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PERSONAL SAFETY

 

CAUTION 

Keep the work area well lit. Make sure there 
is adequate space surrounding the work area. 
Always keep the work area free of obstructions, 
grease, oil, trash, and other debris. Do not use 
equipment in areas near flammable chemicals, 
dust, and vapours. Do not use this product in a 
damp or wet location.

1.  Stay alert, watch what you are doing and use 

common sense when operating equipment.
Do not use a tool while you are tired or under
the influence of drugs, alcohol or medication. A 
moment of distraction when operating equipment
may result in serious personal injury.

2.  Do not overreach. Keep proper footing and

balance at all times. This enables better control of
the power tool in unexpected situations.

ARC RAYS CAN BURN EYES AND SKIN

 

DANGER

Arc rays from the welding process produce 
intense heat and strong ultraviolet rays that can 
burn eyes and skin. 

1.  Use a Welding Helmet or Welding Face 

Shield fitted with a proper shade filter
(refer AS 60974-1, AS/NZS 1337.1 and
AS/NZS 1338.1 Safety Standards) to protect 
your face and eyes when welding or watching.
(See Filter Table on Page 6).

2.  Wear approved safety glasses. Side shields

are recommended.

3.  Use protective screens or barriers to protect 

others from flash and glare; warn others not to
watch the arc.

4.  Wear protective clothing made from durable, 

flame-resistant material (wool and leather) and
foot safety protection.

5.  Never wear contact lenses while welding.

NOISE CAN DAMAGE HEARING

 

CAUTION

Noise from some processes can damage 
hearing.  Use AS/NZS compliant ear plugs or ear 
muffs if the noise level is high.

WORK ENVIRONMENT SAFETY 

 

DANGER

Remove any combustible material from the work area.

1.

 

When possible, move the work to a location well
away from combustible materials. If relocation 
is not possible, protect the combustibles with a 
cover made of fire resistant material.

2.

 

Remove or make safe all combustible materials 
for a radius of 10 meters around the work area. 
Use a fire resistant material to cover or block all
doorways, windows, cracks, and other openings.

3.

 

Enclose the work area with portable fire resistant 
screens. Protect combustible walls, ceilings,
floors, etc., from sparks and heat with fire 
resistant covers.

4.

 

If working on a metal wall, ceiling, etc., prevent
ignition of combustibles on the other side by 
moving the combustibles to a safe location. 
If relocation of combustibles is not possible, 
designate someone to serve as a fire watch,
equipped with a fire extinguisher, during the
welding process and well after the welding is
completed.

5.  Do not weld or cut on materials having a

combustible coating or combustible internal 
structure, as in walls or ceilings, without an 
approved method for eliminating the hazard.

6.

 

After welding, make a thorough examination for
evidence of fire. Be aware that visible smoke or 
flame may not be present for some time after 
the fire has started. Do not weld or cut in 
atmospheres containing dangerously reactive
or flammable gases, vapours, liquids, and dust. 
Provide adequate ventilation in work areas 
to prevent accumulation of flammable gases, 
vapours, and dust.

7.

 

Do not apply heat to a container that has held an 
unknown substance or a combustible material
whose contents, when heated, can produce 
flammable or explosive vapours. Clean and purge
containers before applying heat. Vent closed 
containers, including castings, before preheating,
welding, or cutting.

ELECTRICITY CAN KILL

 

DANGER 

Touching live electrical parts can cause fatal 
shocks or severe burns. The electrode and work 
circuit is electrically live whenever the output 
is on. 

The input power circuit and machine internal 
circuits are also live when power is on. In  
semi-automatic or automatic wire welding, the 
wire, wire reel, drive roll housing, and all metal 
parts touching the welding wire are electrically 
live. Incorrectly installed or improperly grounded 
equipment is a hazard.  

1.

 

Do not touch live electrical parts.

2.

 

Wear dry, hole-free insulating gloves and body
protection.

3.  Insulate yourself from the work and the ground

using dry insulating mats or covers.

4.  Disconnect input power before installing or 

servicing this equipment. Lock input power,
disconnect switch open, or remove line fuses so
power cannot be turned on accidentally.

5.  Properly install and ground this equipment 

according to national, state, and local codes.

6.  Turn off all equipment when not in use.

Disconnect power to equipment if it will be left
unattended or out of service.

7.  Use fully insulated electrode holders. Never dip

the holder in water to cool it or lay it down on the
ground or the work surface. Do not touch holders
connected to two welding machines at the same 
time or touch other people with the holder or 
electrode.

8.  Do not use worn, damaged, undersized, or poorly 

spliced cables.

9.  Do not wrap cables around your body.

10. Connect the work piece to a good electrical 

ground.

11. Do not touch the electrode while in contact with

the work (ground) circuit.

12. Use only well-maintained equipment. Repair or 

replace damaged parts as soon as practical.

13. In confined spaces or damp locations, do not use

a welder with AC output unless equipped with a 
voltage reducer.

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Summary of Contents for XM255PRO

Page 1: ...OR WNVK 2TQEGUU 21 5 78 7 216 21 7 385 6 2 285 1 675 7 0 352 19 57 5 0 00 08 7 352 66 1 0 1 3 6 1685 28 9 0 5 6 2856 7 7 16758 7 21 9 1 5 7 217 176 2 7 6 0 18 25 86 1 285 0 1 PLEASE READ THIS MANUAL...

