Preparation For Welding; Maintenance; Connection To Mains Supply - HERKULES SGS 150 Gebrauchsanweisung

In addition a direct current permanent magnet gear-motor is
installed in an accessible opening in the welder. This gear-
motor can take reels of up to 5 Kg.
The welder also has a torch permanently connected and a
return cable complete with earth clamp.
The welder includes a wheel kit (for certain models).
Power is adjusted by means of switches or a rotary switch
(for certain models); the wire speed is controlled using the
knob on the front panel.
The welder can be set up either for welding with solid wire
and gas or with cored wire and no gas by means of the
terminals situated on the side of the welder or in the opening
containing the wire reel.
A thermostat is fitted which protects the welder from
overheating caused by malfunctions or particularly heavy
use.
The symbol S on the rating plate indicates that the welder
has been designed to be used in locations where there is
increased risk of electric shocks
The code IP indicates the degree of protection of the casing
against solid and liquid substances. The welder with IP 21 IS
NOT suitable for outdoor use (see also paragraph on safety
rules).

PREPARATION FOR WELDING

- Connect the return cable to the piece to be welded.
- If solid wire is used, open and adjust the flow of shielding
gas by means of the pressure reducer.
NOTE: remember to shut the shielding gas off when you
finish work.
- Switch the welder on and set the welding current by
means of the switches or rotary switch (if any).
CAUTION: in some models the contact tip is normally
supplied with voltage; maximum care should be taken to
avoid inadvertent starting.
- Press the welding torch button until the wire comes out of
the contact tip.
- Set the welding parameters by adjusting the speed of the
wire by means of the relevant knob until regular welding is
obtained.
- The warning light will come on in the event of over-heating
and the power supply will be interrupted. This will be
automatically re-connected after a few minutes of cooling.

MAINTENANCE

Torc h
- The arc is dangerous for your eyes: always use and
ensure that others
mask.
- Always wear suitable clothing and gloves during welding
operations.
- Do not direct the gun towards yourself and do not touch
the wire.
- Do not hit or clamp the gun with tools.
- Avoid resting the torch and its cable on hot pieces; this
could cause the insulating materials to melt and so
making the torch immediately unusable.
- Check regularly whether the gas hose and fittings are
tight.
- Each time the wire reel is changed, blow dry compressed
air (max 10 bar) through the wire guide hose and check
the condition of the hose.
- Check at least once a day, the condition and the correct
assembly of the end parts of the torch: nozzle, contact tip,
and gas diffuser.
- Before carrying out any maintenance operation or
replacing parts on the gun, disconnect from the power
supply and let the gun cool.
- Replace the contact tube if the hole is distorted or
enlarged.
- Periodically clean the inside of the nozzle and shroud.
- Frequently check the condition of the welding cables and
replace them if excessively worn.
Fig. A
Fig. B
us e th e pr ot ec ti ve
TAB. 1 - TECHNICAL SPECIFICATIONS TORCH
Wire feeder
- Check the condition of the wire feed rollers and regularly
remove any metallic dust deposited in the feed area
(rollers and entrance and outlet wire guide).

CONNECTION TO MAINS SUPPLY

Connection to the mains should be carried out using the
cable supplied.
Make sure that the mains voltage corresponds to the
operating voltage of the wire system.
THE WELDER SHOULD ALWAYS BE EARTHED, using the
yellow-green wire of the power supply cable, which also has
the label with the symbol W ; the other two wires should be
connected to the mains.
PLUG:
Fit the power supply cable with a standard (2p + e) plug
with adequate current carrying capacity and make use
of a mains socket which is fitted with fuses or an
automatic circuit breaker.
The line - mains socket should be fitted with protection
devices such as fuses or automatic circuit breakers
which should be able to withstand the maximum
absorption of the welder (see reference data on rating
plate).
If extension leads are connected to the main cable, the
cross-section of these should never be lower than the cross-
section of the cable supplied.
WIRE REEL LOADING (Fig. C)
MAKE SURE THAT THE WIRE FEED ROLLERS, THE
WIRE GUIDE HOSE AND THE CONTACT TIP OF THE
TORCH MATCH THE DIAMETER AND TYPE OF WIRE TO
BE USED AND MAKE SURE THAT THESE ARE FITTED
CORRECTLY .
- Insert the wire reel onto the spindle making sure that the
spindle pin is correctly placed in its hole.
- Release the pressure counter-roller and move it away
from the lower roller.
- Free the end of the wire and cut off the bent end making
sure it has no burr. Rotate the reel anti-clockwise and
thread the end of the wire into the entrance wire guide
pushing it into the wire guide of the torch fitting for about
50-100 mm.
- Re-position the counter-roller and set the pressure at an
intermediate value and make sure that the wire is correctly
positioned in the groove of the lower roller.
- Use the adjustment screw to apply a slight braking
pressure on the spindle.
- Switch the welder on by turning the switch to ( l ) and press
the torch button. Wait for the end of the wire to pass
through the whole of the wire guide hose and protrude by
about 10-15 cm from the front part of the torch and then
release the torch button.
CAUTION! During this operation the wire is live and
subject to mechanical stress; therefore if adequate
precautions are not taken the wire could cause
electric shock, injury and inadvertent striking of
electric arc:
- Always wear protective-insulating gloves and clothing.
- Do not direct the mouth-piece of the torch towards parts of
the body.
- Keep the torch away from the gas bottle.
- Re-fit the contact tip and the nozzle onto the torch.
- Check that wire feed is regular; set the roller and spindle
braking pressure to the minimum possible values making
sure that the wire does not slide in the groove and when
feed is halted the loops of wire are not loosened by
excessive reel inertia
- Cut the end of the wire so that 10-15 mm protrude from the
nozzle.
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