Draper 230V Gas/Gasless Turbo MIG Welder Instructions

INSTRUCTIONS FOR
100A 230V
Gas/Gasless MIG Welder
Stock No.16057 Part No. MIG100GG
IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY TO ENSURE THE SAFE AND
EFFECTIVE USE OF THIS PRODUCT.
GENERAL INFORMATION
These instructions accompanying the product are the original instructions. This document is part of the product, keep it
for the life of the product passing it on to any subsequent holder of the product. Read all instructions before assembling,
operating or maintaining this product.
This manual has been compiled by Draper Tools describing the purpose for which the product has been designed, and
contains all the necessary information to ensure its correct and safe use. By following all the general safety instructions
contained in this manual, it will ensure both product and operator safety, together with longer life of the product itself.
AlI photographs and drawings in this manual are supplied by Draper Tools to help illustrate the operation of the product.
Whilst every effort has been made to ensure the accuracy of information contained in this manual, the Draper Tools policy
of continuous improvement determines the right to make modifications without prior warning.
1.
TITLE PAGE
1.1 INTRODUCTION:
USER MANUAL FOR:
100A 230V GAS/GASLESS MIG WELDER
Stock No.16057
Part No.MIG100GG
1.2 REVISIONS:
Date first published August 2016
As our user manuals are continually updated, users should make sure that they use the very
latest version.
Downloads are available from: http://www.drapertools.com/manuals
DRAPER TOOLS LIMITED
HURSLEY ROAD
CHANDLER’S FORD
EASTLEIGH
HAMPSHIRE
SO53 1YF
UK
WEBSITE:
PRODUCT HELPLINE:
GENERAL FAX:
www.drapertools.com
+44 (0) 23 8049 4344
+44 (0) 23 8026 0784
1.3 UNDERSTANDING THIS MANUALS SAFETY CONTENT:
WARNING!
Information that draws attention to the risk of injury or death.
CAUTION!
Information that draws attention to the risk of damage to the product or
surroundings.
1.4 COPYRIGHT © NOTICE:
Copyright © Draper Tools Limited.
Permission is granted to reproduce this publication for personal & educational use only.
Commercial copying, redistribution, hiring or lending is prohibited.
No part of this publication may be stored in a retrieval system or transmitted in any other
form or means without written permission from Draper Tools Limited.
In all cases this copyright notice must remain intact.
2.
CONTENTS
2.1 CONTENTS
PAGE CONTENT
PAGE
1
TITLE PAGE
1.1
INTRODUCTION ............................................................................................... 2
1.2
REVISION HISTORY........................................................................................... 2
1.3
UNDERSTANDING THIS MANUAL ................................................................... 2
1.4
COPYRIGHT NOTICE ......................................................................................... 2
2
CONTENTS
2.1
CONTENTS ........................................................................................................ 3
3
GUARANTEE
3.1
GUARANTEE ..................................................................................................... 4
4
INTRODUCTION
4.1
SCOPE ............................................................................................................... 5
4.2
SPECIFICATION ................................................................................................. 5
4.3
HANDLING AND STORAGE .............................................................................. 5
5
HEALTH & SAFETY INFORMATION
5.1
GENERAL SAFETY INSTRUCTIONS FOR POWER TOOL USE ............................ 6
5.2
SPECIFIC SAFETY INSTRUCTIONS FOR MIG WELDERS .................................... 7
5.3
CONNECTION TO THE POWER SUPPLY ........................................................... 10
6
TECHNICAL DESCRIPTION
6.1
IDENTIFICATION ............................................................................................... 11
7
UNPACKING & CHECKING
7.1
PACKAGING ..................................................................................................... 12
7.2
WHAT’S IN THE BOX ........................................................................................ 12
8
PREPARING THE WELDER
8.1
LOCATION ........................................................................................................ 13
8.2
INSTALLING THE FILLER WIRE.......................................................................... 13
8.3
WIRE DRIVE UNIT ............................................................................................. 14
8.4
GAS/NO GAS WELDING PRINCIPLE .................................................................. 15
8.5
GAS BOTTLE CONNECTION.............................................................................. 15
8.6
POLARITY.......................................................................................................... 15
9
BASIC WELDING OPERATIONS
9.1
ON/OFF SWITCH ............................................................................................... 16
9.2
WELDING CURRENT REGULATION SWITCHES ............................................... 16
9.3
WIRE SPEED ADJUSTMENT ............................................................................. 16
9.4
THERMAL CUTOUT........................................................................................... 17
9.5
MIG WELDING PRINCIPLES............................................................................... 17
10
TROUBLESHOOTING
10.1 WELDING TROUBLESHOOTING GUIDE............................................................ 18
11
MAINTENANCE
11.1 MAINTENANCE................................................................................................. 19
12
EXPLANATION OF SYMBOLS
12.1 EXPLANATION OF SYMBOLS ........................................................................... 20
13
DISPOSAL
13.1 DISPOSAL ......................................................................................................... 21
DECLARATION OF CONFORMITY .....................................................................................ENCLOSED
3
3.
