INSTRUCTION MANUAL FOR MIG WELDER 3.300.844 important operating instructions save these instructions

INSTRUCTION MANUAL FOR MIG WELDER
important operating instructions save these instructions
3.300.844
INSTRUCTION MANUAL FOR MIG WELDER
IMPORTANT:
READ THIS MANUAL CAREFULLY BEFORE INSTALLING, USING, OR SERVICING THE WELDING MACHINE, PAYING SPECIAL ATTENTION TO SAFETY RULES.
CONTACT YOUR DISTRIBUTOR IF YOU DO NOT FULLY
UNDERSTAND THESE INSTRUCTIONS.
1
D
G
H
B
INSTALLATION
F
This machine must be used for welding only. It must not be
used to defrost pipes.
It is also essential to pay special attention to the chapter
on SAFETY PRECAUTIONS.
The symbols next to certain paragraphs indicate points
requiring extra attention, practical advice or simple information.
This manual must be stored carefully in a place familiar to
everyone involved in using the machine. It must be consulted whenever doubts arise and be kept for the entire
life-span of the machine; it will also be used for ordering
replacement parts.
1.1
E
A
C
PLACEMENT
Unpack the machine and place it in an adequately ventilated area, dust-free if possible, taking care not to block the
air intake and outlet from the cooling slots.
CAUTION: REDUCED AIR CIRCULATION causes
overheating and could damage internal parts.
Keep at least 500 mm of free space around the machine.
Never place any filtering device over the air intake points
of this welding machine.
The warranty shall become void if any type of filtering
device is used.
Mount the parts supplied with the machine.
D) Yellow LED
Lights only when the thermostat is tripped and interrupts the machine operation.
E) Green LED
Indicates that the machine is turned on.
F) Welding torch connector
Connector for the welding torch.
G) Spot time adjuster knob.
Use this knob to set the spot welding duration time.
When the button on the welding gun is pressed, the
machine will start spot welding and continue for the
time set on this knob. To start the next welding cycle,
release and press the welding torch button.
H) Rest time adjusting knob
By means of this knob you can adjust the rest time
between a spot weld and the other. Such function is
active only when the spot time (knob H) is on.
3
GENERAL DESCRIPTIONS
3.1 SPECIFICATIONS
This welding machine allows welding of soft steel, stainless steel and aluminium.
2
DESCRIPTION OF THE MACHINE
A) Switch
Turns the machine on and off, and also regulates the
welding voltage range.
B) Setting knob
This knob serves to adjust the welding wire speed.
C) Earth cable
2
3.2 EXPLANATION OF TECHNICAL SPECIFICATIONS
EN 50199
EN60974.1
N°
The welding machine is manufactured
according to these international standards.
serial number, which must always be indicated on any type of request regarding
the welding machine.
single-phase transformer-rectifier.
MIG/MAG.
I2 MAX
Suitable for continuous electrode welding.
Unconventional welding current.
The values represent the maximum levels
attainable in welding.
U0.
Secondary open-circuit voltage.
X.
Duty cycle percentage.
The duty cycle expresses the percentage
of 10 minutes during which the welding
machine may run at a certain current
without overheating.
I2.
Welding current
U2.
Secondary voltage with welding current
I2.
U1.
Rated supply voltage
1~ 50Hz
50-Hz single-phase power supply.
I1 max.
This is the maximum value of the rated
supply current.
I1 eff.
This is the maximum value of the effective
input current, considering the duty cycle.
IP21
Protection rating for the housing.
Grade 1 as the second digit means that
this equipment is suitable for use outdoors in the rain.
S
Suitable for use in high-risk environments.
NOTES: The welding machine has also been designed for use
in environments with a pollution rating of 3. (See IEC 664).
connections must be made in compliance with current
regulations and in full respect of safety laws.
Make sure that the wire diameter corresponds to the one
indicated on the roller, and mount the wire reel. Make sure
that the welding wire passes through the groove in the
small roller 5.
Before connecting the power cable 29, make sure that the
power voltage corresponds to that of the welding machine,
then: a) for permanent connection to the power mains
without a plug, you must insert a main switch
having a suitable capacity in compliance with the
rated specifications.
b) for a plug-socket connection, use a plug having
a suitable capacity in compliance with the rated
specifications. In this case the plug must be used
to completely disconnect the machine from the
mains, after setting the switch 43 to “O” (off).
