910.100.317 REV00 MANUALE TM 215_buck:modello manuale.qxd

Instructions manual
TM 215
20050 RONCO B
RIANTINO (MB)
Italy
Via Brigatti, 59
Tel. +39 039 607
9326 - Fax. +39
039 6079334
www.fimer.com
- info@fimer.c
o
Istruzioni Originali
Original instructions
Übersetzung der Originalbetriebsanleitung
Notice originale
Manual original
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ALTRI DATI TECNICI
SPECIFICHE
TECNICHE
Int. Bipolari: 25A Curva K o C
TENSIONE DI INGRESSO: 230V +/- 10%
PROTEZIONE TERMICA: termostato tipo “thermic SO1”
TEMP. INTERVENTO:
Le prove di riscaldamento sono state effettuate alla temperatura di 40°
FUNZIONE ARC FORCE E ANTI-STICKING: presente
DIAMETRI DEGLI ELETTRODI UTILIZZABILI: Ø 0,6; Ø 0,8; Ø 1,0 mm
ITALIANO
PESO: 17 Kg.
DIMENSIONI: 200x450x480
CARATTERISTICA STATICA: cadente
DISPOSITIVO DI PROTEZIONE DI RETE: Fusibili 25A Ritardati
ADDITIONALSPECIFICATION
TECHNICAL INFORMATION
TECHNICAL
Two-Pole 25A K- or C-Standard Switch
INPUT LOAD: 230V +/- 10%
THERMAL PROTECTION: Thermostat : “Thermic SO1”
INTERVENTION TEMPERATURE:
Overheating tests run at 40° C
ARC FORCE AND ANTI-STICKING FUNCTIONS: Present
ENGLISH
WEIGHT: 17 Kg.
DIMENSIONS: 200x450x480
STATIC CHARACTERISTIC: drooping
POWER SUPPLY PROTECTION: 25A Delay-Fuses
MAX ELECTRODE DIAMETERS: Ø 0,6; Ø 0,8; Ø 1,0 mm
WEITERE TECHNISCHE
DATEN
TECHNISCHE
SPEZIFIKATIONEN
Int. zweipolig: 25A K- oder C-Kurve
EINGANGSSPANNUNG : 230V +/- 10%
WÄRMESCHUTZ: Thermostat Typ „thermic SO1”
EINSATZTEMPERATUR:
Die Erhitzungsprüfungen wurden bei einer Temperatur in Höhe von 40° durchgeführt
ARC FORCE UND ANTISTICKING FUNKTION: vorhanden
DEUTSCH
GEWICHT: 17 Kg.
ABMESSUNGEN: 200x450x480
STATISCHE EIGENSCHAFTEN: fallend
NETZSCHUTZVORRICHTUNG: verzögerte 25A Sicherungen
VERWENDBARE ELEKTRODENDURCHMESSER: Ø 0,6; Ø 0,8; Ø 1,0 mm
AUTRES DONNEES
TECHNIQUES
SPÉCIFICATIONS
TECHNIQUES
Int. Bipolaires 25A Courbe K o C
TENSION D’ENTREE : 230V +/- 10%
PROTECTION THERMIQUE : Thermostat type “thermic SO1”
TEMP. INTERVENTION :
Les essais de chauffe ont été effectués à la température de 40°
FONCTION ARC FORCE ET ANTICOLLANT : present
FRANÇAIS
POIDS: 17 Kg.
DIMENSIONS: 200x450x480
CARACTÉRISTIQUE STATIQUE : cadente
DISPOSITIF DE PROTECTION DE RÉSEAU : Fusées Retardées 25A
DIAMETRES DES ELECTRODES UTILISABLES : Ø 0,6; Ø 0,8; Ø 1,0 mm
ESPECIFICACIONES
TÉCNICAS
OTROS DATOS TÉCNICOS
Int. Bipolares: 25A Curva K o C
TENSIÓN DE ENTRADA: 230V +/- 10%
PROTECCIÓN TÉRMICA : termostato tipo “thermic SO1”
TEMP. INTERVENCIÓN :
Las pruebas de calentamiento se han realizado con una temperatura de 40 ºC.
