OWNERS OPERATING MANUAL CONGRATULATIONS ON YOUR PURCHASE OF A QUALITY WELDCORP WELDER MANUFACTURED IN ITALY, IT WILL PROVIDE YEARS OF RELIABLE OPERATION.
TABLE OF CONTENTS SAFETY INSTRUCTIONS Page 4 INVERTER WELDERS Page 6 DESCRIPTION OF MACHINES Page 7 INVERTER 80 Page 7 INVERTER 125 Page 8 INVERTER 140 Page 9 OPERATION Page 10 WHAT IS AN INVERTER WELDER Page 11 SET UP OF THE INVERTERS Page 11 ESTABLISHING THE ARC Page 12 WELDING BASICS Page 13 WELDING SPEED AND CURRENT Page 13 WELDING INFORMATION Page 14 KEY POINTS Page 14 THERMAL OVERLOAD Page 14 WIRING DIAGRAM INVERTER 80 Page 15 WIRING DIAGRAM INVERTER 125 / 140 Page 15 TROUBLE SHOOTING GUIDE Page 16 SPARE PARTS Page 18 INVERTER 80 Page 18 INVERTER 125 / 140 Page 20 WARRANTY Page 22 WARRANTY FORM Page 23 CONTACT DETAILS Page 24 Page 3
SAFETY INSTRUCTIONS When using power equipment, basic safety precautions should always be followed to reduce the risk of fire, electric shock and personal injury, including the following. If used correctly, welders pose little risk to the operator; however, care should always be taken to ensure safety and proper performance. Read all owner s operating instructions before attempting to operate any product. WARNING: PERSONS FITTED WITH ELECTRONIC DEVICES INCLUDING BUT NOT LIMITED TO PACEMAKERS AND HEARING AIDS SHOULD NOT OPERATE ELECTRONIC INVERTER WELDERS WARNING: CONTACT LENS SHOULD BE REMOVED BEFORE USE FOR SAFE OPERATION: KEEP THE WORK AREA CLEAN: Cluttered working areas (indoor and outdoor) invite injuries. CONSIDER THE WORK ENVIRONMENT: Don t expose power equipment to rain. Don t use welding equipment in damp or wet locations. Keep the work area well lit. Don t use welding equipment in the presence of flammable liquids or gases. GUARD AGAINST ELECTRIC SHOCK: Avoid body contact the grounded surfaces (e.g. pipes, radiator, and electrical appliances). KEEP CHILDREN AND VISITORS AWAY: Keep children, infirmed persons and visitors away from the area of operation. Do not let children, infirmed persons or visitors touch equipment or extension cables. STORE IDLE TOOLS: When power equipment is not in use, keep them in a dry, high or locked area, out of reach of children. WEAR SAFETY GLASSES: Always wear safety goggles or other suitable eye protection when using welding equipment. Page 4
SECURE WORK: Use clamps or a vice whenever possible to secure work. DON T OVERREACH: Keep proper footing and balance at all times. DRESS PROPERLY: DO NOT wear loose clothing or jewellery. They can be caught in moving parts. Wear protective hair covering to cover long hair, and gloves and non-slip footwear is recommended when working outdoors. TAKE CARE OF CABLES: Never carry welding equipment by the cable and never pull the cable to disconnect it from a socket. Keep cables away from heat, oil and sharp edges. Replace damaged cables. DISCONNECT TOOLS: Disconnect welding equipment when not in use, before servicing, and when changing accessories such as blades, bits and cutters. AVOID UNINTENTIONAL OPERATION: Don t carry plugged in welding equipment with a finger on the switch. Be sure that the switch is off when plugging in. OUTDOOR USE EXTENSION CABLES: When electric power equipment is used outdoors, only use extension cables marked as suitable for outdoor use. STAY ALERT: Watch what you are doing. Use common sense. Do not operate welders when you are tired or under the influence of alcohol or drugs. CHECK DAMAGED PARTS: Before using welding equipment, parts that are damaged should be carefully checked to determine that they will operate properly and perform their intended function. Any part that is damaged should be properly repaired or replaced by an authorized service agent. Have defect switches replaced by an authorized repair agent. Do not operate power equipment if it cannot be turned off and on by the switch. REPAIR OF POWER EQUIPMENT BY EXPERTS: Power equipment is built in accordance with relevant safety authority requirements. The repair of power equipment must only be carried out by experts; non-expert repairs may cause considerable danger for the user and void warranty. Page 5
INVERTER WELDERS OPERATING PRINCIPLE The welding machine manages automatically various parameters that allow a good result of the welding operation: FEATURES HOT START Generally when we start welding operation we have some difficulties because the electrode and working piece are cold. During this phase the equipment supplies (for a small time) the starting current with a value higher than value planed. This helps the arc ignition and makes more stable welding process. ARC FORCE During welding operations the electrode is guided by the operator's hand, therefore the distance from the welding point is not always the same. To avoid that electrode approaching the welding melt creates a short circuit, the electronic equipment automatically increases the arc current value to eliminate that. ANTI-STICK If during welding process we have a permanent short circuit, immediately the current value decreases until the value to allow to the electrode be removed from the melt and welding process can proceed regularly. THERMAL PROTECTION When yellow led is ignited is not possible to carry out the welding. Signal light is switch off automatically when temperature goes down, now it is possible to weld again. When equipment is switch on, signal remains about 3 seconds switched on. During this time there is a check of all electronic functions and it is impossible to operate.
