Parweld XTM 404S Instructions

XTM404S
XTM-WF400
OPERATOR MANUAL
ISSUE 2
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 maintenance this equipment should provide years of
reliable service. All our systems conform to ISO9001: 2015 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
www.parweld.com
Contents
1.0
Safety Precautions............................................................4
2.0
Product Description..........................................................5
3.0
Technical Specifications...................................................6
4.0
Description of Controls....................................................6
4.1
5.0
6.0
Machine Front and Rear View....................................7
Installation.........................................................................8
5.1
Unpacking the Machine.............................................8
5.2
Location....................................................................8
5.3
Input and Grounding Connection ..............................8
5.4
Assembly of Separate Wire Feeder............................8
5.5
Output Polarity Connections......................................8
5.6
Changing Drive Roll Sets...........................................8
5.7
Welding Wire Installation............................................8
5.8
Torch Installation........................................................9
5.9
Work Return Lead Connection..................................9
5.13
Shielding Gas Connection.........................................9
Operation...........................................................................9
6.1
Feeding Wire Electrode...........................................10
6.2
Optimising Weld Parameters...................................10
6.3
Additional Welding Controls.....................................10
7.0
Fault Finding....................................................................10
8.0
Accessories.....................................................................11
9.0
8.1
Drive Rolls...............................................................11
8.2
Torch Spares XP8 300A..........................................12
8.2
Torch Spares XP8 350A..........................................14
8.3
Gas Equipment.......................................................16
EC Declaration of Conformity........................................18
9.1
RoHS Compliance Declaration................................18
9.2
WEEE Statement.....................................................19
9.3
Statement of Warranty.............................................19
www.parweld.com
1.0 Safety Precautions
worktable as near the weld as practical.
Insulate work clamp when not connected to work piece to prevent
contact with any metal object.
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.
FUMES AND GASES can be hazardous.
Do not touch live electrical parts.
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.
Wear dry, sound insulating gloves and body protection.
If ventilation is poor, wear an approved respirator.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
ground.
Read and understand the Material Safety Data Sheets (MSDS’s)
and the manufacturer’s instructions for metals, consumable,
coatings, cleaners, and de-greasers.
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.
Turn off all equipment when not in use.
Do not use worn, damaged, under sized, or poorly spliced cables.
Do not drape cables over your body.
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.
Keep all panels and covers securely in place.
4
Welding produces fumes and gases. Breathing these fumes and
gases can be hazardous to your health.
Clamp work cable with good metal-to-metal contact to work piece or
www.parweld.com
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.
Wear an approved welding helmet fitted with a proper shade of filter
lenses to protect your face and eyes when welding or watching
Wear approved safety glasses with side shields under your helmet.
Use protective screens or barriers to protect others from flash, glare
and sparks; warn others not to watch the arc.
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.
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.
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)
2.0 Product Description
The XTM 404S is complete semiautomatic constant voltage DC arc
welding machines built to meet CE specifications. They combine a
constant voltage power source and a constant speed wire feeder with
a microcomputer-based controller to form a reliable high-performance
welding system. A simple control scheme, consisting of a range
voltage and wire feed speed controls, provides versatility with ease of
use and accuracy. Other features include separate wire feed unit for
remote operation, 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.
Digital meters display the actual welding voltage and amperage and
the machine has additional controls for adjustment of burn back and
soft starting.
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.
5
www.parweld.com
3.0 Technical Specifications
11.
2T 4T, when in the 2T position the torch trigger will have a
momentary operation ie the welding operation will start when
the rigger is depressed and stop when it is released. In the 4T
position a short press and release of the trigger will start the
welding operation and a short press and release with stop the
operation. The 4T mode is ideal for long welds as it reduces
operator fatigue. Gas purge. Allows gas to flow through the
welding torch and so allow checking of the gas flow before
starting the welding process.
12.
Wire feed speed adjustment, controls the speed of wire
feeding from 0.8 to 24 m/min. Increasing the wire feed speed
also has the effect of increasing the welding current.
13.
Burn back control affects the wire feed motor over run when
the trigger is released and can be adjusted to ensure that the
wire does not burn back onto the contact tip at the end of the
weld. (Increase to reduce wire stickout).
14.
