USER MANUAL TM 236 PULSE SYNERGIC/GEN

USER MANUAL TM 236 PULSE SYNERGIC/GEN
USER MANUAL
TM 236 PULSE SYNERGIC/GEN
910.100.335GB REV01
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Fimer SpA
Via Brigatti, 59
20050 RONCO BRIANTINO
(MILAN) Italy
Tel. +39 0396079326
Fax. +39 0396079334
www.fimer.com
[email protected]
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USER AND MAINTENANCE MANUAL
Firmer S.p.A. would like to thank you for choosing this welding machine: if used according to the instructions reported in
this user and maintenance manual, it will accompany you in your work for many years without any problem.
The manual is an integral part of the equipment and must always accompany the machine each time it is moved or
resold.
The user is responsible for making sure the machine is complete and in good working order.
Fimer S.p.A. has the right to make changes at any time and without notice.
The rights of translation, reproduction and adaptation, in whole or in part and with any means (including scanned
documents, copies, film and microfilm) are reserved and prohibited without Fimer’s written authorisation.
TABLE OF CONTENTS
DECLARATION OF CONFORMITY ............................................................................................................. 4 NOMINAL DATA ............................................................................................................................................ 5 TECHNICAL SPECIFICATIONS.................................................................................................................... 6 IMPORTANT INSTRUCTIONS ...................................................................................................................... 7 1. GENERAL FEATURES AND NOTES ON CONSULTING THE MANUAL ......................................... 10 2. DESCRIPTION OF THE MACHINE......................................................................................................... 12 3. DESCRIPTION OF THE VARIOUS TYPES OF WELDING................................................................... 15 3.1 MIG/MAG WELDING............................................................................................................15 3.1.1 MANUAL SHORT-ARC MIG WELDING .....................................................................16 3.1.2. SYNERGIC SHORT ARC MIG WELDING..................................................................18 3.1.3 MANUAL PULSED MIG WELDING.............................................................................20 3.1.4 SYNERGIC PULSED MIG WELDING ..........................................................................21 3.2 TIG WELDING .......................................................................................................................24 3.2.1TRADITIONAL TIG WELDING .....................................................................................25 3.2.2 PULSED TIG WELDING ................................................................................................26 3.3 MMA WELDING ....................................................................................................................27 3.3.1 MANUAL MMA WELDING ..........................................................................................28 3.3.2 SYNERGIC MMA WELDING ........................................................................................29 4. POWER SUPPLY CONNECTION ............................................................................................................ 30 5. OUTPUT CONNECTIONS ........................................................................................................................ 30 5.1 CONNECTION FOR MIG WELDING WITH TRADITIONAL TORCH ............................30 5.2 CONNECTION FOR MIG WELDING WITH SPOOL OR PUSH-PULL TORCH..............30 5.3 CONNECTION FOR TIG WELDING ...................................................................................31 5.4 CONNECTION FOR MMA WELDING ................................................................................31 6. INSTALLATION OF THE WELDING WIRE .......................................................................................... 32 7. CONNECTION OF THE GAS CYLINDER AND REGULATOR ........................................................... 33 8. WELDING PROCESSES ........................................................................................................................... 35 8.1 Manual MIG welding...............................................................................................................35 8.2 Synergic MIG welding.............................................................................................................36 8.3 MMA WELDING ....................................................................................................................37 8.4 TIG WELDING .......................................................................................................................38 9. REPLACEMENT OF SHEATH INSIDE THE TORCH CABLE.............................................................. 39 10. REMOTE CONNECTION........................................................................................................................ 40 11.1 MIG WELDING WITH STANDARD TORCH ...................................................................40 11.2 MIG WELDING WITH SPOOL OR PUSH-PULL TORCH ...............................................40 11.3 TIG WELDING .....................................................................................................................40 11.4 MMA WELDING ..................................................................................................................40 11. TROUBLESHOOTING ............................................................................................................................ 41 12. BLOCK DIAGRAM ................................................................................................................................. 42 13. MEMORISATION OF THE WORKING POINT .................................................................................... 42 910.100.335GB REV01
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DECLARATION OF CONFORMITY
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NOMINAL DATA
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TECHNICAL SPECIFICATIONS
CONSTRUCTION DATA
WEIGHT [Kg]:
Dimensions:
Width [mm]:
Depth [mm]:
Height [mm]:
23
Degree of protection:
IP 21S
Height ASL [m]:
1000
Operating temp. [°C]:
-10/+40
Storage temp. [°C]:
-20/+55
Test temp. [°C]:
40
270
560
480
Applicable regulations:
EN.60974-1 EN.60974-10
Group/class:
Group 2 Class A
Thermal protection:
Built-in thermostat
______________________________________________________________________________________________
INPUT ELECTRICAL DATA:
Line voltage:
No. of phases:
Frequency [Hz]:
Effective line current [A]:
Maximum line current [A]:
230
1
50/60
21.6
40.3
Input power [kVA]:
Power supply protections:
5
Delayed 25A fuses or Co K Curve 25A magneto-thermal switches
____________________________________________________________________________________________
OUTPUT DATA:
Static Characteristics:
Wire diameter:
Drop
0.6-0.8-1.0-1.2
First welding method:
Welding range:
No-load voltage [V]:
MIG/MAG
from 15A / 14.75V to 235A / 25.75V
55
Output currents and voltages:
Duty [%]:
I2 [A]:
U2 [V]:
35
220
25
60
160
22
100
130
20.5
______________________________________________________________________________________________
Second welding method:
TIG
Welding range:
No-load voltage [V]:
from 15A / 10.6V to 235A / 19.4V
55
Output currents and voltages:
Duty [%]:
35
60
100
I2 [A]:
220
160
130
U2 [V]:
18.8
16.4
15.2
____________________________________________________________________________________________
Third welding method:
Welding range:
No-load voltage [V]:
Duty [%]:
I2 [A]:
U2 [V]:
910.100.335GB REV01
MMA
from 15A / 10.6V to 185A / 17.4V
55
35
60
100
185
138
109
27.4
25.52
24.36
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IMPORTANT INSTRUCTIONS
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1. GENERAL FEATURES AND NOTES ON CONSULTING THE
MANUAL
The TM236 welding machines use INVERTER technology. They are extremely compact and versatile
machines that can be used in all situations where high performances must be achieved in a limited amount
of space.
These welders are for Synergic MIG/MAG (Short-Arc and Pulsed), conventional MIG/MAG (Short-Arc and
Pulsed), TIG and MMA (Synergic and conventional) welding.
The innovative interface system allows a simple and intuitive use of the machine with the possibility to
personalise nearly every welding parameter.
All the main parameters of the machine are stored on a special memory card (SD-Card); in this way, your
machine will always be up-to-date with the most recent developments in the welding field (e.g. synergic
curves for new materials, etc.).
The removal of the memory card prevents the machine from operating, which therefore makes it an effective
antitheft system and protection device against improper use.
The wire spool of 300 mm necessary for MIG welding is lodged internally.
The advanced control techniques adopted allow reaching quality results that until today were only reserved
to much larger and more expensive machines, while maintaining a very high level of reliability and ease of
use.
This machine allows executing the following types of welding:
MIG Welding: short-arc, manual
MIG Welding: pulsed, manual
MIG Welding: short-arc, synergic
MIG Welding: pulsed, synergic
TIG Welding: Lift-Arc
TIG Welding: Lift-arc, pulsed
MMA Welding: Manual
MMA Welding: Synergic
A traditional and push-pull or spool torch can also be used for MIG welding.
This user manual contains in-depth information on the adjustments and operating modes of the machine: its
complete reading will allow you to appreciate its extreme flexibility and practicality of use.
Please note that the figures most frequently referred to (figures 1 to 4) are grouped together on page 12.
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If you do not consider it necessary to read the manual completely, depending on the type of welding to be
executed, we recommend reading at least the following sections (as well as the warnings on page 6 of this
manual):
MIG Welding: short-arc, manual
TIG Welding
1.
2.
3.
3.1.
3.1.1.
4.
5.
5.1
1.
2.
3.
3.2
3.2.1
4.
