STAYER MINIPRO 100 Gama Plus Instruction Manual

: June 10, 2024
: STAYER

Table of Contents

TECHNICAL DATA
USER’S MANUAL
SAFETY WARNING
DESCRIPTION OF THE WELDING MACHINE
STARTING UP
WELDING PROCESS: DESCRIPTION OF CONTROLS AND SIGNALS
RECOMMENDATIONS FOR USE
MAINTENANCE
WARRANTY GENERAL CONDITIONS
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

MINIPRO 100
Operating instructions

Área Empresarial Andalucía – Sector I
Calle Sierra de Cazorla nº7
C.P: 28320 Pinto (Madrid) SPAIN
[email protected]
www.grupostayer.com

TECHNICAL DATA

| | MINIPRO 100
---|---|---
U1| Vrms| 230
I1max| Arms| 20.4
I1eff| Arms| 10.3
I2| Arms| 100
DUTY IEC 60974-1| %| 25
MASS| Kg| 2.5
DIMENSIONS| cm| 23 X 15.5 X 9
GENERATOR| KVA| 03-Apr

STAYER MINIPRO 100 Gama Plus - overview 1

STAYER MINIPRO 100 Gama Plus - overview 2

Declaration of Conformity
I declare under our responsibility that the product described under “Technical Data” is in accordance with the following standards or standardized documents: EN 60974-1, EN 60974-10, according to regulations 2014/35/EU, 2014/30/EU, 2011/65/UE.

Área Empresarial Andalucía – Sector 1
C/ Sierra de Cazorla, 7
28320 – Pinto (Madrid) SPAIN
Email: [email protected]
Email: [email protected]

Director Manager
2022

KEY TO DANGER, MANDATORY AND PROHIBITION SIGNS

| GENERAL DANGER
---|---
| DANGER OF ELECTRIC SHOCK
| DANGER OF WELDING FUMES
| DANGER OF ULTRA VIOLET RADIATION
| DANGER OF BURNING SPLASHES
| DANGER OF FIRE
| DANGER OF EXPLOSION
| DANGER OF CRUSHING HANDS IN GEARS
| DANGER OF NON-IONIZING RADIATION
| DANGER OF STRONG MAGNETIC FIELD
| DANGER OF BURNS
| BREATHING APPARATUS PROTECTION MUST BE WORN
| PROTEPROTECTIVE MASKS MUST BE WORN
| PROTECTIVE GLOVES MUST BE WORN
| PROTECTIVE GOGGLES MUST BE WORN
| PROTECTIVE CLOTHING MUST BE WORN
| ENTRY NOT PERMITTED TO PERSONS FITTED WITH PACEMAKER

Electrical and electronic equipment disposal: Symbol indicating separate collection for waste of electrical and electronic equipment. When the end-user wishes to discard this product, it must not be disposed of as (unsorted) mixed municipal solid waste but sent to duly authorised collection facilities according the European Guideline 2012/19/CE

USER’S MANUAL

Read the following manual of instructions carefully before using the welding machine.
The MMA coated electrode arc welding systems referred herein as “welding machines” are meant to be used only for industrial and professional use.
Make sure the welding machine is installed and repaired only by a qualified person or experts, in compliance with the law and the accident prevention regulations.
Make sure the operator is appropriately trained in the use and risks related to the arc-welding processes, and in the required measures of protection and emergency procedures.
More detailed information can be found in the “Installation and use or arc- welding equipment” brochure EN 6094-9.

