Replacing The Wire Liner; Gas Cylinder And Regulator Connection; Aluminium Welding - Helvi 77611978 Mode D'emploi

8.3 REPLACING THE WIRE LINER

• Disconnect the torch from the machine.
• Place it on a flat surface and carefully remove the
brass nut (1).
• Pull the liner out of the hose.
• Install the new liner and mount the brass nut (1)
again.
In case you are replacing a Teflon or graphite wire liner,
follow these instructions:
• Install the new liner and insert the wire liner collet
(3) and the O ring (4).
• Mount the brass nut (1).
• Cut the wire liner close to the brass nut
Warning: the length of the new wire liner
must be the same of the liner you have just
pulled out of the hose.
• Connect the torch to the machine and install the wire into the feeding system.
8.4
Mainly we can have 2 types of wire liners: Steel wire liners and Teflon wire liners.
• The steel wire liners can be coated or not coated: the coated wire liners are used for air cooled tor-
ches; the wire liners which are not coated are used for water cooled torches.
• The Teflon wire liners are suggested for the welding of Aluminium, as they allow a smooth feeding
of the wire.
• For Welding of Aluminium a Teflon/Graphite wire liner with copper or brass terminal is required to
ensure a good electric contact of the wire.
Colour
Diameter

8.5 GAS CYLINDER AND REGULATOR CONNECTION

WARNING: Cylinders are highly pressurized. Handle with care. Serious accidents can
result from improper handling or misuse of compresses gas cylinders. Do not drop the
cylinder, knock it over, expose it to excessive heat, flames or sparks. Do not strike it
against other cylinders.
The bottle (not supplied) should be located at the rear of the welder, securely held in position by the chain
provided.
For safety, and economy, ensure that the regulator is fully closed, (turned counter-clockwise) when not welding
and when fitting or removing the gas cylinder.
• Install the Teflon or Graphite wire liner with copper or brass terminal specific for aluminium.
• Turn the regulator adjustment knob counter-clock wise to ensure the valve is fully closed.
• Screw the gas regulator fully down on the gas bottle valve, and fully tighten.
• Connect the gas hose to the regulator securing with clip/nut provided.
• Open the cylinder valve, then set the gas flow on the regulator to approx. 5-15l/min.
• Operate the torch trigger to ensure that the gas is flowing through the torch.

8.6 ALUMINIUM WELDING

The machine will be set up as for mild steel except for the following changes:
• 100% ARGON as welding protective gas.
• Ensure that your torch is set up for aluminium welding:
1. The lenght of the torch should not exceed 3m (it is advisable not to use longer torches).
2. Install a teflon or graphite wire liner with copper or brass terminal (follow the instructions for the re-
newing of the wire liner at paragraph 4.3.3).
3. Ensure that drive rolls are suitable for aluminium wire.
4. 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. To obtain a high duty cycle without
wire feeding problems it is advisable to install the gas diffuser, the contact tip with 8mm thread and
the nozzle.
HOW TO CHOOSE THE WIRE LINER
BLUE
Ø 0,6-0,9
1
1
1
2
1 4 3 2
graphite
GRAFFITE
5
6
7
RED
Ø 1,0-1,2
33
steel
Figure 12
YELLOW
Ø 1,2-1,6