www.astrotools.com
Unpacking
When unpacking, check the parts diagram and part number listing
on pages 8-9 to make sure all parts are included. If any parts are
missing or damage, please call your distributor.
Product: COMBI120 Manual
Dimension: 8.5"x 11"/page
Date: 2008/03/13
Color:
COMBI120
Combination Gas/No Gas
Welder - 120AMP
• Ideal for light industrial applications:
- Auto body
- Light fabrication
- Maintenance and repair
- Farm and ranch
• Lightweight, portable unit
• Combination indoor (gas) and outdoor (no gas) welding
• Fan cooled for increased duty cycle
• Comes complete with:
- 8.3ft. (2.5m) MIG Torch
- 6.5ft. (2m) work cable with clamp
- 2 contact tips for 024 (0.6mm) and 030 (0.8mm) wires
- Dual groove quick-change drive roll for 024 (0.6mm),
030 (0.8mm), and 035 (0.9mm) wires
- 2.2lb. (1kg) spool of 024 (0.6mm) solid wire
- Face shield
- Gas bottle holder
- Regulator/flow gauge and gas hose
Black
PLEASE DO NOT RETURN ANY PRODUCT WITHOUT CALLING
1-800-221-9705 FOR INSTRUCTIONS
Welding Capacity: 3/16" Mild Steel
Flux Core Capacity: 3/16" Mild Steel
Power Input Capacity: 4KVA
Primary Amps: 115 V, 28Amps 60Hz
Welding Amp Range: 28A-120A
Rated Output: 90A at 25% duty cycle
Wire Size: 024 (0.6mm), 030 (0.8mm),
and 035 (0.9mm)
Spool Size Outside Diameter: 101mm±1mm
Spool Size Inside Diameter: 15mm
Dimensions L x W x H: 20-4/5" x 12-2/5" x 12-4/5"
(530 x 315 x 326mm)
Net weight: 58.4lbs. (26.5kg)
SPECIFICATION:
Combination Gas/No Gas Welder - 120AMP
COMBI120
Combination Gas/No Gas
Welder - 120AMP
Page 2
INSTRUCTION MANUAL FOR WIRE WELDING MACHINE
IMPORTANT: BEFORE STARTING THE EQUIPMENT, READ THE CONTENTS OF THIS MANUAL, WHICH
MUST BE STORED IN A PLACE FAMILIAR TO ALL USERS FOR THE ENTIRE OPERATIVE LIFE-SPAN OF
THE MACHINE. THIS EQUIPMENT MUST BE USED SOLELY FOR WELDING OPERATIONS.
1 SAFETY PRECAUTIONS
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.
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
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.
2 GENERAL TECHNICAL DESCRIPTIONS
2.1 SPECIFICATIONS
This manual has been prepared with the intent of instructing the operator on how to install, operate, and properly maintain this
electric arc welding machine.
This machine is a constant voltage power source for MIG/MAG and OPEN-ARC welding.
Upon receiving and unpacking the machine, make a careful inspection to ensure that there are no damaged parts.
Should there be a claim for losses or damages it must be made by the purchaser directly to the shipper who
handled the goods.
When requesting information about this welding machine please state the machine’s part number and serial number to
ensure receiving accurate information relating to your machine.
COMBI120
Combination Gas/No Gas
Welder - 120AMP
Page 3
1-50/60Hz
Single-phase input supply at 50 or 60 Hz.
Uo.
Secondary no-load voltage (peak value).
X
Duty-Cycle Percentage
The duty-cycle is the number of minutes, expressed as a percentage, the machine can operate (arc on) within
a ten minute period without overheating. The duty cycle varies according to the output current.
I2
Output cutting current
I1
Input Amps absorbed corresponding to different output levels (I2).
U2
Secondary voltage with cutting current I2.
U1
Nominal supply voltage
IP21.
Machine case protection class. The 1 in the second digit place means that this unit is not fit to work
outdoors in the rain.
F
Insulation Class
NOTE: This machine has also been designed to work in class 3 pollution areas .
COMBI120
Combination Gas/No Gas
Welder - 120AMP
Page 4
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 u pwards vertical position, of binary or ternary composition.
I
t 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.