SAFETY WARNING

Make sure the power socket the welding machine is connected to, is protected by suitable safety devices (fuses or an automatic switch) and grounded.
Make sure the plug and power cable are both in good condition.
Before plugging into the power socket, make sure the welding machine is switched off.
Switch the welding machine off and pull the plug out of the power socket before connecting the welding cables, replacing any parts in the torch or wire feeder, carrying out maintenance operations, or moving it (always use the carrying handle of the welding machine).
Do not touch any live part with bare skin or while wearing wet clothing. Appropriately insulate yourself from the electrode, the piece to be welded and any grounded accessible metal components. Make sure you use gloves, footwear and clothing especially designed for this purpose, and dry, non-flammable insulating mats.
Use the welding machine in a dry and well-ventilated space. Do not expose the welding machine to rain or direct sunshine.
Use the welding machine only if all panels and guards are mounted and placed correctly.
Do not use the welding machine if it has been dropped or struck, as it may not be safe. Make sure it is periodically checked by a qualified person or an expert.
Eliminate any welding fumes through appropriate natural ventilation or by using a smoke exhauster. A systematic approach must be used to asses the limits of exposure to welding fumes, depending on their composition, concentration and the length of exposure.
Do not weld materials that have been cleaned with chloride solvents or that have been near such substances.
Use a welding mask with adiactinic glass suited for welding. Replace the mask if damaged; it may let the radiation in.
Wear fireproof loves, footwear and clothing to protect the skin from the radiation produced by the welding arc and from sparks. Do not wear greasy garments because a spark could set a fire. Use protective screens to protect people nearby.
Hot metal parts, electrode holder grippers, electrode stubs and freshly welded pieces must not come into contact with bare skin.
Metal-working produces sparks and splinters. The user must wear safety goggles with protective side-eye guards.
Welding sparks can set a fire.
Do not weld nor cut anywhere near inflammable materials, gasses or vapors.
Do not weld nor cut containers, cylinders, tanks or piping, unless a qualified technician or expert has previously checked if it is possible to do so, or they have already made the appropriate preparations before the weld.
Remove the electrode from the electrode holder gripper when you have completed the welding operations. Make sure that no part of the electrode holder gripper electric circuit touches the ground or earthcircuits. An accidental contact could cause overheating or fires

EMF Electromagnetic Fields.
Welding current creates electromagnetic fields (EMF) near the welding circuits and the welder. Electromagnetic fields may interfere with medical prostheses such as pacemakers.
Suitable and enough measures should be implemented in order to protect those operators that suffer from those medical issues. For instance, they should not be allowed to enter the area where a welding equipment is being used. Any operator with health issues should consult their doctor before getting close to those welding areas.
This device meets the specific requirements for the technical standards of the product and is intended for a professional use only in an industrial environment. It is not safe to weld at home, as electromagnetic fields will probably affect those exposed to the process.
Follow these strategies to minimize the exposure to electromagnetic fields (EMF):

Do not place your body between the welding cables. Both welding cables must be on the same side and apart from your body.
Twist both welding cables together and secure them with tape when possible.
Do not wrap the welding cables around your body.
Connect the earth cable to the workpiece as close as possible to the area to be welded.
Keep your head and body as far as possible from the welding circuit. Do not work close to the welder, nor seated or leaning on it. Keep a minimum distance: Fig 5 Da = cm 50; Db = cm 20.

Class A equipment
This equipment has been designed to be used only in professional and industrial environments.
If this equipment is used in domestic environments, and those are directly connected to a low voltage power supply network, which supplies buildings for domestic purposes, it may be difficult to ensure an appropriate electromagnetic compatibility as the result of conducted or radiated disturbances.

Welding in conditions of risk

If welding needs to be done in conditions of risk (electric discharges, suffocation, in presence of inflammable or explosive materials), make sure an authorized expert previously evaluates the conditions. Make sure an expert or a trained person so they may intervene in case of emergency. Use the protective equipment described in normative of EN 60974-9.
If you are required to work higher than the ground level, always use a safety platform.
If more than one welding machine need to be working on the same piece, or maybe electrically connected pieces, the sum of the no-load voltages on the electrode holders or on the torches, may exceed the safety levels.

Make sure an authorized expert previously evaluates the working conditions to see if that risk may appear in order to adopt the appropriate protective measures described in ‘Necessary regulations.

Additional warnings.

Do not use the welding machines for purposes other than those that do not belong to its function, for example, to thaw frozen water pipes.
Place the welding machine on a flat and suitable surface, and make sure it can not move.
It must be positioned in such a way as to allow it to be controlled during its use, but without the risk of being covered with welding sparks.
Do not work with the welding machine hung from its body, use the straps or any other suitable device for that purpose.
Do not lift the welding machine. There are no lifting devices in the equipment.
Do not use cables with damaged insulation or loose connection.

DESCRIPTION OF THE WELDING MACHINE

The welding machine is a high-frequency current transformer for manual arc welding, using MMA.
This welding machine has been developed by the use of the electronic INVERTER technology.
The machine delivers a constant current.
The electrical characteristic of the transformer is that it lowers the voltage.
This manual refers to a range of welding machines that differ in some of their characteristics.
Identify your model in Fig. 1.

