04790,04796

Pleasereadandfullyunderstand theinstruc-
tionsinthismanual beforeoperation. Keep
this manual safe for future reference.
Migmate 135T
Migmate 155T
Gas/Gasless Mig Welder
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03 INTRODUCTION
04 GENERAL SAFETY INSTRUCTIONS
06 SAFETY INSTRUCTIONS
09 ELECTRICAL INFORMATION
10 WIRING DIAGRAM
11 FACE SHIELD ASSEMBLY
12 USING THE WELDER
13 SETTING UP THE WELDER
14 OPERATING AS A GAS MIG
15 OPERATING AS A NO GAS MIG
17 HOW TO WELD GUIDE
24 QUICK START UP GUIDE
30 CONVERTING TO A GAS WELDER
32 WELDING TROUBLESHOOTING
37 ROUTINE MAINTENANCE
39 DECLARATION OF CONFORMITY
WARRANTY CERTIFICATE
Contents
With this welding unit you can now experience the many advantages of the
MIG and Gasless welding processes. This unit will enable you with the
help of this manual and a little practice to obtain a professional finish in
welding car bodywork and many other uses for which you'll find it ideal.
ADDITIONAL PROTECTIVECLOTHING
When welding at higher settings wear a leather apron to protect the operator from spatter.
When welding in the overhead position, a suitable cap should protect the head and neck.
We recommend that you wear industrial footwear including steel toes caps.
HEAT
Wear welding gloves at all times whilst welding. They will protect the hands from ultra-
violet radiation and direct heat of the arc. It is also recommended that overalls are worn.
ARC GLARE
Always usea face shield or welding helmet fitted with the correct glassfilter. Never use
damaged safety equipment.
WELDING FUMES
Toxic gases are given off during the MIG welding process. Always usein awell-ventilated
area.
FIRE PRECAUTIONS
All flammable materials MUST be removed from the welding area.
DO NOT strike an Arc on or near the gas cylinder.
DO NOT attempt to weld fuel or gas containers unless adequate procedures have been
taken to ensure that no vapour remains. Fuel tanks should be thoroughly steamcleaned
before welding.
Savethese instructions for future reference.
Checkthe MIG Welder and loose parts and accessoriesfor transport damage.
IF IN ANY DOUBT PLEASE SEEK OUR PROFESSIONAL ADVICE.
Electrical repairs must only be carried out by a qualified or approved engineer and only
with the welder disconnected from the power supply.
Operati n9 the welder with the covers removed MUST B E AVOIDED.
The unit must be correctly set up.
Disconnect from the mains supply before undertaking servicing or repairs.
MIG welders are simple and safe to operate under normal circumstances. DONOToperate
in rain or very damp conditions.
Do not attempt to lift the welder with the gas cylinder mounted on the rear platform.
Always remove the gas cylinder before lifting.
The unit can be used on a sloping flat surface up to 15.
General safety instructions
Make sure that when changing from gasto no gas and vice versa, you usethe wire feed roller
with the correct size groove for the diameter of wire being used. Do not try to usethe welder
with an incorrect wire drive roller. Serious damage to the torch may result and the performance
of the welder will reduce. Likewise, it is necessaryto ensure that you fit the correct size MIG
tip to avoid damage and performance problems.
Additionally, to convert to a gas MIG, you will need to usethe GasConversion Kit which
includes C02 gas cylinder, gas regulator, 1x 0.8mm MIG wire and the 0.6/ O.8mm wire drive
roller all supplied with this kit.
-ve -ve
R E D P O S T B L A C K P O S T
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N O G A S
W E L D I N G
G A S M I G
W E L D I N G
The machine is supplied set for useas a no gas MIG welder. I t issupplied with astarter spool
of no gas MIG wire (flux cored - 0.9mm dia):To convert it to a gas MIG welder you will need
to change the polarity of the welder output this is achieved simply by swapping over the
power delivery cables under the hinged lid of the welder.
The Power Craft Combination GasI No Gas MIG Welder is a dual purpose MIG welder. This
means that it can be set to operate as a conventional gas MIG welder aswell asano gas MIG
welder.
M odel
C ircuit B reaker
04790 16A
04796 16A
I M P O R T A N T :
1. These units should never be exposed to rain or snow.
2. Do not use in a wet or damp environment.
3. Do not useto thaw pipes.
4. These units should be connected to the mains supply through a circuit breaker with the
following ratings:
G eneral safety instructions
PERSONAL SAFETY
Use Personal Protection Safety Equipment
Wear protective clothing, which is designed for and is stated for usewith MIG welding
applications. Wear protective welding gloves and face/eye masks to the correct standard
for your welder. Avoid exposing your skin to the ultra violet rays given off by welding.
Appropriate approved safety footwear and headgear should worn, for example on
building works, when heavy weights or overhead working are involved,
Dress properly
Do not wear loose clothing or jewellery; it can get caught in moving parts, present a fire risk
or ashock hazard. Non-skid safety footwear is recommended.
