STAYER PLUS 120CGE Welding Machine Instruction Manual

PLUS 120CGE Welding Machine

Product Information

The product is a range of welding machines from STAYER, including PLUS120CGE, 140BGE, 160BGE, PLUS200DIG GE, PROGRESS 1500, 1700L, 1700XP, 2000, 1700PFC GE, 2100PFC GE, 200 PULSED, S100.20 / S250DV / S400T, POTENZA160GE DEFENDER160GE, POTENZA200GE DEFENDER200GE, POTENZA200 CEL GE. The machines have different technical specifications such as voltage, current, power consumption, weight, and dimensions. The machines are compliant with various European Union regulations and standards such as EN60974-1 and EN60974-10.

Product Usage Instructions

The usage instructions for each welding machine may vary. It is recommended to refer to the user manual provided with each product for specific usage instructions. However, some general guidelines are:

• Ensure that the machine is connected to the appropriate power supply as per the technical specifications mentioned in the user manual.
• Make sure that the machine is properly grounded before use.
• Use appropriate personal protective equipment such as gloves and goggles while welding.
• Adjust the current and voltage settings as per the requirement of the welding job.
• Ensure proper ventilation in the workspace to avoid inhaling harmful fumes generated during welding.
• After use, turn off the machine and disconnect it from the power supply.

It is important to follow all safety precautions and guidelines mentioned in the user manual for safe and efficient usage of the welding machines.

EQUIPMENT DESCRIPTION

The present product is a manual metal-welding equipment by means of heat produced by an electric arc.
Technologically, the STAYER WELDING equipment is an electrical power supply source for welding through the transference of high-frequency power managed by smart control logic and the improvement of the welding.
Compared to the traditional technology, based on transformers operating at the 50Hz public grid frequency, the STAYER WELDING Inverter technology presents a higher power density per weight unit, an increased power saving and the possibility of an automatic, precise and instantaneous control of all welding parameters.
As a result, you will easily produce a better weld with lower-consumption and a weightless equipment compared to the equivalent traditional ones based on heavy transformers.
All series of MMA STAYER WELDING equipment are suitable for coated electrode welding and tungsten electrode torch welding with inert gas protection.
Fig 1, 2, and 8.

1. On-off switch
2. Power indicator light
3. Thermal cooling pause indicator light
4. Welding intensity adjustment control
5. Connection terminals of the welding cords
6. Power supply cord and plug of the equipment (model depends on the country)
7. Electrode / TIG mode commuter (only PROGRESS1700L / 1700PFC / 2100PFC models)
8. Welding amperage (A) indicator display
9. Arc Force Regulator (PROGRESS1700PFC / 20100PFC)

Fig 3.

1. Positive welding output borne (+) Plug the working cable to the welding positive output terminal
2. Negative welding output borne (-) Plug the TIG torch to the welding output borne (-)
3. Gas cylinder
4. Cylinder Valve: slightly open the valve for the gas to flow and blow the dirt of it. Close the valve
5. Regulator / Flowmeter
6. Flow adjustment: the typical flow rate is 7,1L/min (15 cubic feet per hour). Plug the torch gas hose to the regulator /flowmeter
7. Gas Valve: The valve placed in the handle controls the gas pre-flow and post-flow. Open the valve on the torch itself right before welding and close it right after it.

Fig 4, 8.

1. Negative welding output borne (-). Plug the working cable to the welding negative output borne.
2. Positive welding output borne (+). Plug the electrode holder to the welding positive output borne.

Fig. 5 – S100.25B Series:

1. Indicator Display
2. Hot Start regulation
3. Arc Force regulation
4. Amperage regulation
5. Power indicator light
6. Alarm and thermal rest indicator light

Figs 9,10

1. Output amperes adjustment
2. ‘Arc Force’ adjustment
3. MMA / TIG Lift Arc selector
4. VRD On/Off selector
5.  Thermal pause indicator
6. GRID / GENERATOR power supply origin selector
7. ‘Hot Start’ adjustment
8. Menu selector button
9. Value increase button
10. Value drop button

Fig. 11

1. Rotary encoder with push button for the parameters’ selec-tion and adjustment
2. Push button’s no-load output voltage reducing device
3. Push button for normal or pulsed welding
4. Selection indicator for peak current adjustment
5. Selection indicator for base current adjustment
6. Selection indicator for peak-over-base percentage adjustment
7. Selection indicator for pulse frequency adjustment
8. Thermal pause by duty cycle indicator
9. ‘ARC FORCE’ adjustment potentiometer