5.
5.3
7.
8.
8.4
5.2
6.
7.
8.
8.1
General features
Description of the machine
Description of the various types of welding
MIG/MAG welding
Manual short-arc MIG welding
Power supply connection
Output connections
Connection for MIG welding with traditional torch and
gas
Connection for MIG welding with Spool or Push-pull
torch and gas
Installation of the welding wire
Connection of the gas cylinder and regulator
Welding process
Manual MIG welding
General features
Description of the machine
Description of the various types of welding
TIG Welding
Traditional TIG welding
Power supply connection
Output connections
Connection for TIG welding
Connection of the gas cylinder and regulator
Welding process
TIG Welding
MIG Welding: pulsed, manual
Pulsed TIG welding
1.
2.
3.
3.1
3.1.3
4.
5.
5.1
1.
2.
3.
3.2
3.2.2
4.
5.
5.3
7.
8.
8.4
5.2
6.
7.
8.
8.1
General features
Description of the machine
Description of the various types of welding
MIG/MAG welding
Manual pulsed MIG welding
Power supply connection
Output connections
Connection for MIG welding with traditional torch and
gas
Connection for MIG welding with Spool or Push-pull
torch and gas
Installation of the welding wire
Connection of the gas cylinder and regulator
Welding process
Manual MIG welding
General features
Description of the machine
Description of the various types of welding
TIG Welding
Pulsed TIG welding
Power supply connection
Output connections
Connection for TIG welding
Connection of the gas cylinder and regulator
Welding process
Pulsed TIG welding
MIG Welding: short-arc, synergic
Manual MMA welding
1.
2.
3.
3.1.
3.1.2
4.
5.
5.1
1.
2.
3.
3.3
3.3.1
4.
5.
5.4
8.
8.3
5.2
6.
7.
8.
8.2
General features
Description of the machine
Description of the various types of welding
MIG/MAG welding
Synergic short-arc MIG welding
Power supply connection
Output connections
Connection for MIG welding with traditional torch and
gas
Connection for MIG welding with Spool or Push-pull
torch and gas
Installation of the welding wire
Connection of the gas cylinder and regulator
Welding process
Synergic MIG welding with gas
General features
Description of the machine
Description of the various types of welding
MMA Welding
Manual MMA welding
Power supply connection
Output connections
Connection for MMA welding
Welding process
Manual MMA welding
MIG Welding: pulsed, synergic
Synergic MMA welding
1.
2.
3.
3.1.
3.1.4
4.
5.
5.1
1.
2.
3.
3.
3.3.2
4.
5.
5.4
8.
8.3.
5.2
6.
7.
8.
8.2
General features
Description of the machine
Description of the various types of welding
MIG/MAG welding
Synergic, pulsed MIG welding
Power supply connection
Output connections
Connection for MIG welding with traditional torch and
gas
Connection for MIG welding with Spool or Push-pull
torch and gas
Installation of the welding wire
Connection of the gas cylinder and regulator
Welding process
Synergic MIG welding with gas
General features
Description of the machine
Description of the various types of welding
MMA Welding
Synergic MMA welding
Power supply connection
Output connections
Connection for MMA welding
Welding process
Synergic MMA welding
Attention: The machine can only be used for the purposes described in this manual and must not be used to
thaw pipes.
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2. DESCRIPTION OF THE MACHINE
1
23456
17
9
10
18
20
8 7
21
-
+
15
16
27
12 13 14 11
Fig. 1
No
Gas
TIG
Gas
26
Fig.2
28
MIG
Gas
23
30
29
22
Fig.4
Fig.3
19
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25
Fig.4A
Fig.4B
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FIGURE 1:
1. Graphic display:
The display shows different screens depending on whether the machine is in welding mode or
setting mode.
In welding mode, the display is divided into five main parts:
Part 1
Pronto a saldare
>
150
26.0
A
INIZIO
INDIETRO
MEM+
Buttons
V
Adjustable
value
Part 3
Arc force
Hot start
20%
20%
T hot start
0.5s
Highlighted
value
Part 5
MMA
Manuale
Part 2
Part 4
Part 1: State of the machine
Part 2: Meaning of the active buttons (buttons 2, 3, 4, 5 of fig. 1)
Part 3: Value of the measurements set
Part 4: Type of welding
Part 5: Indicates the values set for the various welding parameters (to change the set value, highlight
the value with knob 10 and press to confirm; the value is highlighted as a negative. Change the value
by turning the knob and confirm the new value by pressing knob 10 again).
Adjustable value: Indicates the welding parameter that can be changed with knob 9.
Highlighted value: Indicates the welding parameter that is being changed with knob 10.
During the setting mode, the display shows different screens according to the value being set at that
moment (see the following sections relating to the various welding methods).
The display also shows:
- At start-up, the Fimer logo and the Firmware revision are displayed.
2.
3.
4.
5.
6.
7.
8.
9.
Command button: Its meaning is reported in the first line of Part 2 of the display; normally, the
pressing of this button returns to the main screen.
Command button: Its meaning is reported in the second line of Part 2 of the display; normally, the
pressing of this button returns to the previous screen.
Command button: Its meaning is reported in the third line of Part 2 of the display; when this button
is pressed, it memorises the current machine settings (up to a maximum of 32).
Command button: Its meaning is reported in the fourth line of Part 2 of the display; this button
allows the gas to flow without the need to press the torch button.
Wire feed button: When active, the wire (MIG) can be advanced.
SD slot: This slot, covered by a special plastic cover, must contain the SD-Card supplied with the
machine; without this card, the machine remains inactive and a special signal is reported on the
display.
USB port: only for technical assistance.
Knob for setting the main welding parameter: the main welding parameter can be set with this
knob:
MMA Welding: sets the welding current.
TIG Welding: sets the welding current.
Manual MIG welding: sets the welding voltage.
Synergic MIG welding: sets the thickness of the piece to be welded.
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10.
11.
12.
13.
14.
15.
16.
Knob for setting the other welding parameters: The remaining welding parameters can be set
with this knob; turn the knob to select the parameter and press to confirm, turn the knob again to
change the set value and press again to confirm the new value.
“+” front inlet:
MMA Mode: Electrode holder
TIG Mode: Ground clamp
MIG Mode with gas: Not used
MIG Mode without gas: Ground clamp
“-” front inlet:
MMA Mode: Ground clamp
TIG Mode: TIG torch
MIG Mode with gas: Ground clamp
MIG Mode without gas: Not used
Remote connector: This connector allows using the following types of torches:
MIG torch (GAN Spool)
MIG torch (Push-Pull)
TIG torch
GAS outlet:
MMA Mode: inactive (internal tap positioned on NO GAS)
MIG Mode with gas: inactive (internal tap positioned on MIG GAS)
MIG Mode without gas: inactive (internal tap positioned on NO GAS)
TIG Mode: Gas connection to the welding torch (Internal tap positioned on TIG GAS)
Euroconnector: quick connector for welding torch. This connector is used to supply welding gas
to the torch, the electrical contacts of the torch button and the welding current.
Air grills
FIGURE 2:
16.
17.
18.
20.
21.
Air grills
ON-OFF switch: turns the machine on and off.
Input cable: connection cable to the mains power equipped with plug.
Connector for supplying power to the liquid cooling system (Optional): Warning: the connector
contains dangerous voltages: NEVER use it for purposes other than those for which it was
specifically designed.
Welding gas inlet
MMA Mode: Not used
TIG Mode: GAS connection to the cylinder
MIG Mode with gas: GAS connection to the cylinder
MIG Mode without gas: Not used
FIGURE 3:
19.
22.
23.
25.
26.
27.
28.
29.
30.
Nominal data
Wire spool
Gas tap: The gas tap has three positions
MIG GAS Position: sends welding gas coming from connection 21 of the cylinder to the
Euroconnector (use this position for MIG welding with gas)
NO GAS Position: interrupts the gas flow (use this position for MMA welding and MIG welding
without gas)
TIG GAS Position: sends welding gas coming from connection 21 of the cylinder to inlet 14 location
on the front (use this position for TIG welding)
Wire Feeder
Wire pressure regulators: allow regulating the tension of the welding wire.