Stay alert
Watch what you are doing. Usecommon sense. Do not operate the welder when tired or
after taking alcohol or prescription! non-prescription drugs.
f.\ WARNING!. .
~ The welder produces a high current weld at high temperature. Hot molten sparks
will be ejected away from the work piece. Always wear suitable safety glassesand other
appropriate safety equipment when operating, cleaning or servicing. Provide adequate
ventilation, as fumes can be dangerous. Do not operate this machine or its accessoriesnear
other people unless they are wearinq appropriate safety equipment also. All persons in the
work area should be made aware of all the safety issuesrelating to welding.
DANGER Do not look at the welding arc. Failure to use an appropriate welding
mask will seriously damage your ell'esight. Always ensure that safety and protective
equipment is inspecting prior to use and that it is undamaged. Never use the welder
with a face shield having a cracked lense otherwise serious damage to your eyes
may result.
&BE F ORE OPE RATING THE WE LDE R, Y OU MUS T OBS E RVE THE S AF E TY NOTICE S GIVE N BE LOW,
,
GENERAL
E lectrical repairs must only be carried out by a qualified or approved engineer and only
with the welder disconnected from the power supply,
Operating the welder with the covers removed MUS TBE AVOIDE D,
The unit must be correctly set up,
Disconnect from the mains supply before undertaking servicing or repairs.
MIG welders are simple and safe to operate under normal circumstances,
DO NOT operate in rain or very damp conditions.
IF IN ANY DOUBT PLEASE SEEK OUR PROFESSIONAL ADVICE.
Checkthe MIG Welder and loose parts and accessoriesfor transport damage,
S avethese instructions for future reference.
Safety instructions
Do not operate the welder in a confined space
The welder is required to operate in a good air spaceto aid cooling.
Do not touch the work piece, torch or earth clamp
Avoid direct contactwith the welding circuit (work piece, torch and earth clamp) as this
presents a very high risk of electric shock. During operation the work piece, torch and earth
clamp will become very hot. Evenafter usethese will remain hot for sometime. Avoid coming
into contact with these. Do not leave flammable liquids or combustible materials near the
welder or work piece.
Do not let children or pets in the work area
Do not let children or pets come into contact with the welder, cables or work area.
Do not abuse the cables
Never pull the welder by the electrical supply, clamp or torch cables.
Keep cables away from heat and sharp edges.
Do not touch the metal plug pins when connecting or removing the electrical plug.
Do not run the welder in damp conditions
The welder should never be used in an area where it could be exposed to water or excessively
damp conditions. Do not weld in the rain. Damp environments present a high shock hazard.
Do not use this machine if you or any person in the vicinity relies upon electrical or
electronic devices for medical reasons
The electromagnetic field generated by the welding processmay interfere with the operation
of electrical and electronic equipment. Usersof vital electrical or electronic devices(e.g. pace-
makers, respirators etc.) should consult a doctor before entering the vicinity or areas where
this welding machine is being used. Usersof vital electrica! or electronic devicesshould not
usethis machine.
Do not allow routine to lead to mistakes
Do not allow routine, which occurs when using the machine frequently, to leadto mistakes.
Remember that a slight lack of concentration can result in serioLIS injuries in asplit second.
Do not use the welder on ladders
Do not usethe welder whilst on ladders. Ensurecorrect platforms are used.
Do not eat, drink or smoke in the work area
Do not eat, drink or smoke while using this machine or in the work area.
What You MUST NOTDo
OPERATIONALSAFETY
Safety instructions
Keep cables and clamps in good condition
Keep welding cables, torch and the earth clamp in good condition, Poor contacts through
the welding circuit caused by defective cables and clamps can be dangerous and produce
poor welds.
Using the welder
Before using the welder, check every time that the cable connections are fully tightened and
that there are no broken or worn parts.
Avoid unintentional arcing of the welder
When the welder is not in use turn the welder off at the mains. Live electrodes present a
hazard, as they could arc against the earthed metal.
Maintenance of electrical components
You must ensure that a suitably qualified person carries out repairs and maintenance of
electrical components.
Disconnect the welder from power supply when maintaining
Before carrying out any maintenance on the welder. Always switch off and unplug the welder
from the power supply.
Always use personal protective equipment and the face mask
Personal protective equipment and the facemask must always be worn when welding.
Check facemask for damage. Never- use damaged safety equipment.
Keep work area clean and provide the correct working conditions
MIG welding produces sparks and high temperature fused metal projectiles and fumes,
Remove all flammable substances and materials from the work area,
Provide adequate ventilation of facilities where welding takes place.
Do not weld on containers or pipes that hold or have held flammable liquid or gaseous
combustibles (danger of explosions and/or fires) or on materials cleaned with chlorinated
solvents or on varnished surfaces (danger of toxic fumes),
Cluttered areas invite injuries. Make sure the area is clear of obstacles, which could cause
you to trip and fall.
What You MUST 00
Safety instructions
1. Switch
2. Thermal Protection
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Settings
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4. Settings
A C 230V
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Primary Winding N~
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E i. Secondary Winding
NB. E nsure the torch lead is held in a straight line and fully extended when feeding the wire
through the torch, with the tip removed, otherwise there is risk of the wire puncturing the
wire feed liner and torch hose.
