Siegen power S0863 Bedienungsanleitung

S0863 Issue No:1 - 19/11/09

Original Language Version

INSTRUCTIONS FOR

MIG

WELDER

STOCK CODE:

S0863

S0863 Issue No:1 - 19/11/09

Original Language Version

IMPORTANT: BEFORE USING THIS PRODUCT, PLEASE READ THE INSTRUCTIONS CAREFULLY. MAKE CAREFUL NOTE OF SAFETY INSTRUCTIONS,

WARNINGS AND CAUTIONS. THIS PRODUCT SHOULD ONLY BE USED FOR ITS INTENDED PURPOSE. FAILURE TO DO SO MAY CAUSE DAMAGE

OR PERSONAL INJURY, AND WILL INVALIDATE THE WARRANTY. RETAIN THESE INSTRUCTIONS FOR FUTURE USE.

1. SAFETY INSTRUCTIONS

1.1. ELECTRICAL SAFETY

WARNING! It is the responsibility of the owner and the operator to

read, understand and comply with the following:

You must check all electrical products, before use, to ensure that they

are safe. You must inspect power cables, plugs, sockets and any

other connectors for wear or damage. You must ensure that the risk of

electric shock is minimised by the installation of appropriate safety

devices. A Residual Current Circuit Breaker (RCCB) should be

incorporated in the main distribution board. We also recommend that a

Residual Current Device (RCD) is used. It is particularly important to

use an RCD with portable products that are plugged into a supply

which is not protected by an RCCB. If in any doubt consult a qualified

electrician. You may obtain a Residual Current Device by contacting

your Siegen dealer. You must also read and understand the following

instructions concerning electrical safety.

1.1.1. The Electricity at Work Act 1989 requires that all portable electrical

appliances, if used on business premises, are tested by a qualified

electrician, using a Portable Appliance Tester (PAT), at least once a

year.

1.1.2. The Health & Safety at Work Act 1974 makes owners of electrical

appliances responsible for the safe condition of those appliances and

the safety of the appliance operators. If in any doubt about

electrical safety, contact a qualified electrician.

1.1.3. Ensure that the insulation on all cables and on the appliance is safe

before connecting it to the power supply. See 1.1.1. and 1.1.2. and

use a Portable Appliance Tester.

1.1.4. Ensure that cables are always protected against short circuit and

overload.

1.1.5. Regularly inspect power supply cables and plugs for wear or damage

and check all connections to ensure that none is loose.

1.1.6. Important: Ensure that the voltage marked on the appliance matches

the power supply to be used and that the supply is correctly fused.

1.1.7. DO NOT pull or carry the appliance by the power cable.

1.1.8. DO NOT pull the plug from the socket by the cable.

1.1.9. DO NOT use worn or damaged cables, plugs or connectors.

Immediately have any faulty item repaired or replaced by a qualified

electrician.

1.1.10. This Mig Welder S0863 is a single phase machine and must be run

from a minimum 16amp supply. To achieve maximum output this

model will require a 30Amp fused supply. We recommend you

discuss the installation of an industrial round pin plug and

socket with your electrician.

Fit a plug according to the following instructions (UK only).

a) Connect the GREEN/YELLOW earth wire to the earth terminal ‘E’.

b)Connect the BROWN live wire to the live terminal ‘L’.

c) Connect the BLUE neutral wire to the neutral terminal ‘N’.

d)After wiring, check that there are no bare wires, that all wires

have been correctly connected, that the cable outer insulation

extends beyond the cable restraint and that the restraint is tight.

1.1.11. When a cable extension reel is used it should be fully unwound before

connection. A cable reel with an RCD fitted is recommended since any

product which is plugged into the cable reel will be protected. The

cross-section of the cable on the cable reel must be suitable for the unit

and never lower than the cross-section of the mains cable supplied with

the unit.

1.2. GENERAL SAFETY

DANGER! Unplug the welder from the mains power supply before

performing maintenance or service.

Keep the welder and cables in good condition. Take immediate action

to repair or replace damaged parts.

Use genuine parts and accessories only. Unapproved parts may be

dangerous and will invalidate the warranty.