FUNCIÓN FUERZA ARC Y ANTISTICKING : presente
ESPAÑOL
PESO: 17 Kg.
DIMENSIONES: 200x450x480
CARACTERÍSTICA ESTÁTICA : cadente
DISPOSITIVO DE PROTECCIÓN DE RED : Fusibles 25A Retardados
DIÁMETROS DE LOS ELECTRODOS UTILIZABLES : Ø 0,6; Ø 0,8; Ø 1,0 mm
VII
ITALIANO
USE AND MAINTENANCE MANUAL
Fimer S.p.a. thanks you for selecting this unit, it will prove to be a useful, problem-free
tool for many years to come if the instructions contained in this manual are followed scrupulously.
ENGLISH
This manual must be considered as an integral part of the unit and must accompany it
when it change location or is resold.
The user must assume responsability for maintaining this manual intact and legible at all
times.
INDEX
DEUTSCH
Fimer S.p.a. reserves the right to modify this manual at any time without notice.
All rights of translation and total or partial reproduction by any means whatsoever (including scanner, photocopy, film, and microfilm) are reserved and reproduction is prohibited
without the express written consent of Fimer S.p.a.
• WARNING .........................................................................................................
............................................................................................................... pag. 2, 3, 4
FRANÇAIS
pag. 5
pag. 6
pag. 8
pag. 8
pag. 8
pag. 8
pag. 9
pag. 9
pag. 9
pag. 10
pag. 10
pag. 10
pag. 10
pag. 10
pag. 10
pag. 11
pag. 11
pag. 12
pag. 12
pag. 12
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pag. 16
ESPAÑOL
1. GENERAL INFORMATION........................................................................
2. DESCRIPTION OF WELDER ...................................................................
3. WELDING METHODS ...............................................................................
3.1 MIG/MAG WELDING .............................................................................
3.1.1 MANUAL MIG WELDING ....................................................................
3.1.2 SYNERGIC SHORT ARC MIG WELDING ...............................................
3.1.3 SYNERGIC PULSED MIG WELDING ..................................................
3.2 MMA WELDING ....................................................................................
4. CONNECTION TO POWER SUPPLY .......................................................
5. OUTPUT CONNECTIONS ......................................................................
5.1 MIG WELDING CONNECTIONS - with shielding gas and standard torch
5.2 MIG WELDING CONNECTIONS - gasless and standard torch .............
5.3 MIG WELDING CONNECTIONS - with shielding gas and Spool torch........
5.4 MIG WELDING CONNECTIONS - with shielding gas and Spool torch ........
5.5 MMA WELDING CONNECTIONS ...........................................................
6. WELDING WIRE INSTALLATION .............................................................
6.1 WELDING WIRE INSTALLATION .........................................................
7. GAS CYLINDER AND GAS PRESSURE REGULATOR CONNECTIONS.....
8. WELDING METHODS ...........................................................................
8.1 MANUAL MIG WELDING ....................................................................
8.2 SYNERGIC MIG WELDING..................................................................
8.3 MMA WELDING ..................................................................................
8.3.1 DESCRIPTION ................................................................................
8.3.2 MMA WELDING FEATURES....................................................................
8.3.3 MMA WELDING .......................................................................................
9. WIRE LINER REPLACEMENT ...............................................................
10. DEFAULT PARAMETER ADJUSTMENT .................................................
11.TROUBLE SHOOTING ..........................................................................
12. BLOCK DIAGRAM ...............................................................................
1
WARNINg SYMBOLS
DANgER
(Indicating a hazard that could cause injury or damage)
DANgER COMpRESSED gAS
Indicating the risk of injury or death in the event of improper handling or maintenance of compressed gas cylinders or regulators
ELECTRIC SHOCK
(Indicating the danger of electric shock)
FIRE
pRECAUTIONS
DANgER
OF FIRE OR EXpLOSION.
IMpORTANT INFORMATION
Indicating the precautions to be taken when installing and
using the unit.