Torch: Regularly dean the contact tip and shroud to remove spatter that will eventually disturb
the welding performance. Spraying the tip and shroud with anti-spatter spray canreduce the
build up of spatter. Replace the tip regularly to maintain a good electrical contact between
the tip and the wire. Blow clean dry air through the torch liner from time to time to ensure
the wire passesfreely through it. If this hJ S no effect the liner should be replaced.
Welding Cables: Regularly inspect their connections.
E lectrical repairs must only be carried out by aqualified or approved engineer.
Electrical information
Ensurethat your supply voltage corresponds to the voltage stated on the rating plate
onthe welder Thewelder must beconnected to an electrical supply capable of delivering
I) max (asstetec on the data plate, printed on top of the wetcer) Forweldmqcurrents
up to a maximum of 130 on a 13 amp plug maybe used. Above 130 amps welding
current or when using the welder for. a 230V industrial pluq, socket and power supply'
must be used. The brown wire must be connected to the LIVE terminal and the blue
wire must be connected tc the NEUTRAL terminal of the plug.
Ensurethat the yellow/green wire is connected to th( earth terminal. Ensurethat the
appropriate fuse (asstated on the data plate printed on top of the welder)
protects the supply.
I
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Wiring diagram
STEP 4
STEP 2
STEP 3
STEP 1
Face Shield Assembly
You have read and understood the safety section of this instruction manual.
All flammable materials and containers have been removed from the work area.
I There is good ventilation, particularly at the front and rear of the welder.
There is an adequate and suitable fire-fighting appliance close by.
1. Connect the earth clamp onto the metal to be welded.
2. Setoutput and wire feed speed byturning or pressing the appropriate controls
(SeeFig. 1& 2), taking into account the material type and thickness and the wire size.
3. Plug in and switch the welder on.
4. Cut off excesswire to 3mm from the end of the tip.
5. Position the tip 6mm from the point where the welding isto start.
6. Hold the mask in front of your eyes.
7. Pressthe trigger and when the arc strikes, slowly move the torch in the desired direction.
8. If the arc produces a humming sound and a blob forms on the end of the wire, there is
insufficient wire speed and it should be increased. If an erratic sound is given with a feel
that the wire is stubbing against the work and excessivespatter, there is too much wire
speed. When the speed is correct there will be a steady smooth crackling sound.
9. Check the rating plate on welder's cover for the duty cycle, the welder can be
set to deliver different output currents at a duty cycle (written as a percentage).
The percentage represents the welding time in a 10 minute cycle, for example
60% means that the welding time is 6 minutes and the rest time is 4 minutes.
If the welder is used beyond it's duty cycles, the temperatures of some components
might become too high due to over use, then the internal thermal protector will
prevent the welder from operating. The warning light on the front of the machine
will illuminate to warn you, if this happens, allow it to cool down. The thermal
protector will reset automatically after a short period when the components
have cooled, and then you are able to resume welding. Note: Keep the machine
switched on, the fan will cool it quicker.
BEFORE WELDING ENSURE THAT:
Using the welder
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Hold the torch straight. Switch the machine on and operate the torch trigger, the wire
feed roller will turn feeding the wire through the torch.
~. The wire will emerge from the far end of the torch, then feed the tip onto the wire (make
sure the tip isthe correct size for the diameter of wire being used), tighten it and replace
the shroud .
). To reverse the roller, unscrew the two screws securing the roller, supporting bracket and
remove the bracket. The roller can then be removed from it's shaft and reversed.
I. Fastenthe pressure arm down ensuring that the MIG wire is in the groove inthe feed
roller. Ensure that the correct groove is used depending on the diameter of the wire i.e.
for gas welding one groove is for O.6mm and the other for O.8mm, depending upon the
diameter of the wire usethe O.8mm groove or the O.9mm roller for flux cored wire.
Do not put too much pressure on the wire. In the event of a blockage or restriction, the
drive roller needs to skid over the wire to avoid a 'birds nestinq' of the wire.
I. Hinge back the pressure arm and feed the end of the wire into the hole in the end of the
liner. Ensurethat the wire isfitted sothat it isfed into the wire feed mechanismin a straight
line.
:. Locate the free end of the wire usually positioned in a hole on the reel rim. Remove the
end of the wire from the hole and usesharp wire cutters to remove any distorted wire.
Do not allow the wire to become slack on the reel.
NOTE: The Migmate 135T will operate from a standard 13A domestic socket,
the Migmate 155T is a higher power welder and will blow a 13 amp fuse, the
welder must be connected to a 16 amp fused supply via a suite rated plug
and socket. Consult a qualified electrician for guidance.
I Feeding the Wire
When fitting a new reel adopt the following procedure:
1 . Remove the shroud from the torch and unscrew the contact tip.
