MIG/MAG Combination Gas/No Gas Welder
30-135A
9
silverlinetools.com
5. Refit the Spool Retainer, Tension Spring and Spool Nut and tighten so the spool will not unravel
on its own
6. If you need to change or turn the Upper Roller (21), so the correct size groove for the wire is in
line with the inner liner of the Torch Cable (14), remove the 2 screws of the Rollers Cover (17) and
use a spanner to remove the roller securing component (Image I), then turn or replace the roller
with the correct size
7. Lift the metal tension bar clear of the point of the Roller Tension Adjuster (19) and move to the
side so there is a sufficient gap between the Upper Roller and Lower Roller (18) for the wire to
feed through (Image J)
8. Carefully release the end of the wire from the Wire Spool (26) and take care not to let the wire
unravel. Ensure that the wire is straight for 75 – 100mm and is cut off cleanly with a smooth tip
that will not damage the Torch Cable liner. There must be no burrs on the wire
9. Slowly feed the wire into the end of the Wire Input (20) across the rollers and into the Torch Cable
liner. Push a little way into the liner carefully until some resistance is felt
10.Swing the metal tension bar into position, ensuring that the wire is centred in the grooves of
the upper and lower rollers. Tension can be adjusted with the Roller Tension Adjuster (19) if
necessary
IMPORTANT:
The Spool Nut should only be adjusted with enough tension that will cause the spool
only to turn when the wire is feeding correctly into the Torch Cable liner and the Roller Tension
Adjuster should be adjusted so the wire will slip on the rollers if there is resistance in the Torch
Cable liner.
11.Cover the wire feeding mechanism with the flap and secure with the Panel Release (16)
12.Isolate the Earth Clamp (9) by placing on a non-metallic, non-conductive surface
13.Set the Wire Feed Speed Dial (6) to the slowest setting
14.Connect the welder to the mains power supply, switch on, and hold the Torch Handle (13)
15.Move the torch away from the machine, so that the Torch Cable is straight and in line with the
wire feed mechanism so the wire will have minimal resistance
16.Ensure that the torch is not touching anything, and squeeze the Trigger (12). The wire feed
mechanism should drive the wire through to the torch (Image H)
17.If the wire is not driven through, disconnect from the mains power supply and adjust the Roller
Tension Adjuster (19)
18.When the wire is propelled out of the end of the torch, switch off and disconnect from the mains
power supply
19.Refit the Tip and the Shroud, and trim the wire so that approximately 3mm projects from the Tip
IMPORTANT:
Use clean compressed air to clean the Torch Cable liner if the wire will not feed
through.
Removing wire reel and end of wire
1. Open the side flap of the welder using the Panel Release (16) and check if the old Wire Spool
(26) is empty
2. If not empty cut the wire at the Wire Spool and loop back and secure on the Wire Spool if
intending to continue using at a later date
3. Lift the metal tension bar clear of the point of the Roller Tension Adjuster (19) and move to the
side (Image J)
4. Use a pair of pliers to draw the last of the old Wire Spool (26) out through the Tip (10) of the
torch
5. Then proceed as per instructions for ‘Installing wire’ above
Configuring for flux wire operation
1. For ‘no gas’ operation using flux wire spools the polarity of the Earth Clamp (9) and the torch
must be correct. Open the side flap of the case using the Panel Release (16)
2. On the right side the cable connections can be seen (Image G). Check that the black cable
goes to the red left positive connection and the red cable goes to the right side black negative
connection. Reverse if necessary
Configuring for gas operation
1. For ‘gas’ operation using non flux plain wire spools
2. The polarity of the Earth Clamp (9) and the torch must be correct. Open the side flap of the case
using the Panel Release (16)
3. On the right side the cable connections can be seen (Image G). Check that the black cable goes
to right side black negative connection and the red cable goes to the red left positive connection.
Reverse if necessary
4. A regulator is required to connect to the Ø4mm gas tube that will adapt to your chosen gas bottle
or cylinder
5. To mount a gas bottle to the rear of the welder, position the welder in the correct position before
adding the bottle. Secure the bottle securely with the strap provided (Image E) and attach the
regulator (not supplied) following the instructions provided. A typical regulator is shown in
Image F. Read all safety warnings provided with or attached to the gas bottle or cylinder
6. Do a final check for all fittings to ensure they are all satisfactory and safe
Operation
IMPORTANT
• Always wear appropriate personal protective equipment for the job that you are about to do. Use
of this machine requires a welding mask, gloves, heat-resistant clothing and, if appropriate, a
respirator
• Always ensure that you have an appropriate fire extinguisher near to the work area
• Always inspect your machine for damage or wear. Pay particular attention to leads and cables. If
any damage is found, DO NOT USE
• Check that all casings or covers are properly closed and secured
• Position the welder in such a way that it will not move or tip in use. Ensure that there is at least
500mm of clear space around the welder to allow proper ventilation
Setting the machine
• To achieve a good quality weld, the Voltage/Current Selector (7) must be set correctly. See chart
• Use Wire Feed Speed Dial (6) to make minor adjustments to wire speed to provide a steady arc.
The correct setting will depend on distance, current, torch speed, and other factors. Experiment
with wire speeds until you find an optimum setting
Duty Cycle
• This machine is not designed for continuous welding. Excessive continuous welding would cause
overheating and damage to internal components
• The duty cycle defines the number of minutes, in every ten minutes, that the machine can weld
• For a duty cycle of 10%, the machine may be used for 1 minute, and then must be allowed 9
minutes to cool. The 60% duty cycle allows 6 minutes in every 10 minutes. See chart
• If the duty cycle is exceeded, the machine will automatically cut-out
• Using the machine at reduced current settings, and maintaining good ventilation will maximise
the duty cycle
15.5V
16.15V
16.6V
17.9V
19.25V
20.75V
Current 1
2
A
30A
43A
52A
78A
105A
135A
Duty Cycle X %
(minutes per 10
minutes)
100%
(10min)
60%
(6min)
50%
(5min)
20%
(2min)
15%
(1.5min)
10%
(1min)
Metal Thickness
* Approximate
guide
1.2mm
2mm
3.2mm
4mm
5.2mm
6.5mm
IMPORTANT: DO NOT OVER-TIGHTEN THE REGULATOR ON TO THE GAS CYLINDER
Note: Any safety information provided with the regulator or gas bottle supersedes
this information.
When fitting the regulator onto the gas cylinder, check the tap valve is fully turned off and
inside the connection to the gas bottle has satisfactory seals. When fitting the regulator, it is
normal to hear a hiss of gas escape through the pressure relief hole near the bottom of the
regulator. This is to be expected and does not mean that there is a problem. The leakage will
stop as the regulator makes contact with the seal.
Do not over-tighten the regulator onto the gas cylinder as there is a risk unscrewing the
regulator will cause the cylinder to be thrust violently from your hand. When removing
regulators from gas cylinders, always do so at arm’s length. Ensure that the cylinder’s gas valve
is not disturbed. If you see the cylinder’s gas valve start to unscrew it will be caused by an
over-tightened regulator. In these circumstances refit and retighten the regulator immediately
and discharge all gas into the atmosphere by opening the regulator valve before re-attempting
to remove the regulator.
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Summary of Contents for 30-135A
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