Wire-feeder motor
Upper wire feed rollers
Lower wire feed rollers
Wire inlet of the wire feeder motor
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3. DESCRIPTION OF THE VARIOUS TYPES OF WELDING
This chapter briefly describes the various welding methods and the main settings that need to be
set in order to execute them. The reading of this chapter is not sufficient for knowing how to use
the machine correctly. Therefore, it is also important to read the following sections (especially, the
chapters regarding the methods for connecting the torches and ground cables).
N
WELDING
PROCESS
1
MMA
2
TIG
3
MIG
Euroconnector
15 of fig 1
NOT USED
Front inlet
+
11 of fig 1
Front inlet
12 of fig. 1
ELECTRODE
HOLDER
GROUND
CABLE
NOT USED GROUND
CABLE
TORCH
CABLE
NOT
USED
TORCH
CABLE
GROUND
CABLE
3.1 MIG/MAG WELDING
To select this welding method go to the selection menu (if necessary, press button 2: start).
Select MIG-MAG with knob 10 and press to confirm.
Ready to weld
MMA
MIG-MAG
TIG
START
BACK
.
OPTIONS
MIG/MAG welding:
In MIG/MAG (Metal Inert Gas and Metal Active Gas) welding, a metal electrode consisting of a wire
is melted in a weld pool. The wire electrode is continuously fed by a welding torch at a constant
and controlled speed. As the wire is fed, it touches the piece to weld and an electric arc is
produced. The arc melts the wire which is then deposited on the workpiece.
Welding with continuous feeding of the wire allows using a higher current density than that used in
welding with coated electrodes. This allows increasing weld penetration and reducing the number
of passes required to fill the join.
This welding machine can use the following types of wire:
1. Solid wire: must always be used with protective gas – connection of line 3, Fig. 5.
2. Flux-cored wire for welding with gas: its central part contains a mineral product for improving
the welding characteristics (must always be used with gas) – connection of line 3 of Fig. 5.
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For an excellent welding performance, it is recommended to use welding spray. This will increase
the sealing capacity and reduce weld spatter.
There are four main MIG-MAG welding methods:
1 Manual short-arc
2 Synergic Short-Arc
3 Pulsed, manual
4 Pulsed, Synergic
Turn knob 10 to select one of the different MIG-MAG welding methods; press to confirm the
selection.
Select MIG-MAG procedure
.
Short arc ma
Short arc si
Arc puls. m
Arc puls. s
Mig-mag-01 .
Mig-mag-02 .
START
BACK
OPTIONS
MIG-MAG
The MIG-MAG-01, MIG-MAG-02 etc.... welding methods can be saved by the user; up to 32
different settings can be saved using button 4 of fig. 1.
3.1.1 MANUAL SHORT-ARC MIG WELDING
To access this operating mode, turn knob 10 to make the selection shown in the figure.
Select MIG-MAG procedure
.
.
Short arc ma
Short arc si
Arc puls. m
Arc puls. s
Mig-mag-01 .
Mig-mag-02 .
START
BACK
OPTIONS
Once the selection has been made, this screen is displayed:
Ready to weld
>
96
15.5
A
V
2.3
Inductance
2/4 strokes
START
BACK
MEM+
5.0
2t
m/’
MIG-MAG
S.A.M.
P1/2
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Menu 2/2 can be accessed by pressing knob 10 for 3 seconds and turning it:
pre gas t
post gas t
downslope t
burn back t
Timer
Water pump
0.0s
0.5s
0.5s
25ms
5.0s
ON
P2/2
During manual welding, the welding current (whose value is always shown on the display) can be
regulated via knob 9 shown in fig. 1; the display also shows the relative arc voltage and wire
speed.
To regulate the wire speed, turn knob 10 to select the “wire speed” parameter, press the knob to
confirm the value selected, turn the knob again to set the desired speed and press again to
confirm.
The welding current and wire speed must be regulated according to the thickness of the piece to
be welded. Larger pieces require a higher welding current and a faster wire speed. The wire speed
must be adjusted during welding to obtain the best result.
The quality of the welding can be improved even further by regulating the “Inductance” parameter
according to the instructions reported in section 8.1 (the electronic inductance can be regulated by
following the same procedure as that for setting the wire speed).
The 2/4 stroke parameter allows setting the operation in 2-stroke or 4-stroke mode.
2t: In the “2-stroke” operating mode, the torch button welds for the entire time it is pressed.
4t: In the “4-stroke” operating mode, the welding process starts with the first pressing of the torch
button and stops when this button is pressed for a second time.
The “Crater Filler” function is active in this mode. When the torch button is pressed for the second
time (at the end of welding), the current decreases from the set value until it reaches zero in a time
set between zero and ten seconds by the “current downslope t”.
Menu 2/2 can be accessed by pressing knob 10 for 3 seconds and turning it:
pre gas t:
setting of the time in which, upon the pressing of the torch button, the gas flows
without the arc being established.
post gas t:
setting of the time in which, upon release of the torch button, the gas continues
to flow after the arc has been turned off.
current downslope t:
setting of the time in which, upon release of the torch button, the
current decreases by the set value until reaching zero (only in 4-stroke mode).
burn back t:
setting of the burn-back time.
Timer:
timer setting: the timer sets the maximum time for continuous welding (i.e. limits
the time spent welding with the torch button pressed).
Water pump:
if ON, the water pump is enabled, if OFF, the cooling water pump is disabled.
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3.1.2. SYNERGIC SHORT ARC MIG WELDING
To access this operating mode, turn knob 10 to make the selection shown in the figure.
Select MIG-MAG procedure
.
.
Short arc ma
Short arc si
Arc puls. m
Arc puls. s
Mig-mag-01 .
Mig-mag-02 .
START
BACK
OPTIONS
MIG-MAG
Once the selection has been made, the display shows the page for selecting the welding wire
material.
Select the type of wire
Fe
SS
AlMg
AlSi
CuAl
Cusi3
InoxA
Fe A
.
START
BACK
OPTIONS
MIG-MAG
S.A.S
(The parameters that do not appear on the screen can be accessed by turning knob 10.)
Once the type of wire has been selected (by pressing knob 10), the page for setting the diameter of
the welding wire opens.
Select wire diameter
0.6mm
0.8mm
1.0mm
1.2mm
1.6mm
.
START
BACK
OPTIONS
MIG-MAG
S.A.S
SS
Once selected, this screen is displayed:
Ready to weld
>
Arc length
2/4 strokes
Wire speed
Inductance
47
16.3
1.1
START
A
BACK
MEM+
V
mm
-20%
2t
3.0m/’
5.0
MIG-MAG
S.A.M.
Fe
0.6mm
P1/2
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Menu 2/2 can be accessed by pressing knob 10 for 3 seconds and turning it:
pre gas t
post gas t
downslope t
burn back t
Timer
Water pump
0.0s
0.5s
0.5s
25ms
5.0s
ON
P2/2
Synergic MIG welding allows easily adapting the welding parameters to the different materials to
be welded.
During welding with synergic regulation, knob 9 shown in fig. 1 allows adjusting the wire thickness
(i.e. the welding power).
The wire speed is automatically adjusted to the set power in relation to the type and diameter of
the wire selected.
The percentage of the arc length can be changed via the “arc length” parameter.
The welding quality can be improved even further by regulating the “Electronic Inductance”
parameter (to regulate the electronic inductance follow the same procedure as that for setting the
wire speed).
The 2/4 stroke parameter allows setting the operation in 2-stroke or 4-stroke mode.
2t: In the “2-stroke” operating mode, the torch button welds for the entire time it is pressed.
4t: In the “4-stroke” operating mode, the first pressing of the torch button starts the welding
process, and a second pressing stops the welding process.
The “Crater Filler” function is active in this mode: when the torch button is pressed for the second
time (at the end of welding), the current decreases from the set value until it reaches zero in a time
set between zero and ten seconds by the “current downslope t”.
