HSS Hire HW003 Troubleshooting guide

150AMP MMA
Inverter
An inverter based MMA welding unit
giving a maximum 150amp when
MMA welding.
Operating & Safety Guide HW003
Switch the unit ON by moving the ON / OFF
switch to the ‘I’ ON position. The red ‘POWER’
lamp will illuminate.
Turn the welding current selector dial to give the
required welding current.
There is a hot start facility built into this unit and it is fully
automatic, giving a 20% boost of the selected welding
current for 1.5 seconds.
Control the MMA dynamics by adjusting the arc
force dial. At minimum the arc is softer with less
penetration and splatter. At maximum, the arc is rougher
with deeper penetration but more splatter. Note also that
the maximum end of the force range is ideal for
use with cellulosic and low hydrogen electrodes.
You are now ready to weld.
Holding the welding rod/electrode holder at an
angle of 60-70 degrees to the surface, move it
towards the work until it strikes an arc.
Now, keeping the arc about 3mm long, work
slowly along the weld in a series of semicircular
sweeps across the line of the joint.
Chip off any slag build-up on the weld before
making a second pass along the joint.
Note that recommended settings are merely
guides. Changing them slightly may give better
results. So, always make a test weld and adjust the
settings as necessary.
Never push the equipment beyond its design
limits. If it will not do what you want with
reasonable ease and speed, assume you have the
wrong type or size of welder for the job. Ask at
your local HSS Hire Weld Depot for advice.
When not in use, store the equipment somewhere
clean, dry and safe from thieves.
Keep the equipment clean. You will find this less of a
chore if you clean it up regularly rather than wait until
the end of the hire period.
Switch OFF and unplug the unit. Leave everything
to cool then take the earth clamp off the work.
Remove the welding rod and disconnect all leads
and coil them up neatly ready for return to your
local HSS Hire Weld Depot.
FINISHING OFF
EQUIPMENT CARE
BASIC TECHNIQUES
Code 55304
©HSS Hire Service Group Plc 2000 No. HW003/01
Group Office: 25 Willow Lane, Mitcham, Surrey CR4 4TS
Web Site: http://www.hireweld.com
…any comments?
If you have any suggestions to enable us to improve
the information within this guide please fax your
comments or write to the Product Manager at the
address below
Fax: [phone]
HW003/01

For advice on the safety and suitability of this equipment
contact your local HSS Hire Weld Depot.
There is a serious risk of personal injury if you do
not follow all instructions laid down in this guide.
The hirer has a responsibility to ensure that all
necessary risk assessments have been completed
prior to the use of this equipment.
Most welding tasks may be considered as hot work
in site situations and may be subject to specific
permits to work.
This equipment should only be used by an operator
who has been deemed competent to do so by
his/her employer.
This equipment should be used by an able bodied,
competent adult who has read and understood these
instructions. Anyone with either a temporary or permanent
disability, should seek expert advice before using it.
Keep children, animals and bystanders away from
the work area. Cordon off a NO GO area using
cones and either barriers or tape, available for hire
from your local HSS Hire Weld Depot.
Welding screens are also available for hire from
your local HSS Hire Weld Depot.
Never use this equipment if you are ill,
feeling tired, or under the influence of
alcohol or drugs.
This equipment generates potentially harmful
noise levels. To comply with health and safety at
work regulations, ear defenders must be worn by
everyone in the vicinity.
Fumes produced by the welding process, if
inhaled, can be harmful to health. A suitable
mask must be worn when using this equipment.
Respiratory protective equipment is available for
hire, contact your local HSS Hire Weld Depot for details.
Skin must be covered –wear practical,
protective clothing, gloves and footwear.
A head shield with an 11 EW shade MUST be
worn by anyone in the work area –goggles
are not suitable. Avoid loose garments and jewellery
that could interfere with the work.
Warning
If you are wearing an electronic life support
device (a heart pacemaker) you must consult
your doctor before going near or working with
this equipment. Magnetic fields associated with
high currents may affect these devices.
GENERAL SAFETY If the headshield or lens becomes damaged, return
it to your local HSS Hire Weld Depot.
Never use welding equipment near computers or
any sensitive electronic equipment.
Always transport, store and operate the machine
in an upright position.
Keep the power unit’s air vents clear of all
obstructions.
Always switch equipment OFF before making any
adjustments to it. Never leave it switched ON and
unattended.
