AUSMIG M.I.G. Welder User Guide
DANGER OF ELECTROCUTION BEWARE OF SMOKE AND STEAM DO NOT USE NEAR FLAMMABLE OR EXPLOSIVE MATERIAL BEWARE OF RAYS FROM THE ARC WARNING WARNING:Protect yourself and others. Read and understand this manual. ELECTRIC SHOCK: Can kill. FUMES AND GASES: Can be dangerous to your health. ARC RADIATION: Can injure eyes and burn skin. * Read and understand your employer's safety practices. * Keep your head out of fumes. * Use enough natural ventilation, or both, at the fume source to keep fumes and gases from the breathing zone and the general area * Wear correct eye, ear and body protection. * Do not touch live electrical parts. * Refer to AS 1674 and WTIA Technical Note 7 or the manufacturer's recommendations for further information. * Do not change voltage selection while the torch trigger is depressed. * Wiring! Select the correct primary power plug to suit the MIG purchased. * Disconnect MIG from power supply prior to servicing machine. *IMPORTANT NOTICE* AUSMIG MIG welders are covered by a Conditional Warranty. Some Important Conditions of this Warranty are ; * The Warranty Card Must Be Filled Out And Returned To The Manufacturer. (If you do not have a warranty card please contact your local Distributor.) * Any UNAUTHORISED Tampering Or Repairs To This Machine Will Void The Warranty. Repairs To Ausmig MIG Welders Are Only To Be Performed By The Manufacturer Or Service Agent With Written Authorisation. Rev:2.5
CONTENTS page 3 page 3 page 4 page 7 page 12 page 13 page 15 page 16 page 17 page 21 page 22 Bottle Mount Correct Gas Gun Assembly - Steel / Stainless Steel - Aluminium & Non-Ferrous Spool Assembly Wire Feed Rollers Test of Operation Wire Tension Test Regulator Assembly Reverse Polarity Troubleshooting BASIC COMPACT LAYOUT Bottle Holder Fuse 1 Amp Slow Blow Power Switch Wire Speed Control OverHeat Indicator Votlage Selection Wire Drive Compartment Euro Fitting Torch Connection Earth Lead Connection Gas Regulator Transformer MIG Welding Torch Earth lead & Clamp 1
BASIC LAYOUT : TRAVELLER Remote Wire Drive Wire Drive Hanging Bracket Euro Fitting Torch Connection Wire Speed Control Wire Drive Compartment Door Latch Removable Mounting Post Bottle Holder Power Switch Digital Display Volts & Amps Overheat Indicator Fuse 1 Amp Slow Blow Remote Wire Drive Socket Voltage Selection Power Source Negative Connection Transformer Positive Connection Earth Lead & Clamp 8 Metre Power Cable Gas Regulator MIG Welding Torch 2
BOTTLE MOUNT Mount the bottle on the holder Do not drop the bottle onto the machine Secure bottle with the chain CORRECT GAS Stainless Steel Steel Aluminium Argon Shield (ARGON MIX) Argon Shield (ARGON MIX) Pure Argon 3
torch liner (A) GUN ASSEMBLY - For Steel / Stainless Steel Remove liner positioning nut.. *A* Lay gun and liner straight LINER Check for any kinks Disassemble torch head.. Unscrew Pull out Ensure that the correct tip is fitted for the wire being used. A 4
GENTLY feed liner fully through the euro fitting of the torch Screw positioning nut back tightly but DO NOT over tension. Cut excess liner leaving 2mm from the gun neck liner. 2mm 5
Re -assemble torch head Slide nozzle on firmly Align the torch and Euro Fitting. Euro fitting *Slide Together* Screw in the collar until it bottoms. Do not overtighten 6 Do not allow the guide tube to touch rollers. Leave 2mm gap between the two.
