instruction manual for wire welding machine

instruction manual for wire welding machine
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.
FOR THE DIMENSIONS AND WEIGHT OF THIS WELDING
MACHINE, SEE THE SPECIFIC CATALOGUE.
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-industrial environments.
IN CASE OF MALFUNCTIONS, REQUEST ASSISTANCE
FROM QUALIFIED PERSONNEL.
2 GENERAL DESCRIPTION
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°
indi-
The welding machine is manufactured
according to these international standards.
serial number, which must always be
cated on any type of request regarding
the welding machine.
three-phase transformer-rectifier.
MIG/MAG.
I2 max
U0.
X.
I2.
U2.
U1.
3~ 50/60Hz
I1 max
I1 eff
IP21C
Flat characteristic.
Suitable for continuous electrode welding.
Unconventional welding current.
This value represents the max. limit
attainable in welding.
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.
Welding current
Secondary voltage with welding current I2.
Rated supply voltage
50- or 60-Hz three-phase power supply.
Maximum absorbed current value.
This is the maximum value of the actual
current absorbed, considering the duty
cycle.
Protection rating for the housing.
Grade 1 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 supply circuit
by a tool (diameter 2.5 mm).
7
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
60664).
2.3 Overload cut-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 F lights.
3 INSTALLATION
• Only skilled personnel should install the machine .
• All connections must be carried out according to
current regulations, and in full observance of safety
laws.
Make sure that the supply voltage corresponds to the
value indicated on the power cable. If it is not already fitted, connect a plug suited to the power 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 max. of the machine.
3.1.1 Assembling the cooling unit (optional).
Remove the 2 cylinder supports A fastened to the rear
panel B of the weldA
ing machine.
E
B
Unscrew the 2
knobs C, slide the
mobile cylinder support D back, mount
the cooling unit supF
port E on the rear
panel B and screw
the mobile cylinder
C
support D back in
using the 2 knobs C
on the bottom F of
the
welding
fig. 2
machine. (See fig.2).
D
Fasten the cooling
unit to the support E on the rear panel B and to the base
F. (See fig.3).
E
3.1 PLACEMENT
Mount the handle, rear wheels and the two cylinder supports.
The handle must not be used for lifting the welding
machine.
Place the welding machine in a ventilated area.
Dust, dirt, and any other foreign matter entering the welding machine can interfere with ventilation and thus with
smooth operation.
Therefore, in relation to the environment and working
conditions, it is important to keep the internal parts clean.
Clean using a jet of dry, clean air, being careful to avoid
damaging the machine in any way.
Before working inside the welding machine, make sure it
is unplugged from the power mains.
Any intervention carried out inside the welding
machine must be performed by qualified personnel.
fig. 1
8
B
F
fig. 3
Once the cooling unit is attached, insert the 2 red and
blue water hoses leaving
the connection into the
corresponding quick fitA tings G of the unit, being
especially careful to
I
match the colors, the
H
power connection O into
M
the socket P, the service
N connection Q into the
L
socket R, the power cord
Q
H of the unit into the
R
socket I on the power
P
source, and the service
O
connection L into the
connector M on the welding machine.
G
Remount the 2 cylinder
supports A on the panel
fig. 4
N of the cooling unit. (See
fig.4).
3.2
INTERNAL CONNECTIONS
• Any intervention carried out inside the welding
machine must be performed by qualified personnel.
• Before working inside the welding machine, make sure
that the plug is disconnected from the power mains.
• After final inspection, the welding machine is connected to the voltage indicated on the power supply
cable.
• To change the supply voltage, remove the right side
panel and arrange the voltage change terminal board
4 DESCRIPTION OF CONTROLS
4.1 CONTROLS ON THE FRONTOF THE MACHINE.
0
BRAVO
SYNERGIC
C
1
V
1
8
A
2
2
7
3
6
1
3
4
B
4
5
ART.
Nº
3
I2max.