Soft start adjustment which controls the acceleration of the
wire feed motor when the arc starts to reduce spatter and give
a cleaner arc initiation.
15.
Socket for the interconnection cable to link to the wire feeder.
16.
Digital display for Voltage (displayed real time).
17.
Torch connector The Euro connector provided the external
connection for the welding torch.
18.
Mains input connection Input connection for the
pre-installed mains cable.
19.
Water cooling connection from WF unit (optional)
20.
Water cooling connection to WF unit (optional)
21.
24 V AC cooler or small power tools (optional).
22.
Control circuit protection fuse. Auxiliary output (optional).
23.
Welding power connection to connect to the
inter connect cable.
The XTM404S is a separate type machine with the wire feed unit
connected to the power supply by a 5m interconnecting cable.
For use with 3 phase 400V supply.
Feature
XTM 404S
Supply voltage
3 x 400 V, 50 Hz
Supply current, max.
19 A
Supply power
13,2 kVA
Fuse, slow
20 A
Welding range
40 – 350 A
No load voltage
17,0 – 36,0 V
Duty cycle:
100% - 260 A, 60% - 350 A, 35% - 300 A
Voltage steps
30
Welding wire Ø
-
Protection
IP 21
Insulation class
H
Cooling
AF
Dimensions (LxWxH)
865 x 495 x 690 mm
Weight
110 kg
4.0 Description of Controls
1.
On Off switch. The machine is switched off when the light (4)
is off and the fan is not running.
24.
Welding Current Connector
25.
Welding Power Input Connection.
2.
Coarse Voltage selector switch. This switch is used to select
the require welding voltage each position of the switch
represents approximately 4V.
26.
Interconnection cable control socket input.
27.
Shielding gas input connection 3/8 BSP male connection for
the shielding gas input.
28.
Water cooling - to power source (optional)
29.
Water cooling - from power source (optional)
Do Not operate this switch while welding
3.
Fine Voltage selector switch. This switch is used to select the
require welding voltage each position of the switch represents
approximately 0.5V.
Do Not operate this switch while welding
4.
Mains input light This light illuminates when the mains power
is connected and the machine is switched on.
5.
Fault light this light will illuminate when a fault or over
temperature condition has occurred. If this light illuminates
allow the machine to cool with the fan still running until it
extinguished. If the light does not go off when the power
source has cooled down then have the machine checked by a
qualified engineer.
6.
Work return lead connection. This socket allows connection of
the work return lead to the front of the machine.
Note the XTM404S has 2 sockets for the work return lead
please refer below
7.
Work return lead connection. High inductance connection, this
should be used when in spray transfer mode to give a more
stable arc. (Only fitted to XTM404S)
8.
Control Fuse
9.
Function selector: 2-step, 4-step, Gas test
10.
Wire speed adjustment
6
www.parweld.com
4.1 Machine Front and Rear View
16
15
11
12
29
28
27
13
17
14
26
25
5
4
1
18
19
20
21
22
2
23
3
24
8
6
7
1.
ON/OFF switch
17.
Central connector (EU)
2.
Coarse welding voltage setting
18.
Supply cable
3.
Fine welding voltage setting
19.
Water cooling connection from WF unit (optional)
4.
LED, green - power ON, indication
20.
Water cooling connection to WF unit (optional)
5.
LED, orange – OVERLOAD indication
21.
Gas heater socket, 24 V AC (optional)
6.
Return cable connector (-), low inductance
22.
Gas heater fuse (optional)
7.
Return cable connector (-), full inductance
23.
Control connector - to WF unit
8.
Fuse
24.
Welding current connector – to WF unit
11.
2T, 4T Purge Selector
25.
Welding current connector – from power source
12.
Wire speed adjustment
26.
Control connector – from power source
13.
Burn back time
27.
Gas input
14.
Motor ramp time
28.
Water cooling - to power source (optional)
15.
Welding voltage display
29.
Water cooling - from power source (optional)
16.
Welding current display
www.parweld.com
7
5.0 Installation
Read entire installation section before starting installation.
5.6 Changing Drive Roll Sets
1.
Turn off the power source.
2.
Release the pressure on the idle rolls by swinging the
adjustable pressure arm (3) down. Lift the cast idle roll
assembly and allow it to sit in an upright position.
