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5. SETTING UP THE WELDER
5. MAINTENANCE
5.1
CONNECTING THE GAS CYLINDER. Stand the gas cylinder on the base at the rear of the
welder and secure with chain supplied. The welder can be transported with small and medium sized bottles only.
Do not transport the welder with a large bottle attached.
5.2
Remove the protective cap from the new gas bottle and clean any dirt from the thread. Open the valve for a
few seconds and allow a little gas to escape to remove any residual dirt or impurities. If using Argon or Argon
mixtures, you will need to use the "bull nose adaptor" provided. If you intend to use CO2 gas the regulator
will fit directly onto the cylinder. If using the bull nose, fit nose adaptor to the cylinder and tighten with a spanner.
5.3
Remove regulator from box (ReG/MT) and screw it to the bull nose (or CO2 cylinder). Place the small jubilee
clip over the rubber hose from the welder, connect the hose to the regulator "BP" output and secure with the
jubilee clip (fig 3).
5.4
Set the regulator flow rate to 5 - 7 litres/min depending on the material to be welded, also taking into
consideration any draughts which are strong enough to disturb the gas flow.
5.5
If the welder is to be stored for a long time always remove the flow regulator.
5.6
TORCH "Euro Connection". ( See fig.4 ) Your welder is fitted with a "euro Connection" quick release torch.
Simply line the pins in the torch connector (1) up with appropriate holes on the front panel connector (2) and
push in and tighten the locking nut.
5.7
FIT A REEL OF WIRE. ( See fig.5 ) MAKe SURe ThAT The WIRe Feed ROlleRS, The WIRe GUIde
hOSe ANd The CONTACT TIP OF The TORCh MATCh The dIAMeTeR ANd TYPe OF WIRe TO Be
USed ANd eNSURe ThAT TheSe PARTS ARe FITTed CORReCTlY.
5.8
Setting up the wire feed rollers. ( See fig.6 ) If you change the size or type of wire you are using you you will
have to change or reverse the wire feed roller so that the groove in the roller matches the size of wire passing
through it. Remove the screws from the lower roller support as shown in fig.6 - 1 and remove the roller from the
square shaft. The size of each groove is stamped on the adjacent face of the roller. Replace the roller on the shaft
so that the size you require can be seen on the front face. Replace the roller support as shown in fig.6 - 2.
5.9
Ensure the welder is unplugged from the mains power. The welder is supplied with a mini spool of wire, but
will accept up to 15kg spools without modification.Open the side of the unit, remove the spacer from the holder
(A) and push the reel of wire over the plastic end springs and onto the main spindle ensuring that the spool
rotates clockwise with the wire drawing off the reel from the top. large spools of wire have a guide hole (B)
which must be pushed onto the plastic pin located at the back end of the reel spindle. When large reel has been
located on this pin, push the spacer (A) back onto the spindle to keep reel pushed onto the pin (spacer cut outs to
face the wire reel). The pin will stop large reels of wire from free wheeling around the spindle.
5.10
Undo the wire tensioning screw (d) and raise the wire feed tension arm to the vertical position.
5.11
Straighten about 40-50mm of spool wire (do not allow wire to uncoil). Round the end of the wire off ensuring
any burrs or sharp points are removed, and gently push wire through plastic guide (G) and through the 0.6mm or
0.8mm roller groove (F) and through to the torch. Note: Burrs or sharp points at wire tip may damage the liner.
5.12
Return the wire feed tension arm to the closed position and secure with the wire lock screw (d). Turn the screw
through half its adjustment range so that the wire feed pressure roller (C) exerts medium pressure on the wire.
5.13
Remove gas cup (fig.7a) and contact tip (b) from end of torch as follows:
5.14
FEED WIRE THROUGH TO THE TORCH.
a) Take torch in left hand with the torch tip facing to the right.
b) Grasp gas cup firmly in your right hand.( Cup is a friction fit.)
c) Turn gas cup clockwise only (fig 7) and pull cup out to the right.
d) Unscrew the copper contact tip (right hand thread) to remove.
WARNING! do not turn gas cup anti-clockwise, as this will damage the internal spring.
5.15
Check welder is switched off "0", and that the earth clamp is isolated and away from the torch tip. Connect
the welder to the mains power supply and set the voltage switch to "1".
5.16
The wire speed is automatically controlled by the welder. Keep the torch cable as straight as possible and
press the torch switch to feed wire through the torch.
WARNING! When testing the wire feed do not allow the wire to come into contact with the
workpiece or earthing connection as this would inadvertently strike the arc causing potential injury.
To avoid mechanical injury do not direct the wire at yourself or any other persons.
5.17
When wire has fed through, switch welder off, unplug from mains.
5.18
Take torch in left hand and screw contact tip back into place as follow:
5.19
Grasp gas cup in right hand, push onto torch head and turn clockwise only.
5.20
SETTING WIRE TENSION.
IMPORTANT: You must set the correct tension, too little or too much tension will cause problematic wire feed
and result in poor welding.
5.21
Tension between rollers is checked by slowing down the wire between your fingers. If top feed roller skids
the tension is correct. Use as low a tension as possible, too high a tension will deform wire and result in a
blown fuse on the printed circuit board. Adjust tension by turning knob (fig.5 - d).
5.22
CLUTCH ADJUSTMENT
It is essential that the clutch is adjusted correctly. depress the torch switch and release quickly. If spool
overruns it indicates that the clutch is too loose. Tighten the clutch (located in the centre of the wire spool
spindle ( fig.5 - e ), and test the machine as above until the wire stops over running.
WARNING! DO NOT over tighten the clutch as this will cause wire feed problems.
fig 4
Original Language Version
fig 3
fig 5
fig 6
fig 7
eleCTROMIG195.V3
Issue: 3 - 08/03/10
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