Metabo MIG-MAG 160, MIG-MAG 140 User Manual

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Operating Instruction Welding machine

Instructions d'utilisation L’appareil de soudage sous gaz protecteur

Bruksanvisning Dekkgass-sveiseapparatet

Käyttökäsikirja Parhaat onnittelumme tämän korkealaatuisen

Bruksanvisning skyddsgassvets

MIG/MAG 140 MIG/MAG 160

115 164 4534 GB/F/N/SF/S 2508 2.1



Great Britain 1.

France 2.

Norge 3.

Suomi/ Finland 4.

Sverige 5.

Retain proof of purchase! You are only entitled to claim warranty against proof of purchase.

Conservez le reçu d'achat! La garantie ne peut être accordée que sur présentation de ce reçu.

Oppbevar kvitteringen!  Garantiytelser skjer kun på grunnlag av forelagt kvittering.

Säilytä ostokuitti! Takuu on voimassa vain kuittia vastaan.

Förvara kvittot! Garantianspråk erkännes endast mot uppvisande av kvitto.

XS00028E.fm

1Great Britain

Operation elements

1 Connection for torch (+) pole

2 Switch on/off and welding currant

3 Wire feed regulator

4 Overload control light

5 Connection for earth clamp (–) pole

Dear customer, Congratulations to your purchase of this high-quality

MIG/MAG welding machine.  To ensure your personal safety and for reasons of appliance safety we ask you to read the instructions completely before operating this machine and to observe all points.

Basic Information for the Operator

The MIG/MAG welding machine is a DC welding power source with integrated wire feed, designed and manufactured exclusively for MIG and MAG electric arc welding. Any other use of this machine involves dangers and is not permitted.

The welding machine must only be operated on the mains voltage stated on the machine's rating plate. Connection to the supply circuit must be made via an earthed outlet, installed by a qualified electrician. The supply circuit must be protected by a fuse or miniature circuit breaker. Depending on the mains connection conditions at

the point of connection, welding power sources can

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cause disturbances to other consumers in the distribution system. Check with your power utility before connecting to power. (Class A in accordance with CISPR 11)

Keep the welding machine out of the reach of children.

Please note the hazards associated with the welding process and observe any work and fire prevention regulations.

The welding machine is not suitable for outdoor use in rain. Store in a dry place.

The unit is not suitable for unfreezing pipes.

Danger!

person with a heart condition wearing a pace maker must contact their doctor before operating this welding machine.

Safety Information and Accident Prevention Measures

x Keep the welding machine out of the reach of

children.

x Observe all applicable work and fire prevention

regulations when operating this welding machine. Observe all applicable accident prevention regulations.

x With welding a number of different hazards are

associated, which can pose a danger to health under certain circumstances.

x When welding always wear a close fitting, dry

overall (preferably fire retardant welders apparel) unsoiled by combustible substances, sturdy, insulating boots, headgear and leather welders gloves.

x Clothing made of synthetic fabrics and shoes

are not suitable. Dry, insulating gloves worn on both hands protect against electric shock (open-circuit voltage of the welding current circuit), hazardous rays (heat and ultra-violet rays) as well as against glowing metals and slag spatters. The ultra-vio let radiation causes sunburn-like effects on unprotected parts of the body.

Fumes – Vapours – Smoke

x During welding hazardous smoke and metal

dust develops. We strongly recommend the wearing of welding fume respirators, and to weld only in sufficiently vented rooms, to ensure the necessary operator protection.

x For enclosed spaces forced ventilation, installed

below the welding area, must be used.

x The material to be welded must be free from hal-

ogen solvents or degreasing agents, to prevent the generation of toxic vapours.



MIG/MAG 140/160

1.1

x Metals coated with lead, graphite, cadmium,

zinc, mercury or beryllium, or containing any of these materials, can generate much smoke dur ing welding.

x Welding releases ozone, which is a type of oxy-

gen that can lead to irritation or disorder of the respiratory organs.

x Degreasing agents such as trichlorethylene, tet-

rachloroethylene etc. vaporise during welding and are chemically converted into phosgene. Phosgene is poisonous!

