8958696 Pro Point 105I Mig Gas FLux Cored Welder User Manual

8958696 Pro Point 105I Mig Gas FLux Cored Welder User Manual

SPECIFICATIONS

INTRODUCTION

The Pro. Point 105i MIG Gas/Flux-Cored Welder incorporates the latest in IGBT technology for maximum efficiency and longer duty cycles. The welding unit has both a gas and gasless option. The wire feed speed is automatically calibrated based on the wire size and Synergic control knob settings

SAFETY

WARNING! Read and understand all instructions before using this tool. The operator must follow basic precautions to reduce the risk of personal injury and/or damage to the equipment.

Keep this manual for safety warnings, precautions, operating or inspection and maintenance instructions.

HAZARD DEFINITIONS

Please familiarize yourself with the hazard notices found in this manual. A notice is an alert that there is a possibility of property damage, injury or death if certain instructions are not followed.

DANGER! This notice indicates an immediate and specific hazard that will result in severe personal injury or death if the proper precautions are not taken.

WARNING! This notice indicates a specific hazard or unsafe practice that could result in severe personal injury or death if the proper precautions are not taken.

CAUTION! This notice indicates a potentially hazardous situation that may result in minor or moderate injury if proper practices are not taken.

NOTICE! This notice indicates that a specific hazard or unsafe practice will result in equipment or property damage, but not personal injury

WORK AREA

1. Operate in a safe work environment. Keep your work area clean, well-lit and free of distractions.
2. Remove all unnecessary people from the work area when welding. Anyone remaining in the work area must wear the appropriate welding safety equipment.
3. Store tools properly in a safe and dry location. Keep tools out of the reach of children.
4. Do not install or use in the presence of flammable gases, dust or liquids.
5. Welding sparks and ejected molten slag can start a fire. Remove combustible materials within 39 ft (12 metres) of the welding unit. See Fire and Explosion Precautions.
6. Have a fire extinguisher readily available (see Fire and Explosion Precautions).
7. Use protective screens or barriers to protect others from flash and glare; warn others in the area to look away from the arc.
8. Keep the welding unit at least one foot from any wall or structure.
9. Check that the work area is free from fires, sparks or hot debris before leaving.

PERSONAL SAFETY

WARNING! Wear personal protective equipment approved by the Canadian Standards Association (CSA) or American National Standards Institute (ANSI)

HEAD PROTECTION
DANGER! Never look directly at the welding arc without the proper protection. The light can cause flash burn damage and impair vision. Although treatment is possible, multiple occurrences can result in permanent eye damage

1. Protect your eyes from welding light by wearing a welder’s helmet fitted with a filter shade suitable for the type of welding you are doing. The welding process produces intense white light, infrared and ultraviolet light, these arc rays can burn both eyes and skin.
2. Consult the Welding Shade Guide in Appendix A for the minimum shade to protect the eyes based on the amperage and type of welding.
3. An opaque helmet will protect against the ultraviolet or infrared light. A helmet will also protect against ejected hot material and slag. The helmet should protect the face, forehead, ears and neck.
4. Wear a fire-resistant head covering like a skull cap or balaclava hood to protect your head when the faceplate is down or when using a welding hand-held face shield.
5. Wear ventilated safety goggles beneath the welding helmet or behind the hand-held face shield. The cooling weld bead may fragment or eject slag that can damage the eyes, when the helmet or hand-held face shield is not in place.
6. Eye protection equipment should comply with CSA Z94.3-07 or ANSI Z87.1 standards based on the type of work performed.
7. Wear fire resistant ear plugs when welding overhead to prevent spatter or slag from falling into ear.

PROTECTIVE CLOTHING

1. Wear a leather apron or jacket, leather welding gloves and full foot protection. Choose clothing fabrics that resist sparks, heat, flames and splashes of molten material. Artificial fabrics may burn and melt, resulting in a more severe injury.
2. Wear welding capes and sleeves when performing overhead welding.
3. Do not wear clothes or protective gear that are frayed, oily or greasy as they may ignite from the heat or ejected slag and sparks.
4. Wear thick clothes that do not expose the skin. Ultraviolet or infrared light can burn skin with sufficient exposure.
5. Do not wear clothing that can hold hot debris or sparks such as pant cuffs, shirt pockets or boots. Choose clothing that has flaps over pockets or wear clothing to cover the openings such as pant legs over the boots or an apron over the shirt.
6. Gloves should contain an insulating lining to protect against an electric shock.
7. Rubber soled footwear or electrically insulated work boots are recommended while working with a welding unit. The non- skid sole is will also help maintain footing and balance during work.
8. Select boots with steel toe protection to prevent injury from falling objects.

RESPIRATORS

1. Respiratory protection is needed when ventilation is not sufficient to remove welding fumes or when there is risk of oxygen deficiency.
2. Wear a NIOSH approved respirator when working on materials that produce dust or particulate matter.
3. Work in a confined space only if it is well ventilated or while wearing an air-supplied respirator. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe (See Fumes and Gases).
4. The user can take the additional precaution of informing another person in the work area of the potential danger, so that person can watch for indications that the user is suffering from oxygen deprivation.

