Gude 20076 MIG 192 Gas Welding Machine Instruction Manual

Gude 20076 MIG 192 Gas Welding Machine

Device

Welders for manual welding in shielding gas with automatic wire feed enable joining of metal parts by fusing the jointed edges and accessory material. Fusion is induced by an electric arc generated between the welded material and metal wire continuously protruding from the torch end and serving as accessory material for jointing of parts. Higher welding current allows welding of stronger sheets. We do not guarantee for damages caused by neglecting these instructions.

Product Overview

• This gas-shielded Welding Machine MAG series is designed for ease of welding. It conforms to the safety standard EN 60974-1

• The device operates with single phase input voltage and current at the output. It is mainly used for the welding of metals such as copper , steel, low carbon, low alloy steel, stainless steel , etc. .
  This welding machine is mainly characterized by low cost, high productivity and resistance to corrosion. There welded slag-free.

• The unit is very versatile, and the welding can be done in any position.

• The welding machine is like a step-up transformer built and has a built-in wire feed and a feed roller.

• It is characterized by ease of use and low failure rate.

• The feed rollers can be configured to a range of between 0.5 to 5 kg.

• The voltage can be adjusted gradually. Voltage and current can be adjusted to the thickness of the metal .. Multi-speed control of the wire feed .

• Constant voltage

• Equipped with indicator light, heat protection indicators, and cooling fan.

• A device that is easy to carry

• Accessories for the welding machine are a MAG welding gun, a torch, a ground terminal, and a welding hood.

• The device is packaged in a carton.

Welder in MIG 192/6K Shielding Gas

A compact upper-class welder for do-it-yourself works. With its 6 gear levels, it is also suitable for problematic welding. With fluently adjustable wire feed and rich accessories.
Equipment: Welding shield and pressure control valve with two pressure indicators. 2 trundles at the back ­ 2 castor wheels in the front, including Schuko-CEE 16 A adapter, protections against thermal overloading and sets of 2meter hoses.

Scope of delivery

1. Welder with MIG 192/6K shielding gas
2. Set of hoses
3. Grounding terminal
4. Spare nozzles and wire feed pulley
5. Pressure control valve with 2 pressure indicators
6. Power plug
7. Plug with CEE 16 A earthing contact for 230 V
8. Welding shield

Warranty

A warranty period of 12 months applies to commercial use and 24 months apply to private use and commences on the day of purchase of the device.
Warranty applies exclusively to failures due to defective material or workmanship. An original sale slip with indication of date of sale must be presented in case of claiming for the warranty rights.
Warranty does not cover unprofessional use such as device overload, violent use, damage caused by third party or foreign materials, failure to comply with operations and assembly manual, and normal wear and tear.

General Safety Instructions

It is necessary to read through the entire Operating Instructions before first use of the appliance. If there are any doubts concerning connection and operation of the appliance, please contact the manufacturer (service department).
PAY ATTENTION TO THE FOLLOWING INSTRUCTIONS TO ENSURE HIGH SAFETY LEVEL:

Switch-on time

• The appliance output is expressed by the “Einschaltdauer/Switch-on time” (ED%) data on the type label of the appliance, i.e. ratio between the welding and cooling time.
• This factor changes at the same appliance according to load conditions, i.e. according to the welding current delivered.
• It states how long the appliance may work in the given welding current when loaded and always relates to the time interval of 10 minutes.
• E.g. the appliance works continuously for 6 minutes at welding current for ED 60%.
• After this time there is a dead phase so that inner parts could cool down and protection against thermal overloading is restarted then.
• Use of welders and execution of welding works may represent a danger both for person handling the appliance and for others.
• Therefore the person operating the welder is in all circumstances obliged not only to read the safety regulations given here but also know and observe them.
• It is necessary to always bear in mind that cautious, wellinstructed operating staff strictly performing their duties is the best protection from injuries.
• You should read the regulations given in the following text and obey them before connection, preparation, use or transport of the appliance.