UV-Rays

x The arc radiation can cause eye damage and

skin burns.

x For protection against sparks, heat, visible and

invisible rays suitable eye protection gear (welding visor or helmet with standardised filter lenses to class 10 – 15 of DIN 4647, depending on welding current) must be worn.

x Do not look into the arc with unprotected eyes

(risk of blinding and burns). The invisible ultraviolet radiation causes, with insufficient eye pro tection, a very painful conjunctivitis, which appears only hours later.

x Weld only within the range of visibility of other

persons, who can assist you in an emergency.

x Other persons or helpers near the arc must be

made aware of the hazards, and equipped with the necessary protective gear.

x Neighbouring workplaces are to be screened off

to provide protection against radiation.

x When welding inside rooms and buildings suffi-

cient ventilation must be ensured.

Fire

Danger! 

The arc temperature is approx. 2400 °C.

Before starting to weld observe the following information:

x Remove all combustible materials and objects

within a radius of 5 m from the welding point.

x Materials that can not be removed within a 5 m

radius must be protected by covering with sheet metal, wet cloths etc.

x Any wall openings, cracks and the like must be

covered or sealed respectively, to prevent uncontrolled flying of sparks.

x Keep fire extinguishing equipment such as fire

extinguisher, water pale etc. at hand.

x Keep in mind that by heat dissipation from the

welding point a fire may be started on covered parts or in other rooms respectively.

x After completion of the welding work check the

vicinity of the welding point several times within

a period of 6 – 8 hours for heat conduction, glowing combustion spots, hidden seats of fire

etc.

Handling of Shielding Gas Cylinders

x Observe all applicable regulations pertaining to

the handling of gas cylinders. Because of the dangerously high internal pressure (up to 200 bar) shielding gas cylinders are to be specially protected against mechanical damage, falling over or falling down, heating up (max. 50°C), prolonged radiation by sunlight and heavy frost.

x When the welding machine is equipped with a

gas cylinder too large in size this can cause, on uneven ground, the welding machine to fall over. To prevent subsequent damage to the welding machine or the gas cylinder, use only proper size gas cylinders (10l / 20l cylinders).

x Have cylinders refilled only by authorised filling

stations.

Electrical Hazards

x The connection to power mains and servicing of

the welding machine is to be done in accordance with VDE regulations or other standards applicable in your area.

x Ensure proper protective bonding of the supply

circuit.

x Ensure proper protective bonding of the work-

bench.

x Any service or maintenance work must only be

carried out by qualified personnel.

x Replace defective or damaged parts of torch or

torch leads without delay.

x The unit must only be connected to an earthed

outlet as a matter of principle. Only connections, including outlets and extension cables with an earthed plug, having an earth conductor and installed by a qualified electrician, are permitted.

x The fuse protection of the supply circuit must be

in accordance with local regulations. According to these regulations fuses or miniature circuit breakers respectively, suitable for the conductor cross section, must be installed. Installation of a fuse with to high an ampere rating may cause line fire and subsequent fire damage to the building.

x Replace damaged torch insulation and welding

cables without delay.

x Replacement of a damaged power cable, plug

etc. and repairs to the electrical components of the welding machine must be left to a qualified electrician.

x Welding torches must not be held in an armlock,

or in such way that electricity can run through the body.

1.2

MIG/MAG 140/160

x Switch the unit off for longer work breaks.

Unplug when work is completed and before relocating the unit. In case of accidents separate the welding power source at once from the power supply.

General Machine Description

The MIG/MAG welding machine consists of a transformer (static characteristic curve), a series-connected silicon rectifier, a welding circuit choke, and a wire feed unit.

The welding machine is suitable for the welding of different electrode wires (e.g. steel, see "Technical Specifications") under a shielding gas cover (CO2, mixed gas and argon).

The machine is fan cooled and has an overload protection.

