SATA AE7022 User manual

V-AR-7022-1903-01
AE7022

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1. 1 Dual Torch For Steel & Aluminum Car Body Repair.
1. 2 BOSJOB Made Spool Gun for Aluminum: high cost-performance ratio. ABICOR BINZEL 15AK Gun.
1. 3 Specialized Welding Gun Support: Easy take out & Easy put in.
1. 4 High efficiency inverter power source, quick ignition, less spatter, good for car body repair.
1. 5 Good price / quality ratio
WELDING AND ARC CUTTING CAN BE HARMFUL TO YOURSELF AND OTHERS. The user must therefore be
educated against the hazards, summarized below, deriving from welding operations. For more detailed
information, order the manual.
ELECTRIC SHOCK - May be fatal.
Install and earth the welding machine according to the applicable regulations.
Do not touch live electrical parts or electrodes with bare skin, gloves or wet clothing.
Isolate yourselves from both the earth and the workpiece.
Make sure your working position is safe.
FUMES AND GASES - May be hazardous to your health.
Keep your head away from fumes.
Work in the presence of adequate ventilation, and use ventilators around the arc to prevent gases from
forming in the work area.
ARC RAYS - May injure the eyes and burn the skin.
Protect your eyes with welding masks fitted with filtered lenses, and protect your body with appropriate
safety garments.
Protect others by installing adequate shields or curtains.
RISK OF FIRE AND BURNS
Sparks (sprays) may cause fires and burn the skin; you should therefore make sure there are no flammable
materials in the area, and wear appropriate protective garments.
NOISE
This machine does not directly produce noise exceeding 80dB. The plasma cutting/welding procedure may
produce noise levels beyond said limit; users must therefore implement all precautions required by law.
PACEMAKERS
The magnetic fields created by high currents may affect the operation of pacemakers. Wearers of vital
electronic equipment (pacemakers) should consult their physician before beginning any arc welding, cutting,
gouging or spot welding operations.
EXPLOSIONS
Do not weld in the vicinity of containers under pressure, or in the presence of explosive dust, gases or
fumes. . All cylinders and pressure regulators used in welding operations should be handled with care.
ELECTROMAGNETIC COMPATIBILITY

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This machine is manufactured in compliance with the instructions contained in the harmonized standard，
and must be used solely for professional purposes in an industrial environment. There may be potential
difficulties in ensuring electromagnetic compatibility in non- industrial environments.
IN CASE OF MALFUNCTIONS, REQUEST ASSISTANCE FROM QUALIFIED PERSONNEL.
Place the machine in a ventilated area.
Dust, dirt, or any other foreign material that might enter the machine may restrict the ventilation which
could affect the machine’s performance. Fasten the rotating support to the machine top and fix the handle,
the wheeles, the bottle support and, if any, the cooling unit.
All sections concerning the installation of this machine must be read carefully.
This machine must be installed by skilled personnel.
Make sure that the input power plug has been disconnected before inspecting, maintaining, or servicing.
Connect the yellow-green wire to a good electrical ground.
Do not use water pipes as earth conductor.
After a final inspection, the machine should be connected to the input supply voltage marked on the input
power cord.
If you wish to change the input supply voltage, remove the right side panel , locate the voltage-changing
terminal board and arrange the connections as shown in ILLUSTRATION OF WORKING PRINCIPLE.
Model
AE7022
Three-phase
transformer-rectifier
DC output
Metal inert gas
welding
Suitable for general
working
environment
U0
Secondary no-load voltage (peak
value)
42V
X
Duty-Cycle Percentage
20%
100%
I2
Output welding current
200A
90A
U2
Secondary voltage with welding
current I2
24V
19V
U1
Nominal supply voltage
220V
I1max
Rated maximum input current
37.5A
I1eff
Maximum input current
29A
Protection level
IP21S

