instruction manual for tire telding machine

instruction manual for tire telding machine
INSTRUCTION MANUAL FOR WIRE WELDING MACHINE
IMPORTANT OPERATING INSTRUCTIONS
SAVE THESE INSTRUCTIONS
3.300.898
25/09/03
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 GENERAL DESCRIPTION
1.1 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.
1.2 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
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).
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).
1.3 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 Hlights.
2 DESCRIPTION OF THE MACHINE
I
C
G
L
H
D
B
E
A
F
three-phase transformer-rectifier.
MIG/MAG.
I2 max
U0.
X.
I2.
U2.
U1.
1~ 50/60Hz
3~ 50/60Hz
I1 max
I1 eff
IP21C
2
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 single-phase power supply.
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.
fig. 1
A) Selector switch.
Turns the machine on or off and select the welding
ranges.
B) Wire speed adjuster knob.
Use this knob to set the wire feed speed. This knob is
not active when the extension cable is connected to
the connector D
C) 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.
D) Remote connector.
Connector for the extension cable.
E) Welding torch connector.
Connector for the welding torch (supplied) or the
extension cable.
F) Earth cable.
G) Ammeter.(optional)
The ammeter displays the welding current.
H) Yellow led.
This lights up when the thermostat interrupts welder
operation.
I) Green led.
This lights up when the selector switch (A) is on.
L) Rest time adjusting knob.
By means of this knob you can adyst the rest time
between a spot weld and the other. Such function is
active only when the spot time is on (knob C).
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.
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 2.
Before connecting the power cable 14, 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 A to “O” (off).
The yellow-green wire must be connected to the earth
terminal. Connect the earth clamp 24 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 A.
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.
3.1 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.
• The gas cylinder must not be higher than 1m, to
avoid creating hazardous conditions.
• 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 10/12
liters/minute.
4 WELDING
4.1 SPOT WELDING
For spot welding, replace the gas-weld nozzle with the
special spot-weld nozzle. Exert enough pressure with the
torch to achieve a good junction of metal sheets.
This can be obtained by positioning the knob C on "spottime" and adjusting the spot-welding time through the
knob.
ATTENTION: Metal sheets will have to be perf
4.2 WELDING MILD STEEL
4.2.1 With gas protection.
Either 75% ARGON + 25% CO2 or 100% CO2 may be
used for welding mild steel.
Connect the cables as shown in the figure 2.
Select the welding current by means of the rotary switchl
25. Move the torch near the welding point and press the
trigger.
Adjust the potentiometerl knob 31 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.
3
fig. 2
REMEMBER that cleanliness equals quality.
The wire spools must be stored in plastic bags with a
dehumidifier.
See the figure for correct torch inclination.
4.4 WELDING STAINLESS STEEL.
The welding machine must be prepared as for welding
mild steel with gas protection, but with the following differences:
- Reel of stainless steel wire compatible with the composition of the material to be welded.
- Cylinder containing 98% ARGON + 2% 02 (recommended composition)
The recommended torch angle and welding direction are
shown in figure 4.
For the correct welding angle see figure 4.
4.2.2 Without gas protection.
Connect the cables as shown in the figure 3.
fig. 3
fig. 4
5 MAINTENANCE AND CHECKS.
5.1 GENERAL NOTES.
Use only diam. 0.9-1.2mm flux cored wire that complies
with thestandard AWS AS.20 E71 TII or E71 TGS, suitable
for use without gaseous protection.
Connect the earth cable clamp to the workpiece. After
connecting the cables, follow the instructions given in
paragraph 5.2.1.
NOTE: For compact, well-protected welds always work
from left to right and from top to bottom.
Remove all waste after each welding operation.
For the correct welding angle see figure 4.
4.3 WELDING ALUMINIUM
The welding machine must be prepared as for welding
mild steel with gas protection, but with the following differences:
- 100% ARGON as the protection gas for welding.
- A wire having a composition suited to the base material
to be welded.
For welding ALLUMAN: 3÷5% silicon wire
- For welding ANTICORODAL: 3÷5% silicon wire
- For welding PERALUMAN: 5% magnesium wire
- For welding ERGAL: 5% magnesium wire
Use abrasive grinders and tool brushes specifically
designed for aluminium. Never use these tools on other
materials.
4
· Turn off the welding machine and unplug the power
cord from the socket before each checking and maintenance operation.
Moving parts can cause serious lesions
Keep away from moving parts.
INCANDESCENT SURFACES can cause serious burns.
Let the unit cool before servicing.
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.
When replacing the wire roller, make sure the groove is
aligned with the wire and corresponds to the diameter of
the wire used.
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.
