XTM252i - Parweld

XTM252i - Parweld
XTM252i
Operator Manual
ISSUE 1
Welcome
Thank you and congratulations on choosing Parweld. This Owner’s Manual is designed to help you get
the most out of your Parweld products. Please take time to read the Safety precautions. They will
help you protect yourself against potential hazards in the workplace. With proper maintanance this
equipment should provide years of reliable service. All our systems conform to ISO9001: 2000 and
are independently audited by NQA.
The entire product range carries the CE mark, and is constructed in accordance with European
directives and the product specific standards where they apply.
Further Information
Parweld is the UK’s leading supplier of MIG, TIG and Plasma torches and consumables.
For more information about Parweld’s complete range visit: www.parweld.com
Page
1.0 Safety Precautions
4
2.0 Product description
5
3.0 Technical Specifications
6
4.0 Description of controls
6
5.0 Installation
7
5.1 Unpacking the Machine
7
5.2 Location
7
5.3 Input and grounding connection 7
5.4 Output Polarity Connections
7
5.5 Changing drive roll sets
7
5.6 Welding wire installation
7
5.7 torch installation
8
5.8 Work return lead connection
9
5.9 Shielding gas connection 9
6.0 Operation
9
6.1 Feeding wire electrode
9
6.2 Spot Weld Mode
9
6.3 Optimising weld parameters
9
7.0 Fault finding
8.0 Accessories
10
8.1 Drive rolls
11
8.2 Torch spares
12
8.3 Gas equipment
13
9.0 EC declaration of conformity
14
9.1 RoHS Compliance Declaration
14
9.2 WEEE Statement
15
9.3 Statement of warranty
15
11
Contents
Contents
1.0 Safety Precautions
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or severe burns.
The electrode and work circuit is electrically live whenever the output
is on. The input power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding,
the wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
Do not touch live electrical parts.
Wear dry, sound 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
ground.
Additional safety precautions are required when any of the following
electrically hazardous conditions are present: in damp locations
or while wearing wet clothing; on metal structures such as floors,
gratings, or scaffolds; when in cramped positions such as sitting,
kneeling, or lying; or when there is a high risk of unavoidable
or accidental contact with the work piece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, And, do not work alone!
Disconnect input power before installing or servicing this equipment.
Lockout/tagout input power according to Safety Standards.
Properly install and ground this equipment according to national and
local standards.
Always verify the supply ground - check and ensure that input power
cable ground wire is properly connected to ground terminal in the
receptacle outlet.
When making input connections, attach proper grounding conductor
first - double-check connections.
Frequently inspect input power cable for damage or bare wiring replace cable immediately if damaged - bare wiring can kill.
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.
Welding produces fumes and gases. Breathing these fumes and
gases can be hazardous to your health.
FUMES AND GASES can be hazardous.
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
If ventilation is poor, wear an approved respirator.
Read and understand the Material Safety Data Sheets (MSDS’s) and
the manufacturer’s instructions for metals, consumable, coatings,
cleaners, and de-greasers.
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 de-greasing, 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 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.
Turn off all equipment when not in use.
Wear an approved welding helmet fitted with a proper shade of filter
lenses to protect your face and eyes when welding or watching
Do not use worn, damaged, under sized, or poorly spliced cables.
Wear approved safety glasses with side shields under your helmet.
Do not drape cables over your body.
Use protective screens or barriers to protect others from flash, glare
and sparks; warn others not to watch the arc.
If earth grounding of the work piece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground, or
another electrode from a different machine.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Wear a safety harness if working above floor level.
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Wear protective clothing made from durable, flame resistant material
(leather, heavy cotton, or wool) and foot protection. 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 fire. Check and be sure the area is safe
before doing any welding.
WELDING can cause fire or explosion.
Remove all flammables within 10m of the welding arc. If this is not
possible, tightly cover them with approved covers.
Do not weld where flying sparks can strike flammable material.
Protect yourself and others from flying sparks and hot metal.
Be alert that welding sparks and hot materials from welding can easily
go through small cracks and openings to adjacent areas.
Watch for fire, and keep a fire extinguisher nearby. Be aware that
welding on a ceiling, floor, bulkhead, or partition can cause fire on the
hidden side.
Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to local regulations
Connect work cable to the work as close to the welding area as
practical to prevent welding current from travelling along, possibly
unknown paths and causing electric shock, sparks, and fire hazards.
CYLINDERS can explode if damaged.
Protect compressed gas cylinders from excessive heat, mechanical
shocks, physical damage, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping. Keep cylinders
away from any welding or other electrical circuits. Never drape a
welding torch over a gas cylinder. Never allow a welding electrode to
touch any cylinder. Never weld on a pressurized cylinder - explosion
will result. Use only correct shielding gas cylinders, regulators,
hoses, and fittings designed for the specific application; maintain
them and associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Use the right equipment, correct procedures, and sufficient number
of persons to lift and move cylinders.
Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
Cut off welding wire at contact tip when not in use.
Wear oil-free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes, and a cap. Remove any combustibles,
such as a butane lighter or matches, from your person before doing
any welding.
FLYING METAL can injure eyes.
Welding, chipping, wire brushing, and grinding cause sparks and flying
metal. As welds cool they can throw off slag. Wear approved safety
glasses with side shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
Shut off shielding gas supply when not in use. Always ventilate
confined spaces or use approved air-supplied respirator.