GUARANTEE
3.1 GUARANTEE
Draper tools have been carefully tested and inspected before shipment and are guaranteed
to be free from defective materials and workmanship.
Should the tool develop a fault, please return the complete tool to your nearest distributor
or contact Draper Tools Limited, Chandler's Ford, Eastleigh, Hampshire, SO53 1YF. England.
Telephone Sales Desk: (023) 8049 4333 or Product Helpline (023) 8049 4344.
A proof of purchase must be provided with the tool.
If upon inspection it is found that the fault occurring is due to defective materials or
workmanship, repairs will be carried out free of charge. This guarantee period covering
parts/labour is 12 months from the date of purchase except where tools are hired out when
the guarantee period is 90 days from the date of purchase. This guarantee does not apply to
normal wear and tear, nor does it cover any damage caused by misuse, careless or unsafe
handling, alterations, accidents, or repairs attempted or made by any personnel other than
the authorised Draper warranty repair agent.
Note: If the tool is found not to be within the terms of warranty, repairs and carriage charges
will be quoted and made accordingly.
This guarantee applies in lieu of any other guarantee expressed or implied and variations of
its terms are not authorised.
Your Draper guarantee is not effective unless you can produce upon request a dated receipt
or invoice to verify your proof of purchase within the guarantee period.
Please note that this guarantee is an additional benefit and does not affect your statutory
rights.
Draper Tools Limited.
4
4.
INTRODUCTION
4.1 SCOPE
This gas/gasless MIG welder is a limited duty machine designed to perform welding
fabrication on a variety of steel types with solid and flux cored filler wire.
4.2 SPECIFICATION
Stock no .............................................................................................................................16057
Part no ..................................................................................................................... MIG100GG
Input:
Voltage (U1..V)...................................................................................................... 230V~
Phase ..............................................................................................................................1
Frequency................................................................................................................ 50Hz
Rated maximum
Supply current (I1eff).................................................................................................... 6A
Capacity................................................................................................................ 3000W
Output:
No-load voltage (U0..V) ................................................................................... 18.5-30V
Welding current
range (..A to ..A) .........................................................................................21A to 100A
Duty factor 10% ..................................................................................................... 100A
Duty factor 35% ....................................................................................................... 60A
Protection fuse.......................................................................................................... 13A
Welding wire (mm) ..................................................................................................... 0.6 to 0.9
Torch coupling...................................................................................................................Direct
Insulation class.......................................................................................................................... H
Cooling Device.......................................................................................................................Fan
Max. working Temperature................................................................................................ 40ºC
Dimensions .................................................................................................535 × 290 × 410mm
Weight ................................................................................................................................ 25kg
4.3 HANDLING & STORAGE
Environmental conditions can have a negative effect on the condition and operation of this
product. Damp conditions can cause components to rust and corrode. Without regular
cleaning and maintenance, dust and debris can clog the machine resulting in poor
performance.
5
5.
HEALTH & SAFETY INFORMATION
5.1 GENERAL SAFETY INSTRUCTIONS FOR POWER TOOL USE
When using any type of power tool there are steps that should be taken to make sure that
you, as the user, remain safe.
Common sense and a respect for the tool will help reduce the risk of injury.
Read the instruction manual fully. Do not attempt any operation until you have read and
understood this manual.
Most important you must know how to safely start and stop this machine, especially in an
emergency.
Keep the work area tidy and clean. Attempting to clear clutter from around the machine
during use will reduce your concentration. Mess on the floor creates a trip hazard. Any liquid
spilt on the floor could result in you slipping.