Indicating that eye protection is required to avoid
burns and eye damage.
DISpOSAL
INFORMATION
TOXIC gAS
Indicating the risk of toxic gas hazards
INSTALLATION
INSTRUCTIONS
HOT SLAg
Indicating the risk of being burned by hot slag
OpERATINg
INSTRUCTIONS
EYE pROTECTION
Indicating that eye protection is required to avoid flying debris
UNpACKINg
INSTRUCTIONS
READ THE INSTRUCTION MANUAL
SUITABLE FOR ENVIRONMENT WITH INCREASED
HAZARD OF ELECTRIC SHOCK
CAUTION
SAFETY WARNINgS
This equipment is designed solely for industrial or
professional use. As such, only experienced or fully-trained people should use the equipment. The user
and/or owner is responsible for ensuring inexperienced personnel does not have access to the equipment.
Fimer SpA declines all responsibility for injury or damage caused by inexperienced, improper or neglectful use
of its equipment.
A workman must look after his tools carefully ! Remember that
any tool or equipment can become a hazard if it is not looked
after properly.
Equipment in a state of disrepair or neglect can be dangerous. If it
does not operate properly or overheats, the electricity supply should
be removed immediately and the unit should be returned to the supplier for repair.
Read this manual carefully before using your Welder.
You can then do a better and safer job.
By reading this manual you will learn more about the
possibilities, limitations and potential dangers of welding.
Retain this manual for the entire life of the equipment. It should be
kept within the operator’s reach at all times.
The safety information contained in this manual is a guide to
ensure you are not subjected to unnecessary risks. However,
the operator must be competent and careful at all times.
All equipment connected to electric power supplies can be dangerous if the manufacturers instructions are not read and observed. Read, understand and observe these safety instructions
to reduce the risk of death or injury from electric shock. Ensure that
even bystanders are aware of, and understand, the dangers that exist in the welding area.
Fires and explosions can seriously injure or cause damage ! Read, understand and observe all safety warnings
to reduce the risk of death or injury from fire or explosion. Pay particular attention to the fact that even bystanders should
be aware of, and understand, the dangers existing in the welding area.
Remember that welding, by nature, produces sparks, hot spatter, molten metal drops, hot slag and hot metal parts that can cause fires, can
burn skin and damage eyes.
Arc rays can damage your eyes and burn your skin ! Read,
understand and observe all safety warnings to avoid damage from arc rays. Pay particular attention to the fact that
even bystanders should be aware of, and understand, the dangers existing in the welding area. Wear a protective mask and make sure bystanders do the same.
Fumes, toxic gases and vapours can be harmful ! Read,
understand and observe all safety warnings to avoid harm
from toxic welding gases. Pay particular attention to the fact that even
bystanders should be aware of, and understand, the dangers.
Carelessness while using or maintaining the compressed gas cylinders or regulators can injure or kill the
operator and/or bystanders ! Read, understand and observe all safety
warnings to avoid the dangers of compressed gas. Pay particular
attention to the fact that even bystanders should be aware of, and
understand, the dangers.
HIgH VOLTAgE
The unit carries potentially lethal voltage.
The high voltage areas of the equipment have been segregated
and can be reached only by using tools that are not provided with the
Welder.
All maintenance or repair operations requiring access to such areas may
only be performed by Fimer-trained technicians.
FOREIgN OBjECTS
Never block the air vents with foreign objects and avoid
any contact with liquids. Clean using just a dry cloth. These safety precautions apply even when the unit is switched off.
WEIgHT LOADS
The upper part of the Welder was not designed to withstand heavy loads. Never stand on the unit.
CABLE gAUgES
Check that all cables are appropriately gauged for
the input power required by your specific Welder.
This precaution applies also to extension cables, if used. All extension
cables must be straight. Coiled cables can overheat, becoming dangerous. Twisted or coiled cables can also cause Welder malfunction.
OVERLOAD PROTECTION
Check that the power source supplying the Welder carries the
correct voltage and is safety-protected. The power switch must open all the
power supply circuits. (If a single-phase connection is used, both the live and
the neutral poles must be open. If a three-wire connection is used , all three
poles must be open. Four-wire circuits require all poles and neutral open).