2.0 Product Description
The XTM252i is a complete semiautomatic constant voltage DC
arc welding machine built to meet CE specifications. It combines a
constant voltage power source and a constant speed wire feeder
with a microcomputer-based controller to form a reliable highperformance welding system. A simple control scheme, consisting of
range voltage and wire feed speed controls, provides versatility with
ease of use and accuracy. Other features include wire reel spindle
with adjustable brake for 15kg wire spools (300mm), an integral gas
cylinder mounting undercarriage, an adjustable Argon flow regulator
with cylinder pressure gauge and inlet hose, a Parweld MIG torch,
and a 3.0m work cable with clamp.
HOT PARTS can cause severe burns.
Do not touch hot parts with bare handed.
Allow cooling period before working on gun or torch.
To handle hot parts, use proper tools and/or wear heavy, insulated
welding gloves and clothing to prevent burns.
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 hearing.
Noise from some processes or equipment can damage hearing.
Wear approved ear protection if noise level is high.
Shielding gas cylinders contain gas under high pressure.
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3.0 Technical
2
1
3
6
The XTM 252i, Is a compact type machines with integrated wire
feed units for use with single phase 230V supply. The machine
uses inverter technology to allow MIG , TIG and MMA welding to be
performed.
11
9
12
10
4
5
7
13
16
Feature
XTM252i
14
Input voltage
230V +/-10%
15
Hz
50/60
Phases
1
Wire drive
4 roll
Current Draw (A)
26
Rated input
capacitance KVA
No-load voltage
V
Rated working
voltage V
10.4
69V
26.5
LIFT Arc welding
current A
15-250
MIG welding current
A
30-250
Fuse Rating
45
10. MIG/MAG ELECTRICAL INDUCTOR ADJUST KNOB: Its main
function is adjusting arc’s dynamic in MIG/MAG.
Output current (A)
35-255
Load voltage
15.7-26.7
11. CURRENT INDICATOR: When the indicator is on, it means the
current is displayed.
Feed speed m/min
1.5-20
(A)
4.0 Description of Controls
1.
POWER INDICATOR: When the machine is turned on, the
power indicator will be on.
2.
ALARM INDICATOR: When the thermal indicator is on, it shows
the machine is overloaded and the internal temperature is too
high. Weld output will turn off automatically but the fan will still
be working. When the internal temperature is decreased, the
overload light will turn off and the machine will be ready to weld
3.
VRD INDICATOR: When the VRD indicator is on, it means
the welder’s output voltage is safe ≤13V, it will be off when the
welder is working..
4.
CURRENT DISPLAY INDICATOR: It will be display current
preset, and display real-current when the welder is working.
5.
LEFT ADJUST KNOB: Its main function is adjusting welding
current; Users can press down the knob in MIG/MAG then wire
inching function will be activated.
6.
VOLTAGE DISPLAY INDICATOR: It will be display Arc-Force
preset in MMA, and display voltage preset in MIG/MAG, and
display real-voltage when the welder is working.
7.
MIDDLE ADJUST KNOB: Its main function is adjusting ArcForce in MMA, and adjusting welding voltage in MIG/MAG.
Press down the knob in MIG/MAG, and the gas-check function
will be active.
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8.
VOLTAGE AND ARC LENGTH INDICATOR:
9.
MMA ARCFORCE PRE-SET INDICATOR:
12. WFS INDICATOR: When the indicator is on ,it means the wire
speed is display(m/min).
13. WELD FUNTION SELECTION BUTTON: Users can select
MMA LIFT Arc or MIG/MAG function by this button, and the
indicators at the left part of button will indicate the selection
weld function.
14. MIG/MAG TRIGGER MODE BUTTON: Users can select gun
trigger mode in MIG/MAG by this button, and the indicators at
the left part of button will indicate the selection mode.
15. MIG/MAG GAS SELECTION BUTTON: Users can select
protect gas by this button, and the indicators at the left part of
button will indicate the selection gas.
16. MIG/MIG WIRE DIAMETER SELECTION BUTTON: Users can
select wire diameter by this button, and the indicators at the left
part of button will indicate the selection wire.
17. Torch connector The Euro connector provided the external
connection for the welding torch.
18. Work return lead connection. This socket allows connection of
the work return lead to the front of the machine.
19. Gas cylinder restraint chain Use to secure the gas cylinder
when mounted on the rear of the machine
20. Shielding gas input connection 3/8 BSP male connection for the
shielding gas input.
21. Mains input connection Input connection for the pre installed
mains cable.
22. Cylinder stand Rear stand for the gas cylinder
23. Wire spool holder
24. Pressure adjuster Used to adjust the pressure allied by the feed
rollers on the welding wire.
25. Pressure roller Plain roller used to apply pressure on the
welding wire
26. Feed Roller Grooved roller used to drive the welding wire up
the torch the size of the roller should match the size of the wire
in use.
MIG, TIG and MMA welding use different electrode polarities. The
polarity of the MIG torch can be selected by connection of the torch
cable to the + or - socket the front of the welder, (+) polarity. This is
the normal polarity for MIG welding with GAS.
5.0 Installation
Read entire installation section before starting installation.
SAFETY PRECAUTIONS
• ELECTRIC SHOCK can kill.
• Only qualified personnel should perform this installation.
• Only personnel that have read and understood the Operating
Manual should install and operate this equipment.
• Machine must be grounded per any national, local or other
applicable electrical regulations.
• The MIG power switch is to be in the OFF position when
installing work cable and torch and when connecting other
equipment.
5.5 Changing drive roll sets
1.
Turn off the power source.
2.
5.1 Unpacking the Machine
Release the pressure on the idle roll by swinging the adjustable
pressure arm down toward the back of the machine. Lift the
cast idle roll assembly and allow it to sit in an upright position.