APPLIANCE INSTALLATION ·

• Installation and maintenance of the appliance must take place in accordance with local safety regulations.
• Pay attention to the state of wear of cables of connecting elements and plugs.
• They need to be replaced if damaged.
• Execute regular maintenance of the equipment.
• Use cables with sufficient cross-section only.
• Connect the grounding cable as near to the workplace as possible.
• Never use the appliance in a wet environment.
  Make sure the workplace, objects situated around and the welder were dry.

PERSONAL PROTECTION AND PROTECTION OF THIRD PARTIES

• Radiation and heat are generated at the welding process.
• It is, therefore, necessary to ensure use of suitable protective means and take measures for personal protection and the protection of third parties.
• Never expose yourself or other persons to electric arc or red hot metal effects without the necessary protection.
• Ensure suction of the welding smoke or good ventilation of the welding workplace.

PREVENTIVE MEASURES AGAINST FIRE AND EXPLOSION Hot

cinder parts and sparks may cause a fire. Fire and explosion represent other danger. They can be prevented by observing the following rules:

• Do not use the appliance in immediate surroundings of easily combustible materials such as wood, wooden sawdust, “varnishes”, solvents, petrol, petroleum, natural gas, acetylene, propane and similar inflammable materials. Remove them from the workplace or protect them against sparks.
• A suitable extinguisher needs to be around as a measure for fire extinguishing.
• Do not execute any welding or cutting works on closed vessels or tubes.
• Do not execute any welding or cutting works on vessels or tubes even when open if they contain or have contained any materials that could explode or elicit any dangerous reactions due to heat or moisture.

WELDER INSTALLATION

The following regulations must be observed at the welder installation:

• The operating staff must have free access to the operating elements and appliance connectors.
• It is not suitable to install the appliance in tight rooms: Sufficient welder ventilation is very important.
• Avoid heavily dusty or dirty rooms where the equipment could suck in dust or other objects.
• The appliance (including cables) must not be an obstacle in passage or inhibit other persons from working.
• It is necessary to work with the welder on a flat surface and use suitably secured gas bottle for its operation only.

Emergency Action

Apply the first aid adequate to the injury and get qualified medical assistance as quickly as possible. Protect the injured person from more accidents and calm him/her down.
For the sake of an eventual accident, in accordance with DIN 13164, a workplace has to be fitted with a first-aid kit. It is essential to replace any used material in the first-aid kit immediately after it has been used. If you seek help, state the following pieces of information:

1. Accident site
2. Accident type
3. Number of injured persons
4. Injury type(s)

Marking on appliance

Explanation of symbols The following symbols are used in these Instructions and/or on the appliance:

Product safety:

Product is in accordance with appropriate standards of the European Community

Prohibition, general

• Prohibition, general (in connection with any other icon)
• Fire, open light source and no smoking
• No cable pulling
• Appliance not to be used when wet

Warning:

• Warning/Attention
• Warning against dangerous electric voltage
• Warning against danger of trip
• Warning against deleterious gases
• Warning against hot surface

Instructions:

• Use protective boots Use protective gloves
• Use protective clothes Use a shield for face protection
• Pull the power plug out before opening
• Please read the Operating
• Instructions before use

Environment protection:

• Do not throw waste to environment but dispose it properly.
• Packing cardboard material may be delivered to collecting centres designed thereto.
• Any damaged or liquidated electric or electronic devices must be delivered to appropriate collection centre..

Package :

• Protect against humidity
• This side up
• Interseroh-Recycling

Technical data

• Applicable safety standards: EN 60974-1:2005

• U1: Rated Input Voltage (AC) (Tolerance ± 10%)

• I1max: Maximum rated input current

• I1eff: Maximum effective input current

• X: load duration factor Ratio of actual working time to total working time
  Note 1 : This factor is between 0 and 1 and can be specified with a percentage
  Note 2: The default is meant by total working time a cycle of 10 min. A load duration factor of 60% means, for example, that following welding 4 to 6 minutes minutes idle.

