IMPORTANT: BEFORE STARTING THE EQUIPMENT, instructions contained in the harmonized standard

IMPORTANT: BEFORE STARTING THE EQUIPMENT, instructions contained in the harmonized standard
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. For more detailed information, order the
manual code 3.300.758
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
6
instructions contained in the harmonized standard
EN50199, and must be used solely for professional purposes in an industrial environment. There may be potential difficulties in ensuring electromagnetic compatibility in nonindustrial environments.
IN CASE OF MALFUNCTIONS, REQUEST ASSISTANCE
FROM QUALIFIED PERSONNEL.
2 GENERAL DESCRIPTION
This power source must be used exclusively for welding,
and must be located in a suitably ventilated and preferably non-dusty environment, being careful not to block
the flow of air through the cooling fins.
The weight of this welding machine is 22.5 kg.
2.1 SPECIFICATIONS
This manual has been prepared for the purpose of educating personnel assigned to install, operate and service
the welding machine.
This equipment is a constant-voltage power source, suitable for MIG/MAG and OPEN-ARC welding.
Upon receiving the machine, make sure there are no broken or damaged parts.
The purchaser should address any complaints for losses
or damage to the vector. Please indicate the article and
serial number whenever requesting information about the
welding machine.
2.2 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.
Flat characteristic.
Suitable for continuous electrode welding.
Unconventional welding current.
The values represent the minimum and
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
3~ 50/60Hz 50- or 60-Hz three-phase power supply.
I1 Max
Max. absorbed current at the corresponding
current I2 and voltage U2.
I1 eff
This is the maximum value of the actual
current absorbed, considering the duty
cycle.
This value usually corresponds to the
capacity of the fuse (delayed type) to be
used as a protection for the equipment.
IP21
Protection rating for the housing.
MIG/MAG.
I2 max.
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).
2.3 OVERLOAD CUT-O
OUT
This machine is protected by a thermostat, which prevents the machine from operating if the allowable temperatures are exceeded. In these conditions the fan continues to operate and the lamp D lights.
D) Yellow lamp.
Lights only when the thermostat stops welding
machine operation.
E) Earth cable.
F) Welding torch.
4 START-U
UP AND WELDING STEEL WITH FLUXCORED WIRE WITHOUT GAS PROTECTION.
Open the coil compartment and remove the wire from
inside the torch, used for the final machine inspection.
Remove the casing protecting the wire.
3 INSTALLATION
The machine must be installed by skilled personnel. All
connections must be carried out in compliance with and
in full observance of current safety laws.
Make sure that the supply voltage matches the voltage
indicated on the specifications plate of the welding
machine.
If it is not already mounted, mount a plug with an adequate capacity on the supply cable, making sure that the
yellow/green conductor is connected to the earth pin.
The capacity of the overload cutout switch or fuses
installed in series with the power supply must be equivalent to the absorbed current I1 of the machine.
3.1 CONTROLS ON THE FRONT PANEL.
E
F
D
A
5
4
B
Remove the wire from the coil hole and cut as much as
needed for the end to be straight, insert the wire into the
plastic tube of the gearmotor, passing it over the wire feeder roller and inserting it in the torch sheath for at least 30 cm.
Make sure that the wire feeder roller groove is compatible
mm flux-c
cored wire must
with the wire used. The Ø 0.9-m
be drawn using the knurled groove marked 0.8.
To replace the wire feeder roller, proceed as shown in the
figure.
1
6
7
2
3
8
2
9
1
C
3
10
4
REVOLUTION
A) Setting knob.
Adjusts the welding wire speed.
B) Selector switch.
Adjusts the welding voltage.
C) Switch.
Turns the welding machine on and off.
0
I
Lower the roller press arm, making sure that the wire
remains inside the roller groove.
After connecting the mains cable to a suitable power
socket, turn on the welding machine using the switch 32.
Remove the gas nozzle 39 by turning it clockwise,
unscrew the contact tip 40 from the welding torch 27.
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Set the selector switch 37, located inside the coil
compartment, to NO GAS.
Make sure that the earth cable 26 and the power cable of
the torch 27 are correctly inserted on the terminal board
29, so that they observe the correct polarity (see figure).
Press the torch trigger until the wire comes out the end.
Be very careful never to aim the torch at parts of the body
or other people while wire is coming out of the torch.
Screw the contact tip 40 back on, making sure that the
hole diameter is equal to that of the wire used. Insert the
gas nozzle 39, again turning it clockwise.
Use the selector switch 35 to select the welding voltage
according to the thickness to be welded: position 1 will weld
thicknesses of approximately 1mm, while position 4 is for
4/5mm. Connect the earth cable 26 to the workpiece.
Move the torch close to the welding point, position the
safety mask over your eyes, light the welding arc by
pressing the torch trigger 27.
In order to have a stable arc you must keep the gas nozzle as close as possible to the workpiece and adjust the
proper wire speed wire using the knob 2, so that the noise
of the arc is continuous, even and constant.
If the speed is too high the wire tends to stick to the
piece, while vice-versa, if the speed too low the wire
melts into occasional droplets and the arc tends to shut
off often.
At the end of each welding session, remove all waste
using the hammer/brush provided.
For proper welding, adopt the position shown in the figure.
Welding with the Ø 0.9mm flux-cored wire does not
require gas protection and is therefore suitable for out-
door welding.
4.1 WELDING STEEL WITH SOLID WIRE AND GAS
PROTECTION.
