WILTEC 62551 MIG or MAG Welder Machine with 180 A User Manual

WILTEC 62551 MIG or MAG Welder Machine with 180 A User Manual

Introduction

Thank you for choosing to purchase this quality product. To minimize the risk of injury, we ask you to always take some basic safety precautions when using this product. Please read this operating manual carefully and make sure that you understand it. Keep these operation instructions in a safe place.

Initiation

The MIG welder is suitable both for hobby and professional applications. Before using the welder or performing maintenance work, read the user’s manual and keep it in a safe place for future reference.

The welder is small, efficient, and very light. It is easy to carry, no need to use a shoulder strap. The device is also suitable for generator-supplied use on construction sites. The welding voltage and wire feed speed are adjusted with the help of a regulation and corresponding to the thickness of the sheet to be welded. Thus, the regulation of correct parameters is easy. The length of the arc or welding heat is adjusted via a second regulation and does normally not need to be readjusted with a thicker or thinner sheet used as soon as you have found the correct values.

The welding properties of the machine are best with a steel wire of 0.8 mm of diameter. Nevertheless, you can also use 0.6 mm, 0.9 mm, or 1 mm solid or welding wires.

Note: The device is only suitable for welding with steel wire.

On welding

• The welding results not only depend on the individual welding machine, but also on the workpiece and work environment. Therefore, all instructions of this user’s manual must be followed.
• During welding, electric current is led to the welding wire and workpiece via the welding nozzle. A mass cable attached to the workpiece leads the current back to the device, thus creating a closed circuit. The current flows freely when the mass clamp is correctly attached to the workpiece and the contact surface of the workpiece is clean and free of paint and rust.
• For welding, the user must apply shielding gas to prevent air from mixing with the weld pool. Carbon dioxide or a mixture of carbon dioxide and argon is suitable for use as shielding gas. Some welding wires form shielding gas themselves generated during melting of the wire filling; in that case, additional shielding gas is not required.

Safety instructions

This device is safe in application thanks to its not leading plastic cover. The welding gun is equipped with a overheating protection that avoids that the machine overheats during operation. The device is protected both from too low and too high a supply voltage. Nevertheless, some risks persists when welding. Therefore, carefully read and follow the following safety instructions.

Using safety equipment

The arc and its radiation reflected are harmful to unprotected eyes. Always protect your eyes and face with a suitable welding mask. The arc and weld spatters burn unprotected skin; so, do wear protective gloves and clothing while welding.

Using the welding gun safely

• Parts of the device, e.g., the end of the welding wire and the welding gun, become hot during operation. The wire being sharp and moving quickly, pay special attention while you thread it.
• Never carry the device on your shoulder when welding; place it on a level surface. Do not stock the device by hanging it up on the shoulder strap. The shoulder strap is only suitable for carrying.
• Do not move the shielding gas bottle when the regulation valve is attached to it. Fix the gas bottle in upright position to a separate wall rack or bottle trolley. After use, always close the gas bottle.

Fire protection

Welding is hot work. Therefore, obey the fire regulations. Protect the surroundings from weld spatters. Remove flammable material, e.g., flammable liquids, from the vicinity of the welding spot and have suitable extinguishers at hand.

Note: Fire caused by sparks may even form several hours after work.

Warning! Welding in flammable or explosive zone is strictly forbidden.

Supply voltage

• Do not enter a workpiece, e.g., a container, or a car together with this device.
• Do not work on wet surfaces.
• Do not use damaged welding cables.
• Do not use the welding gun or earth clamp directly at the welding machine or another electric device.

Welding fumes

Make sure that there is enough aeration. Take special precautions when welding metals that contain lead, cadmium, zinc, quicksilver, or beryllium. Suff icient fresh-air supply can also be ensured by using a fresh air helmet.

Using the device

• The device comes to you with a 0.8 mm welding wire installed; thus, no further adjustment need to be made.
• If not using the recommended welding wire, make sure that the contact of the welding gun and device is suitable for the size and type of the wire used.

Before using the product

The products are delivered inside a durable, special packaging. Nevertheless, before using the device, make sure that the products have not been damaged during transport. Check as well if the packaging contains the products that you have ordered and the required user’s manuals.