2. Fit the wire reel onto the spindle. The spring mounting must be correctly fitted.
= Live
= Neutral
= Earth
BROWN
BLUE
GREEN/YEllOW
Electrical:
Your MIG welder must be earthed. Connection to a suitable fused isolator switch, with the
wires connected asfollow:
Setting up the welder
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'. Power Output Setting
This machine has a number of output settings, these are controlled by the rotary
switch on the front panel(seefig. A) POWERSETTING
G.Settinq Tt,e Gas Flow f\f..gu lator
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1 Con necti'1 9 The Gas Tube To The Reguiatot' .
(i~WI -I t ' : ' -: ' ~. ' ~ ~ E : : ; L ;be: : ~ j ', i". : S/-WSl the h2C end ir.to trie connector on tht~ re9ula~ol" , It
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3 FItting Cylinder' To The Mounting Bracket
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Connect the earth cldrnp onto the metal to be weided.
Set output and wire teed speed by turning or pressing the appropriate controls (see Fig.
A and 8), taking into account the material type and thickness and the wire size.
Plu~J ill and ~witch the welder on.
Cut of f excess wire to 3'lHn f rom the end of the tip.
You have read and understood the sate-ty section of this instruction manual.
ll.il f l.: : -Immablematerial, and containers have been removed f rom the work area.
There is good ventilation, particularly at the f ront and rear of the 'Neider,
There is an adecuate f ir'e-f ighting appliance close by.
You have correctly set the polarity f or the type of welding you are intending \0do (gas
or no qas).
SING THE WELDER
: ef ore \Neidinq ensure 1hat:
S(-'~the correct polarity.
Fit O.9rnmno gas mig wire into the wire spool holder.
r , Chanel: , the wire drive roller to one with a groove that matches the wire size
Fit aMI G tip that matches the wire size
, Disconnect 1he gas tube f rom any cylinder f itted.
I. Select. the power settinS) (Fig A) .
Operating as a no gas MIG
ig B
J OTE: The wire f (: ~ed)i.)pcd is dutOrJ ldticdlly adjusted when the output is ~elt: (ted Tile win.
peed )CLting control provides f ille-tunin<; J . (See Fig. B)
",'.'ii(hjn~l {rorn (me ~,et!ir1(_;to another automatically 'I l{.reases and decrec; ; es the '-\I j re Spee(l
it,d trH-'kf orr u.e weldir!~1 output. On malef iC'll f rorn O.6mm up 10 1.3r'1"lIT1 select "IJ )',v"
ctt I!HJ (s) and TO r ~hir k('r r~-I ate rial s selecT ; ,Hi 9h" sett i119(s). ..
Operating as a gas MIG
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l . Press li!e ;_;,Yld . - 1r. u VJ r,Hl iI,,=, di e S\li ~:t- ',", sled,_,I;n' ,o\le the torch in the desired direction,
if trw rJ i ( ;' ,[(: : L: cE-"; c, In;in)i nq (,c,uncJ (,ri cJ (i rJ 1D L , terms on th~ end ot the vv. re. there is
insufficient i_. ire:~r. _ :,:,:eci ,-]1' 1\1 r: should be i n ~'E - 'f H. - _ '(_ J . i f an erratic soun d is given wi th a fee!
that the- v. irc is 5tubtJ l!':q ,=: -: ~J iilst_the ./iD r!< and excessive sputter, there: is too much wi re:
:'pCI . _ _ 'cl. \fVliu' , - . I H. ' ~,Pl_ '\_ 'C1 ~ Ullt\_ (. _ L there ,,: ,. ' ,11 IX' d steddy smooth crackling sound. If d
ooro L' - . :. /1'. 1. 1 'c' I ,I~: . '.-i~,(,, I' if' ' -I ti"f "' ]-' ( \)' 1. . t> ." ... C' d" welder the e is insufficient gas tlov
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and it shoi. ld be ir,ued: ,td.
Check the rilti"' Cj r. J lclt' 2ell ;h,!Cj(~r\ (CvE;1 TOI '' (he duty (yck:, the . ,f. : elder call be set to deliver
di f f eren t output c. ;IT2nt~0 <1 a cllltl_i cyell"- (' ,\nitten as a percen tage) The percen tage
represents ti le- weldinq nrnc in i) 10 minute cycle. for example 60 . ' 0 means that the welding
ti me is 6 rr. i n utcs [}' ,d the I' C~t ti me i s 4 nunutcs If the welder i s used beyon d i t's duty
(_y(IC~, the ttln~. : er;: )tur(' s . : d: ,O!!H~components rniqht become too high due to over usc,
then the int!. ?!nal thsrrnal picteClor v. ,rill prevent th(: ;weloer from operating. If this happens,
allov/ i t to COO! dovvn. f lI P thel mal protector vvill reset a utornatically after a short period
when the compon en ts h(lVi :' cooled, an d then you are able to resume weldi n q.
Note, f~ccp the machine sv. itched on, the f em ,,t,/i!lcool it quicker
Pes tiO~1tile ti; 611'111 ;-I' : ): r , if' pcitv \o'/!lC'!'f ' the: ,,'. 'c'd'llq i) to start.
