Magmate MMA 160 User manual

MMA 160
OPERATING MANUAL
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Welcome to a better way of welding
Congratulations on puchasing the MagMate™MMA 160
welding machine.
The products in BOC's manual metal arc range perform with reliability and have
the backing of one of South Pacific's leading welding suppliers.
This operating manual provides the basic knowledge required for MMA and
DC TIG welding, as well as highlighting important areas of how to operate the
MagMate MMA 160 welding machine.
With normal use, and by following these recommended steps, your MagMate
MMA 160 machine can provide you with years of trouble free service.
BOC equipment and technical support is available through our national BOC
Customer Service Centre or contact your local Gas& Gear outlet.
Important Notice: This document has been prepared by BOC Limited ABN 95 000 029 729 ('BOC'),
as general information and does not contain and is not to be taken as containing any specific instructions.
The document has been prepared in good faith and is professional opinion only. Information in this document
has been derived from third parties, and though BOC believes it to be reliable as at the time of printing, BOC
makes no representation or warranty as to the accuracy, reliability or completeness of information in this
document and does not assume any responsibility for updating any information or correcting any error or
omission which may become apparent after the document has been issued. Neither BOC nor any of its agents
has independently verified the accuracy of the information contained in this document.The information in this
document is commercial in confidence and is not to be reproduced.The recipient acknowledges and agrees
that it must make its own independent investigation and should consider seeking appropriate professional
recommendation in reviewing and evaluating the information.This document does not take into account the
particular circumstances of the recipient and the recipient should not rely on this document in making any
decisions, including but not limited to business, safety or other operations decisions.
Except insofar as liability under any statute cannot be excluded, BOC and its affiliates, directors, employees,
contractors and consultants do not accept any liability (whether arising in contract, tort or otherwise) for any
error or omission in this document or for any resulting loss or damage (whether direct, indirect, consequential
or otherwise) suffered by the recipient of this document or any other person relying on the information
contained herein.The recipient agrees that it shall not seek to sue or hold BOC or their respective agents liable
in any such respect for the provision of this document or any other information.
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Welcome to a better way of welding 2
1.0 Recommended Safety Guidelines 4
2.0 Recommended Safety Precautions 5
2.1 Health Hazard Information 5
2.2 Personal Protection 5
2.3 Electrical Shock 7
2.4 User Responsibility 7
3.0 Basic Welding Techniques 8
3.1 Fundamentals of Manual Metal Arc (MMA)
Welding 8
3.2 Fundamentals of GTAW (TIG) Welding 10
4.0 Machine Specifications and Contents 12
4.1 Operating Controls 12
5.0 Operating Functions 13
5.1 Operating Machine 13
5.2 Earthing 13
6.0 Technical Specifications 14
7.0 Periodic Maintenance 15
7.1 Daily Maintenance 15
7.2 Troubleshooting 15
8.0 Terms of Warranty 16
8.1 Terms of Warranty 16
8.2 Limitations on Warranty 16
Contents
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•Repairorreplacedefectivecablesimmediately.
•Neverwatchthearcexceptthrough
lenses of the correct shade.
•Inconnedspaces,adequateventilation
and constant observation are essential.
•Leadsandcablesshouldbekeptclear
of passageways.
•Keepreextinguishingequipmentatahandy
location in the shop.
•Keepprimaryterminalsandliveparts
effectively covered.
•Neverstrikeanelectrodeonanygascylinder.
•Neveruseoxygenforventingcontainers.
1.0 Recommended Safety Guidelines
Diagram and safety explanation
Electrical safety alert
Welding electrode causing
electric shock
Fumes and gases coming from
welding process
Welding arc rays
Read instruction manual
Become trained
Diagram and safety explanation
Wear dry, insulated gloves
Insulate yourself from
work and ground
Disconnect input power before
working on equipment
Keepheadoutoffumes
Use forced ventilation or local
exhaust to remove fumes
Use welding helmet with
correct shade of filter
Some safety precautions BOC recommends are as follows:
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2.1 Health Hazard Information
The actual process of welding is one that
can cause a variety of hazards.