Time-delayed fuses or K-standard circuit breakers should be used.
EARTHING
If the Welder was not already supplied with a plug, connect the
earth wire first. When removing the plug, disconnect the earth
wire last.
PLUG AND POWER SUPPLY
If the Welder already has a plug attached, check that it is appropriate for the wall-socket you intend using. Never tamper with
the power cable.
CABLE COLOURS
The green-yellow wire is for earthing. (Don’t use it for
anything else !)
RELOCATION 1
Some Welders are extremely heavy therefore care should be
taken when relocating the unit. Check the floor or platform weight load limitations before relocating the unit if the Welder is to be used,
even only temporarily, in a non-industrial environment
RELOCATION 2
Never store or move the Welder in an inclined position or on its
side.
SPARE PARTS
Use only manufacturer-recommended spare parts.
Other spare parts could cause equipment malfunction. The use of non-original spare parts will also result in the warranty provisions becoming null and void, releasing the manufacturer
from any responsibility for malfunction or damage resulting as a consequence of such action.
WELDING OPERATION
SAFETY INSTRUCTIONS
CAUTION !
Welding processes can be dangerous for the operator and bystanders
if the safety warnings and instructions are not heeded.
PERSONNEL PROTECTION
Together with the previous instructions, the following
precautions should be strictly observed
PROTECTION MASK
Wear a protective non-flammable welding mask
to protect your neck, your face and the sides of
your head. Keep the front lens clean and replace it if it is broken
or cracked. Place a transparent protection glass between the mask
and the welding area.
CLOTHING
Wear close-fitting, closed, non-flammable, pocketless clothing.
INSTALLATION ENVIRONMENT
The equipment is not suitable for use in washrooms,
shower cubicles, pool areas or similar environments. If
you are obliged to use the unit in such areas, turn off all water supplies and check the area has been evacuated.
EYE PROTECTION
OPERATING AND/OR INSTALLATION ENVIRONMENT 1
The Welder was not designed for installation or use in areas where it
could be subject to blows or vibration, such as road-vehicles, railway
carriages, cable-cars, aircraft, ships or boats or similar environments (including
cranes, conveyor-carriers or any other mobile equipment prone to vibration)
FUMES AND GASES 1
Clean away paint, rust or any other dirt from the item to
be welded to avoid the creation of dangerous fumes.
OPERATING AND/OR INSTALLATION ENVIRONMENT 2
The Welder should never be used or stored in the rain or in snow.
OPERATING AND/OR INSTALLATION ENVIRONMENT 3
Never use the Welder in an explosive, corrosive, abrasive or saline environment.
EXTINGUISHER
Always place an approved fire extinguisher in the immediate vicinity
of the work area. Fire extinguishers should be checked regularly.
LOCATION
Place the Welder well away from heat sources. Place the
Welder in a well-ventilated environment. Place the Welder in
a safe, protected area. It must not be installed outdoors. Do not install the
Welder in dusty environments. Dust can get into the inner parts of the unit
and inhibit cooling. The Welder must be positioned on a flat, stable surface that extends further than the units own dimensions in all directions.
CLEAN LOCATIONS
The installation area must be kept clean and dry to be sure the Welder
fans do not draw in small objects or liquids. Not only could the equipment malfunction but a serious risk of fire outbreak could be created.
REPAIRS
Never attempt to repair the Welder yourself. Always
refer to the manufacturer or an authorized repairer.
All warranty provisions will immediately become null and void if any repair,
or attempt to repair, not specifically authorized in writing or handled by
Fimer S.p.A. is carried out. Furthermore, Fimer S.p.A. will accept no
responsibility for any malfunction or damage resulting as a consequence of such unauthorized action.
TECHNICAL ASSISTANCE
The Welder must be taken to an authorized Technical Assistance Centre if the equipment has been damaged in any way
or if any one of the following events occurs : liquid infiltration; damage caused by falling objects; exposure to rain or humidity (exceeding
the specified limits); malfunction; performance failure or if the equipment has been dropped.