Menu 2/2 can be accessed by pressing knob 10 for 3 seconds and turning it:
pre gas t:
setting of the time in which, upon the pressing of the torch button, the gas flows
without the arc being established.
post gas t:
setting of the time in which, upon release of the torch button, the gas continues
to flow after the arc has been turned off.
current downslope t:
setting of the time in which, upon release of the torch button, the
current decreases by the set value until reaching zero (only in 4-stroke mode).
burn back t:
setting of the burn-back time.
Timer:
timer setting: the timer sets the maximum time for continuous welding (i.e. limits
the time spent welding with the torch button pressed).
Water pump:
if ON, the water pump is enabled, if OFF, the cooling water pump is disabled.
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3.1.3 MANUAL PULSED MIG WELDING
To access this operating mode, turn knob 10 to make the selection shown in the figure.
Select MIG-MAG procedure
.
.
.
Short arc ma
Short arc si
Arc puls. m
Arc puls. s
Mig-mag-01 .
Mig-mag-02 .
START
BACK
OPTIONS
MIG-MAG
Once selected, this screen is displayed:
Ready to weld
>
97
15.1
Wire speed
back ground I
burn back I
burn back t
2/4 strokes
P1/2
A
START
BACK
MEM+
V
3.0m/’
30A
300A
20ms
2t
MIG-MAG
A.P.M.
Menu 2/2 can be accessed by pressing knob 10 for 3 seconds and turning it:
pre gas t
post gas t
downslope t
burn back t
Timer
Water pump
Arc length
0.0s
0.5s
0.5s
25ms
5.0s
ON
+20%
P2/2
During welding with manual regulation, potentiometer 11 shown in fig. 1 regulates the arc voltage
(whose value appears on the display); the display also shows the relative welding current.
To regulate the wire speed, turn knob 10 to select the “wire speed” parameter, press the knob to
confirm the value selected, turn the knob again to set the desired speed and press to confirm.
The other parameters shown in the figure can also be regulated via knob 10.
back-ground I: setting of the base current; i.e. the current that is maintained continually for the
entire duration of the welding and that is increased during the pulse peak.
I peak:
setting of the peak current, i.e. the value that the welding current is increased
during the pulse peak.
burn-back I:
setting of the burn-back current.
burn back t:
setting of the burn-back time (expressed as a percentage).
continuous (i.e. limits the time that can be welded with the torch button pressed).
2/4 strokes:
setting of the 2-stroke or 4-stroke operating mode.
2t: In the “2-stroke” operating mode, the torch button welds for the entire time it
is pressed.
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4t: In the “4-stroke” operating mode, the first pressing of the torch button starts
the welding process, and a second pressing stops the welding process.
The “Crater Filler” function is active in this mode. when the torch button is
pressed for the second time (at the end of welding), the current decreases from
the set value until it reaches zero in a time set between zero and ten seconds
by the “current downslope t”.
Menu 2/2 can be accessed by pressing knob 10 for 3 seconds and turning it:
pre gas t:
setting of the time in which, upon the pressing of the torch button, the gas flows
without the arc being established.
post gas t:
setting of the time in which, upon release of the torch button, the gas continues
to flow after the arc has been turned off.
current downslope t:
setting of the time in which, upon release of the torch button, the
current decreases by the set value until reaching zero (only in 4-stroke mode).
Timer: timer setting: the timer sets the maximum welding time
Water pump:
if ON, the water pump is enabled, if OFF, the cooling water pump is disabled.
Arc length:
setting this parameter (variable from -100% up to +100%) allows shortening
(negative values) or lengthening (positive values) the welding arc.
3.1.4 SYNERGIC PULSED MIG WELDING
To access this operating mode, turn knob 10 to make the selection shown in the figure.
Select MIG-MAG procedure
.
.
Short arc ma
Short arc si
Arc puls. m
Arc puls. s
Mig-mag-01 .
Mig-mag-02 .
START
BACK
OPTIONS
Once the selection has been made, the display shows the page for selecting the welding wire
material.
Select the type of wire
Fe
SS
AlMg
AlSi
CuAl
Cusi3
InoxA
Fe A
910.100.335GB REV01
.
START
BACK
OPTIONS
MIG-MAG
S.A.S
21 of 44
(The parameters that do not appear on the screen can be accessed by turning knob 10)
Once the type of wire has been selected (by pressing knob 10), the page for setting the diameter of
the welding wire opens.
Select wire diameter
0.6mm
0.8mm
1.0mm
1.2mm
1.6mm
.
START
BACK
OPTIONS
MIG-MAG
S.A.S
SS
Once the type of wire has been selected, this screen is displayed:
Ready to weld
>
47
16.3
1.1
Wire Speed
Length
2/4 strokes
Wire speed
Arc
START
A
BACK
MEM+
V
mm
10%
-20%
2t
3.0m/’
MIG-MAG
S.A.M.
SS
0.8mm
P1/2
Menu 2/2 can be accessed by pressing knob 10 for 3 seconds and turning it:
back-ground I
pre gas t
post gas t
downslope t
burn back t
Wire speed
timer
Water pump
0%
0.0s
0.5s
0.5s
25ms
10%
5.0s
ON
P2/2
Synergic Pulsed MIG welding allows obtaining a very “clean” welding (i.e. without any spattering of
the melted materials).
Pulsed welding is particularly suitable for welding materials such as stainless steel (Ni-Cr),
aluminium (Al) and copper silicone (Cu-Si3), but is not suitable for ferrous materials (SG2, SG3)
During welding with synergic regulation, knob 9 shown in fig. 1 allows adjusting the wire thickness
(i.e. the welding power).
The wire speed is automatically adjusted to the set power depending on the type and diameter of
the wire selected.
The wire speed can be changed slightly via the “wire speed” parameter.
The other parameters shown in the figure can also be regulated via knob 10:
Arc length:
setting this parameter (variable from -10 up to +9) allows shortening (negative
values) or lengthening (positive values) the welding arc.
2/4 strokes:
setting of the 2-stroke or 4-stroke operating mode.
2t: In the “2-stroke” operating mode, the torch button welds for the entire time it
is pressed.
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4t: In the “4-stroke” operating mode, the first pressing of the torch button starts
the welding process, and a second pressing stops the welding process.
The “Crater Filler” function is active in this mode: when the torch button is
pressed for the second time (at the end of welding), the current decreases from
the set value until it reaches zero in a time set between zero and ten seconds
by the “current downslope t”.
Menu 2/2 can be accessed by pressing knob 10 for 3 seconds and turning it:
back-ground I: setting of the base current i.e. the current that is maintained continually for the
entire duration of the welding process and which is increased during the pulse
peak (a variation of ±20% can be made in relation to the value automatically
set).
pre gas t:
setting of the time in which, upon the pressing of the torch button, the gas flows
without the arc being established.
post gas t:
setting of the time in which, upon release of the torch button, the gas continues
to flow after the arc has been turned off.
current downslope t:
setting of the time in which, upon release of the torch button, the
current decreases by the set value until reaching zero (only in 4-stroke mode).
burn back t:
setting of the burn-back time (expressed as a percentage).
Timer:
timer setting: the timer sets the maximum time for continuous welding (i.e. limits
the time spent welding with the torch button pressed).
Water pump:
if ON, the water pump is enabled, if OFF, the cooling water pump is disabled.
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3.2 TIG WELDING
To select this welding method, go to the selection menu (if necessary, press button 2:
start).
Select TIG using knob 10 and press to confirm.
Ready to weld
MMA
MIG-MAG
TIG
START
BACK
.
OPTIONS
Arc welding with inert gas (Argon) and infusible tungsten electrode (often shortened to TIG
welding: Tungsten Inert Gas) is a welding procedure where the heat is produced by an arc that
strikes against a non-consumable electrode and the piece to be welded. The welding is executed
by melting the edges of the workpiece and inserting other materials coming from filler irons, thus
creating the join.
The arc is established by touching the workpiece with the electrode.
The TIG procedure is suitable for any type of working position and can be applied on very thin
metal sheets. TIG welding is characterised by its high level of arc control, powerful and
concentrated heat source and greater control of the quality of the filling material. This makes the
TIG procedure particularly suitable for precision welding on a wide range of thicknesses, for
welding in difficult positions and on pipes that require high welding penetration.