All appropriate safety equipment should be
worn at all times, i.e. headwear, respiratory,
hand and body protection. Electrical equipment
should be used in accordance with the
manufacturer’s recommendations.
Eyes:
The process produces ultra violet rays that
can injure and cause permanent damage.
Fumes can cause irritation.
Skin:
Arc rays are dangerous to uncovered skin.
Inhalation:
Welding fumes and gases are dangerous to
the health of the operator and to those in
close proximity.The aggravation of pre-existing
respiratory or allergic conditions may occur in
some workers. Excessive exposure may cause
conditions such as nausea, dizziness, dryness
and irritation of eyes, nose and throat.
2.2 Personal Protection
Respiratory
Confined space welding should be carried out
with the aid of a fume respirator or air supplied
respirator as per AS/NZS 1715 and AS/NZS
1716 Standards.
•Youmustalwayshaveenoughventilationin
confined spaces. Be alert to this at all times.
•Keepyourheadoutofthefumesrisingfrom
the arc.
•Fumesfromtheweldingofsomemetalscould
have an adverse effect on your health. Don’t
breathe them in. If you are welding on material
such as stainless steel, nickel, nickel alloys
or galvanised steel, further precautions are
necessary.
•Weararespiratorwhennaturalorforced
ventilation is not good enough.
Eye protection
A welding helmet with the appropriate welding
filter lens for the operation must be worn at all
times in the work environment.The welding arc
and the reflecting arc flash gives out ultraviolet
and infrared rays. Protective welding screen and
goggles should be provided for others working
in the same area.
Clothing
Suitable clothing must be worn to prevent
excessive exposure to UV radiation and
sparks. An adjustable helmet, flameproof loose
fitting cotton clothing buttoned to the neck,
protective leather gloves, spats, apron and steel
capped safety boots are highly recommended.
Recommended filter shades for
arc welding
Less than 150 amps Shade 10*
150 to 250 amps Shade 11*
250 to 300 amps Shade 12
300 to 350 amps Shade 13
Over 350 amps Shade 14
*Use one shade darker for aluminium
2.0 Recommended Safety Precautions
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Cylinder Safety
1Cylinder valve hand-wheel
2Back-plug
3Bursting disc
Back view of typical cylinder valve
1
2
3
Operator wearing personal
protective equipment (PPE)
in safe position
Ten Points about Cylinder Safety
1Always read the labels and Safety Data Sheet
(SDS) before use.
2Store cylinders upright and use in
well-ventilated, secure areas away from
pedestrian or vehicle thoroughfares.
3Ensure cylinders are appropriately secured
and guarded against being knocked violently
or being allowed to fall.
4Wear safety shoes, glasses and gloves when
handling, connecting and using cylinders.
5Ensure cylinders are appropriately restrained
to mechanical lifting/handling devices prior
to movement.
6Keepinacool,well-ventilatedarea,away
from heat sources, sources of ignition and
combustible materials, especially flammable
gases.
7Keepfullandemptycylindersseparate.
8Keepammonia-basedleakdetection
solutions, oil and grease away from cylinders
and valves.
9Never use force when opening or closing
valves.
10 Never repaint or disguise markings and
damage on cylinders. If damaged, return
cylinders to BOC immediately.
Cylinder Valve Safety
When working with cylinders or operating
cylinder valves, ensure that you wear
appropriate protective clothing – gloves, boots
and safety glasses.
Ensure cylinder value is closed before moving
or disconnecting equipment.
Before operating a cylinder valve:
•Ensurethatthesystemyouareconnecting
the cylinder into is suitable for the gas and
pressure involved.
•Cylindervalvesshouldnotbeopenunlessa
pressure regulator has been fitted.
•Ensurethatanyaccessories(suchashoses
attached to the cylinder valve, or the system
being connected to) are securely connected.
