STAYER MIG 131 Multi Flux Core Welding Wire Machine Instruction Manual

MIG200 Multi
Operating instructions Declaration of Conformity

MIG 131 Multi Flux Core Welding Wire Machine

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.
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
FIG 1: MIG 131 / 160 / 165 / 170 Multi

FIG. 2: MIG 200 Multi

| | MIG131 Multi| MIG160 Multi| MIG165 Multi| MIG170 Multi| MIG200 Multi
---|---|---|---|---|---|---
| V| 230| 230| 230| 230| 230
**| A| 120| 160| 160| 70| 200
| %| 30| 60| 60| 60| 60
| mm| 3.2| 4| 4| 5| 5
| mm| 0.9| 0.8| 0.6 – 0.8 – 0.9| 0.8 – 0.9| 0.8 – 1.0
| kg| 4.3| 8| 13| 17| 22
| kg| 1| 1| 5| 5| 5-15
| KVA| 6| 7| 7| 7| 9
| cm| 26.8×16.6×36.2| 37 x 24 x 18| 32×22.5×46| 23 x 50 x 36| 23 x 50 x36
| | MIG250CM| MIG250CT| MIG350BT| MIG500BT| MIG200 Double Pulse| MIG280 Double Pulse| MIG350 Double Pulse**
---|---|---|---|---|---|---|---|---

| V| 230| 3 x 400| 3 x 400| 3 x 400| 230| 3×400| 3×400
| A| 250| 250| 350 – 271| 500 – 387| 200| 280| 350
| %| 60| 60| 60 – 100| 60 – 100| 60| 60| 60
| mm| 6| 6| 8| 8| 5| 6| 8
| mm| 0.6/ 0.8 /- 1.0| 0.8 – 1.0| 0.8 – 1.0 / 1.0 – 1.| 0.8 / 1.0 – 1.2 / 1.6| .8 / 1.0-1.2| 0.8 / 1.0-1.2 / 1.6| 0.8 / 1.0-1.2 / 1.6
| kg| 48| 49| 45| 50| 17.5| 42| 46.5
| kg| 5-15| 5-15| 5-15| 5-15| 5 – 15| 5 – 15| 5 – 15
| KVA| 10| 10| 17| 27| 10| 14| 15
| cm| 62 x 30 x 68| 62 x 30 x 68| 114 x 30 x 90| 160 x 33 x 100| 58x40x27| 60x62x30| 77.5x94x40

INTRODUCTION

The present unit is a MIG/MAG equipment for continuous wire metal, coated electrode and TIG process welding.
Technologically, the STAYER WELDING equipment is a power supply source for high-frequency power transfer, managed by smart control logic.
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.

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.

SYMBOLS USAGE
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. 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 may 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 inner circuits are also ‘electrically hot’ when the machine is on. While welding with automatic or 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 or not-earthed equipment is a various 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 AC 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 avoidable or accidental contact with the ground or workpiece.
• Disconnect 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 can 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-tometal 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.
• solate the grounding clam when it 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 and allow some time for the equipment to cool itself before using it again.

• ** To operate with hot components, use appropriate tools and wear heavy gloves with welding-isolating and adequate clothes to prevent burns.
  SMOKE and GASES can be dangerous** Welding produces smoke and gases. Breathing those can be dangerous for your health.

• Keep your head out of the smoke. Do not breath it.

• If you are working indoors, make sure you ventilate the area and use forced local ventilation before the arc to take the welding smoke and gases 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 gases 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 at locations 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 steels, 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 of any metal that contains those elements may emanate toxic smoke and gases 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 flameresistant 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 the area is safe before starting any kind of weld.

• Remove all the inflammable material in a 15-meter (49.22ft) 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 material 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 on 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 OSHA 1910.252 (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 can 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 indoors ventilation or an approved respirator that replaces the air.

MAGNETIC FIELDS can affect implemented medical equipment

• People who use cardiac pacemakers and other implemented medial 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 ears. Use approved protection for your ears if the noise level is very high or higher than 75dBa.

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 the 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 instructions of the compressed air cylinders, the 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 in order to meet this unit necessities.

