AHP Tools MIG WELDER Alpha Mig v 140 amp

Transcription

1 AHP Tools MIG WELDER Alpha Mig v 140 amp INSTALLATION AND OPERATING INSTRUCTIONS

2 Alpha Mig 140 ASSEMBLY AND OPERATING INSTRUCTIONS Carefully read the operation manual prior to using, installing and maintaining the electric welding machine for the purpose of preventing damages such as fire, electric shock and etc from occurring. Please keep the manual for the reference in the future PRODUCT SPECIFICATIONS Item Rated Electrical Input Max Voltage at no Load Rated Duty Cycle Wire Feed Rate Wire size /spool size Welding Wire Spool Weight Description 115 VAC/60Hz/20AMP 28 V DC 90A@20% 59to393in/min(1.5-10m/min 10.0m/min Solid Steel Wire Flux cored Wire 4 x5/8 (mounting hole diameter) 8 x 2 (mounting hole diameter) 54lbs Overall Dimensions 16 x9.5 x

3 SAVE THIS MANUAL You will need the manual for safety warnings and precautions, assembly instructions, operating and maintenance procedures, parts list and diagram. Keep your invoice with this manual. Write invoice number and date of purchase on the inside of the manual. Keep the manual and invoice in a safe and dry place for future reference. WARNING! WELDING can be hazardous WARNING: THIS WELDING MACHINE MUST BE CONNECTED TO POWER SOURCE IN ACCORDANCE WITH APPLIANCE ELECTRICAL CODES ADERTISSEMENT: LE RACCIROEMENT DE CETTE MACHINE DE SOUDAGE A L'ALIMENTATION DOIT ETRE CONFORME AUX CODES D'ELECTRICITE PERTINENT S WARNING: DISCONNECT POWER SOURCE BEFORE DISASSEMBLY OF THE TORCH ADVERTISSEMENT: COUPER L'ALIMINTATION AVANT LA DEPOSE DE LA WARNING: DISCONNECT POWER SOURCE BEFORE DISASSEMBLY OF THE TORCH ADVERTISSEMENT: COUPER L'ALIMINTATION AVANT LA DEPOSE DE LA WARNING: THE SHIELD CUP MUST BE INSTALLED PRIOR TO OPERATION OF THE TORCH ADVERTISSEMENT; ZVANT D'UTILBER LE CHALUMEAU S'ASSURER QUE L'ECRAN DE PROTECTION EST EN PLACE WARNING: ALL INSTALLATION, MAINTENANCE, REPAIR OPERATION OF THIS EQUIPMENT SHOULD BE PREFORMED BY QUALIFIED PERSONS ONLY IN ACCORDANCE V~TH NATIONAL, STATE AND LOCAL CODES ELECTRIC SHOCK can KILL Improper use of electric arc welder can cause electric shock, injury and death! Take all precautions described in this manual to reduce the possibility of electric shock. The Alpha Mig 140 power switch is to be in the OFF ("0") position when installing work cable and gun and when connecting power cord to input power. Always wear dry, protective clothing and welding gloves and insulated footwear. Always operate the welder in a clean, dry, well ventilated area. Do not operate the welder in humid, wet, rainy or poorly ventilated areas. Be sure that the work piece is properly supported and grounded prior to beginning and electric arc welding operation. The electrode and work (or ground) circuits are electrically "hot when the welder 2

4 is on. De not touch these "hot" parts with your bare or wet clothing. Ground the work or metal to be welded to a good electrical (earth) ground. FUMES AND GASES can be dangerous. Do not breathe fumes that are produced by the arc welding operation. These fumes are dangerous. Keep the head and face out of the welding fumes. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation. WELDING SPARKS can cause fire or explosion. Do not operate electric arc welder in areas where flammable or explosive vapors. Always keep a fire extinguisher accessible while performing arc welding operations. ARC RAYS can burn. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the rays. Protect other nearby personnel with suitable non-flammable screening or caution them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal. Heat metal can burn Electric arc welding operations cause sparks and heat metal to temperatures that can cause severe burns! Use protective gloves and clothing when performing any metal working operations. Make sure that all persons in the welding area are protected from heat, sparks and ultraviolet rays. Use additional face shields and flame resistant barriers as needed. Never touch work piece until completely cooled. 3

