www.r-techwelding.co.uk I-MIG160 MIG/MMA WELDER OPERATION INSTRUCTIONS 3 Thank you for selecting the R-Tech I-MIG160 Portable Inverter MIG/MMA Welder. The I-MIG160 has many benefits over traditional transformer MIG welders, including infinite power control, adjustable arc force and a compact wire feed mechanism to provide very smooth wire feed and weld characteristics We want you to take pride in operating our I-MIG160 as much pride as we have taken in making this product for you. Please read all information in this manual before operation PLEASE EXAMINE THE CARTON AND EQUIPMENT FOR DAMAGE IMMEDIATELY When this equipment is shipped, title passes to the purchaser upon receipt from the courier. Consequently all claims for material damaged in shipment must be made by purchaser against the transportation company used. Please record your equipment identification below for future reference. This information can be found on the data plate at rear of machine. Product: I-MIG160 Serial No. ___________________________________ Date of Purchase _____________________________ Where Purchased _____________________________ Whenever you request replacement parts or information on this equipment please always supply information you have recorded above. This product is covered by a 2 year parts and labour warranty; we will cover the cost of collecting and returning the item to you. External items, (torch, earth lead etc…) are covered by a 3 month warranty. Any faults/damage found caused by a customer will be charged accordingly. Pay particular attention to the safety instructions we have provided you for your protection The level of seriousness to be applied to each section is explained below WARNING This statement appears where the information must be followed exactly to avoid serious personal injury. CAUTION This statement appears where the information must be following to avoid a minor personal injury or damage to this equipment. Introduction The R-Tech I-MIG160 is a member of our highly acclaimed family of welding products. Premium features include:1. Inverter power source – more efficient to operate, provides smoother weld characteristics than traditional welders 2. Infinite welding voltage to allow fine tuning of weld characteristics 3. Adjustable arc force – controls splatter – ideal for automotive work 4. Digital amp & volt meters 5. Euro type torch fittings for easy torch fitment/replacement 6. 35% Duty cycle at 160 Amps @ 40C 7. 60% Duty cycle at 110 Amps @ 40C 8. Lightweight and portable – Ideal for maintenance and mobile welders Recommended Processes The R-Tech IMIG 160 is recommended for the MIG welding processes within its output capacity of 160 Amps DC Equipment Limitations The R-Tech IMIG 160 is protected from overloads beyond the output ratings and duty cycle as per machine specifications with thermostat protection of the output coils and rectifiers. Welding Capability – Duty Cycle The R-Tech IMIG 160 is rated at 160 Amps at 35% and 110 Amps @ 60% duty cycle on a ten minute basis. If the duty cycle is exceeded a thermal protector will shut the machine off until it cools. Technical Specifications Model No. R-Tech IMIG 160 Input MIG Operation MMA Operation 240V AC 50/60Hz Fuse Rating Rated Output Current Generator required KVA Duty Cycle @ 160 AMPS 13A 160Amps Max 4.8KVA Duty Cycle @ 110 AMPS 60% @ 40ºC 35% @ 40ºC Duty Cycle @ 85 AMPS 100% @ 40ºC Output current Range Fuse Rating 30-160 AMPS 13A Rated Output Current Generator required KVA Duty Cycle @ 130 AMPS 130Amps Max 4.8KVA Duty Cycle @ 100 AMPS 60% @ 40ºC Duty Cycle @ 75 AMPS 100% @ 40ºC 30-130 AMPS 55-75V 18 KG Class F Output current Range No Load Voltage Gross Weight Insulation 35% @ 40ºC Safety Precautions Read entire section before starting installation WARNING! Electric Shock can kill – Only qualified personnel should perform this installation. Turn off input power at the fuse box before working on this equipment. Do not touch electrically live parts. Always connect the machine to an earthed mains supply as per national recommended standards. Select suitable location Place the welder where clean cooling air can freely circulate in and out of the front & rear louver vents. Dirt, dust or any foreign material that can be drawn through vents into welder must be kept to a minimum. Failure to observe these precautions can result in excessive operating temperatures which can lead to plant failure. Grinding Do not direct grinding particles towards the welder. An abundance of conductive material can cause plant failure. Stacking This machine cannot be stacked. Transport – Unloading Never underestimate the weight of equipment, never move or leave suspended in the air above people. Use recommended lifting equipment at all times. WARNING! Falling Equipment can cause injury. Never lift welder with gas bottle attached. Never lift above personnel. Tilting Machine must be placed on a secure