• U0 : Open circuit voltage Open-circuit voltage of the secondary coil

• U2: Working voltage Nominal output voltage during welding

• U2 = (14 +0.05 I2) V A / V – A /

• V : Adjustment of welding current and in working voltage

• IP: protection class example IP21S H: insulation class

Intended Use

Welding machine for thermal compound of iron – ferrous metals by melting the edges and supply of an additional material. Failure to comply with the provisions of the general regulations and the provisions of this manual, the manufacturer for damages can not be held responsible.

Residual risks and protective measures

Mechanical residual risks

Threat| Description| Protective measure| Residual risk
---|---|---|---
Perforation, puncture| Hands can be perforated by wire| Wear protective gloves or keep

hands in safe distance from wire exit.

|

Liquid spraying

|

Spraying drops at welding can cause burns.

|

Wear protective clothes and welder’s mask.

|

Electric residual risks

Threat| Description| Protective measure| Residual risk
---|---|---|---

Direct electric contact

| Faulty cable or plug can cause electric shock.| Avoid contact with wet hands

and ensure corresponding grounding

|
Heat residual risks

Threat| Description| Protective measure| Residual risk

Burns, chilblains

| Contact with the hose nozzle and processed piece can cause burns.| Let the hose nozzle and processed piece cool down after operation finishing.

Wear protective gloves.

|

Exposure to radiation

Threat| Description| Protective measure| Residual risk
---|---|---|---
Infrared, visible and ultraviolet light| Electric arc causes infrared and ultraviolet radiation| Always use a suitable protective welding shield, protective clothes and

protective gloves.

|

Exposure to processed material and other matters

Threat| Description| Protective measure| Residual risk
---|---|---|---

Contact, aspiration

|

Long-term aspiration of welding gases can be harmful to health.

| Use exhaust equipment when working or work in rooms with good ventilation. Avoid direct gas aspiration.|

Fire or explosion

| Hot cinder and sparks can cause fire and explosion.| Never work with the appliance

in an easily combustible environment.

|

Other risks

Threat| Description| Protective measure| Residual risk
---|---|---|---
Slip, trip or fall of persons| Slip, trip or fall of persons| Keep your workplace clean|

Disposal

• Disposal instructions are illustrated in the form of pictograms on the device or packaging.
• A description of the pictograms is given in the “Identification” chapter.
• Disposal of transport packaging Packaging protects the device against damage during transport.
• Packaging materials are usually selected according to their effect on the environment and disposal methods and can therefore be recycled.
• Returning of the packaging back to circulation saves resources and costs for packaging disposal.
• Parts of the packaging (e.g. foil, styropor) may be dangerous for children.
• Risk of suffocation! Keep these parts of the packaging out of reach of children and dispose of as soon as possible.

Operation requirements

The operating staff must carefully read the Operating Instructions before appliance use.

Qualification

No professional qualification is needed for work with the appliance apart from the detailed training provided by a qualified expert.

Minimum age

• Only persons above 18 years of age are allowed to work with the appliance.
• An exception includes cases when the appliance is used by a youngster within professional training to reach skills supervised by a trainer.

Training

Appliance use only requires appropriate instructions. No special training is needed.

Technical data

Control range 230 V

Control range 400 V

| 115 A ~ 15 %/

160 A ~ 10%/

Received material

thickness

| 1-9 mm
Switch-on time| 0,6-1,0 mm
Max. wire thickness| H
Insulation class| IP 21 S
Protection type| 6
Gearing levels| 39,1 kg

Transport and storing

Attention: The appliance can be used and stored in an even working position (on a flat surface).
Please respect the symbols on the package!
Make sure the gas bottle was well fixed and sealed.