3.
Unscrew the screws retaining the lower grooved drive roll and
side off the drive roller.
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.
4.
Ensure the wire size marked on the side of the feed roller
matches the wire size to be used.
•
Machine must be grounded per any national, local or other
applicable electrical regulations.
5.
•
The MIG power switch is to be in the OFF position when
installing work cable and torch and when connecting
other equipment.
Replace the drive rolls 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.
NOTE: Be sure that the torch liner and contact tip are also sized
to match the selected wire size.
6
5.1 Unpacking the Machine
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.
3
7
5.2 Location
2
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.
5.3 Input and Grounding Connection
Check that there
is a gap between
the rollers and
wire guide at
torch installation
(see 5.8)
4
WARNING
Before starting the installation, check that your power supply
is adequate for the voltage, amperage, phase, and frequency
specified on the Machine nameplate.
The 400 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. 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.
5.4 Assembly of Separate Wire Feeder
Lift the wire feeder up onto the power source and locate the post into
the tube on the underside of the wire feeder taking care to ensure it
is fully located on the post.
Connection of the interconnect cable.
Working at the wire feeder end insert the Dinse power connector
and twist it to lock it securely. Connect the gas hose to the inlet on
the rear of the wire feeder followed by the control plug taking care to
align the pins before inserting the plug.
At the power source end connect the Dinse socket and twist to
secure, connect the control socket taking care to align the pins
before inserting the plug. The gas hose should be lead off to the
outlet connection of the gas regulator.
5.5 Output Polarity Connections
The welder, as shipped from the factory, is connected for electrode
positive (+) polarity. This is the normal polarity for MIG welding.
8
www.parweld.com
1
1.
2.
3.
4.
Feeding rolls
Pressure roll
Pressure adjustment
Wire inlet
5
5.
6.
7.
Plate
Motor 42V, 50 W
Pressure arm
5.7 Welding Wire Installation
6.
Open the Wire drum cover by pulling down and out on the
bottom of the cover
7.
Unscrew the plastic retaining wheel from the end of the
spool holder shaft.
8.
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.
9.
Slide the wire spool all the way onto the shaft and refit the
plastic retaining nut.
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. It can be adjusted
by means of the nut visible when the plastic nut is removed.
10.
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 rollers
(ensure the pressure arms are in the raised position.)
11.
Continue to feed the wire through the outlet guide until
20mm of wire is protruding from the front of the machine
torch connector.
12.
Reposition the adjustable pressure arms to there 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,
5.8 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:13.
Remove the tip adaptor and contact tip
14.
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.
15.
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
grease to the O Ring is beneficial.
Fig 1
Fig 2
Parweld recommend the use of its XTS water recirculation system
designed specifically for use with all water cooled MIG, TIG and
Plasma welding torches.
The Parweld XTS recirculation equipment can be fitted with a failsafe flow protection device to prevent overheating or meltdown.
Note. Water flows into the torch through the blue hose. The blue
hose delivers cold water directly to the prime source of heat, the
swan neck and consumables. 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.
5.9 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.
Note the XTM404S has 2 work return lead sockets providing
different inductance settings refer to the Operating Instructions
for your perfered setting.
5.10 Shielding Gas Connection
1.
Connect gas hose to the output connection of a gas
regulator capable of supplying the correct gas flow for the
welding operation.
Note if the gas cylinder is to be stored on the back of the
machine ensure it is secured using the retention chain provided
16.
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.
x
17.
Once the electrode wire has stopped, refit the tip adaptor,
diffuser, contact tip and gas nozzle.
18.
Trim the electrode wire to within 5mm of the face of the
nozzle, this will facilitate jolt free arc initiation.
19.
Press the gas purge button and check the gas flow is
adequate for your application.
20.
An inexpensive flow meter is available from Parweld
reference 806001.
21.
If you are using a water-cooled torch ensure you have the
recommended water flow rate.
Note;- It is essential to ensure adequate flow of clean, cool
water to prevent irreparable torch failure, a minimum of 1.2 l/
min is recommended.
6.0 Operation
1.
Switch on the machine using the switch on the front panel.
2.
Turn the “VOLTAGE SELECTOR” switches Set voltage
midway between high/low voltages.