The yellow-green wire must be connected to the earth terminal.
Connect the earth clamp 20 to the part to be welded.
The welding circuit must not be deliberately placed in
direct or indirect contact with the protection wire except in
the workpiece.
If the workpiece is deliberately grounded using the protection wire, the connection must be as direct as possible,
using a wire at least as large as the welding current return
wire, and connected to the workpiece at the same point as
the return wire, using the return wire clamp or a second
grounding clamp placed next to it.
All precautions must be taken to avoid stray welding currents.
Turn the machine on using the switch 43.
Remove the tapered gas tip by turning it clockwise.
Unscrew the contact tip.
Do not press the torch trigger until you have read the
instructions carefully.
It is important to make sure the machine is turned off whenever changing the wire reel and wire roller, to prevent the
wire feed motor from starting accidentally.
Press the torch trigger and release it only when the welding wire comes out.
Welding wire can cause puncture wounds.
Never aim the torch at parts of the body, other people or
metals when loading the welding wire.
Screw the contact tip back on, making sure that the hole
diameter corresponds to the wire used.
Slide the tapered gas welding tip on, always turning
clockwise.
4.1 CONNECTING THE GAS HOSE
3.3 DESCRIPTION OF PROTECTION
The gas cylinder must be equipped with a pressure
reducer and flow meter.
l If the cylinder is placed on the cylinder holder of the
machine, it must be held in place by the chain provided
and be of an appropriate size to avoid jeopardizing the
stability of the machine.
l Connect the gas hose leaving the back of the machine
to the pressure reducer only after the cylinder is in place.
l Open the gas cylinder and set the flow meter to approximately 8-10 lt./min.
CAUTION: Make sure the gas used is compatible with the
material to be welded.
l
This device is protected by a normally closed thermostat
on the power transformer.
When the thermostat is tripped the machine stops welding, while the motor-driven fan continues to run and the
yellow LED lights.
After it has been tripped, wait a few minutes to allow the
generator to cool down.
4 INSTALLATION
The machine must be installed by skilled personnel. All
3
4.2 GENERAL NOTES
Before using this welding machine, carefully read the
regulations CEI 26/9 or CENELEC HD 407 and CEI 26/11
or CENELEC HD 433. Also make sure that the insulation
on cables, torch and earth cable is intact.
ded composition)
The recommended torch angle and welding direction are
shown in figure.
6
6.1
MAINTENANCE AND CHECKS
GENERAL NOTES
5 WELDING
Turn off the welding machine and unplug the power cord
from the socket before each checking and maintenance
operation.
l Moving parts can cause serious lesions
l Keep away from moving parts.
l INCANDESCENT SURFACES can cause serious burns.
l Let the unit cool before servicing.
l Periodically remove any dust or foreign matter that may
have deposited on the transformer or diodes; to do so, use
a jet of clean, dry air.
l When replacing the wire roller, make sure the groove is
aligned with the wire and corresponds to the diameter of
the wire used.
l Always keep the interior of the gas nozzle clean to avoid
metal bridges created by welding dross between the gas
nozzle and the contact tip. Make sure the outlet hole of the
contact tip has not expanded excessively; if so, replace.
l Strictly avoid striking the torch or allowing it to suffer violent impact.
l
5.1
WELDING MILD STEEL
Either 75% ARGON + 25% CO2 or 100% CO2 may be
used for welding mild steel.
Select the welding current by means of the rotary switch 40.
Move the torch near the welding point and press the trigger.
Adjust the potentiometerl knob until the welding is done
with a constant, continuous noise.
If the speed is too fast, the wire tends to stick to the piece
and cause the torch to skip; if the speed is too low, the
wire melts in spaced drops or the arc does not remain lit.
When you have finished welding, turn off the machine and
close the gas cylinder.
For the correct welding angle see figure.
5.2
WELDING ALUMINIUM
The welding machine must be prepared as for welding
mild steel with gas protection, but with the following differences:
l 100% ARGON as the protection gas for welding.
l A wire having a composition suited to the base material
to be welded.