EXPLANATION OF THE NORMATIVE MARKING

1

2| 3
4| 5

6

|

8

| 10
---|---|---
11| 11a| 11b| 11c

7

|

9

| 12| 12a| 12b| 12c
13| 13a| 13b| 13c
14| 15| 16| 17
---|---|---|---
18|

• Pos. 1 – Name, address and the brand manufacturer, supplier or importer.
• Pos. 2 – Identification of the model
• Pos. 3 – Model traceability
• Pos. 4 – Welding power source symbol
• Pos. 5 – Equipment complied regulations reference
• Pos. 6 – Welding process symbol
• Pos. 7 – Symbol of usage in electric shock increased risk environments
• Pos. 8 – Welding current symbol
• Pos. 9 – Nominal no-load voltage
• Pos. 10 – Voltage range and nominal output current
• Pos. 11 – Power source duty cycle
• Pos. 11a – 45% Duty cycle
• Pos. 11b – 60% Duty cycle
• Pos. 11c – 100% Duty cycle
• Pos. 12 – Nominal cutting current (I2)
• Pos. 12a – Current value for a 45% duty cycle
• Pos. 12b – Current value for a 60% duty cycle Pos. 12c – Current value for a 100%
• Pos. 13 – Load voltage (U2)
• Pos. 13a – Voltage value for a 45% duty cycle Pos. 13b – Voltage value for a 60% duty cycle Pos. 13c – Voltage value for a 100% duty cycle Pos. 14 – Power supply symbol
• Pos. 15 – Power supply current nominal value Pos. 16- Maximum nominal power supply current Pos. 17- Maximum effective power supply current Pos. 18 – IP protection grade

SAFETY INSTRUCTIONS

CAREFULLY READ THE FOLLOWING INSTRUCTIONS.

• Make sure you read and understand the user’s manual before using or operating the equipment.
• Only use the genuine components of the manufacturer.

SYMBOL USAGE
DANGER! – Indicates a hazardous situation that, if not avoided, will result in serious injury or death. The possible dangers are shown in the attached symbols or explained in the text.
Indicates a hazardous situation that, if not avoided, may result in serious injury or death. The possible dangers are explained in the text.

ARC WELDING DANGER
Only qualified users should install, operate, maintain and repair this unit.
While operating, it must be kept away from people, specially kids.

An ELECTRIC SHOCK can kill you.
Touching electric live-load pieces may cause severe burns or a fatal electric shock. The electrode and work circuit become ‘electrically hot’ whenever the machine output is on. Both the output and the internal circuits are also ‘electrically hot’ when the machine is on. While welding with automatic and semiautomatic equipment, the wire, coil, the chassis that holds the feed rollers and all the metal pieces touching the welding wire, are ‘electrically hot’.
An incorrectly installed equipment or one without a proper grounding connection is a very serious danger.

• Do not touch ‘electrically hot’ pieces.
• Use dry and well-insulated gloves with no gaps and whole-body protection.
• You must isolate yourself from the work and the ground contact by using carpets or big enough covers, made of non-conductive materials in order to prevent any kind of physical contact with them.
• Do not use the alternate current output in humid areas, when restricted motion, or if there is a fall risk.
• Use CA output ONLY if the welding procedure requires it.
• If the CA is required, use a remote control if available in your unit.
• Additional safety precautions are required when any of the following dangerous electric conditions are present: in humid places or while wearing wet clothes; in metal structures such as floor, grids or scaffoldings; when the user is in tight positions as seated, kneeled, lying down or when there is a high risk of having an unavoidable or accidental contact with the ground or workpiece.
• Cut the input power or completely stop the unit before installing or servicing it.
• Properly install and connect the unit to the ground according to the manual and the national, state and local codes.
• Always verify the ground supply. Check and make sure the power supply input ground wire is properly plugged to the disconnection box ground terminal, or its plug is appropriately connected to the ground-plugged output receptacle. While plugging output connections, firstly plug the ground conductor and double check its connections.
• Keep the seams and wires dry with no oil or grease stains. Protect them from hot metal and sparks.
• Frequently inspect the current seam output for damages or bare wire. Immediately replace the seam if it is damaged – A bare wire could kill you.
• Turn off the equipment if it is not being used.
• Do not use wasted, damaged, small-sized or bad connected cables.
• Do not wrap your body with the cables.
• If an earth clamp is needed at work, make the grounding connection with a separated cable.
• Do not touch the electrode if you are already touching the grounding circuit, work circuit or another electrode from a different equipment.
• Do not bring two electrode holders together while being connected to different units at the same time or there will be a double current open circuit.
• Use a well-maintained equipment. Repair or replace all the damaged pieces. Maintain the unit according to the manual.
• Use safety straps to prevent the machine from falling if you are working higher than the floor height.
• Keep all the panels and covers on their place.
• Put the clamp of the working cable with a good metal-to-metal contact to the working cable or the work itself, close to the weld for it to be practical.
• Save or isolate the clamp when it is not connected to the working place so there will be no contact with any metal or any other ground object.
• Isolate the grounding clamp when is not connected to the working piece in order to avoid contact with any metal object.

