20072 - Welding machine Güde - Free user manual and instructions

USER MANUAL 20072 Güde

1. Welding machine with protective gas MIG 155/6W

Warranty Titles for in-warranty performance in accordance with warranty sheet attached. General safety instructions It is necessary to read the whole guide for operation before the first use of the machine. In case of any doubts associated to the connection and operation of the machine contact the producer (service department). TO MAINTAIN THE HIGH LEVEL OF SAFETY PLEASE OBSERVE THE FOLLOWING INSTRUCTIONS: ATTENTION! Turned-on period The machine capacities are represented by the data “Einschaltdauer/Turned-on Period“ (ED%) at the machine type plate, i.e. the ration between the welding time and the cooling time. This factor changes for the same machine in accordance to the load conditions, i.e. according to issued welding current. It determines how long the machine can operate at the listed welding current under load and it is always related to the time period of 10 minutes. For example at welding current for ED 60% the machine operates continuously for 6 minutes and after this period an idle phase follows to cool down the internal parts, and then the protection against thermal overload activates again. Using welding machines and performing welding tasks could represent a risk both for the person operating the machine and for other persons. Therefore the person operating the welding machine is unconditionally obliged not only to read the safety regulations presented here but also t know them and to follow them. It is necessary to bear always in mind that cautious and well instructed operator who strictly adheres its obligations is the best provision against injuries. Before connecting, preparation, use or transport or the machine you should read regulations listed in the following text and obey them.

INSTALLATION OF THE MACHINE

• Installation and maintenance of the machine must be performed in accordance to local safety regulations.

• Observe the state of wear the cables of interconnection elements and plugs. If damaged they should be replaced. Perform regular maintenance of the machine. Use only cables that are of sufficient cross-section. Before putting the machine into operation please read this guide for operation carefully. A.V. 1 Surplus print even in shortened version requires permission. Technical changes reserved. 14• Connect the grounding cable as close to the workplace as possible.

• Under no circumstances the machine may not be used in damp environment. Ensure that the workplace is dry in the area of welding and that also objects that are found here including the welding machine itself are dry. PERSONAL PROTECTION AND PROTECTION OF THIRD PERSONS Radiation and neat are generated during the welding process therefore it is necessary to ensure the use of suitable protective means and to take precautions to protect both himself/herself and third persons. Never expose yourself or any other persons to the effects of electric arc or hot metal without necessary protection. Take care of exhaustion of welding fume and possibly proper ventilation of welding workplace.

PREVENTIVE MEASURES AGAINST FIRE AND EXPLOSION

Incandescent parts of slag and sparkles could cause a fire. Fire and explosion represent additional risks. They can be avoided by meeting these precautions:

• Do not use the machine in immediate proximity of easily inflammable materials like wood, chips, „varnishes“, solvents, petrol, kerosene, natural gas, acetylene, propane and similar combustible materials must be removed from the workplace and its ambient or possibly protected from sparkles.

• Suitable extinguishing agent should be ready nearby as a measure to extinguish a fire.

• Do not perform welding or cutting tasks on closed vessels or pipes.

• Do not perform welding or cutting tasks on vessels and pipes even when they are open if they contain or contained materials that could explode or caused other dangerous reaction under the influence of heat or damp.

INSTALLATION OF THE WELDING MACHINE

When installing the machine the following regulations must be observed:

• The operator must have a free access to control elements and connecting points of the machine.

• It is not advisable to install the machine in close-spaced rooms: Sufficient ventilation of the welding machine is very important. When installing avoid heavily dusted or dirty areas where the machine could aspirate the dust or other objects.

• The machine (including cables) may neither form an obstacle in passing nor keep other person from their work.