Environment

• This device is suitable both for indoor and outdoor use; however, it should be protected from heavy rain and direct sunlight. Store the device in a dry and clean place and protect it from sand and dust during use and storage. The operation temperature range recommended is between –20 ℃ and +40 ℃.
• Place the device so that it does not touch any hot surface or comes into contact with sparks or weld spatters. Make sure that the air circulates freely inside the machine.

Cable connections

Mains connection

• The device is equipped with a 3.3 m supply cable and plug. Connect the supply cable to the mains.
• Note: The fuse required is 16 A.
• When using an extension cord, the cross-sectional area of this should to at least be as large as the one of the supply cable (3×2,5 mm²). The maximum length of the extension cord is 50 m.
• The welder can also be operated via a current generator. The minimum power of the generator is 3.5 kVA, the recommended one is 6.0 kVA, so that the device can be used at full capacity.

Earthing

The earth cable is already connected to the machine. Clean the surface of the workpiece and attach the earthing clamp to the piece to establish a closed and failure-free circuit required for welding.

Welding gun

• The welding gun is already connected to the machine. The welding gun leads the shielding gas, welding wire, and electric current to the weldseam. When pressing the trigger of the welding gun, the shielding gas begins to flow and the wire to be fed. The arc ignites when the welding wire touches the workpiece.
• The neck of the welding gun can be rotated by 360°. When rotating t he neck, make sure that the neck is rotated almost to the stop. Thus, you will prevent damages and overheating of the neck.

Note: When using a welding wire with a diameter other than 0.8 mm, adapt the contact tip of the welding gun according to the thickness of the wire.

Shielding gas

• The shielding gas required for steel wires is carbon dioxide or a mixture of argon and carbon dioxide that replaces the air near the arc. The thickness of the welding sheet and the welding power define the gas flow.
• Connect the bayonet coupling of the shielding gas hose to the hose connection of the device and the nozzle to the regulation valve of the gas bottle.

the connection.
2| Adjust the flow with the help of the screw of the regulating valve. A suitable flow is comprised between 8 and 15 ℓ⁄min.
3| After use, close the regulating valve.

Welding wire

The device comes along with the welding gun connected to the positive pole; thus, it is suitable for welding solid steel wires without further adjustments.

Adapting the guide notch of the wire-feed control

Ex-factory, the wire-feed control guide notch is adjusted to match 0.8 to 1.0 mm welding wires. If wanting to use a 0.6 mm welding wire, you need to adapt the guide notch.

1. Open the wire-feed control on the pressure control lever.
2. Switch the device on on the main switch.
3. Press the trigger of the welding gun to bring the feed roll to a position where the fixing screw points upwards and can be unscrewed.
4. Switch the device off on the main switch.
5. Turn half-way the fixing screw of the feed roll with a 2.0 mm socket head wrench.
6. Remove the feed roll from its shaft.
7. Turn the feed roll and replace it on the shaft all the way down, making sure that the screw point upwards.
8. Retighten the fixing screw of the feed roll.

Threading the solid wire

1. Open the coil housing by pressing the opening knob, then set in the wire coil so that it can turn anti-clockwise. This device accepts wire coils of either 5 kg (200 mm diameter) or 1 kg (100 mm diameter).
2. Fix the coil with the coil lock.
3. Detach the end of the wire from the coil, but hold it.
4. Pull approximately 20 cm of wire from the coil and straighten the portion of wire pulled out; cut the wire on the spot where it is straight.
5. Open the pressure control lever to open the wire-feed control drive.
6. Thread the wire through its rear feed and up to the wire feed of the welding gun.
7. Close the wire-feed control drive and lock it with the pressure control lever. Make sure that the wire runs inside the guide notch of the feed.
8. Via the pressure control lever, adjust the compression pressure, but be sure to not exceed the centre line of the scale. With too high a pressure, metal particles are worn off the surface of the wire, which might damage the wire. With too low a pressure, the drive gets out of place, causing
   the wire to run unevenly.

Reversing polarity

Certain solid wires are more suitable for being welded with the gun being attached to the negative pole; in that case, polarity should be reversed. Check the recommended polarity on the package of the solid wire.

1. Pull out the plug.
2. Bend the rubber cover of the mass cable to remove the cable.
3. Remove the nuts and washers holding the poles in place. Pay attention to the order of the washers!
4. Interchange the cables.
5. Re-attach the washers and re-tighten the nuts with a wrench.
6. Re-attach the rubber cover of the mass cable pole. This rubber cover must always protect the mass cable pole.

