Migatronic Automig X User manual

INSTRUCTION MANUAL

AUTOMIG X

Valid from 8647 50170005

CONTENTS:

GENERAL DESCRIPTION............................................................................................................4

INITIAL OPERATING ....................................................................................................................5

CONTROL SWITCHES/INSTRUCTION .......................................................................................6

WELDING TECHNIQUE................................................................................................................7

MAINTENANCE.............................................................................................................................8

FAULTS.........................................................................................................................................9

REPLACEMENT OF CONTROL UNIT........................................................................................10

REPLACEMENT OF WIRE GUIDE LINER.................................................................................11

TECHNICAL DATA......................................................................................................................12

WELDING SCHEDULES.............................................................................................................13

Only first-class materials have been used for the development and production of MIGATRONIC welding

machines. The materials are subject to current control and quality supervison and then processed and

mounted together into MIGATRONIC welding machines.

No matter how good materials we have used and no matter how carefully the mounting has been done, an

advanced product as a MIGATRONIC MIG-MAG-welding machine demands your effort to operate perfectly

for years.

Therefore study carefully this instruction before your initial operating. This should assure a profitable use of

your new MIGATRONIC welding machine.

CONGRATULATIONS!

GENERAL DESCRIPTION

MIGATRONIC welding machines, type Automig: 140 Mono X, 140 X, 180 Mono X, 180 X, 185 X, 200 X, 250 X

and 300 X have been developed for thin plate welding and car body repair.

The Automig 140 Mono X and 180 Mono X are designed to normal single-phase 220-240 V plug

(F+0+earth)/10 Amp(16Amp) where as the Automig 140 X, 180 X, 185 X, 200 X, 250 X, 300 X are designed for

three-phase 220-380 V (3F+earth)/10Amp.

Automig 185 X needs only two phase wires (2F+earth)/16Amp.

The main parts of the machine are the main transformer, the contactor, the rectifier for welding current, the

condenser battery (only 140 M X, 180 M X, 185 X), the control transformer, the wire feed motor, the solenoid

valve and the electronic control.

The welding transformer has been dimensioned to obtain optimum welding capacities, and for a working

temperature of 180°C. For further protection a thermal fuse has been incorporated which automatically cuts out

the machine at 150°C. The overheating protection will switch on automatically when the transformer has cooled.

The rectifier is electronically protected against overloading in case of short circuit of the welding current, the

machine will cut out after approx. 3 sec.

Mode of operation: When the trigger at the welding handle is activated the contactor will couple voltage to the

welding transformer which will give a secundary voltage decided by the position of the voltage switch. In the

rectifier this AC voltage is transformed into a DC voltage which is applied between welding torch and return

cable. At the same time the flow of protection gas and the wire feed motor are started. The number of revolutions

is decided by the adjustment button. When you lift your finger from the trigger the motor will stop and after a

short delay the contactor and the welding current are interrupted.

This delay which is called "burn back delay" has the effect that the welding wire will burn back a little from the

molten pool and thus does not stick to the pool. The time of delay can be set by the lowest trimpotentiometer at

the print card.

The electronic control can be set to the functions "seam" , "spot" , and "interval" .

At "seam" the welding will start when you press the trigger and stop when you release the trigger.

At "spot" the welding will stop after a delay that can be set by the button "welding time". Using this function you

are sure of a uniform interval welding.

In the position "interval" the wire feed motor will stop with intervals that can be set by the buttons "welding time"

and "pause time". When you put "pauses" into the welding, the average heat volume added is reduced to

prevent a burning through on difficult welding tasks.

INITIAL OPERATING

Mains connection:

Input voltage should be as stated on the type plate of the machine. If dual voltage, the tapping must be checked

before mains connection.

Shielding gas connection:

The shielding gas bottle is mounted on the machine and the regulator on the bottle. If the regulator is equipped

with flowmeter, the gas quantity is adjusted on 5-15 litres/min.

Welding hose connection:

The welding hose is put through the hole in the front plate and into the switch on the wire feed console (see page

11). Keep the inlet nozzle as close to the wire feed roller as possible without letting them touch each other.

Fasten the Allen screw and mount the gas hose and the control wire. Check that the hole in the inlet nozzle is in

line with the groove of the wire feed roller.