NOTE: Check that drive rolls, and torch parts are correct for the
wire size and type being used.
3.
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:
4.
Press end of gun against a solid object that is electrically
isolated from the welder output and press the gun trigger for
several seconds.
5.
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 no waviness, the pressure is too low. Tighten the
adjustment knob 1/4 turn, reinstall the gun cable and repeat
the above steps.
9
www.parweld.com
6.1 Feeding Wire Electrode
6.3 Additional Welding Controls
Note 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.
Burn back adjustment. When welding at high amperages the wire
can often burn back onto or close to the contact tip to prevent this
happening you can increase the burn back control (18) located
inside the wire spool cover.
WARNING
When using an open arc process, it is necessary to use correct
eye, head, and body protection.
1.
Position wire over joint. The end of the wire may be lightly
touching the work.
2.
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).
3.
To stop welding, release the gun trigger and then pull the gun
away from the work after the arc goes out.
4.
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.
6.2 Optimising Weld Parameters
Soft Start. The soft start control slows the acceleration of the wire
feed motor as the act starts and so reduces wire snubing and spatter
at the weld start. This control should be adjusted to give a smoother
start to the weld. (17).
Inductance setting XTM404S. This allows 2 levels of inductance to
give the desired arc characteristics typically for low amperage with
dip transfer you should use the low inductance setting as this speeds
the burn off of the wire in dip transfer mode. For higher amperages
and spray transfer the higher inductance setting is preferable.
7.0 Fault Finding
Problem
Cause/Corrective Action
Porosity - small cavities or holes
Resulting from gas
pockets in weld metal.
Inadequate shielding
gas coverage. Check for
proper gas flow rate.
Remove spatter
from gun nozzle.
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.
Check gas hoses for leaks.
Eliminate drafts
near welding arc.
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.
Place nozzle 6-13 mm from
work piece Hold gun near
bead at end of weld until
molten metal solidifies.
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.
Select Wire Speed (Amperage)
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
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).
Welding wire extends too
far out of nozzle.
So based on 3.2 mm material thickness amperage should be 125A if
using 1.0mm wire then the wire feed speed should be
Be sure welding wire
extends not more than 13
mm beyond nozzle.
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
10
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.
www.parweld.com
Incomplete fusion to base metal
Work piece dirty. Remove all
grease, oil, moisture, rust,
paint, coatings, and dirt from
work surface before welding.
Insufficient heat input. Select
higher voltage range and/or
adjust wire feed speed.
Improper welding technique.
Place stringer bead in
proper locations) at joint
during welding.
Adjust work angle or widen
groove to access bottom
during welding.
Problem
Cause/Corrective Action
Problem
Cause/Corrective Action
Incomplete fusion to base metal
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.
Wire feed unit operates, but
does not feed
Incorrect liner
Excessive Penetration –
weld metal melting through
base metal and hanging
underneath weld.
Excessive heat input. Select
lower voltage range and
reduce wire feed speed.
Increase travel speed.
Lack Of Penetration - shallow
Fusion between weld metal and
Base metal.
Improper joint preparation.
Material too thick. Joint
preparation and design must
provide access to bottom of
groove while maintaining
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.
Insufficient heat input. Select
higher wire feed speed and/or
select higher voltage range.
Reduce travel speed.
Burn-Through weld metal melting
Completely through base metal
Resulting in holes where
no metal remains.
Excessive heat input. Select
lower voltage range and
reduce wire feed speed.
Increase and/or maintain
steady travel speed.
Excessive Spatter - scattering of
Molten metal particles that cool
to solid form near weld bead.
Wire feed speed too high.
Select lower wire feed speed.
Voltage too high. Select
lower voltage range.
Electrode extension (stick out)
too long. Use shorter electrode
extension (sick out).
Work piece dirty. Remove
all grease, oil, moisture,
rust, paint, undercoating,
and dirt from work surface
before welding.
Insufficient shielding gas at
welding arc. Increase flow of
shielding gas at regulator/flow
meter and/or prevent drafts
near welding arc.
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
Wire feed unit operates, but
does not feed
Insufficient drive roll pressure
Incorrect drive rolls
Excessive wire
spool brake tension
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
Adjust the burn back
control correctly
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.