Find a suitable location. If the machine is bench mounted; the location should provide good
natural light or artificial lighting as a replacement. Avoid damp and dust locations as it will
have a negative effect on the machine’s performance. If the machine is portable; do not
expose the tool to rain. In all cases do not operate power tools near any flammable
materials.
Beware of electric shock. Avoid contact with earthed surfaces; because they can conduct
electricity if there is an electrical fault with the power tool. Always protect the power cable
and route it away from danger.
Keep bystanders away. Children, onlookers and passers by must be restricted from entering
the work area for their own protection. The barrier must extend a suitable distance from the
tool user.
Unplug and house all power tools that are not in use. A power tool should never be left
unattended while connected to the power supply. They must be housed in a suitable
location, away locked up and from children.
Do not overload or misuse the tool. All tools are designed for a purpose and are limited to
what they are capable of doing. Do not attempt to use a power tool (or adapt it in any way)
for an application it is not designed for. Select a tool appropriate for the size of the job.
Overloading a tool will result in tool failure and user injury: This covers the use of accessories.
Dress properly. Loose clothing, long hair and jewellery are all dangerous because they can
become entangled in moving machinery: This can also result in parts of body being pulled
into the machine. Clothing should be close fitted, with any long hair tired back and jewellery
and neck ties removed. Footwear must be fully enclosed and have a nonslip sole.
Wear personal protective equipment (PPE). Dust, noise, vibration and swarf can all be
dangerous if not suitably protected against. If the work involving the power tool creates dust
or fumes; wear a dust mask. Vibration to the hand, caused by operating some tools for
longer periods must be protected against. Wear vibration reducing gloves and allow long
breaks between uses. Protect against dust and swarf by wearing approved safety goggles or
a face shield. These are some of the more common hazards and preventions; however, always
find out what hazards are associated with the machine/work process and wear the most
suitable protective equipment available.
Do not breathe contaminated air. If the work creates dust or fumes; connect the machine (if
possible) to an extraction system either locally or remotely. Working outdoors can also help if
possible.
Move the machine as instructed. If the machine is hand held, do not carry it by the power
supply cable. If the product is heavy; employ a second or third person to help move it safely
or use a mechanical device. Always refer to the instructions for the correct method.
6
5.
HEALTH & SAFETY INFORMATION
Do not overreach. Extending your body too far can result in a loss of balance and you falling.
This could be from a height or onto a machine and will result in injury.
Maintain your tools correctly. A well maintained tool will do the job safely. Replace any
damaged or missing parts immediately with original parts from the manufacturer. As
applicable; keep blades sharp; moving parts clean, oiled or greased; handles clean; and
emergency devices working.
Wait for the machine to stop. Unless the machine is fitted with a safety brake; some parts
may continue to move due to momentum. Wait for all parts to stop; then unplug it from the
power supply before making any adjustments, carrying out maintenance operations or just
finishing using the tool.
Remove and check setting tools. Some machinery requires the use of additional tools or keys
to set, load or adjust the power tool. Before starting the power tool always check to make
certain they have been removed and are safely away from the machine.
Prevent unintentional starting. Before plugging any machine in to the power supply, make
sure the switch is in the OFF position. If the machine is portable; do not hold the machine
near the switch and take care when putting the machine down; that nothing can operate the
switch.
Carefully select an extension lead. Some machines are not suitable for use with extension
leads. If the tool is designed for use outdoors; use an extension lead also suitable for that
environment. When using an extended lead, select one capable of handling the current
(amps) drawn by the machine in use. Fully extend the lead regardless of the distance
between the power supply and the tool. Excess current (amps) and a coiled extension lead
will both cause the cable to heat up and can result in fire.
Concentrate and stay alert. Distractions are likely to cause an accident. Never operate a
power tool if you are under the influence of drugs (prescription or otherwise), including
alcohol or if you are feeling tired. Being disorientated will result in an accident.
Have this tool repaired by a qualified person. This tool is designed to confirm to the relevant
international and local standards and as such should be maintained and repaired by someone
qualified; using only original parts supplied by the manufacturer: This will ensure the tool
remains safe to use.
5.2 SPECIFIC SAFETY INSTRUCTIONS FOR MIG WELDERS
Warning: When using this product, basic safety precautions should always be followed to
reduce the risk of fire, electric shock and personal injury including the following.
Read all these instructions before attempting to operate this product and save these
instructions.
