BORMANN BIW1545 Lite Series Welding Inverter Instruction Manual

BORMANN BIW1545 Lite Series Welding Inverter

Thank you for your buying our product, for using it correctly, please at first read this manual carefully.

Safety Instructions

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

• Electric shock – may lead to death!

  • Set the earth fitting according to the applied standard.
  • It is dangerous to touch the electrical components with the 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 extractor should be used to prevent the inhaling of gas.

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

  • Use suitable helmet and wear protective garments to protect eye 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 others means to protect ears.
  • Warn others in the vicinity that noise may be harmful to their hearing.

• Malfunction: seek professional assistance.

  • If trouble 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.
    CAUTION! An additional Isolator switch is recommended when using the machine!

Notes & preventive measures

• Environment

  • The machine can perform in environments where conditions are dry with a max humidity level of 90%.
  • Ambient temperature is between -10 degrees to +40 degrees centigrade.
  • Avoid welding in bright sunshine or wet conditions.
  • Do not use the machine in an environment where there is conductive dust or corrosiveness gas in the atmosphere.
  • Avoid gas welding in an environment of strong airflow.

• Health and Safety

  • The welding machine has a protection circuit monitoring voltage, current and heat. When voltage, output current or temperature of machine exceed the rated standard, the welding machine will shut down automatically.

  • The reason for this may be one of the following:

  • The working area is adequately ventilated.
    This is a powerful machine, when it is in operation it generates high currents and room temperature will not adequately cool the machine if used for long peri-ods. It may be necessary to cool the machine with an additional fan. Make sure the air intake is never in block or covered and the user should ensure that the working area is adequately ventilated. This is important for the performance and the longevity of the machine.

  • Do not overload.
    The operator should closely observe the Max permissible current. Continuous welding current is not to exceed the Max cycle current.Over-load current will damage the machine.

  • Power voltage can be found in the diagram of main technical data. The automatic compensation circuit for the voltage will assure that welding current is kept within the allowable range. If power voltage exceeds the allowed range it will damaged the machines components. The operator should observe closely and take preventative measures where necessary.

  •  The grounding connector at the rear on the machine should be grounded via a suitable cable in order to prevent static electricity.

  • If welding time exceeds the maximum cycle and the machine overheats, the welding machine will cease working and the indicator light will show red. Do not unplug the machine as the fan will assist in cooling the machine. When the indicator light turns off the machine is ready for use again.

• Welding
  Fittings, welding materials, environmental factors and supply voltage may affect the quality of your welding. It is important to maintain a good welding envi-ronment.

• Arc-striking is difficult and easy to pause.

  • Make sure of good quality electrode.
  • If the electrode is not dry, it will cause unstable arc with reduced weld quality.
  • If long extension cable is used, this will reduce output voltage and weld quality.

• Input current not to rated value.
  When power voltage is lower that specified, the output voltage will be reduced.

•  Current does not stabilize when machine is in operation.

  • Electric input cable is of insufficient voltage rating.
  • There is harmful interference from electric cable or other equipment in close proximity.

• Too much splatter

  • Possible current is too high and/or rod’s diameter is too small.
  • Output terminal polarity connection is incorrect, switch polarity, eg. The rod holder should be connected to negative polarity and the work piece should be connected to positive.
    CAUTION! This machine will produce radio waves so people in the surrounding area should be made aware of the dangers of being in close proximity when this machine is being operated.

Technical data

• 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 appli-cations. 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 techni-cians 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.

Operating instructions

Installation
This welding machine is equipped with a power voltage compensation device. When power voltage alters between±15% of rated voltage it will continue to operate normally. When long cable is in use, thicker cable is suggested in order to prevent voltage from dropping. If the cable of the torch is too long it may affect the performance of the power system. We suggest you to use the configured length.

1. Ensure the intake of the machine is not blocked or covered, lest the cooling system will not operate efficiently.
2. Use inducting cable of not less than 6 mm² to connect the housing to ground. This is done by way of ground-connection at the back of the machine.
3. Ensure the cable, holder and fastening plug have been connected to ground. Insert the fastening plug into the “-” polarity socket and fasten it clockwise.
4. Attach cable to “+” polarity on the front panel, fasten it clockwise, this cable then clamps to the work piece.
5. Be aware of the connecting polarity correctly, this machine has two connections: a positive and a negative connection.
6. Positive connection: holder connects with “-” polarity, while work piece is connected to “+”polarity.
7. Negative connection: work piece to “-”polarity, holder to “+” polarity.
8. Choose the suitable connection for the job at hand. If the connection is unsuitable it will cause unstable arc, more spatters and conglutination. If such issues occur, change the polarity.
9. Ensure your power supply is of the correct voltage for this machine or it is within permissible range. Instalment is now complete

Operation

1. Turn on the power, the screen will display set current volume and ventilator will commence operation.
2. Adjust welding current and arc-strike according to requirements.
   WARNING! Ensure that power is disconnected before connecting the welding cable and ground cable to the machine. Ensure they are firmly connected before connecting to your power source.

Description of main parts

Maintenance

1. Remove dust by dry and clean compressed air regularly, if welding machine is operating in environments of high pollution the machine will need more regular cleaning.
2. Compressed air should not be too powerful as this may damage fragile components inside the machine.

NEVER OPEN THIS MACHINE WITHOUT FIRST DISCONNECTING POWER.

1. Avoid water and steam in close proximity to the machine, in it comes into contact with water, DO NOT USE.
2. If welder is not used for a long period, store in dry environment.
   WARNING! It is recommended that only a qualified technician tests and attempts repair on this high voltage machine. Incorrect diagnoses or repair may lead to serious injury or death!

Troubleshooting

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