level surface or on a recommended undercarriage/trolley. This machine may topple over if this procedure is not followed. Environmental Rating The welding power source carries the IP21S rating. It may be used in normal industrial and commercial environments. Avoid using in areas where water / rain is around. Read and follow the ‘Electric Shock Warnings’ in the safety section if welding must be performed under electrically hazardous conditions such as welding in wet areas or water on the work piece. Electrical Installation WARNING! ELECTRIC SHOCK CAN KILL Machine grounding and High Frequency Interference Protection This welder must be grounded to earth. See national electrical codes fro proper grounding methods. The high frequency generator being similar to a radio transmitter may cause interference to radio, TV and other electronic equipment. These problems may be the result of radiated interference. Proper grounding methods can reduce or eliminate this. Radiated interference can develop in the following ways 1. Direct interference from welder power source 2. Direct interference from the welding leads 3. Direct interference radiated from feedback into power lines 4. Interference from re-radiation by un-grounded metallic objects. Keeping these contributing factors in mind, installing equipment as per following instructions should minimize problems. 1. Keep the welder input power lines as short as possible and enclose as much of them as possible in metal conduit or equivalent shielding. There should be a good electrical contact between this conduit and ground (Earth). 2. Keep the work and electrode leads as short as possible. Tape the leads together where practical. 3. Be sure the torch and earth leads rubber coverings are free from cuts and cracks that allow welding power leakage 4. Keep earth lead connection to work in good condition – Clean area on workbench where earth clamp is situated on a regular basis. Input Connections Make sure the voltage, phase and frequency of input power is as specified on machine rating plate located at rear of machine. Have a qualified electrician provide suitable input power as per national electrical codes. Make sure machine is earthed / grounded. Make sure fuse or circuit breaker is correct rating for machine. Using fuses or circuit breakers smaller than recommended will result in ‘nuisance’ shut off from welder inrush currents even if welding at low amperages. Failure to follow these instructions can cause immediate failure within the welder and void machines warranty. Turn the input power OFF at the mains switch & fuse box before working on this equipment. Have a qualified electrician install & service this MIG welding equipment. Allow machine to sit for 5 minutes minimum to allow the power capacitors to discharge before working inside this equipment. Do not touch electrically live parts The IMIG 160 MIG Welder requires a 240V 50/60Hz 1-Phase supply. It requires a 13A supply. It comes with a 3 metre mains cable attached. Connect wires according to national coding. Brown wire – Live - Blue wire – Neutral - Green/Yellow Wire – Earth (Ground) Connecting to an Engine Driven Generator If connecting this machine to an engine driven generator please ensure the following Minimum Generator KVA Output – 4.8 KVA continuous Generator to be fitted with AVR (automatic voltage regulation) DO NOT USE ON A GENERATOR WITHOUT AVR. Connecting to a generator without the above minimum requirements will in-validate your warranty Connections for IMIG 160 Setup machine as per two diagrams below: Fig 1 Fig 2 1. Earth / Workpiece connector Connect the earth lead (negative -) to this connector. Insert male connector into socket and twist clockwise until tight. Secure other end of earth lead to Workpiece via the earth clamp. 2. Euro torch connector Connect Euro type MIG torch to euro torch connector, align torch connector to machine connector and then turn retaining ring clockwise to secure. Ensure torch is secured tightly to avoid weld power problems To avoid electric shock keep the MIG torch in good condition and replace if any of the insulation is damaged. 3. Mains input cable Fit required plug as per your electrical installation 4. Gas inlet connection Connect gas hose to rear of machine and then to regulator on gas bottle. Ensure all connections are tight to ensure no loss of gas. Make sure gas bottle is secured to machine securely using supplied chain to avoid injury. 5. On/Off Power Switch This turns the IMIG 160 MIG Welder on and off. 6, Gas(+)/no gas(-) plug: gas style connect with “+”socket and no gas style connect with ““socket. 