YesWelder Flux-135PRO MIG Flux Core Welder User Manual

YesWelder Flux-135PRO MIG Flux Core Welder

INSTALLATION

TECHNICAL SPECIFICATION: FLUX-135PRO

SELECT SUITABLE LOCATION

This machine can operate in harsh environments However, simple preventative measures must be followed to ensure long life and reliable operation:

• Do not use this machine for pipe thawing
• This machine must be located where clean air is free circulation without restrictions for air movement to
  and from the air vents. Do not cover the machine with paper, cloth, or rags when switched on
• Dirt and dust that can be drawn into the machine should be kept to a minimum
• This machine has a protection rating Of IP21S Keep it dry when possible and do not place it on wet ground or in puddles
• Locate the machine away from radio-controlled machinery Normal operation may adversely affect the operation of nearby radio-controlled machinery, which may result in injury or equipment damage. Read the section on electromagnetic compatibility in this manual.
• Do not operate in areas with an ambient temperature above 40 degrees C.

STACKING

The inverter FLUX-135PRO cannot be stacked.

TILTING

Place the machine directly on a secure, level surface. Do not place or operate this machine on a surface with an incline greater than 150 from horizontal. The machine may topple over if this procedure is not followed.

INSTALLATION

INSTALLING 4-INCH SPOOL (SEE FIGURE FOR PART IDENTIFICATION)

• Open the access panel.
• Remove the nut (A), nut washer (C), spring (E), and spool spacer (D)
• Remove the outer wrapping from the spool of wire and then find the leading end of the wire (it goes through a hole in the outer edge of the spool and is bent over the spool edge to prevent the wire from unspooling) but do not unhook it yet.
• Place the spool On the WIRE SPOOL SPINDLE so that the wire unspools from the bottom, and the spool will rotate counterclockwise
• Place the spool spacer, spring, nut washer, and nut back.
• proceed to the “FEEDING WIRE THROUGH THE MIG TORCH” instructions below

INSTALLATION

FEEDING WIRE THROUGH THE MIG TORCH

• Unhook the wire and hold the wire end and the spool in one hand. Use the other hand to tighten the nut (A) to some extent so that when the spool is released, it does not spin freely and uncoils the wire. Tightening the nut too much may cause inconsistent wire feeding. Leaving it too loose will allow the wire to straighten freely from the spool, leaving a mess of wire in the cabinet.
• While holding the wire in place, use a wire cutter to cut the bent end of the wire so that only a straight end remains
• Hold the wire end in one hand and release the drive roller pressure arm (l) by pulling the pressure arm adjustment knob (G) toward you. Hold the drive roller pressure arm up off of the drive roller and insert the leading end of the wire into the inlet guide tube (H) Push the wire across the drive roller (J) and into the torch assembly approximately six inches
• Align the wire up in the inner groove Of the drive roller and allow the drive pressure arm to drop onto the drive roller. Pull the pressure arm adjustment knob back over the pressure arm and tighten (turn clockwise) the pressure adjusting knob until the pressure roller applies enough force on the wire to prevent it from slipping out of the drive assembly.
• Let go of the wire
• Remove the nozzle (K) and contact tip (L) from the end of the torch assembly (M).
• Plug the welder’s INPUT POWER CABLE into the AC power source Adjust the settings at the front panel per the setup chart on the welding machine’s inside door according to the wire and workpiece size
• Pull the trigger on the MIG torch to feed the wire through the torch assembly Check if the drive roller is slipping on the wire and increase pressure on the pressure arm adjustment knob if necessary.
• When at least an inch of wire sticks out past the end of the torch, release the trigger.
• Slide the contact tip (L) over the wire protruding from the end of the torch Screw the contact tip into the end of the torch and hand tighten securely
• Install the nozzle (K) on the torch assembly
• Cut off the excess wire that extends past the end of the nozzle.
• Fine-tune the wire drive pressure with the pressure arm adjustment knob (G)
• Turn the pressure adjustment knob clockwise to increase the driving pressure until the wire seems to feed smoothly without slipping.
• When the driving pressure is set correctly, there should be no slippage between the wire and the drive roller. But if an obstruction occurs along the wire feed path, the wire should slip on the drive roller. You can check it by squeezing the wire between two fingers with moderate force as it comes out Of the torch. If this stops the wire from feeding, increase the pressure until the wire feeds through your fingers without issue
• Double-check your spool tension: When wire feeding stops, the wire comes Off the spool with some curvatures while it should not relax so much that the wire loosens on the spool. e of the curvature the coiled wire naturally reverts to. It should also not relax so much that the wire begins to loosen on the spool.

FLUX-CORE WELDING

Select a suitable filler wire according to the process being used (W-type drive roll for gasless flux-cored welding). The wire diameter must be matched to the drive roll, the liner, and the contact tip Open the side panel of the wire feeder and mount the wire spool post The end Of the wire must be at the bottom Of the Wlre spool, opposite wire feeder inlet guide tube

The spool post is fitted with a brake, and the wing nut in the center of the spool post adjusts the brake tension. Pull the wire from the reel by hand and adjust the tension to provide some drag clockwise will increase the braking and anticlockwise reduce it Release the wire tensioning device on the drive rolls, insert the filler wire, and into the inlet guide tube of the wire feeder, align wire with the drive roll groove and feed a short length into the torch connector so that it protrudes out of the front panel, then replace the tensioner over the wire.

