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Operation Manual

MIG-MAG Alu welding - brazing / VAS 821 003

Wieländer + Schill

Page 9

3 SAFETY AND FIRE INSTRUCTION

Keep this device away from children. You must follow the safety and fire instructions when

you work with the welding device and for welding in a protective atmosphere. Follow all

regulations for the prevention of accidents during "welding, cutting and similar working

activities".

WARNING FIRE HAZARD!

Be sure the area is safe before doing any welding.

Remove all flammable material within 10m of the welding area.

Quench hot metal or allow it to cool before handling or before letting

it touch combustible materials.

Never weld containers with potentially flammable materials inside –

they must be emptied and properly cleaned first.

Ventilate potentially flammable atmospheres before welding

WARNING EXPLOSION RISK!

It’s possible that harmless substances in closed containers may

generate excessive pressure when heated.

Move containers with flammable or explosive liquids away from the

working area!

Never heat explosive liquids, dusts or gases by welding!

CAUTION TOXIC FUMES!

Smoke and gases can lead to breathing difficulties and poisoning

Use local exhaust ventilation to remove fumes from the air.

Remove all coatings and solvents from the metal before welding.

Wear suitable breathing apparatus if appropriate!

Never weld containers with potentially toxic materials inside. Empty

and properly clean the container first.

CAUTION Noise exposure!

Prolonged exposure to noise from welding, cutting or similar work

can damage hearing.

Use approved ear protection.

Warn others nearby about the noise hazard.

WARNING ARC RAYS CAN BURN EYES AND SKIN!

The welding arc produces intense visible and invisible rays that can

burn eyes and skin.

Wear eye protection (welding helmet) with appropriate lens shading

to protect your eyes from the arc’s ultraviolet and infrared rays.

Wear protective clothing to protect against burns caused by

ultraviolet light, sparks and hot metal.

Flame-retardant clothing to cover all exposed areas.

Use protective screens or barriers to protect others from flash and

glare.

Содержание VAS 821 003

Страница 1: ...02 2021 MIG MAG ALU welding brazing Operation Manual REV 1 0 VW AG I VAS 821 003 UK ...

Страница 2: ...LDING IN THE ENVIRONMENT WITH HIGHER ELECTRICAL DANGER 10 4 OPERATION 11 4 1 SWITCHING ON THE MACHINE 11 4 1 1 Power on sequence 11 4 2 OPERATING PANEL 11 4 2 1 Welding mode selection 12 4 2 2 Welding process selection 14 4 2 3 Selection of the additional material 15 4 2 4 Selection of the additional material diameter 16 4 2 5 MENU 16 4 2 5 1 Global menu parameters 17 4 3 SET UP ADJUSTMENT AND DIS...

Страница 3: ...G WELDING 24 7 1 1 Steel welding wire 24 7 1 2 CrNi welding wire 24 7 1 3 Aluminium welding wire 24 7 1 4 CuSi welding wire 25 7 2 AVERAGE SHIELDING GAS CONSUMPTION FOR MIG MAG WELDING 25 7 2 1 MIG MAG steel welding 25 7 2 2 MIG MAG aluminium welding 25 7 3 AVERAGE SHIELDING GAS CONSUMPTION FOR WIG WELDING 25 8 TROUBLESHOOTING 26 9 DISTRIBUTORS WORLDWIDE 28 10 EU DECLARATION OF CONFORMITY 29 ...

Страница 4: ...21 003 machine repairs are possible on all types of vehicles with fine quality results Be aware of danger resulting from welding and follow the safety and fire instructions It s necessary to keep the device in a dry place to protect it against moisture It s not advisable to use the device in the open air during rain 2 SETUP 2 1 Setup conditions When welding it s necessary to set the device in a dr...

Страница 5: ... 16Amp melting safety fuse or circuit breaker The device is delivered without plug Please ensure that only plugs and or sockets are used that comply with the CEE standard 2 4 Connecting the MIG MAG torch The torch connection supplied is a EURO Standard torch connector Please tighten the connector well to avoid any contact resistance A loose connection can cause damage to the machine and torch Neve...

Страница 6: ...eflon liner is used it is also necessary to attach a brass flexible contact neck liner to provide good current conduction to the fill wire Material Wire diameter Liner material Liner color Fe 0 8mm steel spiral or Teflon 1 0mm 1 2mm Inox 0 8mm Teflon 1 0mm 1 2mm AlMg AlSi 1 0mm Teflon 1 2mm CuSi3 0 8mm Teflon 1 0mm 1 2mm CuAl8 0 8mm Teflon 1 0mm Liner color Blue Art N 337139 Red Art N 337142 Black...