Assembly and first put into operation

• Assembly set 1 ­ Assembly of wheels on the appliance: Fig. 2, Fig. 3, Fig. 4
• Assembly set 2 ­ Appliance handle assembly: Fig. 5
• Assembly set 3 ­ Installation of the gas bottle on the appliance Fig. 6, Fig. 7
• Assembly set 4 – Welder’s shield assembly: Fig. 8, Fig. 9

Safety instructions for first putting into operation

• Make sure the electric connection is sufficiently protected.
• Use the prescribed protective clothes (pic.10).
  • Welder’s helmet
  • Welder’s apron
  • Welding gloves
• Ensure there are no other persons near the workplace or in dangerous areas.
• Make sure there are no flammable materials near the workplace.
• Plug the cable into appropriate outlet, the outlet must be protected by a safety fuse or power interlock switch.

Caution Installation only by qualified electricians!

• Power factor (cos ): 0.70
• H07RN- F4G1.5 mm ² power cable
• H01N2-D 1   16 mm ² welding cable

The power cable and any extension cable must have at least identical cross- section.

ATTENTION!

• Electric safety is only guaranteed when the appliance is in accordance with valid regulations for electric equipment, properly connected to efficient grounding equipment.
• Check whether the power voltage and frequency you dispose of correspond to the data on the appliance type label.

Procedure

• Proceed in the mentioned order at the assembly of individual parts.
• Keep correct layout of the assembly parts according to the given pictures.
• The appliance is not functional yet.
• Open the gas flow by 5-7 l/a min pressure.
• Protect the gas outlet against wind gust.

In addition, it is necessary to respect the following information:

• The first switch levels 1-2 serve for welding of thin-walled sheets with other levels serving for thicker walls.
• Wire feed speed also needs to be set at each switch level change.
• If a drop is formed on the wire end at welding, the wire feed speed must be increased whereas if wire pressure is perceivable against the hose, you must reduce the speed.
• As parts being welded are very hot always use pliers if you want to move them and remove deposits on the torch end.
• As soon as the electric arc has been ignited hold the hose at an angle of app. 30° to the perpendicular.

Welding wire installation

1. Open the left side door of the welder by pulling the lever.

2. Insert the welding wire spool (weight depends on the appliance model) so that it was possible to pull the wire out of the spool at the top.
   Caution:
   Make sure the wire did not uncoil from the spool and that its end was straight and without fray. The spool resistance can be adjusted to a fixing nut in the centre.

3. Open the turning knob.

4. Lift the stirrup element.

5. Check whether the grooves on the wire feed pulley correspond to the wire diameter and, if necessary, remove the wire pulley fixation by loosening the screws.

6. Position now the stirrup element and tighten the turning knob so that the wire on pulleys ran evenly. If the wire on pulleys slips, tighten more the turning knob. Attention: Do not tighten it too firmly as the extreme pressure to pulleys could cause damage to the wire feed engine.

7. Select 230V or 400V voltage. For 230V, use the supplied adapter plug, for 400V, connect the lead-in cable directly by CEE 16A red plug.

8. Now, switch on the welder by setting the selector voltage switch to voltage selected in point 7.

9. After you have checked that all safety measures have been taken set the changeover switch to level 1 and wire feed regulation to level 1.

10. Remove the gas nozzle and current nozzle and let the wire get out of the hose by pressing the pressure switch on the hose. Re-fit both nozzles subsequently.

11. Set the necessary gas volume on the gas bottle armature.
    Tip: (0.6 mm-wire 6 l/an hour); (0.8 mm-wire 8 l/an hour); (1.0 mm-wire 10 l/an hour)

12. The appliance is now ready for welding.

General information on welding and shielding gas

The main area of application is in shops, can be applied universally, suitable both for thinner sheets and thicker materials. The more welding levels the appliance has, the better utilisation at work with sheets applies. Necessary accessories: Co 2/Argon mixed gas, welding wire, welder’s shield, pressure control valve. It is also suitable for aluminium and VA premium steel, using suitable gas and wire. (Clean argon/VA-wire/aluminium wire), potentiometer.

Control

1. Connection of set of hoses
2. Grounding terminal connection
3. Wire feed speed setting
4. Welding level setting
5. 230V/400V selector switch
6. “Thermal protection” signal light
7. Operation” signal light
8. Power plug connection

Safety instructions fro operating staff

• Use the appliance only after you have carefully readthe Operating Instructions.
• Respect all safety instructions mentioned in theInstructions.
• Behave responsibly to other persons.
• Attention!!! Never use a rusted welding wire.