PERSONAL PRECAUTIONS

Control the tool, personal movement and the work environment to avoid personal injury or damage to the tool.

1. Do not operate any tool when tired or under the influence of drugs, alcohol or medications.
2. Avoid wearing clothes or jewelry that can become entangled with the moving parts of a tool. Keep long hair covered or bound.
3. Remove all jewelry or metal items from your person before welding. Metal items may connect to the welding unit’s electrical circuit, causing an injury or death.
4. Do not overreach when operating the tool. Proper footing and balance enable better control in unexpected situations.
5. Support the workpiece or clamp it to a stable platform. Holding the workpiece by hand or against your body may lead to personal injury.
6. Do not wear any personal grooming products that are flammable, such as hair preparations, perfume or cologne with an alcohol base.
7. Remove any combustibles, such as butane lighters or matches, from your person before doing any welding. Hot welding sparks may light the matches or ignite leaking lighter fuel.

SPECIFIC SAFETY PRECAUTIONS

WARNING! DO NOT let comfort or familiarity with product (gained from repeated use) replace strict adherence to the tool safety rules. If you use this tool unsafely or incorrectly, you can suffer serious personal injury.

Welding produces sparks, molten slag, intense white light, plus infrared and ultraviolet light. A cooling bead can eject chips or fragments of slag. Any of these can cause direct harm to the eyes and skin of the welder or bystanders.

1. Use the correct tool for the job. This tool was designed for a specific function. Do not modify or alter this tool or use it for an unintended purpose.
2. Protect against reflected arc rays. The rays can reflect off a shiny surface behind the user, into the helmet and off the filter lens into the eyes. Remove or cover any reflective surface behind the user such as a glossy painted surface, aluminum, stainless steel or glass.
3. Welding produces sparks and molten slag. A cooling bead can eject chips or fragments of slag. Any of these can cause direct harm to the eyes or skin of the user or bystanders.
4. Erect protective screens or barriers to protect bystanders from the flash and glare; warn others in the area not to watch the arc. Do not strike a welding arc until all bystanders and you (the user) have welding shields and/or helmets in place.
5. Immediately replace a cracked or broken helmet or a scratched or damaged lens filter to avoid damage to the eyes or face from arc flash or ejected molten material.
6. Do not allow the welding torch to accidentally touch the ground clamp or grounded work. An arc flash will result from contact and can injury the unprepared user and bystanders.
7. Do not handle hot metal or welding wire stubs with bare hands. Handling may result in a burn injury.
8. Do not use the welding unit if personal movement is confined or if there is a danger of falling.
9. Keep all panels and covers securely in place when operating the welding unit.
10. Insulate the ground clamp when not connected to a workpiece to prevent contact with any metal object.
11. Do not operate the welding unit if the welding torch or welding cable is wet. Do not immerse them in water. These components and the welding unit must be completely dry before attempting to use them.
12. Do not point the welding torch at any body part of yourself or at anyone else.
13. Do not use a welding unit to thaw frozen pipes.
14. Insulate yourself from the work and the ground using dry insulation. Make certain that the insulation is large enough to cover your full area of physical contact.
15. When not welding, make certain that no part of the welding wire circuit is touching the workpiece or the ground. Accidental contact can cause overheating and create a fire hazard.
16. Maintain good ventilation of the louvres on this equipment. Good ventilation is of critical importance for the normal performance and service life of this equipment.

FIRE AND EXPLOSION PRECAUTIONS

Welding can produce sparks, hot slag or spatter, molten metal drops and hot metal parts that can start fires.

1. Clear the floor and walls of an area of all combustible and/or flammable materials up to 39 ft (12 metres) away from the welding unit. Hot debris ejected during welding can land at a considerable distance away. Solid floors of concrete or masonry is the preferred working surface.
2. Cover any combustible material with fire resistant covers or shields, if it cannot be removed. The covering must be tight and should not leave openings for sparks or ejected slag to enter.
3. Check both sides of a panel or wall for combustible material. Remove the combustible material before welding.
4. A combustible floor should be protected with a fire-resistant covering. Alternatives are to spray the floor with water to keep it wet for the duration of the welding or cover with damp sand. Care must also be taken to avoid an electric shock when this is done. A combustible floor directly laid onto concrete does not need to be sprayed with water.
5. Seal cracks and openings to adjacent areas that a spark or slag can enter. Seal any openings found with a fire-resistant cover. Shut doors and windows that do not provide ventilation or erect protective screens in front of them when possible.
6. Avoid welding near hydraulic lines or containers containing flammable contents.
7. Do not perform any welding work on containers that held flammable or toxic substance until they are cleaned by a person trained in removing toxic and flammable substances and vapours per the American Welding Standard AWS F4.1.
8. Open a container before performing any welding work on it. The heat generated by the welding process will cause the air and gases to expand. The internal pressure may cause a sealed or closed container to rupture, possibly causing an injury or death.
9. Do not weld pipes or metal that are covered in combustible material or in contact with combustible structure such as a wall. Only weld if the covering can be safely removed.
10. Follow all safety precautions and legal requirements before welding a workpiece that contains Asbestos or attempting to remove the Asbestos covering. This requires expert knowledge and equipment.
11. Molten slag can run down the inside and outside of a pipe and start a fire. Be aware where the pipe terminates and take precautions.
12. Do not weld a panel that is a sandwich construction of combustible and metal materials.
13. Have a fire extinguisher available for immediate use. A dry chemical fire extinguisher for Types A, B and C is suggested.
14. Welding a combustible metal like zinc, magnesium or titanium requires a Type D fire extinguisher.
15. Do not use liquid-based fire extinguishing methods near the electric welding unit, as it may cause a shock hazard.
16. Ventilation systems should be positioned so sparks or molten slag isn’t carried to an adjacent area.
17. Have a Fire Watcher observing areas outside of the welder’s view, such as the opposite side of a wall or behind the welder. A fire may also start on the other side of a structure that could not be removed. The Fire Watcher will extinguish a fire or raise the alarm to evacuate if the fire cannot be contained by the extinguishing equipment.
18. A fire watch extends at least 30 minutes after the welding is complete to ensure there are no fires caused by smoldering sparks or ejected material