For welding ALLUMAN: 3÷5% silicon wire
l For welding ANTICORODAL: 3÷5% silicon wire
l For welding PERALUMAN: 5% magnesium wire
l For welding ERGAL: 5% magnesium wire
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.
See the figure for correct torch inclination.
5.3
WELDING STAINLESS STEEL
The welding machine must be prepared as for welding
mild steel with gas protection, but with the following differences:
l Reel of stainless steel wire compatible with the composition of the material to be welded.
l Cylinder containing 98% ARGON + 2% 02 (recommen4
6.2
REPAIRING THE WELDING MACHINE
Experience has shown that many accidents are caused by
repairs performed incorrectly. That is why it is just as
important to check a repaired welding machine carefully
and completely as it is for a new welding machine.
In addition, this protects the manufacturer from being held
liable for defects when the true fault lies elsewhere.
6.2.1 Instructions for performing repairs
l After rewinding the transformer or inductance, the welding machine must pass the applied voltage tests as indicated in table 2 of paragraph 6.1.3 of the standard EN
60974.1 (CEI 26.13). Compliance must be verified as specified in 6.1.3.
l If no rewinding has been done, a welding machine that
has been cleaned and/or revised must pass an applied
voltage test with test voltage values equal to 50% of the
values given in table 2 of paragraph 6.1.3. Compliance
must be verified as specified in 6.1.3.
l After rewinding and/or replacing parts, the no-load voltage must not exceed the values given in paragraph 10.1
of EN 60974.1.
l If the repairs have not been performed by the manufacturer, repaired welding machines in which some components have been replaced or altered must be marked in
such a way that the person who performed the repairs is
clearly identifiable.
l After making repairs, take care to re-order the wiring so
that there is certain insulation between the primary side
and the secondary side of the machine. Prevent the wires
from coming into contact with moving parts or parts that
heat up during operation. Replace all clamps as on the original machine to prevent a connection from occurring
between the primary and secondary side if a conductor
accidentally breaks or disconnects.
6.3
TROUBLESHOOTING GUIDE GUIDE
ROUBLE
PROBABLE CAUSE
REMEDY
The welding machine supplies limited
current
Line fuse blown
Replace line fuse
Burnt out diode or diodes
Replace
Burnt out electronic board
Replace
Loosened torch or earth Tighten all connections
connections or any other
electrical power connections
Welding with a lot
of metal spatter
The wire jams or
entangles between
the drive rolls and
the torch infeed wire
guide
Voltage adjustment switch Replace the switch
has a loose contact
Improper adjustment of
welding parameters
Select the correct parameters through the weldingvoltage switch and the
wire-speed
adjustment
potentiometer
Insufficient grounding
Check grounding connections
Contact tip with wrong dia- Replace
meter
Misalignment of the drive Realign
roll groove
Obstructed
liner
or
clogged Remove and clean
No wire feed or irre- Drive roll with too large a Replace the drive roll
groove
gular wire feed
Obstructed
liner
or
clogged Remove and clean
Wire holding roller not Tighten
completely tightened
Porosity in the welding seam
all
the
Clogged contact tip
Replace
Insufficient shielding gas
Increase gas delivery
way
Excess oxidation of the Thoroughly clean the
edges to be welded
edges with a metal brush
Gas nozzle partially or Remove and clean or
completely clogged by replace being careful not
spatter
to clog the gas outlets
7 SAFETY PRECAUTIONS
7.1 FIRE
l Avoid causing fire because of sparks,
slag, hot metal or pieces.
l Make sure that suitable fire-fighting equipment is available close to welding area.
l Remove all flammable and combustible material from
the welding area and its surrounding (32 ft minimum).
l Do not weld containers of combustible or flammable
material, even when empty. These must be carefully cleaned before being welded.
l Allow the welded material to cool down before touching
it or putting it in contact with combustible or flammable
material.
l Do not weld parts with hollow spaces, containing flammables.
l Do not work under conditions with high concentrations of
combustible vapours, gases, or flammable dust.
l Always check the work area half an hour after welding
so as to make sure that no fire has started.
l Do not keep any combustible material such as lighters or
matches in your pockets.