DESCRIPTION OF MACHINES These models are portable Inverter Arc Welders which are compact. The robust format makes them a versatile and efficient for a variety of uses. The welders compliance to current regulations and the optimum quality of materials used will ensure a long working life with complete safety. INVERTER 80 SPECIFICATIONS Mains Voltage 230V Welding Current 5 80 Amps Minimum Electrode 1.6 mm Maximum Electrode 2.5 mm Weight 3.4 Kg ACCESSORIES Electrode Holder Work Clamp Instructional DVD Shoulder Strap FEATURES ANTI-SHOCK CLAMP 10 AMP SINGLE PHASE ACCESSORIES INCLUDED EUROPEAN CONFORMITY ANTI-SCRATCH PAINT FAN HOT START, ANTI STICK, ARC FORCE DEVICE GENERATOR SAFE
INVERTER 125 SPECIFICATIONS Mains Voltage 230 V Welding Current 5-125 Amps Minimum Electrode 1.6 mm Maximum Electrode 3.25 mm Weight 4.3 Kg ACCESSORIES Electrode Holder Work Clamp Hand Held Face Mask Combination Chipping Hammer with Wire Brush Instructional DVD Shoulder Strap FEATURES ANTI-SHOCK CLAMP 10 AMP SINGLE PHASE ACCESSORIES INCLUDED EUROPEAN CONFORMITY ANTI-SCRATCH PAINT FAN HOT START, ANTI STICK, ARC FORCE DEVICE GENERATOR SAFE PORTABLE Page 8
INVERTER 140 SPECIFICATIONS Mains Voltage 230 V Welding Current 5-140 Amps Minimum Electrode 1.6 mm Maximum Electrode 4.0 mm Weight 4.5 Kg ACCESSORIES Electrode Holder Work Clamp Hand Held Face Mask Combination Chipping Hammer with Wire Brush Instructional DVD FEATURES ANTI-SHOCK CLAMP Shoulder Strap 10 AMP SINGLE PHASE ACCESSORIES INCLUDED EUROPEAN CONFORMITY ANTI-SCRATCH PAINT FAN HOT START, ANTI STICK, ARC FORCE DEVICE GENERATOR SAFE PORTABLE Page 9
OPERATION For all Inverters Insert earth lead (earth clamp). Insert electrode lead (electrode holder). For all Inverters Select amperage from the guide located on page 14 choosing the correct amperage required for the electrode and material thickness. For all Inverters Select the correct diameter electrode accordingly to the thickness of the piece that you intend to weld. (A table is located on page 13). Press the side lever to open the clamp, insert the electrode into the V-groove and release side lever. Ensure that the electrode is correctly inserted inside the electrode holder. For all Inverters To ensure earth has good contact, clean the work piece with a wire brush. Attach the earth clamp to the clean area to ensure good contact. For all Inverters Switch machine on to start welding. Page 10
WHAT IS AN INVERTER WELDER Inverter welders are welders that transform high voltage, low amperage power into low voltage, high amperage power which is required for welding. This is done by using a transformer. The difference between inverters and other types of welders is that inverter welders increase the frequency of the primary power supply, which in turn reduces the size of the transformer. This is done through an on/off action of high power solid state switches that creates AC power. By controlling the power on the primary side of the transformer and boosting the frequency, the inverter welders are able to created light weight solution compared to ARC and MIG welder types. SET UP OF THE INVERTERS ELECTRODE HOLDER WELDING MACHINE ELECTRODE ARC WORK GROUND EARTH CABLE ELECTRODE LEAD Page 11
ESTABLISHING THE ARC STRIKING THE ARC Strike the metal to be welded with the electrode as pictured. MAKING THE WELD 30 40 ELECTRODE TACKWELD The weld is made by feeding the electrode into the molten pool and at the same time move the electrode along the joint at a 30 to 40 angle at a speed needed to deposit the required size of weld. Pictured to the left. 30 40 W E L D I N G T I P S F O R BEGINNERS 16 mm The easiest welding method for beginners is known as Touch Welding. This welding method is performed by lightly resting the electrode on the work piece and drawing it away slightly while welding at a 40 angle towards the direction of travel.. Refer the pictures to the left. This forms only a short arc. This will flatten and widen the welding bead. WARNING: NEVER TOUCH THE ELECTRODE WHILE THE MACHINE IS TURNED ON. IT CAN RESULT IN INJURY AND ELECTRICUTION. Page 12