8.0 Accessories
8.1 Drive Rolls
Wire
0.8/1.0
1.0/1.2
1.2/1.6
Mild steel
DR4V0810
DR4V1012
DR4V1216
Stainless Steel
DR4V0810
DR4V1012
DR4V1216
Aluminum
DR4U0810
DR4U1012
DR4U1216
Flux cored
DR4K0810
DR4K1012
DR4K1216
www.parweld.com
11
8.2 TORCH SPARES
XP8 300A
Air Cooled MIG Welding Torch
Rating: 300A, 8.7kW, Mixed Gas (80/20) @ 80% Duty Cycle, EN60974-7 .030-.045"/0 0.8mm
to 1.2mm wires
12
7
8
6
4
14
5
15
9
3
2
10
1
D
13
11
C
B
A
19
21
25 24 23
18
22
E
21
20
12
www.parweld.com
17
16
8
Model
Components
Stock Code 3M
4M
5M
Model Description
XP300A
-40E
-50E
Welding Torch c/w Euro Fitting
-30E
1
Stock Code
Description
XP2004B*
Diffuser-Plastic – M8 Head
* Denotes Standard Build
Nozzles
NI XP2004C
Diffuser-Ceramic – M8 Head
Stock Code
Description
2
Diffuser-Moulded c/w Ceramic Insert – M10 Head
NI XP3004C
Diffuser-Ceramic – M10 Head
A XP2002-10
Tapered Nozzle 3/8”/10mm
3
XP2005*
Head Assembly – M8 Tips
XP2002-13
Tapered Nozzle 1/2”/13mm
4
XP3005
Head Assembly – M10 Tips
XP2002-16*
Conical Nozzle 5/8”/16mm
5
XP2006A*
XP2002-16L
Conical Nozzle 5/8”/16mm-Extended
NI XP2006B
Heat Shield Moulded – M8 Head
XP2002-19
Cylindrical Nozzle 3/4”/19mm
6
Aluminium Heat Shield – M10 Head
XP2002-19L
Cylindrical Nozzle 3/4”/19mm-Extended
NI XP3006B
Heat Shield Moulded – M10 Head
B XP3002-13
Tapered Nozzle 1/2”/13mm
7
XP3001
Swan Neck
XP3002-16
Conical Nozzle 5/8”/16mm
8
XP2016
Lock Nut M12
XP3002-16L
Conical Nozzle 5/8”/16mm-Extended
9
XP3008
Ball Joint and Cable Support
XP3002-19
Cylindrical Nozzle 3/4”/19mm
10 XP2009
Handle Lock Nut
XP3002-19L
Cylindrical Nozzle 3/4”/19mm-Extended
11 XP3010-30
Cable Assembly x 3m/10ft
XP3010-40
Cable Assembly x 4m/13ft
Contact Tips
Stock Code
Description
C XP2003-08
Contact Tip .030”/0.8mm M8 CuCrZr
XP2003-09
Contact Tip .035”/0.9mm M8 CuCrZr
XP2003-10
Contact Tip .040”/1.0mm M8 CuCrZr
XP2003-10A
Contact Tip .040”/1.0mm Aluminium M8 CuCrZr
XP2003-12*
Contact Tip .045”/1.2mm M8 CuCrZr
XP2003-12A
Contact Tip .045”/1.2mm Aluminium M8 CuCrZr
XP2003-13
Contact Tip .052”/1.3mm M8 CuCrZr
D XP3003-08
Contact Tip .030”/0.8mm M10 CuCrZr
XP3003-09
Contact Tip .035”/0.9mm M10 CuCrZr
XP3003-10
Contact Tip .040”/1.0mm M10 CuCrZr
XP3003-10A
Contact Tip .040”/1.0mm Aluminium M10 CuCrZr
XP3003-12
Contact Tip .045”/1.2mm M10 CuCrZr
XP3003-12A
Contact Tip .045”/1.2mm Aluminium M10 CuCrZr
XP3003-13
Contact Tip .052”/1.3mm M10 CuCrZr
XP3004B
XP3006A
XP3010-50
Aluminium Heat Shield – M8 Head
Cable Assembly x 5m/16ft
12 XP2011
Cable Terminal Female
13 XP2012
Handle Kit c/w Lock Nut
14 XP2013
Hanger Hook
15 XP2014
Trigger
16 XP2015
Cable Terminal Male
17 XP3017
Cable Support
18 XP2018
Air Cooled Gun Plug Housing c/w Nut
19 XP2019
Gun Plug Screw