Page 2: ...L ADJUSTING WIRE FEED TENSION 1 CONNECTING THE WELDER 1 GASLESS MIG OPERATION FCAW 1 GAS SHIELDED MIG OPERATION GMAW 1 SPOOL GUN OPERATION 1 MMA WELDING OPERATION 1 TIG WELDING OPERATION 1 MIG WELDING...

Page 3: ...e specially designed to lter out microscopic particles 8 People with pacemakers should consult their physician s before using this machine WARNING Electromagnetic elds in close proximity to a heart pa...

Page 4: ...ng process and well after the welding is completed 5 Do not weld or cut on materials having a combustible coating or combustible internal structure as in walls or ceilings without an approved method f...

Page 5: ...nimum Shade Number of Filter s Manual Metal Arc Welding Covered Electrodes MMA Less than or equal to 100 8 100 to 200 10 200 to 300 11 300 to 400 12 Greater than 400 13 Gas Metal Arc Welding GWAW MIG...

Page 6: ...in 10m of the welding site 4 Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas 5 Watch for re and keep a re extinguisher nea...

Page 7: ...5m 1 Argon Gas Regulator with CO2 Adaptor 1 Gas Hose with clamps 8mm x 2m 1 V Groove Wire Drive Roller Set 0 8 1 0mm 1 Knurled Groove Wire Drive Roller Set 0 8 0 9mm 1 Instruction Manual 1 Instruction...

Page 8: ...hich in turn affects the heat input and the penetration The wire speed feed simply controls the rate at which the welding wire is fed into the weld pool For any voltage position setting there will be...

Page 9: ...Professional Welding Gloves Argon Regulator 5 5 MIG Welding Tip Dip Gel 120g 7 Welding Magnet 5 0 MIG Wire 0 6mm Mild Steel 5kg MW5KG06 MIG Wire 0 8mm Mild Steel 5kg 0 MIG Wire 0 8mm Flux Cored 5kg 0...

Page 10: ...mp to the work piece Contact with the work piece must be rm with clean bare metal with no corrosion paint or scale Connect the MIG Power Connection Lead to the MIG Torch Power Connection Socket 11 and...

Page 11: ...e mains power using the Mains Input Power Lead 21 Switch the Mains Power Switch 16 to ON to power up the machine Connect the Work Lead Clamp Quick Connector to the Positive Welding Power Output Socket...

Page 12: ...supplied gas or gas mixture The process is normally applied semi automatically however the process may be applied automatically or by machine It is commonly used to weld large diameter electrodes in t...

Page 13: ...e Longitudinal Angle Axis of Weld Nozzle Angle Right Handed Operator Fig 1 10 Leading or Pushing Angle Forward Pointing Trailing or Pulling Angle Backward Pointing 90o Direction of Travel Establishing...

Page 14: ...h nozzle Do not restrict gas ow by allowing spatter to build up inside the torch nozzle Check that the MIG torch O rings are not damaged WARNING Disengage the feed roll when testing for gas ow by ear...

Page 15: ...ge too high Adjust voltage and current by adjusting the voltage control and the Current Wire Speed control Wire is wandering Replace contact tip Incorrect shielding gas Check shielding gas Insuf cient...

Page 16: ...e to the porosity caused by gas held in this type of iron Copper and Alloys The most important factor is the high rate of heat conductivity of copper making pre heating of heavy sections necessary to...

Page 17: ...st scale dirt grease etc Slag should be removed from oxy cut surfaces Typical joint designs are shown in Figure 1 19 Open Square Butt Joint Fig 1 19a Gap varies from 1 6mm 1 16 to 4 8mm 3 16 depending...

Page 18: ...o short there is the danger of it being blanketed by slag and the electrode tip being solidi ed in If this should happen give the electrode a quick twist back over the weld to detach it Contact or tou...

Page 19: ...completion of each side motion pause for a moment to allow weld metal to build up at the edges otherwise undercut will form and too much metal will accumulate in the centre of the weld Figure 1 26 ill...

Page 20: ...lectrode Electrode too large for joint Use smaller gauge electrode Insuf cient deposit time at edge of weave Pause for a moment at edge of weave to allow weld metal build up Power source is set for MI...

Page 21: ...3 32 100 165 3 2mm 1 8 135 200 4 0mm 5 32 190 280 4 8mm 3 16 250 340 Tungsten Electrode Types Electrode Type Ground Finish Application Features Colour Code Thoriated 2 DC welding of mild steel stainl...

Page 22: ...ement of ller rod Re position ller rod Electrode melts or oxidises when an arc is struck Torch lead connected to positive welding terminal Connect torch lead to negative welding terminal No gas owing...

Page 23: ...mponents causing electrical short circuits Check for damaged parts Do not use the welder with damaged parts before further use a damaged welder must be carefully checked by a quali ed person to determ...

Page 24: ...KH H SHQVH RI WKH RZQHU 7KHVH 0LJ LWHPV LQFOXGH EXW DUH QRW OLPLWHG WR RQWDFW 7LSV 1R OHV XQ LQHUV ULYH 5ROOHUV HOW LUH OHDQHU Q DGGLWLRQ WKLV ZDUUDQW GRHV QRW H WHQG WR DQ GDPDJH FDXVHG E WKH XQWLPHO...

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