This procedure allows using a variety of different materials such as iron, nickel alloy, copper,
titanium, magnesium, etc. However, this type of welding is not suitable for aluminium.
During welding, the potentiometer (11 in figure 1) regulates the welding current.
The correct connection of the torch and ground cable is shown in line 2 of figure 5.
The machine does not include the TIG torch necessary for welding; this can be purchased
separately.
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3.2.1TRADITIONAL TIG WELDING
To access this operating method, turn knob 10 to make the selection shown in the figure.
Select TIG procedure
Lift arc
Lift arc pul
START
BACK
.
OPTIONS
TIG
Once selected, this screen is displayed:
Ready to weld
>
2/4 strokes
pre gas t
post gas t
150
16.0
START
A
BACK
MEM+
V
2t
3s
2s
TIG
Lift Arc
P1/2
Menu 2/2 can be accessed by pressing knob 10 for 3 seconds and turning it:
initial I
final t
downslope t
Water pump
30A
20A
0.5s
ON
P2/2
During welding, knob 9 shown in figure 1 allows regulating the welding current (whose value is
continually displayed on the display); the display also shows the relative arc voltage.
The other parameters shown in the figure can also be regulated via knob 10:
2/4 strokes:
pre gas t:
post gas t:
setting of the 2-stroke or 4-stroke operating mode.
2t: In the “2-stroke” operating mode, the torch button welds for the entire time it
is pressed.
4t: In the “4-stroke” operating mode, the first pressing of the torch button starts
the welding process, and a second pressing of this button stops the welding
process.
setting of the time in which, upon the pressing of the torch button, the gas flows
without the arc being established.
setting of the time in which, upon release of the torch button, the gas continues
to flow after the arc has been turned off.
Menu 2/2 can be accessed by pressing knob 10 for 3 seconds and turning it:
Initial I:
setting of the initial value of the current when the torch button (only active in 4stroke mode).
final I:
setting of the final value of the current after the current_downslope_t of the
torch button (only active in 4-stroke mode).
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downslope t:
Water pump:
setting of the time in which, upon release of the torch button, the current
decreases by the set value until reaching the “final I” value (only in 4-stroke
mode).
if ON, the water pump is enabled, if OFF, the cooling water pump is disabled.
3.2.2 PULSED TIG WELDING
To access this operating method, turn knob 10 to make the selection shown in the figure.
Select TIG procedure
START
BACK
Lift arc
Lift arc pul
.
OPTIONS
TIG
Once the selection has been made, the following welding screen opens:
Ready to weld
>
150
16.0
2/4 strokes
pre gas t
post gas t
START
A
BACK
MEM+
V
2t
3s
2s
TIG
Lift Arc
P1/2
Menu 2/2 can be accessed by pressing knob 10 for 3 seconds and turning it:
back ground I
initial I
final I
current downslope
t:
total period t
pulse period t
Water pump
Timer
80A
30A
20A
0.5s
12ms
5ms
ON
5.0s
P2/2
During welding, knob 9 shown in figure 1 regulates the welding current (whose value appears on
the display); the display also shows the relative arc voltage.
The other parameters shown in the figure can also be regulated via knob 10:
2/4 strokes:
setting of the 2-stroke or 4-stroke operating mode.
2t: In the “2-stroke” operating mode, the torch button welds for the entire time it
is pressed.
4t: In the “4-stroke” operating mode, the first pressing of the torch button starts
the welding process, and a second pressing of this button stops the welding
process.
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pre gas t:
post gas t:
setting of the time in which, upon the pressing of the torch button, the gas flows
without the arc being established.
setting of the time in which, upon release of the torch button, the gas continues
to flow after the arc has been turned off.
Menu 2/2 can be accessed by pressing knob 10 for 3 seconds and turning it:
back-ground I: setting of the base current i.e. the current that is maintained continually for the
entire duration of the welding process and that is increased during the pulse
peak.
Initial I:
setting of the initial value of the current when the torch button (only active in 4stroke mode).
final I:
setting of the final value of the current after the current_downslope_t of the
torch button (only active in 4-stroke mode).
current downslope t:
setting of the time in which, upon release of the torch button, the
current decreases by the set value until reaching the “final I” value (only in 4stroke mode).
current upslope t: setting of the time in which, upon pressing of the torch button, the current
increases by the “initial I” value until it reaches the set value (only in 4-stroke
mode).
total period t:
setting of the pulse period.
pulse period t: setting of the duration of the pulse.
Water pump:
if ON, the water pump is enabled, if OFF, the cooling water pump is disabled.
Timer:
timer setting: the timer sets the maximum time for continuous welding (i.e. limits
the time spent welding with the torch button pressed).
3.3 MMA WELDING
To select this welding method go to the selection menu (if necessary, press button 2: start).
Select MMA with knob 10 and press to confirm.
Ready to weld
MMA
MIG-MAG
TIG
.
START
BACK
OPTIONS
Arc welding with MMA (Metal Manual Arc) coated electrode or SMAW (Shielded Metal Arc
Welding) is a manual welding procedure that makes use of the heat generated by an electric arc
that strikes against a coated fusible electrode and the piece to be welded. This procedure is
commonly used in welding because of its versatility. In fact, it allows making joints in any position:
in the machine shop, outdoors, in confined areas or hard to access areas. A vast range of
electrodes is also available on the market for meeting the most varied requirements.
The striking of the arc occurs by bringing the electrode close to the workpiece.
During welding, the following functions are active:
Arc Force: allows increasing the welding current to prevent the arc from extinguishing itself.
Hot Start: allows temporarily increasing the percentage of the welding current that the machine
can force once the arc has been established.
This helps igniting the arc quickly and reliably.
Antisticking: allows decreasing the output current if the operator makes an error and sticks the
electrode to the workpiece; this decrease allows removing the electrode from the holder without
creating sparks which can damage the electrode holder.
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The correct connection of the electrode holder and the ground cable is shown in line 1 of figure 5:
in this way, the electrode holder is connected to the positive pole and the ground cable to the
negative pole. Always check the correct connection on the electrode packet and, if necessary,
invert them.
3.3.1 MANUAL MMA WELDING
To access this operating mode, turn knob 10 to make the selection shown in the figure.
Select MMA procedure
Manual
Synergic
START
BACK
.
OPTIONS
MMA
Once the selection has been made, the following welding screen opens:
Ready to weld
>
Arc Force
Hot start
Hot start t
151
26.0
START
A
BACK
MEM+
V
20%
20%
0.5s
MMA
Manual
Knob 9 shown in figure 1 allows regulating the welding current (thicker welding pieces require
higher currents).
The other parameters shown in the figure can also be regulated via knob 10:
Arc Force: allows increasing the percentage of the current (proportional to the set current) that
the welding machine can force in order to keep the arc well established.
Hot Start:
allows increasing the percentage of the welding current (proportional to the set
current) that the welding machine can force once the arc has been established.
Hot start T: allows setting the time in which the hot start current can be forced.
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3.3.2 SYNERGIC MMA WELDING
To access this operating mode, turn knob 10 to make the selection shown in the figure.
Select MMA procedure
START
BACK
Manual
Synergic
.
OPTIONS
MMA
Once selected, the display shows the page for selecting the type of electrode.
Select MMA procedure
START
BACK
Rutile
Basic
Inox
Cellulosic
Aluminium
.
OPTIONS
MMA
Synergic
Once the type of electrode has been selected (by pressing knob 10), the page for setting the
diameter of the electrode opens.
Select MMA procedure
1.5mm
2.0mm
2.5mm
3.2mm
4.0mm
5.0mm
6.0mm
8.0mm
START
BACK
.
OPTIONS
MMA
Synergic
In this way, the welding process has all the data necessary for setting the correct value of the
welding current.
Ready to weld
>
Arc Force
Hot start
Hot start t
56
26.0
START
A
BACK
MEM+
V
20%
20%
0.5s
MMA
Synergic
Basic
2.0mm
Knob 9 shown in figure 1 allows fine-tuning the welding current.