Fitting the welding wire:

Turn the tension spring aside and tip it up. Check that the wire feed roller, the wire guide liner and the contact tip

correspond to the wire diameter, the wire feed roller is designed for two wire dimensions and should be turned

around until the outer side is showing the wire size being used. The following wire guide liner is recommended

WIRE DIAMETER FE.WIRE

mm WIRE GUIDE LINER INT.DIAM.

ø 0.6

ø 0.8 - ø 1.0 ø 1.0 (ø 1.5)

ø 1.5

WIRE DIAMETER AL.WIRE

mm WIRE GUIDE LINER INT.DIAM.

ø 0.8

ø 1.0 ø 1.5

ø 1.5

When using aluminium wire use a special guide liner where the internal liner goes all the way through the inlet

nozzle. This prevents the aluminium wire from being damaged.

The reel of wire is put on the hub, and the wire is put through the wire feed unit and some centimeters into the

hose. As the wire guide liner is vulnerable to burrs at the point of the wire, it is important to file the point of the

wire in order to remove all burrs and it is equally important to straighten out the first 10-15 cm. Unscrew contact

nozzle. Tip up the lever. Set the wire speed at 6, press the start button, the wire runs through the hose. When

the wire is through the hose, stop the machine and mount the contact nozzle. The pressure of the lever is

adjusted to allow the wire feed roller just to slide on the wire when this is stopped at the

contact nozzle.

Automig 185 X

The special welding hose is mounted at the quick clutch of the machine and the Jack-sleeve and the welding

handle is mounted with the desired electrode holder.

For planishing of dents with carbon the voltage switch of the machine shall be set at step 8 whereas voltage step

7 is used when welding nails or discs. Using this method it is important for a satisfactory result that you do not

press the handle too hard against the workpiece as the contact resistance between nail (discs) and the piece is

reduced and the desired generation of heat is decreased.

You must also take care that the return clip is in good contact with the piece and is not attached too far from the

welding point.

CONTROL SWITCHES/INSTRUCTIONS

1. Welding time: With this switch the welding time is chosen, when 2 is in position: interval and spot.

2. Switch:

Seam:

The switch is set at seam. The trigger on the welding handle is activated, welding starts. By letting go the

trigger you stop the welding process.

Spot:

The switch is set at spot. When the trigger on the welding handle is activated, welding starts. Welding

automatically stops, depending on the time adjusted by button 1 (0.2-1.5 sec.)

Interval:

The switch is set at interval. When the trigger is activated, welding starts. The welding automatically

stops, depending on the time adjusted by button 1. After an interval fixed at button 3 the same cycle

continues automatically and is only interrupted when the trigger on the welding handle is released.

3. Adjustable pausetime: With this button the pause time is chosen, when button 2 is in position: interval.

4. Wire speed: With this button the wire feed speed is adjusted, depending on the welding voltage and wire

diameter.

Wire speed range: 2-12 m/min.

5. Control lamp: Lights when the machine is on.

6. Fuse

7. Adjustment of welding voltage and main switch ON-OFF.

8. Earth cable (only at Automig 185X).

9. Connection for bolt welding hose (only at Automig 185 X).

10. Pilot cable for bolt welding hose (only at Automig 185 X).

WELDING TECHNIQUE

Setting of the machine

The setting of a MIG-MAG welding machine demands some practice from the welder, the machine having two

control points that have to conform. These two are the wire feed speed and the welding voltage. The welding

current is determined by the wire feed speed, and it should correspond to the workpiece. The current will

increase with increased wire speed, resulting in a shorter arc. Less wire speed will reduce the current and

lengthen the arc. Increasing the welding voltage hardly alters the current intensity, but lengthens the arc. By

decreasing the voltage a shorter arc is obtained with little change in current intensity.

When using CO2as shielding gas, increase the voltage by about 5 Volts per 100 Amp.

When changing the wire diameters, different control settings are required. A thinner wire needs more speed to

acquire the same current strength. A satisfactory weld cannot be obtained if extreme values are exceeded.

If the feed speed is too high for the welding voltage, blockage will occur in the torch as the wire dips into the

molten pool and does not melt. Welding in these conditions normally gives faults due to lack of fusion. If,

however, the welding voltage is too high, large drops will form on the end of the wire, causing spatter.