Страница 7: ... the wire feeding wheels are set up you can see on the front side of the wheel the assigned welding wire diameter value is in mm 2 8 Connecting the pressure bottle While adjusting the gas flow rate the welding unit must be switched on and the torch trigger must be pressed to open the solenoid valve To avoid unnecessary wire consumption open the leaf spring of the wire feeder Determination of the g...

Страница 8: ...9 Connecting the ground cable It s necessary to connect the grounding clamp earth in the near vicinity of the welded place The transfer contact must be metallic and free from dust and paint 2 10 MMA TIG welding connection TIG Connection MMA Connection Work piece TIG Torch Stick Holder ...

Страница 9: ...h flammable or explosive liquids away from the working area Never heat explosive liquids dusts or gases by welding CAUTION TOXIC FUMES Smoke and gases can lead to breathing difficulties and poisoning Use local exhaust ventilation to remove fumes from the air Remove all coatings and solvents from the metal before welding Wear suitable breathing apparatus if appropriate Never weld containers with po...

Страница 10: ... protective equipment depending on the application Never touch live components such as welding current sockets or stick tungsten or wire electrodes Always place torches and electrode holders on an insulated surface The device must be placed out of higher electrical danger environment You can be in the endangered environment with a torch only CAUTION ELECTROMAGNETIC FIELDS Device is constructed acc...

Страница 11: ...ed on the operating panel to give the user information about the firmware At first all segments are lit up then the following information is displayed a Firmware type in material Volt window EA ACT panel b Model in Ampere window 270 c Firmware revision in Ampere window r11 major minor revision numbers 4 2 Operating Panel 4 4 JOB Mode 4 2 5 MENU 4 3 1 Welding power set up 4 3 2 Arc length correctio...

Страница 12: ...s possible to adjust the speed for manual feed Feeding is activated by pressing the trigger button 2 TACT Mode 4 TACT Mode 2 TACT 4 TACT relates to the function of starting button trigger on the welding torch Differences in operation of this two modes are shown in following pictures t P PHOT PWELD t TRIGGER 2 TACT MIG MAG operation t P Hot start level Welding Crater fill level t TRIGGER cFt hSt 4 ...

Страница 13: ... the interval welding program the pause time must be set greater than 0 factory setting To disable interval welding feature set the pause time parameter to 0 menu parameter number 1 9 PAU Interval function is available in both 2cycle and 4cycle operation t P PHOT PWELD t TRIGGER PAu Act 2 TACT MIG MAG operation ...

Страница 14: ... process EcoPulse only MIG MAG Double Pulse welding process MMA welding process WIG welding with Lift Arc ignition Synergy parameters for MIG MAG welding hSL hSt Welding voltage Wire speed cSS cFL cFt EPL EPt bbt Time diagram of MIG MAG weld Synergy parameters for standard Pulse Up PL bcL FcL PF EPL Prr PFr Time diagram of Pulsed weld without Hot start Crater fill level ...

Страница 15: ...e pulse time characteristic frequency Amplitude Double pulse weld AlSi5 1 0mm wire 4 2 3 Selection of the additional material Not available if MMA TIG selected Fe ACT alloyed non alloyed steel inert gas 82 Ar 18 CO2 LED shines Fe ACT Steel thin sheets ACT welding inert gas 82 Ar 18 CO2 LED flashes CrNi Stainless steel AWS308LSi gas 87 5 Ar 2 5 CO2 AlMg Aluminum magnesium shielding gas 100 Ar AlSi ...

Страница 16: ...ing VAS 821 003 _Operation Manual Page 16 Wieländer Schill 4 2 4 Selection of the additional material diameter 0 6mm 0 8mm 1 0mm 1 2mm 4 2 5 MENU For enhanced adjustment is available MENU function Press and hold for 3 seconds ...

Страница 17: ...l thickness are referred to as general parameters All these parameters can be set by the user in the menu They remain saved and unchanged as long as the user does not change the setting The parameter group includes 1 Gas pre flow time 2 Gas post flow time 3 Hot start level Hot start level in percent based on the preselected Welding current Can only be 100 4 Crater fill level Crater fill level in p...

Страница 18: ... with one main rotary encoder By press of the encoder button wire speed in meters min or material thickness in millimeters can be selected In MMA and TIG mode is only Ampere setup possible 4 3 2 Arc length correction synergic mode In all MIG MAG modes is possible to adjust length of the welding arc By turning the encoder in any direction is display switching from Voltage mode to Arc length correct...

Страница 19: ...job number is set by pressing the encoder button actual set up is saved under this job number To edit actual job set job number to change by long pressing the JOB button the material thickness start to flesh and any change of any parameter can be made After changes are made by short press of the encoder button the settings will be stored 4 5 Selecting the active feeder Active feed unit selection i...