Use an air hose to regularly blow out any dirt from the liner and keep

the welder clean for best and safest performance.

Check and spray the gas cup and contact tip regularly with

anti-spatter spray which is available from your Siegen dealer.

Locate the welder in a suitable work area. Ensure that the area has

adequate ventilation as welding fumes are harmful.

Keep work area clean, tidy and free from unrelated materials. Also

ensure that the work area has adequate lighting and that a fire

extinguisher is at hand.

WARNING! Use welding head shield to protect eyes and avoid

exposing skin to ultraviolet rays given off by electric arc. Wear

safety welding gauntlets.

Remove ill fitting clothing, remove ties, watches, rings and other loose

jewellery and contain long hair.

Ensure that the workpiece is correctly secured before operating the welder.

Avoid unintentional contact with workpiece. Accidental or uncontrolled

use of the torch may be dangerous and will wear the nozzle.

Keep unauthorised persons away from the work area. Any persons

working within the area must wear protective head shield and gloves.

Operators must receive adequate training before using the welder.

Stand correctly, keeping a good footing and balance, and ensure that

the floor is not slippery. Wear non-slip shoes.

Turn voltage switch to OFF when not in use.

DO NOT operate the welder if it or its cables are damaged and DO

NOT attempt to fit any unapproved torch or other parts to the welder unit.

DO NOT get welder wet or use in damp or wet locations or areas

where there is condensation.

DANGER! DO NOT weld near inflammable materials, solids,

liquids, or gases, and DO NOT weld containers or pipes which

have held flammable materials or gases, liquids or solids. Avoid

operating on materials cleaned with chlorinated solvents or near

such solvents.

DO NOT stand welder on a metal workbench, car bodywork or similar

object.

DO NOT touch any live metal parts of the torch or electrode while the

machine is switched on.

DO NOT pull the welder by the cable or the torch and DO NOT bend

or strain cables. Protect cables from sharp or abrasive items and DO

NOT stand on them. Protect from heat. Long lengths of slack must be

gathered and neatly coiled. DO NOT place cables where they could

endanger other people.

DO NOT touch the torch or workpiece immediately after welding as

they will be very hot. Allow to cool.

DO NOT operate welder while under the influence of drugs, alcohol or

intoxicating medication, or if tired.

When not in use store the welder in a safe, dry, childproof area.

1.3. GAS SAFETY

Store gas cylinders in a vertical position only and ensure that the

storage area is correctly secured.

DO NOT store gas cylinders in areas where temperature exceeds

50°C. DO NOT use direct heat on a cylinder. Always keep gas

cylinders cool.

DO NOT attempt to repair or modify any part of a gas cylinder or valve

and DO NOT puncture or damage a cylinder.

DO NOT obscure or remove any official cylinder labels. Always check

the gas identity before use. Avoid getting gas cylinders oily or greasy.

DO NOT lift a cylinder by the cap, guard or valve. Always keep caps

and guards in place and close valve when not in use.

2.1 Features heavy-duty high output transformer and forced-air cooling

to ensure the highest level of performance. Includes spot weld timer

for even and consistent spot welds when joining two panels together.

Suitable for welding with CO², Argon or CO²/Argon mix. Binzel® non-live

Euro torch is comfortable in the hand thus ensuring a steadier weld bead.

Includes industrial gas regulator, spool of wire, contact tips 0.6, 0.8mm

and gas cup.

2.2 IMPORTANT: These instructions contain information you require to

prepare your machine for welding, together with a maintenance and

trouble shooting section. If you have no previous experience the instructions

are not intended to show you how to become a welder . Should you have no

experience, we recommend that you seek training from an expert

source. MIG welding is relatively easy to perform, but does require a

steady hand and time practising under supervision with scrap metal

as it is only with continued practice that you will achieve the desired

results.

2. INTRODUCTION & SPECIFICATION

INSTRUCTION MANUAL

MIG WELDER 180AMP

WITH EURO TORCH 230V

STOCK CODE:

S0863

Thank you for purchasing a Siegen product. Manufactured to a high standard this product will, if used according to these instructions

and properly maintained, give you years of trouble free performance.