A hose, for example, can potentially flail
around dangerously if it is accidentally
pressurised when not restrained at both ends.
•Standtothesideofthecylindersothat
neither you nor anyone else is in line with
the back of the cylinder valve. This is in
case a back-plug is loose or a bursting disc
vents. The correct stance is shown in the
diagram above.
When operating the cylinder valve:
•Openitbyhandbyturningthevalvehand-wheel
anti-clockwise. Use only reasonable force.
•Ensurethatnogasisleakingfromthecylinder
valve connection or the system to which the
cylinder is connected. DO NOT use ammonia-
based leak detection fluid as this can damage
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the valve. Approved leak detection fluid, can be
obtained from a BOC Gas & Gear centre.
•Whennishedwiththecylinder,closethe
cylinder valve by hand by turning the valve
hand-wheel in a clockwise direction. Use only
reasonable force.
Remember NEVER tamper with the valve.
If you suspect the valve is damaged,
DO NOT use it. Report the issue to
BOC and arrange for the cylinder to be
returned to BOC.
2.3 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boots
•Wearingdryleathergloves
•Neverchangingelectrodeswithbare
hands or wet gloves
•Nevercoolingelectrodeholdersinwater
•Workingonadryinsulatedoorwhere
possible
•Neverholdtheelectrodeandholder
under your arm.
2.4 User Responsibility
•ReadtheOperatingManualpriorto
installation of this machine.
•Unauthorisedrepairstothisequipmentmay
endanger the technician and operator and will
void your warranty. Only qualified personnel
approved by BOC should perform repairs.
•Alwaysdisconnectmainspowerbefore
investigating equipment malfunctions.
•Partsthatarebroken,damaged,missingor
worn should be replaced immediately.
•Equipmentshouldbecleanedperiodically.
BOC stocks a huge range of personal protective
equipment.This, combined with BOC’s
extensive Gas and Gear network, ensures fast,
reliable service throughout the South Pacific.
PLEASE NOTE that under no circumstances
should any equipment or parts be altered
or changed in any way from the standard
specification without written permission
given by BOC.To do so, will void the
Equipment Warranty.
Further information can be obtained
from Welding Institute of Australia
(WTIA) Technical Note No.7
‘Health and Safety Welding’
Published by WTIA,
PO Box 6165 Silverwater NSW 2128
Phone [phone].
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3.1 Fundamentals of Manual
Metal Arc (MMA) Welding
Welding Technique
Successful MMA welding depends on the
following factors:
Selection of the correct electrode.
Selection of the correct size of the electrode
for the job.
Correct welding current.
Correct arc length.
Correct angle of electrode to work.
Correct travel speed.
Correct preparation of work to be welded.
Electrode selection
As a general rule, the selection of an electrode
is straight forward, in that it is only a matter of
selecting an electrode of similar composition
to the parent metal. However, for some metals
there is a choice of several electrodes, each
of which has particular properties to suit
specific classes of work. Often, one electrode
in the group will be more suitable for general
applications due to its all round qualities.
Electrode size
The size of the electrode generally depends on
the thickness of the section being welded, and
the thicker the section the larger the electrode
required. In the case of light sheet, the electrode
size used is generally slightly larger than the
work being welded.This means that, if 2.0 mm
sheet is being welded, 2.5 mm diameter
electrode is the recommended size.
Welding current
Correct current selection for a particular job
is an important factor in arc welding.With the
current set too low, difficulty is experienced
in striking and maintaining a stable arc.
The electrode tends to stick to the work,
penetration is poor and beads with a distinct
rounded profile will be deposited.
Excessive current is accompanied by
overheating of the electrode. It will cause
undercut and burning through of the material,
and will give excessive spatter. Normal current
for a particular job may be considered as the
maximum, which can be used without burning
through the work, over-heating the electrode
or producing a rough spattered surface (i.e. the
current in the middle of the range specified
on the electrode package is considered to be
the optimum).
Arc length
To strike the arc, the electrode should be gently
scraped on the work until the arc is established.