=
450A
U0
MIG-MAG
45V
615
EN 50199-IEC 60974-1
40A/16V - 400 A/34 V
X
I2
40% 60%
400 A 330 A
U2
34 V 30,5 V
3~
100%
U1 230V I1max= 49A
50/60Hz
250 A
U1 400V I1max= 28A
26,5 V
MADE IN ITALY
S
I1eff= 31A
I1eff= 18A
IP 21C
MIG 4540 / TS
fig. 5
connections as shown in the figure 5.
• The supply voltage may not be changed on singlephase power sources.
• Do not use the welding machine without its cover or
side panels for obvious safety reasons, and to avoid altering the cooling conditions for internal components.
D
3.3 EXTERNAL CONNECTIONS
3.3.1 Connecting the mass clip.
• - Connect the earth cable terminal to the socket V of the
welding machine, and connect the earth clamp to the
workpiece.
3.3.2 Cylinder placement and connecting the gas hose
• Position the cylinder on the cylinder holder of the welding machine, using the straps provided to fasten it to the
rear panel of the machine.
• Periodically check for wear on the straps, and order
replacements if necessary.
• The cylinder must be equipped with a pressure regulator complete with flow gauge.
• Only after positioning the cylinder, connect the outgoing
gas hose from the rear panel of the machine to the pressure regulator.
• Adjust the gas flow to approximately 10/18
liters/minute.
3.3.3 Connecting the wire feeder
This power source accepts the wire feeders Art.1652 and
Art. 1654.
To connect the power source and wire feeder, use the
extension Art. 1182 (5 m) or Art. 1182.20 (10 m).
The performance and operating options of the wire feeder are described in the instructions enclosed with the wire
feeder itself.
fig.6
A - Selector switch
Fine-tunes the welding voltage within the range previously selected via selector switch
S.
1
8
2
7
3
6
4
5
B- Selector switch
2
1
Select the ranges of welding
voltage.
3
4
9
C - Switch
Turns the machine on or off.
0
1
V
D- Earth sockets.
Sockets to which to connect the earth cable.
4.2 CONTROLS ON GENERATOR REAR PANEL
fig.7
5 WELDING
5.1 Installation
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.
5.2 THE MACHINE IS READY TO WELD
• Connect the earth clamp to the workpiece.
• Set the switch Q to 1.
• 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.
• 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.
5.3 WELDING CARBON STEELS WITH GAS
PROTECTION.
E
H
F
G
E - 230V power supply socket.
440 W max. power. For cooling unit only. (Warning: Do not
connect other equipment to this socket.).
F - 6-pin socket connector.
For the 6-pin plug connector on extension lead.
G - Socket.
For the extension lead power supply connector (‘+’ pole).
H - Socket.
For connection to the safety device on the cooling unit.
N.B. If no cooling unit is used with the machine, plug the
connector supplied with the machine into the socket H.
10
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% up. 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.
5.4 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.
5.5 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.
6 WELDING DEFECTS
8 ACCESSORIES
1 DEFECT- Porosity (within or outside the bead)
CAUSES
• Electrode defective (rusted surface)
• Missing shielding 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 spatter
- gas outlet holes clogged
- air drafts in welding area.
2 DEFECT - Shrinkage cracks
CAUSES
• Wire or workpiece dirty or rusted.
• Bead too small.
• Bead too concave.
• Bead too deeply penetrated.
3 DEFECT - Side cuts
CAUSES
• Welding pass done too quickly
• Low current and high arc voltages.
4 DEFECT - Excessive spraying
CAUSES
• Voltage too high.
• Insufficient inductance.
• No preheating of the CO2 protection gas
Art. 1680 Cooling unit.
Art. 1652 Wire feeder with 2 rollers
Art. 1654 Wire feeder with 4 rollers
Art. 1182 Connection (5 m) between power source and wire
feeder
Art. 1182.20 Connection (10 m) between power source and
wire feeder
7 MAINTAINING THE SYSTEM
• Shielding gas nozzle
This nozzle must be periodically cleaned to remove weld
spatter. 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) Weld spatter 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.
11
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