Electric shock can kill:
– Remove the plug from the socket before carrying out adjustment, servicing or
maintenance.
– Allow 5 minutes waiting time for the capacitors to discharge before removing the panels
for any maintenance operations
– Do not touch live electrical parts.
– Never use electrode holders or cables with damaged or deteriorated insulation.
– Keep working environment, equipment, cables and clothing free from grease, oil,
moisture and dirt.
– Ensure welding machine has been correctly earthed and all panels are fitted securely.
– The operator must be insulated from the floor and work bench using a dry insulation
mat.
7
5.
–
–
HEALTH & SAFETY INFORMATION
Wear isolating footwear and gloves that are in good condition, i.e. without holes.
In hazardous conditions of increased electric shock always ensure a second person is
present in case of accident.
– Never change electrodes with bare hands or damp gloves.
– Keep welding cables away from power cables.
– Regularly inspect the condition of the welding, earth, and power cables for signs of
damage.
– Do leave machine unattended and remove plug from socket when not in use.
– Do not use welding cables unsuitable for the amperage.
– Ensure earth clamp is adjacent to weld seam, secured to bare metal and when not in use
is insulated for safety.
– Keep all equipment well maintained.
– The operator shall prevent gas cylinders in the vicinity of the work piece from becoming
part of the welding circuit.
Fumes & gases can be harmful:
– The welding process generates hazardous fumes as a by-product. Inhalation of these
fumes is hazardous to health.
– Keep your head away from the weld to avoid breathing the fumes.
– If welding in confined spaces ensure adequate ventilation and use a fume extractor.
– Welding fumes displace oxygen. Danger of suffocation.
– By-products of welding can react with other chemical vapours to produce a
toxic/explosive environment.
Welding can cause fire or explosion:
– Arc welding and allied processes can cause fire and explosions and precautions shall be
taken to prevent these hazards.
– Before starting a weld ensure the area is clear of flammable materials.
– Remove any inflammables to a safe distance, especially substances likely to generate a
dangerous vapour.
– The welding arc can cause serious burns. Avoid contact with skin.
– Sparks and molten metal are cast out during welding. Take precautions to prevent fire
igniting and wear protective clothing.
– Sparks and molten metal can pass through gaps. Be aware that fire can start out of sight.
Flammables in a locked cabinet may not be safe.
– Do not weld pressurised containers.
– Do not weld tanks, drums or other vessels until they have been correctly cleaned/prepared
for welding.
– Always have appropriate and fully maintained fire fighting equipment suitable for the
materials used and for use in electrical environments available in close proximity at all
times.
– Keep clothing free from oil and grease.
– Wear hat, flame-proof apron, woollen clothing, gloves, long sleeve tops with closed neck,
trousers (without turn-ups) to cover non-slip boots.
– Protective head and shoulder coverings should be worn when overhead welding.
8
5.
HEALTH & SAFETY INFORMATION
–
–
Avoid taking any fuels with you e.g. cigarette lighters or matches.
Hot spots and their immediate surroundings should be observed until their temperature
has dropped to normal.
Personal Protection:
– The body should be protected by suitable clothing.
– The use of neck protection may be necessary against reflected radiation.
– Wear safety glasses when chipping, wire brushing, grinding or when near cooling welds
as metal filings or slag can be thrown up. Fully enclosed goggles are advisable.
– Arc machines generate a magnetic field which is detrimental to pacemaker recipients.
Consult your doctor before going near welding equipment/operations.
– The UV and IR radiation generated by welding is highly damaging to the eye, causing
burns. This can also affect the skin. Protect the eyes and face.
– The face and eyes shall be protected by suitable welding shields equipped with
appropriate occural protection filters.
– Where environments are subject to pedestrians and traffic ensure a protective screen is
used to avoid accidental arc glare.
– Do not weld in the vicinity or children or animals and ensure no one is looking before
striking up.
– In the welding environment, damaging levels of noise can exist. Wear hearing protection
if the process dictates.
– Do not touch hot equipment or metal. Allow the weld time to cool, use the correct tool
and wear protective welding gauntlets.
– Wear flame retardant clothing (leather, wool, etc.).
– Take care when adjusting or maintaining the torch that it has had time to cool sufficiently
and is disconnected.
