Autojack IMIG200DP Manual de instalación

SAFETY AND OPERATING MANUAL

Dual Pulse MIG Welder

iMIG200DP

ORIGINAL INSTRUCTIONS

iMIG200DP

Welcome to Autojack!

Dear Customer, Congratulations on your purchase.

Before using this product for the first time, please be sure to

read these instructions for use.

They provide you with all the information necessary for using

the product safely and to ensure its long service life.

Closely observe all safety information in these instructions!

General Power Tool Safety Warnings 3

Symbol Chart 8

Technical Specification/Package Contents 9

Operation 10

Maintenance 12

Troubleshooting 13

Autojack Guarantee 14

Declaration of Conformity 17

Machine Schematic 18

Welding Spec Tables 19

TABLE OF CONTENTS

iMIG200DP

WARNING, please read all safety

warnings and instructions.

Failure to follow the warnings and instructions

may result in electric shock, fire and/or serious

injury.

Save all warnings and instructions for

future reference.

The term “Power tool” in the warnings refers to

your electric (corded) power tool or battery-

operated (cordless) power tool.

1. Work area safety

a) Keep work area clean and well lit.

Cluttered or dark areas invite accidents.

b) Do not operate power tools in explosive

atmospheres, such as in the presence of

flammable liquids, gases or dust. Power tools

create sparks which may ignire the dust or

fumes.

c) Keep children and bystanders away while

operating a power tool. Distractions can cause

you to lose control.

2. Electrical safety

a) Power tool plugs must match the outlet.

Never modify the plug in any way.

Do not use any adaptor plugs with grounded

power tools. Unmodified plugs and matching

outlets will reduce risk of electric shock.

b} Avoid body contact with grounded surfaces,

such as pipes, radiators, ranges and

refridgerators. There is an increased risk of

electric shock if your body is grounded.

c) Do not expose power tools to rain or wet

conditions. Water entering a power tool will

increase the risk of electric shock.

GENERAL POWER TOOL SAFETY WARNINGS

d) Do not abuse the cord. Never use the cord for

carrying, pulling or unplugging the power tool.

Keep cord away from heat, oil, sharp edges or

moving parts. Damaged or entangled cords

increase the risk of electric shock.

e) When operating a power tool outdoors, use an

extension cord suitable for outdoor use. Use of a

cord suitable for outdoor use reduces the risk of

electric shock.

f) If operating a power tool in a damp location is

unavoidable, use a residual current device (RCD)

protected supply. Use of an RCD reduces the risk

of electric shock.

3. Personal safety

a) Stay alert, watch what you are doing and use

common sense when operating a power tool. Do

not use a power tool while you are tired or under

the influence of drugs, alcohol or medication. A

moment of inattention while operating power

tools may result in serious personal injury.

b) Use personal protective equipment. Always

wear eye protection. Protective equipment such

as dust mask, non-skid safety shoes, hard hat, or

hearing protection used for appropriate conditions

will reduce personal injuries.

c) Prevent unintentional starting. Ensure the

switch is in the off position before connecting to

power source and/or battery pack, picking up or

carrying the tool. Carrying power tools with your

finger on the switch or energizing power tools that

have the switch on invites accidents.

d) Remove any adjusting key or wrench before

turning the power tool on. A wrench or a key left

attached to a rotating part of the power tool may

result in personal injury.

iMIG200DP

e) Do not overreach. Keep proper footing and

balance at all times. This enables better

control of the power tool in unexpected

situations.

f) Dress properly. Do not wear loose clothing

or jewellery. Keep your hair, clothing and

gloves away from moving parts. Loose

clothes, jewellery or long hair can be caught in

moving parts.

g) If devices are provided for the connection

of dust extraction and collection facilities,

ensure these are connected and properly

used. Use of dust collection can reduce dust-

related hazards.

4. Power tool use and care

a) Do not force the power tool. Use the correct

power tool for your application. The correct

power tool will do the job better and safer at

the rate for which it was designed.

b) Do not use the power tool if the switch

does not turn it on and off. Any power tool

that cannot be controlled with the switch is

dangerous and must be repaired.

c) Disconnect the plug from the power

source and/or the battery pack from the

power tool before making any adjustments,

changing accessories, or storing power tools.

Such preventive safety measures reduce the

risk of starting the power tool accidentally.

d) Store idle power tools out of the reach of

children and do not allow persons

unfamiliar with the power tool or these

instructions to operate the power tool.

Power tools are dangerous in the hands of

untrained users.

