IMPORTANT: BEFORE STARTING THE EQUIPMENT, ELECTROMAGNETIC COMPATIBILITY

IMPORTANT: BEFORE STARTING THE EQUIPMENT, ELECTROMAGNETIC COMPATIBILITY
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
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
non-iindustrial environments.
IN CASE OF MALFUNCTIONS, REQUEST ASSISTANCE
FROM QUALIFIED PERSONNEL.
2 GENERAL DESCRIPTIONS
2.1 SPECIFICATIONS
This welding machine is a power source made using
INVERTER technology, suitable for synergic pulsed
MIG/MAG welding, non-pulsed synergic MIG/MAG, conventional MIG/MAG.
The equipment may be used only for the purposes
described in the manual.
The equipment must not be used to defrost pipes.
2.2 EXPLANATION OF TECHNICAL SPECIFICATIONS
IEC 60974.1 The welding machine is manufactured
EN 50199 according to these international standards
N°.
Serial number. Must be indicated on any
type of
request regarding the welding machine.
single-phase static frequency converter
1~
transformer-rectifier.
f1
f2
MIG
Suitable for MIG welding.
U0.
X.
Secondary open-circuit voltage.
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 current I2
U1.
Rated supply voltage
1~ 50/60Hz 50- or 60-Hz single-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 curent 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.
IP23 C.
Protection rating for the housing.
Grade 3 as the second digit means that this
equipment is suitable for use outdoors in the
rain.The additional letter C means that the
equipment is protected against access to
the live parts of the power circuit by a tool
(diameter 2.5 mm ).
S
Suitable for use in high-risk environments.
NOTE: The welding machine has also been designed for
use in environments with a pollution rating of 3. (See IEC
664).
9
2.3 PROTECTIONS
3 INSTALLATION
2.3.1 Block protection
In the event of a malfunction, a number with the following
meaning may appear on the display G:
52 =
Start button pressed during start-up.
53 =
start button pressed during thermostat reset.
56 =
Extended short-circuit between the welding
electrode and the material to be welded.
Shut the machine off and turn it back on.
If different numbers appear on the display, contact technical service.
Make sure that the supply voltage matches the voltage
indicated on the specifications plate of the welding
machine.
Mount a plug with an adequate capacity for 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 START-U
UP
2.3.2 Mechanical protection (safety button)
When the movable side is opened, this activates the safety button which prevents operation of the welding
machine. This protection, indicated when the flashing
message "OPn" appears on display G, avoids hazardous
situations when the operator replaces the roller of the
wire feeder unit or the welding electrode.
The machine must be installed by skilled personnel. All
connections must be carried out according to current
regulations, and in full observance of safety laws (regulation CEI 26-10 - CENELEC HD 427)
2.3.3 Thermal protection
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 display G flashes the abbreviation "OPn".
A- Yellow Hold LED
Signals that the current shown on display G is the one
actually used in welding. Activated at the end of each
welding session.
3.2 CONTROLS ON THE FRONT PANEL.
G
A
B
®
INVERTER
5
MIG 2035 / M
C
PULSE
SINERGIC
6
5
7
7
4
3
8
3
8
2
9
2
9
1
Art.
MIG
PULSE
A
6
4
MIG
H
888
HOLD
1
10
I
10
V
285
L
M
D
4
6
7
4
3
8
3
2
9
2
1
E
5
6
88
7
8
9
1
10
P
F
5
2
10
1
0
1
O
2
3
3
4
4
5
N
5
P
Q
R
S
Fig. 1
10
B- Wire speed adjustment knob.
By adjusting this knob:
• when conventional programs are used, the display G
shows the speed in meters per minute.
• when synergic programs are used (pulsed or conventional), the display G shows the current at which welding
will take place.
• when pulsed synergic programs are used, the display Q
shows, for approximately 2 seconds, the recommended
thickness for the current being set; after which it returns
to displaying the number of the selected welding program.
C - Green LED.
Signals activation of the spot or dash welding mode when
lit together with LED M.
D - Setting knob.
This knob adjusts the spot welding or working time during dash welding.
E - Central adapter
This is where the welding torch is to be connected.
F - Earth socket
Grounding cable socket.
G - 3-d
digit display
This display shows:
• when selecting synergic programs (button R), the type
of material corresponding to the program selected (FE =
Iron, AL = Aluminium, SS = Stainless steel).
• in conventional programs, before welding, the wire
speed and current after welding.
• in synergic programs, before welding, the speed or preset current, and after welding the actual current used.
• in conventional and pulsed or conventional synergic
programs, the variations in arc length (knob I) and variations in impedance (knob P) from the recommended zero
position.
• the abbreviation "OPn" (flashing) if the motor compartment door is opened.
• the message "OPn" (flashing) if the thermostat is
tripped.
