BORMANN BIW1135 Mig or Mag Electric Welding Machine User Manual

BIW1135 Mig or Mag Electric Welding Machine

BIW1135
034698
2 YEAR WARRANTY
User’s manual

Ιmportant Parts

1. Function Switch Button
2. Current Knob
3. Νegative Output “-“
4. Positive Output “+”
5. Welding Cable

TECHNICAL DATA

Welding Machine MIG/MAG NO GAS + MMA + LIFT TIG
Data / Model| BIW1135
Voltage (V)| 230 V
Frequency (Hz)| 50/60
Rated Power Input (kVA)| 4,5
No-load voltage (V)| 62
Output current (A)| 130
Rated Duty Cycle| 60%
Wire Diameter (mm)| 0,8 – 0,9
Welding electrode (mm)| 1,6 – 3,2
Tungsten electrode (mm)| 1,0 – 2,4

• The manufacturer reserves the right to make minor changes to product design and technical specifications without prior notice unless these changes significantly affect the performance and safety of the products. The parts described/illustrated in the pages of the manual that you hold in your hands may also concern other models of the manufacturer’s product line with similar features and may not be included in the product you just acquired.
• Please note that our equipment has not been designed for use in commercial, trade, or industrial applications. Our warranty will be voided if the machine is used in commercial, trade, or industrial businesses or for equivalent purposes.
• To ensure the safety and reliability of the product and the warranty validity, all repair, inspection, repair, or replacement work, including maintenance and special adjustments, must only be carried out by technicians of the authorized service department of the manufacturer.
• Always use the product with the supplied equipment. Operation of the product with non-provided equipment may cause malfunctions or even serious injury or death. The manufacturer and the importer shall not be liable for injuries and damages resulting from the use of non-conforming equipment.

A

1. Function Switch Button: MMA, LIFT TIG, FLUX-CORED MIG WIRE 0,8 – 0,9 mm
2. Current knob
3. Fixed MIG Torch
4. Positive output “+”
5. Negative output “-“
6. Power switch ON/OFF
7. Adjustment of welding voltage compensation for MIG/MAG function

B Installation Instructions for MIG/MAG function (Flux-Cored MIG Wire):
C Installation Instructions for LIFT TIG function:

D Installation Instructions for MMA function:

Safety Precautions

In the process of welding, there will always exist a possibility of injury, so please take protection into consideration during operation. For more details please review the Operator Safety Guide which complies with the necessary preventive requirements.

Electric shock – may lead to death!

• Set the earth fitting according to the applied standard.

• It is dangerous to touch the electrical components and electrodes with naked skin.

• Wear approved gloves and clothing.

• Make sure you are well insulated from the ground.

• Make sure you are in a safe and secure position.
  Gas may be harmful to your health!

• Do not inhale the gas.

• When arc welding, an air extractor should be used to prevent the inhaling of gas.

Arc radiation: Harmful to your eyes and can burn your skin.

• Use a suitable helmet and wear protective garments to protect the eyes and body.
• Use suitable protective equipment or curtain to protect any on-lookers and warn all onlookers about the possible risk to their eyes.

Fire

• Welding sparks may cause fire, make sure the welding area is fire safe.
  Noise: Extreme noise is harmful to the ear.

• Use ear protectors or other means to protect ears.

• Warn others in the vicinity that noise may be harmful to their hearing.

Malfunction: seek professional assistance.

• If troubles arise with installation and operation, please re-check the set-up within this manual.
• If you fail to fully understand this manual you should contact the suppliers or another professional for assistance.

About this machine
This product is a rectifier adopting the most advanced inverter technology available and it can be described as an Inverter Synergic NO GAS MIG/MAG+ MMA+ LIFT TIG 3 in 1 welding machine.
The development of inverter gas shielded welding equipment profits from the development of the inverter power supply theory and components. Inverter gas- shielded welding utilizes the high-power component IGBT to transfer 50/60HZ frequency up to 100 kHz, then reduces the voltage and commutate output high- power voltage via PWM technology. Because of the reduction of the main transformer’s weight and volume, the efficiency increases by 30%. The appearance of inverter welding equipment is considered to be a revolution in the welding industry.
CO2 shielded welding equipment adopts the most advanced inverter technology. The welding machine is equipped with an electronic reactor circuit that can accurately control the process of the electric short transition and blending transition and result in excellent welding characteristics. Compared with synergic welding machines and other machines, it has the following advantages: stable wire speed, compact, power saving, and no electromagnetic noise. Continuous and stable operation with a small current, especially suitable for welding sheets of low-carbon steel, alloyed steel, and stainless steel. Automatic voltage pulsation compensation capability, small sparkle, good arcing, uniform welding pool, high duty cycle, and so on.

