WP MIG 135i Owner'S Manual Download Page 15 | Manualshive

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WP MIG 135i Owner'S Manual Download Page 15

11

Front panel description

1 …........ ON/OFF switch

2 …........ Welding voltage adjustment

3 …........ Wire speed adjustment

4 …........ LED – ON indication

5 …........ LED – Overload indication

6 …........ Central connector (EU)

7 …........ Return cable connection

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Summary of Contents for MIG 135i

Page 1: ...efully read this manual to assure faultless operation Take special care in complying with Safety Instructions Dear customer We congratulate You for buying our quality welding device You are kindly asked to carefully read this manual to assure faultless operation Take special care in complying with Safety Instructions Weldpartner Gompenstraat 9 5145 RM Waalwijk www weldpartner nl ...

Page 2: ......

Page 3: ...anual WP 135i WP 165i are designed and produced according to the following EU Directives Low Voltage Directive No 2006 95 EEC EMC Directive No 2004 108 EEC with their amendments and inspected according to following EU Norms EN 60 974 1 EN 60 974 10 Every intervention on these machines from an unauthorized person makes this Declaration invalid Waalwijk 03 July 2015 Weldpartner Nederland Joost van d...

Page 4: ... 8 MAINS SUPPLY 8 TORCH CONNECTION 8 GROUND CONNECTION 8 SHIELDING GAS CONNECTION 9 INSTALLATION OF WIRE REEL 9 POLARITY CHANGE 9 4 OPERATION 10 DUTY CYCLE AND OVERHEATING 10 FRONT PANEL DESCRIPTION 11 SETTING IN OPERATION 12 MIG GMAW WELDING 12 OVERLOAD CONTROL 12 5 MIG GMAW WELDING GUIDELINES 13 WORK PIECE PREPARATION 13 TYPICAL MACHINE SETTINGS 14 POSITIONING THE WELDING TORCH 15 GUN MOVEMENT D...

Page 5: ...ts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard Do not touch live electrical parts Wear dry hoIe free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground Do not use AC output in damp areas if movement i...

Page 6: ...sure the breathing air is safe Do not weld in locations near degreasing cleaning or spraying operations The heat and rays of the arc can react with vapours to form highly toxic and irritating gases Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary while wearing an air supplied r...

Page 7: ...ply when not in use Always ventilate confined spaces or use approved air supplied respirator HOT PARTS can cause severe burns Do not touch hot parts bare handed Allow cooling period before working on gun or torch MAGNETIC FIELDS can affect pacemakers Pacemaker wearers keep away Wearers should consult their doctor before going near arc welding gouging or spot welding operations NOISE can damage hea...

Page 8: ...Do not block or filter airflow to unit STATIC ESD can damage PC boards Put on grounded wrist strap BEFORE handling boards or parts Use proper static proof bags and boxes to store move or ship PC boards MOVING PARTS can cause injury Keep away from moving parts Keep away from pinch points such as drive rolls WELDING WIRE can cause injury Do not press gun trigger until instructed to do so Do not poin...

Page 9: ...uded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce mag...

Page 10: ...ic welding machine after finishing work or before a long break DO NOT make any modifications to the machine It may cause changes in the features and deterioration of technical data Any adaptations to this machine are prohibited and may void the warranty Warranty is void if any damage to the machine is caused by misuse Acceptable range of ambient temperature is from 10 40 C Acceptable range of humi...

Page 11: ...A 16 A Welding range 20 135 A 20 165 A No load voltage 17 23 V 17 25 V Duty cycle 100 50 A 60 70 A 35 90 A 100 80 A 60 100 A 35 130 A Welding wire diameter 0 6 mm 0 8 mm steel 0 6 mm 0 9 mm steel Protection IP 23 IP 23 Insulation class H H Cooling AF AF Dimensions 400 x 290 x 310 mm 400 x 290 x 310 mm Weight 12 kg 14 kg ...

Page 12: ...e feeder 3 Gas tank and supply 4 Ground cable and wire current and gas conduit EU connector 5 Welding torch Mains supply INPUT primary cable is supplied with machine Connect the machine to mains according to legislation of the country where machine is being used Connection can be effected through plug or directly Supply system should be protected at all times by the fuse stated in technical data s...

Page 13: ...work easier Ensure both wire inlet guide and the feeding rollers groove are aligned Push the welding wire to the inlet of the torch connection Replace the pressure handle to reestablish pressure on the wire If handle pressure is too strong the wire could be transformed flattened If the pressure is too low the wire could slip in the feeding groove Use tension knob to adjust this 1 Feeding rolls 2 P...

Page 14: ...it overheats thermostat s opens output stops and cooling fan runs Wait fifteen minutes for unit to cool Reduce amperage or duty cycle before welding 60 Duty Cycle at 100 A Overheating Welding machine must be used according to technical data from this manual If the machine is overloaded failures may occur that are not be covered by warranty ...