3.
Cut banding and lift off cardboard carton. Cut banding holding the
machine to the skid. Remove corrugated packing material. Remove
accessories from Gas Bottle Platform.. Roll the machine off the skid
Unscrew the plastic knob retaining the lower grooved drive roll
and side off the drive roller.
4.
Ensure the wire size marked on the side of the feed roller
matches the wire size to be used.
5.
Replace the drive in reverse of the above procedure ensuring
the wire size to be used is marked on the outward facing side
of the roller as it is refitted.
5.2 Location
Locate the welder in a dry location where there is free circulation
of clean air into the louvres in the back and out the front. A location
that minimizes the amount of smoke and dirt drawn into the rear
louvres reduces the chance of dirt accumulation that can block air
passages and cause overheating.
NOTE: Be sure that the torch liner and contact tip are also sized
to match the selected wire size.
5.6 Welding wire installation
1.
Open the Wire Drive Compartment Door by lifting the 2 finger
catches on the side panel.
2.
Unscrew the plastic retaining wheel from the end of the spool
holder shaft.
WARNING
3.
Before starting the installation, check that your power supply
is adequate for the voltage, amperage, phase, and frequency
specified on the Machine nameplate.
Position the wire spool so that it will rotate in a direction when
feeding so as to be de-reeled from the bottom of the coil.
4.
Slide the wire spool all the way onto the shaft and refit the
plastic retaining nut.
5.3 Input and grounding connection
The 230 volt 50 Hz machine is supplied with a 4m input cable and
without plug, ensure that you connect a plug that is suitably rated for
the power draw of the machine and the environmental location.
Note:- there is a friction brake on the reel hub assembly to
prevent the wire spool over running when welding stops ensure
the this is slackened to the minimum setting. I can be adjusted
by means of the nut visible when the plastic nut is removed.
Using the, have a qualified electrician connect the input plug. For
long runs over 30m , larger copper wires should be used. The green/
yellow wire in the input cable connects to the frame of the machine.
This ensures proper grounding of the machine when the machine
plug is inserted into the receptacle.
5.
Turn the Spool until the free end of the electrode is accessible.
While securely holding the electrode, cut off the bent end and
straighten the first six inches. (If the electrode is not properly
straightened, it may not feed properly through the wire drive
system Manually feed the wire from the wire reel and through
the wire guide and then over the top of the wire feed roller
(ensure the pressure arm is in its raised position.)
5.4 Output Polarity Connections
6.
Continue to feed the wire through the outlet guide until 20mm
of wire is protruding from the front of the machine torch
connector.
7.
Reposition the adjustable pressure arm to its original position to
apply pressure. Adjust pressure as necessary.
Note the pressure arm should be adjusted in order to give
the minimum amount of pressure on the wire to allow reliable
feeding,
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5.7 torch installation
Your Parweld MIG/MAG Welding Torch has been supplied ready to
weld. It has been supplied with the standard consumables denoted
in the product brochure.
To connect the torch to the power source:1.
Remove the tip adaptor and contact tip
2.
Inch the wire from the exit of the wire guide on the feed unit
as Figure 1. Ensure that it does not short out on any machine
panels.
3.
Carefully slide the electrode wire into the torch liner and
slowly locate the torch gun plug body into the feed unit central
connector and tighten the gun plug nut as Figure 2
Note; To aid the initial location of a new torch and to prevent
damage to the gas nipple O-ring a very light application of
Fig 1
Fig 2
hose delivers cold water directly to the prime source of heat, the
swan neck and consumable. The re circulated water is then passed
through the torch power cable to cool the power cable as it is
returned to the cooler through the red water return lead.
Ensure all air is removed from the water cooling circuit before
welding.
5.8 Work return lead connection
Insert the work return lead connector into the receptacle on the front
panel of the machine and twist it clockwise until tightly secured.
Connect the earth clamp to the work piece as close as possible to
the point to be welded and ensure that a good electrical connection
is created to bare metal.
5.9 Shielding gas connection
4.
5.
Keeping the torch as straight as possible, use the power source
inch facility or torch trigger to feed the electrode wire 50mm
from the end of the liner conduit.
diffuser, contact tip and gas nozzle.
1.
Using the gas hose supplied connect the hose to the gas inlet
connection on the rear of the machine and tighten it with a
spanner.
2.
Connect the opposite end of the gas hose to the output
connection of a gas regulator capable of supplying the correct
Note if the gas cylinder is to be stored on the back of the
machine ensure it is secured using the retention chain provided
6.0 Operation
1.
Switch on the machine using the mains on/off switch, This lights
the Green LED above the voltage selector switch.
2.
Select the welding mode using push button (13) and switching
option with Button (14)
6.1 MIG welding Feeding wire electrode
x
You can MIG weld in 2 modes Manual and Synergic the manual
mode takes more skill to setup.
Synergic MIG,
Select the Synergic MIG mode using button (13)
6.
7.
8.
9.
Trim the electrode wire to within 5mm of the face of the nozzle,
this will facilitate jolt free arc initiation.
Select the wire diameter using button (16)
for your application.
806001.
If you are setting a water-cooled torch ensure you have the
water to prevent irreparable torch failure, a minimum of 1.2 l/
min is recommended.
Parweld recommend the use of its XTS water recirculation system
8
Select the wire type using button (15)
Plasma welding torches.