WELDING BASICS The welding surface should be free of rust or paint. Choose the electrode in accordance with the material being welded. It is advisable to initially test the electrode and amperage on some scrap metal. Place the electrode at a distance of 2 cm from the work piece and place the face shield in position to protect the eyes. Strike the arc by bringing the electrode into contact with the work piece with a light tapping and scrapping action. Through the face shield you will see the arc which should be in length on to one and half the diameter of the electrode. It is important to maintain a constant length of the arc. As the electrode melts and its length decreases, a gradual downward movement is needed to maintain the correct distance and the arc itself. To stop welding simply withdraw the electrode away from the work piece. It is advisable to lift into the weld seam to avoid a porous crater. Be careful the metal and electrode tip will be hot. Remove the surface slag when cooled by lightly tapping with a chipping hammer. Welding may be resumed from the same spot having first ensured the removal of the slag. WELDING SPEED AND CURRENT The speed and the current that you weld at has an effect on what the weld will be. Refer the pictures below: NORMAL WELDING TOO SLOW SPEED TOO FAST WELDING CURRENT TOO HIGH TOO LOW Page 13
WELDING INFORMATION TABLE FOR SELECTION OF THE WELDING CURRENT ACCORDING TO THE ELECTRODE AND METAL THICKNESS Weldable Metal Thickness Diameter Electrodes E6013 / E7018 Minimum Current [A] Maximum Current [A] 1.20 1.50 mm 1.6 mm 30 50 1.50 2.00 mm 2.0 mm 40 80 2.00 4.00 mm 2.5 mm 60 100 4.00 6.00 mm 3.2 mm 100 130 6.00 7.00 mm 4.0 mm 120 170 NOTE: Weldable metal thickness can be increased by multiple welds. KEY POINTS Get the amperage right from the charts provided. Check you have the right electrode. Use the correct angle, 30 40 degrees to the work piece Arch weld from left to right. Remember the safety aspects, preparation for welding and use the correct equipment. THERMAL OVERLOAD This welder is fitted with a thermal overload cut out which operates automatically to stop the transformer overheating. The machine will become operational again automatically once the temperature has reduced itself to an acceptable working temperature. Page 14
WIRING DIAGRAM INVERTER 80 WIRING DIAGRAM INVERTER 125/140 Page 15
TROUBLE SHOOTING GUIDE FAULT REASON REMEDY Excessive Electrode Consumption Improper size/or geometry of electrode for current required Use larger electrode Excessive heating in holder Check for proper contact Contaminated Electrode Electrode Dimensions Cable Layout Contaminated electrode Base metal is dirty or greasy Contaminant elements that our gas may exist within the base material itself Check for electrode contamination Be sure electrode dimensions are appropriate for application In so far as possible, try to layout cables from power supply to welding torch as straight as possible Replace electrode For surface cleanliness use appropriate chemical cleaners alcohol, wire brush or abrasive If possible, improve base material. Modify welding parameters to accommodate out gassing effect Remove contaminated portion of electrode, regrind electrode Electrode tip dimensions vary according to the welding application refer to the guide on page 10 Occasionally, cables are coiled like a garden hose. The coil becomes a giant inductor causing resistance that reduces starting energy. Inductance effects can also be caused by having welding power cables very close to grounded steel plates. Grounding Problems Make sure clamps and clamp inserts are clean of oxidation. Make sure ground clamp is not worn. Oxidation and/ or worn equipment can cause poor ground between part and clam/ inserts which may hinder arc starting, wander and other inconsistencies. Page 16