He- deJ I f i e- ll1ci ',k 11' 1 11,1"\ 01 \r: ,tn P\'t'S -
Operating as a no gas MIG
Remember you must always use O.9mm diameter flux cored MIG Wire with your Wolf
combination MIG welder 30-135 amp, when using as a no gas MIG welder.
Should you need any further advice, please contact our Technical Helpdesk.
Do not attempt to weld the J ob in hand until you have first practised on some scrap metal.
In the next few pages are some general hints and do's and dont's to help you during your
early days of welding.
Pleaseensure that before carrying out any welding on a vehicle you must disconnect the car
battery and disconnect the vehicle's alternator electrical terminal to avoid damage to the
vehicle's electircal system.
MIGwelding isone of the simplest methods of welding and.isparticularly goodfor
welding thin steel as car panels. The SIPMigmate 135T/155T DP gas/gasless
MIGWelder isaDCwelder, which canbeusedwith both flux coredand solidwire
asthe 'filler wire' , which makes it ideal for all forms of MIGwelding.
How to weld guide
DURING WELDING
If current istoo low: wire stubsinto work
If current istoo high: arcis unstable(spatter)
Setvoltage midway between highllow voltage
~----
When deeper penetration than 3mmisrequired
on thicker steel,then grooving a'v' at the
junction of the butt and2or morepasseswith
the welding torch or welding on both sidesof a
butt joint will givedeeper penetration.
~---
NO GAS MIG WIRE O.9MM DIA WIRE SIZE WELDS AT ALL
AMPERAGE SETTINGS ON YOUR MIG WELDER.
---~---
Bun JOINTING
(J OINING2 PIECESOF STEEL)
1/8 or
.138 in (3.Smm)
Material thicknessdetermines weld
parametersfor full penetration.
TypicalWelding ProcessControl SettingsForWeld Penetration.
NOTE: At full power, the MIGwelder iscapableof creating aweld penetration of 3mm
when butt jointing.
MIG WELDING PROCEDURES
How to weld guide
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END VIEW OF WORK ANGLE S IDE VIEW OF TORCH ANGLE
FILLETWELDS
Figure 3. Holding & Positioning Welding Torch
Figure3 illustrates the correct welding position for right-handed people
(Forleft - handed it isopposite):
a. Hold the torch in your right hand
b. Touchleft hand to under sideof right hand.
c. Thewelding torch trigger iscontrolled by the right hand.
Weld with two the handswhenever possible.
Whenever possible,weld from left to right (if right-handed).
This enablesyou to seeclearlywhat you are doing.
Hold the torch at aslight angle asshown in Figure3.
END VIEW OF WORK ANGLE S IDE VIEW OF TORCH ANGLE
GROOVE WELDS
\
\
~ _ _ -r_ _ ....J LZ
90
NOTE: Welding wire isenergised when the torch trigger is pressed. Before lowering helmet
and pressing trigger, be sure wire is no more than 1 / 2 in (13mm) past endof nozzle,
and tip of wire is positioned correctly on seam.
. ,\ 1. Hold torch and control
'.\ ./ \
\ / \ .... < :c torch trigger
3 2 (:_ /2"'" 2. Workpiece
,)". \ \ /...,- ).~_. __._( 3. Work earth clamp
r, " '/ , :::.t.,._. I "
"'< "", ::~";'7;"""/ ;Y'-""~:' "-" 5 4. Electrode Extension (S tickout) 1 / 4 to
(.; '... ,.r.(~=- ~~::::; ; :/ 1/2in (6 to 13mm)
~ ...!:/;._ _.. 5. Cradle gunand rest hand onworkpiece
- - _ 4
HOLDING AND POSITIONING WELDING TORCH
How to weld gu.. ide
Figure 4. Conditions That Effect Weld Bead Shape
Oncethe archasbeenestablished,maintaining the correctarclength becomesextremely
important. Thearcshould beshort, approximately 1.5- 3.0mmlong. Asthe wire burns off
the wire must befed to the work to maintain correct arc length.
Theeasiestwayto tell whether the archasthe correct length is bylistening to itssound.
A nice, short archasadistinctive, "crackling" sound, very muchlike eggsfrying in a pan.
Theincorrect, long arc hasa hollow, blowing or hissingsound.
TORCH TRAVEL SP EED
No,ma\
,Q,
FILLET WELD ELECTRODE EXTENSIONS (STICKOUT)
ELECTRODE EXTENSIONS (STICKOUT)
l : J
U ~
<;" 1>11 Nnnn.tl Long
TORCH ANGLES AND WELD BEAD P ROFILES
1"-,' ,!i
..9 ~
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_: Gr-~
-
P elpend,ctllni
NOTE: Weld beadshapedependson torch angle, direction of travel, electrode extension
(stickout), travel speed,thicknessof basemetal, wire feed speed& welding current.