Rotating the amperage button (5) select the desired welding
amperage. you can refer to the table at the rear of the instruction
book for recommended welding amperages. The machine will
adjust the welding voltage automatically but you may trim it and the
inductance to your personal preference by adjustment of the Voltage
knob (7) and inductance (10) The voltage will increase or decrease
penetration and the inductance affects the arc stability and droplet
transfer.
Manual MIG
Select the Manual MIG mode using button (13)
Select the desired welding voltage using the knob (7)
Select the desired welding amperage (wire speed) using the knob (5)
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Note: Check that drive rolls, and torch parts are correct for the
wire size and type being used.
3.
4.
5.
1.
The optimum idle roll pressure varies with type of wire, wire
diameter, surface conditions, lubrication, and hardness. As a
general rule, hard wires may require greater pressure, and soft,
or aluminium wire, may require less pressure than the factory
setting. The optimum idle roll setting can be determined as
follows:
Press end of gun against a solid object that is electrically
isolated from the welder output and press the gun trigger for
several seconds.
If the wire “bird nests”, jams or breaks at the drive roll, the idle
roll pressure is too great. Back the adjustment knob out 1/2
turn, run new wire. If the only result was drive roll slippage,
loosen the Hand nut on the central connector and pull the gun
forward about 6” (15cm) away from the power source. There
should be a slight waviness in the exposed wire. If there is not
waviness, the pressure is too low. Tighten the adjustment knob
1/4 turn, reinstall the gun cable and repeat the above steps.
When triggering, the electrode and drive mechanism are
electrically “LIVE” relative to work and ground and remain
“LIVE” several seconds after the gun trigger is released.
WARNING
When using an open arc process, it is necessary to use correct
eye, head, and body protection.
2.
Position wire over joint. The end of the wire may be lightly
touching the work.
3.
Lower welding helmet, operate gun trigger, and begin welding.
Hold the gun so the contact tip to work distance is about 3/8”
(10 mm).
4.
To stop welding, release the gun trigger and then pull the gun
away from the work after the arc goes out.
5.
When no more welding is to be done, close valve on gas
cylinder (if used), momentarily operate gun trigger to release
gas pressure and turn off the machine.
NOTE These settings are guidelines only. Material and wire
type, joint design, fit up, position, shielding gas, etc. affect
settings. Produce test welds to be sure they comply to
specifications.
Wire Size
Feed speed
0.8 mm
0.05m/min per Amp
1.0 mm
0.04m/min per Amp
1.2 mm
0.025m/min per Amp
So based on 3.2 mm material thickness amperage should be 125A if
using 1.0mm wire then the wire feed speed should be
0.04 X 125= 5m/min
Wire speed (amperage) controls weld penetration
4.
Select Voltage. Voltage controls height and width of weld
bead.
Low Voltage: wire stubs into work
High Voltage: arc is unstable (spatter)
Set voltage midway between high/low voltages.
And then fine tune accordingly
6.2 MMA/TIG welding
Output Polarity Connections
Electrode polarity
MMA electrodes are generally connected to the ‘+’ terminal and the
work lead to the ‘-‘terminal
But if in doubt consult the electrode manufacturer’s literature.
IF TIG welding the torch should always be connected to the ‘-’
terminal.
Torch installation
MMA cable connections
Connect electrode lead to positive terminal on the front panel
TIG welding cable connection
Connect the TIG torch to the - terminal
Work return lead connection
MMA cable connections
Connect work lead to negative terminal
TIG welding
Material thickness determines weld parameters.
1.
Convert Material Thickness to Amperage (A) (0.25mm= 1 Amp)
3.2mm = 125 A
2.
Select Wire Size
Amperage Range Wire Size
40 - 145 A
0.8 mm
50 - 180 A
1.0 mm
75 - 250 A
1.2 mm
3.
Select Wire Speed (Amperage)
Connect the work return lead to the + terminal
MMA/TIG welding Operation
WARNING
When using an open arc process, it is necessary to use correct
eye, head, and body protection.
MMA Welding Guide
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CONTROLS
Using the selector button 13 toggle through the functions until the
MMA light is illuminated
Stainless steel
You can adjust he welding amperage using the knob (5) and the arc
force using the knob (7)
TIG Welding guide
Effects of MMA welding various materials
High tensile and alloy steels
The two most prominent effects of welding these steels are the
formation of a hardened zone in the weld area, and, if suitable
precautions are not taken, the occurrence in this zone of under-bead
cracks. Hardened zone and under-bead cracks in the weld area may
be reduced by using the correct electrodes, preheating, using higher
current settings, using larger electrodes sizes, short runs for larger
electrode deposits or tempering in a furnace.
Manganese steels
The effect on manganese steel of slow cooling from high
temperatures is enbrittlement. For this reason it is absolutely
essential to keep manganese steel cool during welding by quenching
after each weld or skip welding to distribute the heat.
Cast iron
Most types of cast iron, except white iron, are weldable. White iron,
because of its extreme brittleness, generally cracks when attempts
are made to weld it. Trouble may also be experienced when welding
white-heart malleable, due to the porosity caused by gas held in this
type of iron.
Copper and alloys
The most important factor is the high rate of heat conductivity of
copper, making preheating of heavy sections necessary to give
proper fusion of weld and base metal.
Types of electrodes
Arc welding electrodes are classified into a number of groups
depending on their applications. There are a great number of
electrodes used for specialized industrial purposes which are not of
particular interest for everyday general work. These include some
low hydrogen types for high tensile steel, cellulose types for welding
large diameter pipes, etc. The range of electrodes dealt with in this
publication will cover the vast majority of applications likely to be
encountered; are all easy to use and all will work on even the most
basic of welding machines.