Symbols Used

Danger!  Disregard of the following warnings could cause serious personal injury or material damage.

6 Manufacturer

7 Machine designation

8 Serial number

9 Standard information – This machine meets

the requirements of the standards mentioned

10 CE mark – This machine conforms to EC

directives as per declaration of conformity

11 Waste disposal symbol – the machine can be

disposed of through the manufacturer

12 Electrical performance data

13 Date of manufacture

Commissioning

Taking out of enclosed parts

All enclosed parts are inside the wire feed compartment and can be taken out after the wire feed compartment cover is removed..

Read operating instructions before initial operation

Wire feed speed

Do not use in rain.

Welding machine suitable for welding in environments with an increased electrical hazard.

Excess temperaturer

Information on the name plate:

78910

1213

Installation Conditions

x The protective gas welding unit must be

installed in a dry environment with sufficient room for cooling.

x If the unit is placed on an inclined surface it must

be secured against falling: place the unit on a suitable level support surface.

x The unit is designed for use in covered areas.

Welding outside in the rain is not permitted.

Mains connection

x Check to see that mains voltage matches the

voltage shown on the machine's rating plate.

x Set welding step switch to "0" before plugging

in.

Shielding gas cylinder connection

x Place gas cylinder onto the welding machine's

cylinder rack and secure with the chain to the cylinder holder at the rear of the unit. Take off the cylinder cap and open cylinder valve briefly, facing away from your body.

x Screw pressure reducer to the gas cylinder

valve. Run gas hose from pressure reducer to gas inlet port of the unit.

x Recommended gas flow rate in draft-free

rooms: 5-10 l/min.

MIG/MAG 140/160

1.3

x When using adjustable pressure reducers set

flow rate according to litre scale in the clock with the T-screw. Turning the T-screw in increases the gas flow rate, turning it out reduces the gas flow rate.

x While setting the gas flow rate, the unit must be

switched on and the torch's trigger switch held down, so the solenoid gas valve is open. To prevent wasting electrode wire swing the wire feed unit's leaf spring to the side.

Modifications and repairs to pressure reducers are strictly prohibited due to the hazards involved. Send faulty pressure reducers to a service centre.

Earth lead connection

Connect earth clamp of the unit's earth cable as close as possible to the welding point. Ensure good metal to metal contact.

Hints for Setting and Welding Techniques

Switching the unit on

The unit is switched on with the combination ON/ OFF – welding step switch. With the switch in the "0"- position the unit is electrically separated from the power supply.

The unit is fitted with an embedded temperature detector, which shuts the unit down in case of an thermal overload.

The tripping of the thermal overload protector is indicated by the front panel control light. Welding power source and wire feed are temporarily disabled.

After cooling down the welding power source is automatically activated again, the control light extinguishes.

Preparation of the welds

The joint section of the workpieces to be welded must be free of colour, metall covering, dirt, rust, grease and humidity.

The preparation of the welds is to be done under observation of all welding techniques regulations.

The right joint

The list gives hints for the shaping of the joints.

Form of joint Execution

Setting the welding parameters

After preparation of the welding machine the welding can begin.

To do so, welding voltage and wire feed have to be matched to suit the welding task. If the wire feed speed is increased the welding current increases accordingly.

For every electrode wire diameter and every welding task optimal parameters can be found. They are recognisable at the typical humming sound of the arc, amongst other.

If there is too much deviation from the optimal parameters, a satisfactory welding is not possible.

Platethick-

ness

s (mm)

Gapwidth

b (mm)

I-joint onesided < 1,5

I-joint on both sides

V-joint

> 1,5

2 – 4 < 2

3 – 6 < 1

1.4

< 2

MIG/MAG 140/160

Form of joint Execution

Platethick-

ness

s (mm)

Gapwidth

b (mm)

K-joint

Double-K-joint

Cornerjoint

Care and Maintenance

The unit is nearly maintenance-free.

Danger – Voltage! 