– The arc generates
• ultra-violet radiation (can damage skin and eyes);
• visible light (can dazzle eyes and impair vision);
• infra-red (heat) radiation (can damage skin and eyes);
– Such radiation can be direct or reflected from surfaces such as bright metals and light
coloured objects.
Limitations:
– Do not use for;
• operations in severe conditions (e.g. extreme climates, freezer applications,
strong magnetic fields etc).
• operations subject to special rules (e.g. potentially explosive atmospheres,
mines etc).
• operations that require ingress protection greater than IPX0, e.g. in rain or
snow etc.
General:
– Training should be sought out in
• the safe use of this equipment;
• the processes;
• the emergency procedures;
9
5.
–
–
HEALTH & SAFETY INFORMATION
Welding power sources are not
1~
1~
to be used for pipe thawing.
IEC 60974-1
Take precautions against
21A/15V – 100A/19V
toppling over, if the power
source shall be placed on a tilted
X%
10%
100%
plane.
U0 18.5V
I2
100
32
30V
All equipment should be kept in
V2
19
15.5
good working condition,
inspected and, when defective,
I1eff 6A
1~50/60Hz U1 230V I1max 13A
promptly repaired or withdrawn
IP 21S
H
NO
from service - All equipment
should be placed so that it does
not present a hazard in
passageways, on ladders or stairways, and should be operated in accordance with the
manufacturer's instructions.
In the vicinity of an arc, non-reflective curtains or screens shall be used to isolate persons
from the arc radiation. A warning, e.g. a symbol for eye protection, should refer to the
hazard of arc radiation.
S
–
–
5.3 CONNECTION TO THE POWER SUPPLY
Caution: Risk of electric shock. Do not open.
Make sure the power supply information on the machine’s rating plate is compatible with
the power supply you intend to connect it to.
This product comes supplied with a UK standard 3 pin plug fitted. It is designed for
connection to a domestic power supply rated at 230V AC.
Because it is constructed mostly of metal parts, it is a Class 1 machine; meaning, it must have
an earth connection in the power supply. This is to prevent electrocution in the event of a
failure.
Apart from replacing the fuse in the plug, no other electrical work is recommended on this
product.
10
6.
TECHNICAL DESCRIPTION
6.1 IDENTIFICATION
Direct torch connection
Handle
Min/Max switch
(welding current)
1/2 switch
(welding current)
On/Off switch
Thermal cutout
warning light
Power cable
Earth clamp cable
Earth clamp
connector
Wire feed
speed control
Arm
Tension roller
Tensioner
Wire guide
Spool hub assembly
MIG torch
Earth clamp
Ventilation grille
Top cover
Gas bottle connection
Positive terminal (red)
Negative terminal (black)
11
7.
UNPACKING & CHECKING
7.1 PACKAGING
Carefully remove the product from the packaging and examine it for any sign of damage
that may have happened during shipping. Lay the contents out and check them against the
parts shown below. If any part is damaged or missing; please contact the Draper Helpline
(the telephone number appears on the Title page) and do not attempt to use the machine.
The packaging material should be retained at least during the guarantee period: in case the
machine needs to be returned for repair.
Warning! Some of the packaging materials used may be harmful to children. Do not leave
any of these materials in the reach of children.
If any of the packaging is to be thrown away, make sure they are disposed of correctly;
according to local regulations.
7.2 WHAT´S IN THE BOX?
As well as the product itself, there are extra accessories:
12
Hand held mask
Chipping hammer
Spool of solid wire
8.
PREPARING THE WELDER
Warning! Do not make any adjustments, maintenance or servicing with the machine
connected to the power supply.
8.1 LOCATION
Locate the machine in close proximity to the correct power supply and allow 500mm air gap
around to ensure sufficient ventilation. There is one cooling fan located in the rear of the
machine housing which must be kept clear. Equally, ensure no debris can be drawn into the
machine.
Make certain the location does not pose any hazards as detailed in the safety instructions,
before attempting to start the machine.
8.2 INSTALLING THE FILLER WIRE
– FIGS. 1 – 3
FIG.1
The welding machines are designed to accept the
standard size drums of wire up to 500g.
Do not let the filler wire become uncoiled or tangled
as this will lead to problems with delivery to the
welding torch.
Select the filler wire suitable for the parent metal and
with a gauge to match the welder specification.