FUMES AND GASES

WARNING! Stop welding and move to a location with ventilation if your eyes, nose or throat become irritated. This indicates the ventilation is not adequate to remove the fumes. Do not resume welding until the ventilation is improved and the discomfort ceases. Seek medical attention if the symptoms do not diminish or if the welder experiences nausea, dizziness or malaise.

Welding may produce hazardous fumes and gas during the welding process. A well-ventilated work area can normally remove the fumes and gases, but sometimes the welding produces fumes and gases that are hazardous to your health

1. Only work in a confined space if the area is well ventilated or while wearing a respirator or an air-supplied respirator. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe. Always have a trained watchperson nearby.
2. If ventilation in the work area is poor, use an approved air-supplied respirator. All the people in the work area must also have air-supplied respirators.
3. Oxygen displacement can occur in confined areas when the shielding gas fills the area and pushes out air. Argon, Propane and Carbon Dioxide are heavier than air and will fill a confined space from the bottom up.
4. Avoid positions that allow welding fumes to reach your face. Always attempt to weld ‘upwind’ of the workpiece with the airflow across the face of the welder. Airflow from behind may create a low-pressure area in front of the welder and draw the fumes to the person.
5. Ventilate the work area to remove welding fumes and gases. The fumes and gases should be drawn away from the user.
6. Ventilation should be enough to disperse fumes, but not enough to disturb the shielding gas or flame during welding.
7. Ventilation exhaust shall be directed to a non-work area to avoid exposing other people to potential toxic or dangerous fumes.
8. Air removed from the work area by the ventilation system must be replenished with fresh air to avoid oxygen starvation or a build-up of fumes or gases. Only use air to provide ventilation. Any other combination of gases may be explosive or toxic to people in the work area.
9. Ventilation methods that remove gas and fumes from the welding point before they reach the welder’s face should be given preference.
10. Avoid welding in a work area that has vapours from cleaning, degreasing or any spraying operations. The heat and light from welding can react with the vapour and form irritating or potentially toxic gases. Wait for the vapours to disperse.
11. Consult the manufacturer’s Safety Data Sheets (SDS) for instructions and precautions about metals, consumables, coatings, cleaners and degreasers.
12. Do not weld on coated metals such as galvanized, lead or cadmium plated steel, unless the coating is removed from the weld area. The coatings and any metals containing these elements can give off toxic fumes during the welding process.
13. Do not weld, cut or heat lead, zinc, cadmium, mercury, beryllium or similar metals without seeking professional advice and inspection of the welding area’s ventilation. These metals produce extreme toxic fumes, which can cause discomfort, illness and death.
14. Do not weld or cut near chlorinated solvents or in areas that chlorinates solvents can enter. The heat or ultraviolet light of the arc can separate chlorinated hydrocarbons into a toxic gas (phosgene) that can poison or suffocate the user or bystanders.
15. Check the Safety Data Sheet for the proper handling and safety precautions for consumable welding rods as the coating can have multiple chemicals.

COMPRESSED GAS CYLINDER PRECAUTIONS

WARNING! Improper handling or maintenance of compressed gas cylinders and regulators can result in serious injury or death. Do not use a cylinder or its contents for anything other than its intended use.