To weld steel, you may use blends of inert gases containing Argon and percentages of Co2 ranging from 25% to
18%, or pure Co2. Using Co2 alone will produce metal
splatters while welding, and is therefore not recommended for jobs where appearances are important.
The gas cylinder must be equipped with a pressure regulator and flow gauge.
If the cylinder is located on the cylinder shelf of the wire
feeder art. 1432, it must be fastened using the chain provided. Connect the gas hose leaving the rear of the
machine to the pressure regular, only after positioning the
cylinder.
The gas flow must be adjusted to approximately 8-10
liters/minute.
See paragraph 4 for instructions on mounting the wire
inside the torch and the welding technique to be used.
This power source uses wires Ø 0.6mm and Ø 0.8mm.
You may weld thicknesses ranging from a minimum of
0.6mm to a maximum of 4/5mm.
Set the selector switch 37, located inside the coil
compartment, to GAS.
Make sure that the earth cable 26 and the torch 27 are
correctly inserted on the terminal board 29, so that they
observe the correct polarity (see figure).
Welding carried out using gas does not produce waste,
and may not be carried out in drafty environments.
4.2
WELDING STAINLESS STEEL
The welding machine must be set up as for welding steel
with gas protection, applying the following variations:
- Coil of stainless steel wire with a composition suited to
the base material to be welded.
- Argon gas and a percentage of O2 2% (recommended
composition).
This power source uses a wire Ø 0.6mm.
It is possible to weld thicknesses ranging from a minimum of 1 mm to a maximum of 3 mm.
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4.3
WELDING ALUMINUM
The welding machine must be set up as for welding steel
with gas protection, applying the following variations:
- Argon gas.
- Coil of aluminum wire with a composition suited to the
base material to be welded.
For welding aluminum it is important that the base material be cleaned with tools that have only been used on
aluminum.
This power source uses a wire Ø 0.8mm.
It is possible to weld thicknesses ranging from a minimum
of 1 mm to a maximum of 3 mm.
5 WELDING DEFECTS
1- DEFECTCAUSES
2- DEFECTCAUSES
3- DEFECTCAUSES
4- DEFECTCAUSES
Porosity (within or outside the bead)
•Electrode defective (rusted surface)
• Missing safety gas due to:
- low gas flow
- flow gauge defective
- regulator frosted due to no preheating
of the CO2 protection gas
- defective solenoid valve
- contact tip clogged with sprays
- gas outlet holes clogged
- air drafts in welding area.
Shrinkage cracks
• Wire or workpiece dirty or rusted.
• Bead too small.
• Bead too concave.
• Bead too deeply penetrated.
Side cuts
• Welding pass done too quickly
• Low current and high arc voltages.
Excessive spraying
• Voltage too high.
• Insufficient inductance.
• No preheating of the CO2 protection
gas
using dry compressed air.
The liners are subjected to constant wear and tear, and
therefore must be replaced after a certain amount of time.
Gearmotor group. Periodically clean the set of feeder
rollers, to remove any rust or metal residue left by the
coils. You must periodically check the entire wire feeder
group: hasp, wire guide rollers, liner and contact tip.
7 ERRORS DURING USE
NOTE: All tasks should be carried out only by skilled personnel.
Disconnect the power supply cable from the mains before
working on the cables or opening the machine.
The machine is equipped with a safety thermostat that
trips in case of overload. You must wait a few minutes
after this intervention to allow the source to cool.
The table below lists the most common errors, causes
and solutions.
8
ACCESSORIES
Art. 1432 Power source trolley.
Art. 1450 Flow meter with 2 pressure gauges.
Art. 1475 Coil of copper-coated Fe wire Ø 0.6/5 kg .
Art. 1477 Coil of copper-coated Fe wire Ø 0.8/5 kg .
Art. 1580 Coil of copper-coated Fe wire Ø 0.6/0.8 kg.
Art. 1581 Coil of copper-coated Fe wire Ø 0.8/0.8 kg.
Art. 1582 Coil of Aluminium wire Ø 0.8/0.2 kg.
Art. 1583 Coil of Stainless steel wire Ø 0.6/0.5 kg.
Art. 1586 Coil of Flux-cored wire Ø 0.9/0.9 kg.
Art. 1587 Coil of Flux-cored wire Ø 0.9/4.5 kg.
Art. 1457 Contact tip Ø 0.6.
Art. 1459 Contact tip Ø 0.8.
Art. 1462 Contact tip Ø 0.9 flux-cored wire.
Art. 1461 Welding gas nozzle.
Art. 1463 Spot-welding gas nozzle.
6 MAINTAINING THE SYSTEM
Safety gas nozzle . This nozzle must be periodically
cleaned to remove sprayed metal. Replace if distorted or
squashed.
Contact tip. Only a good contact between this contact tip
and the wire can ensure a stable arc and optimum current
output; you must therefore observe the following precautions:
A) The contact tip hole must be kept free of grime and
oxidation (rust).
B) Sprayed metal sticks more easily after long welding
sessions, blocking the wire flow. The tip must therefore
be cleaned more often, and replaced if necessary.
C) The contact tip must always be firmly screwed onto
the torch body. The thermal cycles to which the torch is
subjected can cause it to loosen, thus heating the torch
body and tip and causing the wire to advance unevenly.
Wire liner. This is an important part that must be checked
often, because the wire may deposit copper dust or tiny
shavings. Clean it periodically along with the gas lines,
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