3.3.3 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.
3 INSTALLATION
3.1 SETUP
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.
3.2 INPUT POWER CONNECTIONS
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 figure 1.
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.
3.3 OUTPUT CONNECTIONS
3.3.1 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.
3.3.2 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
4 DESCRIPTION OF CONTROLS
4.1 CONTROLS ON GENERATOR FRONT PANEL
2.2 DESCRIPTION OF TECHNICAL SPECIFICATIONS
MODEL:
The model of the machine
EN 60974-X
international standards.
SN
Machine Serial Number which must appear on requests or inquiries concerning the machine
Single-phase transformer-rectifier
Three-phase transformer-rectifier
4.2 CONTROLS ON GENERATOR REAR PANEL
A: Over heated pilot of main transformer
(red) Light up while over duty cycle
B: Power pilot (green): Light up when turn
on the power switch
C: Adjustable feeding wire knob: Adjust the
speed of feeding wire (The larger the
number, the faster the feeding wire.)
D: Rotary weld voltage switch:
The switch adjusts the weld voltage
range and turns the machine on and off
E: Gas switch: use gas or no gas
F: The torch
G: Work return lead
COMBI120
Combination Gas/No Gas
Welder - 120AMP
Page 5
COMBI120
Combination Gas/No Gas
Welder - 120AMP
Page 6
Call 1.800.221.9705 for questions concerning performance of the product
or other inquiries.
Page 8
372 Old US Highway 52 South
Mount Airy, NC 27030
COMBI120-01
COMBI120-02
COMBI120-03
COMBI120-04
COMBI120-08
COMBI120-10
COMBI120-13
COMBI120-14
COMBI120-17
COMBI120-19
COMBI120-19A
COMBI120-20
COMBI120-25
COMBI120-27
COMBI120-30
Front Panel
Power Lamp
Over Heated Lamp
Knob
M8 Connector
Work Clamp
Control Circuit Board Pcb
Steps Switch
Inside Baffle
Wire Feeder Motor
Wire Feed Roller
Wire Feeder Reel
Magnetic Switch
Bottom Board
Main Transformer With Chock
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
2
3
4
8
10
13
14
17
19
19A
20
25
27
30
Index
No.
COMBI120
Combination Gas/No Gas
Welder - 120AMP
COMBI120-31
COMBI120-34
COMBI120-35
COMBI120-36
COMBI120-37
COMBI120-40
COMBI120-41
COMBI120-56
COMBI120-58
COMBI120-61
COMBI120-67
COMBI120-68
COMBI120-70
COMBI120-71
COMBI120-74
Rectifier
Right Panel
Back Panel
3m Power Cable
2m Gas Pipe
Solenoid Valve
Fan
Heat Switch
2m Work Return Lead
Torch
Closing
Handle
Cable Holder
Door Panel
Hinge
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
31
34
35
36
37
40
41
56
58
61
67
68
70
71
74
Index
No.
COMBI120
Combination Gas/No Gas
Welder - 120AMP
Page 7
1
2
3
4
5
6
control board
gas / no gas
motor
relay
thermal lamp
thermal switch
fan
power
power switch
gas in
VALVE
J3
J1
110 V
GAS
GAS
COMBI120
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.
9 Welding machine servicing
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.
9.1 Prescriptions to follow for servicing
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
.
Note: All repair work must be done by qualified personnel.
Welding with a lot of
metal spatter
Wire not advancing or
advancing unproperly
The wire jams
or entangles
between the
drive rolls and the torch
infeed wire guide
Wrong adjustment of the welding
parameters
Wire advancing unproperly
Damaged contact tip
Insufficient grounding
Wire roller with too wide groove
Obstructed or clogged liner
Loose wire pressing roller.
Coil reel friction too tight
Current nozzle clogged
Wrong current nozzle diameter
Wrong Roller Groove Alignment
Obstructed Or Clogged Sheath
Select the correct parameters through the welding
voltage switch and the wire-speed adjustment
potentiometer
Uncorrected sheath diam
Change the contact tip
Check grounding connections
Replace roller
Extract it and clean
Tighten it
Loosen and adjust it
Replace it
Replace it
Align it
Remove and clean
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.