TROUBLE SHOOTING GUIDE FAULT REASON REMEDY Extension Cables Overheat Lights Come On Difficulty in Arc Starting Arc Does Not Transfer Ensure that any extension cables are of adequate capacity Overheating of unit Damaged Electrodes Low voltage problem Loose, missing cable connections Power supply not recognising start signal Low quality/ capacity cables will result in voltage drops and hinder starting Allow 3 5 minutes of cool down time. If condition is not resettable, take welder to repair agent for service. Check condition of electrodes Check the power supply Check the AMP settings Check earth connection for loose or poor ground Check all connections NOTE: If you are still having difficulty with your welder, do not hesitate to contact our service team on: 1800 001 1812
SPARE PARTS INVERTER 80
NUMBER DESCRIPTION PRODUCT CODE PICTURE 1 FRONT LABEL M00505SP 2 KNOB S087760SP 3 EARTH CLAMP M611020SP 4 ELECTRODE HOLDER M611520SP 5 GEM S082810SP 6 MANTLE S351400SP 7 ON-OFF SWITCH M484200SP 8 FRONTAL BACK S087316SP 9 POWER CORD M581170SP 10 BELT WITH CLIPS M389920SP 11 FERRITE + CABLE M708250SP 12 CABLE STOPPER S074350SP 13 ROUE A AUBUES M500251SP 14 BOTTOM S331400SP 15 PCB SUPPORT S089250SP 16 CARD AW5679SP
SPARE PARTS INVERTER 125 / 140
NUMBER DESCRIPTION PRODUCT CODE PICTURE 1 BELT WITH CLIPS M389955SP 2 KNOB S087500SP 3 FRONT, POSTERIOR, DEEP PANEL S351460SP [Only for Inverter 125] S00454SP [Only for Inverter 140] 4 DINSE CONNECTION M431122SP 5 FRONTAL BACK S052500SP 6 MANTLE S351460SP 7 YELLOW GEM S082800SP 8 RED GEM S082802SP 9 ON-OFF SWITCH M485100SP 10 POWER CORD M581170SP 11 FUN GRID M500900SP 12 FERRITE AND CABLE M708250SP 13 PCB SUPPORT S089250SP 14 ENCODER M560515SP 15 CARD AW5699JAB [Only for Inverter 125] MQ5680R [Only for Inverter 140] 16 EARTH CLAMP M613660SP 17 ELECTRODE HOLDER M613050SP 18 MASK 90350SP 19 BRUSH M830750SP 20 STICKER M00531SP
WARRANTY Subject to the warranty conditions below, this Weldcorp product (hereinafter called the product ) is warranted by Weldcorp (thereinafter called the company ) to be free from defects in material or workmanship for a period of 12 months from the date of original purchase covering both parts and labour. Under the terms of this warranty. The repair or replacement of any part shall be the opinion of the Company or its authorised agent. Should service become necessary during the warranty period, the owner should contact the Authorised Weldcorp Retailer from whom the Product was purchased. In order to obtain warranty service, the owner must present the sales docket and Warranty Certificate to confirm the date of purchase. This product is sold by the dealer or agent as to give any additional warranty or guarantee on the Company s behalf except as herein contained or herein referred to. WARRANTY CONDITIONS This warranty only applies provided that the Product has been used in accordance with the manufacture s recommendations under normal use and reasonable care (in the opinion of the Company) and such warranty does not cover damage, malfunction or failure resulting from misuse, neglect, abuse or used for a purpose for which it was not-designed or is not suited and no repairs, alterations of modifications have been attempted by other than an Authorised Service Agent. This guarantee will not apply if the tool is damaged by accident or if repairs arise from normal wear and tear. Certain legislation including the Trade Practices Act, 1974 (as amended) and other state and territorial laws give rights to the buyer and impose liability on the seller in certain circumstances. Nothing herein shall have the effect of excluding, restricting or modifying any condition, warranty, right or liability imposed, to the extent only that such exclusion, restriction or modification would render any term herein void. Page 22
WARRANTY FORM THIS WARRANTY FORM SHOULD BE REAINED BY THE CUSTOMER AT ALL TIMES For your record and to assist in establishing date of purchase (necessary for inwarranty service) please keep your purchase docket and this form completed with the following particulars. PURCHASED FROM SUBURB DATE MODEL NO SERIAL NO Present this form with your Purchase Docket when WARRANTY service is required. CALL 1800 001 1812 Page 23
Manufactured in Italy F H Prager A Division of ITW Retail Group Pty Ltd. ABN 95 000 043 872 73C ELIZABETH STREET WETHERILL PARK NSW 2164 Free Call: 1800 001 1812 www.weldcorp.net