Instructions step by step

The welded zone must be free of rust and varnish. Always use a protective welder’s shield, welding gloves and suitable protective clothes. The angle of the set of hoses setting should be app. 30 degrees with respect to the processed piece.

• Polish a large surface on the processed piece at the weld seam and grounding terminal connection until glossy.
• Mount the grounding terminal to the prepared spot of the processed piece.
• Set parameters of the welder according to the user table for welding
• Set necessary volume of gas on the gas bottle armature
• Tip: (0.6 mm-wire 6 l/an hour); (0.8 mm-wire 8 l/an hour); (1.0 mm-wire 10 l/an hour)
• You can start welding if you have protective clothes on.
• Tip: Before you start working do some testing welding to test the optimum setting of the welding parameters and reach an optimum result. Fig.14
• Parameters for welding are set optimally when uniform noise is present and the welding seam is well penetrated in the material, i.e. it is relatively flat during work.

Tips for welding

• The welded zone should be free of rust and varnish.
• The torch is selected according to material type.
• We recommend first trying the current strength on a waste piece.

Failures – Causes – Removal

will automatically be reset after transformer has cooled

down (after app. 10 minutes, pay attention to ED!)

The welding current is not available at all.

The interlock power switch or RCD has failed

| 1.     The line fuse has failed| 1.         Have the fuse checked

2.         Switch on the interlock power switch

3.         Switch on RCD

The welding current is not available.

| 1.        Poor contact between the grounding terminal and welded piece.

2.        Any failure in the grounding cable or grounding guide

3.        Any failure in the torch guide

| 1.         Clean and refine the welded area and part surface.

2.         Repair or replace the grounding cable.

3.         Repair or replace the torch.

The wire feed engine

does not work, the signal light is switched on.

| 1.        The gear ring is failed or blocked.

2.        Faulty engine.

| 1.         Replace the gear ring.

2.         Replace the engine (contact your customer service).

The wire feed engine does not work, pulleys are turning.

| 1.        The pulley pressure is not set correctly.

2.        Impurities, dust, etc. on the torch current nozzle.

3.        Faulty gas nozzle.

4.        Warped wire.

5.        The wire guidance tube is dirty or damaged.

| 1.         Set the pulley pressure correctly.

2.         Clean the appliance contact tube. Use an air compressor for that. Replace the contact tube when heavily dirty.

3.         Replace the gas nozzle and check the edge.

4.         Check the pulley pressure and set it correctly if necessary.

5.         Clean it with compressed air and, if necessary, have the hose set replaced.

Wire feed is irregular.

| 1.        Impurities on the wire guidance. The gas nozzle is worn-out or faulty.

2.        The gas nozzle is clogged.

3.        There is an obstacle in the wire feed pulley guide.

4.        The wire feed pulley guide has been deformed.

5.        Faulty wire voltage.

| 1.         Clean the appliance wire guidance with air compressor.

2.         Replace the gas nozzle or contact tube.

3.         Clean or replace the gas nozzle.

4.         Clean the wire feed pulleys.

5.         Replace the wire feed pulleys.

6.         Set the wire voltage correctly.

Instable burning of the electric arc.

| 1.        Faulty wire speed setting.

2.        Impurities on the welded area.

3.        The gas nozzle is worn-out or faulty.

| 1.         Set the wire speed according to recommended parameters.

2.         Clean or polish the welded surface.

3.         Replace the gas nozzle and check the edge.

Welded seam is porous.

| 1.        No gas.

2.        The nozzle holder is clogged.

3.        Rusty or damp material.

4.        The torch is too far or you are holding it at a wrong angle to the welded spot.

| 1.        Open the gas and set the gas supply.

2.        Clean or replace the gas nozzle.

3.        Arrange the spot of welding properly or increase the gas supply.

4.        Clean or polish the material.

5.        The distance between the gas nozzle and processed piece must be 8-10 mm and the hose needs to be held at an angle of 30°.