Страница 20: ...his procedure will delete all stored jobs and will reset all parameters to the state at delivery Make sure that the machine is conected to the power supply and switched off Hold this button depressed and switch the machine on until the initial display test sequence is over and the code menu is displayed Once in the code menu you will have to enter the unique code U 01 A 01 B 01 C 01 Individual num...

Страница 21: ...orch is wearing up subsequently When the hole in the nozzle is too large it is necessary to change the nozzle The metal drops are embedding in the inner walls of the torch cover Take them out if necessary The separator is helpful and it is also a prevention against the firm spatter build up Any damaged cables must be changed at once 5 1 Disposal of the machine Do not dispose of electrical equipmen...

Страница 22: ...8V 40 No load output voltage Uo 96V for MIG 96V for TIG 72V for MMA Efficiency 86 Idle power consumption in MIG mode 45W Idle power consumption in MMA TIG mode 120W Power factor 0 75 Current adjustment range 10 280Amp 1Amp step Voltage adjustment range 10 50V 0 1V step Wire speed range 0 5 22 m min Wire feed roll diameter 37mm Wire spool diameter 2 x 200mm 2x7kg max Thermal class H 180 C Temperatu...

Страница 23: ... No load output voltage Uo 96V for MIG 96V for TIG 72V for MMA Efficiency 85 Idle power consumption in MIG mode 45W Idle power consumption in MMA TIG mode 120W Power factor 0 73 Current adjustment range 4 280Amp 1Amp step Voltage adjustment range 10 50V 0 1V step Wire speed range 1 5 22 m min Wire feed roll diameter 37mm Wire spool diameter 2 x 200mm 2x7kg max Thermal class H 180 C Temperature ran...

Страница 24: ... 2 6kg h 10m min 2 2kg h 3kg h 3 7kg h 12m min 2 7kg h 3 6kg h 4 4kg h 7 1 2 CrNi welding wire Wire feed rate 0 6 mm Welding wire diameter 0 8 mm Welding wire diameter 1 0 mm Welding wire diameter 2m min 0 5kg h 0 6kg h 0 8kg h 3m min 0 7kg h 0 9kg h 1 1kg h 5m min 1 1kg h 1 5kg h 1 9kg h 7m min 1 6kg h 2 1kg h 2 7kg h 10m min 2 3kg h 3kg h 3 8kg h 12m min 2 7kg h 3 6kg h 4 6kg h 7 1 3 Aluminium w...

Страница 25: ... 2 8kg h 10m min 2 4kg h 3 2kg h 4kg h 12m min 2 9kg h 3 8kg h 4 8kg h 7 2 Average shielding gas consumption for MIG MAG welding 7 2 1 MIG MAG steel welding Welding wire diameter 0 6mm 0 8mm 1 0mm 1 2mm Average gas consumption 8 l min 9l min 10l min 7 2 2 MIG MAG aluminium welding Welding wire diameter 0 6mm 0 8mm 1 0mm 1 2mm Average gas consumption 12l min 15l min 7 3 Average shielding gas consum...

Страница 26: ...ttle wire Adjust the wire feed regulator 3 The workpiece clamp is loose or transfer resistance is too high rust paint Make a good contact between workpiece and clamp 4 The contact nozzle is worn up or the diameter is wrong Change it 5 The gas flow is not correct Adjust the gas flow 6 The workpiece is not clear in the welding area Remove paint rust fat etc 7 Performance grade malfunction Take the d...

Страница 27: ...nge the contact nozzle if the wire is deformed lower the pressure on wire Device turns OFF and the Err t is displayed 4 Time of make is exceeded TM Let the device cool down and follow the instructions for TM according to device type The protective gas still flows 4 Magnetic valve is dirty and it is still open Disconnect the torch connector and connecting hose alternately flow a pressure air into t...

Страница 28: ...03 _Operation Manual Page 28 Wieländer Schill 9 Distributors Worldwide Here you can find our worldwide distributors https www wielanderschill com service vertretungen weltweit https www wielanderschill com en service distributors worldwide ...

Страница 29: ...ol type Inert gas welding equipment Model name VAS 821 003 Developed and manufactured in accordance with the standards and guidelines listed below by Applied EN 60974 1 2012 harmonized EN 60974 5 2013 standards EN 60974 10 2014 EMV guideline 2014 30 EU Low Voltage Directive 2014 35 EU EU Machinery directive 2006 42 EG We hereby declare that The products marked accordingly comply with the requireme...

Страница 30: ...MIG MAG Alu welding brazing VAS 821 003 _Operation Manual Page 30 Wieländer Schill ...

Страница 31: ...Operation Manual MIG MAG Alu welding brazing VAS 821 003 Wieländer Schill Page 31 ...

Страница 32: ...MIG MAG Alu welding brazing VAS 821 003 _Operation Manual Page 32 Wieländer Schill ...

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