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After having changed the supply voltage, re-place the upper cover.
This machine must never be used without the top and side covers. This is both for obvious safety reasons
and to avoid interference with the machine’s internal cooling system. The warranty is to be considered null
and void it this machine is used without the protection of its top and side covers.
Mount a plug on the power supply cable that corresponds to the input power drawn by the machine.
4.3.1 Wire feeder connection
This power source is compatible with the wire feeders. To connect the power source to the wire feeder units
use the extension art. Performances and operating features of the wire feeder are described in the
operating manuals supplied with the wire feeder itself.
4.3.2 Connecting the work return lead clamp.
Some versions have one impedance socket only.
Connect the male end of the work return lead to one of the impedance taps on the front panel of the
machine. The impedance tap designated by the provides the maximum amount of impedance which
will produce nicely filleted weld beads. This tap is recommended when welding aluminium, stainless steel,
and carbon steels of binary or ternary composition. The impedance tap designated by the provides the
least amount of impedance and is recommended when using carbon dioxide as a shielding gas to weld
carbon steels, in the upwards vertical position, of binary or ternary composition.
It is generally advisable to use low impedance values for small diameter wires and high values for big
diameter wires.
After having selected the proper impedance tap, attach the work return clamp to the work to be welded.
Make sure that the ground clamp is tightly fastened to the work return cable and periodically check that
this connection remains well tightened. A loose connection can cause weld current drops or overheating of
the work return lead and clamp which, in turn, creates the risk of burns from accidental contact with the
work return lead. The weld circuit must not be placed deliberately in direct or indirect contact with the
ground conductor if it is not in the work to be welded.
If the work to be welded is attached deliberately to the ground by a protection lead, then the connection
must be the most direct possible and it must be done using a lead that has a cross section that is at least
equal to the cross section of the work return lead being used for the weld circuit. The protection lead must
also be attached to the work at the same spot as the work return lead. To do so, a second ground clamp,
fitted to the protection lead, must be attached next to the ground clamp of the work return lead.
4.3.3 Connecting the gas hose.
Keep the cylinders in an upright position by chaining them to their support.
Keep the cylinders in a place where they cannot be damaged.
Do not lift the machine with the cylinder on its support.
Keep the cylinder away from the welding area and uninsulated electric circuits.
Cylinders containing inert gas have to be equipped with a pressure reducer and a flowmeter.
After having positioned the cylinder, connect the gas hose that comes out from the rear of machine to the
pressure reducer output.
Regulate the gas flow to 8-10 L/min.
4.4.1 INSTALLATION AND STARTER
Machine installation must be done by a competent staff. All connections must correspond to the rules in

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force and must respect laws concerning accidents.
Check that the wire diameter corresponds to that indicated on the roll and mount the wire coil.
Connect the pipe coming out of the extension with the cylinder flowmeter.
Position the welding machine so as to allow free air circulation inside it and avoid that metal or any other.
4.4.2 THE MACHINE IS READY TO WELD
Connect the ground terminal to the part to be welded.
Turn the machine on.
Extract the conic gas nozzle by rotating it clockwise.
Unscrew the current nozzle.
Press the torch trigger to feed the wire until it comes out from the torch.
WARNING: Keep your face away from the terminal nozzle while the wire comes out.
Screw the current nozzle again, making sure that the hole diameter be the same as that the wire used.
Insert the welding conic gas nozzle by rotating it clockwise. Open the gas cylinder and adjust flowmeter at
8-10L/min.
WARNING: Check that the gas used is compatible with the material to be welded.
4.4.3 WELDING CARBON STEELS.
To weld carbon steels the following things are necessary:
1) The use of a binary shielding gas which is most commonly Argon and Carbon dioxide, in a ratio of 75-80 %
Argon and 25-20% Carbon dioxide. Some applications, however, may require a mix of three gases: Argon,
Carbon dioxide (CO2), and dioxide (O2). These gas mixtures generate heat during welding and as a result the
weld bead will be well filleted and neat in appearance. The penetration, however, will not be deep.
The use of Carbon dioxide as the shield gas results in a narrow weld bead with deep penetration but the
ionization of the gas will have an influence on arc stability.
2) The use of a filler wire of the same quality as the steel to be welded. It is recommended that high quality
wires be used and that welding with rusted wires be avoided because they can give rise to defects in the
weld bead. Generally, the current range within which a wire can be used is calculated in the following
manner:
Ø of wire x 100= minimum number of Amperes.
Ø of wire x 200= maximum number of Amperes.
Practical example: 1.20 Ø wire= 120 Amps minimum and 240 Amps maximum. These amperages are based on
the use of an Argon/CO2mixture as the shield gas and welding in the Short Arc transfer mode.
3) Avoid welding on rusted work pieces or work having spots of oil and grease present on the surface.
4) The use of a welding torch suitable to the welding currents that are going to be used.
5) Periodically check that the two handles making up the ground clamp are not damaged and that the
welding cables (torch cable and the work return lead) do not have any cuts or burn marks that would reduce
their efficiency.
4.4.4 WELDING STAINLESS STEEL
Welding stainless steels in the 300 series (the austenitic series) must be done using a shield gas mixture of
predominantly Argon with a small percentage of O2 added to stabilize the arc. The recommended mixture is
AR/O2 in the ratio of 98/2. Do not use CO2 or AR/CO2mixtures as the shield gas.
Do not touch the welding wire with your bare hands.
The filler metal (the wire) must be of a higher quality than the work to be welded and the weld area must be
clean.