CONDITIONS THAT EFFECTWELD BEAD SHAPE
How to weld guide
Figure 6. Poor Weld Bead Characteristics
1. large Spatter Deposits
2. Rough, UnevenBead
3. Slight Crater DuringWelding
4. BadOverlap
5. PoorPenetration
Poor Weld Bead Characteristics
Figure 5. Torch Movement During Welding
The Correct Welding Speed
Theimportant thing to watch while welding isthe puddle of molten metal right behind the
arc. DO NOT watch the arc itself. It isthe appearanceof the puddle andthe ridgewhere
the molten puddle solidifies that indicate correctwelding speed.
Most beginnerstend to weld too fast, resulting in athin, uneven, "wormy" looking bead.
Theyare not watching the molten metal.
IMPORTANT: Forgeneral welding it isnot necessaryto weavethe arc;neither forwards and
backwardsnor sideways.Weld alongat asteadypace.Youwill find it easier.
NOTE: When welding onthin plate, youwill find that youwill haveto increasethewelding
speed,whereaswhen welding on heavyplate, it isnecessaryto go moreslowlyinorder to
get good penetration.
.1
- \._- -
[-aa: '\\)\J\;\)\~i
1. StringerBead- Steady
MovementAlongSeam
2. WeaveBead- Sideto Side
MovementAlongSeam
3. WeavePatterns
Useweavepatternsto cover
awide areain onepassof
the electrode.
NOTE: Normally, asinglestringer beadissatisfactoryfor mostnarrowgrooveweld joints;
however, for wide grooveweld joints or bridging acrossgaps,aweavebead or
multiple stringer beads works better.
TORCH MOVEMENT DURING WELDING
How to weld guide
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Do the following:
1) learn to strike the arc. Besure the angle of the torch is right.
2) When you can strike an arc, practice the correct arc length.
Learn to distinguish it by its sound.
3) When you are surethat you can hold a short, crackling arc, start moving. Look at the molten
puddle constantly, and look for the ridge where the metal solidifies.
4) Run beads on a flat plate. Run them parallel to the top edge (the edge farthest away from
you). This gives you practice in running straight welds. and also, it gives you an easyway
to check your progress the 10th weld will look considerably better than the first weld.
By constantly checking on your mistakes and your progress, welding will soon be a matter
of routine.
Usethe following:
Mild Steel Plate: 2 mm or heavier Current Settings: 4 - 6
Practice Of Welding
The best way of getting practice in the three skills that enable vou to maintain:
1. Correct Welding Position '
2. Correct Way to Strike An Arc
3. Correct Arc Length and Welding Speed
isto spend a little more time on the following exercise.
Figure 6. Good Weld Bead Characteristics
4. No Overlap
5. Good Penetration Into BaseMetal
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I _... _ _ ._ _...... _ _ . _ _.~_ .
Weld a new bead or layer for each 1/8 in (3.2mm)
thickness in metals being welded .
".
' .~.
1. Fine Spatter
2. Uniform Bead
3. Moderate Crater During Welding
Good Weld Bead Characteristics
How to weld guide
Regardless of the type of metal being welded, it is important in order to get aquality weld
that it be free of oil, paint, rust or other contaminants.
Typical applications include plates, axles, connecting rods, shafts, plowshares andscraper
blades. These higher carbon steels can be welded successfully in most cases;however, care
must be taken to follow proper procedures, including preheating the metal to bewelded
and, in some cases,carefully controlling the temperatures during and after the welding
process. For further information on identifying various types of steel and other metals ,and
for proper procedures for welding them, we suggest you seekspecialist advice.
Most metals found around the farm or small shops are low carbon steel, usually referred to
as mild steel. Typical items made with this type of steel include most sheet metal, plate, pipe
and rolled shapes suchas channels, angel irons and "I" beams. This Type of steel can usually
be easily welded without special precautions. Some steel, however, contains higher carbon.
Common Metals
How to weld guide
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4. Unscrew rctclini(HJ knob and rornove It
toqetner with the washer and sprinq from
the s;:',oo!helder
2. Ren~<)/eall clc(essorie~.
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3. When installing the handle, bolt it into place
using the fixings provided
1. To open the side, sin~;)lypush down on the
button, the latch will (lick and open the door.
Quick start up guide
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t o VClt l(,)i posit '(W
6. Rep!;;. cE' i IV; ~"\-. c' : r, siving and knurle-d nut on
top uf t he spool. Ti9ht en svin~1su t hat spool
r:~lnbe rol. d~eclbul not spun.
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7. U''\,\. 'j')cl . ;pproxirh:l~elvlOCl:'~';iI:of \. . . /ire,
S"IIP off t he end of t he wire t oensure i. ! (!c: ,: ]: I
(\!~ds('(t io') wit r-out any bends ()I' bLJ 'T<;
5. P (lCE' \,virp spool on TO i'Foldc'!' (n,ok!~'S' P!; t<; ,: ; 1
t llE~~pOU: is fit :ed \/,. ,it :it he 1 . 1 \. ; ,(: ' \. '\uunci
clockwise so t hat l~~eend of . he wire ali()"~s
t o :hc \vi rp ';'fE"der).
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Quick start up guide
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12. Tl9htE'n slightly th'? wire dr. ve tension
control knob (do not over tiqhten).