GENERAL POWER TOOL SAFETY WARNINGS

e) Maintain power tools. Check for

misalignment or binding of moving

parts, breakage of parts and any other

condition that may affect the power

tool’s operation. If damaged, have the

power tool repaired before use. Many

accidents are caused by poorly

maintained power tools.

f) Keep cutting tools sharp and clean.

Properly maintained cutting tools with

sharp cutting edges are less likely to

bind and are easier

g) Use the power tool, accessories and

tool bits etc. in accordance with these

instructions, taking into account the

working conditions and the work to be

performed. Use of the power tool for

operations different from those

intended could result in a hazardous

situation.

5. Service

a) Have your power tool serviced by a

qualified repair person using only

identical replacement parts. This will

ensure that the safety of the power tool

is maintained.

b) If the replacement of the

supply cord is necessary, this has

to be done by the manufacturer

or its agent in order to avoid a

safety hazard.

Use power tools only with specifically

designated battery packs. Use of any other

battery packs may create a risk of injury or fire

iMIG200DP

Additional Safety

Instructions for welders

Welders have many sources of danger. It

is therefore particularly important for the

welder to comply with the following rules

so as not to place themselves or others in

danger and to avoid endangering people

and equipment.

Have all work on the mains voltage

system, for example on cables, plugs,

sockets, etc., performed only by trained

electricians. This particularly applies to

configuring intermediate cables.

If an accident occurs, disconnect the

welding power source from the mains

immediately.

If electric touch voltages occur, switch

off the welding set immediately and have

it checked by an expert.

Always check for good electrical

contacts on the welding current side.

GENERAL POWER TOOL SAFETY WARNINGS

e) Wear insulating gloves on both hands for

welding. These offer protection from electric

shocks (idling voltage in the welding circuit),

harmful radiation (Heat and UV radiation) and

from glowing metal and slag spatter.

f) Wear firm, insulated footwear. Your

shoes should also protect you in wet

conditions. Open- toed footwear is not

suitable since falling droplets of glowing

metal will cause burns.

g) Wear suitable clothing, do not wear

synthetic clothes.

h) Do not look into the arc with

unprotected eyes, use only a welding

safety shield with the proper safety glass in

compliance with DIN standards. In addition

to light and heat, which may cause dazzling

and burns, the arc also gives off UV

radiation. Without proper protection, this

invisible ultraviolet radiation causes very

painful conjunctivitis, which will only be

noticeable several hours later. In addition,

UV radiation will cause sunburn-type

symptoms on unprotected parts of the

body.

i) Personnel or assistants in the vicinity of

the arc must also be notified of the

dangers and provided with the required

protection; if necessary install safety walls.

j) Ensure adequate ventilation for

welding, particularly in small rooms

since the process causes smoke and

harmful gases.

k) Do not carry out any welding work on

tanks that have been used to store gases,

fuels, mineral oil or the like, even if they

have been empty for a lengthy period of

time, since any residue will result in a

danger of explosion.

iMIG200DP

l) Special regulations apply in areas where

there is a potential risk of fire and/or

explosion.

m) Welds that are exposed to large stresses

and must comply with safety requirements

may only be completed by specially trained

and approved welders. Examples of such

welds include pressure vessels, rails, trailer

hitches, etc.

n) It must be noted that the protective

conductor in electrical systems of

appliances may be destroyed by the

welding current in the event of negligence,

for example if the earth terminal is placed

on the welding set casing to which the

protective conductor of the electrical

system is connected. The welding work is

completed on a machine with a protective

conductor connection. It is therefore

possible to weld on the machine without

having connected the earth terminal to it.

In this case the welding current will flow

from the earth terminal through the

protective conductor to the machine. The

high welding current may cause the

protective conductor to melt.

o) The fuses on the supply cables to the

mains sockets must comply with the

relevant regulations (VDE 0100). To

comply with these regulations, only fuses

or circuit breakers suitable for the cross-

section of the cables may be used (for

earthing contact sockets max. 16 A fuses or

16 A circuit breakers). The use of too high

a fuse may result in the cable burning and

fire damage to the building.

GENERAL POWER TOOL SAFETY WARNINGS

8. Additional Safety Instructions for

Constricted and wet areas

When working in constricted, wet or

hot areas, use insulating supports and

intermediate layers as well as slip-on

gloves made of leather or other non-

conductive materials to insulate your

body against the floor, walls,

conductive parts of the machine and

the like.

If you use small welding transformers

for welding in places with an increase

electrical risk, for example in

constricted areas with conductive

walls, (tanks, pipes, etc.), in wet areas

(which make work clothes wet) and in

hot areas (perspiration on work

clothes), the output voltage of the

welding set when idling must not

exceed 48 V (effective value).