• in the service functions (see chapter 5 for further clarification) displays the messages: dSP, Job, PrF, PoF, Acc,
bb, HSA, SC, Len, Slo, 3L, CrC, 2-4.
• in the memory menu the letter P followed by two digits
representing the memory number. Read chapter 6 for further clarification.
H - Green LED.
Signals that the program used for welding is pulsed synergic.
I - Setting knob.
Adjusts the welding voltage in conventional programs.
Range from 1 to 10
In synergic and pulsed synergic programs, the indicator
of this knob must be set to the "SYNERGIC " symbol in
the center of the setting range; this symbol represents the
setting recommended by the manufacturer. Adjusting this
knob allows you to correct the arc length value. Changes
to this figure, greater than or less than the "SYNERGIC"
setting, are shown on the display G, which will show the
previous size 2 seconds after the last correction.
L - Green LED.
Indicates that continuous welding mode is activated.
M - Green LED.
Indicates that dash welding mode is activated. It lights
together with LED C.
N - Setting knob.
This knob adjusts the pause time between spot welds.
O - Key.
Pressing and releasing this key increases the numerical
value of the display Q.
When pressed together with the key R, allows selection of
the service and memory functions and saves programs.
(See chapter 6)
P- Setting knob.
In conventional programs adjustment from 1 to 10
This knob adjusts the impedance value.
For each synergic program, the optimum value is position
0. The machine automatically sets the correct impedance
value based on the program selected. The operator may
correct the set value: adjusting the potentiometer
towards + will produce warmer, less penetrating welds,
while vice-versa adjusting towards - will produce colder
and more penetrating welds
When welding with a synergic program, adjusting + or from the central 0 may require corrections to the working
voltage using the potentiometer I.
The variation is shown on the display G, which shows the
previous setting 2 seconds after the last correction.
Q - 2-d
digit display.
This display shows:
• the number of the selected program.
• for 2 seconds, the value of the thickness when knob B
is adjusted in pulsed synergic programs.
• within the service functions, the numerical value of the
figure shown on the display G or the messages "On, OF,
Au, A, SP, 0, 1, 2, 4". Read chapter 5 for further clarification.
• in the memory menu, indicates the program number to
which the memory save or recall refers. Read chapter 6
for further clarification.
R - Key.
Pressing and releasing this key reduces the numerical
value of the display Q.
When pressed together with key O, it allows the user to
select the service and memory functions. (See chapters
on the functions listed)
S - 10-p
pin connector.
This connector must be connected to the 10-pin male of
the Pull 2003 torch.
11
3.3 CONTROLS ON THE REAR PANEL
4 WELDING
4.1 Start-u
up
®
T
Via A.Costa, 24 - 40057-Cadriano-Bologna-Italy
1~ f1
f2
64V
EN 60974-1
X(40°C) 35% 60% 100% EN 50199
I2
200A 160A 145A
U2
24V
U1 230V 50/60 Hz
Nº
0
MIG 2035/M Art.
285
PULSE
15A/14,7V-200A/24V
U0
V
Make sure that the wire diameter corresponds to the
diameter indicated on the wire feeder roller, and that the
selected program is compatible with the material and
type of gas. Use wire feeder rollers with a "U"-shaped
groove for aluminum wires, and with a "V"-shaped groove
for other wires.
22V 21,2V
I1max = 32A
I1eff = 20A
S
IP 23C
MADE IN ITALY
1
U
V
V
4.1.1 Connecting the gas hose
The gas cylinder must be equipped with a pressure regulator and flow gauge.
If the cylinder is placed on the cylinder shelf of the wire
feeder, it must be fastened using the chain provided.
Connect the gas hose leaving the rear of the machine to
the pressure regulator, only after positioning the cylinder.
The gas flow must be adjusted to approximately 8-10
liters per minute.
4.2 THE MACHINE IS READY TO WELD
When using the Pull-2003 type torch, follow the instructions enclosed with the torch.
• Connect the earth clamp to the workpiece.
• Set the switch U to 1.
• Choose the program to be used from the list provided
in an envelope on the mobile side panel (Fig. 4).
Fig. 2
T - Gas hose fitting.
U-S
Switch.
Turns the machine on and off.
V- Points for attaching the 15Kg coil kit Art. 129
3.4 CONNECTOR TYPE DB9 (RS 232) (Fig. 3)
To be used for updating the microprocessor programs.
Fig. 4
W
Fig. 3
12
• Display the number corresponding to the program on
display Q using the keys O and R.
• If a pulsed synergic program is used, turn the knob B
until the display Q shows the thickness you will be using.
At the same time the display G shows the current for the
selected thickness.
• If a synergic program is used, make sure that the indicator of the knobs I and P show the message "SYNERGIC" and the scale zero, respectively.
• Remove the gas nozzle.