Strictly avoid striking the torch or allowing it to suffer
violent impact.
·
·
·
·
·
·
·
·
5.2 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.
· If the repairs have not been performed by the manufac-
5.2.1 Instructions for performing repairs
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.
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.
After rewinding and/or replacing parts, the no-load voltage must not exceed the values given in paragraph 10.1
of EN 60974.1.
·
·
·
turer, 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.
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.
·
5.3
TROUBLESHOOTING GUIDE.
TROUBLE
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 connections or any
other electrical power connections
Tighten all connections
Voltage adjustment switch has a loose contact
Replace the switch
Improper adjustment of welding parameters
Select the correct parame- ters through the
welding-voltage switch and the wire-speed
adjustment poten-tiometer
Insufficient grounding
Check grounding connections
The wire jams or
entangles
between the
drive rolls and
the torch infeed
wire guide
Contact tip with wrong diameter
Replace
Misalignment of the drive roll groove
Realign
Obstructed or clogged liner
Remove and clean
No wire feed or
irregular wire
feed
Drive roll with too large a groove
Replace the drive roll
Obstructed or clogged liner
Remove and clean
Wire holding roller not completely tightened
Tighten all the way
Clogged contact tip
Replace
Insufficient shielding gas
Increase gas delivery.
Excess oxidation of the edges to be welded.
Thoroughly clean the edges with a metal brush
Gas nozzle partially or completely clogged by
spatter
Remove and clean or replace being careful not
to clog the gas outlets
Welding with a
lot of metal
spatter
Porosity in the
welding seam
5
6 SAFETY PRECAUTIONS
6.1 Fire
·
·
·
·
·
·
·
6.2 Burns
Wear fire-proof clothing all over your body in order to
protect your skin against burns caused by ultraviolet radiation given off by the arc, and from weld metal sparks and
slag.
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.
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.
Avoid oil or greasy clothing. A spark may ignite them.
Hot metal such as electrode stubs and workpieces
should never be handled without gloves.
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.
Ear plugs should be worn when working on overhead or
in a confined space. A hard hat should be worn when others work overhead.
Flammable hair preparations should not be used by
persons intending to weld or cut.
·
·
·
·
·
·
·
6.3 Fumes
Welding operations give off harmful fumes and
metal dusts which may be hazardous to your
health, therefore:
Work in a well-ventilated area.
Keep your head out of fumes.
In closed areas, use suitable exhaust fans.
If ventilation is not enough, use breathing sets approved
for this procedure.
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
6
·
· Avoid causing fire because of sparks, ·
slag, hot metal or pieces.
· Make sure that suitable fire-fighting
equipment is available close to welding area.
Remove all flammable and combustible material from
the welding area and its surrounding (32 ft minimum).
Do not weld containers of combustible or flammable
material, even when empty. These must be carefully
cleaned before being welded.
Allow the welded material to cool down before touching
it or putting it in contact with combustible or flammable
material.
Do not weld parts with hollow spaces, containing flammables.
Do not work under conditions with high concentrations
of combustible vapours, gases, or flammable dust.
Always check the work area half an hour after welding
so as to make sure that no fire has started.
Do not keep any combustible material such as lighters
or matches in your pockets.
·
·
·
·
·
the arc, and create phosgene gas.
Do not weld plated metals or those containing lead,
graphite, cadmium, zink, chrome, mercury or beryllium,
unless you have the proper breathing set.
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.
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.
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.
·
·
6.4 Explosions
Do not weld above or near containers under pressure.
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
of the arc, thus you should take special precautions:
·
A) CYLINDERS
· Do not directly connect cylinder to the machine gas
hose without a pressure regulator.
· Handle or use pressure cylinders in conformity with the
existing rules.
· Do not use leaking or damaged cylinders.
· Do not use cylinders which are not well secured.
· Do not carry cylinders without the protection of the
installed valve.
· Do not use cylinders whose content has not been clearly identified.
· Never lubricate cylinder valves with oil or grease.
· Do not put the cylinder in electrical contact with the arc.
· Do not expose cylinders to excessive heat, sparks,
molten slags or flame.
· Do not tamper with the cylinder valves.
· Do not try to loosen tight valves by means of hammers,
keys, or any other object.
· NEVER DEFACE or alter name, number, or other markings on a cylinder. It is illegal and hazardous.
· Do not lift cylinders off the ground by their valves or
caps, or by chains, slings or magnets.
· Never try to mix any gases in a cylinder.
· Never refill any cylinder.
·Cylinder fittings should never be modified or exchanged.
B) PRESSURE REGULATORS
· Keep pressure regulators in good condition. Damaged
regulators may cause damages or accidents, they should
only be repaired by skilled personnel.