Installation

The welding equipment is equipped with a power voltage compensation set. When power voltage changes between ±15% of rated voltage, it still works normally. When using a long cable, in order to minimize the reduction of voltage, a cable of the big section is suggested. If the cable is too long, it will affect the performance of arcing and other system functions, so the stated length is suggested.

1. Make sure the intake of the machine is not covered or blocked to prevent the malfunction of the cooling system.
2. Use an earth cable that the section no less than 6 mm2 to connect the housing and earth, the method is from the connection in the back of the machine to the earth set, or make sure the earth end of the power switch reaches the earth. Both ways can be used for better security.

Installation:

1. Connect the gas flask with the CO2 decompression flow meter and the CO2 mouth behind the machine via gas cable.

2. Insert the swift plug of earth cable into the swift socket in the front panel.

3. Set the wire wheel with wire on the wheel axis, the wheel hole should be matched with the wheel fixer.

4. Choose the wire slot according to the wire size.

5. Loosen the screw of the wire-pressing wheel, put the wire into the slot via a wire-lead tube, and tune the wire-pressing wheel to fix the wire from gliding, but pressure should be suitable in case the wire distorts and affects were sending.

6. The wire roll should turn clockwise rotation to let out the wire, to prevent the wire from gliding, the wire is usually set to the fixed hole on the wheel side. To prevent the
   bent wire from getting stuck, please cut off this part of the wire.

7. The MIG torch has been settled inside of the machine just need to put the wire into the torch by hand.

Operation

1. Put the air switch to the “ON” position, open the valve of the CO2 cylinder and adjust the flow.
2. Adjust the wire diameter of the wire machine to a rated number according to wire diameter.
3. Choose torch loophole span based on wire diameter.
4. Tune the voltage knob, speed knob, and inductance knob to the right position based on the thickness of the workpiece and mechanics.
5. Press the torch switch to let out the wire to the torch head and begin to work.

Notes & Preventive Measures

A. Environment

1. The machine can perform in environments where conditions are dry with a max humidity level of 90%.
2. The ambient temperature is between 10 degrees to 40 degrees centigrade.
3. Avoid welding in bright sunshine or wet conditions.
4. Do not use the machine in an environment where there is conductive dust or corrosive gas in the atmosphere.
5. Avoid gas welding in an environment with strong air flows.

B. Health and Safety
The welding machine has installed a protection circuit for over-voltage and current and heat. When the voltage and output current and temperature of the machine are exceeding the rate standard, the welding machine will stop working automatically. Because that will damage the welding machine, the user must pay attention as follows.

1. The working area is adequately ventilated!
   A welding machine is a powerful machine, when it is being operated, it is generated by high currents, and natural wind will not satisfy machine cool demands.
   So there is a fan in the inter-machine to cool down the machine. Make sure the intake is not in a block or covered, it is 0.3 meters from the welding machine to objects of the environment. The user should make sure the working area is adequately ventilated. It is important for the performance and longevity of the machine.

2. Do not overload!
   The operator should remember to watch the max duty current (Response to the selected duty cycle).
   Keep welding current is not exceed max duty cycle current.
   Over-load current will damage and burn up the machine.

3. No overvoltage!
   Power voltage can be found in the diagram of the main technical data. An automatic compensation circuit of voltage will assure that the welding current keeps in the allowable arrangement. If power voltage is exceeding the allowance arrangement limit, it damaged the components of the machine. The operator should understand the
   situation and take preventive measures.

4. There is a grounding screw behind the welding machine, and there is a grounding marker on it Mantle must be grounded reliably with a cable whose section is over 6 square millimeters in order to prevent static electricity and leaking.

5. If welding time is exceeded duty cycle limited, the welding machine will stop working for protection. Because the machine is overheated, the temperature control switch is on “ON’’ position and the indicator light is red. In this situation, you don’t have to pull the plug, in order to let the fan cool the machine. When the indicator light is OFF, and the temperature goes down to the standard range, it can weld again.

