2 - Connect the earth clamp as close as possible to the work piece and connect the other side of the cable to the ma-
chine (in the desired position depending on the polarity). The contact surface with the work piece should be as large
as possible. Make sure that the surface is completely clean and free of paint and rust.
The following table shows the cable section, recommended by Solter Soldadura, according to amperage and opera-
ting cycle for lengths of less than 25m. These data are for reference and may NOT suit all applications. If the cable
overheats, use a larger cable section.
3 - Connect the MIG torch in its position taking special care to ensure it is tightly screwed to the SCART. Make sure
that the torch to be used is suitable for the current levels and operating cycle the application requires. You can use an
air-cooled or water-cooled torch. If you have the Aerocool cooling unit, make sure the operating mode is disabled for
air-cooled torches or activated in normal mode for water-cooled torches. See P.36 programme function in this ma-
nual.
4 - Connect the gas tube to the rear nozzle of the power unit and the other end of the tube to the gas cylinder flow re-
gulator. Be sure to use the proper gas mixture for the material to be welded. Set the gas flow rate to a typical value of
8 - 10 l/min. A wrong flow setting can cause defects in the weld bead. Remember to close the gas bottle valve when
you finish welding.
5 - Connect the welding machine to a socket with earth wire (the plug must have an earth connection). Make sure
that the voltage is within the range of /- 15% 3ph. Outside this voltage range, the machine may malfunction.
Aeroprocess 4200 DV machines are supplied with a 4 meters 4x4mm
2
power cord without plug. If a longer power
cord is required, it can be replaced.
For lengths of over 25 metres a cable section of 6mm2 is recommended. The machine does not need neutral con-
nection. The yellow - green cable must always be connected to the machine casing.
Welding current (A)
100
150
200
250
300
350
400
Section (mm
2
) for X<60 %
16
25
25
35
50
50
70
Section (mm
2
) for X>60 %
16
25
35
50
70
70
90
ATTENTION
Do not connect the gas cylinder directly to the wire feeder, as it has no solenoid. The solenoid and the
shielding gas pressure sensor are located in the power unit in order to save gas consumption.
ATTENTION
The installation or replacement of the power cord and plug should be carried out only by qualified per-
sonnel.
SOLTER
SOLDADURA S.L.
AEROPROCESS
7
