BORMANN PRO BIW1300 Welding Machine User Manual

BORMANN® PRO BIW1300 Welding Machine User Manual

BIW1300
028277

v2.1

Safety Warnings

Warning: Please read the follow safety warning before operation.

All to defend and other
Ear cap shall be put on when welding, and very operation is also important during welding. So:

1. The welding helmet, face shield and protective goggles shall be prepared, when in the working area at any time.
2. The appropriate face shield with filter and skin face shall be used to protect eyes, face, neck, and ears form electrical spark and arc ray. And the  spectator should not watch the arc and keep rain sack away from the arc ray and splash.
3. The appropriate protective clothing, shoes and helmet shall be worn to protect from arc ray, sparing and splattering.
4. All the buttons shall o done up to avoid the sparking and splattering.
5. The nonflammable partition and door curtain shall be used protect the other workers from electric ray and sparking.
6. The protective goggles shall be used when cleaning welding spatter.

Fire and Burse
The heat of frame and arc can cause fire So:

1. Keep the flammable materials including wooden, cloth, wet fuel and gas fuel and so on away from the welding working area.
2. All the walls and floor in the working area should be untracked to avoid the smoldering and fire.
3. Ensure that all the working pieces are cleared before doing welding, and do not do weld on the sealed container to avoid burst.
4. The fire-fighting equipment shall be prepared near the welding working area.
5. Do not use the equipment overloading.
6. The fire monitor shall be used after welding.

Electric shock
Please do not use the welding source in the wet area to avoid any injure or death So:

1. To ensure the source underpan and earthing system of input source are connected.
2. To ensure the working pieces and good electric are connected.
3. To ensure the working cable and working piece are connected.
4. To change the damaged or abrasion cable in time.
5. Keep dry, including cloth, working area, wire, welding torch, soldering turret and power supply.
6. Keep the body insulated from the work piece and ground.
7. The operator shall stand on a dry wooden board or insulating platform of rubble shoes when working in a sealed on moist area.
8. The dry and sealed glove snail be wore before turning on the power.
9. The power should be turned off before taking off the glove.

Safely Warning
Electromagnetic field
It can bring dangerous. So:

1. The worker that the heart pacemaker imbedded shall do some consultation with the doctor before doing welding; because the electromagnetic field may disturb the normal work of have pacemaker.
2. The electromagnetic is unhealthful.
3. The worker shall take the following measures to down times exposing himself to the electromagnetic field:
4. Put the electrode cause and work cable together, and also the tape can used if possible.
5. Do not wind the welding touch cable and work cable round yourself.
6. Put the welding torch cable and work cable on one side of yourself.
7. Connect the work cable to the work piece, and make it to the welding area as nearly as possible.
8. Make yourself away from welding source and cable as much as possible

Fog and gas
The welding fog and gas can make the worker uncomfortable, on hunted, especially In the limited icescape, so do not breathe the fog and gas. So:

1. The aerator natural on mechanical shall be prepared in the working area. Do not do welding on the following metals (galvanized, seed, stainless steel, copper, zinc, read, beryllium or calcium), and also do not breathe the welding fog and gas in.
2. Does not welding near the degreasing or spraying operation to avoid the poisonous gas phosgene or other imitates gas.
3. If you feel little imitate to the eyes, nose or threat. You shall stop welding and perfect the aerator. And you should stop welding at once if feeling comfortlessness.

Equipment maintenance
The wrong or inappropriate equipment maintenance can cause injury or death. So:

1. The licensed people can do assembly, maintenance and some other operation.
2. The power source shall be turned off when any maintenance work in the power source needed.
3. Ensure that the cable, earth wire, connector, main lead and power supply are in the normal work.
4. Do not abuse equipment and firing.
5. Keep the safe equipment and cabinet dos shall in peace and good condition.
6. Do not change any equipment.

The sign used in the manual means: take care! On guard! Involve your personal safety.

DANGER! Means sudden danger: It can get people injured or dead if it is inevitable.

WARNING! Means potential danger, it also get people injured or dead.

CAUTION! Means danger, it can get people injured

OVERVIEW

THE CONTROL PANEL

1. Led display
2. Wire speed control knob. As a general rule, a higher current requires a higher wire speed
3. Ampere control knob
4. MIG/MMA switch. This switch between MIG function and MMA function when welding requested
5. Thermal overload light. If the duty cycle is exceeded as a result of welding too long with a high current, the yellow overload light will illuminate and the welder will turn off. When the welder has cooled down (approx. 5 to 10 minutes), the power will be restored and welding can recommence.
6. Current overload light.

MOUNTING THE WELDING WIRE SPOOL

WARNING: Ensure that the welder is not connected to the mains supply.

NOTE: Spools of welding wire are available from your dealer.

1. Open the side panel, by pushing the latch down and allowing the side panel to drop down.
2. Remove the locking knob and retaining disc.
3. Place the spool of welding wire (not supplied) over the spindle so that it sits on the spring.
   • Do not release the tension on the wire as it will unravel causing feeding problems later.
   • The wire will feed off the spool anticlockwise from the bottom of the reel.
   • The spool must be fitted with the correct orientation otherwise it will not feed correctly.

SETTING THE DRIVE ROLLER SIZE

1. Loosen the tensioning knob and pivot it towards you
2. Lift up the arm.
3. Take hold of the triangular knob on the drive roller cover and rotate it 90°anticlockwise to release it
4. Pull the roller retainer off the drive spindle to reveal the roller.
5. Pull the roller off the drive spindle.
   • The groove size is stamped on the corresponding side of the roller. Select the groove size according to the size of the wire you are using and put the roller back on the spindle with your chosen side facing you.
6. Replace the drive roller cover back onto the drive spindle with the opening facing right.
7. Ensure that the flanges at the base of the drive roller cover, seat fully into the circular recess in the main moulding and then rotate the drive roller  cover through 90° to lock it in place.

