WP MIG 135i Owner'S Manual Download Page 6

 
 
 
 

  Do not touch electrode if you are in contact with 

the  work,  ground,  or  another  electrode  from  a 
different machine. 

  Use only weII-maintained equipment. Repair or 

replace  damaged  parts  at  once.  Maintain  unit 
according to manual. 

  Wear  a  safety  harness  if  working  above  floor 

level. 

  Keep all panels and covers securely in place. 

  Clamp  work  cable  with  good  metal-to-metal 

contact to work piece or worktable as near the 
weld as practical. 

  Insulate  work  clamp  when  not  connected  to 

work  piece  to  prevent  contact  with  any  metal 
object. 

  Do  not  connect  more  than  one  electrode  or 

work cable to any single weld output terminal. 

 

 

SIGNIFICANT  DC  VOLTAGE  exists  after 
removal of input power on inverters.

 

 

  Turn  off  inverter,  disconnect  input  power,  and 

discharge  input  capacitors  according  to 
instructions  in  Maintenance  Section  before 
touching any parts. 

 

FUMES AND GASES can be 
hazardous. 

Welding  produces  fumes  and 
gases.  Breathing  these  fumes 
and  gases  can  be  hazardous 
to your health. 

 

  Keep  your  head  out  of  the  fumes.  Do  not 

breathe the fumes.  

  If inside, ventilate the area and/or use exhaust 

at the arc to remove welding fumes and gases. 

  If  ventilation  is  poor  use  an  approved  air-

supplied respirator. 

  Read  the  Material  Safety  Data  Sheets 

(MSDSs)  and  the  manufacturers’  instructions 
for  metals,  consumables,  coatings,  cleaners, 
and degreasers. 

  Work  in  a  confined  space  only  if  it  is  well 

ventilated,  or  while  wearing  an  air-supplied 
respirator. Always have a trained watch-person 
nearby. Welding fumes and gases can displace 
air and lower the oxygen level causing injury or 
death. Be 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 
respirator.  The  coatings  and  any  metals 
containing  these  elements  can  give  off  toxic 
fumes if welded. 

 

ARC RAYS can burn eyes 
and skin. 

Arc  rays  from  the  welding 
process 

produce 

intense 

visible and invisible (ultraviolet 
and  infrared)  rays  that  can 
burn eyes and skin. Sparks fly 
off from the weld. 

 

  Wear  a  welding  helmet  fitted  with  a  proper 

shade  of  filler  to  protect  your  face  and  eyes 
when  welding  or  watching  (see  Safety 
Standards). 

  Wear approved safety glasses with side shields 

under your helmet. 

  Use  protective  screens  or  barriers  to  protect 

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

  Wear  protective  clothing  made  from  durable, 

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

 

WELDING can cause fire or 
explosion. 

Welding 

on 

closed 

containers,  such  as  tanks, 
drums,  or  pipes,  can  cause 
them  to  blow  up.  Sparks  can 
fly  off  from  the  welding  arc. 

The  flying  sparks,  hot  work  piece,  and  hot 
equipment  can  cause  fires  and  burns.  Accidental 
contact  of  electrode  to  metal  objects  can  cause 
sparks, explosion, overheating, or lure. Check and 
be sure the area is safe before doing any welding. 

 

  Protect  yourself  and  others  from  flying  sparks 

and hot metal. 

  Do  not  weld  where  flying  sparks  can  strike 

flammable material. 

  Remove all flammables within 35 ft (10.7 m) of 

the  welding  arc.  If  this  is  not  possible,  tightly 
cover them with approved covers. 

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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