• The welding machine may be operated only on a flat base and the gas cylinder used for its operation should be properly secured. Procedure in case of emergency Perform first-aid measures corresponding to the type of injury and call the qualified medical aid as soon as possible. Protect the injured person from other bodily harm and becalm him/her. Marking on the machine Explanation of symbols The following symbols are used in this guide or on the machine: Safety of the product: The product is in accordance with relevant standards of the European Community Restrictions: Ban, general (in connection with other pictogram) Fire, open source of light and smoking forbidden Tugging the cable forbidden Do not use the machine in wet conditions Caution: Caution/Attention Warning from dangerous electrical voltage Caution-danger of tumbling over Warning from gases harmful for health Warning from hot surface Orders: Wear protective shoes Wear protective gloves Wear protective clothing Wear the shield for face protection Pull out the mains plug before opening Read the guide for operation before use 15Environmental protection: Do not litter the waste freely, after their selection dispose them expertly. The packaging material from the cardboard can be handed in for recycling at points intended for that. Electric or electronic appliances that are damaged or intended for disposal must be handed over for recycling at points intended for that. Packaging: Protect from moisture Orientation on the packaging upwards Attention fragile Technical specifications: Connection to the mains Weight 230 V 400 V Specific for the product: Welding transformer Safeguard of the mains Thermal protection Use in accordance with designation The welding machine for welding inside the protective gas intended to thermal joining of iron – metals by fusing the edges and feeding the additional material. In case that either instructions implying from universal regulations or instructions contained in this guide are not observed, the producer cannot assume responsibility for any damage. Residual risks and preventive measures Mechanical residual risks Threat Description Protective measure Residual risk Punching, incision Hands may be punched with a wire. Use protective gloves or perhaps also keep your hands in safe distance from wire output Splashing of liquids splashing drops when welding could cause burns. Wear protective clothes and welding mask. Electrical residual risks Threat Description Protective measure Residual risk Direct contact with electricity Direct contact with electricity by damp hands could cause an electric shock. Avoid touching by damp hands and be particular about proper grounding. Thermal residual risks Threat Description Description Residual risk Burns, frost-bites Contact with hose nozzle and with piece being treated could cause burns. The hose nozzle and piece being treated should be cooled after operation ended first. Wear protective gloves. 16Danger from radiation Threat Description Protective measure Residual risk Infrared, visible and ultraviolet light Electric arc generates infrared and ultraviolet radiation. Use suitable protective welding shield, protective clothes and protective gloves. Danger from the material being treated and other substances Threat Description Protective measure Residual risk Contact, aspiration Prolonged aspiration of welding gases could be harmful for health. When working use an exhaustion facility or work in areas with good ventilation. Avoid direct inhalation of gases. Fire or explosion Hot slag and sparkles could cause a fire. Never operate the machine in the environment where a fire could occur easily. Other dangers Threat Description Protective measure Residual risk Slipping, tipping up, or fall of persons Cables and hoses could be the cause of tripping up and falls. Keep the workplace in order.. Disposal Instructions for waste disposal implying from pictograms that are located on the machine or possibly on the packaging. The explanation of such signs can be found in chapter “Marking on the machine“. Requirements for operators The operator must read the guide for operation carefully before any use the machine. Qualification No special qualification except detailed instruction session led by an expert is necessary for use of the machine. Minimum age The machine may be operated by persons older than 18 years only. The exception when operation of the machine by a juvenile person is the case when the machine is used during a special training to get skills under supervision of a trainer. Training For the operation of the machine just corresponding instruction is required. No special training is necessary. Technical specifications

Weight approx. 25 kg Product No. 20072 17Transport and storage Attention: The machine may be used and stored in straight operation position (on the plane base). Please respect the symbols on the cover! Ensure that gas cylinder is properly fixed and closed. Assembly and putting into operation for the first time Assembly set 1 – assembly of casters and shanks: Fig. 2, Fig. 3, Fig. 4, Fig. 5 Assembly set 2 – Machine holder assembly: Fig. 6 Assembly set 3 – Gas cylinder installation: Fig. 7, Fig. 8 Assembly set 4 – Welding shield assembly: Fig. 9, Fig. 10 Safety instructions for putting into operation for the first time Fig. 11

• Pay attention to sufficient safeguarding of electric supply.

• Wear specified protective clothing (fig.11).

• Make sure that no other persons are present in the work area or in possible dangerous area.

• Pay attention to avoid any inflammable material in the work area.

• Insert the plug into the corresponding socket, the socket must be secured by a fusible cut-out or power protective switch.

• The mains cable and possible extending cables must be at least of the same crosscut.

• ATTENTION! Electric safety is ensured only on the condition that the machine is properly connected to effective grounding equipment in accordance to regulations for electrical equipment in force.

• Make sure that useful mains voltage and frequency correspond to the data specified at the machine type plate. Procedure When assembling individual parts proceed in the illustrated order. Keep proper arranging of assembly parts according to figures. The machine has not been workable yet. Open the gas flow t the pressure of 5-7 l/min. Protect the gas output from wind blasts. In addition to that it is necessary to bear in mind the following information too: First levels of the switch 1-2 serve for welding of thin sheet metals while other levels server for thicker walls. At any change of the switch level also the wire feeding speed should be adjusted. If a drop forms at the end of the wire during welding the speed of wire feeding must be increased, on the other hand if you feel the pressure of the wire against the hose you should decrease the speed. Because parts being just welded are very hot always use pliers in case you want to move them and remove sediments at the end of the burner. As soon as the electric arc ignites hold the hose approx. at angle of 30° in relation to the perpendicular. Threading of the welding wire Fig.12