Note: If the welding machine is not regularly used,
remove the wire which is prone to rusting and will
cause feed problems next time.
i. Lift the latch to release the top cover .
ii. Remove the large plastic ring (turning it
clockwise). Sit the reel on to the hub and
make sure the peg locates in the back of the
reel. Refit the large plastic ring .
iii. Fit the wire spool so that it feeds off the roll
towards the wire drive unit.
FIG.2
FIG.3
13
8.
PREPARING THE WELDER
8.3 WIRE DRIVE UNIT – FIGS. 4 – 5
FIG.4
The wire is fed down the torch lining by the wire drive
motor. Tension of the rollers must be adjusted
correctly to prevent the filler wire slipping or jamming.
iv. Loosen tensioner anticlockwise enough to
swing it outwards and lift arm , moving the
tension roller .
v. Trim 10cm of wire and discard it, before
flattening out the next 15cm. Do not let the
wire lose tension.
vi. Pass the filler wire through the guide and
over the top of the drive roller fitted under
securing nut . The drive roller comes with
FIG.5
two grooves for different wire gauges. Remove
nut to see the groove size that is NOT in use.
Note: The wire must sit in the appropriate
groove for the wire gauge. The groove size is
etched on the side of the roller. To reverse the
roller, remove nut and flip the drive roller over
before refitting nut .
vii. Make sure the wire is well inside the torch liner
before closing the arm and tensioner .
viii. Connect the welding machine to the power
supply. Position the switch to ‘on’.
ix. Unscrew/remove the gas shroud and with
a small spanner unscrew and remove the tip . Pull the trigger and observe
the wire feed mechanism. If the wire is being fed correctly it will come out of the
swan neck. Pass the tip over the wire and secure back onto the swan neck. Do not over
tighten. Resecure the gas shroud and trim the wire back as required.
Note: Ensure the tip size matches the wire size prior to installing.
14
8.
PREPARING THE WELDER
8.4 GAS/NO GAS WELDING PRINCIPLE
For a successful weld joint, the molten metal must be protected from contaminating gases
found in the air. This is either achieved by supplying the torch with gas from a bottle or
setting the machine up for no-gas and using a flux cored filler wire. The flux shield is
produced as the wire melts.
8.5 GAS BOTTLE CONNECTION – FIGS. 6
We recommend the use of a medium capacity gas
bottle for ease of connection.
–
Attach a suitable gauge gas hose to the
gas bottle connector and secure with a
hose clip and attach the other end to a suitable
regulator and gas bottle.
FIG.6
8.6 POLARITY – FIG. 7
The polarity of the torch and earth clamp must be
made correctly to suit the gas setup.
The connectors and terminals can be accessed by
lifting the top cover .
i
Attach the earth clamp connector
to the positive (red) terminal .
ii Attach the direct (welding torch) connector to the negative (black) terminal .
Note: This configuration is for no-gas (flux cored)
welding. Reverse the torch and earth clamp for gas
welding.
FIG.7
15
9.
BASIC WELDING OPERATIONS
9.1 ON/OFF SWITCH – FIG.8
The on/off switch is a rocker switch. Press the top
half in to switch the welder 'on' and the bottom half
in to switch the welder 'off'.
FIG.8
9.2 WELDING CURRENT REGULATION
SWITCHES – FIG.9
The current regulation switches and regulate
the welders power in four steps. Min +1, Min +2 and
Max +1, Max + 2. Regulate the welding current in
conjunction with the wire speed to achieve the
optimum arc for the workpiece thickness and type.
FIG.9
9.3 WIRE SPEED ADJUSTMENT – FIG.10
Wire speed is dependent on material thickness and
welding current. Being able to judge the correct wire
speed based on the sound and quality of the weld will
only come from practice.
• Too fast will result in holes blowing in the weld
or the wire hitting the metal will force the torch
backward.
• Too slow will result in the wire burning back to
the torch into a ball and clogging the tip.
Note: When using the welder on a low amp
setting/low wire speed, it is necessary that the wire
drive tension is increased on the adjustment to avoid
the spool stalling.
16
FIG.10
9.
BASIC WELDING OPERATIONS
9.4 THERMAL CUT OUT – FIG.11
If the duty cycle† of the welder is exceeded, the
thermal cut out will activate to prevent damage to the
internal components or further overheating.
When the thermal cut out warning light is lit, the
welder must be left to cool down before it can be
restarted.