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4.4.5 WELDING ALUMINIUM
The following is required for aluminium welding:
1) 100% Argon as welding protection gas.
2) A torch wire of composition suitable for the basic material to be welded.
For ALUMAN welding wire 3.5% silicon.
For ANTICORODAL welding wire 3.5% silicon.
For PERALUMAN welding wire 5% magnesium.
For ERGAL welding wire 5% magnesium.
3) A torch prepared for aluminium welding.
If you only have a torch for steel wires, the same shall be modified in the following way:
- Make sure that length of torch cable does not exceed 118 inches (it is advisable not to use longer torches).
- Remove the brass sheath-holding nut, the gas and the current nozzles, then slip the sheath off.
- Insert the teflon sheath for aluminium and ensure it protrudes from both ends.
- Screw the current nozzle so that the sheath adheres to it.
- Insert the sheath holding nipple, the O-Ring in the free end of the sheath and secure with the nut without
tightening too much.
- Slip the brass tube on the sheath and insert both into the adapter (after removing the iron tube which was
fitted inside the adaptor).
- Cut the sheath diagonally so that it stays as close as possible to the wire slide roller.
4) Use drive rolls that are suitable for aluminium wire. The drive rolls, when being installed, must be
tightened as tight as possible.
5) Use contact tips that are suitable for aluminium wire and make sure that the diameter of the contact tip
hole corresponds to the wire diameter that is going to be used.
6) Use abrasive grinders and tool brushes specifically designed for aluminium. Never use these tools on
other materials. REMEMBER that cleanliness equals quality.
The wire spools must be stored in plastic bags with a dehumidifier.
1- DEFECT- Porosity (in, or on the surface of the weld bead)
CAUSES Bad wire (rust on the surface).
Insufficient gas shielding due to:
- Inadequate gas flow due to a block in the gas line.
- Defective flowmeter.
- Gas regulator covered with frost because a gas heater was not used to heat the
CO2 shielding gas.
- Failure of gas valve solenoid.
- Gas nozzle plugged up with spatter.
- Gas flow holes plugged up.
- Air drafts in the welding area.
2- DEFECT- Shrinkage Cracks
CAUSES Welding wire or work to be welded dirty or rusty.