HOT COMPONENTS can cause severe burns

• Do not touch hot components with bare hands. Use adequate gloves.
• Allow some time for the equipment to cool itself before using it again.
• To operate with hot components, use appropriate tools and use welding-isolated heavy gloves and adequate clothes to prevent burns.

SMOKE and GAS can be dangerous
Welding produces smoke and gas. Breathing those can be dangerous for your health.

• Keep your head out of the smoke. Do not breath it.
• If you are indoors, make sure you ventilate the area and use forced local ventilation before the arc to take the welding smoke and gas away.
• If the ventilation is bad, use an approved air respirator.
• Make sure you READ and UNDERSTAND all the Material Safety Data Sheets (MSDS’s) and the manufacturer instructions about metals, consumables, coatings, cleaners and degreasers.
• Work indoors ONLY if there is a proper ventilation or there is a working air respirator. Always be next to a well-trained person. Welding smoke and gas may move the air and decrease the oxygen level, causing health damage or even death. Make sure the air you breathe is safe.
• Do not weld in environments close to grease, cleansing or jet painting operations. The heat and the arc rays can make a reaction with the vapor and create highly toxic and irritating gas.
• Do not weld on coating materials like galvanized steel, lead or cadmium coated steel unless the coating is removed from the welding area, the area has a proper ventilation and there is a working respirator with air source. Coatings can be made of any metal that contain these elements that can emanate toxic smoke when welded.

ARC RAYS can burn your eyes and skin.
Arc rays from a welding process produce an intense heat and strong UV rays that can burn the eyes and skin.

• Use the approved welding mask that has an appropriate trace of lens-filter to protect your face and eyes while welding or observing. Look at the safety standards ANSI Z49.1, Z87.1, EN175 and EN379.
• Use approved safety lenses that have side protection.
• Use protection screens or barriers to protect others from reflections and sparks. Tell others not to look at the arc.
• Use protective clothes made of a durable and flame-resistant material (leather, thick cotton or wool), and feet protection.

WELDING can produce fire or explosion
Welding inside empty places, such as tanks, drums or tubes, may cause explosion. Sparkles can go all around the place from the welding arc. The sparkles, hot working piece and equipment, may cause fires and burns. An accidental contact of the electrode with metal objects can cause sparkles, overheating, explosion or fire. Check and make sure the area is safe before starting any kind of weld.

• Remove all the inflammable material in a 11-meter (35.09ft) area from the welding arc. If not possible, make sure it is tightly covered with proper covers.
• Do not weld where welding sparkles may impact any kind of inflammable material. Protect yourself and others from the sparkles and hot metal.
• Be aware of that the welding sparkles and hot materials may go through small cracks or holes in adjacent areas.
• Make sure there is no flame around and always keep a fire extinguisher near you.
• Be aware of that, while welding the roof, floor, wall or any kind of separation, heat may cause fire in non-seen hidden parts.
• Do not weld on closed receptacles such as tanks, drums or tubes, unless they have already been prepared for that according to the AWS F4.1 .
• Do not weld where there is inflammable dust, gas or liquid vapor (as gasoline) present in the working atmosphere.
• Connect the working cable to the working area as close as possible to the place where welding will take place. That will prevent the welding current from going inside unknown parts causing an electric shock, sparkles and risk of fire.
• Never use a welding unit in order to unfreeze frozen tubes.
• Remove the electrode from the electrode holder or cut the welding wire near the contact tube when not in use.
• Use protective non-greasy clothes like leather gloves, heavy shirt, loose and sealed trousers, high shoes or boots and a hat.
• Take away from you all kind of combustibles, like butane lighters or matchers, before welding.
• After finishing working, inspect the area and make sure there are no sparkles, flames or embers.
• Only use appropriate breakers and fuses. Do not use a bigger size or try to pass them through one side.
• Follow the OSHA1710.252 (a) (2) (iv) and NFPA51B regulations for hot working. Also, keep a fire extinguisher near as well as a person able to take control of it.