Metals being joined & electrode comments
Mild steel 6013 ideal electrodes for all general purpose work. Features include
outstanding operator appeal, easy arc starting and low spatter.
Mild steel 7014 all positional electrode for use on mild and galvanized steel
furniture, plates, fences, gates, pipes and tanks etc. Especially
suitable for vertical down welding.
Cast iron
99% nickel suitable for joining all cast irons except white cast iron
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318l-16 high corrosion resistance. Ideal for dairy work, etc. On
stainless steels.
Using the selector button 13 toggle through the functions until the
DC TIG light is illuminated
You can adjust he welding amperage using the knob (5) and the arc
force using the knob (7)
Tig welding cable connection
Connect the TIG torch to the - terminal and the work lead to the +
terminal for direct current straight polarity. Direct current straight
polarity is the most widely used polarity for DC TIG welding. It allows
limited wear of the electrode since 70% of the heat is concentrated
at the work piece. Connect the gas hose on the TIG torch to the gas
outlet on the gas regulator. Move the selector switch on the front
panel of the machine to the LIFT-TIG position.
Torch starting in LIFT-TIG mode
Ensure the gas supply is switched on and gas is flowing from the
front of the torch nozzle. Briefly contact the tip of the tungsten
electrode down onto the work piece with the torch at around 700 from
vertical, lift the torch up from the work piece to draw out an arc. To
prevent melting of the end of the tungsten so this in a smoth rapid
movement
TIG welding guide ranges
7.0 Fault Finding
Problem
Cause/Corrective Action
Problem
Cause/Corrective Action
Porosity - small cavities or holes
Inadequate shielding gas
coverage. Check for proper
gas flow rate.
Excessive Penetration – weld
metal melting through base
metal and hanging underneath
weld.
Excessive heat input. Select
lower voltage range and
reduce wire feed speed.
Lack Of Penetration - shallow
Improper joint preparation.
Material too thick. Joint
preparation and design must
provide access to bottom of
groove while maintaining
Resulting from gas pockets in
weld metal.
Remove spatter from gun
nozzle.
Check gas hoses for leaks.
Eliminate drafts near welding
arc.
Fusion between weld metal and
Base metal.
Place nozzle 6-13 mm from
work piece Hold gun near
bead at end of weld until
molten metal solidifies.
Increase travel speed.
Proper welding wire extension
and arc characteristics.
Improper weld technique.
Maintain normal gun angle of
0 to 15 degrees to achieve
maximum penetration. Keep
arc on leading edge of weld
puddle. Ensure welding wire
extends not more than 13 mm
beyond nozzle.
Wrong gas. Use welding
grade shielding gas; change to
different gas.
Dirty welding wire. Use clean,
dry welding wire. Eliminate
pickup of oil or lubricant on
welding wire from feeder or
liner.
Insufficient heat input. Select
higher wire feed speed and/or
select higher voltage range.
Work piece dirty. Remove all
grease, oil, moisture, rust,
paint, coatings, and dirt from
work surface before welding.
Use a more highly deoxidizing
welding wire (contact supplier).
Burn-Through - weld metal
melting
Increase and/or maintain
steady travel speed.
Welding wire extends too far
out of nozzle.
Resulting in holes where no
metal remains.
Excessive Spatter - scattering of
Wire feed speed too high.
Select lower wire feed speed.
Be sure welding wire extends
not more than 13 mm beyond
nozzle.
Reduce travel speed.
Completely through base metal
Molten metal particles that cool
to solid form near weld bead.
Excessive heat input. Select
lower voltage range and
reduce wire feed speed.
Voltage too high. Select lower
voltage range.
Electrode extension (stick out)
too long. Use shorter electrode
extension (sick out).
Incomplete fusion to base metal
Work piece dirty. Remove all
grease, oil, moisture, rust,
paint, coatings, and dirt from
work surface before welding.
Work piece dirty. Remove all
grease, oil, moisture, rust,
paint, undercoating, and dirt
from work surface before
welding.
Insufficient heat input. Select
higher voltage range and/or
adjust wire feed speed.
Insufficient shielding gas at
welding arc. Increase flow of
shielding gas at regulator/flow
meter and/or prevent drafts
near welding arc.
Improper welding technique.
Place stringer bead in proper
locations) at joint during
welding.
Adjust work angle or widen
groove to access bottom
during welding.
Momentarily hold arc on
groove side walls when using
weaving technique.
Keep arc on leading edge of
weld puddle. Use correct gun
angle of 0 to 15 degrees.
Dirty welding wire. Use clean,
dry welding wire. Eliminate
pickup of oil or lubricant on
welding wire from feeder or
liner.
Wire feed unit operates but no
gas flow .
Gas cylinder empty
Gas regulator closed
Faulty solenoid
Restriction in torch cables
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11
Problem
Cause/Corrective Action
Wire feed unit operates, but
does not feed
Insufficient drive roll pressure
Incorrect drive rolls
Excessive wire spool brake
tension
Incorrect liner
Blocked liner
Bird nesting
Burn back
Bird nesting
Excessive feed roll pressure
Incorrect or blocked liner
Incorrect contact tip size
Contact tip overheating
Restriction in torch cable
Misaligned drive rolls or wire
guides
Excessive cable kinkage
Burn back
Improper voltage setting
Improper stick out
Erratic wire feed
Incorrect or blocked liner
Contact tip overheating
Excessive cable kinking
Erratic Wire Feeding or Arc
Improper drive roll tension
Improper drive roll size
Worn drive rolls
Incorrect or blocked liner
Incorrect wire guide size
Misaligned drive rolls or wire
guide
Gaps at liner or wire guide
junctions
Incorrect contact tip size
Contact Tip overheating
Spatter adhesion on exit
geometry of tip bore
Excessive cable kinkage
Poor earth or cable
connections
Weld joint area dirty
Yellow temperature light
illuminates
Power source has over heated
leave the machine running
to allow it to cool down.