S0863 Issue No:1 - 19/11/09

Original Language Version

SPECIFICATION, Model No:......................................................................S0863

Welding Current:.....................................................................................30 - 180A

Wire Capacity - steel:................................................................................ 5 - 15kg

Duty Cycle:.............100%@56Amps, 75%@65Amps, 60%@73Amps, 15%@145Amps

Cooling System:.....................................................................................Forced Air

Gas Type:.................................................................CO², Argon & CO²/Argon mix

Torch: ...........................................................................Euro Non Live - BINZEL ®

Power Input.............................................................................................230V 1ph

Absorbed power........................................................................................... 5.7kW

3. ASSEMBLY & PREPARATION

fig.1

3.1 ASSEMBLING GAS PLATFORM: (Refer to 'P' in figs.1 & 2) Turn the

welder upside down on a smooth non-abrasive surface. The welder

should be turned over by two people as it is very heavy.

3.1.1 The gas platform is held in place with 7 M6 x 10mm bolts requiring a

10mm spanner. The casing has pre-prepared threaded inserts ready to

take the fixings. Place the platform onto the base of the welder with the

axle uppermost and fix in place with 3 bolts. See (X) in fig.1 below.

3.1.2 Insert the remaining four bolts through the two fixing flanges laying on the

back of the welder. See (X) in fig.2. Finally, tighten all 7 bolts.

3.2 ASSEMBLING THE WHEELS: (Refer to fig.1)

3.2.1 Slide a wheel (Y) over each end of the solid axle attached to the gas

platform. Slide a washer over each end of the axle and insert a split pin

(Z) through the hole in each end of the axle and bend it over to retain the

wheels.

3.2.2 Bolt the two castors (W) to the front end of the base using the 8 bolts

provided. The casing has pre-prepared threaded inserts ready to take the

fixings. See fig.1.

3.2.3 With the assistance of another person turn the welder the right way up

onto its wheels.

3.3 ASSEMBLING THE EARTH CLAMP: (Refer to fig.3) Feed the eyelet on the

end of the earth lead through the hole in the clamp arm as shown in fig.3A.

3.3.1 Drop the eyelet over the terminal and firmly fix with the bolt provided as

shown in fig.3B.

fig.3

fig.2

3.4 INSTALLING THE GAS CYLINDER. The welder is designed to

accommodate small or medium sized gas cylinders up to a maximum

height of 1000mm. Contact your local Gas dealer for supply.

3.4.1 Place the gas cylinder onto the rear platform of the welder. See fig.2-P.

Place one end of the fixing chain into one side of the retaining

bracket. Draw the chain around the cylinder and place it into the slot

on the other side of the bracket leaving as little slack in the chain as

possible.

3.5 ATTACHING THE REGULATOR. Whichever gas you are using it is

advisable to 'crack' the cylinder valve before attaching the regulator.

This means opening and closing the valve very quickly in order to

blow away any dust and dirt that may have accumulated in the gas

outlet. Stand to one side whilst doing this.

3.5.1 CO² GAS.Ensure that the threads on the gas bottle are undamaged

and free of oil and grease before attaching the regulator. (Oil or

grease in the presence of high pressure gases can be explosive).

Ensure that the regulator has an undamaged gasket fitted. The

regulator will screw directly to the threads on the gas bottle. Tighten

with a spanner.

3.5.2 ARGON GAS OR ARGON MIXTURES.Cylinders containing Argon

gas and Argon mixtures have a female thread and will require the use

of a Bull Nose Adaptor to attach the regulator to the cylinder as

indicated in fig.4. Ensure that the threads on the gas bottle are

undamaged and free of oil and grease before attaching the regulator.

(Oil or grease in the presence of high pressure gases is explosive).

Fit the Bull Nose Adaptor to the cylinder first and tighten with a

spanner. Ensure that the regulator has an undamaged gasket before

fitting onto the Bull Nose Adaptor. Tighten with a spanner.

3.5.3 Slide a clip over each end of the gas hose supplied. Push one end

of the hose onto the regulator outlet and the other end over the gas

inlet spigot on the back of the welder. See fig.2G. Tighten the clips

to ensure a good seal.

3.5.4 Close the regulator valve by turning it anticlockwise before opening

the cylinder valve. Stand to one side when opening the cylinder valve.

