Gude Flux-Cored Welder SG 120 A Instruction Manual

1. Introduction

This manual provides essential instructions for the safe and efficient operation, setup, and maintenance of your Gude Flux-Cored Welder SG 120 A. Please read this manual thoroughly before using the device to ensure proper handling and to prevent injury or damage.

2. Safety Instructions

Welding operations involve significant risks. Adhere to all safety precautions to prevent electric shock, burns, fire, and exposure to harmful fumes and radiation.

• Always wear appropriate personal protective equipment (PPE), including a welding helmet with suitable shade, welding gloves, and protective clothing.
• Ensure the welding area is well-ventilated to disperse fumes.
• Never weld near flammable materials or liquids.
• Ensure the welder is properly grounded.
• Disconnect power before performing any maintenance or changing accessories.
• Do not touch live electrical parts.
• Keep children and unauthorized personnel away from the welding area.
• The machine is equipped with overheating protection. Allow the unit to cool down if it activates.

3. Product Overview and Components

The Gude Flux-Cored Welder SG 120 A is designed for flux-cored welding without the need for shielding gas. It includes the main welding unit, a welding torch, a ground clamp, and basic accessories.

Figure 1: Gude Flux-Cored Welder SG 120 A and included accessories.

This image displays the Gude Flux-Cored Welder SG 120 A unit, which is blue and black, featuring control knobs and switches on its front panel. Connected to the unit are a welding torch with its cable, a ground clamp, and a basic black welding mask. Also visible are a wire brush and spare contact tips, indicating the complete setup for flux-cored welding.

Key Components:

• Welding Unit: Main power source and control panel.
• Welding Torch: Delivers the flux-cored wire and welding current to the workpiece.
• Ground Clamp: Connects to the workpiece to complete the electrical circuit.
• Welding Mask: Provides eye and face protection from arc flash and sparks.
• Wire Brush: Used for cleaning welds.
• Contact Tips: Consumable parts for the welding torch.

4. Setup

1. Unpacking: Carefully remove all components from the packaging. Inspect for any shipping damage.
2. Power Connection: Connect the welder to a 230V, 50Hz power supply with a 16A circuit breaker. Ensure the power switch on the welder is in the "OFF" position before plugging it in.
3. Wire Installation:
   • Open the wire compartment.
   • Mount the flux-cored wire spool (up to 0.9 mm diameter) onto the spindle.
   • Feed the wire through the guide tube and into the drive rollers.
   • Adjust the drive roller tension to prevent slipping or crushing the wire.
   • Close the compartment.
4. Torch and Ground Clamp Connection:
   • Ensure the welding torch is securely connected to the front panel of the welder.
   • Attach the ground clamp cable to the designated terminal on the welder.
5. Workpiece Preparation: Clean the workpiece thoroughly to remove rust, paint, oil, or other contaminants that could affect weld quality.

5. Operation

1. Power On: Switch the welder to the "ON" position.
2. Attach Ground Clamp: Securely attach the ground clamp to the workpiece, ensuring good electrical contact.
3. Select Power Level: The SG 120 A offers two power levels: 60A and 90A. Select the appropriate level based on the material thickness.
   • For thinner materials (e.g., 1.5 mm), use the lower setting (60A).
   • For thicker materials (up to 5 mm), use the higher setting (90A).
4. Adjust Wire Feed Speed: Use the control knob to adjust the wire feed speed. Start with a moderate setting and adjust as needed to achieve a stable arc and good weld penetration.
5. Welding:
   • Position the welding torch approximately 10-15 mm from the workpiece.
   • Press the trigger on the torch to initiate the arc and wire feed.
   • Maintain a consistent travel speed and torch angle to create a uniform weld bead.
   • Flux-cored welding produces slag, which will need to be removed after welding.
6. Overheating Protection: If the welder overheats, the thermal protection will activate, and the unit will temporarily shut down. Allow it to cool down before resuming operation.
7. Power Off: After welding, release the torch trigger, switch the welder to "OFF," and disconnect it from the power supply.

6. Maintenance

Regular maintenance ensures the longevity and safe operation of your welder.

• Cleaning: Regularly clean the welding unit, especially the ventilation openings, to prevent dust and debris buildup. Use compressed air if available.
• Torch Maintenance:
  • Inspect the contact tip for wear and replace if necessary.
  • Ensure the nozzle is clean and free of spatter.
  • Check the torch cable for damage.
• Wire Drive System: Periodically check the wire drive rollers for wear and ensure they are clean.
• Ground Clamp: Ensure the ground clamp is clean and provides a secure connection.
• Storage: Store the welder in a dry, clean environment when not in use.

7. Troubleshooting

8. Technical Specifications

• Model: Gude SG 120 A (Model Number: 20070)
• Input Voltage: 230 V
• Frequency: 50 Hz
• Max. Net Power: 3.2 kVA
• Net Protection: 16 A
• No-Load Voltage: 31 V
• Welding Current: 60 A / 90 A (2 levels)
• Material Thickness: 1.5 - 5 mm
• Max. Wire Diameter: 0.9 mm (flux-cored)
• Product Dimensions: 48.01 x 35.99 x 22 cm
• Weight: 14 kg

9. Warranty and Support

For warranty information, technical support, or service inquiries, please refer to the documentation provided with your purchase or contact your retailer or the manufacturer directly. Keep your proof of purchase for warranty claims.