METAL OR DIRT IN THE AIR can hurt your eyes

• Welding, wire-brushing, chipping or grinding could cause sparkles and flying metal pieces. Whenever the welds are cold, these could produce some dirt.
• Use approved safety glasses with side safeguards even under your mask.

GAS CONCENTRATION can cause you illness or kill you

• Close the protective gas when not in use
• Always make sure there is an appropriate ventilation indoors or an approved respirator that replaces the air.

MAGNETIC FIELDS may affect implemented medical equipment.

• People who use cardiac pacemakers and other implemented medical units should stay away.
• People who use implemented medical units should ask their doctor and the equipment manufacturer before getting close to an arc welding, point welding, plasma cutting or induction heating procedures.

NOISE can damage your ears

• Some procedures or equipment noises can damage your ear.
• Use approved protection for your ears if the noise level is very high or higher than 75 dBa

CYLINDERS may burst if they are damaged
Cylinders that contain protective gas, have it contained under high pressure. If they are damaged, the cylinders may explode. As they are usually a part of the welding process, always treat them carefully.

• Protect the compressed air cylinders from the excessive heat, mechanic shocks, physical hurt, dirt, flames, sparkles and arcs.
• Install and secure the cylinders in a vertical position, securing them to a stationary support or a cylinder holder in order to prevent them from falling or collapsing.
• Keep the cylinders away from the welding and electric circuits.
• Never wrap the gas cylinder with the welding torch.
• Never allow a welding electrode to make contact with any cylinder.
• Never weld a pressure cylinder: an explosion will occur.
• Only use the correct protective gas as well as regulators, hoses and designed connections for the specific application; keep them, like the rest of components, in a good condition.
• Always keep your face away from the output valve while operating the cylinder valve.
• Keep the protective cover on its place on the valve except when the cylinder is in use or connected to be used.
• Use the right equipment and procedures, and enough people to lift and move the cylinders.
• Read and follow the compressed air cylinders instructions, associated equipment and the Compressed Gas Air (CGA) P-1, along with the local regulations.

Danger of FIRE OR EXPLOSION

• Do not place the unit on, above or near combustible surfaces.
• Do not install the unit near inflammable objects.
• Do not overcharge your building wires – make sure your power supply is appropriate in height and capacity, plus protected to achieve this unit necessities.

A FALLING EQUIPMENT may cause injuries

• In heavy equipment only use the appropriate way to lift it, never doing it from the chassis, gas cylinders or any other accessories.
• Use an adequate capacity equipment to lift the unit.
• If you use a forklift to move the unit, make sure its corners are long enough to extend beyond the opposite side of the unit.

OVERUSE can cause EQUIPMENT OVERHEATING

• Allow a cooling period. Continue the nominal work cycle.
• Reduce the current or working cycle before welding again.
• Do not block or filter the unit air flow.

FLYING SPARKLES can cause injuries

• Use a safeguard for the face and eyes protection.
• Give form to a tungsten electrode in a grinder only with the appropriate safeguards in a safe ubication. Use the necessary protection for your face, hands and body.
• Sparkles can cause fire – keep the inflammables away..

WELDING WIRE can cause injuries

• Stay away from every moving part, as fans.
• Keep all the tables, panels, covers and safety guards kept in their places.
• Let only qualified people remove the doors, panels, covers or safeguards, and give them as much maintenance as necessary.
• Reinstall doors, covers or safeguards once the maintenance is over and always before the input power reconnection.

HIGH-FREQUENCY RADIATION can cause interference

• High-frequency (H.F.) radiation may interfere with the radio navigation, safety services, computers and communication equipment.
• Make sure only qualified people, familiarized with electronic equipment, install the equipment.
• The user is responsible for having a qualified electrician near, able to quickly correct any kind of problem caused by the installation.
• Make sure the installation receives a regular check and maintenance.
• Keep the high-frequency source doors and panels completely closed. Keep the distance from the sparkle on the platins on its correct fixing. Make sure you make earth connection and protect it against current.