3.5.5 Set the regulator flow rate to 5-8 litres/min depending on the

material to be welded, and whether there are draughts which are

strong enough to disturb the gas flow.

fig.4

S0863 Issue No:1 - 19/11/09

Original Language Version

3.6 CONNECT THE TORCH CABLE TO THE WELDER. Align the pins

on the Euro connector with the socket on the welder front panel as

shown in fig.5. Push the connector into the socket and rotate the

locking ring (A) clockwise so that it draws the plug into the socket as

shown in fig.6.

Note: damage to torches and cables is not covered by warranty.

3.7 FITTING A 15KG REEL OF WIRE. Ensure that the wire diameter

used, is matched by the correct groove size in the drive wheel and

the correct tip size on the torch as well as the correct torch liner.

Failure to do this could cause the wire to slip and/or bind.

3.7.1 Unscrew the locking knob from the end of the spool holder (see

fig.7C) and remove the spacer (B). The spacer is not required for

15kg reels of wire. Slide the reel of wire onto the spool holder and

ensure that the clutch pin at the back of the spool holder (E)

engages into the guide hole in the wire reel moulding. This will

prevent the wire reel from freewheeling on the spool holder. Ensure

that the wire is coming off the bottom of the reel in the direction of

the wire drive unit as shown in fig.8 below.

3.8 FITTING A 5KG REEL OF WIRE. Ensure that the wire diameter

used, is matched by the correct groove size in the drive wheel and

the correct tip size on the torch as well as the correct torch liner.

Failure to do this could cause the wire to slip and/or bind.

3.8.1. Unscrew the locking knob from the end of the spool holder (see

fig.7C) and remove the spacer. Slide the reel of wire onto the spool

holder and ensure that the clutch pin at the back of the spool holder

(E) engages into the guide hole in the wire reel moulding. This will

prevent the wire reel from freewheeling on the spool holder. Slide

the spacer onto the spool holder and retain it by screwing the knob

into place as shown above in fig.9. Ensure that the wire is coming

off the bottom of the reel in the direction of the wire drive unit as

shown in fig.10.

fig.5

fig.6

fig.7

fig.8

fig.9

fig.10

3.9 FEED WIRE THROUGH TO TORCH. Referring to fig.12 open the wire

feed mechanism by pushing the locking/wire tension knob (1) down to

the right allowing the pressure roller carrier (2) to spring up revealing

the feed roller. Ensure that the required feed groove (0.6 or 0.8) is in

line with the wire path. See Section 3.12 on how to reverse or change

the roller.

3.9.1 Release the wire from the reel and cut off any bent portion ensuring

that there are no burrs left on the end of the wire. Keep the wire under

tension at all times to prevent it uncoiling.

3.9.2 Straighten about 40-50mm of wire and gently push it through the

flexible metal sheathed cable (3) and through the 6 or 8mm feed roller

groove and on into the torch cable liner.

3.9.3 Push down the pressure roller carrier onto the wire feed roller and hold

it down. Lift up the locking/wire tension knob so that it enters the slot

in the pressure roller carrier and snaps into the indent in its top surface.

See fig.13. Rotate the tension knob to a medium setting i.e. between 2

and 3.

3.9.4 Remove gas cup (fig.11-2) and contact tip (1) from end of torch as follows:

a) Take torch in left hand with the torch tip facing to the right.

b) Grasp gas cup firmly in your right hand.

c) Turn gas cup clockwise only and pull it off end of torch tip.

WARNING! do not turn gas cup anti-clockwise, as this will damage

the internal spring.

d) Unscrew copper contact tip (right hand thread) to remove.

3.9.5 Check welder is switched off “0”, and that the earth clamp is away

from the torch tip. Connect the welder to the mains power supply and

set the voltage switch to one.

fig.11

S0863 Issue No:1 - 19/11/09

Original Language Version

3.10 SETTING WIRE TENSION.Adjust the wire tension by rotating the

wire tension knob. Turn clockwise to increase the tension and

anticlockwise to decrease the tension. See (1) in fig13.

IMPORTANT: Too little or too much tension will cause problematic

wire feed and result in poor welding.