The correct setting of voltage and speed can be seen in an even and calm arc.

See tables.

Influence of the welding position

The position of the torch and the work piece is important for the quality and appearance of the seam.

The diagrams on the next page show some of the many possibilities and indicate schematically the

importance of these positions. In practice one of course uses all combinations of welding positions, torch

directions and positions of the work piece.

Together with the figures, the diagram below may help when an estimation of the importance of separate

factors for welding quality is needed.

The terms drawing weld and thrusting weld mean:

Drawing weld: torch sloped in direction of weld

Thrusting weld: torch sloped away from direction of weld.

Drawing weld is sometimes designated "dragging welding" and thrusting weld "stabbing" welding

Thrusting weld Drawing weld

Width of seam wider narrower

Upper bead smaller larger

Penetration decrease increase

Tendency to lack of fusion greater lesser

MAINTENANCE

The following items demand special attention:

Wire feed unit

This unit is to be checked regularly at the wire feed roller and the wire nozzles, as it is of great importance for

a satisfactory welding result and a minimum of wear and tear that the wire passes through the mechanism

without any deformations of the wire or the wire feed roller.

The wire nozzles should often be checked and changed if the copper coating of the wire is damaged on its

way through the nozzles. Copper dust may totally hinder free passage through the wire liner.

A weekly check and cleaning of the nozzles as well as the wire feed roller is recommended.

Welding hose

Great care should be taken that the welding hose is not overloaded. It should not be pulled over sharp edges,

and other heavy machines should not run over it as it may damage the wire lines. The hose should be

dismantled every week and blown out with dry air.

Welding torch

There are many parts in the welding torch that have to be cleaned regularly. The main ones are the contact tip

and the gas nozzle. During the welding process, these parts are bombarded with spatter that sticks in the

nozzles. This may disturb the shielding gas flowing from the gas nozzle down to the molten pool.

Otherwise, if the gas nozzle is blocked up with spatter, there is a danger that a short-circuit will occur between

the contact tip and the gas nozzle. The spatter should therefore be removed regularly and spatter remover

applied in order to prevent spatter from burning into the nozzles. During the cleaning process, the gas nozzle

should be removed.

DO NOT CLEAN BY BEATING THE TORCH

Power source

The rectifier and transformer should be blown out with dry air occasionally, otherwise the air circulation will be

affected by the dust.

FAULTS

FAULT:

Too little welding effect

The welding seam forms a bead.

PROBABLE CAUSE:

1. One of the three fuses in the main switch is not

working (one phase is missing).

2. The welding voltage is too low.

Switch one setting higher.

The wire feed is blocking. 1. The inlet nozzle and the wire are not in alignment

with each other.

2. The reel of wire is too taut, the wire must come off

the reel evenly.

3. The inlet or contact tip is worn out or is blocked up.

4. The welding wire is not clean or it is rusty. It could

also be of an inferior quality.

5. The pressure roller has to be tightened.

Spatter 1. The wire feed is too fast for the voltage setting.

2 Worn out contact tip.

Porous weld.

A cone is formed when spot welding 1. Insufficient gas - not enough pressure or the bottle

is empty.

2. Contact tip is blocked up.

3. Leakage - air is pumped in and mixes with the

shielding gas.

The arc does not look normal, and there is a lot of

spatter 1. The material is dirty, underseal or paint.

The wire keeps sticking in the contact tip and is very

slow 1. The wire can be malformed.

The damaged wire should be cut off, pulled out

and replaced. The pressure on the wire feed roller

should be checked.

2. Worn out contact tip.

No welding voltage 1. Working voltage interrupted due to overloading of

the transformer. Automatic switch on after cooling

(15-30 min.).

REPLACEMENT OF CONTROL UNIT

1. Switch off current.

2. Remove buttons on the front plate.

3. Remove side panel.

4. Disconnect multiplug outlets and unscrew the nuts.

5. Dismount potentiometer for pause time.

6. Pull out control unit.

7. Mount the new control unit inversely.

8. Do not connect the machine before the multiplug is in the right place.

Nut

Plug

Nut

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