There is a simple rule for the proper arc length;
it should be the shortest arc that gives a good
surface to the weld.An arc too long reduces
penetration, produces spatter and gives a
rough surface finish to the weld.An excessively
short arc will cause sticking of the electrode
and rough deposits that are associated with
slag inclusions.
For down hand welding an arc length not
greater than the diameter of the core wire will
be most satisfactory. Overhead welding requires
a very short arc so that a minimum of metal will
be lost.
Electrode angle
The angle that the electrode makes with the
work is important to ensure a smooth, even
transfer of metal.
Correct travel speed
The electrode should be moved along in the
direction of the joint being welded at a speed
that will give the size of run required.At the
3.0 Basic Welding Techniques
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same time, the electrode is fed downwards to
keep the correct arc length at all times.
Correct travel speed for normal welding
applications varies between approximately
100 and 300 mm per minute, depending on
electrode size, size of run required and the
amperage used. Excessive travel speeds lead to
poor fusion, lack of penetration etc, while too
slow a rate of travel will frequently lead to arc
instability, slag inclusions and poor mechanical
properties.
Correct work preparation
The method of preparation of components to
be welded will depend on equipment available
and relative costs. Methods may include sawing,
punching, shearing, machining, flame cutting
and others.
In all cases edges should be prepared for the
joints that suit the application.
Generally Recommended Current Range
for MMA electrodes
Size of Electrode (mm) Current Range (Amp)
2.5 60–95
3.2 110–130
4.0 140–165
5.0 170–260
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3.2 Fundamentals of GTAW
(TIG) Welding
The Gas Tungsten Arc Welding – commonly
referred to as Tungsten Inert Gas (TIG) –
process uses the heat generated by an electric
arc struck between a non-consumable tungsten
electrode and the workpiece to fuse metal in
the joint area and produce a molten weld pool.
The arc area is shrouded in an inert or reducing
gas shield to protect the weld pool and the
non-consumable electrode.
The process may be operated autogenously
(without filler), or filler may be added by feeding
a consumable wire or rod into the established
weld pool.
•Theadditionofllerisoptional
•Onlyinertorreducinggasescanbeusedas
the shielding gas
•TIGweldingisahighquality,versatileand
commonly-used process
•TIGissuitableforweldingferrousandnon-
ferrous materials
•TheTIGprocesscanberunonDC-,DC+,
or AC
The TIG process is capable of producing very
high quality welds in a wide range of materials
and in thicknesses up to about 8 or 10 mm.
It is particularly suited to welding of sheet
material and for putting in the root run of pipe
butt welds.
The process tends to be very clean, producing
little particulate fume, although it is capable of
generating ozone in appreciable amounts and is
not regarded as a high-productivity process.
Operation
Direct or alternating current power sources
with constant current output characteristics
are normally employed to supply the welding
current. For DC operation, the tungsten may
be connected to either output terminal, but is
most often connected to the negative pole.
The output characteristics of the power source
can have an effect on the quality of the welds
produced. Shielding gas is directed into the arc
area by the welding torch, and a gas lens within
the torch distributes the shielding gas evenly
over the weld area. In the torch, the welding
current is transferred to the tungsten electrode
from the copper conductor.The arc is then
initiated by one of several methods between
the tungsten and the workpiece.
Operating Modes
The TIG process may be operated in one of the
following modes:
•DirectCurrentElectrodeNegative(DCEN)
•DirectCurrentElectrodePositive(DCEP)
•AlternatingCurrent(AC)
The mode used is largely dependent on the
parent material being welded.
1Shielding gas
2Arc
3TIG filler rod
4Weld pool
5Collet
6Tungsten Electrode
7Workpiece
1
2
3
4
5
6
7
Schematic of the TIG welding process
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DC Electrode Negative (DCEN)
In this mode the tungsten electrode is the
negative pole in the welding circuit, the
workpiece being the positive pole.
DC Electrode Positive (DCEP)
In this mode the tungsten electrode is the
positive pole in the welding circuit, the
workpiece being the negative pole.
