Magmate 180P Operating Manual

Summary of 180P

  • Page 1

    180 p o p e r at i n g m a n u a l.

  • Page 2

    2 welcome to a better way of welding congratulations on purchasing a magmate 180p welding machine. This operating manual provides the basic knowledge required for mig welding, as well as highlighting important areas of how to operate the magmate machine. With normal use and by following these recomm...

  • Page 3: Contents

    3 contents 1.0 recommended safety precautions 4 1.1 health hazard information 4 1.2 personal protection 4 1.3 electrical shock 5 1.4 user responsibility 5 2.0 mig operating manual 6 2.1 introduction to metal inert gas (mig) 6 2.2 introduction to flux cored arc welding (fcaw) 6 2.3 introduction to me...

  • Page 4: 1.2  Personal Protection

    4 1.1 health hazard information the actual process of mig welding is one that can cause a variety of hazards. All appropriate safety equipment should be worn at all times, i.E. Headwear, hand and body protection. Electrical equipment should be used in accordance with the manufacturer’s recommendatio...

  • Page 5: 1.3  Electrical Shock

    5 1.3 electrical shock • never touch ‘live’ electrical parts. • always repair or replace worn or damaged parts. • disconnect power source before performing any maintenance or service. • earth all work materials. • never work in moist or damp areas. Avoid electric shock by: • wearing dry insulated bo...

  • Page 6: Gas (Mig)

    6 2.1 introduction to metal inert gas (mig) mig welding embraces a group of arc welding processes in which a continuous electrode (the wire) is fed by powered feed rolls (wire feeder) into the weld pool. An electric arc is created between the tip of the wire and the weld pool. The wire is progressiv...

  • Page 7

    7 as with mig, direct current power sources with constant voltage output characteristics are normally employed to supply the welding current. With flux-cored wires the terminal that the filler wire is connected to depends on the specific product being used, some wires running electrode positive, oth...

  • Page 8: Arc Welding (McAw)

    8 it is also common to use longer contact tip to workplace distances with flux cored arc welding than with solid wire mig welding and this also has the effect of increasing the resistive heating on the wire further accentuating the drop in welding current. Research has also shown that increasing thi...

  • Page 9

    9 will run on either. The work return lead is then connected to the opposite terminal. Electrode negative operation will usually give better positional welding characteristics. The output characteristics of the power source can have an effect on the quality of the welds produced. The wire feed unit ...

  • Page 10

    10 and arc voltage settings cause the electrode to intermittently short-circuit with the weld pool at a controlled frequency. Metal is transferred by the wire tip actually dipping into the weld pool and the short-circuit current is sufficient to allow the arc to be re-established. This short- circui...

  • Page 11

    11 wire diameter. High deposition rates are possible and weld appearance and reliability are good. Most metals can be welded, but the technique is limited generally to plate thicknesses greater than 6mm. Spray transfer, due to the tendency of the large weld pool to spill over, cannot normally be use...

  • Page 12: And McAw

    12 process dip transf er globular transf er spra y transf er pulsed transf er metal inert gas (mig) ● ● ● flux cored (gas shielded) ● ● * flux cored (self shielded) ● ● metal cored ● ● ● * not true spray 2.4 fundamentals of mig, fcaw and mcaw welding technique successful welding depends on the follo...

  • Page 13

    13 if the cast is too large the wire will move in an upward direction from the tip when welding and if too small the wire will dip down from the tip. The result of this is excessive tip wear and increased wear in the liners. If the helix is too large the wire will leave the tip with a corkscrew effe...

  • Page 14

    14 3.0 general welding information 3.1 recommended welding parameters argoshield light gas code 060 (australia) 500 (new zealand) indicative welding parameters dip transfer spray transfer material thickness (mm) 1–1.6 2 3 4 3 welding position horizontal / vertical horizontal / vertical horizontal / ...

  • Page 15

    15 4.0 correct application techniques correct application techniques direction of welding. Mig welding with solid wires takes place normally with a push technique. The welding gun is tilted at an angle of 10° towards the direction of welding. (push technique) 10° the influence of changing the torch ...

  • Page 16

    16 electrical stickout 1 gas nozzle 6 contact tube 2 contact tube setback 7 visible stickout 3 consumable electrode 8 arc length 4 workpiece 9 electrical stickout 5 standoff distance 1 2 3 5 6 7 8 9 4 the electrical stickout is the distance between the end of the contact tip and the end of the wire....

  • Page 17: Power Source

    17 power source component fault symptom cause primary cable no or low welding output bad or incorrect primary connection, lost phase earth cable and clamp arc will not initiate damaged, loose or undersized cables and clamps connectors and lugs overheating of connectors and lugs loose or badly crimpe...

  • Page 18: Welding Gun

    18 welding gun component fault symptom cause type welding gun overheats welding gun underrated for welding application liners erratic wire feed, wire snarls up at outlet guide liner of incorrect type and size for wire in use, worn or dirty liner, liner too long or too short gas distributor inadequat...

  • Page 19

    19 magmate 180p part no. Mag180p input power (v) 240 ± 15% single phase frequency (hz) 50 / 60 rated input current (a) 20.3 output current adjustment (a) 50–180 output voltage adjustment (v) 14–26 duty cycle (%) 60 power factor 0.73 efficiency (%) 80 type of wirefeeder machine compact wire speed (m ...

  • Page 20: 7.1  Machine Setup

    20 7.0 operating controls and contents 1 wire inch switch 2 pressure adjusting knob 3 flexible conduit 4 torch connector 5 conduit 6 roller 7 posititive terminal 8 negative terminal 9 spool holder 10 gas inlet 11 wire speed (voltage control) 14–26 v 12 fully adjustable current setting from 20–180 a ...

  • Page 21: 8.1  Power Source

    21 the working environment or amount of use the machine receives should be taken into consideration when planning maintenance frequency of your magmate welder. Preventative maintenance will ensure trouble free welding and increase the life of the machine and its consumables. 8.1 power source • check...

  • Page 22: 9.1  Terms Of Warranty

    22 9.1 terms of warranty the magmate ™ machine has a limited warranty that covers manufacturing and material defects only. The warranty is affected on the day of purchase and does not cover any freight, packaging and insurance costs. Verbal promises that do not comply with terms of warranty are not ...

  • Page 23

    23 • repair or replace defective cables immediately. • never watch the arc except through lenses of the correct shade. • in confined spaces, adequate ventilation and constant observation are essential. • leads and cables should be kept clear of passageways. • keep fire extinguishing equipment at a h...

  • Page 24

    24 magmate ™ is distributed by: boc limited abn 95 000 029 729 riverside corporate park 10 julius avenue north ryde, nsw 2113 australia boc is a trading name of boc limited, a member of the linde group, © boc limited 2009. Reproduction without permission is strictly prohibited. Details given in this...