Ensure entry and exit vents
on machine are clear and
machine has a good supply of
cooling air.
Reduce operating duty cycle
and or amperage.
12
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Everyday 150A
Air Cooled MIG Welding Torch
Rating: 180A CO2 150A mixed gas, @ 60% duty cycle. EN60974-7 .0239-.0409/0.6-1.0mm
wires
10
5
3
6
4
9
1
B
8
7
2
11
A
13
12
19
21
22
17
16
20
15
7
14
C
18
Model
Components
Stock Code
3M
4M
Model Description
ECR1500
-30ER -40ER Everyday Welding Torch
c/w Euro Fitting
Nozzles
Stock Code Description A ECO1530*
Everyday Conical Nozzle 15/329/12mm Bore
B1529
Everyday Cylindrical Nozzle 5/89/16mm Bore
B1531
Everyday Tapered Nozzle 7/169/11mm Bore
B1532
Everyday Bottle Nozzle 1/29/13mm Bore
B1533
Everyday Spot Welding Nozzle 5/89/16mm Bore
Contact Tips
Stock Code Description B ECO1527-06 Everyday Contact Tip 0.0239/0.6mm M6 Eco
ECO1527-08* Everyday Contact Tip 0.0309/0.8mm M6 Eco
Liners
Stock Code Description C ECO1535-30 Everyday Steel Liner .0239-.0309/0.6-0.9mm x 3m
ECO1535-40 Everyday Steel Liner .0239-.0309/0.6-0.9mm x 4m
Stock Code Description* Denotes Standard Build
1 B1504
2 B1507 L/H
3 ECO1501
4 ECO1502
5 B2519
6 B1515/ER
7 B1505
8 ECO8016
9 B1521
10 B1541
11 ECO2514
12 ECO2516
13 B1517-30
B1517-40
B1517-50
14 B1522
15 B1841
16 B1518/BK
17 B1526
18 B1519PL/BK
19 Fixed Pin
20 ECB1528
21 B1524
22 B1525
Shroud Spring
Tip Adaptor
Swan Neck c/w Tip Adaptor & Insulation Sleeve
One Piece Neck Insulation Sleeve
Hexagonal Fitting
Ergo Handle Location Body
Lock Nut
Spring Cable Support c/w Knuckle Joint
Cable Terminal – Female
Handle Screw
Everyday Ergo Handle Kit
Everyday Ergo Trigger
Cable Assembly x 3.0m
Cable Assembly x 4.0m
Cable Assembly x 5.0m
Cable Terminal – Male
Cable Support
Gun Plug Housing c/w Nut
Gun Plug Screw
Gun Plug Nut, Plastic c/w Insert
Fixed Pin Assembly
Gun Plug Body c/w Fixed Pins
Gun Plug ‘O’ Ring
Liner Nut
13
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XP8 200A
Air Cooled Mig Welding Torch
Rating: 200A, 6kW, Mixed Gas (80/20) @ 80% Duty Cycle, EN60974-7 .0239-.0459/0.6mm to
9
1.2mm wire
4
3
12
11
2
5
6
1
7
B
10
A
8
16
18
22
21 20
B
C
Stock Code 3M
XP200A
-30E
4M
5M
Model Description
-40E
-50E
Welding Torch c/w Euro Fitting
Stock Code
Description
Tapered Nozzle 3/89/10mm
XP2002-13
Tapered Nozzle 1/29/13mm
XP2002-16*
Conical Nozzle 5/89/16mm
XP2002-16L
Conical Nozzle 5/89/16mm-Extended
XP2002-19
Cylindrical Nozzle 3/49/19mm
XP2002-19L
Cylindrical Nozzle 3/49/19mm-Extended
Contact Tips
Stock Code
Description
B XP2003-06
Contact Tip .0239/0.6mm M8 CuCrZr
XP2003-08
Contact Tip .0309/0.8mm M8 CuCrZr
XP2003-09
Contact Tip .0359/0.9mm M8 CuCrZr
XP2003-10*
Contact Tip .0409/1.0mm M8 CuCrZr
XP2003-10A
Contact Tip .0409/1.0mm Aluminium M8 CuCrZr
XP2003-12
Contact Tip .0459/1.2mm M8 CuCrZr
XP2003-12A
Contact Tip .0459/1.2mm Aluminium M8 CuCrZr
Liners
Stock Code
XP2024PS-12-30Polyamide-Steel Liner .0309-.0459/0.8/1.2mm x
10ft/3m
XP2024PS-12-40Polyamide-Steel Liner .0309-.0459/0.8-1.2mm x
13ft/4m
A XP2002-10
13
XP2024PS-12-50Polyamide-Steel Liner .0309-.0459/0.8-1.2mm x
16ft/5m
Nozzles
5
17
Model
14
15
19
Description
C XP2024-09-30
Steel Liner .0239-.0359/0.6mm/0.9mm x 10ft/3m
XP2024-09-40
Steel Liner .0239-.0359/0.6mm/0.9mm x 13ft/4m
XP2024-09-50
Steel Liner .0239-.0359/0.6mm/0.9mm x 16ft/5m
XP2024-12-30* Steel Liner .0409-.0459/1.0mm/1.2mm x 10ft/3m
XP2024-12-40* Steel Liner .0409-.0459/1.0mm/1.2mm x 13ft/4m
XP2024-12-50* Steel Liner .0409-.0459/1.0mm/1.2mm x 16ft/5m
NIXP2024PC-12-30Polyamide-Copper Liner .0309-.0459/0.8-1.2mm x
10ft3m
XP2024PC-12-40Polyamide-Copper Liner .0309-.0459/0.8-1.2mm x
13ft/4m
XP2024PC-12-50Polyamide-Copper Liner .0309-.0459/0.8-1.2mm x
16ft/5m
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Components
Stock Code Description
* Denotes Standard Build
1 XP2004B*
Diffuser – Plastic – M8 Head
NI XP2004C
Diffuser – Ceramic – M8 Head
2 XP2005*
Head Assembly-M8 Tips
NI XP2006B
Heat Shield Moulded – M8 Head
3 XP2006A*
Aluminium Heat Shield – M8 Head
4 XP2001
Swan Neck
5 XP2016
Lock Nut M12
6 XP2008
Ball Joint and Cable Support
7 XP2009
Handle Lock Nut
8 XP2010-30
Cable Assembly x 3m / 10ft
XP2010-40
Cable Assembly x 4m / 13ft
XP2010-50
Cable Assembly x 5m / 16ft
9 XP2011
Cable Terminal Female
10 XP2012
Handle Kit c/w Lock Nut
11 XP2013