1. Only use inert or nonflammable gas with the welding unit, such as Carbon Dioxide, Argon or Helium with the welding unit.
2. Never use flammable gases, as they will ignite and may result in an explosion or fire that can cause death or injury.
3. Do not attempt to mix gases or refill a gas cylinder. Exchange a cylinder or have it refilled by a professional service.
4. Do not deface or alter the name, number or other markings on a cylinder. Do not rely on a cylinder’s colour to identify the contents. Do not connect a regulator to a cylinder that contains a gas that the regulator was not designed to handle.
5. Do not expose a cylinder to excessive heat, sparks, slag, flame or any other heat source.
6. A cylinder exposed to temperatures above 130 °F will require water spray cooling. This method may not be compatible with electric welding units due to the hazard of electrocution
7. Do not expose a cylinder to electricity of any kind.
8. Do not attempt to lubricate a regulator. Always change a cylinder carefully to prevent leaks and damage to the cylinder’s walls, valve or safety devices.
9. Gases in the cylinder are under pressure. Protect the cylinder from bumps, falls, falling objects and harsh weather. A punctured cylinder under pressure can become a lethal projectile. If a cylinder is punctured, do not approach until all pressure is released.
10. Protect the valve and regulator. Damage to either can result in regulator’s explosive ejection from the cylinder.
11. Always secure a gas cylinder in a vertical position to a welding cart or other fixed support with a steel chain, so it cannot be knocked over.
12. Away from areas where they may be struck or subjected to physical damage.
13. A safe distance from welding or cutting operations and any other source of heat, sparks or flame.
14. Do not use as an improvised support or roller.
15. Always place the cylinder cap securely on the cylinder unless it is in use or being serviced.
16. Do not use a wrench or hammer to open a cylinder valve that cannot be opened by hand. Notify your supplier for instructions.
17. Do not modify or exchange gas cylinder fittings.
18. Close the cylinder valve and immediately remove the faulty regulator from service for repair, if any of the following conditions exist:
19. Gas leaks externally.
20. Delivery pressure continues to rise with the downstream valve closed.
21. The gauge pointer does not move off the stop pin when pressurized or fails to return to the stop pin after pressure is released.
22. Do not attempt to make regulator repairs. Send faulty regulators to the manufacturer’s designated repair centre.
23. Do not weld on the gas cylinder.
24. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
25. Compressed gas cylinders must not be located in a confined space with the person welding to prevent the possibility of leaks displacing the oxygen.

ELECTRICAL SAFETY

1. Do not come into physical contact with the welding current circuit. The welding current circuit includes:
2. The workpiece or any conductive material in contact with it.
3. The ground clamp.
4. The welding wire.
5. Any metal parts on the welding torch.
6. The output terminals.
7. Insulate yourself from the electrical current and ground using electrical insulating mats or covers big enough to prevent physical contact with the workpiece or ground.
8. Connect the ground clamp as close to the welding area on the workpiece as practical to prevent welding current from traveling along an unexpected path and causing an electric shock or fire hazard.
9. An option is to attach the ground clamp to a bare metal spot on a metal workbench. The circuit will complete as long as the workpiece is also in full contact with the bare metal workbench.
10. Do not weld on damp surfaces that can transmit the electric current without taking precautions for the welder and bystanders. The welding wire, welding head and nozzle are electrically ‘hot’.
11. Only use insulated connectors to join welding cables.
12. Ensure there are no contacts between the workpiece and work area that would allow it to ground, other than through the ground cable circuit
13. Do not exceed the duty cycle or amperage required for the type of welding. Excessive amperage can cause the deterioration of protective insulation and create a shock hazard.
14. Unplug the welding unit when not in use as the unit as current is still entering the unit, even when it is turned off.
15. Frequently inspect input power cable for wear and tear, replace the cable immediately if damaged. Bare wiring is dangerous and can kill.
16. Do not use damaged, under sized or badly joined cables.
17. Do not disconnect the power cord in place of using the ON/OFF switch on the tool. This will prevent an accidental startup when the power cord is plugged into the power supply.
18. In the event of a power failure, turn off the machine as soon as the power is interrupted. The possibility of accidental injury could occur, if the power returns and the unit is not switched off.
19. Make certain the power source conforms to requirements of your equipment (see Specifications).

POWER TOOL PRECAUTIONS

This equipment requires a dedicated 120 volt, 20 amp single-phase alternating current circuit equipped with a similarly rated circuit breaker or slow blow fuse. Do not run other appliances, lights, tools or equipment on the circuit while operating this welding unit.

1. Do not drape or carry coiled welding cables on your body when the cables are plugged into the welding unit.
2. Do not start the tool when the welding wire is touching the workpiece.
3. Hold the tool by the insulated gripping surfaces when performing an operation where it may contact hidden wiring or its own cord and cables. Contact with a ‘live’ wire will electrify exposed metal parts and shock the operator.
4. Take work breaks to prevent the tool’s motor from overheating and/or overloading. Refer to the welding unit’s duty cycle in Specifications.
5. Keep hands away from the welding wire and the area it is being applied to when the tool is in operation.
6. Do not connect the welding unit ground clamp to an electrical conduit. Do not weld on an electrical conduit.
7. Do not touch the welding wire or welded surface immediately after use. The surface will be hot and may cause an injury.
8. Never use a tool with a cracked or worn welding wire. Change the welding wire before using and discard the damaged one.

POWER CORD

Insert the power cord plug directly to the power supply whenever possible. Extension cords are not recommended for use with this welding unit.

ELECTROMAGNETIC FIELDS

WARNING! Stop welding immediately and move away from the welding unit if you feel faint, dizzy, nausea or shocks. Seek medical attention.