THREADING THE WIRE

IMPORTANT: Do not release the tension on the wire as it will unravel causing feeding problems later.

1. Pull out the end of the wire from the spool, taking care not to release the tension.

   • We recommend you cut off and discard the first 10 cm of wire from the spool to avoid burrs and then straighten the next 15 cm of wire to help  with feeding.

2. Loosen the tension knob and pivot it towards you.

3. Lift up the arm.

4. Pass the wire through the guide, over the drive roller and into the torch liner.

   • Push about 10-15 cm into the torch liner.

5. Lower the arm and replace the tensioning knob.

   • Tighten the tensioning knob sufficiently to hold firmly, but do not fully tighten.
     NOTE: Correct tension will allow the wire to feed into the torch liner smoothly, but will allow the drive roller to slip in the event of a blockage.

6. Close the side panel of the welder.

7. Pull off the torch shroud with a twisting movement, then unscrew the contact tip.

8. Connect the welder to the power supply and switch ON.

9. Set the ‘WIRE FEED’ rotary control on the front panel to position 7 or 8 and squeeze the trigger on the torch body.

   • The wire will feed through the hose until it appears at the torch tip.
   • Ensuring the hose is free from kinks during this process will assist the wire in its passage through the hose liner.

10. Release the trigger and switch off the welder and disconnect the machine from the mains supply.

11. Refit the appropriate size contact tip (0.8 mm is supplied fitted*) to suit your wire. the replace the shroud.

    • A spare 1.0 mm tip is supplied loose and should be used when using 0.9 mm flux cored wire the contact tip and shroud.*

12. Trim the welding wire so that it protrudes no more than 5 mm from the end of the contact tip.

*Not included with all models.

MIG WELDING PRINCIPLES

MIG (Metal Inert Gas) welding allows you to fuse together two similar metals without altering the properties of the metal. A consumable wire electrode is continuously fed through the welding torch that is fitted with a concentric gas nozzle. the wire is connected to a high voltage supply which creates an electric arc between the electrode (the wire) and the workpiece. The arc is used to create the required heat to turn the metal into a molten state. The wire is used as both the electrode and as a filler.
The gas is used to prevent oxidation and to shield the arc and the weld from atmospheric contamination.
The choice of gas is dependent upon the material being welded.

*Under certain conditions
When using the welder in a gasless configuration the shielding gas is created from the flux within the welding wire. When using the welder outside, you may need to erect a wind break to make sure the shielding gas is not blown away, thereby leaving a poor quality weld.

GAS/NO-GAS SELECTION

The welder can be configured to weld, with or without a gas supply according to the type of welding wire being used.

• Solid core (With Gas)
• Flux Core (No Gas)

WELDING WITH GAS

1. If using solid wire, connect the terminal as shown.
   • The earth cable (Thicker Lead) should be connected to the negative (Black) terminal.
   • The cable from torch (Thinner Lead) should be connected to the positive (Red) terminal.

CONNECTING THE GAS SUPPLY

2. Connect a bottled gas supply to the small tube at the back of the welder.

WELDING WITHOUT GAS

1. If using flux cored wire, connect the terminal as shown.
   • The earth cable (Thicker Lead) should be connected to the positive (Red) terminal.
   • The cable from torch (Thinner Lead) should be connected to the Negative (Black) terminal

OPERATING THE WELDER

PREPARING THE WORKPIECE

The area being welded should be perfectly clean. Any coating, plating or corrosion must be removed, otherwise a good weld will be impossible to achieve. Attach the earth clamp to the workpiece as close to the point of weld as possible, without it being intrusive.

OPERATION

1. With the welding current set and the wire trimmed, set the wire feed control to 6.
2. Plug the machine into the mains supply and switch ON the machine.
3. Cover your face with a welding mask or welding helmet.
   • This is essential.
4. Lower the torch to the workpiece with one hand and approach the work with the torch tip at an angle of about 350 and pull the torch trigger fully.
   • As the wire touches the workpiece, an arc will be struck.
5. In order to produce a satisfactory weld, the controls may be fine tuned as required. This will come with practice.

NOTE: MIG welding is an acquired skill, it is strongly advised that, if you are not fully familiar with this type of welding, you practice on a piece of material with the same characteristics as your workpiece, until you are satisfied with the result, and you have fine tuned your welder to produce a satisfactory weld.

NOTE: One of the problems experienced with novice welders, is the welding wire sticking to the contact tip. This is as a result of the wire feed speed being too slow. It is always better therefore to start with too high a speed, and back off slightly, to avoid the possibility of the wire welding itself to the  tip. This is the reason position 6 is recommended for start up.

NOTE: The Wire Feed control is for fine tuning the wire speed. The speed of wire delivery will increase automatically as the current is increased. Therefore, once the ideal speed is achieved by fine tuning, it should not be necessary to adjust this control when the welding current is changed.

NOTE: Listen to the sound made. An irregular crackling sound denotes too high a wire speed. Decrease the speed until a regular, strong buzzing sound is heard.

THERMAL OVERLOAD

The ‘Thermal Overload’ shuts off the welder when it becomes too hot, due to the duty cycle being exceeded. This is to prevent any damage to the machine.
When this occurs, the warning lamp shown will glow (amber). Allow the welder to cool, until the amber light extinguishes before resuming work.

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