Welding
Fittings, welding materials, environmental factors, and supply powers maybe have something to do with welding. Users must try to improve the welding environment.

A. Arcing-striking is difficult and easy to pause:

1. Make sure the earth cable clincher connects the workpiece well.
2. Check whether each connecting point is connected or not.

B. Output current can not reach rated volume:
That supplied voltage is different from the rated will lead to unconformity of the output current and the adjusted current. When supplied voltage lower than
the rated, the max output current will be lower than the rated.

C. Current is not stabilizing when the machine is been operating:

1. Electric wire net voltage has been changed
2. There is harmful interference from electric wire nets or other equipment.

Maintenance

1. Remove dust by dry and clean compressed air regularly, if the welding machine is operating in an environment that is polluted with smoke and polluted air, the machine needs to remove dust every day.
2. The pressure of compressed air must be inside a reasonable arrangement in order to prevent damage to small components of the inter-machine.
3. Check inter circuit of the welding machine regularly and make sure the cable circuit is connected correctly and connectors are connected tightly (especially insert connector and components). If scale and loose are found, please give a good polish to them, then connect them again tightly.
4. Avoid water and steam entering into inter-machine, if they enter into machine. Please dry the inter-machine then check the insulation of the machine.
5. If the welding machine will not be operated for a long time, it must be put into a package and stored in a dry environment.
6. When the wire machine operates every 300 hours, the electric carbon brush and armature rectifier should be polished, the reducer should be cleaned, and the lubricator should be added to the turbo and bearing. Caution: It is recommended that only a qualified technician tests and attempts repair on this high volt-age machine. Incorrect diagnoses or repairs may lead to serious injury or death! Before Maintenance and checking, power must always be turned off, and before any opening of the housing, make sure that the power plug is pulled off.

Troubleshooting

If the user wants to operate the machine as follows, the operator must be personnel in a specific field of electricity and safety and hold the relevant certificate that proves their ability and knowledge. Before maintenance, contact with our for authorization is suggested.

1.  Make sure the air switch is closed.
2.  Check if the electric wire net is in work.
3.  Some of the heat-variable resistors(four) of the power panel is damaged, when it happens, the general DC24v relay is open or connectors are in poor contact.
4.  Power panel(bottom board) is damaged, DC 310V voltage cannot be output.
(1)  Silicon bridge is broken or connector of silicon bridge poor contact.
(2)  Power panel has been burned up.
(3)  Check the wire from the power switch to the input cable is in poor contact or not
5. Auxiliary power of the control panel is at fault.
The power indicator is lit, the fan works, and no welding output| 1.  Check if all kinds of cables of inter-machine are in poor contact.
2.  Output connector is cut off or poorly contacted.
3. Control cable or switch of the torch is broken.
4. Control circuit is broken.
The power indicator is lit, the fan works, and the abnormal indicator is lit.| 1.  Maybe it is overheating protection, please turn off the machine first, then turn on the machine again after the abnormal indicator is off.
2.  Maybe it is overheating protection, wait for 2-3 minutes.
3.  Maybe the inverter circuit is at fault:
(1)  If the abnormal indicator is still lit, some of the IGBT is damaged on the main board, find out and replace it with the same model.
(2)  If the abnormal indicator is not lit,
a.  Maybe the transformer is damaged, measure inductance volume and Q volume of the main transformer by inductance bridge.
b.  Maybe the secondary rectifier tube of transformer is damaged, find out faults and replace rectifier tube with it.

If the machine fails to work normally after maintenance and check, please contact us.

C hecking faults
When an abnormal situation such as failure of welding, unstable arc, or poor welding result, do not consider that it must be some faults. The machine may be well but just some reasons cause abnormality such as that some connectors are loosened, forget to turn on the switch, wrong setting, broken cable and gas pipe, etc. So before maintenance, Please check it up first, some problems may be solved.
The following is an earlier checking diagram in this way. In the top right corner item you can find the problem, please check according to the diagram for the one with the “O” mark.