Switches and indicating diodes

Current adjustment with MMA welding mode

• The welding power is adjusted according to the thickness of the sheet to be welded. The device is also equipped with an arc length trimmer. The control diode indicated the standby mode of the device and informs you on a possible overheating.
• When you switch the device on, a green standby diode is lit. At the same time, the blinking main switch light is lit. In case the device is overheating or the supply voltage is too low or too high, the welding process is automatically interrupted, the yellow overheating diode is lit. It goes out as soon as the device is again ready for use. Make sure that there is sufficient space around the device to allow the air to circulate freely and cool down the device.

Adapting the welding power

• Adapting the welding power to the thickness of the sheet will also affect the wire feed speed and current flow to the wire. This allows welding in various operating situations. However, the type of connection and root opening might influence the amount of welding power needed.

• Choose the proper parameter via the welding power regulator according to the sheet thickness of the fillet weld welded. If the sheet thickness of the fillet welds is different, adjust an average value as standard.

• The sheet thickness scale is given in millimeters, based on the wire diameter of 0.8 mm. When using a 0.6 mm wire, the welding power regulation must be adjusted to a value that is a little higher than the sheet thickness; when using a 0.9–1 mm wire, adjust a value that is a little lower.

• The arc length regulator shortens or lengthens the arc, thus influencing the welding temperature.
  A shorter arc is less hot, a longer one is hotter. The arc length trimmer influences also the welding properties of the arc and the spatters with the different combinations of diameters of the welding wire and shielding gases.

• In case the weld is too convex, the arc is too short or too cold. In that case, lengthen or heat the arc by turning the regulator clockwise. In case you wish to weld with a cooler arc, e.g., to avoid a hole is burnt to the base material, shorten the arc by turning the regulator anticlockwise. You can adapt the welding power if necessary.

• After trimming the arc, it does normally not need to be re-adjusted in case the thickness of the sheets welded changes.

Maintaining and cleaning

When maintaining the device, consider the utilization ratio and environmental conditions. If used properly and maintained regularly, the device will spare you unnecessary dysfunctions.

Warning! Unplug the device before working on electric cables.

Daily maintenance

• Remove weld spatters from the contact tip of the welding gun and checks the individual parts. Immediately replace damaged components.
• Check if the insulating tips of the welding gun neck are not damaged and are properly fixed. Isolating parts damaged require immediate replacing.
• Check the tightness of cable connections of the welding gun and earthing cable.
• Check the condition of supply voltage and welding cable, and replace defective cables.

Maintaining the wire feed mechanism

The wire feed mechanism should be maintained at least when replacing the coil.

• Check the wear and tear of the notch of the wire feed roller and replace the roller if necessary.
• Clean the wire feed of the welding gun with the help of compressed air.

Cleaning the welding gun

The pressure applied on the feed roller causes the removal of metal dust from the surface of the welding wires; this dust gets into the wire feed mechanism. In case the wire feed is not cleaned, it will get stuck gradually, causing dysfunctions of the wire feed. Clean the wire feed as follows:

1. Remove the gas nozzle of the welding gun, the contact nozzles, and contact nozzle adapter.
2. Apply pressurized air through the feed with the help of a pneumatic gun.
3. Also blow out the feed control and coil housing with compressed air.
4. Reattach the components of the welding gun. Re-tighten the contact tip and the contact tip adapter to ensure fixedness.

Replacing the wire feed

In case the wire feed is too much worn or completely clogged, replace it as follows:

1. Disconnect the welding gun from the device.
   • Disconnect the supply cord of the gun from the terminal of the device.
   • Disconnect the plug of the discharge lines of the device.
   • Open the fixing nut of the gun.
   • Carefully remove the gun from the device as soon as all parts emerge through the cable hole of the front part.
2. Open the fixing nut that exposes the end of the wire feed.
3. Align the cable of the welding gun and remove the wire feed from the collect.
4. Slide a new feed into the gun. Make sure that the wire feed enters completely into the contact nozzle adapter and that there is an O-ring at the end of the guide that is directed towards the device.
5. Tighten the wire feed with the help of the fixing nut.
6. Cut off the wire feed at approximately 2 mm before the fixing nut and lime the sharp edges of the cut-off spot round.
7. Reattach the gun to its place and tighten all components.