A FALLING EQUIPMENT may cause injuries

• In heavy units only use the appropriate way to lift them, 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. If the thermal protection appears, patiently change to another more powerful unit.
• 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. Do not breathe the filings.
• Sparkles can cause fire – keep the inflammables away.

WELDING WIRE can cause injuries

• Do not press the trigger of the torch until it is required.
• **** Do not point at any part of your body with the torch tip, nor at any other person or metal object while the wire is going through it.

MOVING PARTS can cause injuries

• Stay away from every moving part, as fans.
• Keep all the doors, panels, covers or 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 panels and doors completely closed. Keep the distance from the sparkles on the platins on their correct fixing. Make sure you make earth connection and protect it against current.

ARC WELDING may cause interference

• The electromagnetic energy can interfere with sensitive electronic equipment like computers or computer-impulse equipment, as industrial robots.
• Make sure all the equipment in the welding arc is electromagnetically compatible.
• In order to reduce the possible interferences, keep the welding cables as short and near as possible, or directly on the ground, if viable.
• Operate your welding 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.

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

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.
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. 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 unit must be placed in a safe, dry and flat location.
ASSEMBLY
MODELS WITH INNER WINDER
Are completely assembled.
MODELS WITH EXTERNAL WINDER
The power, water and logic connections to the unit are made through the bond hose. Simply connect the positive cable, logic connector and water circuit (MIG500BT) sited in the main machines along the corresponding winder connectors.
The negative connection will be independently made from the hose.
The MIG500BT model comes with an installed water-cooling unit for the water- cooled torch. Fill with water the frontal deposit and prime, if necessary, the circuit.
Both models come with an already installed gas cylinder support tray. Use the included chain to secure the welding cylinder to avoid tipping.
GRID CONNECTION
Welding units need an appropriate power supply and enough capacity to get a highest-performance work. All the range is certified generator-ready that meet the normative requirements and correctly work. The minimum power to be supplied is:

MODEL| VOLTAGE| MINIMUM POWER,KVA| RECOMMENDED POWER, KVA| Amperage and voltage for magnetothermal
and differential switches
---|---|---|---|---
MIG 131 Multi| 230, monofasico| 4| 6| 2 poli, 230v, 32 Ah
MIG 160 Multi| 230, monofasico| 5| 7| 2 poli, 230v, 32 Ah
MIG 165 Multi| 230, monofasico| 5| 8.| 2 poli, 230v, 32 Ah
MIG 170 Multi| 230, monofasico| 5| 7| 2 poli, 230v, 32 Ah
MIG 200 Multi| 230, monofasico| 6| 7| 2 poli, 230v, 32 Ah
MIG 250 BM| 230, monofasico| 8| 10| 2 poli, 230v, 40 Ah
MIG 250 BT/CT| 3×400 trifasico| 8| 10| 3 poli, 400v, 40 Ah
MIG 350 BT| 3×400 trifasico| 14| 16| 3 poli, 400v, 25 Ah
MIG 500 BT| 3×400 trifasico| 25| 27| 3 poli, 400v, 40 Ah
MIG 280 DOUBLE PULSE| 3×400 trifasico| 18| 20| 3 polos, 400v, 40 Ah

ILLUSTRATED FUNCTIONS DESCRIPTION

1. Arc welding voltage indicator screen
2. Arc welding intensity indicator screen
3. DINSE connection – positive borne
4. DINSE connection – negative borne
5. Thread output speed adjustment
6. Arc welding amperage adjustment
7. General switch of the unit
8. Arc welding Arc Force adjustment| 9. Arc welding voltage adjustment
10. Arc welding inductance adjustment
11. Coated electrode / TIG or MIG selector
12. 2T/4T selector
13. Manual/Synergic selector
14. Wire diameter selector
15. Gas type selector / Metal type
16. Gas purge button| 17. On light
18. Thermal overload light / diagnosis
19. Unit welding light
20. Priming thread button
21. Wire torch connector
22. Cooling water input
23. Cooling water output
24. Cooling circuit filling
25. Cooling circuit purge
---|---|---