Main parts Fig. 1
A) Power cable
B) ON/OFF switch
C) Indicator light on.
D) Welding current adjustment
E) Thermal cooling pause indicator light.
F) Display
G) Couplings for welding cables

Technical data
A data plate is affixed to the welding machine. Fig. 2 shows an example of this plate
A) Manufacturer name and address.
B) European standard reference for the construction and safety of the welding equipment.
C) Symbol of the welding machine internal structure.
D) Symbol of the foreseen welding process: D1: MMA welding.
E) Symbol of the continuous current delivered.
F) Input power required:
1” alternate single-phase voltage, frequency: F1: from electrical power supply; F2: from motor generator.
G) Level of protection from solids and liquids.
H) A symbol indicating the possibility of using the welding machine in environments potentially subjected to electric discharges.
I) Welding circuit performance. UoV Minimum and maximum open circuit voltage (open welding circuit) I2, U2 Current and delivered corresponding normalized voltage distributed around the welding machine. X Duty cycle. Indicates how long the welding machine can work for, and how long it must rest in order to cool down. The time is expressed in % on the basis of a 10-minute cycle (e.g. 60% means 6 min. work and 4 min. rest) A/V Current adjustment area and corresponding arc voltage.
J) Power supply data. U1 Input voltage (allowed tolerance: +/- 10%) I1 eff Effective absorbed current. I1 max Maximum absorbed current.
K) Serial number.
L) Weight.
M) Safety symbols: Refer to Safety Warnings.

STARTING UP

The installation of the necessary electrical mains supply must be done according to national and international legal conformities.
Connections to the mains must be made by an expert or a qualified person.
Before to start make sure that electrical supply installation is made according to points 1 and 2 and is in perfect state.
Make sure the welding machine is switched off and the plug is not connected to the power socket before carrying out this procedure.
The device must be only connected to a supply system, with an earthed ‘neutral’ lead.
Always visually check or make check by a qualified technician that as minimum machine has earth connection is connected through a differential switch (30 mA 30ms trip) and a magneto thermal switch with class C tripping and a minimum recommended amperage of 32 amperes. If, for example, you connect to a minor amperage (say 10 amperes, for example) switch they can trip if the adjust of power is high. This is not a machine’s problem is a not correct capacity of the electrical installation for the welding machine.
Avoid, if possible, extension cords. If you must please use it as short as possible and as high conductor area as possible. For avoiding extra loses don’t roll the extension cord in your axle. Minimum section allowable is 2.5mm2, recommended is 4mm2. Don’t use cheap 1.5mm2 extension cords !!.

ASSEMBLY AND ELECTRICAL CONNECTIONS
Check that the electrical supply delivers the corresponding voltage and frequency to the welding machine, and make sure it is fitted with a delayed fuse suited to the maximum delivered rated current (I2max). Fig. 3,1.
The requirements set out in the IEC/EN61000-3-12 standard, do not apply to this equipment. If this equipment is connected to a low voltage power supply network, either the installer or the user are responsible for checking that this can be done (consult the distribution system operator if required).
In order to comply with the requirements, set out in the EN61000-311 (Flicker) standard, it is recommended to connect the welder to the supply network interface points, having a lower impedance than the reference Zmax = Fig. 3,4.
To comply with the requirements of the EN61000-3-12 standard, the welding machine must be connected to the interface points of the power supply network that present a short-circuit power equal to or greater than 8062 kW. Plug. If the welding machine is not fitted with a plug, fit a normalized plug (2P+T for 1Ph) of a suitable capacity for the power cable Fig. 3,2.

CONNECTION TO MOTOR GENERATORS
Some welding machines may be powered by a motor generator.
Make sure this has a power of at least 6 kVA, and does not deliver voltage higher than 270V.

PREPARING THE WELDING CIRCUIT MMA
Connect the ground lead to the welding machine and the piece to be welded, as close as possible to the point to be welded.
Connect the cable with the electrode holder gripper to the welding machine, and mount the electrode on the gripper.
In welding machines that deliver direct current, most of the electrodes are connected to the positive attachment.
Refer to the electrode manufacturer’s instructions, concerning the connection and the welding current.

WELDING PROCESS: DESCRIPTION OF CONTROLS AND SIGNALS

Once you have put the welding machine into operation, switch it on and apply the required adjustments.

Adjusting the welding current
Select the welding current depending on the electrode type, joint and welding position.
Indicatively, the different currents to be used with the different electrode diameters, are listed in Fig. 4.
To strike the welding arc with the coated electrode, brush it onto the piece to be welded and, as soon as the arc is struck, constantly hold it at a distance equal to the electrode diameter and at an angle of approximately 20º – 30º in the direction in which you are welding.

Heating stop indication
If the warning light is switched on (E), means that the thermal protection is already on.
If the duty cycle “X” shown on the data plate is exceeded, a thermal cutout stops the machine before any damage is caused. Wait for the operation to be restored and, if possible, wait for a few minutes more until the gear factor is complied.
If the thermal protection is continuously on, means that the machine is overworking.