Electromagnetic Fields (EMF) can interfere with electronic devices such as pacemakers. Anyone with a pacemaker should consult with their doctor before working with or near a welding unit. The following steps can minimize the effects of electromagnetic fields.

1. Twist or tape cables together and prevent coils.
2. Do not drape cables on your body.
3. Keep the welding power source and cables as far away from the user as practical. A minimum of 24 in. is recommended.
4. Connect the workpiece clamp as close to the weld as possible, but lay the welding wire and workpiece cables away from the user.
5. Use the lowest current setting possible during welding.
6. Avoid long and regular bursts of energy while welding. Apply the welding wire in short strokes and intermittently. This will prevent the pacemaker from interpreting the signal as a rapid heartbeat.
7. Do not allow the welding wire to touch the metal while welding.
8. Wrap the lead cable and ground cable together whenever possible.
9. Keep the lead cable and ground cables on the same side of your body.

UNPACKING

WARNING! Do not operate the tool if any part is missing. Replace the missing part before operating. Failure to do so could result in a malfunction and personal injury.

Remove the parts and accessories from the packaging and inspect for damage. Make sure that all items in the parts list are included.

Contents

• Gasless MIG Welder
• Ground Lead
• MIG Torch
• Regulator
• Role of Flux core Wire 0.030 in

A Wire Size Selector
B Synergic Control Knob
C Positive Outlet Socket (+)
D Negative Outlet Socket (-)
E Welding Torch Cable
F Weld Power Lead
G Input Power Cable
H Fan
I Power Switch
J Gas Inlet
K Ground Clamp cable (not shown)

ASSEMBLY & INSTALLATION

Letter references in parenthesis (A) refer to the included Identification Key. Dashed numbers in parenthesis (Fig. 1-1) refer to specific point of an illustration or image

1. Connecting the cables:

2. Connect the ground cable (K) into the negative outlet socket (D) when using gas or a shielded wire.

3.  Connect the ground cable (K) to the positive outlet socket (C) for gasless wire.

4. Connect the power cable (F) to the opposite outlet socket.

5. Fit the gas line onto the gas inlet (J) barb. Secure with a hose clamp if necessary.

6. Connect the gas regulator (Fig. 2) to the gas cylinder or compressor.

7. Connect the other end of the gas line to the regulator’s barbed gas outlet.

8. Install the welding wire if needed (See Wire Installation and Setup).

9. Open the valve on the gas cylinder and set the flow to 0.35 CFM (8-10 L/min).

CHECK FOR GAS LEAKAGE

Check for gas leakage after each time the welding unit is set up and at regular intervals.

The recommended procedure is as follows:

1. Connect the regulator and gas hose assembly, then tighten all connectors and clamps.
2. Slowly open the cylinder valve.
3. Set the flow rate on the regulator to approximately 0.35 CFM (8 to 10 L/min).
4. Close the cylinder valve and pay attention to the needle indicator on the regulator’s pressure gauge. If the needle drops away towards zero there is a gas leak. Sometimes a gas leak can be slow and to identify. Leave the gas pressure in the regulator and line for an extended time period. Perform the test as above. Close the cylinder valve and check after a minimum of 15 minutes.
5. After confirming there is a loss of gas, check all connectors and clamps for leakage by brushing or spraying with soapy water. Bubbles will appear at the leakage point.
6. Tighten clamps or fittings to eliminate gas leakage. Replace the clamps and fittings if this fails to solve the problem.

WIRE INSTALLATION AND SET UP

The correct installation of the wire spool and the wire into the wire feed unit is critical to achieving an even and consistent wire feed. Poor set up of the wire into the wire feeder is a major cause of fault with MIG welding machines. The guide below will assist in the correct setup of your wire feeder.

1. Open the welding unit’s top cover (Fig. 3).
   

2. Remove the spool retaining nut (Fig. 4). The spool retaining nut is left-hand threaded.

3. Note the tension spring adjuster and spool locating pin (Fig. 5).

4. Fit the wire spool onto the spool holder. Fit the locating pin into the location hole on the spool. Reinstall the spool retaining nut tightly (Fig. 6)

5. Choose a drive roller based on the thickness of the welding wire. Twist the retainer knob and flip the cap up (Fig. 7). Place the roller onto the spindle with the correct wire size on top. Flip the cap down and twist to lock in place.

6.  Flux-Core – Install a knurled drive roller. Apply a light amount of pressure to the drive roller. Too much pressure will crush the cored wire.

7. Loosen the tension knob and swing it up and out of the way (Fig. 8). Swing the pressure roller arm out of the way as well.

8. Snip the wire carefully, be sure to hold the wire to prevent the spool uncoiling. Carefully feed the wire into the inlet guide tube of the wire feed unit (Fig. 8).

9. Feed the wire through the drive roller and into the outlet guide tube of the wire feeder.

10. Swing the pressure arm into place against the roller and lock it into place with the tension arm. Tighten the knob to apply a medium amount of pressure (Fig. 9).

11. Remove the gas nozzle and contact tip from the torch neck (Fig. 10)

12. Press and hold the welding torch trigger to feed the wire through to the torch neck. Release the trigger when the wire exits the torch neck.