Hanger Hook
12XP2014
Trigger
13 XP2015
Cable Terminal Male
14 XP2017
Cable Support
15 XP2018
Air Cooled Gun Plug Housing c/w Nut
16 XP2019
Gun Plug Screw
17 XP2020
Gun Plug Nut
18 Spring Pin 2
Spring Pin Assembly
19 XP2022
Gun Plug Body c/w Spring Pins
20 XP2023
Gun Plug Body O Ring
21 XP2025
Liner Nipple O Ring
22 XP2026
Liner Retaining Nut
8.0 Accessories
8.2 Torch spares
8.3 Gas equipment
Everyday Gas Regulators – 300
BAR
Single Stage
Features
Flow rate up to 96m3/h (3389 ft3/h)
•Full 300 bar capability
• Outlet pressure indicated on the bonnet
•Bottom entry design suited for top outlet
cylinder valves
Fittings
•Fitted with standard 3/89 BSP outlet
•Fitted with 5/89 BSP inlet connections
Stock Code
Description
Maximum Outlet Pressure
E700140
Argon Preset Regulator
3.0 Bar
E700141
Argon Indicator Regulator 3.0 Bar
E700113
1 Gauge Argon 30 lpm flow
E700123
2 Gauge Argon 30 lpm flow
Flow Meters
Features
•Designed from brass bar whilst
the tube and cover are moulded
from high quality polycarbonate
to ensure high impact resistance
and clarity
•Calibrated to operate at an inlet
pressure
of 30PSI
•Sensitive needle valve provides
easy adjustment and the
downward facing outlet connection eliminates hose kinking.
Fittings
•Fitted with standard 3/89 BSP inlet and outlet connections
Stock Code
Description
706101
Flow Meter Mixed Gas 25 lpm (MIG)
Gas flow Tester
•Designed to check gas flow at the front of
Mig Torches.
Stock Code
Description
806001
Gas flow Tester
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SETTING CHART -MIG
In Synergic mode enter the welding amperage only the machine will preset the voltage
Steel
Gasless Flux
Cored Wire E71T11
Mild Steel Solid
Wire
No Gas
Wire Type
Ar80%-CO2 20% Ar95%-CO2 5%
Material
Gas
Flow
Rates
15-25
Diameter
of Wire
0.9mm
1.2mm
0.8mm
0.9mm
1.0mm
1.2mm
ER316L Solid wire
Ar98%-CO2 2%
Stainless
Steel
0.8mm
0.9mm
1.0mm
1.2mm
ERCuSI-A
100% Argon
Silicon
Bronze
0.8mm
0.9mm
1.0mm
16
www.parweld.com
1.0mm
AlSi
100% Argon
Aluminum
1.2mm
1.2mm
1.0mm
AlMg
1.2mm
Plate T
Parameter
1 mm
1.5mm
2mm
2.5mm
Amps
65
80
125
150
Volts
13
14
14.5
18.5
Amps
65
80
125
150
Volts
13
14
14.5
18.5
Amps
60
80
110
140
Volts
14.5
14.8
16.7
18
Amps
65
80
120
155
Volts
15.2
17
19.5
20.1
Amps
70
90
130
140
Volts
15.2
17
18.9
20.1
Amps
70
99
148
159
Volts
15.5
15.9
17.9
18.5
Amps
55
80
100
122
Volts
13.5
15.5
13.5
19.2
Amps
53
83
107
148
Volts
13.5
15.2
16.9
20
Amps
53
100
130
160
Volts
13.5
15.2
16.9
20.5
Amps
53
100
130
160
Volts
13.5
15.2
16.9
20.5
Amps
90
105
11
140
Volts
14.7
14.9
15.9
17
Amps
62
100
125
155
Volts
13.5
17
19.5
20.3
Amps
80
110
130
140
Volts
14
17
19.5
20.3
Amps
80
110
130
140
Volts
14
17
19.5
20.3
Amps
62
83
100
120
Volts
13
14.2
15.5
16.5
Amps
71
91
115
128
Volts
14.9
15.9
16.8
17.9
Amps
69
85
105
125
Volts
13.9
15.2
16.6
16.9
Amps
72
91
115
128
Volts
14.9
15.9
16.8
17.9
Plate Thickness
mm
2.5mm
3mm
4mm
5mm
6mm
25
150
160
200
220
249
4.5
18.5
21
24
24.9
25.1
25
150
160
200
220
249
4.5
18.5
24
25
26
27.1
10
140
160
180
200
250
6.7
18
19.7
22.3
24.5
28.5
20
155
180
200
220
250
9.5
20.1
23.1
23
24.5
28.5
30
140
199
220
240
250
8.9
20.1
21.9
24.5
26.5
28.5
48
159
200
225
239
245
7.9
18.5
21.9
24.9
26
27.1
00
122
145
150
190
200
3.5
19.2
20.7
22.5
22.9
23.5
07
148
165
200
210
220
6.9
20
22.1
22.5
23.5
23.5
30
160
180
200
215
225
6.9
20.5
21.1
22.5
23.5
23.9
30
160
180
200
220
240
6.9
20.5
21.1
22.5
23.5
24.1
11
140
146
166
180
200
5.9
17
17.9
19.3
21.5
23.5
25
155
170
200
185
205
9.5
20.3
20.1
23.5
21.5
23.5
30
140
170
200
189
210
9.5
20.3
20.1
23.1
22.1
23.5
30
140
170
200
195
220
9.5
20.3
20.1
23.5
22.5
24.5
00
120
146
160
190
210
5.5
16.5
19.9
22.5
23.8
24.8
15
128
140
160
195
210
6.8
17.9
19.9
22.5
24.8
24.8
05
125
140
160
195
210
6.6
16.9
19.9
22.5
24.8
24.8
15
128
140
160
195
210
6.8
17.9
19.9
22.5
24.8
24.8
17
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9.0 EC declaration of conformity
Hereby we declare that the machines as stated below
Type: XTM252i
Conform to the EC Directives:
Low Voltage Directive 2006/95/EC
EMC Directive 2004/108/EC
Harmonised European standard: EN/IEC 60974-1
This is to certify that the tested sample is in conformity with all provisions of the above detailed EU directives and product standards.
9.1 Rohs Compliance Declaration
Directive 2011/65/EU of the European Parliament