Do not use regulators for gases other than those for
which they are manufactured.
Never use a leaking or damaged regulator.
Never lubricate regulators with oil or grease.
·
·
·
C) HOSES
· Replace hoses which appear damaged.
6.8. Caution!
· Keep hoses unwound in order to avoid bending.
wire can cause puncture wounds.
· Keep the excess hose wound and out of the working Welding
Do not press gun trigger until instructed to do so.
·
area in order to avoid any damage.
· Do not point gun toward any part of the body, other
6.5 Radiations
Ultra-violet radiation created by the arc may
damage your eyes and burn your skin. Therefore:
Wear proper clothing and helmet.
Do not use contact lenses!! The intense heat coming
from the arc may cause them to stick to the cornea.
Use masks with grade DIN 10 or DIN 11 safety lenses
at the least.
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.
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.
Replace mask lenses whenever damaged or broken.
·
·
·
·
·
·
6.6 Electric shock
Electric shock can kill.
All electric shocks are potentially fatal.
Do not touch live parts.
Insulate yourself from the piece to be cut and from the
ground by wearing insulated gloves and clothing.
Keep garments (gloves, shoes, hats, clothing) and body
dry.
Do not work in humid or wet areas.
Avoid touching the piece to be welded.
Should you work close to or in a dangerous area, use all
possible precautions.
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.
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.
Frequently inspect the power supply cable.
Disconnect power supply cable from mains before
replacing cables or before removing unit covers.
Do not use the unit without protection covers.
Always replace any damaged parts of the unit, with
original material.
Never disconnect unit safety devices.
Make sure that the power supply line is equipped with
an efficient earth plug.
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.
·
·
·
·
·
·
people, or any metal when threading welding wire.
6.9. Moving parts can cause injury.
Moving parts, such as fans, can cut fingers and hands
and catch loose clothing.
Keep all doors, panels, covers, and guards closed and
securely in place.
Have only qualified people remove guards or covers for
maintenance and troubleshooting as necessary.
Keep hands, hair, loose clothing, and tools away from
moving parts.
Reinstall panels or guards and close doors when servicing is finished and before starting the machine.
·
·
·
·
6.10 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.
·
·
·
·
·
·
·
·
·
6.7 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.
·
7
8
WIRING DIAGRAM COLOUR CODE
A
B
C
D
E
F
G
H
K
J
I
L
M
N
O
P
Q
R
S
T
U
V
BLACK
RED
GREY
WHITE
GREEN
PURPLE
YELLOW
BLUE
BROWN
AORANGE
PINK
PINK-BLACK
GREY-PURPLE
WHITE-PURPLE
WHITE-BLACK
GREY-BLUE
WHITE-RED
GREY-RED
WHITE-BLUE
BLACK-BLUE
YELLOW-GREEN
BLUE
9
10
5
1
6
7
35
8
2
41 42
4
3
10
13 12
9
40
11
43
14
37
44
36
39
34
38
45
50 49
47
15
9
46
15 52
20
33
21
30 25
32
19
31
29
28
27
26
24
23
22
51
48
16
18
17
pos
DESCRIPTION
pos
DESCRIPTION
01
HINGED SIDE PANEL
27
FRAME
02
WIRE FEED ROLLER
28
RUBBER PROTECTION
03
WIRE FEED MOTOR
29
KNOB
04
COIL SUPPORT
30
RUBBER PROTECTION
05
HINGE
31
KNOB
06
COVER
32
ADAPTOR BODY
07
RUBBER MAT
33
CAP
08
GAS CYLINDER SUPPORT
34
HANDLE
09
BELT
35
CLOSING
10
BACK PANEL
36
KNOB
11
FITTING
37
AMPERMETER
12
SOLENOID VALVE
38
CIRCUIT BOARD
13
FITTING
39
TERMINAL BOARD
14
POWER CORD
40
INSIDE BAFFLE
15
STRAIN RELIEF
41
AUXLIARY TRANSFORMER
16
FIXED SIDE PANEL
42
SUPPORT
17
CAP
43
CONTACTOR
18
FIXED WHEEL
44
SUPPORT
19
AXLE
45
RECTIFIER
20
SUPPORT
46
SHUNT
21
BOTTOM
47
GAS CYLINDER SUPPORT
22
SWIVELING WHEEL
48
CHOKE
23
FRONT PANEL
49
FAN
24
EARTH CABLE
50
MOTOR
25
SWITCH
51
TRANSFORMER
26
CONTROL PANEL
52
THERMOSTAT
When ordering spare parts please always state the machine item and serial number and its purchase data, the spare
part position and the quantity.
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