WARNING! Ensure the unit is disconnected from the mains power supply before performing any maintenance or service.
10.1
Regularly check all welding cables and secondary terminals to ensure they are in good order and connected correctly, also check during welding to
ensure they are not overheating.
10.2.
Check that the gas hose connections are tight and that there are no gas leaks.
10.3.
Regularly inspect the machine interior according to the frequency of use and dust in the working area. When removing dust from transformer, choke
tap and rectifier always use dry air of not more than 10bars.
NOTE:
Care must be taken NOT to direct compressed air towards the control modules, which may be cleaned with a soft brush.
10.4. Wire feed unit.
Check the wire feed unit at regular intervals. The feed roller wire guide plays an important part in obtaining consistent results. Poor
wire feeding affects welding. Clean the rollers weekly, especially the feed roller groove, removing all metallic dust deposits.
10.5. Changing Wire Feed Roller IMPORTANT: ( Refer to section 5.8 )
Make sure that the wire feed rollers, The wire guide hose and the contact tip of
the torch match the diameter and type of wire to be used and ensure that these parts are fitted correctly..
10.6. Torch.
( Check condition at least once a day )
Protect torch cable assembly from mechanical wear. Clean liner from the machine forwards by using compressed air. If the liner is clogged it must be
replaced.
10.7. Contact Tip.
The contact tip is a consumable item and must be replaced when the hole becomes enlarged or oval. The contact tip
MUST
be kept
free from spatter to ensure an unimpeded flow of gas.
10. MAINTENANCE
9. WELDING PROCESS
8.4
Brazing.
Brazing is a process for joining similar or dissimilar metals using a filler metal that typically contains a base of copper combined with silver,
nickel, zinc or phosphorous. Brazing covers a temperature range of 900
O
F - 2200
O
F (470
O
C - 1190
O
C). Brazing differs from welding in that brazing does
not melt the base metals, therefore brazing temperatures are lower than the melting points of the base metals. For the same reason, brazing is a superior
choice in joining dissimilar metals. Brazed joints are strong. A properly made joint (like a welded joint) will in many cases be as strong or stronger than the
base metals being joined. Typically brazing is employed in manufacturing compressors, diesel engine circulation tubes, mining tools, plumbing fixtures,
jewellry, musical instruments, refrigerators, condensors etc.
NOTE:
We recommend that you obtain specialist advice from your local supplier of welding/brazing materials on the correct choice of wire and
gas for the particular brazing task you wish to perform. If you have not performed Mig Brazing before we also recommend that you seek
advice from your local training establishment on the required technique and setting of welding parameters.
WARNING: Use welding head shield to protect eyes and avoid exposing skin to ultraviolet rays given off by electric arc. Wear safety welding
gauntlets.
Should you have no welding experience, we recommend you seek training from an expert source to ensure your health and safety. You must familiarise
yourself with welding applications and limitations, and specific potential hazards peculiar to welding. Good MIG/MAG welding may only be
achieved with continued, supervised practice.
9.0
IMPORTANT. If welding a car, disconnect the battery or fit an electronic circuit protector. Ensure you read and understand the the safety instructions
in Section 1. If difficult welds are to be performed and the welding parameters are unknown, it is advisable to carry out several trial runs on test pieces in
order to determine the right welding current and gas flow.
9.1
Connect the earth clamp to the workpiece.
To ensure a complete circuit, the earth lead must be securely attached to the work piece that is to be welded.
Best connection is obtained by grinding the point of contact on the workpiece before connecting clamp to the workpiece. The weld area must
also be free of paint, rust, grease, etc.
9.2
Turn on the gas.
Adjust the regulator to a flow of 5 - 7 litres/min depending on the material to be welded
9.3
Switch on the welder
using the rotary power switch below the main control panel. In general current settings 3,4,5 & 6 are for average thickness welding
and current settings 1 & 2 are for reduced thickness welding.
9.4
Set the controls.
MATERIAL.
Select the type of material by repeatedly pressing the MATeRIAl button until the led next to your choice lights up.
GAS.
Select the type of gas by repeatedly pressing the GAS button until the led next to your choice lights up.
WIRE.
Select the diameter of wire by repeatedly pressing the WIRe button until the led next to your choice lights up.
9.5
The readout will show the current programmed for welding. By pressing the dual function button the readout will display the factory set wire feed rate.
Under these conditions the deFAUlT led will be illuminated. The wire feed rate can still be altered by turning the rotational knob below the readout and
the deFAUlT led will go out.
9.6
Select welding mode.
(2T)
Two touch weld cycle.
(4T)
Four touch weld cycle. Spot Welding
.
(See below for explanations.)
9.7
Commence welding
by pressing the torch button. during welding the actual welding current will be shown on the readout.
9.8
It is possible to alter the wire feed rate during welding just by turning the rotational knob. As you do this the readout will display the wire feed setting and
then revert to displaying the current as soon as the knob stops moving.
9.9
Under critical conditions the wire diameter led will flash.
9.10 When switched off the welder will memorise the parameters selected at the time.
9.11
TORCH DUAL FUNCTION PUSH BUTTON.
The torch push button can control the switching of the power in two different modes depending on your
welding requirements. These modes are selected using the ‘WeldING’ push button on the front panel. ( See Section 6. )
9.12
(2T) Two touch weld cycle.
In this mode the push button is pressed and held down to strike the arc and to continue welding. When the end of the weld is
reached the push button is released and the arc is switched off.
9.13
(4T) Four touch weld cycle.
This mode allows you to complete long welds without having to continuously hold down the torch button and affords a degree
of control over the weld current using the torch button. ( See Rapid Touch Function ). The push button is first held down which strikes the arc and then
provides power at a base current level as long as the button continues to be held down. Once the push button is released the current rises to the level set
by the welding current control and stays at this level even though the push button has been released. If the button is then pressed and held down again the
current will decrease to the base level and remain there whilst the button is held. When the button is released the current is turned off.
9.14
Rapid touch function.
This function is available in four touch mode only. during the course of welding at the current you have set ( with the torch button
released ) the current can be made to dip down towards base current and back again by momentarily pressing and releasing the torch button.
This function can be used as a sequence of rapid presses which can help to control heat and penetration during difficult welds. At the end of a rapid
sequence of presses when the button is released, the current will remain at the weld current set and the welder will continue to function as previously
described in four touch mode.
9.15
Spot Welding
.
Remove the gas cup and fit a spot welding gas cup. Select spot welding by pressing the welding mode button. Press the
dual function button below the readout until the spot welding led lights up above the readout. Set the spot weld duration according to the thickness of the
metal sheets using the rotational knob . drill a small hole in the top workpiece. Push the spot gascup onto the material to be
welded (fig 9). The castellations on the cup keep it the correct distance from the weld pool and allow you to push the two pieces
being welded together. Press the torch trigger to commence welding. The wire will feed through during the allotted time and
welding will stop automatically.
fig 9
Original Language Version
eleCTROMIG195.V3 Issue: 3 - 08/03/10