7.2 BURNS
l Wear fire-proof clothing all over your body in order to pro-
tect your skin against burns caused by ultraviolet radiation
given off by the arc, and from weld metal sparks and slag.
l Wear protective clothing-gauntlet gloves designed for
use in welding, hat and high safety-toe shoes. Button shirt
collar and pocket flaps, and wear cuff-less trousers to
avoid entry of sparks and slag.
l Wear helmet with safety goggles and glasses with side
shields underneath, appropriate filter lenses or plates
(protected by clear cover glass). This is a MUST for welding to protect the eyes from radiant energy and flying
metal. Replace cover glass when broken, pitted, or spattered.
l Avoid oil or greasy clothing. A spark may ignite them.
Hot metal such as electrode stubs and workpieces should
never be handled without gloves.
l First-aid facilities and a qualified first-aid person should
be available for each shift unless medical facilities are
close by for immediate treatment of flash burns of the eyes
and skin burns.
l Ear plugs should be worn when working on overhead or
in a confined space. A hard hat should be worn when
others work overhead.
l Flammable hair preparations should not be used by persons intending to weld or cut.
7.3 FUMES
Welding operations give off harmful fumes and
metal dusts which may be hazardous to your
health, therefore:
l Work in a well-ventilated area.
l Keep your head out of fumes.
l In closed areas, use suitable exhaust fans.
l If ventilation is not enough, use breathing sets approved
for this procedure.
l Clean the material to be welded of any solvents or halogen degreasers giving rise to toxic gases. Some clorine
solvents may decompose with the radiation emitted by the
arc, and create phosgene gas.
l Do not weld plated metals or those containing lead,
graphite, cadmium, zink, chrome, mercury or beryllium,
unless you have the proper breathing set.
l The electric arc creates ozone. A long exposure to high
concentrations may cause headaches, nasal, throat and
eye irritation as well as serious congestions and chest
pains.
IMPORTANT: DO NOT USE OXYGEN FOR VENTILATION.
l Gas leaks in a confined space should be avoided.
Leaked gas in large quantities can change oxygen concentration dangerously. Do not bring gas cylinders into a
confined space.
l DO NOT WELD where solvent vapors can be drawn into
the welding atmosphere or where the radiant energy can
penetrate to atmospheres containing even minute
amounts of trichloroethylene or perchloroethylene.
7.4 EXPLOSIONS
Do not weld above or near containers under pressure.
l Do not weld in environments containing explosive dusts, gases or vapours.
This welding machine uses inert gases such as CO2,
ARGON, or a mixture of ARGON + CO2 for the protection
5
of the arc, thus you should take special precautions:
A) CYLINDERS
l Do not directly connect cylinder to the machine gas hose
without a pressure regulator.
l Handle or use pressure cylinders in conformity with the
existing rules.
l Do not use leaking or damaged cylinders.
l Do not use cylinders which are not well secured.
l Do not carry cylinders without the protection of the
installed valve.
l Do not use cylinders whose content has not been clearly
identified.
l Never lubricate cylinder valves with oil or grease.
l Do not put the cylinder in electrical contact with the arc.
l Do not expose cylinders to excessive heat, sparks, molten slags or flame.
l Do not tamper with the cylinder valves.
l Do not try to loosen tight valves by means of hammers,
keys, or any other object.
l NEVER DEFACE or alter name, number, or other
markings on a cylinder. It is illegal and hazardous.
l Do not lift cylinders off the ground by their valves or
caps, or by chains, slings or magnets.
l Never try to mix any gases in a cylinder.
l Never refill any cylinder.
l Cylinder fittings should never be modified or exchanged.
B) PRESSURE REGULATORS
l Keep pressure regulators in good condition. Damaged
regulators may cause damages or accidents, they should
only be repaired by skilled personnel.
l Do not use regulators for gases other than those for
which they are manufactured.
l Never use a leaking or damaged regulator.
l Never lubricate regulators with oil or grease.
C)
HOSES
l Replace hoses which appear damaged.
l Keep hoses unwound in order to avoid bending.
l Keep the excess hose wound and out of the working
area in order to avoid any damage.