6.        Check the rubber hose, connector and

assemblage of the set of hoses – Press the gas nozzle down to a correct position.

The welding wire stops near the current nozzle.| 1.        The current nozzle is worn-out.

2.        The welding wire is warped.

3.        The wire feed speed is too low.

| 1.         Replace the current nozzle.

2.         Check the pulley voltage pressure.

3.         Follow the wire feed speed instructions.

The welding pressure is irregular.| 1.     The welding wire has been blocked on the spool.| 1.     Check and, if necessary, adjust the pulley voltage pressure.
Penetration is too weak.| 1.        Too weak welding current.

2.        Too long electric arc.

| 1.        Increase the welding current and wire feed.

2.        Hold the hose near the processed piece.

Penetration is too strong.

| 1.        Too high welding current.

2.        The wire feed speed is too low.

3.        Incorrect distance of the torch from the processed piece.

| 1.        Reduce the welding current and wire feed.

2.        Move the torch slowly and smoothly.

3.        The nozzle distance from the processed piece must be 8-10 mm.

Inspection and maintenance

Hose set maintenance

Regular maintenance needs to be executed for perfect function of the hoses. The gas nozzle needs to be regularly sprinkled by protective nozzle spray and freed of deposits inside.
The following steps need to be taken for this case:

1. Remove the nozzle (1) by pulling forward
2. Free the nozzle of any deposits formed by the weld cinder.
3. Sprinkle it with protective nozzle spray.
4. If the nozzle is rusty, it needs to be replaced.

Current nozzle maintenance

The following steps need to be taken for this case:

1. Remove the nozzle (1) by pulling forward.
2. Unscrew the current nozzle (2)
3. Check whether the hole the wire goes through is not too wide or, in case of need, replace it before reassembly.
4. Press the button on the hose so that the wire protruded and remount the current nozzle.

Nozzle holder maintenance

The following steps need to be taken for this case (see pic. 15):

• Holes for gas drainage can sometimes be slightly stuffed, in such a case the gas nozzle needs to be disassembled by pulling (1),
• unscrew then the current nozzle (2),
• unscrew the gas distributor (3) and replace with a new one.

Safety instructions for inspection and maintenance
Only a regularly maintained and treated appliance can become a reliable helper. Insufficient care and maintenance can be a cause of unpredictable accidents and injuries.

Service

Any technical questions? Complaint? Do you need spare parts or operation manual? Go to our website www.guede.com and the section Service will help you quickly and without bureaucracy.
Please, help us to help you. In order to identify your device in case of complaint, please indicate serial number, order number and year of manufacture.
All information is available on the product label.
To have all information always at hand, put them down.

Serial number:
Order number:
Year of manufacture:

• Phone: +49 (0) 79 04 / 700-360
• Fax: +49 (0) 79 04 / 700-51999
• E-Mail: support@ts.guede.com

Important information for the customer

Please be sure to know that returning the product in or after the warranty period must be made in the original packaging.

Inspection and maintenance plan

Remove the nozzle (1)

by pulling forward.

| Remove the nozzle (1) by pulling forward.|

EC-DECLARATION OF CONFORMITY

We, hereby declare the conception and construction of the below mentioned appliances correspond – at the type of construction being launched – to appropriate basic safety and hygienic requirements of EC Directives. In case of any change to the appliance not discussed with us the  Declaration expires.

• Article No 20076 MIG 192/6K
• Appropriate EU Directives 2006/95/EC 2004/108/EC
• 2000/14/EC_2005/88/EC
• Noise: guaranteed LWA dB (A)
• Harmonised standards used
  • EN 60974-1:2005
  • ZEK 01.4-08/11.11
  • EN 60974-10:2007
• Technical documentation

GÜDE GmbH & Co. KG Birkichstrasse 6 74549 Wolpertshausen Deutschland
Tel.: +49-(0)7904/700-0
Fax.: +49-(0)7904/700-250
eMail: info@guede.com

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