Disconnect from power before servicing!

x Check feed roller, pressure roller and wire lead-

in nozzle at regular intervals for dirt build-up, clean if necessary.

x At appropriate intervals the complete torch

including torch leads should be cleaned, as rubbed-off parts and dust build-up inside.

x The torch's contact tip is a wearing part. If its ori-

fice has enlarged the contact tip must be replaced.

x On the inside of the plug-on gas shroud spatters

build up. These have to be removed when nec essary. An anti-spatter spray eases this job and keeps spatters from sticking to the shroud.

x Replace damaged cables without delay.

Trouble Shooting

Mechanical faults are mostly indicated by an irregular or completely blocked wire feed. Electrical faults cause a malfunction of the unit, in part or complete.

> 0,6 –

0,6 – 1,5 –

> 0,6 –

> 1 –

2. Check of fuse for continuity and contact.

3. Visual check for possible shorts or overloads of windings (discoloring).

Fault, Likely causes Remedy

• Noisy or unstable arc?

Incorrect welding voltage

Too much/too little wire feed

Earth clamp loose or high contact resistance (rust, paint)

Contact tip worn or

incorrect diameter Incorrect gas flow rate

setting Workpiece not clean in

seam area Power unit faulty Have machine checked by

Spiral liner dirty Clean or replace Wire feed faulty See below

Correct with welding step switch

Correct with wire feed pot

Ensure good contact between earth clamp and workpiece

Replace

Correct

Remove paint, rust, grease etc.

service centre

Danger - Voltage!

Electrical fault finding must be left to a qualified electrician.

Further fault finding can proceed according to the wiring diagram supplied.

Fault find should first start with the unit de-energized, and in the following order:

1. Check of the power supply cable connection and all other connections on switches, transformer and choke, as well as all plug-and-socket connections and soldered connections for tightness.

MIG/MAG 140/160

• Excessive spattering

Wire feed rate too high Correct with wire feed pot Welding voltage too

high Workpiece not clean Clean

Correct with welding step switch

1.5

• Wire feed motor does not run

No power Check power supply Welding step switch in

"0" position Torch trigger switch not

activated Fuse blown Have replaced by a qualified

Motor faulty Have repaired by service

Set to a welding step

Activate torch trigger switch

electrician

centre

Technical Specification

• No wire feed

Pressure roller loose Increase pressure of leaf

spring with knurled thumb screw

Wire kinked at wire feed

Groove in feed roller worn

Electrode wire stuck to contact tip

• Machine shuts down, overload control light comes on

Duty cycle exceeded Let machine cool down,

Power unit faulty Have repaired by service

Adjust wire lead-in nozzle

Replace

Replace contact tip, if wire is deformed, reduce pressure of pressure roller

observe duty cycle stated on nameplate

centre.

MIG/MAG 140 MIG/MAG 160

Power supply 1 x 230 V, 50/60 Hz 1 x 230 V, 50/60 Hz

Power input max. 5,1 kVA 5,3 kVA

Current draw max. 22 A 23 A

Mains fuse, time-lag 16 A 16 A

Open-circuit voltage 17,5 – 28 V 19 – 30 V

Welding current range 30 – 140 A 30 – 160 A

max. Duty cycle (40°C) 4 % 8 %

Welding steps 4 4

Wire feed rate 1,0 – 12 m/min 1,0 – 12 m/min

Electrode wire diameter 0,6 – 0,8 mm 0,6 – 0,8 mm

Protection class IP 21 IP 21

Length x Width x Height 590 x 260 x 420 mm 590 x 260 x 420 mm

Weight 21 kg 26,5 kg

Current setting range

Position MIG / MAG 140 MIG / MAG 160

130A30A 250A60A 380A100A 4140A160A

1.6

MIG/MAG 140/160

XS0028F.fm

2France

Eléments de commande

1 Branchement chalumeau Pôle (+)

trique des prises de courant doit être protégé par fusibles ou par interrupteur automatique. Selon les conditions de branchement sur secteur au

point de jonction, les sources de courant de soudage peuvent entraîner des perturbations dans le sec-

teur pour d’autres consommateurs. Pour résoudre ce problème et pour éviter de telles perturbations, il est nécessaire de se renseigner avant le branche ment auprès de l’entreprise chargée de l’alimentation en courant. (Classe A selon CISPR 11)

Il faut tenir l’appareil hors de la portée des enfants. Tenez compte des risques que représentent les travaux de soudage et respectez le règlement du travail ainsi que les consignes de prévention d’incendie.