7.5 RADIATIONS
Ultra-violet radiation created by the arc may
damage your eyes and burn your skin. Therefore:
l Wear proper clothing and helmet.
l Do not use contact lenses!! The intense heat coming
from the arc may cause them to stick to the cornea.
l Use masks with grade DIN 10 or DIN 11 safety lenses at
the least.
l Protect people in the surrounding welding area.
Remember: the arc may dazzle or damage the eyes. It is
considered dangerous up to a distance of 15 meters (50
feet). Never look at the arc with the naked eye.
l Prepare the welding area so as to reduce reflection and
transmission of ultra-violet radiation. Paint walls and exposed surfaces in black to reduce reflection, install
sheathings or curtains to reduce ultra-violet transmissions.
l Replace mask lenses whenever damaged or broken.
7.6 ELECTRIC SHOCK
Electric shock can kill.
All electric shocks are potentially fatal.
l Do not touch live parts.
6
Insulate yourself from the piece to be cut and from the
ground by wearing insulated gloves and clothing.
l Keep garments (gloves, shoes, hats, clothing) and body
dry.
l Do not work in humid or wet areas.
l Avoid touching the piece to be welded.
l Should you work close to or in a dangerous area, use all
possible precautions.
l If you should feel even the slightest electric shock sensation, stop welding immediately. Do not use the machine
until the problem is identified and solved.
l Always fit an automatic wall switch with adequate power,
possibly close to the machine, allowing you to immediately
switch the machine off in case of an emergency.
l Frequently inspect the power supply cable.
l Disconnect power supply cable from mains before replacing cables or before removing unit covers.
l Do not use the unit without protection covers.
l Always replace any damaged parts of the unit, with original material.
l Never disconnect unit safety devices.
l Make sure that the power supply line is equipped with an
efficient earth plug.
l Make sure that the work bench and the workpiece are
connected to an efficient earth plug.
l Any maintenance should only be carried out by qualified
personnel aware of the risks due to dangerous voltages
necessary for the operation of the unit.
l
7.7 PACE MAKER
Magnetic fields from high currents can affect pacemaker
operation. Persons wearing electronic life support equipment (pacemaker) should consult their doctor before
going near arc welding, gouging or spot welding operations.
l
7.8 CAUTION! WELDING WIRE CAN CAUSE PUNCTU
RE WOUNDS.
l Do not press gun trigger until instructed to do so.
l Do not point gun toward any part of the body, other people, or any metal when threading welding wire.
7.9. MOVING PARTS CAN CAUSE INJURY.
Moving parts, such as fans, can cut fingers and hands and
catch loose clothing.
l Keep all doors, panels, covers, and guards closed and
securely in place.
l Have only qualified people remove guards or covers for
maintenance and troubleshooting as necessary.
l Keep hands, hair, loose clothing, and tools away from
moving parts.
l Reinstall panels or guards and close doors when servicing is finished and before starting the machine.
7.10 NOISE
These power source alone do not produce noise
levels exceeding 80 dB. The welding procedure,
however, may produce noise levels in excess of
80 dB. in which case the machine operator must take the
necessary safety precautions as prescribed by the national safety regulation.
ART
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
DESCRIPTION
COVER
RUBBER MAT
FLANGE
SPACER
DRIVE ROLL
WIRE FEED MOTOR
CIRCUIT BOARD
HINGED SIDE PANEL
CLOSING
WASHER
ADAPTOR
PRESSURE SPRING
KNOB
CENTRE DEVIDER
KNOB
RUBBER PROTECTION
ART
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
DESCRIPTION
KNOB
RUBBER PROTECTION
FRONT PANEL
EARTH CABEL
SWIVELLING WHEEL
FIXED SIDE PANEL
COVER
WHEEL
AXLE
SUPPORT
UNDERCARRIAGE
WIRE PRESSURE CLAMP
INPUT POWER CABLE
BACK PANEL
SUPPORT
FITTING
ART
33
34
35
36
37
38
39
40
41
42
43
44
45
46
DESCRIPTION
SOLENOID VALVE
FITTING
BELT
SUPPORT
COIL SUPPORT
SUPPORT
RECTIFIER
REINFORCEMENT
MOTOR
FAN
SWITCH
TRANSFORMER
THERMOSTAT
SUPPORT
7
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