwise)when not welding and when installing or removing the gas cylinder.

• Turn the regulator adjustment knob counter-clock wise to ensure the valve is fully closed.

• Install the gas regulator on the gas cylinder, tighten the connecting nut firmly to insure against gas leakage.

• Connect the gas hose to the gas regulator.

• Open the cylinder valve, then set the gas flow to approx. from 5 to 15l/min. on the regulator.

7.1.6 FLUXCORE WIRE WELDING, “FCAW”

• Connect the ground cable to the positive terminal of the Polarity Change Board inside the spool compartment.

• Connect the working cable to the negative terminal of Polarity Change Board inside the spool compartment.

7.1.7 MIG WELDING, “GMAW”

• Connect the ground cable to the negative terminal on the Polarity Change Board inside the spool compartment.

• Connect the working cable to the positive terminal of the Polarity Change Board inside the spool compartment.

7.2 MIG / NO GAS MANUAL WELDING

Before connecting the unit to the mains, verify that all the accessories are correctly installed and mounted for electric welding (torch, wire spool etc ...).

• Select Manual MIG Welding function with the Selector Switch (6) on the front panel.

• Switch the unit ON thru the ON/OFF switch (13) on the back side of the unit.

• Press the torch trigger to load the wire.

• Set the welding parameters:

1. Wire feed speed: use Left Knob (8) to adjust the wire speed expressed in mm on the Left Display (4).

2. Arc voltage: use the Right Knob (7) to adjust arc voltage value (no load) from 12V to 26V. Refer to the Setting Chart on the access panel to get a guideline on the welding parameters setting. (Figure 9 on page 15)

• Bring the torch close to the work piece and press the trigger.

1. Wire feeder Slope-Up Time (Min. to Max. speed transition time), adjustable with the potentiometer located inside the access panel (16).

2. At the end of the Slope-Up Time, the wire feed speed reaches the value adjusted with the Left knob (8).

• To stop welding, release the trigger. The arc stays ON accordingly to the set B.B.T. (Burn back time). B.B.T. is the amount of time that the weld output continues after the wire stops feeding. It prevents the wire from sticking in the puddle and prepares the end of the wire for the following arc start.

7.3 SYNERGIC MIG WELDING

• Select the wire type and thickness (MIG Syn) thru the Selector Switch (6) on the front panel.

• MIG Synergy functions permits the operator to get the optimal welding parameters simply setting the thickness of the material to be welded (Right Knob -7-). Once this parameter is set, the synergic function automatically adjusts the welding voltage and the wire speed allowing the operator to balance this last value if necessary with the Left Knob (8).

• Switch the unit ON thru the ON/OFF switch (13) on the back side of the unit.

• Press the torch trigger to load the wire and check that the gas is flowing from the welding torch.

• Select the thickness of the material to be welded using the Right Knob (7).

Figure 8

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8.0 PROTECTION GASES GUIDE

METAL

Mild steel

Aluminium

Stainless steel

Copper, Nickel and Alloys

GAS CO2 Argon + CO2 Argon + CO2 + Oxygen

Argon

Argon + Helium

Argon + CO2 + Oxygen Argon + Oxygen

Argon Argon + Helium

NOTE

Argon controls spatters Oxygen improves arc stability

Arc stability, good fusion and minimum spatter. Higher heat input suitable for heavy sections. Minimum porosity.

Arc stability. Minimum spatter.

Suitable for light gauges because of low flowability of the weld pool. Higher heat input suitable for heavy sections.

Contact the technical service of your gas supplier to know the percentages of the different gases which are the most suitable to your application.

9.0 WELDING HINTS AND MAINTENANCE

• Always weld clean, dry and well prepared material.

• Hold gun at a 45° angle to the workpiece with nozzle about 5 mm from the surface.

• Move the gun smoothly and steadily as you weld.

• Avoid welding in very drafty areas. A weak pitted and porous weld will result due to air blowing away the protective welding gas.

• Keep wire and wire liner clean. Do not use rusty wire.

• Sharp bends or kinks on the welding cable should be avoided.

• Always try to avoid getting particles of metal inside the machine since they could cause short circuits.

• If available, use compressed air to periodically clean the hose liner when changing wire spools

IMPORTANT: Disconnect from power source when carrying out this operation.

• Using low pressure air (3/5 Bar=20-30 PSI), occasionally blow the dust from the inside of the welder. This keeps the machine running cooler. Note: do not blow air over the printed circuit board and electronic components.

• The wire feed roller will eventually wear during normal use. With the correct tension the pressure roller must feed the wire without slipping. If the pressure roller and the wire feed roller make contact (when the wire is in place between them), the wire feed roller must be replaced.

• Check all cables periodically. They must be in good condition and not cracked.