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
The unit is on by pressing the switch 7 in all the models. Before turning the equipment on, verify its safety and fulfil its labour risks prevention plan. Then, carry out the following explained functions according to the machine’s type of service.
COATED ELECTRODE WELDING (MMA)
Connect the mass cable to the unit connector 4, and the earth clamp to the workpiece. Make sure there is a proper electric contact in a clean and solid surface. Connect the electrode holder mass cable of the unit to the connector 4. Plug the electrode to the electrode holder clamp, securing the directional grooves to fit it. Select the coated electrode mode on the selector 11 and adjust its intensity with the setting 6. In the MIG350BT/MIG500BT models, adjust the Arc Force 8, put it on a minimum-medium for basic electrode and on a medium-maximum for cellulosic electrode.
Note: The electrode is mostly connected to the positive terminal (reverse polarity). In some determined circumstances though, it should be connected to the negative terminal (direct polarity), as it usually happens with the basic electrode. Refer to the electrode documentation to be assured.
TIG WELDING
It is necessary for you to obtain a TIG torch (ask your STAYER supplier) whose gas is controlled by a valve placed in its handle. Connect the TIG torch to the connector 4 and the mass to the connector 3 of the equipment (direct polarity). Press the button 11 to MMA mode. Now, the unit will be regulated only by the amperes control 6. In with HOT START / ARC FORCE control models put the control 8 at its minimum.
MIG/MAG WELDING
Connect the earth cable 2 to the unit’s connector 4. Connect the torch to the Euro torch output 21 of the unit. Secure the connection by screwing the connector’s safety ring of the torch. When hollow-wire is used (flux core, no gas supply needed), it is necessary to reverse the polarity from inverse to direct (positive to the workpiece). Use the exchange connection borne ready for the effect in all the models.
TOOLS REPLACEMENT
It is explained here the consumables replacement from the three execution devices: electrode holder for coated electrodes, continuous wire torches in MIG/MAG processes and tungsten electrodes torches in TIG processes.
MMA PROCESS (COATED ELECTRODE)
Replace the coated electrode by using the 4 pressor grooves caved on the electrode holder clamp in order to secure the position and a better electric contact of the electrode. Make sure the clamp presses the bare metal of the electrode and there is no ‘fake’ contact by reaching the metallic soul coating of the electrode.
TIG PROCESS
The TIG torch tungsten electrode is the wear and tear element. Despite the great performance, it is recommended to avoid thorium doped electrodes (red strip) for an absolute safety reasons about pollution, explained down below. Along the electrode, the electrode holder clamp and the gas conducting nozzles themselves, also suffer from wear and tear.
The electrode holder clamp will always be used with the same diameter as the electrode. The nozzle will be of the diameter (indicated by its number) according to the work kind and gas consumption.
The elements are manually easy-disassembled by the plain threads and knurling systems.
Do not use nor sharpen thorium doped tungsten electrodes 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.
MIG/MAG PROCESS
The torch contact tip is the main tear and wear element in this process, that must always be replaced according to the continuous wire diameter that is being used. The torch nozzle will also suffer tear and wear due to the high temperatures and projections. The elements are manually easy-disassembled by the plain wide passage threads systems. For an aluminium special welding, please contact your supplier for the inner conduct replacement (liner) to low- friction Teflon.
The mechanism of the winder has a simple operation of the grooved rollers replacement. It is manually done by the threaded knob that releases the pulleys, whose position can be reversed in order to select the complementary diameter (For ex. 0.8mm at one side and 1mm at the other).
Note: be careful not to lose the cotter pin of the winder when releasing the pulley.
The welding wire is received on its coil and installed by introducing it inside the winder exe and leading it to the torch output through the traction pulleys, torch hose and torch contact tip. The contact tip is accessible by manually twisting the torch nozzle.
The contact tip may be removed with an open-end wrench or pliers and must be of the same diameter as the welding wire.
Pulleys are accessible by freeing the pressure bearings that release them. Once the wire goes through the pulleys, should you close the pressure rollers and adjust pressure so the wire can correctly advance and not skid nor end up destroyed.
The pulley groove must be of the same diameter as the welding wire.
When using hollow wire, the nozzle can be removed as it is not necessary. By doing that, you will have a wider vision and the nozzle will not get damaged.
SETTING OPERATIONS MMA PROCESS (COATED ELECTRODE)
Stayer offers high-quality coated electrode in the references down below. For all the models, use as a first approximation, the following amperage adjustment table:

For higher than a 3.25mm diameter, refer to the intensities recommended by your supplier.
TIG PROCESS
For all the models, use as a first approximation the amperage and gas flow adjustment in the following table (steel in general):

Workpiece thickness| Tungsten electrode diameter| Filler rod diameter
---|---|---
mm| mm| mm
0.6| 1.0 – 1.6| 0 – 1.0
1| 1.0 – 1.6| 0 – 1.6
1.5| 1.0 – 1.6| 0 – 1.6
2.5| 1.6 – 2.4| 1.6 – 2.4
3| 1.6 – 2.4| 1.6 – 2.4
4| 2.4| 1.6 – 2.4
5| 2.4 – 3.2| 2.4 – 3.2
6| 2.4 – 3.2| 2.4 – 3.2
8| 3.2 – 4.0| 3.2 – 4.0
12| 3.2 – 4.0| 3.2 – 4.0
Amperage adjustment range| Argon gas flow| Joint size
---|---|---
A| L/min| mm
15 – 30| 5-Apr| 1
25 – 30| 7-Apr| 1
50 – 70| 9-Jun| 1
65 – 95| 9-Jun| 1
65 – 95| 9-Jun| 1
110 – 150| 15-Oct| 3-Feb
120 – 180| 15-Oct| 3-Feb
150 – 200| 15-Oct| 3-Feb
160 – 220| 18-Dec| 5-Apr
180 – 240| 18-Dec| 8-Jun
180 – 240| 18-Dec| 8-Jun

MIG/MAG PROCESS
For all the models, use the following table as a first approximation for the adjustment with carbon steel. The wire speed will variate depending on the piece thickness and the required welding mode.

Diameter (mm)| Amperages (A)| Voltage (V)| Gas flow (L/min)
---|---|---|---
0.6| 40 – 80| 14 – 20| 10-Jun
0.8| 50 – 100| 15 – 21| 12-Jul
1| 60 – 120| 16 – 22| 12-Aug
1.2| 120 – 250| 22 – 28| 14-Dec
1.6| 200 – 500| 25 – 32| 14 – 16

MIG/MAG special adjustment
According to each transference mode, for example if the user wants to work with short arc mode (thick drop, cut circuit) or wants to work with long arc mode (thin drop, spray), you can take action over the two detailed setting controls. For the special settings of the MIG 280 DP see below.
SYNERGIC MODE: Press 13
Amperage: In order to make a precise general power adjustment, it must be done through the master amperage control, placed on the upper part of the winder frontal panel, buttons 6 and 9. These controls are found duplicated on the main unit.
Voltage: In order to make a precise arc characteristics adjustment, it must be done through the master voltage control, 9, placed on the lower part of the winder frontal panel. When turning the control to the left, the voltage lowers and the arc is closed while producing deposition in a high-penetration cut circuit mode, minimum projections and a characteristic sound. As the voltage increases, the high-performance and silent spray welding mode will be preferred. It is recommended to start regulating the voltage to a medium point, indicated by the SYNØ range, varying inside the synergic working mode area.
When turning the control to the right, the right display of the unit will show an opening arc referential between -30 and 30.
The reference value will be shown in a 3-second period of time. After those three seconds, it will show the work voltage value measured by the unit itself.
Wire speed: the amperage control modifies at the same time the wire output speed depending on the working conditions indicated in the unit. If special conditions affect the setting of the exact speed, an increaser or decrease of the speed can be selected by adjusting the wire speed at the originally installed superior or lower immediate measurement.
D. MANUAL MODE: Pulse 13
-With the control 6 you can adjust the wire output speed from 1.6m/s to 20m/s
-With the control 9 you can adjust the unit output voltage from 13V to 40V
SPLASH CONTROL
The electric inductance 10 allows a splash reduction from the wire welding process. Empirically try to increase or low the control until achieving the best result.
Workpiece size limitation The main restriction over the piece to weld is its thickness, which is limited by the unit power.
As the power increases, you could be able to make correct welds (with an adequate welding cord penetration) on higher thickness pieces with less filler cords at a higher speed. The following table may be useful as orientation:
C. – PULSED MIG
The equipment is configured using the front control panel.
It consists of keypads (12, 11/13, 14, 15, 16 and 26), two multifunction rotary encoders (5/6 and 9/10), displays (1 and 12) and 34 configuration status LEDs.
The operation is intuitive from the buttons that indicate the procedures (2T, 4T,…) for each type of welding (button 12), the types of welding (MMA, MIG,…) on the button (11/13), the thicknesses and materials to be welded for synergic configuration (0.8, 1.0, 1.2,… / Fe, AlSi,…) on buttons 14 and 15, the gas purge on button 16 and the specific selection of parameters to adjust with the encoders on button 26.
This machine is synergistic, which means that by configuring the parameters of the work to be carried out, the machine automatically configures itself to perfectly perform the requested work, occasionally having to vary slightly the main energy parameter 5/6.
The MIG 280 DOUBLE PULSED model adds to the previous functions the synergistic automatic configuration depending on the type of material and its thickness, as well as the capacity of single pulse for better quality of steel beads and double pulse for a maximum quality of aluminum cords, very close to TIG AC.
It is not possible to give training in a user manual on the technical basis and specific procedures of pulse welding.
Compared to conventional non-pulsed MIG / MAG welding, it provides, if used correctly, great advantages in quality and performance.
As an introduction to the concept, refer to the following image taking into account that the abscissa axis is time.