910.100.335GB REV01
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The other parameters shown in the figure can also be regulated via knob 10:
Arc Force: allows increasing the percentage of the current (proportional to the set current) that
the welding machine can force in order to keep the arc well established.
Hot Start:
allows increasing the percentage of the welding current (proportional to the set
current) that the welding machine can force once the arc has been established.
Hot start T: allows setting the time in which the hot start current can be forced.
4. POWER SUPPLY CONNECTION
Before connecting the machine, check the voltage, number of phases and frequency of the power
supply. The power supply voltage allowable is indicated in the “Technical Specifications” section of
this manual and on the machine’s nominal data label. Check that the welding machine has been
correctly connected to the ground terminal. Also, check that the plug supplied with the machine is
compatible with the local mains power outlet. Make sure there is sufficient power to run the
machine. The “Technical Specifications” section of this manual contains information on the type of
power supply protection devices to use. The machine comes with a special power cord (18 of
Figure 2) which should not be extended. If an extension cord is necessary, use one that has the
same or a larger cross-section than the machine’s power cord depending on the length of the cord.
Use a “+” bipolar ground cord with a cross-section equal to or greater than 2.5 mm².
5. OUTPUT CONNECTIONS
The welding cables are connected by means of a quick coupling system that uses special
connectors.
5.1 CONNECTION FOR MIG WELDING WITH TRADITIONAL TORCH
1) Connect the ground cable to the appropriate “-” connector positioned on the front panel (12 of
Fig 1). Align the key with the groove and insert; tighten the connector by turning it in a clockwise
direction until it stops. Do not over tighten!
2) Connect the torch to the connector positioned on the front panel (15 of fig. 1) by turning it in a
clockwise direction until it stops. Do not over tighten!
Attention: The machine comes with a standard MIG welding torch (Fig. 4).
This accessory will have a long duration if the periodic checks are conducted on the gas nozzle
(Fig. 4A) and the wire-guide tip (Fig. 4B). These parts must be kept clean and intact. Replace the
wire-guide when the wire does not slide properly.
5.2 CONNECTION FOR MIG WELDING WITH SPOOL OR PUSH-PULL TORCH
1) Connect the ground cable to the appropriate “-” connector (12 shown in figure 1).
Insert by aligning the key with the groove and tighten by turning in a clockwise direction
until it stops. Do not over tighten!
2) Connect the torch to the connector positioned on the front panel (15 shown in fig. 1) by
turning it in a clockwise direction until it stops. Do not over tighten!
3) Connect the signal connector of the torch to the appropriate female jack (19).
4) Turn the tap (23 shown in figure 3) to the “MIG GAS” position (counter-clockwise direction).
If the Spool torch cannot be connected with connector 15 and therefore, it is not possible to
proceed with step 2, follow these instructions:
1) Connect the ground cable to the appropriate “-” connector (12 shown in figure 1).
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2)
3)
4)
5)
Insert by aligning the key with the groove and tighten by turning in a clockwise direction
until it stops. Do not over tighten!
Connect the torch cable to the “+” connector (11 shown in figure 1).
Insert by aligning the key with the groove and tighten by turning in a clockwise direction
until it stops. Do not over tighten!
Connect the gas hose of the torch to the appropriate inlet (14 shown in figure 1).
Connect the signal connector of the torch button to the appropriate female jack (13).
Turn the tap (23 shown in figure 3) to the “TIG GAS” position (clockwise direction).
5.3 CONNECTION FOR TIG WELDING
1) Connect the ground cable to the appropriate “+” connector positioned on the front panel (11
of Fig 1). Align the key with the groove and insert; tighten the connector by turning it in a
clockwise direction until it stops. Do not over tighten!
2) Connect the torch to the “-” connector positioned on the front panel (12 of Fig. 1).
3) Insert by aligning the key with the groove and tighten by turning in a clockwise direction
until it stops. Do not over tighten!
4) Connect the gas hose of the torch to the appropriate inlet (14 shown in figure 1).
5) Connect the signal connector of the torch button to the appropriate female jack (13).
6) Turn the tap (23 shown in figure 3) to the “TIG GAS” position (clockwise direction).
5.4 CONNECTION FOR MMA WELDING
1) Connect the cable of the electrode holder to the “+” connector located on the front panel
(11 of Fig. 1).
Insert by aligning the key with the groove and tighten by turning in a clockwise direction
until it stops. Do not over tighten!
2) Connect the ground cable to the appropriate “-” connector positioned on the front panel
(12 of Fig 1). Align the key with the groove and insert; tighten the connector by turning it
in a clockwise direction until it stops. Do not over tighten!
3) Turn the tap (23 shown in figure 3) to the “NO GAS” position (central position).
Attention: Some types of electrodes require the negative polarity on the electrode holder and the
positive polarity on the ground cable: if so, invert the connection.
Make sure to follow the instructions on the electrode packet for the correct polarity!
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6. INSTALLATION OF THE WELDING WIRE
Only for MIG welding: in case of MMA or TIG welding, skip this whole section.
Attention: Before installing the wire, always remove the gas nozzle (Fig. 4A) and the wire-guide tip
(Fig. 4b) from the welding torch (Fig. 4).
1. Disconnect the power supply cord (18 of Fig. 2)
2. Unscrew the knob positioned at the centre of the spool holder (22 of Fig. 3), if necessary,
remove the used spool.
3. Remove the plastic protection of the new spool and position the spool on the holding reel (22 of
Fig. 3). Replace the knob. Remember that the Allen screw positioned at the centre of the reel is the
braking system of the wire. Screw it to obtain the best braking condition: if tightened too much, it
can cause too much braking which tends to block the motor of the wire-feeder. However, if not
tightened enough, the wire may not stop immediately at the end of the welding process.
4. Unscrew the knobs of the wire-feeder (26 of Fig. 3) and turn them towards the outside. This lifts
the upper wire-feeder rollers (28 of Fig. 3).
Remove any wire remaining in the previous welding spool.
5. Insert the wire in the inlet tube (30 of Fig. 3) of the wire-feeder motor and let it slide under the
wire-feeder rollers.
6. Lower the upper rollers (28 of Fig. 3) and close the plastic knobs (26 of Fig. 3) of the wire
pressure regulator.
Tighten gently; if too tight, the wire may block and cause damage to the motor; however, if too
loose, the rollers will not be able to pull the wire.
7. Connect the power supply cord, turn on the switch (17 of Fig. 2) and press the wire
advancement button (6 of Fig. 1).
At this point, the welding wire will slide into the torch cable. When it exits from the torch, release
the button. Turn off the machine and replace the wire-guide tip (Fig. 4B) and gas nozzle (Fig. 4A)
on the torch.
Attention: Keep the torch away from your face to prevent injuring yourself with the wire.
Attention: When in movement, the wire-feed rollers may crush your fingers.
N.B. Periodically check the state of the wire-feed rollers and replace them when they are worn out;
failure to replace the rollers may compromise the correct feeding of the wire.
N.B. When changing the wire diameter, make sure the value corresponding to the diameter of the
wire used is facing towards the outside of the machine. Remember that the rollers with a “V”
shaped cavity are suitable for pulling iron or steel wires.
While, rollers with a “U” shaped cavity are suitable for aluminium wires.
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7. CONNECTION OF THE GAS CYLINDER AND REGULATOR
Only for MIG and TIG welding. In case of MMA welding, skip this whole section.
Fig.6
Cylinder and pressure reducer
Before connecting the gas cylinder, first choose the most suitable type of gas for the welding to be
executed. This section contains some recommendations.
MIG WELDING OF CARBON STEEL:
For welding this type of material, use a welding gas mixture consisting of ARGON (80%) +CO2
(20%). This gas mixture allows obtaining well-joined and aesthetically pleasing weld beads.
Pure CO2 can be used which will result in tight beads and more penetrating welds, but with a
significant amount of spatter.
MIG WELDING OF STAINLESS STEEL AND WELD BRAZING WITH CU-S13 WIRES:
For welding these types of materials, use a welding gas mixture consisting of ARGON (98%) +CO2
(2%) or ARGON (98% min) + O2 (2%).