Ensure the work area is well lit and ventilated, a
fume extractor or smoke eliminator should be used. If in
doubt, ask about lighting and ventilation equipment at
your local HSS Hire Weld Depot.
Do not work near flammable gases or liquids, petrol
or paint thinner fumes for example. Keep combustible
materials at a safe distance - at least 5m.
Make sure you know how to switch this machine
OFF before you switch it ON in case you get into
difficulty.
Check the condition of the equipment before use.
If it shows signs of damage or excessive wear, return it to
your local HSS Hire Weld Depot.
COSHH information sheets are available from your local
HSS Hire Weld Depot.
The HSS 150A MMA inverter welder can be
plugged into a standard 230V 13amp power
socket, or a 110V generated supply. Where a
transformer is used to step the voltage down from
230V to 110V, the transformer MUST be a
minimum 5kVA continuous rated.
ELECTRICAL SAFETY
Vehicle Safety
Before carrying out welding work on cars/lorries
and similar vehicles...
Remove the vehicle’s battery and disconnect the
alternator.
Remove all combustible material and other
fire/explosion hazards.
Let It Cool
Handle welding equipment and work with care
–it will be hot. Leave equipment to cool before
changing welding rods, moving earth clamps,
and so on.
The unit is fitted with a voltage sensor, which
determines the supply voltage. When the unit is
switched ON, the set defaults automatically to 230V
operation. If the supply voltage is 230V the set will
work correctly. If the supply voltage is 110V, the set
will not work until the red button on the rear panel
is pressed.
If a break in the power supply occurs the unit will
revert to 230V operation and the red light next to the
red button will flash. To return to 110V operation,
the red button must be pressed twice, once to clear
the fault situation when the red light will extinguish
and the second time to reset to 110V operation.
Is a supply fault condition keeps occurring it may be
due to a problem with the mains installation. Either
too small a transformer or an extension cable that is
too long or of the wrong thickness of wire.
If the equipment fails, or if its power supply cable
or plug becomes damaged, return it. Never try to
repair it yourself.
Keep cables out of harm’s way, and clear of the
work area.
Extension leads should be fully unwound and
loosely coiled, away from the equipment. Never run
them through water, over sharp edges or where they
could trip someone. If running the unit from a 110V
supply, it is important that any
extension cable is of the correct
size, see chart.
Keep the equipment dry,
using electrical equipment in
very damp or wet conditions can be dangerous.
To reduce the risk of electric shock, always
use a suitable RCD (Residual Current-Operated
Device) available from your local HSS Hire Shop. Or power
the equipment from a mains circuit with a built in RCD.
Ensure the welder and power socket are switched
OFF before plugging into the power supply.
This guide is designed to help the user to safely set
up and dismantle the welder. It is not intended as
a guide to welding techniques as it is assumed
that the user already has the necessary
training/knowledge and experience.
It is important that the
equipment duty cycle is taken
into consideration when in
use.
If you exceed the duty cycle, the units’
thermostatic control will switch the welding
current OFF and the amber overload warning
lamp will illuminate. If the unit does overload you
GETTING STARTED
will have to wait for the warning lamp to go out
before you can use the unit.
Place the unit on a suitable surface and make sure
that there is a minimum of 200mm clearance
around the unit to allow a good circulation of air.
DO NOT use the unit in the rain or in extremely
damp environments.
Set the unit’s ON/OFF switch to the ‘0’OFF
position and plug the unit into its power supply.
Connect the electrode
holder cable to the
positive (+) terminal and
the earth clamp cable to
the negative (-) terminal
(see illustration).
Clamp workpieces
securely in their final
positions to stop them
moving during welding.
Clip the earth clamp
onto the work piece,
choosing an area of clean,
bright metal close to the
proposed weld to ensure a
good electrical connection.
Now, insert a welding
rod into the notch in the
electrode holder’s jaws.
Squeeze the lever to open
them; release to close.
Duty Cycle
150A 60%
125A 100%
ON/OFF
Switch
Earth
Terminal
Electrode
Terminal
Arc
Force
Dial
Welding
Current
Selector
Dial
Overload
Warning
Lamp
Power
Lamp
ON
OFF
Earth Clamp
Electrode Holder
150AMP MMA Inverter
Cable Cable
Length Diameter
5M 4mm2
10M 6mm2
20M 10mm2
30M 16mm2