• Unscrew the contact tip.
• Insert the wire in the wire liner of the torch, making sure
that it is inside the roller groove and that the roller is in the
correct position. Then close the door.
• Press the torch trigger to move the wire forward until it
comes out of the torch.
Caution: keep your face away from the gun tube assembly while the wire is coming out.
• Screw the contact tip back on, making sure that the
hole diameter is the same as that of the wire used.
• Assemble the gas nozzle.
• Open the cylinder
4.3 WELDING CARBON STEEL
In order to weld these materials you must:
• Use a welding gas with a binary composition, usually
ARGON + CO2 with percentages of Argon ranging from
75% upward. With this blend, the welding bead will be
well jointed and attractive.
Using pure CO2 as a protection gas will produce narrow
beads, with greater penetration but a considerably
increase in splatters.
• Use a welding wire of the same quality as the steel to
be welded. It is best to always use good quality wires,
avoiding welding with rusted wires that could cause
welding defects.
• Avoid welding rusted parts, or those with oil or grease
stains.
4.4 WELDING STAINLESS STEEL
Series 300 stainless steels must be welded using a protection gas with a high Argon content, containing a small
percentage of O2 or carbon dioxide CO2 (approximately
2%) to stabilize the arc.
Do not touch the wire with your hands. It is important to
keep the welding area clean at all times, to avoid contaminating the joint to be welded.
4.5 WELDING ALUMINUM
In order to weld aluminum you must use:
• Pure Argon as the protection gas.
• A welding wire with a composition suitable for the base
material to be welded.
• Use mills and brushing machines specifically designed
for aluminum, and never use them for other materials.
• For welding aluminum you must use the torch: PULL
2003 Art. 2003.
5 SERVICE FUNCTIONS
The abbreviations of these functions are shown on the
display G.
From within this menu, the operator may customize the
machine according to his needs.
To enter these functions press the key R and, while holding it down, briefly press and release the key O; release
the key R when the message "dSp" appears.
The same movement is used to exit these functions and
return to the welding programs.
Press the torch trigger to switch from one function to
another.
Exiting the service functions confirms the changes made.
CAUTION. Welding is not possible from within the service
functions.
5.1 DESCRIPTION OF THE FUNCTIONS
• dSp (display)
Active only in pulsed synergic welding programs.
The display Q reads "A," which means that the display G
in normal conditions displays the Amperes. Pressing the
key O causes display Q to show SP (speed). This selection, in welding conditions, will make display G show the
wire speed in meters per minute.
NOTE: The speed will be shown before welding, because
after welding the display G shows the current used and
LED A remains lit.
• Job
Active in all welding programs.
The display Q reads "0", LED L is lit, and the machine is
ready for continuous welding.
Pressing the key O causes LED L to shut off, and display
Q reads "1"; LEDs C and M light, and the machine is
ready for dash welding.
Pressing the key O again makes the display Q read "2";
LED M shuts off and LED C remains lit, indicating that the
machine is ready for spot-welding.
automatic)
• 2 - 4 (manual-a
The display Q shows the number 2 = two-stage = manual welding
If the key O is pressed, display Q shows the number 4 =
4-stage = Automatic.
• (HSA) Automatic Hot Start
Active only in pulsed synergic welding programs .
Caution: If the function HSA is activated, the function 3L
is automatically not included.
Display Q shows the message OF =OFF = Off
Pressing the key O causes the display Q to show the
message On = Active.
If this function is activated, pressing the torch trigger
causes the following messages to appear in sequence:
-S
SC (Start current)
Range 1-20 (10-200%) of the wire speed corresponding to the welding current set using knob B in
the welding programs. Manufacturer setting 13
(130%). Changed using keys O and R.
-L
Len (Duration)
This is the duration, expressed in seconds, of the previously displayed start current.
Range 0.1-10 sec., manufacturer setting 0.7.
Changed using keys O and R.
-S
Slo (Slope)
Range 0.1-10 sec., manufacturer setting 0.5.
Changed using keys O and R.
Defines the interface time between the first current
(SC) and the welding current set using knob B in the
welding programs.
How it works in practice:
Welding takes place in manual mode (two stages).
The operator begins welding with the current corresponding to the percentage greater than or less than
the wire speed set in SC (in this specific instance,
30% higher). This current will have a duration, in seconds, corresponding to the time set in Len (in this
specific instance, 0.7 sec), after which the current will
13
drop to the current set using knob B (welding) in the
time set with Slo (in this specific instance, 0.5 sec).
We recommended this function for spot welding
sheet aluminium.
If this function is not activated, pressing the torch trigger
activates the function:
• 3L (three levels)
Active in pulsed synergic curves
Caution: If the function 3L is activated, the function HSA
is automatically not included.
Display Q shows the message OF =OFF = Off
Pressing the key O causes the display Q to show the
message On = Active.
