Work Environment; Operation; Warn By Standers To Shield Their Eye; Setting Up Gun For Aluminum Welding - Welding Industries Malaysia WIM200 Instruction Manual

3.12 WORK ENVIRONMENT

The machine should be used in doors always from strong draughts, which may cause gas
dissipation. If the machine is to be covered, the natural cooling air circulation must not be
interrupted. Before commencing welding, clear area of flammable materials.

4.0 OPERATION

Set the voltage and wire feed controls to positions suitable for welding the thickness of the material
being welded. Welding current varies in direct relationship to wire feed speed. For low welding current
output, the wire feed speed control should be set at the low end of the wire feed speed scale.Turning
the wire feed speed control knob clockwise, will result in increased wire feed speed and welding
current. Welding voltage is adjusted to match the wire feed speed (welding current).For welding in the
low current range, set the voltage switch to a low position number. Progressively select higher voltage
positions with increases in wire speed. Low wire feed speed settings for a given voltage will cause a
large ball to form on the end of the welding wire and cause excessive spatter. High wire feed speed
settings for a given voltage will cause wire stubbing. Position the torch over the seam to be welded
with the nozzle approximately 70º to the work surface. The nozzle to work distance should be
approximately 10mm.
4.1 WARN BY STANDERS TO SHIELD THEIR EYES
Lower your helmet and press the welding torch trigger. As the weld is deposited, push the torch from a
right to left direction, slowly along the seam at a constant speed. Using the wire feed speed control;
adjust for a 'crisp' sounding arc.
4.2 SETTING UP GUN FOR ALUMINIUM WELDING
1. The welding Gun
Remove the liner positioner nut from the adaptor block at the wire feed end of the gun cable.
Remove the gas nozzle contact tip from the welding torch and remove existing liner if fitted.
Carefully push the teflon liner, with brass neck liner attached, through the gun cable until the end of
the liner protrudes from the swan neck and withdraw the liner back into the swan neck. Refit the
contact tip and gently push the liner to seat it into the back of the contact tip. Replace the gas
nozzle. At the adaptor block end of the gun cable, slide the brass nipple and '0' ring over the liner
until they are located in the recess in the adaptor block and replace the liner retaining nut. Do not
cut the Teflon liner yet!!
2. The Welding Machine
With a pair of long-nosed pliers, remove the steel inlet guide tube from the central adaptor on the
face of the welding machine. With the Teflon liner still protruding from the adaptor block, feed the
liner through the inlet of the central adaptor until the adaptor block is butted against the central
adaptor. Fasten into position with adaptor block lock nut. Cut the liner in the shape of a 'V' using a
sharp knife so that it butts up to the feed rollers.Remove the welding gun from the machine and cut
the brass support tube so that it is 3mm shorter than the protruding Teflon liner. Slide the brass
support tube over the liner and enter the Teflon liner with brass support tube fitted into the inlet in
the central adaptor. Feed through until the adaptor block is butted against the central adaptor and
tighten the lock nut. Replace the wire hub tension by backing off the nut in the centre of the hub
until the tension of the hub is minimal. After confirming the wire feed roll is the correct size for the
aluminium wire being used, and that the wire is fed through the gun cable, back-off the wire feed
roll pressure screw until the feed roll no longer feeds the wire and retighten approximately 2 turns.
Too much pressure will deform the soft aluminium wire and cause the wire to jam in the contact tip.
NOTE: TO HELP PREVENT WIRE DEFORMATION:
A 'U' groove feed roller is a better alternative than a 'V' groove feed roller.
3. Contact Tip
Aluminium welding requires a contact tip with greater clearance than that used for steel. Special
clearance contact tips are available for welding aluminium and are designed with a suffix e.g. 0.9A,
1.2A.
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disposal such as copying and passing on to third parties. Specification may vary from country to country. V1.1.06