3.10.1 Tension between rollers is checked by slowing down the wire between

gloved fingers. If top feed roller skids the tension is correct. Use as

low a tension as possible, too high a tension will disfigure wire and

result in a blown fuse.

3.11 CLUTCH ADJUSTMENT.Note: It is essential that the clutch is adjusted

correctly.

3.11.1 Once the wire is fed through the torch, switch on the machine and set

the wire speed to maximum.

3.11.2 Depress torch switch and release quickly. If the spool overruns it

indicates that the clutch is too loose.

3.11.3 Tighten the clutch nut located in the centre of the wire spool holder

with a spanner (fig.7-D) and test the machine as above until the wire

stops over running.

Note: DO NOT over tighten the clutch as this will cause wire feed

problems and strain the motor.

3.12 TURNING/CHANGING THE DRIVE ROLLER.(See fig.14) Ensure

that the wire diameter used, is matched by the correct groove size in

the drive wheel and the correct tip size on the torch as well as the

correct torch liner. Failure to do this could cause the wire to slip and/

or bind.

3.12.1 Referring to fig.12, open the wire feed mechanism by pushing the

locking/wire tension knob (1) down to the right allowing the pressure

roller carrier (2) to spring up revealing the feed roller.

3.12.2 Referring to fig.14, loosen and unscrew the black feed roller retaining

knob (C) and put to one side.

3.12.3 The roller carrier (A) is keyed to the main drive shaft and the drive

roller (B) is keyed to the carrier, see below. Place a finger onto the

end of the drive shaft to prevent the carrier moving and slide the drive

roller off the carrier with your other hand.

3.12.4 The size of each wire feed groove is printed on the edge of the roller

on the same side as the groove.

3.12.5 Turn the roller over to use the other groove or use a roller with

different sized grooves as required. The groove to be used should be

positioned furthest away from you to be in line with the drive path.

3.12.6 Check that the key in the carrier (A) is properly seated in its slot.

Ensure that the slot on the inside face of the drive roller (B) is aligned

with the key and slide the roller back onto the carrier.

3.12.7 Screw the black roller retaining knob (C) back on to the end of the

drive shaft and tighten.

3.9.6 Set the wire speed knob to position 5 or 6. Keep the torch cable as

straight as possible and press the torch switch. The wire will feed

through the torch.

3.9.7 When the wire has fed through, switch welder off, unplug from mains.

a) Take torch in left hand, slide the contact tip over the wire and

screw back into place.

b) Grasp gas cup in right hand, push onto torch head and turn

clockwise only. Do not turn gas cup anti-clockwise, as this will

damage the internal spring.

c) Cut wire so that it is just protruding from the cup.

fig.12

fig.14

fig.13

A spool of welding wire is positioned on

the welder’s spool holder and

automatically fed through an insulated

liner in the torch to the tip. The torch

assembly consists of a switch, liner, gas

hose, and control cable. The switch

activates the wire feed roller and the gas

flow. Conversely, releasing the switch

stops the wire feed and gas flow. The

weld current is transferred to the

electrode (the wire) from the contact tip

at the end of the torch. A gas cup fits

over the contact tip to direct the gas flow towards the weld ensuring that the

arc welding process is shielded from oxidising air contaminates. The shielding

gas also assists heating of the weld materials. The torch is connected to the

positive side of a DC rectifier, and the negative clamp is attached to the

workpiece.

IMPORTANT: Should you have no welding experience, we recommend

you seek training from an expert source to ensure your personal health &

safety. Good Mig welding may be achieved only with continued,

supervised practice.

4. 1 PREPARATION FOR WELDING

IMPORTANT: BEFORE YOU COMMENCE, MAKE SURE THE

MACHINE IS SWITCHED OFF AT THE MAINS. IF WELDING A CAR,

DISCONNECT THE BATTERY OR FIT AN ELECTRONIC CIRCUIT

PROTECTOR. WE STRONGLY RECOMMEND THE USE OF A

Sealey “PROSAF/12V OR 24V IN ORDER TO PROTECT

SOPHISTICATED ELECTRONICS. ENSURE YOU HAVE READ &

UNDERSTOOD THE ELECTRICAL SAFETY INSTRUCTIONS IN

CHAPTER 1.