MIG WELDING OF ALUMINIUM:
For welding this type of material, use pure ARGON as a protection gas.
TIG WELDING:
Before connecting the gas cylinder, check that it contains pure Argon gas. Do not use other gases.
Refer to Figure 6 and carefully follow the procedure below:
1. Connect the pressure gauge (2) to the cylinder (3). Tighten the nut (6) connecting the gauge (2)
to the cylinder (3). Be careful to not over tighten; too much force could damage the valve (1) of the
cylinder.
2. Connect the gas hose (4) to the gauge (2) and secure with a pipe clamp (5).
3. Connect the other end of the gas hose (4) to the appropriate inlet positioned on the back of the
machine (21 of Fig. 2), and secure with a pipe clamp.
4. Open the valve (1) of the cylinder (3). Press the torch button and check that the gas flows
correctly.
Attention: The cylinders contain highly pressurised gas. Handle with care. Improper handling
910.100.335GB REV01
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could lead to serious accidents. Do not place the cylinders on top of each other and do not expose
to excessive heat, flames or sparks. Do not allow the cylinders to strike against each other.
Contact your gas supplier for more information on how to use and handle the cylinders.
Attention: Do not use the cylinder if you find oil leaks, grease or damaged parts. Immediately
contact your gas supplier if these conditions exist.
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8. WELDING PROCESSES
8.1 Manual MIG welding
N.B. These instructions are for reference only and are applicable for welding thicknesses up to
around 4 mm.
The regulation depends on the materials, wire thickness, connection, position and welding gas.
Step 1: Selection of the current
Convert the thickness of the material to
be welding in Ampere (A) according to
this proportion: 0.025 = 1A
e.g. 3mm = 125A
Step 2: Selection of the wire diameter
Ampere (Min-Max)
40-90 A
60-140A
80-160A
100-200A
Wire diameter
0.6mm
0.8mm
1mm
1.2mm
.
Step 3: Selection of wire speed
Wire diameter
0.6mm
0.8mm
1mm
1.2mm
Recommended value
90mm/min per ampere
50mm/min per ampere
40mm/min per ampere
30mm/min per ampere
Wire speed
90x120=11m/min
50x120=6m/min
40x120=5m/min
30x120=3.5m/min
.
Step 4: Selection of electronic inductance
Material
Ferrous materials (SG2 SG3)
Stainless steel (Ni-Cr)
Aluminium (Al)
Copper-Silicone (Cu-Si3)
Copper-Aluminium (CU-AI8)
Regulation of electronic inductance
min med
Med
med max
med max
med max
Figure 7: Reference values for the current, wire diameter, wire speed and electronic
inductance
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To weld in MIG manual mode, follow these steps:
1. Set the welding current in relation to the thickness of the workpiece and the diameter of the wire
using knob 9 shown in figure 1 (Step 1 of Fig. 7).
Display 16 of Fig. 1 shows the current value.
2. Depending on the current, select the diameter of the wire (Step 2 of Fig. 7).
3. Depending on the diameter of the wire, set the advancement speed using knob 10 of Fig. 1.
4. According to the material used, adjust the electronic inductance.
5. Connect the ground terminal to the workpiece.
6. Start welding keeping the length of the electric arc between 5 and 10 mm.
7. If necessary, adjust the wire speed (knob 10 of Fig. 1). To obtain the best welding result: adjust
potentiometer 10 until you hear a strong and regular buzzing noise (similar to the sound of oil being
fried).
It is recommended to carry out some test welds on a metallic sheet that has been removed of any
coating, rust or paint.
To obtain the best results, follow these tips:
1. Keep the torch at a 45° angle from the workpiece. Keep the gas nozzle (Fig. 4A) at a distance of
circa 6 mm from the workpiece.
2. Continuously move the torch.
3. Weld with a small zigzag movement in order to adjust the size of the weld bead to the desired
value.
4. Do not weld in the presence of strong wind. Strong wind could carry the gas away from the weld
pool which could lead to porous welding.
5. Keep the wire clean: never use rusty wires.
6. Do not bend or twist the torch cable.
7. When changing the wire spool, clean the wire-guide tube with compressed air.
8. Periodically remove any dust from the air inlets using low-pressure compressed air. Always
direct the jet of air from the inside of the machine towards the outside in order to prevent dirt from
being pushed inside the welding machine.
Pulsed Mode:
This operating mode is only for expert users: it is mainly used as an alternative to MIG-Synergic
Pulsed welding in rare cases when, due to special type of materials, a satisfying result cannot be
found using the pre-set programs.
In this operating mode, knob 9 of figure 1 sets the welding current.
Knob 10 of figure 1 sets all the other parameters as described in section 3.1.3.
8.2 Synergic MIG welding
Synergic MIG welding allows automatically adjusting the machine settings to the different materials
and different thicknesses to be welded. Compared to manual welding, it has a pre-set program
menu capable of satisfying practically any type of welding requirement.
However, as described in more detail below, a certain liberty is available for changing the
parameter set automatically.
To weld in Synergic MIG mode, follow these steps:
1 – Depending on the material to be welded, select one of the following programs using Knob 10
shown in figure 1 (section 3.1.2):
• FE: this program is for welding with solid iron wire.
• SS: this program is for welding with stainless steel wire (Ni-Cr).
• Al-Mg: this program is for welding with aluminium magnesium wire.
• Al-Si: this program is for welding with aluminium silicone wire.
• Al: this program is for welding with aluminium wire.
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• Cu-Al: this program is for welding with copper-aluminium wire.
• Cu-Si3: this is for welding with Cu-Si3. This material is suitable for weld brazing, especially
galvanised sheet-iron for automobiles.
• Inox A: this program is for welding with flux-cored steel wire.
• Fe A: this program is for welding with flux-cored iron wire.
2 – Set the diameter of the welding wire (section 3.1.2).
3 – Set the thickness of the workpiece using knob 9 shown in figure 1 (section 3.1.2).
4 – Connect the ground terminal to the workpiece.
5 – Start to weld, keeping the electric arc at a length between 5 and 10 mm.
This usually achieves a very good welding result; however, the result may require further finetuning, if so, proceed as follows:
6 – If too much incandescent material is generated, increase the inductance value by setting the
appropriate parameter via knob 10 shown in figure 1 (section 3.1.2). If instead, there are difficulties
in sustaining the arc, decrease the inductance value.
To obtain the best results, follow these tips:
1. Keep the torch at a 45° angle from the workpiece. Keep the gas nozzle (Fig. 4A) at a distance of
around 6 mm from the workpiece.
2. Continuously move the torch.
3. Weld with a small zigzag movement in order to adjust the size of the weld bead to the desired
value.
4. Do not weld in the presence of strong wind. Strong wind could carry the gas away from the weld
pool which could lead to porous welding.
5. Keep the wire clean: never use rusty wires.
6. Do not bend or twist the torch cable.
7. When changing the wire spool, clean the wire-guide tube with compressed air.
8. Periodically remove any dust from the air inlets using low-pressure compressed air. Always
direct the jet of air from the inside of the machine towards the outside in order to prevent dirt from
being pushed inside the welding machine.
8.3 MMA WELDING
Diameter (mm)
1.6
2.0
2.5
3.25
4.0
5.0
Current (A)
35-50
40-70
60-100
80-140
120-170
180-250
Fig. 8: Welding currents in relation to the electrode diameter
To weld in MMA manual mode, follow these steps:
1. Select the manual MMA welding mode as described in section 3.3.
2. Using knob 9 shown in figure 1, set the welding current in relation to the type of electrode and
thickness of the workpiece (the current value set appears on the display). Figure 8 shows the
indicative current values suitable for the various electrode diameters: however, always check to
see if different values are reported on the electrode packet.
3. Connect the ground terminal to the piece to weld.
4. Position the electrode in the electrode holder.
5. Start to weld keeping a distance of 3-4 mm between the electrode and the workpiece. Weld with
a small zigzag movement in order to adjust the size of the weld bead to the desired value.