13. Fit the correct sized contact tip and feed the wire through it, screw the contact tip into the tip holder of the torch head. Clip the wire close to the tip unless testing the drive tension.

14. Fit the gas nozzle to the torch head (Fig. 10).

15. A simple check for the correct drive tension is to bend the end of the wire over hold it about 4 in. from your hand and let it run into your hand, it should coil round in your hand without stopping and slipping at the drive rollers, increase the tension if it slips (Fig. 11).

16. Insufficient tension on the wire spool can allow it to spin after the wire feeding mechanism stops, forcing loops of wire off the spool to become tangled. Increase the pressure on the tension spring inside the spool holder assembly by adjusting the tension screw if this happens (Fig. 6)

OPERATION

FEATURES

THERMAL OVERLOADPROTECTION

Constantly exceeding the duty cycle can damage the cutting unit. An internal thermal protector will open when the duty cycle is exceeded, shutting OFF all cutting unit functions except the cooling fan. Leave the cutting unit turned ON with the fan running. The thermal protector will automatically reset and the cutting unit will function normally again once it has cooled.

Wait at least another 10 minutes after the thermal protector opens before resuming cutting. Starting before this additional time may result in a shortened duty cycle.

OVER-VOLTAGE This equipment has an automatic voltage compensation function, which enables the unit to maintain the voltage within the given range. In case that the input voltage or amperage exceeds the stipulated value, it is possible to damage the equipment’s components. Please ensure your primary power supply is correct (see Specifications).

OPERATING THE WELDING UNIT

1. Switch the wire size selector (A) to match the wire diameter installed.
2. Turn the synergic control knob (B) to select the power. The higher the number, the more power is applied to the weld.
3. Turn the gas on at the cylinder, unless you are using flux cored wire.
4. Turn the power on with the power switch (I).
5. Squeeze the welding torch trigger to start welding. The welding unit will automatically control the wire speed.
6. Adjust the wire speed and power with the synergic control knob.
7. Release the trigger when the weld is complete

MIG (METAL INERT GAS) WELDING

MIG (metal inert gas) welding, also known as GMAW (gas metal arc welding) or MAG (metal active gas welding), is a semi-automatic or automatic welding process in which a continuous and consumable wire welding wire and a shielding gas are fed through a welding torch. A constant voltage, direct current power source is most commonly used with MIG welding.

SHORT-CIRCUIT TRANSFER
Short-circuit transfer is the most common used method. The wire welding wire is fed continuously down the welding torch until it exits from the contact tip. The wire touches the workpiece and causes a short-circuit. The wire heats up and begins to form a molten bead, the bead separates from the end of the wire and forms a droplet that is transferred into the weld pool. This process is repeated about 100 times per second, making the arc appear constant to the human eye.

1. The wire approaches the workpiece and touches the work creating a short-circuit between the wire and the base metal, because there is no space between the wire and the base metal there is no arc and current flows through the wire (Fig. 13)

2. The wire cannot support all the current flow; resistance builds up and the wire becomes hot and weak and begins to melt (Fig. 14)

3. The current flow creates a magnetic field that begins to pinch the melting wire forming it into droplet (Fig. 15).

4. The pinch causes the forming droplet to separate and fall to-wards the now creating weld pool (Fig. 16).

5. An arc is created at the separation of the droplet and the heat and force of the arc flattens out the droplet into the weld pool. The heat of the arc melts the end of the wire slightly as it feeds towards the base metal (Fig. 17).

6. The wire feed speed overcomes the heat of the arc and the wire again approaches the work to short-circuit and repeat the cycle (Fig. 18).

BASIC MIG WELDING GUIDE
Good weld quality and weld profile depends on the gun angle, direction of travel, welding wire extension (stick out), travel speed, thickness of base metal, wire feed speed (amperage) and arc voltage. To follow are some basic guides to assist with your setup.

GUN POSITION – TRAVEL DIRECTION, WORK ANGLE
Gun position or technique usually refers to how the wire is directed at the base metal, the angle and travel direction chosen. Travel speed and work angle will determine the characteristic of the weld bead profile and degree of weld penetration.

PUSH TECHNIQUE
The wire is located at the leading edge of the weld pool and pushed towards the un-melted work surface. This technique offers a better view of the weld joint and direction of the wire into the weld joint. Push technique directs the heat away from the weld puddle allowing faster travel speeds providing a flatter weld profile with light penetration – useful for welding thin materials. The welds are wider and flatter allowing for minimal clean up / grinding time (Fig. 19).

PERPENDICULAR TECHNIQUE
The wire is fed directly into the weld, this technique is used primarily for automated situations or when conditions make it necessary. The weld profile is generally higher and a deeper penetration is achieved (Fig. 20).