4.1.1 Connecting the Earth Lead.

To ensure a complete circuit, the earth lead must be securely

attached to the work piece that is to be welded.

a) Best connection is obtained by grinding clean the point of contact

on the workpiece before connecting the earth clamp.

b) The weld area must also be free of paint, rust, grease, etc.

c) When welding a vehicle, be sure the vehicle battery is

disconnected or fit an Electronic Circuit Protector available from

your Sealey dealer.

4. MIG/MAG WELDING

S0863 Issue No:1 - 19/11/09

Original Language Version

4.1.2 Power Output switch. Set the switch to position 1 or 2 for welding

up to 2mm thickness. Use settings 3,4,5,6. for thicker welds.

4.1.3 Setting the welder controls. In principle, the lower the amperage

required, the slower the wire speed. See setting chart below for

voltage and corresponding wire speeds. Note: these settings are only

a guide and will vary according to the operator's experience.

4.1.4 Welding mild steel.

To weld mild steel you can use CO²gas for most tasks where spatter

and the high build up of weld do not pose a problem. Welding with a

long arc reduces penetration and widens the arc. This in turn results

in more spatter. A long welding arc can be appropriate for welding butt

joints in thin materials. Welding with a short arc, at the same weld

settings, results in greater penetration and a narrower weld and

reduces the amount of spatter. To achieve a consistent spatter free

and flat weld, you must use an Argon/CO²mixture.

4.1.5 To weld aluminium use:

Argon gas,

0.8mm Contact Tip,

0.8mm Aluminium Wire,

4.1.6 Overload Protection. Thermostatic overload protection is provided.

When an overload has occurred, leave the unit to cool. The

thermostat will automatically reset the unit when the temperature has

returned within limits

4.1.7 Spot Welding. Spot welding may be carried out as shown in fig.16.

It will be necessary to fit a spot welding gas cup.

(a) Overlapping metal sheets with a

maximum thickness of 0.8 mm may be

welded as indicated.

(b) Alternatively they may be welded

edge to surface as indicated.

holes may be employed.

4.1.8 Use the wire feed control in conjunction

with the spot weld timer beside it. To

activate the timer turn the knob clockwise.

The settings indicated in the black portion

of the chart are for guidance only and

may vary with operators experience.

6.1. 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 feed affects welding. Clean the rollers weekly, especially the feed roller groove, removing all dust deposits.

6.2. TORCH Protect the torch cable assembly from mechanical wear. Clean the liner from the machine forwards by using compressed air. If the liner is

clogged it must be replaced.

6.3. CHANGING FEED ROLLER (See Section 3.12)

6.4. 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. Refer to fig.11 and section 3.9 for removal and replacement.

6.5. GAS CUP The gas cup must also be kept clean and free from spatter. Build up of spatter inside the gas cup can cause a short circuit at the contact tip

which will result in either the fuse blowing on the printed circuit card, or expensive machine repairs. To keep the contact tip free from spatter, we

recommend the use of Sealey anti-spatter spray (MIG/722308) available from your Sealey Dealer. Refer to fig.12 and section 3.9 for removal and

replacement.

6.6. REPLACING THE LINER Wind the wire back on to the spool and secure it. Unscrew the torch from the machine and undo the brass nut. The liner should

now be visible. Pull it out and replace with a new one.

6. MAINTENANCE

On the front of the welder is the ratings plate, giving the

following data:

1 - The standard relating to the safety and construction

of arc welding and associated equipment.

2 - Single phase transformer - rectifier.

3 - Welding with a continuous flow of welding wire.

4 - Single-phase AC supply.

5 - Rating of internal protection provided by casing.

6 - Output

U0: Rated minimum & maximum no load voltage.

I2, U2: Current and corresponding voltage.

X: Welding ratio based on a 10 minute cycle. 20% indicates 2 minutes welding and 8 minutes rest, 100% indicates continuous welding.

7 - Mains Supply U1: Rated supply voltage and frequency. Imax: Maximum current. I1eff: Maximum effective current.

8 - Welding current range.

9 - Serial Number. Specifically identifies each welder.