1. Open upper lid of welding machine and secure the lid with safety pin.

2. Insert the coil with welding wire so that the wire can be drawn into feeding straight.

Caution: Pay attention that the wire does not unroll from the coil and its end is flat and without any burr. The coil resistance can be adjusted at clamping nut in the centre.

revolving handle (fig. 13 - B) counter-clockwise, remove the pulley and insert it into correct groove. Now seat the stirrup element (fig.13 - F) and tighten the revolving knob (fig. 13 - A) until the wire coils up uniformly. If the wire slips off the pulley tighten the knob even further. Attention: Do not tighten too tightly otherwise the excessive pressure to the pulley could cause damage to the wire feeding motor.

6) Now turn the welding machine on.

7) Then, after ensuring the performance of all safety measures, set the switch (fig. 21/1) to level 1 and wire feed

adjustment (fig. 21/2) to level 1.

8) Remove gas and stream nozzles and holding the pressure switch on the hose depressed let the wire protrude from

it (when the hose is tensed fig. 18). Than replace stream and gas nozzles again back.

9) Adjust the necessary amount of gas at the fittings of the gas cylinder.

Tip: (0.6 mm-wire → 6 l/h); (0.8 mm-wire → 8 l/h); (1.0 mm-wire → 10 l/h)

10) Now the machine is ready for welding.

18good bad Fig. 15 General information on welding in protective gas The main area of use in workshops, universal use, suitable both for thinner sheet metals and for thicker materials. A rule holds that the more welding levels are in the machine the better is its utilisation in work with sheet metal. Necessary accessories: gas mixture Co 2/Argon, welding wire, welding shield, reducer valve. It fits also for aluminium and high-grade steel VA when using a suitable gas and wire. (Pure argon/VA-wire/aluminium wire), potentiometer. Operation MIG 155/6W Fig. 13

1. Adjustment of welding level

2. Adjustment of wire feeding speed

4. Grounding clamp connection

5. Mains connection plug

Safety instructions for operator

• Start using the machine only after having read the guide for operation carefully.

• Respect all safety cautions provided in the guide.

• Behave responsibly towards other persons.

• Attention!!! Never use corroded welding wire. Step-by-step guide The zone to be welded should be free of any rust and varnish. Always use protective welding shield, protective welding gloves and suitable protective clothing. The angle of the hose position towards the treated piece should be approx. 30 degrees.

1. Grind bright large surface at the processed piece in the areas of weld seam and connection of grounding clamp.

2. Now clamp the grounding clamp to the prepared place of treated piece.

3. Adjust parameters of the welding machine in accordance to the user table for welding (chap. 3).

4. Adjust required gas volume at the gas cylinder fittings.

5. Tip: (0.6 mm-wire → 6 l/h); (0.8 mm-wire → 8 l/h); (1.0 mm-wire → 10 l/h)

6. If you have worn a complete protective clothes you may start welding.

Tip: Before starting your own task please perform a trial welding to get an optimum adjustment of the welding achieving an optimum result. Fig. 14 Parameters for welding are set to optimum in case that a uniform noise can be heard and the welded seam has good penetration into the material, namely it is relatively flat. Tips for welding Fault Cause and remedy Example Piece being treated is curved

1. Bad preparation of seam

2. Straighten the edges and fix (fasten) for welding

1. Idle run voltage too low

2. Welding speed too low

3. Improper adjacent angle of the welding burner

1. Too high welding speed

2. Too low voltage for the welding speed

Welds have oxidized appearance

1. Weld in a pit at long electric arc

2. Adjust the voltage

3. Wire is warped or it protrudes from the wire guide too much

4. Improper wire feeding speed

Insufficient fusing of the root

1. Irregular or insufficient distance

2. Improper adjacent angle of the welding burner

1. Wire feeding speed to high

2. Improper adjacent angle of the welding burner

3. Distance too large

19The zone to be welded should be rid of rust and varnish. The burner is selected according to the type of material. It is recommended to try the strength of current on a defective piece first. Faults - Causes - Elimination Fault Cause Elimination Welding current drops out

1. – Protection against excessive temperature

fell out due to overload.

1. Protection against excessive temperature will

perform automatic reset after cooling the transformer (approx. after 10 minutes, take care of ED!) Welding current not available at all. Protective power switch or RCD fell out

1. Mains fuse fell out 1. Let the fuse checked

Welding current is not available .

1. Bad contact between grounding clamp and

2. Rupture in grounding cable or grounding line

3. Rupture in burner line

1. Clean and grind the welded area and surface of the

Wire feeding motor does not operate, pilot lamp is on.