DRAG TECHNIQUE
The gun and wire are dragged away from the weld bead. The arc and heat are concentrated on the weld pool, the base metal receives more heat, deeper melting, more penetration and the weld profile is higher with more build up (Fig. 21)

TRAVEL ANGLE
Travel angle is the right to left angle relative to the direction of welding. A travel angle of 5° to 15° is ideal and produces a good level of control over the weld pool. A travel angle greater that 20° will give an unstable arc condition with poor weld metal transfer, less penetration, high levels of spatter, poor gas shield and poor-quality finished weld (Fig. 22)

ANGLE TO WORK
The work angle is the forward or back angle of the gun relative to the workpiece.
The correct work angle provides good bead shape, prevents undercut, uneven penetration, poor gas shield and poor-quality finished weld (Fig. 23).

STICK OUT
Stick out is the length of the unbelted wire protruding from the end of the contact tip.
A constant even stick out of 1/8 to 1/4 in. (Fig. 24) will produce a stable arc and an even current flow providing good penetration and even fusion (Fig. 25). A stick out that is too short will cause an unstable weld pool, produce spatter and overheat the contact tip (Fig. 26). A stick out too long will cause an unstable arc, lack of penetration, lack of fusion and increase spatter (Fig. 27).

TRAVEL SPEED
Travel speed is the rate that the gun is moved along the weld joint and is usually measured in mm per minute. Travel speeds can vary depending on conditions and the welder’s skill and is limited to the welder’s ability to control the weld pool. Push technique allows faster travel speeds than Drag technique. Gas flow must also correspond with the travel speed, increasing with faster travel speed and decreasing with slower speed. Travel speed needs to match the amperage and will decrease as the material thickness and amperage increase.

TOO FAST TRAVEL SPEED
A too fast travel speed produces too little heat per inch of travel resulting in less penetration and reduced weld fusion, the weld bead solidifies very quickly trapping gases inside the weld metal causing porosity. Undercutting of the base metal can also occur and an unfilled groove in the base metal is created when the travel speed is too fast to allow molten metal to flow into the weld crater created by the arc heat (Fig. 28).

TOO SLOW TRAVEL SPEED
A too slow travel speed produces a large weld with lack of penetration and fusion. The energy from the arc dwells on top of the weld pool rather than penetrating the base metal. This produces a wider weld bead with more deposited weld metal per mm than is required resulting in a weld deposit of poor quality (Fig. 29)

CORRECT TRAVEL SPEED
The correct travel speed keeps the arc at the leading edge of the weld pool allowing the base metal to melt sufficiently to create good penetration, fusion and wetting out of the weld pool, producing a weld deposit of good quality (Fig. 30).

WIRE TYPES AND SIZES
Use the correct wire type for the base metal being welded. Use stainless steel wire for stainless steel and steel wires for steel.

Use a smaller diameter wire for thin base metals. For thicker materials use a larger wire diameter and larger machine, check the recommended welding capability of your machine.
As a guide refer to the Welding Wire Thickness Chart in Table 3.

GAS SELECTION
The purpose of the gas in the MIG process is to protect/shield the wire, the arc and the molten weld metal from the atmosphere. Most metals when heated to a molten state will react with the air. Without the protection of the shielding gas, the weld produced would contain defects like porosity, lack of fusion and slag inclusions. Some of the gas becomes ionized (electrically charged) and helps the current flow smoothly.
The correct gas flow is also very important in protecting the welding zone from the atmosphere. Too low of a flow will give inadequate coverage and result in weld defects and unstable arc conditions.

Too high of a flow can cause air to be drawn into the gas column and contaminate the weld zone.

USE THE CORRECT SHIELDING GAS
Co2 is good for steel and offers good penetration characteristics, the weld profile is narrower and slightly raised than the weld profile obtained from an Argon/Co2 mixed gas. Argon/Co2 mix gas offers better weld ability for thin metals and has a wider range of setting  tolerance on the machine. Argon 75%/Co2 25% is a good all round mix suitable for most applications (Fig. 31)

CARE & MAINTENANCE

1. Maintain the tool with care. A tool in good condition is efficient, easier to control and will have fewer problems.
2. Inspect the tool fittings, alignment, hoses and power supply cord periodically. Have damaged or worn components repaired or replaced by an authorized technician. Only use identical replacement parts when servicing.
3. Exposure to extremely dusty, damp, or corrosive air is damaging to the welding unit. In order to prevent possible failure or fault of this welding equipment, clean the dust at regular intervals with clean and dry compressed air.
4. Follow instructions for lubricating and changing accessories.
5. Only use accessories intended for use with this tool. 6. Keep the tool handles clean, dry and free from oil/grease at all times.
6. Maintain the tool’s labels and name plates. These carry important information. If unreadable or missing, contact Princess Auto Ltd. for replacements.

WARNING! Only qualified service personnel should repair the tool. An improperly repaired tool may present a hazard to the user and/or others.

DISPOSAL

Recycle a tool damaged beyond repair at the appropriate facility.

Contact your local municipality for a list of disposal facilities or by-laws for electronic devices, batteries, oil or other toxic liquids.

TROUBLESHOOTING

Visit a Princess Auto Ltd. location for a solution if the tool does not function properly or parts are missing. If unable to do so, have a qualified technician service the tool.