6 WELDING DEFECTS
1- DEFECT-
Porosity
(in, or on the surface of the weld bead)
CAUSES Bad wire (rust on the surface).
I
nsufficient 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.
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.
Contact tip is damaged. Please note that contact tip should be replaced every time wire is changed.
7 MACHINE MAINTENANCE
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.
8 TROUBLESHOOTING
TROUBLE
Limited electric output
PROBABLE CAUSE
A phase missing
A line fuse is burnt
Wrong connection on the voltage
changer terminal board
The rectifier diode are burnt
Loosened torch or ground connections
Welding regulation commutator has an
uncertain contact
Transformer wire interrupted on the
commutator
REMEDY
Check the phase of the feed line and/or the remove
control switch contacts
Replace it
Check the terminal board connections by following the
plate scheme
Replace the rectifier
Tighten all connections
Replace the commutator
Unscrew the commutator contact remove the wire
insulation and put it under the contact
5 WELDING
5.1 INSTALLATION AND STARTER
Machine installation must be done by a competent staff. All connections must correspond to the rules in 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.
5.2 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.
5.3 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 ration of 75% Argon and 25% 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.
5.4 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.
5.5 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.
A: Gas pipe connecter
B: Input power cable (Confirm the power voltage
before use)
•Astro Pneumatic Tool Co. warrants our products to the original user against
defective material or workmanship for a period of 1 year from the date of 1st use.
Astro reserves the right to determine whether the product failed because of defective
material, workmanship or other causes and to charge back for missing parts. Astro
Pneumatic Tool Co., at its discretion, will repair products covered under this warranty
free of charge. The original user is to return the product (with the exceptions listed
below) with the distributor’s name, address, adequate proof of date of purchase or a
copy of warranty card, and a short note explaining the problem.
Failures caused
by accident, alteration, or misuse are not covered by this warranty.
•
If one part of this product fails, please do not return the entire product.
Astro will replace free of charge component parts of this product that fail
within 1 year of first use by the original user. Items included in this category
include but are not limited to kits, hand tool kits and any other product where
there are multiple items or components that make up the unit. Please contact
the phone number below in order to obtain the replacement components
covered under warranty.
•Astro Pneumatic Tool Co. or its authorized service representatives must perform all
warranty repairs. Any repair to the product by unauthorized service representatives
voids this warranty. The rights under this warranty are limited to the original user
and may not be transferred to subsequent owners.
•This warranty is in lieu of all other warranties, expressed or implied, including
warranties of merchantability and fitness for a particular purpose. Some states do
not allow the exclusion of limitations of incidental or consequential damages so the
above limitations may not apply to you. All claims must be sent to:
Astro Pneumatic Tool Company
372 Old US Highway 52 South
Mt. Airy, NC 27030
1 YEAR LIMITED WARRANTY
A
B
C
D
E
F
G
Call 1.800.221.9705 for questions concerning performance of the product
or other inquiries.
Page 9
372 Old US Highway 52 South
Mount Airy, NC 27030
COMBI120-75
04023
04024
COMBI120-78
COMBI120-79
COMBI120-80
04032
COMBI120-82
COMBI120-83
COMBI120-84
COMBI120-85
COMBI120-86
COMBI120-87
COMBI120-88
Swan Neck for 15AK
o
12mm/53L
0.6 Contact Tip
o
6x25L M6x5
0.8 Contact Tip
o
6x25L M6x5
1.0 Contact Tip
o
6x25L M6x5
Standard Gas Nozzle Holder For 15AK-L
Spring For Tip Holder 14/ 15AK
15AK Standard Nozzle
Handle Set For Torch
Connector For Swan Neck
Gas Connector
Switch Of Torch
Cable Support
Nut
Liner
1
1
1
1
1
1
1
1
1
1
1
1
1
1
75
76
77
78
79
80
81
82
83
84
85
86
87
88
Index
No.
COMBI120
Combination Gas/No Gas
Welder - 120AMP
76
81
77
79
78
80
75
82
84
83
85
86
87
88
COMBI120-61 - Torch
* Please notice that Index number
78 is sold separately.
It is not included in COMBI 120.
REVISED NOT PRINTED
A
40