11. Ensure the \o\,lire slots into the groove: of the
wire drive roller and replace the wire drive
tens.oner.
10. Pushthe wire SOmm into the torch liner.
9. Open wire drive roller and feed wire through
the alignment tube. across the groove of the
drive roller into the wire liner of the torch.
Quick start up guide
iG. ,:"\,:") ~h' ,.' .." 'I:" (,t,~,~:-,,'. 1"',-,\"" C ,ljj-:;',Iy <v-:e
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:'.:'f~~;'::'~~)I"i. i. i'":t~l.;': ..:d,lll(I! t\l~:l '-~~dlth
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),I~'J (j:::: (,.::I\j,\C T or j'-F" .,..,:0\\lILI.
'14. ::y'lvr: f)r,) (::>kx/.'<, :(:;'1)(".'(.' tI,,~:sbrouc
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15. U",S( .e 'f,,' :1'1~" (~') p fi r- r r,~I(~t I Ii i1 ~'~:-l "c':;'\()'/('.
13. C losethe door by pushingthe button (.10\."";\,
as this will open the latch. Pusht~'ledoor
t.ov\!drds the rtlc1Chi '1(', In(10 of 'iJ "lE ? burton
and1his locke; thf: door iii;:; plf:H~.
Quick start up glJjide
' . r ,
20. Replacethe shroud.
18. When the wire hasfed through, turn off
power, then slidethe MIG tip over the wire
and reconnect onto the torch.
19. Snipthe surplus wire from the end of the
MIG tip leaving approximately 3mm
remaining.
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17. Stretch the torch straight and squeezethe
trigger until the wire appearsfrom the end
of the torch. (If the wire does not appear
checkthe tension onthe wire tension knob
and increaseslightly if necessary).
Note: When welding
itisimportantthatthe
wiredrive motor has
the abilityto beable.
to turn as and when
the weldingwire
becomesobstructed.
Quick start up guide
Before you start welding ensure you have carefully read and understood all the
safety instructions and precautions you must take.
22. Closethe lid by pushing the button
downwards, whichwill openthelatch. Then
pushthe door towards the machineand let
go of the button, asthis will lockthe door
shut.
Z3. The welder isnow readyfor use.
n. Open lid and checkthat the wire istaut.
Quick start up guide
Turn the control knob fully clockwise and
then turn it back anti-clockwise
approximately 1 / 2 to 1turn depending on
welcling conditions.
Connecting the gas tube to the regulator.
Fit the free end of the gas tube into the
connector on the regulator. Then pull the
strap across to hold thecylinder in place.
3. Fitting the requletor to the cylinder. Before 4.
starting ensure that the gas flow valve on
the regulator is turned off. Remove the
cover from the cylinder thread and careiully
screw the regulator on. Gas will escape untit
the regulator is fully fitted. A hi V <'J yS detach
the regulator from the cylinder VI/henyou
have finished ,-,velding.
1. Set the correct polarity ( Red/Positive). 2.
Converting to a gas welder
5. The power output setting is controlled
by the switch on the front panel.
Converting to a gas welder
Corrective Actions
Remove spatter from torch nozzle
Eliminate drafts near welding arc.
Place nozzle 1/4to 1 / 2 in (6-13rnm) from workpiece
Hold gun near bead at end of "veld until molten metal
solidifies.
Use clean,dry welding wire.
Eliminate pick Lipof oil or lubricant on weldmg wire from
feeder or liner.
Remove all grease, oil, moisture, rust, paint, undercoating
and dirt from work surface before welding.
Be sure welding wire extends not more than 1 / 2 in (13mm)
beyond nozzle.
Porosity - small cavities or
holes resulting from gas
pockets in weld metal.
Welding wire extends too
far out of nozzle.
Workpiece dirty.
Dirty welding wire.
Possible Causes
Poor quality mig wire.
Partly blocked torch nozzle.
Being used in too strong
wind conditions.
Remove all grease, oil, moisture, rust, paint. undercoating
and dirt from work surface before welding.
Useclean, dry welding wire.
Eliminate pickup of oil or lubricant on welding wire from
feeder or liner.
Correcti ve Actions
Select lower wire feed speed.
Select lower voltage range.
Useshorter electrode extension (stickout).
ExcessiveSpatter ~
scatter: ng of molten
particles that cool to solid
form near weld bead.
Porosity
Dirty welding wire,
Possible Causes
Wire feed speed too high.
Voltage too high.
Electrode extension
(stickout) too long
Workpiece dirty.
:xcessive Spatter
Welding troubleshooting
<!ri:J '~~I\~
.... :;.:; :,":7.~,~W"a~~l
Increasetravel speed.
Corrective Actions
Select lower power setting and reduce wire feed speed.
ExcessivePenetration - weld
metal melting through base
metal and hanging
underneath weld.
ossible Causes
xcessiveHeat Input.
:XCtlSS1Ve Penetration GoodPenetration
Placestringer bead in proper location(s) at joint during
welding.
Adjust work angle or widen groove to accessbottom
during welding.
Momentarily hold arc on groove side walls when using
weaving technique.