• Adjust the wire speed using the Left Knob (8) if necessary. Possible variation is +/-40% on the base value adjusted by default ( “0” on the display).

• Bring the torch close to the work piece and press the trigger.

1. Wire feeder Slope-Up Time (Min. to Max. speed transition time), adjustable with the potentiometer located inside the access panel (16).

2. At the end of the the Slope-Up Time, the wire feed speed reaches the value adjusted with the Left knob (8).

7.4 ALUMINUM WELDING

The machine needs to be set up as follows:

• 100% ARGON as welding protective gas.

• Ensure that your torch is set up for aluminum welding:

1. The lenght of the torch should not exceed 3m (it is advisable not to use longer torches).

2. Install a teflon wire liner (follow the instructions for the replacing of the wire liner).

3. Use contact tips that are suitable for aluminum wire and make sure that the diameter of the contact tip hole corresponds to the wire diameter that is going to be used.

• Ensure that drive rolls are suitable for aluminum wire.

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10.0 TROUBLESHOOTING

This chart will assist you in resolving common problems you may encounter. These are not all the possible solutions.

PROBLEM

POSSIBLE SOLUTION

POSSIBLE CAUSE

No “life” from welder

Fan operates normally, but when gun trigger pulled, there is no wire feed, weld output or gas flow

Feed motor operates but wire will not feed

Lack of penetration

Wire is birdnesting at the drive roller

Wire burns back to contact tip

Check for proper input cable connection

Check fuse and replace as necessary

Replace torch trigger

Allow welder to cool. The extinguishing of the pilot lamp / switch on the front panel indicates the thermostat has closed.

Check that the contact tip diameter is correct for the loaded welding wire.

Replace wire feeding motor

Increase roller pressure

Re-cut wire square with no burr

Clear with compressed air or replace liner.

Replace contact tip.

Re-adjust the welding parameters or select the Synergy Mode.

Clear with compressed air and tighten all connections.

Replace the contact tip.

Tighten or replace torch.

Replace the earth cable.

Use correct size welding wire.

Load again the welding wire ensuing it is well stretched and without creases.

Move the gun smoothly and not too fast.

Adjust pressure on drive roller.

Replace wire liner.

Replace contact tip.

Cut wire liner at the right lenght.

Replace the contact tip.

Increase wire speed or descrease arc voltage.

Input cable, plug or main switch malfunction. Wrong size fuse.

Faulty trigger on gun

Thermostat intervention

Wrong contact tip diameter.

Faulty wire feeding motor (rare)

Insufficient feed roller pressure

Burr on end of wire

Liner blocked or damaged.

Contact tip clogged or damaged.

Voltage or wire feed speed too low.

Loose connection inside the machine (rare).

Worn or wrong size contact tip.

Loose gun connection or faulty gun assembly.

Undersized or damadged earth cable.

Wrong size wire.

Wire inside the liner is not well stretched.

Torch moved too fast.

Eccessive pressure on drive roller.

Gun liner worn or damaged.

Contact tip clogged or damaged.

Liner stretched or too long.

Contact tip clogged or damaged.

Wire feed speed to slow or arc voltage too high.

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Workpiece clamp and/or cable gets hot.

Gun nozzle arcs to work surface.

Wire pushes torch back from the workpiece

Poor quality welds

Weld deposit “stringy” and incomplete

Weld deposit too thick

Wrong size contact tip.

BBT time is too long.

Bad connection from cable to clamp.

Bad connection between clamp and workpiece.

Slag buildup inside nozzle or nozzle is shorted.

Wire feed speed too fast.

Voltage too low.

Clogged nozzle.

Torch held too far from the workpiece

Insufficient gas at weld area

Rusty, painted, damp, oil or greasy workpiece

Rusty or dirty wire

Poor ground contact

Incorrect gas / wire combination

Torch moved over workpiece too quickly

Gas mixture incorrect

Torch moved over workpiece too slowly

Welding voltage too low

Use correct size contact tip.

Adjust BBT time with the potentiometer located on the spool compartment (18).

Tighten connection or replace cable.

Clean and/or strip the workpiece on the point of contact with the clamp.

Clean or replace nozzle.

Decrease wire feed speed or adjust Slope Up.

Increase the voltage by acting on the regulation potentiometer (7).

Clean or replace nozzle

Hold the torch at the right distance

Check that the gas is not being blown away by drafts and if so move to more sheltered weld area. If not check gas cylinder contents gauge, regulator setting and operation of gas valve.

Ensure workpiece is clean and dry.

Ensure wire is clean and dry.

Check ground clamp/workpiece connection

Check on the manual for the correct combination

Move the torch slower

See shielding gas table

Move the torch faster

Increase welding voltage

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