Alternating Current (AC)
In this mode the polarity of the tungsten
electrode and the workpiece alternate between
negative and positive at the frequency of the
applied welding current.
Application
The TIG process is very versatile and may be
used to weld any metal or alloy system over
a wide range of thicknesses, but is usually
restricted to 10mm and under for economic
reasons. It is particularly suited to welding
sheet materials and for the root run in pipe
butt welds.
DCEN is the most common mode of operation
and is widely used for welding all carbon,
alloy and stainless steels, as well as nickel
and titanium alloys. Copper alloys, with the
exception of those containing aluminium in
significant amounts, can also be welded with
this polarity.
DCEP is used for aluminium alloys when
welding, with pure helium as the shielding gas,
since this polarity has a strong cathodic cleaning
effect capable of removing the tenacious
aluminium oxide film from the surface. It may
also be used for TIG welding magnesium alloys.
AC polarity is used most commonly when
welding aluminium and its alloys with pure
argon or argon-helium mixtures to take
advantage of the combination of the cyclic
heating and cleaning action. It is also suitable
for welding magnesium alloys and aluminium
bronze.
Applications
•Highqualityfabricationsinstainlesssteel
•Aluminium,copperandnickelalloys
•Weldingreactiveandrefractorymetalssuch
as titanium, tantalum and zirconium
The process is used extensively in the
nuclear and aerospace industries and in the
construction and maintenance of chemical and
cryogenic process plant and pipework. It is also
used for fabrication of tube heat-exchangers in
petrochemical and power-generation plant, and
for brewing and food-processing vessels.
TIG Welding Equipment
The equipment used for TIG welding consists of:
•Powersource
•Weldingtorch
•Tungstenelectrode
•Leadsandconnectors
•Gassupplysystem
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1Power indicator light
Overtemperature indicator
2LED Display
3MMA / Lift TIG indicator
4Welding current adjustment
5Process selector switch MMA/Lift TIG
6Negative '35' dinse connector
7Positive '35' dinse connector
4.0 Machine Specifications and Contents
4.1 Operating Controls
12
7
4
3
6
5
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12
4
3
5
1Power indicator light
Overtemperature indicator
2LED Display
3MMA / Lift TIG indicator
4Welding current adjustment
5Process selector switch MMA/Lift TIG
For MMA welding
Connect the electrode holder to the positive
(+)outputterminal 7and the work return
lead should be connected to the negative (-)
output terminal 6.
The welding current can be adjusted with the
welding current adjustment knob 4.
5.1 Operating Machine
Manual Metal Arc welding (MMA)
■Select the current as per the
recommendations of the consumable
manufacturer.
■Select the polarity of the electrode cable as
pertherecommendations(+/-)
■Select the process selector switch to MMA
DC TIG welding (Lift TIG)
■Select the current as per the
recommendations of the consumable
manufacturer.
■Connect the TIG torch to the negative (-)
pole of the welding machine.
■Select the process selector switch to
'Lift TIG'
■When Lift TIG is selected the tungsten
electrode can be touched onto the
workpiece.The arc will be initiated as the
electrode is moved upwards and the current
will revert to the adjusted current.
Connecting the shielding gas.
Fit the supplied shielding gas regulator to the
appropriate shielding gas cylinder ensuring
safety steps are followed as outlined on page 6
of this manual.
Open the cylinder and set the required gas
flow using the pressure adjustment knob on the
regulator.
NOTE:
When changing either the TIG torch or the MMA electrode
holder the machine should be switched off using the power switch
on the machine. In addition, the main supply must be turned off
and the plug removed from the outlet socket.
5.2 Earthing
For the welding process to be most effective
it is important to ensure that there is a solid
connection between the work return clamp and
the workpiece.
Always ensure that the return clamp is as close as
practically possible to the area to be welded.
Ensure that the workpiece is clean and free from
rust, scale paint or oil and grease before affixing
the work return clamp.