Keep arc leading edge of weld puddle.
Usecorrect torch angle of 0 to 15degrees.
Incomplete Fusion - failure
of weld metal to fuse
completely with basemetal
or a preceeding weld bead.
Corrective Actions
Removeall grease, oil, moisture, rust, paint, undercoating
and dirt from work surface before welding.
Select higher power setting and / or adjust wire feed
speed.
xeesslve Penetration
nproper welding technique
isuffkient heat input.
ossible Causes
J orkpiece dirty.
rcomplete Fusion
Nelding troubleshooting
Corrective Actions
Select lower power setting and reduce wire feed speed.
Increase and / or maintain steady travel speed.
Possible Causes
Excessiveheat input.
Burn-Through - weld metal
melting completely through
base metal resulting in holes
where no metal remains.
Burn Through
Keep an arc on leading edge of weld puddle.
Besurewelding wire extends not more than 1/2in(13mm)
beyond nozzle.
Selecthigher wire feed speed and / or select higher power
setting
Reducetravel speed.
Insufficient heat input.
Possible Causes
Improper weld techniques.
Corrective Actions
Material too thick. J oint preparation and design must
provide accessto bottom of groove while maintaining
proper welding wire extension and arc characteristics.
Corrective Actions
Maintain normal torch angle of 0to 15degrees to achieve
maximum penetration.
Possible Causes
Improper joint preparation.
LackOf Penetration - shallow
fusion between weld metal
and base metal.
Lack Of Penetration
.'I:~,,', 'I'
Welding troubleshooting
Increase travel speed.
Weld in small segments and allow cooling between welds.
Corrective Actions
Use restraint (clamp) to hold base metal in position
Make track welds along joint before starting welding
operation.
Select lower power setting and lor reduce wire feed
speed.
'ossible Causes
xcessive heat input.
. Distortion - contraction of
weld metal during
welding that forces base
metal to move.
)istortion
J nsteady hand.
Corrective Actions
Besurewelding wire extends not more than 1 / 2 i n (13mm)
beyond shroud
Support hand on solid surface or usetwo hands.
'ossible Causes
Velding wire extends too far
.ut of shroud
Waviness of bead - weld
metal that is not parallel
and does not cover joint
formed by base metal.
Vaviness Of Bead
Nelding troubleshooting
Check torch trigger and it's connections.
Thermal overload cut out - allow to cool.
Welder does not operate with trigger pressed.
Check mains connection.
Check supply fuse.
Welder does not operate (mains indicator not lit).
Earth lead or torch cable in open circuit.
Poor earth clamp connection.
Noarc produced.
Welding out put too high.
Torch moved erratically or too slowly.
Burning holes in work piece.
Welding output too low.
Wire feed speed too low.
Torch moved too fast.
Lackof weld penetration.
Torch held too closeto the work piece.
Break in the welding circuit. Possiblecauses:
- Incorrect sizeof contact tip for wire.
- Contact tip damaged - replace.
- Contact tip loose - tighten.
- Feedrollers worn - replace.
- Welding wire corroded - replace.
- Pressureroller adjustment incorrect - adjust.
- Pressureroller sticking -lubricate or replace.
- Wire tangled on reel.
Replace the torch shroud.
Wire repeatedly burns back.
Rust, paint or grease on the work piece.
Torch held too far from the work piece.
Replacethe torch shroud.
Arc unstable, excessivespatter and weld porosity.
Torch moved over the work piece too quickly. Weld deposit incomplete and stringy.
Welding voltage too low.
Torch moved over the work piece too slowly.
Weld deposit too thick.
POSSIBLE CAUSES PROBLEM
Welding troubleshooting
Torch: Regularly clean the contact tip and shroud to remove spatter that will eventually disturb
the gas flow. Spraying the tip and shroud with anti-spatter spraycan reduce the build up of
spatter. Replace the tip periodically to maintain a good electrical contact between the tip
and the wire. Blow clean dry air through the torch liner from time to time to ensure the wire
passesfreely through it. If thishas no effect the liner should be replaced.
NB. Ensurethe torch lead is held in a straight line and fully extended when feeding the wire
through the torch, otherwise there is risk of the wire puncturing the wire feed liner and torch
hose.
Welding Cables: Regularly inspect their connections.
Electrical repairs must only be carried out by aqualified or approved engineer.
Routine maintenance
C E
Signed: 17S~.
M r. Paullppaso
Director
Date:8th J uly 2009
EMC Directive
EN55014-1:2000+A 1+A2
ENS5014-2:1997+A 1
EN61000-3-2:2000+A2
EN61000-3-3:1995+A1 +A2
EN61000-3-11 :2000
2004/108/EC
Complies with the following EEC Directives their supporting Statutory
Instruments and the relevant standard where applicable:
WE
SIP LTD
GELDERS HALL ROAD
SHEPSHED
LOUGHBOROUGH
LEICESTERSHIRE
LE129NH
Declare that the
The Combination Table/Mitre Saw SIP Pt No.04790/04796
DECLARATION OF CONFORMITY