7, Spool gun socket: When use spool gun function, connect spool gun control plug(7pins) with this socket and spool gun main cable connect with euro torch socket. Controls and Settings Fig 3 1. Welding Voltage This adjusts the welding voltage (weld power) from 0 to 10. Adjust knob for power output required by job, preset welding voltage is shown in LED (Fig3.4) 2. Wire Speed This adjusts the wire feed speed from 0-100% Adjust the wire speed to suit welding voltage (Fig3.1) and job requirements When adjusting the wire feed speed a value is shown in the amperage LED (Fig3.5) This feature allows you to record this value along with the preset welding voltage for easy setup to specific job when several different welding jobs are being done 3. Arc Force Gives further adjustment on weld characteristics, on traditional transformer machines this was known as choke. Lower setting = softer weld with less splatter and less penetration – for thinner materials Higher setting = harsher weld with more splatter and penetration – for thicker materials 4. Voltage LED Display This shows the preset welding voltage when no welding is being carried out When welding this shows the actual welding voltage This allows the machine to be calibrated to BS if required by your company 5. Amperage LED Display This shows the preset wire feed speed when no welding is being carried out When welding this shows the actual welding amperage This allows the machine to be calibrated to BS if required by your company. When the function is in MMA, it shows the preset is welding amps. 6. Warning LED This warning light will come on under these situations: Duty cycle of machine has been exceeded, the machine will stop working and the fan will continue to run until machine has cooled down. The light will go off and welding may be carried out again. If duty cycle has not been exceeded the warning light comes on to warn of either low input voltage has been sensed or there is an internal fault with machine 7. Power LED This lights when machine is switched on 8. Switch MIG/MMA. Wire Spool Fitment 1. Wire reel retainer Push and twist in, to retain wire roll adaptor onto wire reel 2. Roller tensioner Do not over tighten wire feed pressure roller as this can cause premature motor and roller failure. Correct way to adjust tensioner is to slacken off pressure so that MIG welding wire does not feed, slowly adjust pressure until wire feeds smoothly, you should be able to stop wire feeding by holding wire and it should slip on rollers. If you have too little pressure wire will slip when welding causing unwanted Burnback into tips 3. Wire Feed Drive Assembly Make sure rollers are correct size for wire diameter selected, to change roller size release retaining screw, remove roller turn roller around and slide onto shaft making sure the right size groove is in line with wire and refit retaining screw. The INV160 comes fitted with a dual roller 0.6mm and 0.8mm 4. Wire reel adaptor Remove the wire reel retainer and wire reel adaptor, slide on roll of wire and refit the reel adaptor. Operating the Machine SAFETY PRECAUTIONS WARNING! ELECTRIC SHOCK CAN KILL Do not touch electrically live parts or electrode with skin or wet clothing. Insulate yourself from work and ground Always wear dry insulating gloves WARNING! FUMES AND GASES can be dangerous Keep your head out of fumes & gases produced from welding. Use ventilation or exhaust to remove fumes & gases from breathing zone and general area. WARNING! WELDING SPARKS can cause fire or explosion Keep flammable material away from work area. Do not weld on containers that have held combustibles WARNING! ARC RAYS can burn Wear eye, ear and body protection – Make sure work area is protected by proper shielding to avoid injury to passers by. Operating the Machine in MIG mode Once you have set machine up as per above instructions. 1. Select welding voltage (power) required on front panel 2. Select wire feed speed required on ‘wire speed’ knob 3. Set ARC force switch to middle position for medium weld inductance (know as choke on traditional welding power sources) Low setting = Soft ARC (less splatter & penetration) High setting = Strong ARC (more penetration) 4. Ensure you are wearing the correct safety clothes & equipment for welding (I.E Welding mask, gloves, apron etc) 5. Press torch trigger to start welding process and adjust welding current knob to adjust wire feed accordingly. Note: You can finely adjust the welding current knob to fine tune weld arc length to either DIP or SPRAY welding DIP is when the wire is melting very close to the workpiece (Short arc length) SPRAY is when the wire is melting far away from workpiece (Long arc length) 6. When welding actual voltage and amperage will be shown in corresponding LED display meters on machine 1. Tips on welding aluminium When welding aluminium as the wire is much softer than steel wire you have to fit a Teflon liner in place of the steel liner in MIG torch, this is so the wire feeds much smoother and stops it snarling at rollers. To fit a Teflon liner, remove steel liner from torch and fit Teflon liner so you have about 10 inches left coming out end of MIG torch at the machine end. In the