6. To end the welding process, interrupt the arc by moving the electrode away from the workpiece.
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To weld in Synergic MMA mode, follow these steps:
1. Select the Synergic MMA welding mode as described in section 3.3.
2. Set the type of electrode using knob 9 shown in figure 1 (section 3.3.2).
3. Connect the ground terminal to the piece to weld.
4. Position the electrode in the electrode holder.
5. Start to weld keeping a distance of 3-4 mm between the electrode and the workpiece. Weld with
a small zigzag movement in order to adjust the size of the weld bead to the desired value.
6. To end the welding process, interrupt the arc by moving the electrode away from the workpiece.
Attention: If using “Basic” electrodes, before resuming an interrupted welding process, remove
any excess from the protection cover by tapping the electrode on a metallic surface (otherwise, it
will not be possible to re-establish the welding arc).
8.4 TIG WELDING
To weld in TIG mode, follow these steps:
1. Select the TIG program via knob 9 shown in figure 1.
2. Using this knob, select Lift-Arc or Pulsed Lift Arc program.
3. Set the welding current via knob 10 shown in figure 1.
4. Connect the ground terminal to the workpiece.
5. Press the torch button in order to start the gas flow and regulate the flow via the tap positioned
on the cylinder (indicatively, 6 litres/minute).
6. Rest the ceramic of the torch on the workpiece and turn in order to bring the tungsten electrode
in contact with the workpiece.
7. Slowly lift the tip of the tungsten electrode from the workpiece using the ceramic end of the TIG
torch as a lever.
8. Once the arc has been established, the current gradually rises until it reaches the set value.
9. Start to weld keeping the same distance from the weld pool that is being created.
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9. REPLACEMENT OF SHEATH INSIDE THE TORCH CABLE
Follow these instructions to replace the sheath of the wire guide:


Torch side: remove gas nozzle (A)
Unscrew the wire-guide tip (B)
A





B
C
Connector side (C): unscrew the end nut (D, E) and take hold of the end of the sheath
with some pliers and start to extract it (F).
Complete the extraction of the sheath (G)
F
D
E
Insert the new sheath and push it all the way down (H).
Re-screw the wire-guide tip (B) onto the torch.
Complete by re-screwing the gas nozzle (A).
G
H
Figure 9: Replacement of wire-guide sheath
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10. REMOTE CONNECTION
A
_
M
+
F
B
Fig 10
G
C
Sw
E
D
P
Figure 10 shows the connections of the remote connector (13 shown in figure ).
Where:
Sw
is the torch button
P
is the potentiometer for controlling the current
M
is the external wire-feeder motor
11.1 MIG WELDING WITH STANDARD TORCH
The connector is not used because all the necessary contacts are made using Euroconnector 13
shown in figure 1.
11.2 MIG WELDING WITH SPOOL OR PUSH-PULL TORCH
If using a Spool torch supplied by Fimer, the connection to the remote connector is direct. If not,
connect the two wires of the torch button to terminals A and E of the connector, the negative of the
torch’s wire-feeder motor to terminal F and the positive to terminal G (as shown in figure 10).
Some types of torches also allow regulating the welding power at a distance.
Turn the potentiometer on the torch to set the welding power in a range between zero and the set
value.
This requires connecting the potentiometer (P) to the torch as shown in figure 10.
The value of the potentiometer is not critical: components between 2.2kOhm and 10kOhm 1/2W
can be used.
11.3 TIG WELDING
Connector 13 in Figure 1 connects the torch’s welding button to the machine by means of terminals
A and E shown in figure 10.
The connection is made automatically by connecting the TIG welding torch.
11.4 MMA WELDING
Remote connector 13 shown in figure 1 allows bringing the current regulation close to the
welding point.
This requires connecting the potentiometer (P) to the torch as shown in figure 10.
The value of the potentiometer is not critical: components between 2.2kOhm and 10kOhm
1/2W can be used.
Turn the potentiometer on the torch to set the welding current in a range between zero
and the set value.
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11. TROUBLESHOOTING
The most common problems you may encounter and the relative solutions are listed below.
DEFECT
CAUSE
SOLUTION
Machine turns off
[Display: OFF]
1) No power on the mains power source
1) Restore the mains power
[Display: network error]
2) Check the mains voltage
2) Restore the mains power
The machine suddenly stops operating
after prolonged use [Display:
temperature rise or overheating
of inverter]
The machine does not work
[display: inverter under power]
1) The machine has overheated due to
excessive use and the thermal protection
has kicked in
1) Let the machine cool down until the
error message disappears
1) MIG: Short circuit on the welding torch
2) MMA: electrode in contact with the
ground connection
1) Dirt on the wire-guide tip.
1) Check the torch
2) Move the electrode away from the
ground connection
1) Blow with air; replace nozzle
2) Too much friction on the spool
2) Loosen
3) Faulty torch
1) Faulty gas nozzle
3) Check the wire-guide sheath
1) Replace
2) Burning in the gas nozzle
3) Dirt on the throat of the wire-feed roller
2) Replace
3) Clean
4) Throat of the wire-feed roller worn
1) Bad contact between the ground clamp
and the workpiece
2) Short circuit between the contact nozzle
and the gas guide tube
1) No gas shield due to encrustations in
the gas nozzle.
2) Incorrect angle distance of the torch
4) Replace
1) Tighten the clamp and control
The wire does not advance when the wirefeed roller turns.
Wire works in jerks or sporadically
No arc
Porous weld bead
3) Not enough gas
4) Wet pieces
Hot cracks
Low penetration
Low melting rate
Side incisions
Breaks
Too much spatter
[display: no SD card]
[display: low water pressure]
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5) Welding arc too long
1) Pieces dirty
2) Welding with very high thermal input
3) Poor quality welding wire
4) Base materials with elevated quantities
of carbon, sulphur and other impurities.
1) Current too low
2) Irregular wire power supply
3) Major differences in the edges
4) Bevel too small
1) Brusque movements of the torch
2) Incorrect inductance value
3) Oxidized material
1) Welding speed too fast
1) Unsuitable type of wire
2) Poor quality of the workpieces
1) Current too high
2) Incorrect inductance value
3) Torch too angled
1) The SD card was removed
See the manual of the cooling unit
2) Clean or replace the contact nozzle and
wire-guide nozzle.
1) Remove the encrustations
2) The distance between the torch and the
piece must be 5-10 mm; the angle must
not be less than 60° in respect to the
workpiece.
3) Increase the quantity
4) Dry with a hot air pistol or other
instruments
5) Shorten the arc
1) Clean
2) Reduce the welding current
3) Change the welding wire
1) Increase the current
2) See previous points
1) Move the torch continuously
2) Change the inductance value
3) Clean
1) Reduce the welding speed
1) Change the type of wire
1) Reduce the current
2) Increase the inductance
3) Straighten the torch
1) Insert the SD card
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12. BLOCK DIAGRAM
M 5
4
AC Input
6
9
1
2
3
+
Output
-
8
7
1
2
3
4
5
6
7
8
9
Input switch
Input and control power board
Power module
Solenoid valve
Wire-feeder motor
Display
Auxiliary transformer
Fans
Current sensor (mounted on block 2)
13. MEMORISATION OF THE WORKING POINT
As illustrated in the previous sections, the welding machine allows significantly personalising the
working point (in both manual operation and synergic operation).
The best working point for a workpiece can be saved in the memory and quickly retrieved later.
Follow these instructions to save a new working point:
Ready to weld
>
96
Save with name
[ABCD
]
Wire speed
Inductance
2/4 strokes
P1/2
A
V
3.0m/’
5.0
2t
<
>
back sp
OK
MIG-MAG
S.A.M.
1 - Press the MEM+ key (4 in figure 1).
2 – Turn knob 10 (figure 1) to select the first letter of the
name in which you want to save the working point.
3 – Press knob 10 to confirm the selection of the letter.
4 - Repeat steps 2 and 3 until the entire name has been
spelled out.
5 – Confirm the name by pressing the “OK” key.
From this moment onwards, the working point is
memorised with its own name and is displayed together
with the other welding procedures.
Meaning of the buttons:
back sp: cancels the last letter entered.
>: moves the cursor to the right
<: moves the cursor to the left
OK: confirms the name of the working point
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