5. RATINGS PLATE

Wire 0.6mm Steel

Argon / CO2 Mix

Voltage

Step: 1 2 3 4 5 6

Wire

Speed: 5 6 7 8 9 10

SETTINGS SHOWN

AS GUIDE ONLY

Spot Welding Timer 6

fig.15

fig.16

S0863 Issue No:1 - 19/11/09

Original Language Version

6 . TROUBLESHOOTING

PROBLEM POSSIBLE CAUSE REMEDY

1. Power source stops Overheating protection activated due to overload Protection automatically resets when transformer has cooled (about 15 min)

2. No weld current Rectifier blown Replace rectifier

3. No weld current Bad connection between clamp & workpiece Clean or grind contact surface and weld area

Break in earth lead Repair or replace earth lead.

Break in torch lead Repair or replace torch

4. Feed motor not working, lamp is on Gear damaged or worn Replace gears. (Contact service agent)

Motor defective Replace motor (Contact service agent)

5. Wire does not feed, feed roller rotates Pressure roller improperly adjusted Adjust tension

Dirt, copper, dust, etc, has collected in torch liner Clean the liner from the machine forward. Use compressed air. If too much dirt,

replace the liner.

Gas cup (Nozzle) or tip defective Replace gas cup (nozzle) and/or tip. (Section 3.9.4 to 3.9.7)

Deformed wire Check roller tension and adjust it if necessary (Section 3.10)

6. Wire feeds unevenly Dirt, etc, in liner Clean the liner from the machine forward. Use compressed air

Gas cup (Nozzle) or Tip defective Replace gas cup (nozzle) and/or tip. (Section 3.9.4 to 3.9.7)

Gas cup (Nozzle) spattered Clean or replace gas cup (nozzle) (Section 3.9.4 to 3.9.7)

Feed roller groove clogged Clean feed roller. (Section 3.12).

Feed roller groove deformed Replace feed roller. (Section 3.12)

Pressure roller tension improper Adjust tension. (Section 3.10)

7. Unstable arc Incorrect settings Check settings. (Section 4)

Impurities in weld area Clean and/or grind workpiece. (Section 4.1.1)

Worn or defective gas cup (nozzle) Replace gas cup (nozzle). (Section 3.9.4 to 3.9.7)

8. Porous weld No gas Open gas cylinder, regulate gas flow

Gas cup clogged Clean or replace cup. (nozzle) (Section 3.9.4 to 3.9.7)

Draft blowing away shielding gas Screen off welding site or increase gas flow

Rusty or dirty joints Clean and/or grind workpiece. (Section 4.1.1)

Torch too far from or at wrong angle to work The distance from gas cup to workpiece should be 8 to 10mm

Gas leak Check hoses, connections and torch assembly. (Section 3.5). Press the gas cup

in correction position

Faulty Electrovalve Clean out or replace

9. Electrode sticking in gas cup (nozzle) Worn or defective gas cup (nozzle) Replace gas cup (nozzle). (Section 3.9.4 to 3.9.7)

Electrode deformed Check roller tension. (Section 3.10)

Wire speed too slow See recommendations for wire speed

10. Irregular weld bead Torch incorrectly held Use correct torch angle

Wire weaving in weld pool Check roller tension and adjust as needed. (Section 3.10)

11. Weld bead too narrow and raised Weld current too low Increase power and wire speed. (Section 4)

Weld speed too high Move torch slower and weave a little more

12. Weld bead too wide Weld current too high Decrease power and wire speed. (Section 4)

Weld speed too low Move torch faster and weave less

Arc too long Bring torch closer to workpiece

13. Poor penetration Weld current too low Increase power and wire speed. (Section 4)

Arc too long Bring torch closer to workpiece

14. Excessive penetration Weld current too high Decrease power and wire speed. (Section 4)

Weld speed too slow Move torch faster

incorrect distance of torch to workpiece Torch distance should be 8-10mm

NOTE: It is our policy to continually improve products and as such we reserve the right to alter data, specifications and component parts without prior notice.

IMPORTANT: No liability is accepted for incorrect use of this equipment. WARRANTY: Guarantee 12 months from purchase date, proof of which will be required for any claim.