brass euro body where torch fits onto you will see a brass guide tube, remove this tube (you will have to remove circlip to allow this) and fit torch to machine and cut off excess Teflon liner as required. You want the Teflon liner to get as close to the wire feed rollers as possible. Best way to cut liner is with a sharp knife blade. Adjust the wire tensioner to minimum pressure and tighten down until wire is gripped, too much pressure will deform wire and end up with snarls by rollers. The IMIG 160 is fitted with rollers suitable for both steel and alloy wire as standard. Fit oversize welding tip. These are available and have and ‘A’ after tip size. I.E 0.8A where as for steel wire it would just say 0.8 2. Tips on using gasless wire When using gasless wire is may be required to change the polarity of the arc. This can be done simply by reversing the cables inside wire feed cabinet Gas wire = Positive torch – Negative work (machine is set as standard) Gasless wire = Negative torch – Positive earth Operating the Machine in MMA mode Connect the following: 1. Negative welding power connector Connect the earth cable dinse plug into here and twist to secure 2. Positive welding power connector Connect the electrode holder cable dinse plug into here and twist to secure Most popular rods have a positive welding electrode and negative earth. If you are using special electrodes check the manufacturer’s recommendation for correct polarity of welding electrodes and connect as required. 1. 2. 3. 4. 5. Ensure machine is setup as previously stated Fit desired electrode size in electrode holder Switch on machine Select desired welding power Touch electrode on to workpiece and the arc will start When the machine is switched on, output terminals are always live, take care and do not touch electrode and earth by person at same time, otherwise an electric shock will occur. Maintenance Routine and periodic maintenance WARNING! ELECTRIC SHOCK CAN KILL Turn the input power OFF at the mains switch & fuse box and remove mains plug from socket before working on this equipment. Have a qualified electrician install & service this equipment. Allow machine to sit for 5 minutes minimum after disconnection from mains power to allow the power capacitors to discharge before working inside this equipment. Do not touch electrically live parts 1. Periodically (3-6 months depending on use / environment), remove the side/top panels of machine and clean out machine with a low pressure dry air line paying particular attention to PC Boards, Fan blades and switchgear Failure to maintain plant can void manufacturers warranty. 2. Inspect input and output cables & hoses for fraying and cuts, replace if damaged present 3. Keep the MIG torch and earth cables in good condition 4. Clean the air vents to ensure proper air flow and cooling 5. The fan motor has sealed bearings which requires no maintenance Troubleshooting Service & repair should only be performed by R-Tech welding trained personnel. Unauthorized repairs performed on this equipment may result in danger or injury to the technician and machine operator and will invalidate your warranty. For your safety and to avoid electric shock, please observe all safety notes and precautions detailed throughout this manual The troubleshooting guide is provided to help you locate possible machine malfunctions If fault / problem is not listed below check our Mig Welder Support page on our website: www.r-techwelding.co.uk/support.php or contact R-Tech by phone. Contact details can be found on our website Output Problems No output - Power light is not lit Check machine on/off switch is in the ‘on’ position Check Input power to machine Check plug wiring Check mains trip / fuses No output - Fan runs - Power light is lit Check torch connections are secure and torch switch operation, try replacing MIG torch. No output - Power light is lit - Warning light is lit Welding application may have exceeded recommended duty cycle, allow machine to cool down until the warning light goes out. No output – Power light is lit – Gas at torch tip – No wire feed Check wire feed unit protecting fuse on rear of machine, if blown replace with new fuse of same rating, if the fuse blows again contact R-Tech Machine keeps overheating - Warning light is lit on machine Check if fan is running – if not contact R-Tech. Check the cooling vents for obstruction, blow out machine with clean dry low pressure air supply. Check for adequate ventilation around machine Porosity in weld – No / low gas at torch tip Check gas supply from gas bottle Check flow rate on regulator Check gas hose for restrictions Check for draughts in local area, open doors etc Replace MIG torch – may have gas restriction Poor weld penetration Check condition of earth lead and clamp and ensure clamp is connection via a clean area on work piece. Check the condition of the MIG torch, try another MIG torch.