ARC WELDING can cause interference

• The electromagnetic energy can interfere with sensitive electronic equipment such as computers or computer-impulse equipment, as industrial robots.
• Make sure all the equipment in the welding area are electromagnetically compatible.
• To reduce the possible interference, keep the welding cables as short and near as possible, or directly on the ground, if viable.
• Operate your weld at, at least, 100m away from any kind of electronically sensitive equipment.
• Make sure the welding unit is installed and earth-connected according to this manual.
• If the interference still occurs, the operator must use extra measurements as moving the welding equipment, using armoured cables and line filters, or shielding the working area.

EMF INFORMATION

To reduce the electromagnetic fields (EMF) in the working area, follow the next procedures:

1. 1. Keep the cables as close as possible, twisting or wrapping them with sticky tape. You can also use a cable cover.
   2. Place the cables aside, far from the operator.

2. 3. Do not hang or wrap the cables on your body.
   4. Keep the welding power sources and cables as far as practical.
   5. Plug the clamp (earth clamp) to the piece you are working with as close to the welding as possible.

Precaution: In locations with an increased risk of shock and fire, as in closeness to inflammable products, explosives, height, restricted freedom of movement, physical contact with conductive parts, warm and humid environments that reduce the electric resistance of the human skin and equipment, you should pay attention to the occupational risks preventions and the national and international dispositions that may correspond.

COMMISSIONING INSTRUCTIONS

COLOCATION
The machine must be placed in a dry and ventilated area with at least 15cm of separation with any wall. The equipment may slip if it is supported on surfaces with more than a 3º inclination, so it MUST be on a flat and dry surface. For a higher slope surface, please, secure the machine with chains or belts.

ASSEMBLY
The environmental limits of the equipment must be respected in order to be assembled, as well as finding the adequate placement.
The equipment shall be installed according to the indicated requirements in the technical plate of the unit.

POWER CONNECTION
The equipment is fed by the power supplied by means of the cable and the supplied slow-feature differential switch and electromagnetic switch according to the technical characteristics table. Every connection must possess a normative earth-connection and achieve all the national electric regulations and must be done by an authorized installer.
Usage with no regulatory ground connection is totally prohibited.

In addition to the mandatory and legal safety, ground connection prolongs the unit’s service life by allowing current peaks and EMI inner discharge for protection circuits through the ground, leaving them unprotected if not connected.
In the case of an electric generator you must observe all the indicated power necessities on the technical characteristics. It will be taken into account that an equipment could work with a lower power generator than the indicated along with the limitation of using it at a maximum intensity, lower than the nominal.
Model BITENSIÓN 20/14 is able to work in the range of 100V power supply voltage to 240V, 50Hz-400Hz.
The computer automatically detects the input voltage and configures itself.

ENVIRONMENTAL CONDITIONS LIMITATION
The equipment must be installed under its IP21 classification, which means that the equipment is protected from a maximum of a vertical water drops fall and the dangerous parts access with a finger, against strange solid bodies of 12,5mm ø and bigger.
The equipment is ready for working on a temperature range from -15º to 70ºC in consideration of the performance drop limitation (duty cycle) from room temperatures over 40ºC.

OPERATING INSTRUCTIONS

PLACEMENT AND TESTING
All the MMA STAYER WELDING series must be manipulated by its habilitated transport handler. A free space of at least 15cm around the machine must be habilitated, as well as securing a free air circulation for a correct heat dissipation.
Before any kind of work, the right condition and the proper tightening of all the equipment external elements must be verified: power supply plug, cable, chassis maintenance and connection borne and switches.

TOOLS REPLACEMENT
All the Stayer Welding series machines own a quick half-inch or 3/8-inch DINSE connector for the welding cables. For connecting or removing the connector, it is enough to turn right or left a quarter turn thereof.
PRECAUTION: Always fully connect the DINSE connector and make sure the joint with the cable is in good condition and the contact surface is cleaned. A bad joint or a dirty connection will reduce the performance and will produce an overheating, melting itself or the frontal panel burnt.

ADJUSTMENT OPERATIONS
All the Stayer Welding machines contain a complex electronic system and are completely calibrated, so it is not allowed for the user to manipulate the unit because of safety and efficiency reasons. If any doubt of malfunction, please, contact your supplier or our customer service system.