5 OPERATOR'S MANUAL ELECTRIC AND MANGETIC FIELDS may be dangerous The electric magnetic field that is generated during arc welding may interfere with the operation of various electrical and electronic devices such as cardiac pacemakers. Persons using such devices should consult with their physician prior to performing any electric welding operations. Exposure to electromagnetic fields during welding may have other health effects which are not known. I. UNPACKING When unpacking, check to make sure all the parts shown as following are included Alpha-MIG140 welder 2 Torch 3 Work clamp 4 Gas Regulator 5 Hose 6 1Kgs Spool of 0.6mm MAG Wire 7 0.8mm,0.9mm Contact tip 8 Operator's manual 4

6 II. COMPONENTS AND CONTROLS 1. Mig gun connection 2. Ground Clamp connection 3. Power switch 4. Output Voltage control 3 5. Wire feed speed adjustment control 6. Access cover Latch 5 7. Power Cord 8. Reset overload switch the overload Protection will trip the circuit if the welding machine is in excess of the maximum load, after which the switch must be manually reset. 9. Shielding gas inlet fitting. 10.Wire feed drive motor 11.Wire spool spindle/shaft. 12.Wing screw to fasten the welding torch cable 13.Positive(+) and negative(-) output terminals 14.Control cable connection of the welding torch

7 III INSTALLATION Welding Torch Installation (See Figure C-1) There is one coil of 0.6mm solid core welding wire attached to the delivery of the equipment by the plant. With regard to the 0.6 mm current contact nozzle 1 of the default installation to the welding torch, please change it to be the one of 0.8 mm current contact nozzle where 0.8 mm welding wire shall be used. In the event that 0.9 mm welding wire shall be used, please change it and use 0.9 mm current contact nozzle instead. 1 Figure C-1 (See Figure C-2, Figure C-3) NOTE: This method of connection is GMAW. Where other methods of welding are applied, please refer to the Reference Table T-2 in page Connect the welding torch to the welding machine. (See Figure C-2, Figure C-3) 1. Power off the welding machine, namely the switch is positioned at "O". 2. Plug the welding torch into the hole 1 and plug it into to the end of it, thread the control wire of the welding torch pass through the rectangular orifice of the hole 1 and inset the control wire into the connector 5 after it is girded around the wire feeder. 3. Screw tight the butterfly screw 3 attached to the connector of the wire feeder and fasten the welding torch onto the connector Figure C-2 Figure C-3 4 If Optional Spool gun is to be used then push switch to Spool gun from Mig gun on front panel and install spool gun as above. 6

8 Wire Drive Roll Installation (See Figure C-4) The reversible dual groove wire drive roll that is Supplied with the Alpha Mig 140 has two wire grooves; One for.025 (0.6mm) solid welding wire and the other for ( mm) solid or flux-cored welding wire. The factory default installation is.025 (0.6mm). 2 In the event that.030 (0.8mm) (0.9mm) welding wires are used, the wire feed roll groove must be changed. 1. Ensure that the Alpha Mig 140 welding machine is powered off. 2. Unlatch the spring loaded pressure arm and Figure C-4 open the idle roll arm. (1) and lift up the idle roll arm. (2) Figure C-4 3. Loosen the hex bolt (3) that attaches the wire drive roll. 4. Remove the wire drive roll (4) and flip the wire drive roll over so that the.030 (0.8mm) mark faces the user. 5. Reinstall by putting back the wire drive roll and tighten the hex bolt Welding Wire Installation Your Alpha Mig 140 welding machine can use both a 8 and 4 diameter spool of wire (the maximum width of the spool can be no more than 2.2 ). There is a plastic tube (2 diameter) attached to the wire drive. The spring screw can adjust the resistance of the welding wire spool to prevent the wire from loosening off. For installation (See Figure D-1) of wire spool of 8 "(200 mm) diameter, install the spool over the plastic barrel 2 with 50mm in diameter attached to the welding machine. The positioning tab on the plastic barrel should be lined up with the positioning hole on the wire spool pole of the plastic barrel and this will lock the spool onto the spool wire holder once the spring tension nut is tightened. (Note: the wire spool will rotate clockwise when wire is pulled off.) Remove the 2 diameter plastic spool when using a 4 Spool Unscrew the wing nut and remove Securing spacer (6) and the 2 plastic tube Install the 4 diameter spool onto the metal shaft and slip spacer back on and tighten with wing nut. 7