L’appareil doit être rangé à l’abri de l’humidité et n’est pas conçu pour être utilisé dehors, lorsqu’il pleut.

L'appareil ne convient pas au décongelage de tubes.

Danger! 

Les personnes qui portent un stimulateur cardiaque doivent obligatoirement consulter leur médecin avant de travailler avec l’appareil à soudage!

2 Interrupteur marche/arrêt et courant de

soudage

3 Régulateur d’avancement du fil

4 Indicateur de surcharge

5 Branchement pince à électrodes à la

masse Pôle (–)

Cher client, chère cliente, nous vous félicitons d’avoir acheté cet appareil de

soudage sous gaz protecteur de haute qualité. Afin de garantir votre sécurité et la sécurité de l’appareil, nous vous prions de bien vouloir lire com plètement et consciencieusement ces instructions avant la mise en service, et de respecter ces instructions en tous points.



Conseils de principe pour l’utilisateur

L’appareil de soudage sous gaz protecteur MIG/ MAG est une source de courant continu avec avancement du fil intégré, conçue et construite uniquement pour le soudage à l’arc MIG, voire MAG.  Toute autre utilisation de l’appareil est soumise à des risques et donc interdite.

L’appareil ne peut être mis en service que sous la tension secteur indiquée sur la plaque signalétique. Le branchement ne peut se faire qu’avec des prises de courant de sécurité, qui auront été installées par un spécialiste autorisé en électricité. Le circuit élec-

Conseils de sécurité et mesures préventives contre les accidents

x L’appareil à soudage sous gaz protecteur doit

être tenu hors de la portée des enfants.

x Lorsque l’on travaille avec l’appareil à soudage

sous gaz protecteur, il faut respecter le règlement du travail ainsi que les consignes de prévention d’incendie en vigueur. Il faut également respecter les instructions préventives en vigueur contre les accidents !

x Lors du soudage, différentes sortes de risques

pourraient éventuellement causer des domma ges à la santé.

x Lors du soudage, il faut porter une combinaison

fermant hermétiquement, ne portant pas de tra ces de substances qui s’enflamment facilement, et sèche (mieux encore une combinaison pour soudeur très résistante aux flammes), des chaussures robustes, isolantes (bottes), une protection sur la tête et des gants à fourreau en cuir.

x Les vêtements en matières synthétiques ainsi

que les chaussures basses ne sont pas adéquats. Des gants isolants aux deux mains protègent des secousses électriques (tension à vide du circuit électrique de soudage), des radiations nocives (rayons thermiques et ultraviolets) de même que des éclaboussures de métal ardent et de laitier. La radiation ultraviolette a un effet semblable aux coups de soleil sur les parties du corps qui ne sont pas protégées.

MIG/MAG 140/160

2.1

Gaz – vapeurs – fumée

x Pendant le soudage, il y a formation de fumée

nocive et de poussière de métal. Nous vous conseillons d’utiliser des masques de protection contre la fumée et de veiller à une alimentation suffisante d’air frais dans les locaux où s’effectue le soudage, afin de garantir la protection nécessaire du personnel.

x Dans des locaux fermés, il est absolument indis-

pensable d’utiliser des exhausteurs qui devront être installés en-dessous de la zone de soudage.

x Le matériel que l’on veut souder ne doit pas por-

ter de traces de dégraissants à solution halogène, pour empêcher la formation de gaz toxiques.

x Les métaux qui sont recouverts de plomb, de

graphite, de cadmium, de zinc, de mercure ou de béryllium ou qui contiennent ces matériaux, sont susceptibles de dégager beaucoup de fumée au cours du soudage.

x Lors du soudage, il y a dégagement d’ozone. Il

s’agit d’une sorte d’oxygène qui peut entraîner des irritations ainsi que des maladies des orga nes respiratoires.

x Les produits solvants de graisse comme le tri-

chloréthylène, le perchloréthylène, etc. s’évaporent pendant le soudage et se transforment, dû à une modification chimique, en gaz phosgène. Le gaz phogène est toxique!