Technical specifications

| M I G / M M A – 140| M I G / M M A – 160| M I G / M M A – 180| M I G / M M A – 200| M I G / M M A – 250
---|---|---|---|---|---
Intake  voltage (V)| 1~220 ±10 % / 1~230 ±10 %
Frequency (㎐)| 50/60
Capacity (kVA)| 3.9| 4.5| 5.0| 5.6| 7.0
Current (A)| 50–140| 50–160| 50–180| 50–200| 50–200
Nominal oper- ating time (%)| 60
P ower factor| 0.93
E ff iciency (%)| 85
W ire-feed control| internal
W ire feed speed (m⁄min)|

2.5–10

| 2.5–12| 2.5–12| 2.5–12|

2.5–12

Roller diameter (㎜)| R=200
Diameter of wire (㎜)| 0.6/0.8/1.0
Dimensions L×W×H (㎜)| 420×220×350
W eight (㎏)| 10.6
Insulation class| H
Pr otection class| IP21S

Troubleshooting

Check if feed roller is too much worn.
Check if wire channel is clogged.
Check if there are no spatters on the tip of the line and if the hole is not narrowed of worn out.
The control diode of the  main switch  is not lit.| The device has no supply voltage.| Check fuses of supply voltage.
Check cable and plug of supply voltage.
Bad welding performance| The welding result is influenced by several factors| Check  cutting  adjustments  of  welding power regulator and arc length.
Check if earth clamp is properly attached, if clamping point is proper, and if cable and connections are not damaged.
Check shielding gas flow from tip of weld- ing gun.
The supply voltage is irregular, too low, or too high.
Overheating mode diode is lit| The device is overheated.| Check if cooling air flow is free.
The volume ratio of the device has been exceeded; wait for the control diode to go out.
The supply voltage is too low or too high.

Regulations for waste disposal

The Waste Electrical and Electronic Equipment Directive (WEEE Directive, 2012/19/EU) of the EU was implemented in the German law related to electrical and electronic equipment and appliances.

All WilTec electric devices that fall under the WEEE directive are labelled with the symbol of a crossed out wheeled rubbish bin. This symbol indicates that this electric device must not be disposed of with the domestic waste.

WilTec Technik GmbH is registered with the German registration authority EAR (Stiftung ElektroAltgeräte Register) under the WEEE-registration number DE45283704.

Disposal of used electrical and electronic devices (intended for use in the countries of the European Union and other European countries with a separate waste collection system for these devices). The symbol on the packaging or the product itself indicates that this product must not be treated as normal domestic waste but must be disposed of at a recycling collection station for electrical and electronic waste. By disposing of this product correctly, you contribute to the protection of the environment and the health of your fellow people. Inappropriate disposal threatens the environment and health.

Material recycling helps to reduce the consumption of raw materials.

Additional information about the recycling of this product can be provided by your local commune, the municipal waste disposal facilities, or the store where you purchased the product.

The information contained in this document may alter at any time without prior notice. No part of this document may be copied or otherwise duplicated without prior written consent. All rights reserved. WilTec Wildanger Technik GmbH cannot be held liable for any possible mistakes in this operating manual, nor in the diagrams and illustrations shown.

Although WilTec Wildanger Technik GmbH has made every possible effort to ensure that this operating manual is complete, accurate, and up-to-date, errors cannot be ruled out entirely. If you have found an error or wish to suggest an improvement, we look forward to hearing from you.

Contact

Send us an e-mail to: [email protected] or use our contact form: https://www.wiltec.de/contacts/

The most recent version of this manual in several languages can be found in our online shop: https://www.wiltec.de/docsearch

Our postal address is

WilTec Wildanger Technik GmbH Königsbenden 12 52249 Eschweiler Germany.

Do you wish to collect your goods? Our address for collection is:

WilTec Wildanger Technik GmbH Königsbenden 28 52249 Eschweiler Germany

In order to shorten the waiting time and to allow for an easy on-site processing, we kindly ask you to contact us briefly beforehand or to place your order via the webshop.

E-mail: [email protected]
Tel: +49 2403 55592–0
Fax: +49 2403 55592–15

To return your goods for exchange, repair, or other purposes, please use the following address. Attention! To allow for a trouble-free complaint or return, it is important to contact our customer service team before returning your goods.

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