5.0 Operating Functions
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6.0 Technical Specifications
MagMate™MMA 160
Part No. MAGMMA160
Powervoltage (V) Single phase AC 220V ± 15%
Frequency (Hz) 50 / 60
Rated input plug (A) 15A
MMA TIG
Output current adjustment (A) 40-160 20-160
Output voltage (V) 21.6-26.4 10.8-16.4
No-load voltage (V) 64
Duty cycle (%) 20
Power factor 0.73
Efficiency (%) 80
Insulation grade F
Housing protection grade IP21S
Weight (kg) 4.8
Overall dimensions (mm) 288 x 160 x 234
KVa 8
Standards IEC 60974.1
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In maintenance of the unit, take into
consideration the rate of use and the
environment it is used in.When the unit is used
properly and serviced regularly you will avoid
unnecessary disturbances in use and production.
7.1 Daily Maintenance
Perform the following maintenance daily:
•CleanelectrodeholderandTIGtorch'sgas
nozzle. Replace damaged or worn parts.
•CheckTIGtorch'selectrode.Replaceor
sharpen, if necessary.
•Checktightnessofweldingandearthcable
connections.
•Checkconditionofmainsandweldingcables.
•Seethatthereisenoughspaceinfrontofand
back of the unit for ventilation.
7.2 Troubleshooting
Main switch signal light is not lit.
Unit does not get electricity.
•Checkmainsfuses.
•Checkmainscableandplug.
Unit does not weld well.
Arc is uneven and goes off. Electrode gets stuck
in weld pool.
•Checkweldingsettingsandadjustwhen
necessary.
•Checkthatearthclampisproperlyxedand
that contact surface is clean and the cable is
undamaged.
Signal light for overheating is lit.
The unit has overheated. See 5.0 Operating
Functions.
•Checkthatthereisamplespaceinfrontof
and back of the unit for ventilation.
•Checkweldingsettings.See5.0Operating
Functions.
If problems in use are not solved with above
mentioned measures, please contact your local
BOC representative.
7.0 Periodic Maintenance
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Warranty for MagMate™MMA 160
8.1 Terms of Warranty
BOC provides a warranty for the MagMate
MMA 160 sold by it against defects in
manufacture and materials.
Machines under warranty will be
exchanged and not repaired.
•Validfor18monthsfromdateofpurchase.
•Freight,packagingandinsurancecostsareto
be paid for by the claimant.
•Noadditionalexpresswarrantyisgivenunlessin
writing signed by an authorised manager of BOC.
•Thiswarrantyisinadditiontoanyotherlegal
rights you may have.
•Electrodeholdersandtorchesarenot
covered.
8.2 Limitations on Warranty
The following conditions are not covered:
•Noncompliancewithoperatingand
maintenance instructions such as connection
to incorrect faulty voltage supply including
voltage surges outside equipment specs and
incorrect overloading.
•Naturalwearandtearandaccidentaldamage.
•Transportorstoragedamage.
The Warranty is void if:
•Changesaremadetotheproductwithoutthe
approval of the manufacturer.
•Repairsarecarriedout.
8.0 Terms of Warranty
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MagMate™is distributed by:
BOC Limited
ABN 95 000 029 729
10 Julius Avenue
North Ryde, NSW 2113
AUSTRALIA
BOC is a trading name of BOC Limited, a member of The Linde Group, © BOC Limited 2013. Reproduction without permission is strictly
prohibited. Details given in this document are believed to be correct at the time of printing. Whilst proper care has been taken in the
preparation, no liability for injury or damage resulting from its improper use can be accepted.
BOC Limited
970– 988 Great South Road
Penrose,Auckland
NEW ZEALAND
For more information on MagMate products or service,
call the BOC Customer Service Centre on:
AUSTRALIA
131 262
Email: [email protected]
Website: www.boc.com.au
NEW ZEALAND
0800 111333
Email: customer.ser[email protected]
Website: www.boc.co.nz
MP12-0759 . FDAUS . 0313
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