WORKPIECE SIZE LIMITS
The main restriction about the welding piece size is its thickness, which is limited by the equipment power.
The higher the power is, the thicker the proper welds the user will be able to create will be (with an adequate penetration of the welding cord).
The following table may be worth of orientation:

WORKPIECE

THICKNESS

| E6013 ELECTRODE

DIAMETER

| AMPERAGE

ADJUSTMENT RANGE

---|---|---
1 a 2 mm| 1,6mm| 30 – 60
1,5 a 3mm| 2,0mm| 50 – 70
2,5 a 5mm| 2,5mm| 60 – 100
5 a 8mm| 3,2mm| 85 – 140
8 a 12mm| 4,0mm| 120 – 190
More than 12mm| 5,0 – 6,0mm| 180 – 350

GENERAL USE INSTRUCTIONS
Before starting, make sure you read, comprehend and apply all the safety instructions as well as the rest included in the present manual.
Then, you will find a series of general indications that will help you to introduce yourself in the world of welding and know how to efficiently work.
In the present manual, you will be instructed about the coated electrode welding rudiments, of a relatively moderated execution difficulty, and TIG welding, of a relatively higher difficulty. Take into account that professional welding is a qualified and specialized activity. Refer to specialized books and regulated professional training for more information.

Duty cycle and protection input
Duty cycle refers to the time where the unit is able to work with a specific output characteristic.
This time is measured as a 10-minute period percentage. Tests are done with air at 40ºC
For example, a 120A unit at a 30% duty cycle will be able to work at 120A for 3 minutes straight. Then, the user will have to wait for 7 minutes before going back to work for another 3 minutes.
An equipment working at a 100% duty cycle will be able to do a continuous non- stopping work as long as the air temperature does not go higher than 40ºC.
When the unit works over the indicated working time on its plate, it may lead to the situation where it stops and enters itself in a protection cooling mode. This is indicated through a yellow LED light included in all the models, except for the CITIWORK range in which will be shown through the message “HEA” on its display while being in this protection mode.

Coated electrode welding
In this type of electric arc welding, the electrode itself produces heat through an electric arc due to the environment protection, the improved electrode coating and the filler metal of the electrode metallic soul merging while welding.
You must choose the adequate electrode (type and size) according to the work you are going to do. The electrode we recommend because of its medium characteristic, validity for most of the works and easiness to find, is the E-6013. Better known as “rutile electrode”. The coated electrode welding material par excellence is carbon steel. The attached table may be helpful as an initial orientation for choosing the electrode type and operation amperage adjustment for a S275 type medium carbon steel.
After confirming all the security measurements and the equipment inspection, cleaning, preparing and holding the welding piece, the cords are connected according to the table indications. For a casual use of the E-6013 electrode, the negative polarity output (marked with a -) will be plugged to the piece through the earth clamp. The positive polarity output (marked with a +) will be plugged to the electrode holder clamp, which will have the working electrode connected to its bare extreme.
The welder must wear their individual protection equipment using mask or welding helmet, all adequate for the work, and covering every inch of their skin to avoid radiation or welding splashing.
The arc priming weld will take place. There are various procedures, being the piece scraping the simplest one.
Once the arc is started, the electrode will be put at an approximated distance equal as the same electrode diameter. Then, the welding progress will start, pulling back as if an Occidental right-handed person was writing. The electrode must be kept in an almost vertical position (65º to 80º), regarding to the horizontal one, and balanced regarding to weld coating.
Depending on the pass type (filler or initial) and the union coverage need, keep going in a straight line, a zig-zag movement or small circles. A good welding position, speed and intensity adjustment will result in a nice and soft sound, similar to the one of a good barbecue roast. When a proper work is done, the resulting cord will be homogeneous, with uniform half-moon surface marks. The transversal profile will not be either protuberant nor collapsed. The formed dirt will be easily removed.
Once the weld rod is done, you must remove the dirt with a hammer before doing a possible following one.

