BORMANN BIW1110 Welding Gun User Guide

BORMANN BIW1110 Welding Gun

Thank you for buying our product, and 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 consider protection 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 helmets and wear protective garments to protect the eye and body.
• Use suitable protective equipment or curtains 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 trouble with installation and operation, please re-check the setup 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 maximum humidity level of 90%.
• The 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 corrosive 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 the voltage, output current, or temperature of the machine exceeds 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 periods. 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 maximum cycle current. Over-load current will damage the machine.
• Power voltage can be found in the diagram of the main technical data. The automatic compensation circuit for the voltage will ensure that the welding current is kept within the allowable range. If the power voltage exceeds the allowed range it will damage the machine components. The operator should observe closely and take preventative measures where necessary.
• The grounding connector at the rear of the machine should be grounded via a suitable cable to prevent static electricity.
• If the 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 environment.

Arc-striking is difficult and easy to pause.

1. Make sure of a good quality electrode.

2. If the electrode is not dry, it will cause an unstable arc with reduced weld quality.

3. If a long extension cable is used, this will reduce output voltage and weld quality.

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

   • The current does not stabilize when the machine is in operation.

   1. The electric input cable is of insufficient voltage rating.
   2. There is harmful interference from electric cables or other equipment nearby.

Too much spatter

1. The possible current is too high and/or the rod’s diameter is too small.
2. Output terminal polarity connection is incorrect, switch polarity, eg. The rod holder should be connected to negative polarity and the workpiece 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 nearby when this machine is being operated.

Technical data

• Voltage: 230 V
• Frequency: 50 Hz
• Rated input capacity : 2.6 kVA
• Welding current: 20-140 A
• Operation cycle : 25%
• Electrode diameter: 1.6-3.2 mm
• Weight : 1.3 kg
• Other features : Digital screen
• Includes : Electrodes torch & ground clamp
  • Hot start/Arc force/Anti-stick
• 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.
• 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.

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 the long cable is in use, a thicker cable is suggested 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 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 an inducting cable of not less than 6 mm² to connect the housing to the ground. This is done by way of a ground connection at the back of the machine.
3. Ensure the cable, holder, and fastening plug have been connected to the ground. Insert the fastening plug into the “-” polarity socket and fasten it clockwise.
4. Attach the cable to the “+” polarity on the front panel, and fasten it clockwise, this cable then clamps to the workpiece.
5. Be aware of the connecting polarity correctly, this machine has two connections: a positive and a negative connection.
6. Positive connection: The holder connects with the “-” polarity, while the workpiece is connected to the “+” polarity.
7. Negative connection: workpiece to “-” polarity, holder to “+” polarity.
8. Choose a suitable connection for the job at hand. If the connection is unsuitable it will cause an 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. The installment is now complete

Operation

1. Turn on the power, the screen will display the set current volume and the 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

1. Power indicator light
2. Fault indicator light
3. 3+
4. Current adjusting buttons
5. Digital display
6. Fixed electrode (1.6-3.2 mm)
7. Power switch ON/OFF (press and hold for 3 seconds)
8. Ground clamp connection

Maintenance

1. Remove dust by drying and cleaning compressed air regularly, if the 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 near the machine, if it comes into contact with water, DO NOT USE.
2. If the welder is not used for a long period, store it in a 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

The power indicator is not lit, the fan is not working and there is no welding output.| A. Make sure the power switch is “on”.

B.  Make sure the input cable has power.

The power indicator is lit, the fan does not work and there is no welding output.| A. 220v power is not stable (input cable possibly low in voltage) or the input cable is not securely connected.

B.  Turn the power switch off and on again as possibly the protection circuit has kicked in It may be necessary to leave for 5-10 minutes to allow a reset.

C.  Check Plug is firmly connected to a working power source.

The fan is working, welding current is not stable or out of the required voltage range| A. Quality of 1K regulation resistance could be faulty and requires replacement.

B.  Terminal of output not making a secure connection.

The fan is working but the indicator is not lit, and there is no welding output.| A. Check all components for poor connections.

B.  Check the voltage between the power source board and the IGBT board

The fan is working normally and ly, and the indicator is lit, but there is no welding output.| A. Possibly the over-current protection is operating, switch off the machine and leave for 5 to 10 minutes, then try again.

B.  Possible inverter circuit fault;

(1) IGBT is faulty, replacement is necessary.

(2) Possibly secondary rectifier tube is faulty, replacement is necessary.

D. Feedback circuit could be at fault.

Safety Instructions

To avoid transportation damages, the tool has to be delivered in solid packaging. Packaging as well as the unit and accessories are made of recyclable materials and can be disposed of accordingly. The tool’s plastic components are marked according to their material, which makes it possible to be environmentally friendly and differentiated because of available collection facilities.

Only for EU countries
Do not dispose of electric equipment together with household waste material! In observance of European Directive 2002/96/EC on waste electrical and electronic equipment and its implementation by national law, electric tools that have reached the end of their life must be collected separately and returned to an environmentally compatible recycling facility.

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WARRAΝΤΥ

The power tools have been manufactured according to strict standards, set by our company, which are aligned with the respective European quality standards. The power tools of our company are provided with a warranty period of 24 months for non-professional use, 12 months for professional use, and 12 months for chargers and batteries. The warranty is valid from the date of purchase of the product. Proof of the warranty right is the purchase document of the tool (retail receipt or invoice). Under no circumstances shall the company cover the relevant cost of spare parts and respective required working hours unless a copy of the purchase document is presented. In case the repair has to be done by our service department the cost of transportation (to and from) is entirely borne by the sender (client). The tools must be sent for repair to the company or to an authorized workshop in the appropriate way and means of transport.

WARRANTY EXEMPTIONS AND RESTRICTIONS

1. Spare parts that wear out naturally as a consequence of being used (brushes, cables, switches, chargers, chokes, etc.).
2. Tools damaged as a result of non-compliance with the instructions of the manufacturer.
3. Tools poorly maintained.
4. Use of improper lubricants or accessories.
5. Tools are given to third entities free of charge.
6. Damage due to an electrical connection at a voltage other than that indicated on the appliance plate.
7. Connection to a non-earthed power supply.
8. Change in current voltage.
9. Damage resulting from the use of salty water (e.g., washing machines, pumps).
10. Damage or malfunction resulting from improper cleaning procedure of the tool.
11. Contact of the tool with chemicals, or damage as a result of moisture or corrosion.
12. Tools that have been modified or opened by unauthorized personnel.
13. Tools used for rent.

The warranty covers only the free-of-charge replacement of the component that presents a manufacturing defect or material failure. In case of a lack of a specific spare part, the company reserves the right to replace the tool with another corresponding model. After all warranty procedures have been concluded, the warranty period of the tool shall not be extended or renewed. Replacement of a spare part with a repair charge is covered by a 1-year warranty of good operation, subject to compliance with the warranty terms. The spare parts or tools that are replaced remain in the possession of our company. Requirements, other than those mentioned in this warranty form, regarding power tools repair or damage thereof, do not apply. Greek law and relative regulations apply to this warranty.

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