Rayons ultraviolets

x Les rayons de l’arc électrique peuvent provo-

quer des blessures aux yeux et des brûlures de la peau.

x Pour se protéger des étincelles, de la chaleur,

des rayons visibles et invisibles, il faut porter des protections optiques adéquates (écran pro tecteur ou coiffe protectrice pourvus de verres de protection contre les rayons d’échelons 10 à 15 normés DIN 4647, selon la puissance électri que).

x On ne doit pas regarder l’arc électrique si les

yeux ne sont pas protégés (risque d’éblouissement et de brûlure). Si la protection est insuffisante, la radiation ultraviolette invisible provoquera une conjonctivite douloureuse que l’on ne remarquera que quelques heures plus tard.

x Pour effectuer le soudage, il est nécessaire

d’avoir à proximité des personnes qui pourront venir à l’aide immédiatement, en cas d’accident.

x Les personnes ou les assistants qui sont à

proximité de l’arc électrique doivent être informés des dangers existants et être équipés de la protection adéquate.

x Il est nécessaire de protéger les places de tra-

vail environnantes de la radiation: installer les écrans de protection en conséquence.

x Lors de travaux de soudage dans des pièces et

des bâtiments, il faut veiller à une bonne circulation de l’air.

Feu

Danger! 

La température de l’arc électrique s’élève environ à 2400 °C.

Avant de commencer les travaux de soudage, veuillez suivre les conseils suivants:

x Dans un rayon de 5 m de l’endroit de soudure, il

faut éloigner toutes les substances et les objets.

x Les substances se trouvant dans un rayon de 5

m et qui ne peuvent pas être éloignées doivent être protégées correctement: on les recouvre de tôles d’acier, de linges mouillés, etc.

x Les ouvertures, fentes, orifices dans les murs,

etc., doivent être recouverts ou calfeutrés afin de les protéger des flammèches incontrôlées.

x Les moyens d’extinction tels que les extincteurs

de feu, les seaux à eau, etc., sont à tenir à disposition.

x N’oubliez pas que, dû à la conduction de cha-

leur au point de soudure, un incendie peut se déclarer sur des objets recouverts ou dans d’autres pièces.

x Après avoir terminé les travaux de soudage,

assurez-vous à plusieurs reprises dans les 6 – 8 heures qui suivent, qu’il ne reste pas d’endroits incandescents, de foyers ardents ou de conduc tion thermique aux environs de l’endroit où le soudage a eu lieu.

Maniement des bouteilles de gaz protec-

teur

x Pour le maniement des bouteilles de gaz protec-

teur, il faut respecter les consignes de sécurité en vigueur. Il faut tout particulièrement protéger les bouteilles de gaz protecteur, à cause de leur haute pression interne (jusqu’à 200 bar), des détériorations mécaniques, empêcher qu’elles ne basculent ou dégringolent. Il faut également empêcher qu’elles ne se réchauffent (max. 50

°C), ne soient exposées trop longtemps aux

rayons du soleil ou à un gel extrême.

x Lorsque l’on équipe l’appareil MIG/MAG de la

bouteille de gaz protecteur, il faut être conscient du fait que de trop grandes bouteilles, posées un sol inégal, peuvent faire basculer l’appareil. Pour éviter les dommages qui en résulteraient pour l’appareil, voire pour la bouteille de gaz, on ne doit utiliser que des bouteilles de taille conve nable (bouteilles de 10 ou 20 litres).

2.2

MIG/MAG 140/160

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