Special adjustments for CEL XP, PFC, S250DV, S400T and POTENZA 200 PULSED series (Fig. 5, 6, 8, 10 and 11)
In order to maximize the adaptation, manual adjustments are offered for professional welders:

Nº2: HOT START manual control
Regulates the initial power increase when starting the arc (prime). Adjust the control depending on the electrode kind, joint type and the temperature of the workpiece. Begin on the medium position and look for a start, avoiding stuck electrodes and projections. If stuck electrodes, increase the power turning the control to the right. In case of projections, reduce the power turning the control to the left.
If you are going to use the unit as TIG welding, low the control to the minimum.
Nº3: ARC FORCE manual control
Regulates the arc behaviour when a voltage dynamic fall is produced. Depending on the electrode type, initially adjust:

• – To the minimum (completely to the right) for acid rutile electrodes (Ex. E6013)
  – To the middle for basic electrodes (Ex. E7018)
  – To the maximum for cellulosic electrodes (Ex. E6010)

Nº4: Amperage manual control
Standard welding amperes regulation. Look at the previous section for details.

Nº5: A/V selector
Makes the display 1 to show the welding amperes or voltage.

Nº6: VRD selector
Makes no-load voltage standard or reduced under special conditions where necessary.

Nº7: Amperage remote control. Plug here the cable connector. GRID / GENERATOR
Arc priming adaptative response (only in PFC series). The selector 6 allows the equipment usage in very low power generators when choosing the ‘GENERATOR’ position. While in ‘GRID’ position, the connection will be to the standard power grid by the power supply company, achieving a light improvement of the arc priming dynamic during the first half-second of use

Progress 1700 XP special adjustment
Use the button 8 in order to select the parameters adjustment. The selected parameter will be indicated by the light of the corresponding led.
As an indicative mode, use as a first work approximation the following parameters and amperage adjustment table according to each electrode and its diameter

CLASS| MODEL ARC FORCE HOT START           2.5 mm 3.2 mm| 4 mm
---|---|---
RUTILE| E 6013| 20| 40| 60-90 A| 90-130 A| 130-170 A
E 7024| 20| 40| –| 100-140 A| 140-170 A
BASIC| E 7016| 50| 50| 80-100 A| 100-140 A| 140-170 A
INOX| E 316L| 30| 30| 60-80 A| 80-110 A| 110-140 A
CAST| E NiFe-Cl| 60| 40| 70-90 A| 90-130 A| 120-160 A
CELLULOSIC| E 6010| 30| 40| 40-70 A| 60-100 A| 90-150 A

POTENZA 200 CEL GE (Fig. 7) special adjustments
Nº1: Electrode type selector
Press ‘Normal’ for basic and rutile electrodes work.
Press ‘Cel & Al’ for cellulosic and aluminium electrodes work.

Nº2: Process type selector
Press ‘MMA’ for coated electrode welding.
Press ‘TIG LA’ for Lift Arc priming TIG welding.

Coated electrode pulsed welding
The POTENZA 200 PULSED (Fig. 11) model, along the standard welding mode, counts with an advanced pulsed welding selector (Num. 3). This mode allows a superior control of the heat contribution and the drop transfer in the weld pool. In this mode of operation, thin thicknesses and unstainable steel can be welded with a minimum of projections and a similar TIG welding quality.
Unlike the standard mode where the current contribution is monotonous, during the pulsed mode a peak current is established for the exact drop-by-drop contribution, and a base current to keep the welding arc active without overheating the workpiece. According to the material, dimensions and joint type, the user could optimize the process by adjusting the base and peak distribution through the peak % selection. The user will also be able to adjust the frequency (cycles per second) of each pulsed welding cycle (peak + base).
For adjustment, first press 3 to enter through pulsed mode and then, press encoder (Fig. 11, nº1) in order to select the adjustment parameter. Adjust the value by turning the encoder.
The adjustable value ranges are:

%

| Cycle frequency
20 – 200| 30 – 100| 10 – 100| 0,5 – 6

TIG welding

In the electric arc made by protected tungsten electrode through inert gas welding, the consumable material is not the own electrode but a filler rode of a similar or compatible material when welding.
In comparison with the coated electrode system, the TIG system presents less productivity and a higher difficulty but with a high-quality welding on all metals and their alloys, including all the stainless metals and situations of low-thickness unions with or without filler.
There is no dirt, projections or smoke in the welding.