“Hot start”
The welding machine is fitted with an automatic device that facilitates the striking of the arc, increasing the current only at that very moment.

“Antisticking”
The welding machine is fitted with an automatic device that interrupts the current for a few seconds after having detected that the electrode has tuck to the piece to be welded. By doing so, the electrode will not overheat.

RECOMMENDATIONS FOR USE

Only use an electrical extension cord when absolutely necessary, and providing it has an equal or larger section to the power cable and is fitted with a grounding conductor.
Do not block the welder air intakes. Do not store the welder in containers or on shelving that does not guarantee a suitable ventilation.
Do not use the welder in any environment where in presence of gas, vapors, conductive powders (e.g: iron shavings), brackish air, caustic fumes or other agents that could damage the metal parts and the electrical insulation.
The electric parts of the welder have been treated with protective resins. When used for the first time, smoke may be noticed; this is caused by the resin drying out completely.
The smoke should only last for a few minutes.

MAINTENANCE

Switch off the welder and remove the plug from the power socket before carrying out any maintenance operation.
Extraordinary maintenance of the machine must be periodically carried out by expert staff or qualified electrical mechanics, depending on the use.

Inspect the inside of the welder and remove any deposited dust on the electrical parts (by using compressed air), and in the electronic cards (using a very soft brush and appropriate cleaning products).
Check that the electrical connections are tight and the insulation on the wiring is not damaged.

WARRANTY GENERAL CONDITIONS

In STAYER IBERICA S.A. (from now on “STAYER”), strict control processes are conducted to comply with the security and quality required.
To understand the application area of this text, we differentiate the following users:
– Users or consumers, as private individuals whose acts are not related to their main comercial, business activity or their main profession or trade. Legal persons and entities without legal personality which act with non-profit means in an unrelated comercial or corporate enviroment.
– Professionals, whom obtain comercial, business or working profits by using any STAYER product. STAYER offers a guarantee for all of its power tools, garden tools and welding tools, subject to the following conditions:

STAYER offers a 36 month guarantee against manufacturing defects or consistency issues, bearing in mind that any issue must be easily visible or provable, as the product will be tested at our labs to verify said issues. If the product has been subjected to industrial or professional use, said guarantee will cover exclusively 12 months since the first buyer aquired the product.
The following cases are exempt from the guarantee:
a. Any kind of defect or malfunctioning caused by not applying the safety and maintenance instructions given in the User’s guide.
b. Any damage caused by using other brand’s accessories, incompatible accessories with the tool model or faulty accessories.
c. Any manipulation, modification or repair conducted by staff unrelated to STAYER or its associated Technical Support Services.
d. Products with minimal deviations from the features that do not impact on the tool’s optimal performance and its value.
e. Products which have been connected to a different voltage tenssion grid than the one stated on the tool’s features, causing an electrical failure.
f. Products or components which have suffered wear due to the normal use of the tool, being said components consumables, accessories or components subject to wear that must be replaced by the owner.
g. Products that show any kind of misuse or application which deviates from its original intended uses, listed in the Users guide.
h. Products that show lack of correct maintenance from the owner. The owner is responsible for the tool’s maintenance in order to preserve its service life.
i. Accessories and tool consumables, as their intended use has a limited service life that includes wear.
In order to claim the guarantee rights, the tool owner must first fill the repair order either digitally or physically, and process it with the tool’s vendor or the Authorized Technical Support Services before shipping the tool. A copy of the purchase receipt or invoice must be attached to the form where the purchase date can clearly be seen. Shipping costs are not included if the product is delivered to the vendor or the Technical Support Services without processing the repair form first.
If the Authorized Technical Support or STAYER is unable to locate the defect or issue, STAYER will not assume the shipping costs, nor the costs derived from testing the tool to locate the issue.
Guarantee transfer is completely forbidden, the guarantee does not cover second-hand products.
During the guarantee application due to manufacturing defects or consistency issues, the product will remain under STAYER’s custody in its facilities or its Authorized Technical Support Services. During this period of time the tool’s owner is not entitled to receive a substitution tool in place of the product that is being repaired.
In order to correct the manufacturing defects or consistency issues contemplated in the guarantee terms, STAYER will only repair or substitute all the necessary components free of charge in order for the tool to perform according to the quality and safety standards. STAYER withholds the right to substitute the product for a similar one in cases where reparations would not be possible.