Therefore, the appliance may not be

used for these purposes because its

output voltage is higher than this.

iMIG200DP

9. Additional Safety Instructions for safety

clothing

a) While working, the welder must protect his

entire body from radiation and burns by wearing

suitable clothing and a face guard.

b) Slip-on gloves made of a suitable material

(leather) must be worn on both hands. They must

be in perfect condition.

c) Suitable aprons must be worn to protect

clothing from sparks and burns. A safety suit and if

necessary, head protection must be worn if

required by the type of work in question, e.g.

overhead welding.

d) The safety clothing used as well as all

accessories must comply with the “Personal Safety

Equipment” directive.

10. Additional Safety Instructions for

Protection from radiation and burns.

a) Provide information about the risk to eyes at

the working site in the form of a poster with the

wording “Caution – do not look at the flames”.

Workplaces are to be screened off wherever

possible so that personnel in the vicinity are

protected. Unauthorized persons are to be kept

away from the welding work.

b) The walls in the immediate vicinity of

stationary workplaces should not have a light

color or a sheen. Windows up to head height are

to be protected against radiation passing

through them or reflecting off them, for example

by coating them with a suitable paint.

Do not store or use the equipment in wet

conditions or in the rain. Use the equipment only

indoors.

GENERAL POWER TOOL SAFETY WARNINGS

11. Using an Extension Cable.

If an extension cable is required, use an

approved triple core extension cable

suitable for the power input of the tool.

Grounded tools always require a three

wire extension cable.

As the distance from the supply outlet

increases you must use a heavier gauge

extension cable. Using extension cables with

inadequately sized wire causes a serious drop

in voltage, resulting in loss of power and

possible tool damage.

The smaller the gauge number of the wire

the greater the capacity of the cord.

When using a cable reel, always unwind

the cable completely.

iMIG200DP

SYMBOL CHART

iMIG200DP

SPECIFICATION

iMIG200DP

Mains Voltage

230V

Rated Input Power

7.7 KVA

No-load Voltage

60 V

MIG Rated Welding Voltage

16.5 ~ 24V

MMA Rated Welding Voltage

20.8 ~ 27.2 V

MIG Welding Current

50 ~ 200 A

MMA Welding Current

20 ~ 180 A

Pulse MIG Welding Current

30 ~ 170 A

Rated Duty Cycle

60%

Steel Wire Diameter

0.8 –1.0 mm

Al-Si/Al-Mg Wire Diameter

1.0 –1.2 mm

Efficiency

85%

Insulation Class

Enclosure Protection

IP21S

Cooling Type

Fan

Weight

14.4KG

Dimensions

535*230*370 mm

Package Contents

iMIG200DP Welder

3Mtr SN24 MIG Torch

1.8Mtr 300A Electrode Holder

1.2Mtr 300A Earth Clamp

Steel Liner

500g Hammer and Wood Brush

3 Gas Pipe Clamps

Contact 0.8/1.0/1.2mm Tips (2 of each)

V type 0.8/1.0mm Rollers

TECHNICAL SPECIFICATION

iMIG200DP

At this point, you are ready to begin welding.

Turn the welder on and ensure that your

workpiece is clean of rust or dirt and attach the

clamp to it. Make sure that the gas regulator is

attached to your bottle if necessary and turn it

anti-clockwise to meet the demands of your weld

whilst pressing the torch trigger. The current will

need to be adjusted as you are welding to find

the correct variables to match your wire feed

speed.

OPERATION

To begin MIG welding, you must first connect your welder up to a 230V supply using

the plug provided and plug the torch in to the torch connection on front panel. The

first image below shows where the input is for the mains supply.

Next, you will need to install the welding wire if applicable, to do this, you must lift

the side panel and locate the wire feed motor. The wire size needed will depend on

your workpiece but you will need the corresponding roller and tips for the wire size

fitted, e.g. a 1mm roller, lining and tips will be used with 1mm wire. To fit the wire,

you put the wire feed reel on the hub of the motor and tighten it accordingly. Once

this has been done, you can push the wire through the rollers and then the lining,

ensuring it is not too tight (if the wire is too tight between the rollers it can snag and

stop feeding/cause too much resistance on the motor) and press the trigger on the

torch for it to start feeding. The wire should be fed through until it comes through

the nozzle by a few cm. Then the correct size tip can be screwed onto the nozzle.

The above listed techniques are both adequate for welding depending on your workpiece.

The image to the right shows a few

types of welding techniques that are

administered when MIG welding.

The pushing weld is when the torch is

angled against the direction of the

weld.

The pulling weld is when your torch is

angled towards the direction of the

weld.

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