9 Feed the Welding Wire though the Wire Feeder by following the instructions as shown below (Figure D-3) 1. Release the spring tensioned pressure arm1 of the wire feeder and lift up the idle roll arm2, verify that the groove size matches that of the wire diameter being used.( see previous chapter describing installation of feed rollers) 2. Pull out the welding wire3 from the welding wire spool taking care to keep the wire under tension until after step 5 in the procedure so as to prevent the spooled wire from unwinding. 3. Inspect wire end to make sure it is straight for easy installation into the tube feed guide. Have at least 3 of straight wire to allow for easy installation into wire feeder.. 4. Feed the welding wire through the wire feed tube (4) and over the grooved roller into the main feed tube (6) feed approximately 3 to 6 of wire into the mig gun line. 5. Place the idle arm into the operating position and secure with 2 and secure it with the spring loaded tension bar1 6. Set wing nut on tension bar so as to allow smooth feeding of the welding wire with no slipping or binding being present Figure D-3

10 Protective Gas Installation Compressed gas cylinder containing a mixed gas of 75% Argon and 25% CO2 is the most common gas used in MIG ( GMAW Gas Metal Arc Welding) The flow regulator, and supply line is included with your Alpha Mig 140 Welder.You can source Compressed gas cylinders from your local welding supplier. 1.Secure your gas cylinder with a chain, strap or other devise to prevent the cylinder from falling.bottle must be secured in the upright position. 2. After securing the cylinder, remove the safety cap and have the supply valve opening facing away from you. Crack open the valve momentarily to clean out any dust or dirt in the supply valve opening. 3. Install flow regulator (CGA-580) to the supply valve connection on the gas cylinder and tighten using a wrench 4. Install the supplied hose from the flow meter to the rear of the Alpha Mig 140 and tighten using a wrench (connections used are common 5/8-18 threaded fittings) 5. Open the gas cylinder valve slowly 6. Depress the mig gun trigger and set flow to between 20to 30cfh (7 to 17. Close valve when you are not using welder. When welding is completed close main valve on cylinder and release gas from mig gun line by depressing trigger Valve of air bottle Flow regulator Air pipe Connector aperture of protective gas input 9

11 Welding Operations 1. Power on the Alpha Mig 140 Welding Machine 3. Straighten Mig gun line 4. Remove contact tip from gun nozzle ( allows wire to feed easier at end)depress mig gun trigger so as to feed welding wire into line. Stop when wire is exposed at nozzle end. pressing 5. Reinstall the contact tip and nozzle. 6. Cut exposed wire back to approximately ¼ to 3/8 from tip. 7. Place protective safety equipment on (jackets, gloves, Masks ) and you are ready for welding. Welding Process 1. Please refer to the welding Manual and select the correct welding wire and protective gas based on the metal thickness. 2. A reference chart is attached to the inside door panel. This chart gives the correct voltage and wire speeds for the corresponding metal thickness from 24 gauge to 5/16 thick. 3. Check the output polarity for your welding process. if using solid wire gas shielding then your Ground ( work ) clamp should be attached to the negative output terminal ( - ) inside the AlphaMig 140 access panel if Flux Cored Wire is used then the polarity must be changed for the Ground ( Work ) clamp to be on the Positive ( + ) output terminal and Mig gun connected to the negative terminal. 4 Connect the ground clamp to the work piece that is making sure there is a good ground connection made. The material may need to be cleaned in order to get the best ground,this can be done by grinding the work piece to a polished finish. 5. The mig gun should have enough slack line so as to be easily maneuvered along the area to be welded. 6. Flip down the welding helmet, and press the trigger of the Mig gun and begin to weld. Keep the contact nozzle of the welding gun at around 3/8 away from the weld surface joint. 7. Release trigger to stop the weld process. 8. After welding, close the valve of gas cylinder ( If solid wire is used) and depress Mig gun trigger to release stored gas. Finally, power off the welding machine 10

12 VI. Overload Protection Device Overload protection for power supply to welding There are two protection devices that are temperature controlled and overload breaker equipped on the Alpha Mig 140 Mig welder. Both protection devices will be activated to protect the welding machine whenever the output of the machine is operated in excess of its maximum output. If either one is activated it will cut of the output voltage and wire feed drive roller motor. The cooling fan will remain on in order to cool the welder and to bring it back to within operating parameters. If the Overload relay is triggered then you will need to reset the breaker button. This needs to be done after giving the unit time to cool down to the operating parameters (normally several minutes for cooling). If there is no voltage output and the breaker has not tripped than it is the thermal overloads on the heat sink that have been activated and have shut down output voltage. The unit needs to be left running for several minutes to allow the fans to cool down the welder before it will reset and begin operating once again. Overload Protection to Wire feeder The Alpha Mig 140 model has two automatic circuits to protect the motor of the wire feeder, if there is fault detected to the motor, the circuit will power off the wire feeder and cut off the output.. When the trigger of the mig gun is pressed again and is released the circuit cutting off the wire feeder will be automatically reset. 11

13 12

14 13