5. RATINGS PLATE
On the front of the welder is the ratings plate, giving the following data:
1 -
The standard relating to the safety and construction of arc
welding and associated equipment.
2
- Inverter-transformer-rectifier.
3 -
Welding with a continuous flow of welding wire.
4 -
Single-phase AC supply.
5 -
Rating of internal protection provided by casing.
6 -
Output
U
0
: Maximum open-circuit voltage.
I
2
, U
2
: Current and corresponding voltage.
X: Welding ratio based on a 10 minute cycle. 30% indicates 3 minutes welding and 7 minutes rest, 100% indicates continuous
welding.
A/V-A/V: Welding current adjustment range and corresponding voltages.
7 -
Mains Supply
U
1
: Rated supply voltage and frequency.
I
max
: Maximum current.
I
1eff
: Maximum effective current.
8 -
: Delayed fuse for supply protection and ‘symbols referring to safety’.
9 -
Serial Number. Specifically identifies each welder.
10 -
S: Indicates welding may be carried out in environments with a heightened risk of electric shock e.g. very close to large metallic objects.
4.1.
Mig/Mag welding
Welding wire is automatically fed through an insulated liner to the tip of the torch. The torch consists
of a switch, liner, gas hose, and control cable. The switch activates the wire feed roller and the gas
flow. Releasing the switch stops wire feed and gas flow. The weld current is transferred to the
electrode (the wire) from the contact tip at the torch end. Four settings control the current to the
electrode. Settings are Min/1 = low, then Min/2, Max/1 and Max/2 = high. Wire speed must be
adjusted according to current output. The higher the current the faster the wire speed. A gas cup fits over
the contact tip to direct gas flow towards the weld, ensuring that the arc welding process is shielded
from oxidisation. The shielding gas also assists heating of the weld. The torch is connected to the
positive side of a DC rectifier, and the negative clamp is attached to the workpiece.
4.2.
Spot welding
(The PM150XT torch can be fitted with a spot welding gas cup.)
Remove the existing gas cup and fit a spot welding gas cup. Select the highest current and wire
speed settings. Drill a small hole in the top workpiece. Push the spot gas cup onto the material to be
welded. The castelations on the cup keep it the correct distance from the weld pool and allow you to
push the two workpieces together. Press the torch trigger and hold for 2 to 3 seconds. The wire will feed through during the allotted time
and create the weld.
4.3.
Preparation for welding
IMPORTANT!
BEFORE YOU COMMENCE, MAKE SURE THE MACHINE IS SWITCHED OFFAT THE MAINS. IF WELDING A CAR,
DISCONNECT THE BATTERY OR FIT AN ELECTRONIC CIRCUIT PROTECTOR. ENSURE THAT YOU READ, UNDERSTAND AND
APPLY THE SAFETY INSTRUCTIONS IN SECTION 1.
4.3.1.
To ensure a complete circuit, the negative lead must be securely attached to the workpiece, close to the weld area. Best connection is
obtained by grinding the point of contact on the workpiece before connecting the clamp.
4.3.2.
The weld area must be free of paint, rust, grease, etc.
4.4.
Gas types and their use
Welding mild steel with CO
2
gas (supplied with unit) is appropriate for most welding tasks where spatter and high build up of weld do not pose a problem.
To achieve a spatter free and flat weld however, requires an Argon/CO
2
mixture.
4.4.1. To weld aluminium use:
#
Argon Gas
#
0.8mm Contact Tip
#
0.8mm Aluminium Wire (MIG/2/KAL08).
4.4.2.
The following table is an estimated duration of cylinders based on a flow rate of 2 litres per minute. Actual duration will be dependant upon various
job conditions including the operator’s welding technique. All times are therefore approximate.
a) Refillable cylinder:
CO
2
/200 300g = 1 hour (refill service via Sealey dealers).
b) Disposable cylinders:
CO
2
/100 390g = 1-1/4hours. CO
2
/101 600g = 2 hours.
Argon ARG/100 300g = 1 hour.
Argon/CO
2
MIX/100 300g = 1 hour.
Note: When comparing prices, always check fill weights.
4. WELDING PRINCIPLES
3.3.5.
Feeding the wire through to the torch.
MODELS E130XT & PM140XT. Unscrew and remove the gas cup (fig.8a) and the copper contact tip (fig.8b).
Then follow points 3.3.7. to 3.3.10.
3.3.6.
MODEL PM150XT ONLY. Remove gas cup and contact tip from end of torch as follows:
a) Take torch in left hand with the torch tip facing to the right and grasp gas cup with your right hand.
b) Turn gas cup
clockwise only
and pull cup out to the right (fig. 8).
!
WARNING!
Do not turn gas cup anti-clockwise, as this will damage the internal spring.
c) Unscrew the copper contact tip (
right-hand thread
) to remove.
3.3.7. Check welder is switched off “O”, (I/O switch, figs.10 & 11) and that the earth clamp is away from the torch
tip. Connect the welder to the mains power supply and set the current switches (Max/Min and 1/2 switches,
figs.10 & 11) to ‘Min 1’.
3.3.8. Set the wire speed knob to position 5 or 6 (figs.10 & 11) (the higher the number the faster the speed).
3.3.9.
Switch the welder on “I”, keep the torch cable as straight as possible and press the torch switch. The wire will
feed through to the torch.
3.3.10. When wire has fed through, switch welder off
and unplug from mains
.
3.3.11 Models PM EM130XT & PM140XT. Thread contact tip over wire and screw into place. Screw gas cup back onto torch.
3.3.12. Model PM150XT only.
a) Thread contact tip over wire and screw into place.
b) Grasp gas cup in right hand, push onto torch head and turn
clockwise only
.
!
WARNING!
Do not turn gas cup anticlockwise, as this will damage the internal spring.
3.3.13. All models. Cut wire so that it is protruding approximately 1/4” from the tip.
3.4.
Setting wire tension
IMPORTANT: Too little or too much tension will cause erratic wire feed and result in poor welding.
3.4.1. For 0.6mm mild steel wire the wire feed tension screw must be tightened fully and undone approximately two
complete turns (fig. 9).
3.4.2. Tension
between rollers is checked by slowing down the wire between your fingers. If top feed roller skids
the tension is correct. Use as low a tension as possible, too high a tension will deform the wire and result in a
blown fuse.
fig. 8
PM150XT
only
fig. 11
fig. 10
fig. 9
EM130XT.V3, PM140XT.V2, PM150XT.V2 - 3 - 130206