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Weld bead too small.
Weld bead too concave.
Too much weld bead penetration.
3- DEFECT- Lateral cracking
CAUSES Welding speed too fast.
Low current and high arc voltages.
4- DEFECT- Too much Spatter
CAUSES Voltage too high
Insufficient impedance
No gas heater used for CO2 shielding gas.
Adjust the weld voltage range
This is where the welding torch is to be
connected
Select the normal torch or spool gun for
welding
(Confirm the power voltage before use)
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Gas nozzle . Periodically clean the nozzle of all weld spatter that may have accumulated during welding
operations If the nozzle should become distorted or oval in shape then it must be replaced.
Contact tip . A good contact between the contact tip and the wire ensures a stable arc and optimal current
output. Therefore, following steps must be followed:
A) The contact tip hole must be kept free of dirt or oxidation.
B) After lengthy welds, spatter can easily accumulate on the contact tip and prevent the wire from being fed.
The contact tip must be cleaned regularly and if necessary it must be replaced.
C) The contact tip must always be screwed tightly on to the body of the torch. The thermal cycles which the
torch undergoes during operation may loosen the contact tip which, in turn, may cause the torch body and
nozzle to overheat or cause unsteady wire feed.
The Wire Liner is an important part that must often be checked since, during normal operations, the wire
can deposit copper dust or tiny metal shavings in the lining. Periodically clean the liner and the gas line with
a jet of dry, compressed air. Wire liners are exposed to continual wear and therefore they must be replaced
after a certain period of time.
Wire feed motor. Periodically clean the wire feed assembly and the drive rolls from any rust or metal
shavings due to the feeding of the wire. A periodic check of all the components of the wire feed assembly,
spool holder, drive rolls, wire liner and the contact tip is recommended.
TROUBLE
PROBABLE CAUSE
REMEDY
Limited electric
output
A phase missing
Check the phase of the feed line and/or the
remove control switch contacts
A line fuse is burnt
Replace it
Wrong connection on the voltage
changer terminal board
Check the terminal board connections by
following the plate scheme
The rectifier diode are burnt
Replace the rectifier
Loosened torch or ground connections
Tighten all connections
Welding regulation commutator has an
uncertain contact
Replace the commutator
Transformer wire interrupted on the
commutator
Unscrew the commutator contact remove the
wire insulation and put it under the contact
Welding with a
lot of metal
spatter
Wrong adjustment of the welding
parameters
Select the correct parameters through the
welding voltage switch and the wire-speed
adjustment potentiometer
Wire advancing unproperly
Uncorrected sheath diam.
Insufficient grounding
Check grounding connections
Wire not
advancing or
Wire roller with too wide groove
Replace roller
advancing
unproperly
Obstructed or clogged liner
Extract it and clean
Loose wire pressing roller.
Tighten it
Coil reel friction too tight
Loosen and adjust it
Current nozzle clogged
Replace it

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The wire jams
or entangles
between the
drive rolls and
the torch
infeed wire
guide
Wrong current nozzle diameter
Replace it
wrong roller groove alignment
Align it
Obstructed or clogged sheath
Remove and clean
Note: All repair work must be done by qualified personnel.
Disconnect the power input cable from the mains supply before replacing cables or before removing the
unit covers. The machine is equipped with a thermostat that shuts the machine down when the power
source overheats. After the thermostat intervenes, let the power source cool down for several minutes
before resuming welding operations.
The troubleshooting table lists troubles, causes and remedies for those troubles that occur most commonly.
Experience has shown that many fatal accidents originated from servicing improperly executed. For this
reason, a careful and thorough inspection on a serviced welding machine is just as important as one carried
out on a new welding machine.
Furthermore, in this way producers can be protected from being held responsible for defects stemming
from repairs not carried out by the manufacturer.
After rewinding the transformer or the inductance, the welding machine must pass the applied-voltage test
in accordance with indications of the international standard.
If the servicing is not done by the manufacturers, the repaired welding machines which underwent
replacements or modifications of any component shall be marked in a way such that the identity of the
person having serviced it is clear.
After making repairs, take care to re-order the cables so that there is sure to be insulation between the
primary and secondary sides of the machine. Make sure that the wires cannot come into contact with
moving parts or parts that heat during operation. Replace all clamps in their original positions on the
machine, to prevent a connection between the primary and secondary circuits if a conductor accidentally
breaks or disconnects.

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