2. Toothed rim is faulty or blocked.

3. Motor is defective.

Wire feeding motor does not work, Pulleys rotate.

1. The pressure to the pulley is not adjusted

2. There is dirt, dust etc. on the stream nozzle of

3. Gas nozzle is defective.

4. The wire is warped.

5. Inner tube of the wire guide is dirty or

1. Adjust the pressure to pulleys correctly.

2. Clean the machine contact tube. Use an air

compressor to do so, in case of heavy contamination replace the contact tube

3. Replace the gas nozzle and check the tip.

5. Clean with compressed air and let the hose replaced

if necessary. Wire feeding is irregular.

1. Dirt at the wire guide. Gas nozzle is worn-out

2. Gas nozzle is clogged.

3. An obstacle restrains the wire feeding pulleys

4. Wire feeding pulleys guiding has deformed.

5. Improper tension of the wire

4. Clean the wire feeding pulleys.

5. Replace the wire feeding pulleys.

6. Adjust the wire tension properly.

Electric arc burns in unstable way.

1. Improper wire speed adjustment

2. Dirt at the welded place.

3. Gas nozzle is worn-out or defective.

1. Adjust the wire speed according to recommended

2. Clean or polish the welded surface.

3. Replace the gas nozzle and check the tip.

Welded joint is porous.

2. Nozzle holder is blocked

3. Material is rusty or damp

4. Burner is too far or you hold it at incorrect

angle towards the point being welded.

1. Open the gas and adjust the gas intake flow.

2. Clean or replace the gas nozzle.

3. Properly treat the place of welding or increase the

5. Distance between the gas nozzle and processed

piece must be 8-10 mm and the hose should be held at an angle of 30°.

6. Check the rubber hose, connection and hose set

assembly. – Depress the gas nozzle into proper position. Welding wire stops in proximity of stream nozzles

1. Stream nozzle is worn-out.

2. Welding wire is warped.

3. Wire feeding speed is too low.

3. Follow the instructions for wire feeding speed.

Welding pressure is irregular

1. Welding wire blocked on the coil 1. Check the pressure of pulley tension and adjust if

necessary. Too weak penetration

1. Welding current too weak

2. Electric arc too long

1. Increase the welding current and wire feeding.

2. The hose should be held near the piece being

processed. Too strong penetration

1. Welding current too high

2. Wire feeding speed too slow

3. Improper distance of the burner from piece

1. Reduce the welding current and wire feeding.

2. The burner should be moved calmly and

3. The distance of the nozzle from the piece being

processed must be 8-10 mm. Inspection and maintenance Maintenance of hose set Regular maintenance must be performed to ensure faultless function of hoses. Gas nozzle must be sprayed by protective spray for nozzles and remove sediments inside regularly. For this case the following steps should be performed (see Fig. 26):

1. Remove the nozzle (1) by pulling it forward.

202. Remove sediments that formed from welding slug, from the nozzle.

3. Spray it with protective spray for nozzles.

4. If the nozzle is rusty, it must be replaced.

Maintenance of Stream nozzle For this case the following steps should be performed (see Fig. 26):

1. Remove the nozzle (1) by pulling it forward.

2. Unscrew the stream nozzle (2)

3. Check whether the hole that the wire goes through is not too wide, before reassembly replace it if required.

4. Depress the button at the hose so that the wire goes out and then assembly the stream nozzle back.

Maintenance of nozzle holder Fig.16 For this case the following steps should be performed (see Fig. 26):

1. Openings for gas exhaustion could be slightly clogged, in such a case it is necessary to remove the gas nozzle by

its pulling off (1),

2. then unscrew the stream nozzle (2),

3. unscrew the gas distributor (3) and replace it with a new one.

Safety instructions for pro inspection and maintenance Only regularly maintained and treated machine can become a reliable assistant. An insufficient care and maintenance could be the cause of unforeseen injuries and accidents. Inspection and maintenance plan Time period Description Other possible details Regularly• Maintenance of the hose set (blowing off and cleaning of inner tube of the wireguide, pulley for wire feeding, gas nozzle and gas distributor) Spare parts

Do you have any technical questions? Any claim? Do you need any spare parts or operating instructions? We will quickly help you and without needles bureaucracy at our web pages at www.guede.com in the Servicing part. Please help us be able to help you. In order to identify your device in case of claim we need the serial No., product No. and year of production. All this data can be found on the type label. Please enter it here for future reference:Serial No._____________________________Product No.:___________________________Year of production_______________________ Tel.: +49 (0) 79 04 / 700-360 Fax: +49 (0) 79 04 / 700-

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