Fault
Place an item to be checked| No arcing| No gas| Cannot Send Wire| Poor Arcing Initiation| Unstable arc| Welding margin unclean| Wire and Material congou- tinted| Wire links Electric leading hole for conglutinated| Have air hole
---|---|---|---|---|---|---|---|---|---
Power supply box
(input protective set)| 1.  connected or not
2.  fuse broken
3.  loosened connector| •| •| •| •| •| •|  |  |
Input Cable| 1.  Broken or not
2.  Loosened Connector
3.  Overheat| •| •| •| •| •| •|  |  |
Power| 1.  Switched or not
2.  lack phase| •| •| •| •| •| •| •| •|
Gas cylinder & ad- juster| 1.  Open the cover
2.  Remains of gas
3.  Flow setting volume
4.  Connecting point loosen| | | | | •|  |  |  | •
Gas pipe (access from the high-pressure cylinder to torch)| 1.  Connecting point loosened
2.  Pipe broken| | | | | | | | | •
Wire sending equipment| 1.  Wheel and leading tube don’t match
2.  Wheel broken, slot blocked or lack thereof| | | •| •| •| •|  | •|

Welding Power Supply (Daily Check)

Position| Checking keys| Remarks
Control panel| 1.  Switch condition of operation, transfer, and installment.
2.  Test the power indicator| None.
Cooling fan| 1. Check if there is wind and if the sound is normal or not.| If abnormal noise and no wind, check the inner.
Power part| 1.  When electrified, abnormal smell or not.
2.  When electrified, abnormal vibration and buzz or not.
3.  Color changing and heating or not in appearance.| A technician will be needed for support.
Periphery| 1.  Gas pipe broken, loosen or not.
2.  Housing and other fixed parts loosen or not.| A technician will be needed for support.
Welding Torch (Daily Check)

Position| Checking keys| Remarks
Wire sending tube| 1.  Check the extended size of the pipe.
2.  Wire diameter and the tube inner diameter match or not.
3.   Partial winding and extended.
4.   Block caused by dirt in the tube and the remains of the wire plating lay.
5.  Wire sending tube is broken or circle wears out.|

1.  Have to be changed when less than 6mm, when the extended part is too small, the arc will be unstable.
2.  Reason for unstable arc, please use a suitable tube.
3.  Reason for poor wires sending and unstable arc, please change.
4.  Reason for poor wire sending and unstable arc, (use kerosene to wipe or change a new one.)
5.   a. Pyrocondensation tube broken, change new tube
b. Change the new O circle

Gas bypass| Forget to insert or the hole blocked, or different factory component.| May lead to vice (splash) because of poor gas shield, torch body gets burned (arc in the torch), please handle.

Wire Sending Machine (Daily Check)

Position| Checking keys| Remarks

Pressing arm

| 1. If put the arm to the suitable indicating level. (notes: not to damage wire less than Ф1.0mm)| Lead to unstable arc and wire sending.

Wire Lead Tube

| 1. If powder or residue is stored up in the mouth of the tube. 2. Wire diameter and the tube inner diameter match or not.
3. If the tube mouth center matches the wire wheel slot center or not.| Clean the residue and check the reason and solve it. If not matched, lead to unstable arc and residue.
If unmatched, lead to unstable arc and residue.
Wire wheel| 1. Wire diameter matches the wheel’s requirement 2.If the wheel slot blocked| 1.  Lead to unstable arc and residue, and block wire tube.
2.  Change new one if necessary

Cable (Daily Check)

Position| Checking keys| Remarks
Torch cable| 1.  If the torch cable is over bent.
2. If the metal connecting point of the mobile plug loosens| 1.  Cause poor wire sending
2.  Unstable arc if cable over bent.
Output cable| 1.  Wearing-out of the cable insulated material.
2.  Cable connecting head naked (insulation damage), or loosen (the end of power supply, and cable of main material connecting point.)| For life security and stable welding, adopt suitable methods to check according to the working place.
–  Simple check daily
–  Careful and in-depth check on a fixed period
Input cable| 1.  If the connection of power supply input, protective equipment input, and the output end is fixed or not.
2.  If the security equipment cable is reliably connected.
3.  If the power input end cable fixed
4.  If the input cable is worn out and bares the conductor.
Earth cable| 1.  If the earth cable that connects the power supply is broken and connected tightly.
2.  If the earth cable that connects the main part is broken and connects tightly.| To prevent creep age and ensure security, please make daily checks.

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