Restriction of use of certain hazardous substances in electrical and electronic equipment
Type: XTM252i
The above listed products are certified to be compliant with the rohs directive with all homogeneous component parts being controlled to ensure
material contents as per the list below.
Cadmium 0.01% by weight
Lead 0.1% by weight
Mercury 0.1% by weight
Hexavalent chromium 0.1% by weight
Polybrominated biphenyl’s (pbbs) 0.1% by weight
Polybrominated diphenyl ethers (pbdes) 0.1% by weight
It should be noted that under specific exempted applications, where lead is used as an alloying element the following limits are applied in
accordance with the regulations.
Copper and copper alloy parts use less than 4% by weight of each homogeneous component.
Steel and steel alloy parts use less than 4% by weight of each homogeneous component.
18
Aluminium and aluminium alloy parts use less than 4% by weight of each homogeneous component.
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Only dispose off in authorised sites for electrical and electronic waste do not dispose of with general refuse or landfill waste.
9.2 WEEE Statement
WEEE (Waste Electrical & Electronic Equipment) 2002/96/EC
In relation to implementing the legislation, Parweld has established relevant recycling and recovery methods. We have been fully compliant
against the marking requirements since August 2005. Parweld is registered in the UK with the Environment agency as detailed below. For
WEE compliance outside the UK please contact your supplier/Importer
Parweld is registered with a compliance scheme Official registration number is WEE/FD0255QV
When your equipment reaches the end of its service life you should return it to Parweld where it will be reconditioned or processed for
recycling.
9.3 Statement of warranty
Limited Warranty:
Parweld Ltd, hereafter, “Parweld” warrants its customers that its products will be free of defects in workmanship or material. Should any failure
to conform to this warranty appear within the time period applicable to the Parweld products as stated below, Parweld shall, upon notification
thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Parweld’s specifications,
instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident,
correct such defects by suitable repair or replacement, at Parweld’s sole option, of any components or parts of the product determined by
Parweld to be defective.
Parweld makes no other warranty, express or implied. This warranty is exclusive and in lieu of all others, including, but not limited to any
warranty of merchantability or fitness for any particular purpose.
Limitation of Liability:
Parweld shall not under any circumstances be liable for special, indirect or consequential damages, such as, but not limited to, lost profits and
business interruption. The remedies of the purchaser set forth herein are exclusive and the liability of Parweld with respect to any contract, or
anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any
goods covered by or furnished by Parweld whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not,
except as expressly provided herein, exceed the price of the goods upon which such liability is based. No employee, agent, or representative
of Parweld is authorized to change this warranty in any way or grant any other warranty.
Purchaser’s rights under this warranty are void if replacement parts or accessories are used which in Parweld’s sole judgement may impair the
safety or performance of any Parweld product.
Purchaser’s rights under this warranty are void if the product is sold to purchaser by non-authorized persons.
The warranty is effective for the time stated below beginning on the date that the authorized Distributor delivers the products to the purchaser.
Notwithstanding the foregoing, in no event shall the warranty period extend more than the time stated plus one month from the date Parweld
delivered the product to the authorized distributor.
Main Transformers and Rectifiers 2 Years
19
Other machine parts 2 year
www.parweld.com
Parweld Limited
Bewdley Business Park
Long Bank
Bewdley
Worcestershire
England
DY12 2TZ
tel. +44 1299 266800
fax. +44 1299 266900
www.parweld.com
[email protected]
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