If this function is activated, pressing the torch trigger
causes the following messages to appear in sequence.
-S
SC (Start current)
Range 1-20 (10-200%) of the wire speed corresponding to the welding current set using knob B in the
welding programs. Manufacturer setting 13 (130%).
Changed using keys O and R.
-S
Slo (Slope)
Range 0.1-10 sec., manufacturer setting 0.5.
Changed using keys O and R.
Defines the interface time between the first current
(SC) and the welding current set using the knob B in
the welding programs, and between the welding current and the third "crater filler" current CrC.
-C
CrC "Crater filler" current
Range 1-20 (10-200%) of the wire speed corresponding to the welding current set using knob B in the
welding programs. Manufacturer setting 6 (60%).
Changed using keys O and R.
How it works in practice:
Welding takes place in automatic mode, thus the execution times are decided by the operator.
Especially recommended for MIG welding of aluminium.
Three currents are available, which may be called up
during welding using the torch start button.
Welding begins when the torch button is pressed. The
welding current used will be the one set using the SC
function (in this specific instance 13 =130%). This
current will be kept for as long as the torch trigger is
held down; when released, the first current changes
to the welding current, set with the knob B, within the
time established by the Slo function (in this specific
instance, 0.5 sec.), and will be kept until the torch
trigger is pressed again. The next time the torch trigger is pressed, the welding current will switch to the
third or "crater-filler" current, set with the function
CrC (in this specific instance, 6 = 60%), in the time
established by the function Slo (in this specific
instance, 0.5 sec), and will be maintained as long as
the torch trigger is held down. Welding stops when
the trigger is released.
If this function is not activated, pressing the torch trigger
activates the next function.
gas)
• PrF (Pre-g
Active in all welding programs.
Range 0.0 - 9.9 sec. Setting 0.1 sec. Changed using keys
O and R.
14
gas)
• PoF (post-g
Active in all welding programs.
Range 0.1 - 9.9 sec. Setting 3.0 sec. Changed using keys
O and R.
• Acc (Soft Start)
Active only in pulsed synergic welding programs .
Range Auto - 1-99%
This is the wire speed, expressed as a percentage of the
speed set for the welding, before the wire touches the
workpiece.
Note: This adjustment is important in order to always
achieve good starts.
Manufacturer setting "Au" automatic.
Changed using keys O and R. If, after changing, you wish
to return to the manufacturer setting, press keys O and R
simultaneously until the abbreviation "Au" appears on
display Q.
back)
• bb (Burn-b
Active in all welding programs.
Range 00 - 99. Manufacturer setting "Au" automatic.
Serves to adjust the length of the wire leaving the gas
nozzle after welding. The higher the number, the more the
wire burns.
• PPF (Push Pull Force)
Adjusts the drive torque of the push-pull torch motor.
Serves to make the wire advance in a linear fashion.
Range 9/-9, manufacturer setting 0.
Changed using keys O and R.
6 SAVING AND CALLING UP MEMORIES
Ten memory slots are available, from P01 to P10.
• To save, weld a small section using the parameters you
wish to save, then:
-Press the key R and, holding it down, press the key
O until the flashing abbreviation P01 appears on the
display G, then release the buttons.
NOTE: The flashing abbreviation indicates free programs, those that do not flash are saved programs.
Display Q indicates the number of the program to
which that saved welding program refers.
-Use the keys O and R to choose the program number to save, then press the key O until the program
abbreviation no longer flashes.
-Release the key O to exit saving.
-Should you intend to overwrite a program, when the
button O is held down for longer than 3 sec, the number starts flashing, then returns to steady mode to
signal overwriting.
Overwriting must take place while the display G
shows the program number (5 sec).
• To call up a saved program, repeat the same steps
described above
(keys R and O held down until the abbreviation PXX
appears); the last program saved appears. Five seconds
after the last time the keys R and O are pressed, the
machine is ready to weld.
Before welding with a saved program, display G shows its
number. When welding begins display G shows the cur-
rent, and when it ends LED A lights. All knobs are disabled.
To see the setting of the service function related to the
saved program, press the key R and hold it down; after 2
sec. the display G shows the first message dSP. Pressing
the torch trigger will display the abbreviations of the various functions in sequence, and display Q shows the setting.
To return to welding with a saved program, release the
key R.
To exit saved programs, press the key R and, while holding it down, briefly press and release the key O.
7 MAINTENANCE
• Safety gas nozzle
This nozzle must be periodically cleaned to remove splattered 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.
B) Splattered 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, 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.
8 ACCESSORIES
Art. 1434
Wire feeder.
Art. 1242 Torch 3.5mt
Art. 129
Kit for coil diameter 300 Kg 15
Art. 2003 Pull 2003 torch with UP/DOWN command
on grip.
15
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