GUN ASSEMBLY - For Aluminium & Non-Ferrous A TORCH TEFLON LINER (A) BRASS NECK LINER (B) Unscrew liner positioning nut (E) Remove steel liner if fitted Disassemble torch head BRASS TUBE (C) SECURING COLLET (D) LINER POSITIONING NUT (E) Teflon liner (A) Brass spring neck liner (B) Lay gun and liner out straight Screw liner into brass spring neck tightly on the opposite end from the securing collet 7
(B) GENTLY feed the connected insert fully through until 2mm is protruding from the gun head 2mm Slide securing collet & washer (D) through to the end of the euro fitting Screw back positioning nut (E) through the liner *Do Not Overtighten* DO NOT CUT EXCESS LINER YET!! 8
Re -assemble torch head NOTE ALUM You MUST use aluminium contact tip Remove steel guide tube from feed roller TIP.. use a piece of mig wire to hook and remove steel guide tube TEFLON LINER (A) TORCH Connect euro fitting to mig machine 9
Cut excess liner ensuring a 2mm space is left between roller and liner 2mm Remove torch to align brass tube Using a hacksaw, cut brass tube (C) to exactly the same length as the protruding liner LINER 10
2mm Slide the brass tube over the liner until 2 mm of the liner protrudes from the neck Reconnect euro fitting to mig machine * Do not overtighten* Check that 2mm gap is between the liner and the roller. DO NOT let them touch. Ensure a U Groove Roller is fitted. 11
TOGGLE SWITCH Steel Select the appropriate wire speed for your application. Slow speed for Steel. Fast for Aluminium. Alum The Switch is located on the back of the unit. WIRE SPOOL ASSEMBLY Locating Pin Locking Nut Spool hub Adjustment 15 Kg Wire Spool When fitting a spool of wire, ensure that the locating lug is correctly aligned with the spool. Do not overtighten the locking nut. 12
WIRE FEED ROLLERS Release Wire-Drive Tensioner Install the appropriate drive roller to match the selected wire. NOTE Liners should be blown through with compressed air every time a roll of wire is replaced. 13
Feed wire through until it is 30mm into the guide tube 1 2 Return roller 1 then tensioner 2 814
Startup Procedure Plug into mains, switch machine on Depress &hold trigger down 6 5 9 8 7 4 3 1 2 Adjust wire speed control knob to start wire drive rollers Twist tensioner until wire begins to roll through Keep trigger depressed until wire protrudes out from the gun head at approximately 300mm 15
WIRE TENSION TEST If wire slips through the rollers.. Not enough tension Gun head No wire movement.. Hold wire Twist tensioner accordingly. 3 ~ 3.5 Maximum Check setup if more is required. Wire sways and runs through the rollers without slipping Continuous feed.. 16 16
REGULATOR ASSEMBLY Remaining gas Flow rate. Gas Outlet. Screw regulator onto gas bottle Screw nut & tail with gas hose connected to the regulator. 17
Screw in pressure adjustment knob until slight resistance is felt. Slowly open the gas bottle valve. 18
Adjust control knob according to the desired flow rate STEEL STAINLESS STEEL ALUMINIUM 10-15 l/min 10-15 l/min 15-25 l/min NOTE:The more the control knob is screwed in, the higher the flow rate TIP.. When exchanging bottles, be sure to turn flow rate control knob all the way to the left to protect diaphragm inside the guage from damage. 19
Typical Control Settings Use low voltage selection and low wire speed for light and thin materials. Increase voltage and wire speed as material thickness increases. MACHINE MAINTENANCE Grinding Dust is the greatest enemy of any machine and the frequency for cleaning your machine is dependant on the environment you are working in. After disconnecting the machine from its power source, remove the side panels, and with compressed air remove any dust from the transformer windings, diode pack, fans and switches etc. Other Key components to inspect are : Spool Post ~ Earth Lead ~ Do not touch components or wiring while panels are removed. Check for Tension / smooth operation Grease periodically Broken / frayed cabling Damaged / burnt clamp Torch ~ Damaged lead Worn tip / Diffuser / Tip holder / Nozzle Drive System ~ Tension (Average setting 3) Drive rollers - check for wear Guide tube alignment / wear *DO NOT LUBRICATE* 20 DO NOT OPERATE THE WELDER WITH THE SIDE PANELS REMOVED.
REVERSE POLARITY For wires that require reverse polarity, exchange the two cables around. Positive (+) to negative (-), Negative (-) to positive (+). Only available as standard equipment on TRAVELLER models; Optional on compact machines. 21
TROUBLE SHOOTING Symptom Possible Causes & Solution Too porous, bubbly.. Faulty gun Dirty liner Windy area No liner Faulty gauge Insufficient or out of gas Rusty or Contaminated material Large build-up Loss of power No Penetration Incorrect polarity Poor power Long extension lead Wire speed too fast Loose cables Incorrect polarity (3-phase only) phase out or diode out Dirty liner Wire Slips Machine not running Wire burning through to the tip (sticks to it) Tighten rollers Incorrect roller size Exceeded duty cycle Thermal protection cutout Loss of primary power Blown Fuse Wrong size rollers Not enough wire tension Wrong size tip Liner cut too short Dirty liner Liner is kinked 22 Wire jumps off spool Spool hub needs tensioning AUSMIG MIG WELDERS ARE A QUALITY AUSTRALIAN MADE PRODUCT. FOR MORE INFORMATION PLEASE CONTACT, AUSLINK WELDING EQUIPMENT P/L 23 RESEARCH DRIVE CROYDON PH 03 9761.4915 FAX 03 9761.4916