(The filler wire can be fed through the torch cable once the input power is switched on pressing the trigger Of MIG torch.) (SEE FIGURE A 1 And FIGURE A.2)

Install the torch control switch on the control switch socket. Connect the MIG torch cable to the e) terminal of the machine and the work clamp to the (+) terminal. Insert the connector with the key lining up with the replay and turn clockwise. Do not over-tighten. ) (SEE FIGURE A.3)

STICK WELDING

First, determine the proper electrode polarity for the electrode to be used. Consult the electrode data for this information Then connect the Output cables to the Output terminals of the machine for the selected polarity Shown here is the connection method for DC (+) welding (SEE FIGURE A 4)

Connect the electrode cable to the (+) terminal and the work clamp to the (-) terminal Insert the connector with the key lining up with the keyway turn clockwise. Do not over-tighten For DC (-) welding, switch the cable connections at the machine so that the electrode cable is connected to (-) and the work clamp is connected to (+).

TIG WELDING

This machine does not have a built-in gas solenoid, so a one-piece gas valve TIG Torch is required. Most TIG welding is done with DC (-) polarity shown here (SEE FIGURE A 5) Connect the torch cable to the (-) terminal Of the machine and the work clamp to the (+) terminal. Insert the connector with the key lining up with the keyway and turn clockwise. Do not over-tighten.

PRODUCT DESCRIPTION (PRODUCT CAPABILITIES)

This small portable wire feed welder is capable Of flux-cored (FCAW) welding on steel, mild steel, and stainless steel. The wire feed welder is also capable Of STICK welding (SMAW) and DC lift TIG welding (GTAW)  Self Shielding Flux-cored Welding does not require a separate shielding gas to protect the weld since the welding wire has special additives known as flux to protect the weld until it cools.

Flux-cored welding is ideal for medium to thicker material and if welding on painted or rusty steel. Flux-cored welding is also ideal in outdoor applications Flux-cored welding produces a good-looking weld but does not produce an excellent weld appearance as MIG welding does

This machine does not have a built-in Gas Solenoid so a piece gas valve TIG Torch is required, The gas valve must be opened manually before welding and closed manually when welding is completed. The arc is activated using a lift arc technique.

OPERATION

CONTROLS AND OPERATIONAL FEATURES

1. Welding Mode Button
2. Diameter Button
3. Feed Wire Button
4. Parameter Button
5. Digital Display
6. Value Knob
7. MIG Torch Socket
8. Control Switch Socket
9. Positive Output Terminal
10. Negative Output Terminal
11. Input Power Cable
12. Power Switch
13. Ground Screw
14. Rating Plate
15. Fan

FRONT PANEL CONTROLS

Model: FLUX-135PRO Flux-core welder

1. Mode Switch
   For switching welding mode: Stick welding, Lift TIG welding, Flux core welding
2. Wire Diameter Switch
   For switching the diameter Ofwelding wire: 030’/ 035
3. Feed Wire Button
   For manual wire feeding, the longer you press the button, the faster the speed is
4. Parameter Switch
   Stick mode: For switching amperage/arc force/hot start preset Lift TIG: For amperage preset
   Flux core: For switching the wire feeding speed preset/voltage trimming
5. Value Knob
   For adjusting the value Of wire feeding speed/voltage/amperage/arc force level/hot start level
6. Digital Display
   • When switching the welding mode, the corresponding indicator will light up
   • When switching the wire diameter, the corresponding indicator will light up
   • When pressing the feed wire button, the indicator will flash
   • When switching the parameter, the corresponding indicator will light up. (On Stick mode, only the indicator of amperage, arc force, and hot start can light up; On Lift TIG mode, only the indicator Of amperage can light up; On Flux core mode, Only the indicator Of wire feeding speed and voltage can light up.)
   • When adjusting amperage/wire feed speed, the degree indicator near synergic the knob will gradually light up/off to indicate an increase or decrease in degree.
   • The protection indicator will turn on when the machine is overheated or over-current/low voltage When the indicator turns Off, the machine will work normally again.

WORKPIECE CLEANING BEFORE WELDING

Please keep the workpiece clean, and remove existing rust, greasy dirt, water and paint, etc.

Stick Welding Steps

• Connect the electrode lead to the positive (+) output terminal on the front of the machine
• Connect the work clamp lead to the negative (-) output terminal on the front of the machine.
• Turn on the power switch, and the fan will work.
• Set the welding mode button on “STICK”
• Set the welding amperage (20-135A) with the knob
• If necessary, set the “PARAM” button on “ARC FORCE” to adjust the arc force level (0-10) The arc force function can maintain arc stability, control potential arcs, increase welding depth, etc.

Lift TIG Welding steps (Optional TIG Torch Required)

• The TIG welding torch should be connected to the negative (-) output terminal, and the work clamp leads to the positive (+) output terminal
• Turn on the power switch, and the fan will work.
• Turn on the gas regulator on the gas cylinder, the gas pressure is shown on the gauge
• Set the welding mode button on “LIFT TIG”
• Set the welding amperage (15-135A) with the knob

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.

step 1. LOCATE PROBLEM (SYMPTOM)

Look under the column labeled “PROBLEM (SYMPTOM)” This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting

step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists the obvious external possibilities that may contribute to the machine’s symptoms

step 3. RECOMMENDED COURSE OF ACTION

The third column labeled “POSSIBLE SOLUTION” provides a course of action for the Possible Cause If you do not understand or are unable to perform the recommended Course of Action safely, Contact YESWELDER, at support@yeswelder.com.

For more manuals by YesWelder visit, ManualsLibraryy

YesWelder Flux-135PRO MIG Flux Core Welder-FAQs