20 XP2020
Gun Plug Nut
21 Spring Pin 2
Spring Pin Assembly
22 XP2022
Gun Plug Body c/w Spring Pins
23 XP2023
Gun Plug Body O Ring
24 XP2025
Liner Nipple O Ring
25 XP2026
Liner Retaining Nut
Liners
Stock Code
Description
E XP2024-0-30
Steel Liner .023-.035”/0.6mm/0.9mm x 10ft/3m
XP2024-0-40
Steel Liner .023-.035”/0.6mm/0.9mm x 13ft/4m
XP2024-0-50
Steel Liner .023-.035”/0.6mm/0.9mm x 16ft/5mt
XP2024-12-30*
Steel Liner .040-.045”/1.0mm/1.2mm x 10ft/3m
XP2024-12-40*
Steel Liner .040-.045”/1.0mm/1.2mm x 13ft/4mt
XP2024-12-50*
Steel Liner .040-.045”/1.0mm/1.2mm x 16ft/5m
NI XP2024PC-12-30 Polyamide-Copper Liner
.030-.045”/0.8mm-1.2mm x 10ft/3mt
XP2024PC-12-40 Polyamide-Copper Liner
.030-.045”/0.8mm-1.2mm x 13ft/4m
XP2024PC-12-50 Polyamide-Copper Liner
.030-.045”/0.8mm-1.2mm x 16ft/5mt
XP2024PS-12-30 Polyamide-Steel Liner
.030-.045”/0.8mm-1.2mm x 10ft/3m
XP2024PS-12-40 Polyamide-Steel Liner
.030-.045”/0.8mm-1.2mm x 13ft/4m
XP2024PS-12-50 Polyamide-Steel Liner
.030-.045”/0.8mm-1.2mm x 16ft/5m
Note: For flux core wire 1.6mm liner is recommended –
Stock Code: XP2023-16-30
13
www.parweld.com
XP8 Mig Torch Packages
XP8
350A
Air Cooled MIG Welding Torch
Rating: 350A, 10.5kW, Mixed Gas (80/20) @ 80% Duty Cycle, EN60974-7 .040-1/16"/1.0mm
to 1.6mm wires
9
4
5
11
3
12
6
2
7
10
1
B
8
A
23
17
19
22
21
16
20
14
C
18
14
www.parweld.com
13
15
Model
Components
Stock Code 3M
4M
5M
Model Description
XP350A
-40E
-50E
Welding Torch c/w Euro Fitting
-30E
1
Stock Code
Description
XP3004B*
Diffuser – Moulded c/w Ceramic Insert – M10 Head
* Denotes Standard Build
Nozzles
NI XP3004C
Diffuser – Ceramic – M10 Head
Stock Code
2
XP3505*
Head Assembly-M10 Tips
3
XP3506A*
Aluminium Heat Shield – M10 Head
Description
A XP3002-13
Tapered Nozzle 1/2”/13mm
NI XP3506B
Heat Shield – Moulded – M10 Head
XP3002-16*
Conical Nozzle 5/8”/16mm
4
XP3501
Swan Neck
XP3002-16L
Conical Nozzle 5/8”/16mm-Extended
5
XP3507
Lock Nut M14
XP3002-19
Cylindrical Nozzle 3/4”/19mm
6
XP3008
Ball Joint and Cable Support
XP3002-19L
Cylindrical Nozzle 3/4”/19mm-Extended
7
XP2009
Handle Lock Nut
8
XP3510-30
Cable Assembly x 3m/10ft
XP3510-40
Cable Assembly x 4m/13ft
Contact Tips
Stock Code
Description
XP3510-50
Cable Assembly x 5m/16ft
XP2011
Cable Terminal Female
10 XP2012
Handle Kit c/w Lock Nut
11 XP2013
Hanger Hook
12 XP2014
Trigger
13 XP2015
Cable Terminal Male
14 XP2016
Lock Nut M12
15 XP3017
Cable Support
16 XP2018
Air Cooled Gun Plug Housing c/w Nut
17 XP2019
Gun Plug Screw
Description
18 XP2020
Gun Plug Nut
19 Spring Pin 2
Spring Pin Assembly
C XP3524-12-30*
Steel Liner .040”/1.0mm-.045”/1.2mm x 10ft/3m
20 XP2022
Gun Plug Body c/w Spring Pins
XP3524-12-40*
Steel Liner .040”/1.0mm-.045”/1.2mm x 13ft/4m