FIG.11
9.5 MIG WELDING PRINCIPLES – FIG.12
FIG. 12
The MIG welding process allows two similar materials
to be fused together without altering the properties
of the material. The electric arc created between the
electrode (the welding wire) and the work piece
produces the required heat for turning the metal into
a molten state. The gas creates a shield around the arc
35°
and the molten metal, on this welder the shield comes
from the flux cored welding wire that must be used.
The area to be welded and the earth point must be
clean of grease, dirt, paint and rust. Clean with a wire
brush as necessary. Position the earth clamp as close as
possible to the working area and ensure a tight grip is
achieved.
Select the welding current based on the thickness of
the material. A thick piece will require a high current,
however due to the duty cycle this will effect the
75°
welding time by significantly reducing it. A thin piece
will only require minimal heat and so the current can
be less. This will allow a longer period of welding. The
position of the torch is critical to the arc and end
results.
The position of the welding torch is important to achieve a good quality bead. Position the
torch at approximately 35 vertically and 75 horizontally and up to 20mm distance from the
join. 20mm is the maximum that can be achieved on the maximum setting. Ensure the gas
shroud remains clean of spatter. Likewise and more importantly the wire feed tip must be
kept clean to avoid the wire becoming blocked or restricted.
Use of an anti-spatter spray (Draper Stock No.05709) will help keep the end result more tidy.
†
Duty cycle: The duty cycle is the percentage of 10 minutes that the machine can weld for at
a set amperage (10%=1min up to 100%=10mins). The higher the amperage, the lower the
welding time.
17
10. TROUBLESHOOTING
10.1 WELDING TROUBLESHOOTING GUIDE
Example
Term
Cause
Insufficient penetration.
–
–
–
–
Incorrect arc distance.
Welding current too low.
Wire speed to low.
Welding line not central
to butt.
Overlap.
–
Wire size too large for
application.
Torch speed too slow.
–
Pitting.
–
–
–
–
Untidy weld.
–
–
Burn through.
–
–
18
Contamination in the
metal (eg rust).
Flux shield breakdown.
Incorrect arc distance.
Area cooling down too
fast.
Unsteady torch
movement.
Worn wire tip.
Current too high for
material thickness
Torch speed too slow
11. MAINTENANCE
11.1 MAINTENANCE
Warning: Remove the plug from the power supply. Periodically the welder must be checked
as detailed below.
•
•
•
•
•
•
Check the torch cable and ground cable connections.
Clean the contact tip and the gas shroud with an iron brush. Replace if worn.
Clean the outside of the welder with a damp cloth.
Every time the wire spool is replaced:
Check the alignment, cleanliness and state of wear of the wire roll.
Remove any metal powder deposited on the wire feeder mechanism and then dry with
compressed air.
• Check the condition of the warning labels.
• Replace any worn parts.
19
12. EXPLANATION OF SYMBOLS
12.1 EXPLANATION OF SYMBOLS
Warning!
Read the instruction manual.
Warning!
Disable the machine before
attempting to maintain it.
Always wear welding gloves/gauntlets.
Always wear suitable protective clothing.
Always wear suitable eye/face protection.
WEEE
Do not dispose of Waste Electrical & Electronic
Equipment in with domestic rubbish.
20
Danger!
Electricity. Keep your distance.
13. DISPOSAL
13.1 DISPOSAL
–
At the end of the machine’s working life, or when it can no longer be repaired, ensure
that it is disposed of according to national regulations.
– Contact your local authority for details of collection schemes in your area.
In all circumstances:
•
•
•
•
Do not dispose of power tools with domestic waste.
Do not incinerate.
Do not abandon in the environment.
Do not dispose of WEEE*
as unsorted municipal waste.
* Waste Electrical & Electronic Equipment.
21
NOTES
22
NOTES
23
CONTACTS
- DRAPER TOOLS LIMITED,
Hursley Road, Chandler's Ford,
Eastleigh, Hampshire. SO53 1YF. U.K.
- Helpline: (023) 8049 4344
- Sales Desk: (023) 8049 4333
- General Enquiries: (023) 8026 6355
- Service/Warranty Repair Agent
For aftersales servicing or warranty repairs, please
contact the Draper Tools Helpline for details of an
agent in your local area.
YOUR DRAPER STOCKIST
KCCH0816
drapertools.com
">