STAYER SUPER PLUS 120 Inverter Welding Machine Instruction Manual

STAYER SUPER PLUS 120 Inverter Welding Machine

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
PROTE PROTECTIVE 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

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.

Read the following manual of instructions carefully before using the welding machine.
The MMA and TIG 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 Adi actinic 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 earth circuits. 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 coated electrodes and TIG with a torch that strikes the arc by contact.

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) Welding current adjustment
D) Display
E) 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; D2:
TIG 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 EN61000-3- 11 (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.

PREPARING THE TIG WELDING CIRCUIT

• Connect the ground lead to the welding machine and the piece to be welded, as close as to the point to be welded.
• Connect the TIG torch power connector to the negative attachment on the welding machine, and mount the electrode. The torch must be fitted with a gas flow adjustment valve.
• Connect the TIG torch gas pipe to the output of the pressure reducer mounted on an ARGON protection gas cylinder.

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.
To strike the welding arc with the TIG torch, make sure the protection gas valve is open. With a rapid, confident move, touch and then take away the electrode point from the piece to be welded.

Heating stop indication
If the warning light is switched on (or see “HEA” in the display), 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.

PROGRESS 1600 Additional instructions.
This equipment has an advanced control panel formed by 8 LEDs, a 3×7 segment display, two buttons and an adjustment knob.
Parameters are selected with the two lower buttons marked with a triangle.
The left button selects the left parameters and the right button selects the right ones.
The selection is made in a circular move, so the selected parameter is indicated by a led light.
The specific value of the parameter is adjusted with the center knob.

Left side controls description
Led Current: When the display is on, it indicates the configured welding amps.
Led Arc Force: Indicates on the display a value from 0 to 10- It is used to adapt the best response depending on the type of electrode.
As a general rule, select low values for rutile electrodes (ex: E6013), average values for basic electrodes (ex: E7018) and high values for cellulosic electrodes (ex: E6011).
Led VRD ON/OFF: For certain jobs, a low voltage for vacuum-brazing process is mandatory. Consult your manager or site manager. If so, turn VRD (voltage reduction device) ON. If not required, it is recommended to keep VRD switched OFF, as the electrode priming will have a superior quality due to the higher no-load voltage.
MMA Led: Indicates equipment configured to weld coated electrodes.

LIFT TIG Led: Indicates that the equipment is set for TIG welding with lift- arc ignition. In order to weld TIG, you will need a system (not supplied along this machine; consult your Stayer supplier) consisting of a TIG torch with a gas regulation valve, a 3/8” DINSE power connection and gas connection suitable for a supply of technical protective gas, normally pure argon. To start the arc is not necessary to scrape (and contaminate the workpiece), simply touch the part with the tungsten electrode and lift 3mm to comfortably start the arc.
Right side settings: Determined by the type of welding process (MMA/TIG) and the electrode to be used. Once those parameters have been selected, a correct range of use is set for any of the three diameter selections. If you need a more delicate adjustment of the welding current, use the central knob.

Specific instructions for the PROGRESS 2021K model.

This equipment has an advanced control panel with 8 LEDs, a 3×7 segment display, two buttons and an adjustment knob. The parameters are selected with the two lower buttons marked with a triangle.
The left button selects the left parameters and the right the thickness of the electrode to be used. The specific value of the parameter is adjusted with the center knob.

Controls description

Hot Start : Indicates on the display the value from 0 to 100. It is used to regulate the ignition current in the arc. Set value 0 when using TIG.
Arc Force : Indicates the value from 0 to 100 on the display. It is used to adjust the best response depending on the type of electrode.
As a general rule, select low values for Rutile-type electrodes. (ej: E6013), medium values for basic electrode (eg E7018) and high values for cellulosic electrodes (eg E6011). Set value 0 when using TIG
VRD On/Off : Press and hold the left button for 2 seconds to change this value.
Low vacuum welding voltage is mandatory for certain jobs. Consult your manager or site manager.
If so, set VRD (Voltage Reduction Device) to ON.
If it is not required, it is recommended to select VRD in OFF since the electrode priming is of superior quality thanks to the higher voltage in no- load.

Led diameters MMA : Selection of the thickness of the electrode to be used and limits the current values, if no LED is on, the current can be selected from 20 to 200 amps.

Using the LIFT TIG

This equipment has a synergic system, it is not necessary to select TIG welding, simply connect a system (not supplied, consult your Stayer dealer) consisting of a TIG torch with gas regulation by valve, 1/2 ”DINSE power connection and gas connection compatible with a supply of technical protective gas, normally pure Argon. To start the arc it is not necessary to scrape (and contaminate the part) simply touch the part with the tungsten electrode and lift 3mm to comfortably start the arc. Take into account leaving Hot Start and Arc Force values at “0”.

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.

Customer Support

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

References

• Inicio - Grupo Stayer
• STAYER - Herramientas y maquinaria diseñadas para profesionales

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