MIG WELDING

PROBLEM(S)| P OSSIBLE CAUSE(S)| SUGGESTED SOLUTION(S)
---|---|---
Excessive Spatter|

1. Voltage too high.
2. Wrong polarity set.
3. Stick out too long.
4. Contaminated base metal.
5. Contaminated MIG wire.
6. Inadequate gas flow or too much gas flow.

|

1. Select a lower voltage setting
2. Select the correct polarity for the wire being used – see machine setup guide.
3. Bring the torch closer to the work.
4. Remove materials like paint, grease, oil and dirt, including mill scale from base metal.
5. Use clean dry rust free wire. Do not lubricate the wire with oil, grease etc.
6. Check the gas is connected, check hoses, gas valve and torch are not restricted. Set the gas flow rate to 0.35 CFM (8-10 L/min). Check hoses and fittings for holes, leaks etc. Protect the welding zone from wind and drafts.

Porosity – small cavities or holes resulting from gas pockets in weld metal.|

1. Wrong gas
2. Inadequate gas flow or too much gas flow.
3. Moisture on the base metal.
4. Contaminated base metal.
5. Contaminated MIG wire.
6. Gas nozzle clogged with spatter, worn or out of shape
7. Missing or damaged gas diffuser.

|

1. Check that the correct gas is being used.
2. Check the gas is connected, check hoses, gas valve and torch are not restricted. Set the gas flow rate to .35 CFM (8-10 L/min). Check hoses and fittings for holes, leaks etc. Protect the welding zone from wind and drafts.
3. Remove al moisture from base metal before welding.
4. Remove materials like paint, grease, oil and dirt, including mill scale from base metal.
5. Use clean dry rust free wire. Do not lubricate the wire with oil, grease etc.
6. Clean or replace the gas nozzle.
7. Replace the gas diffuser.

Wire stubbing during welding|

1. Holding the torch too far away.
2. Welding voltage set too low.

|

1. Bring the torch closer to the work and maintain stick out of 3/16 to 3/8 in.
2. Increase the voltage.

Lack of Fusion − failure of weld metal to fuse completely with base metal or a proceeding weld bead|

1. Contaminated base metal.
2. Not enough heat input.
3. Improper welding technique.

|

1. Remove materials like paint, grease, oil and dirt, including mill scale from base metal.
2. Select a higher voltage range and /or adjust the wire speed to suit.
3. Keep the arc at the leading edge of the weld pool. Gun angle to work should be between 5 and 15°. Direct the arc at the weld joint Adjust work angle or widen groove to access bottom during welding. Momentarily hold arc on side walls if using weaving technique.

Excessive Penetration – weld metal melting through base metal| Too much heat.| Select a lower voltage range .
Lack of Penetration − shallow fusion between weld metal and base metal|

1. Poor in incorrect joint preparation.
2. Not enough heat input.
3. Contaminated base metal.

|

1. Material too thick. Joint preparation and design needs to allow access to bottom of groove while maintaining proper welding wire extension and arc characteristics. Keep the arc at the leading edge of the weld pool and maintain the gun angle at 5 and 15° keeping the stick out between 3/16 to 3/8 in.
2. Select a higher voltage range and /or adjust the wire speed to suit Reduce travel speed.
3. Remove materials like paint, grease, oil and dirt, including mill scale from base metal.

---|---|---

MIG WIRE FEED

PROBLEM(S)| P OSSIBLE CAUSE(S)| SUGGESTED SOLUTION(S)
---|---|---
Inconsistent / interrupted wire feed|

1. Wrong polarity selected.
2. Incorrect wire speed setting.
3. Voltage setting incorrect.
4. MIG torch lead kinked or too sharp angle being held.
5. Contact tip worn, wrong size, wrong type.
6. Liner worn or clogged (the most common causes of bad feeding).
7. Blocked or worn inlet guide tube.
8. Wire misaligned in drive roller groove.
9. Incorrect drive roller size.
10. Wrong type of drive roller selected.
11. Worn drive rollers
12. Drive roller pressure too high.
13. Too much tension on wire spool hub.
14. Wire crossed over on the spool or tangled.
15. Contaminated MIG wire.

|

1. Select the correct polarity for the wire being used – see machine setup guide
2. Adjust the wire feed speed.
3. Adjust the voltage setting.
4. Remove the kink, reduce the angle or bend.
5. Replace the tip with correct size and type.
6. Try to clear the liner by blowing out with compressed air as a temporary cure, it is recommended to replace the liner.
7. Clear or replace the inlet guide tube.
8. Locate the wire into the groove of the drive roller
9. Fit the correct size drive roler eg; 0.030 in. wire requires 0.030 in. drive roller.
10. Fit the correct type rol er (e.g. knurled rollers needed for flux cored wires).
11. Replace the drive rollers.
12. Can flatten the wire welding wire causing it to lodge in the contact tip -reduce the drive roler pressure
13. Reduce the spool hub brake tension.
14. Remove the spool untangle the wire or replace the wire.
15. Use clean dry rust free wire. Do not lubricate the wire with oil, grease etc.

APPENDIX A

References

• princessauto.com

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