CAUTION : Do not use nor sharpen thorium doped tungsten electrodes with red mark due to the moderate radioactive activity risk of the material. You will be able to recognize the thorium dioxide presence and concentration by its indicative strap on the electrode, according to EN ISO 68848:2004 (colors: yellow, red, purple and orange).
Avoid these electrodes and use substitutes with no content. For example, lanthanum and cerium derived electrodes (straps: black, grey, blue, gold) which do not show radioactive activity.
Prepare the electrode by sharpening its tip on the emery stone so it will stay as a cone with an approximated height of twice the electrode diameter. For a better arc and current managing capacity, the proper attack from the tip to the stone must be longitudinal, and the tip should be slightly flat.
For a correct electrode positioning in the torch, it should project beyond the nozzle for about 5mm.
As a general rule, plug the output contrary to the usual TIG torch electrode connexion to the negative terminal of the equipment, while the earth clamp goes connected to the positive one.
Prepare and secure the piece. Adjust the current intensity according to the material type necessities and the union to be made, firstly trying it out on a testing piece.
Refer to the tables and specialized literature or to regulated professional qualification for further information about it.
Inert gas should be provided to the torch (usually pure argon) coming from a cylinder through a pressure reducer system. It must be able to adequately regulate the necessary gas flow.
All the units need a TIG torch with a direct connection to the flowmeter and gas control through the gate valve, incorporated in the TIG torch itself.
To start the arc in all the models except S60.17L. PROGRESS1700L and T100.20H, the torch tip should be slightly sharpened till the work arc start.

The S60.17L, PROGRESS1700L and POTENZA 200 CEL series, show an improved starting system by Lift Arc. This system allows a minimum electrode contamination.
To start the TIG welding, the user has to move the commuter 7 to the TIG position, open the gas output valve and place the torch tip in contact with the welding piece. Then, wait for 2 seconds and softly lift the torch for the arc not to automatically start.
Once the arc is started, the user now must proceed to execute the welding according to its needs. As a general orientation, you should continue in a conversely way to the electrode welding so that, instead of pulling it back, the focus will be on pushing forward as if it was helping the gas flow on the welding coating. Tilt the torch in order to focus it on a very close vertical position (70º to 80º) with respect to the horizontal and central one, regarding to the welding coating.
Slowly deposit the filling rod material, successively approaching it to the fluxed material coating. To end, simply calmly separate the torch until the arc is interrupted and close the manual gas gate valve.
Lastly, close the inert gas cylinder general gate valve.

POTENZA TIG 170 HF GE model incorporates two completion welding adjustment

1.  “Down Time” 11 control establishes an intensity drop ramp when welding is stopped. The ramp starts with the selected work intensity and ends in zero amperes. Its duration time (from 0 to 5 secs) gets adjusted with the control. The aim is to have a mild arc stop and a precise control of the cord finalization crater. As a general rule, the time should be increased as the welding amperage increases.
2. “Post Time” 12 control establishes the additional gas (argon) output time (from 0.5 to 7 secs) after finalizing the welding arc. The aim is to get a non-contaminated weld coating by the air when it is still liquid or too hot. As a general rule, the time should be increased as the welding amperage increases.

MAINTENANCE AND SERVICE INSTRUCTIONS

CLEANING, MAINTENANCE, LUBRICATION AND SHARPENING

Always turn off the equipment before cleaning and wait for, at least, 10 minutes for a safe discharge of the power capacitors. Clean the chassis with a lightly-wet cloth. Depending on the pollution in the working area air, or at least every 1000 hours, clean the inside with dry compressed air, removing the casing and cleaning the dust, metallic pollution and fluffs, always putting special attention to the fan and the dissipaters.
The equipment does not need a specific maintenance from the user, but a careful usage in between the environmental limits that will provide the best guarantee for years of a perfectly safe service. It is recommendable to send the equipment to the technical service every 3000 working-hours or every 3 years to be verified and recalibrated.

REPARATION SERVICE ADDRESS

STAYER IBERICA
Área Empresarial Andalucía – Sector I Calle Sierra de Cazorla No. 7 ZIP: 28320 Pinto (Madrid) SPAIN

User’s replaceable pieces list
Due to the complexity and risk potential, it is necessary the qualified intervention for minor reparations as connection inspection, standard supply plug replacement and welding cables revision. Therefore, they are not considered replaceable pieces by the user but by a qualified person.

REGULATIONS

TECHNICAL SPECIFICATIONS

Documents / Resources

| STAYER PLUS 120CGE Welding Machine [pdf] Instruction Manual
PLUS 120CGE Welding Machine, PLUS 120CGE, Welding Machine, Machine
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References

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

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