21 XP2023
Gun Plug Body O Ring
XP3524-12-50*
Steel Liner .040”/1.0mm-.045”/1.2mm x 16ft/5m
22 XP2025
Liner Nipple O Ring
XP3524-16-30
Steel Liner .063”/1.6mm x 10ft/3m
23 XP2026
Liner Retaining Nut
XP3524-16-40
Steel Liner .063”/1.6mm x 13ft/4m
XP3524-16-50
Steel Liner .063”/1.6mm x 16ft/5m
NI XP2024PC-12-30
Polyamide – Copper Liner
.030-.045”/0.8mm-1.2mm x 10ft/3mt
XP2024PC-12-40
Polyamide – Copper Liner
.030-.045”/0.8mm-1.2mm x 13ft/4m
XP2024PC-12-50
Polyamide – Copper Liner
.030-.045”/0.8mm-1.2mm x 16ft/5m
XP3524PC-16-30
Polyamide – Copper Liner
.045-.063”/1.2mm-1.6mm x 10ft/3m
XP3524PC-16-40
Polyamide – Copper Liner
.045-.063”/1.2mm-1.6mm x 13ft/4m
XP3524PC-16-50
Polyamide – Copper Liner
.045-.063”/1.2mm-1.6mm x 16ft/5m
XP2024PS-12-30
Polyamide – Steel Liner
.030-.045”/0.8mm-1.2mm x 10ft/3m
XP2024PS-12-40
Polyamide – Steel Liner
.030-.045”/0.8mm-1.2mm x 13ft/4m
XP2024PS-12-50
Polyamide – Steel Liner
.030-.045”/0.8mm-1.2mm x 16ft/5m
XP3524PS-16-30
Polyamide – Steel Liner
.045-.063”/1.2mm-1.6mm x 10ft/3m
XP3524PS-16-40
Polyamide – Steel Liner
.045-.063”/1.2mm-1.6mm x 13ft/4m
XP3524PS-16-50
Polyamide – Steel Liner
.045-.063”/1.2 mm-1.6mm x 16ft/5m
B XP3003-10
Contact Tip .040”/1.0mm M10 CuCrZr
XP3003-10A
Contact Tip .040”/1.0mm Aluminium M10 CuCrZr
XP3003-12*
Contact Tip .045”/1.2mm M10 CuCrZr
XP3003-12A
Contact Tip .045”/1.2mm Aluminium M10 CuCrZr
XP3003-13
Contact Tip .052”/1.3mm M10 CuCrZr
XP3003-14
Contact Tip .055”/1.4mm M10 CuCrZr
XP3003-16
Contact Tip 1/16”/1.6mm M10 CuCrZr
Liners
Stock Code
9
15
www.parweld.com
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 3/8" BSP outlet.
• Fitted with 5/8" BSP inlet connections.
Stock Code
E700140
Description
Argon Preset Regulator
Max Outlet Pressure
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 3/8" 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
16
www.parweld.com
www.parweld.com
17
www.parweld.com
9.0 EC Declaration of Conformity
Hereby we declare that the machines as stated below
Type: XTM404S
Complies with Low Voltage Directive 2014/35/EEC
EMC Directive 2014/35/EEC
European standard: EN/IEC 60974-1 – EN 60974-10
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
Amended 2015/863 and 2017/2102
Restriction of use of certain hazardous substances in electrical and electronic equipment
Type: XTM404S
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.
www.parweld.com
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) 2012/1”/EU
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.
19
www.parweld.com
Parweld Limited
Bewdley Business Park
Long Bank
Bewdley
Worcestershire
England
DY12 2TZ
Tel. +44 1299 266800
www.parweld.com
[email protected]