The welding waveform at the top of the image can be achieved by single pulse in which there is a single amplitude modulation to create the base current (lower trace) and the peak current, upper trace. The simple pulsed arc allows ‘Spray’ transfer with less intensity than with conventional nonpulsed welding and yet with higher performance, less area affected by heating, greater cleaning and less spatter and projections. Simple pulse processes are especially suitable for all types of carbon steels.
The welding waveform at the top of the image can also be achieved by double pulse in which there are two modulations, one in pulse width at static frequency and the other in variable amplitude to create (on average) the same waveform. from the top of the image. This procedure adds to the single pulse greater, more precise control and greater adaptation to the specific welding of aluminum, with the possibility of narrower and penetrated beads and a smooth bead surface.
This procedure is valid for all types of aluminum, including selectable (silicon and magnesium aluminum) synergistically in the equipment.
ATC function
ATC stands for advanced temperature control. It is recommended to select this procedure in welding of small thickness aluminum. The selection is made using the navigation button 15 and is indicated by the flashing of the corresponding led in the material selection.

MMA WORK TYPES

PIECE THICKNESS| ELECTRODE| ADJUSTMENT
1,5 a 5 mm| 2,0 a 3,25 mm| 40 – 140A
2,5 a 5 mm| 4,0 mm| 120 – 190 A
5a 12 mm| 5,0 mm| > 180 A
TIPI DI LAVORO MIG

FILO| SPESSORE PEZZO
0,6 mm| 1 – 8 mm
0,8 mm| 2 – 10 mm
1,0 mm| 2 -25 mm
1,2 – 1,6 mm| 5 – 50 mm