Page 15: ...11 Front panel description 1 ON OFF switch 2 Welding voltage adjustment 3 Wire speed adjustment 4 LED ON indication 5 LED Overload indication 6 Central connector EU 7 Return cable connection ...

Page 16: ...n Use steps from 1 to 4 for welding and position Gas test for checking the gas flow For normal welding torch must be held at a certain distance from the welding spot When placed too far welding area cannot be protected with gas which causes a porous weld When placed too close welding material and torch components such as welding tip can burn out Before starting the welding it is recommended to mak...

Page 17: ... all determine joint type Around the groove work pieces should be dry and clean free of rust metallic coating dirt colour or grease Joint type Groove shape Weld shape Metal thickness mm Work piece spacing mm Square butt joint single sided up to 1 5 from 1 5 0 to 2 Square butt joint double sided 2 to 4 up to 2 3 to 6 up to 1 V butt joint 3 to 6 up to 1 Square T joint single sided from 0 6 Square T ...

Page 18: ... 30 35 30 40 15 20 8 0 0 8 1 6 380 420 37 38 40 50 15 20 Butt joint 12 0 1 2 1 6 420 480 38 41 50 60 15 20 Thickness mm Wire diameter mm Welding current A Welding voltage V Welding speed cm min Gas flow L min Joint shape 1 0 0 8 70 80 17 18 50 60 10 15 L 1 2 1 2 1 0 85 90 18 19 50 60 10 15 L 1 2 1 0 1 2 100 110 18 19 5 50 60 10 15 L 1 2 1 6 1 2 120 130 19 20 40 50 10 20 L 1 2 2 0 1 0 1 2 115 125 1...

Page 19: ...d correctly on seam 1 Hold torch and control trigger with one hand 2 Work piece 3 Earth clamp 4 Electrode extension Stickout to in 5 Cradle torch with the other hand and rest it on work piece Heat distribution and weld material flow are specific for groove welds and fillet welds Optimal torch position differs from one to another Weld bead shape differs depending on electrode extension when welding...

Page 20: ...ragging the torch results in deeper penetration and narrower weld Arc strength prevents slag to enter the molten material When pushing the torch penetration will be shallower and the weld wider This movement is suitable for thin plates because of smaller heat input 1 Stringer bead steady movement along seam 2 Wave bead side to side movement along seam 3 Wave patterns Use weave patterns to cover a ...

Page 21: ...ELD BEAD 1 Fine spatter 2 Uniform bead 3 Moderate crater during welding 4 No overlap 5 Good penetration into base material POOR WELD BEAD 1 Large spatter deposits 2 Rough uneven bead 3 Slight crater during welding 4 Bad overlap 5 Poor penetration ...

Page 22: ...sity Small cavities or holes resulting from gas pockets in weld material Possible causes Corrective actions Wrong gas Use welding grade shielding gas change to different gas Welding wire extends too far out of nozzle Be sure welding wire extends no more than in beyond nozzle Work piece dirty Remove all grease oil moisture rust paint undercoating and dirt from work surface before welding Use a high...

Page 23: ...cteristics Improper welding technique Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration Keep arc on leading edge of weld puddle Be sure welding wire extends no more than in beyond nozzle Insufficient heat input Select higher wire feed speed and or select higher voltage range Reduce travel speed Distortion Contraction of weld metal during welding that forces base metal to ...

Page 24: ... edge of weld puddle Use correct gun angle of 0 to 15 degrees Insufficient heat input Select higher wire feed speed and or select higher voltage range Burn through Weld metal melting completely through base metal resulting in holes where no metal remains Possible causes Corrective actions Excessive heat input Select lower voltage range and reduce wire feed speed Increase and or maintain steady tra...

Page 25: ... to the outlet in a straight line Rolls groove diameter must correspond wire diameter Carbon steel and stainless steel wire use V groove rolls aluminium and flux core wire use U groove rolls Pressure from upper rolls must be strong enough to prevent wire from slipping inside the groove Excessive pressure poses unnecessary stress on rolls and bearings When wire slides across rolls scraps of rolls a...

Page 26: ... UH UH 03 2 X10 X1 X2 X6 X4 X6 X7 UH7 UH02 U2 U1 X9 X8 X2 X1 X6 X2 X3 X4 X5 XH06 6 1 M2 7x 6x TG Torch switch P2 Wire speed LD1 Power LED LD2 Thermal LED P1 Welding current POWER SUPPLY POWER MODULE S01 MIG 135 i MIG 165 i CONTROL MODULE FRONT PANEL UH02 2 MV M1 UH04 X3 X9 ze ru ...

Page 27: ...65 037 Poz 1 Drive roll Poz 2 Pressure roll Poz 3 Pressure adjustment Poz 4 Wire inlet Roll Code V 0 6 R 0 8 765 039 V 1 0 U 1 0 765 053 V 0 6 V 0 9 765 081 R 0 9 R 0 9 765 079 U 0 8 U 1 0 765 083 U 0 6 U 0 9 765 084 V 0 8 V 0 9 765 085 U 0 9 V 0 9 765 133 V 0 6 V 0 8 765 134 ...

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