GENERAL USAGE INSTRUCTIONS SPECIFIC MMA WELDING INSTRUCTIONS (COATED ELECTRODE)
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.
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 working and covering every inch of their skin to avoid radiation or welding splashing. The arc priming welding 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 needs, 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.
Specific TIG welding instructions 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 higher-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. 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 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 (not included – STAYER references 38.71 and 38.73) with a direct connection to the flowmeter and gas control through the gate valve, incorporated in the TIG torch itself.
Once the arc is started, you now must proceed to execute the welding according to its needs. As a general orientation, you should keep going in a conversely way to the electrode welding so that, instead of pulling it back, the focus will be 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. Then, close the manual gas gate valve. Lastly, close the inert gas cylinder general valve.
Specific MIG/MAG wire welding instructions The welding torch should keep a correct position for the gas to conveniently protect the melting pool. Hold the torch with both hands and try to get a fixed support point for a higher cord stability.
It is recommendable an inclination, with respect to the vertical one, of 10º. The free wire length will be contained between 8 and 20mm in order to get a better observation of the molten pool and avoid the gas nozzle projections adherence. Avoid working with airflows that may snatch the welding cord technical gas.
Possible problems and solutions to MIG/MAG wire welding:
INTERRUPTED THIN WELDING CORD
a ) Excessive wire progress speed
b ) Low gas output (begin with 5-7l/min and open the manometer tap if necessary)
VERY HIGH WELDING CORD
a ) Very low wire progress speed
b ) Low welding current
UNSTABLE ARC – WELDING POROSITY
a ) Distant torch from the piece
b ) Dirty piece, with oil, grease, rust.
c ) Not enough gas flow. Check the gas regulator and cylinder content
STUCK WELDED WIRE IN THE CONTACT TIP
a ) Very low wire progress speed
b ) Torch too close to the piece
c ) Momentaneous welding circuit interruption. Possible causes:

1. Rusty contact tip
2. Wire progress mechanism difficulty
3. Wire and contact tip have different diameters
4. Damaged torch connection 5
5. Low pressure on wire progress
6. Tangled wire coil or normal wire progress stopped or hindered due to wrongly placed wire

LACK OF WELDING PENETRATION
a ) Too high torch progress speed
b ) Low welding current
c ) Very low wire progress speed
ARC DOES NOT APPEAR
a ) Check unit, torch and earth clamp connections
UNIT IS NOT ON WHEN THE TORCH SWITCH IS CONNECTED
a ) Thermostat intervention
b ) Check torch switch operation
UNIT DOES NOT WORK – LUMINOUS SWITCH IS NOT ON
a ) Verify the electric grid connection
b ) Verify the differential switch or the electric grid fuse wire

SERVICE AND MAINTENANCE INSTRUCTIONS

Specific torches instructions:
– Clean the torch nozzle adhered projections to avoid cut circuits and gas turbulences. Use a steel brush.
– Avoid projections adherences, using a specific silicone-free spray
– Periodically check the pinch rollers and breaking reel
– Verify the wire properly goes through
– Control the calibrated contact tip and replace it when necessary in order to avoid wire contact loss with the nozzle
Do not use the torch as a hammer to eliminate welding dirt or to align sheets.
Reparation service
The technical service staff will advise you with all the doubts and questions you may have about the reparation or the maintenance of your product, just as with replacement components. All the illustrations and lists of parts of the unit are also available in the web from: [email protected] Our technical advisors’ team will gladly guide you about acquisition, application and adjustment of the products and accessories.
Disposal
We recommend the electric tools, accessories and packaging to be under an eco- friendly recovering process.
Only for EU countries:
Do not throw electric tools to the trash bin!
According to the European Directive 2012/19/
UE on electric and electronic devices, after its transposition into national law, electric tools must be separately collected in order to be ecologically recycled.
Modification rights reserved

REGULATORY MARKING

REGULATORY MARKINGS EXPLANATION

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
TECHNICAL FEATURES

| =Tension input
---|---
| =Current input
| =Current input
| =Duty cycle
| =Mass
| =Coil weight
| =Electrode diameter
| =Generator power
| =Dimensions

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:

1. 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.

2. 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.

3. 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.

4. 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.

5. Guarantee transfer is completely forbidden, the guarantee does not cover second-hand products.

6. 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.

7. 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.
   You can find this information in other languages at: https://www.stayer.en/

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

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

Documents / Resources

| STAYER MIG 131 Multi Flux Core Welding Wire Machine [pdf] Instruction Manual
MIG 131 Multi, MIG160 Multi, MIG165 Multi, MIG170 Multi, MIG200 Multi, MIG250 CM CT, MIG 200 DOUBLE PULSED, MIG 280 DOUBLE PULSED, MIG 350 DOUBLE PULSED, MIG 350 BT, MIG 500 BT, Flux Core Welding Wire Machine, MIG 131 Multi Flux Core Welding Wire Machine
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References

• Inicio - Grupo Stayer
• Inicio - Grupo Stayer

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