VENTILATION
Weld in a well-ventilated environment that does not have
direct access to other work areas.
NEVER look at the arc without appropriate eye protection.
FUMES AND GASES 2
NEVER weld on metals containing zinc, mercury, chromium, graphite, heavy metals, cadmium or beryllium unless
the operator and the bystanders use appropriate air-supplied respirators.
HIGH VOLTAGE PROTECTION
Together with the previous instructions, the following precautions should be strictly observed
CONFINED SPACES
When welding in small environments, leave the power
source outside the area where welding will take place and
attach the grounding clamp to the part to be welded.
HUMIDITY
Never weld in wet or humid environments.
DAMAGED CABLES
Never use damaged cables. (This applies to both
the power and the welding cables.)
DAMAGED CABLES
Never remove the unit side panels. If the side panels
can be opened, always checked they are closed
tightly before starting any work.
FIRE PREVENTION
Together with the previous instructions, the following precautions should be strictly observed.
Welding operations require high temperatures therefore
the risk of fire is great.
WORK-AREA FLOORING
The work-area flooring MUST be fireproof.
WORK-AREA SURFACES
Work benches or tables used during welding
MUST have fireproof surfaces.
3
WALL AND FLOOR PROTECTION
The walls and flooring surrounding the welding
environment must be shielded using non-flammable materials. This
not only reduces the risk of fire but also avoids damage to the walls and floors during welding processes.
EXTINGUISHER
Place an approved and appropriately-sized fire extinguisher in
the work environment.
Check its working order regularly (carry out scheduled inspections)
and ensure that all parties involved know how to use one.
CLEAN ENVIRONMENT
Remove all flammable materials away from
the work environment.
DAMAGED GAS CYLINDERS
NEVER use damaged or faulty cylinders.
CYLINDER RELOCATION
NEVER lift a gas cylinder by holding the regulator.
GAS CYLINDERS
Do not expose gas cylinders to excessive heat sources, sparks, hot slag or flames.
GAS HOSE 1
Check the gas hose is not damaged.
GAS HOSE 2
Always keep the gas hose well away from the work
area.
ELECTRIC SHOCK
SERIOUS DANGER ! 1
NEVER weld in confined spaces (e.g. in a container vehicle, a cistern or a storeroom etc.) where toxic, inflammable or explosive materials are, or have been, located or stored.
Cisterns, in particular, may still contain toxic, flammable or explosive gases and vapours years after they have been emptied.
SERIOUS DANGER ! 2
NEVER weld a cistern that contains (or has stored)
toxic, inflammable or explosive materials. They could
still contain toxic, flammable or explosive gases and vapours years
after they have been emptied. If you are obliged to weld a cistern,
ALWAYS passivate it by filling it with sand or a similar inert substance before starting any work.
SERIOUS DANGER! 3
NEVER use the Welder to melt frozen water
pipes.
VENTILATION
Together with the previous instructions, the following precautions should be strictly observed
WELDING ENVIRONMENT VENTILATION
Ventilate the welding environment carefully. Maintain
sufficient air-flow to avoid toxic or explosive gas accumulation.
Welding processes on certain kinds or combinations of metals can
generate toxic fumes. In the event of this happening, use air-supply respirators. BEFORE welding, read and understand the welding alloy safety provisions.
PROTECTIVE WELDING GASES
Together with the previous instructions, the following
precautions should be strictly observed when welding
with protective gases
GAS TYPES
These welders use only inert (non-flammable) gases for welding
arc protection. It is important that the appropriate type of gas is
chosen for the type of welding being performed.
UNIDENTIFIED GAS CYLINDERS
NEVER use unidentified gas cylinders.
PRESSURE REGULATOR 1
NEVER connect the cylinder directly to the Welder.
Always use a pressure regulator.
PRESSURE REGULATOR 2
Check the regulator is performing its function properly.
Read the regulator instructions carefully.
PRESSURE REGULATOR 3
Never lubricate any part of the regulator.
PRESSURE REGULATOR 4
All regulators are designed for a specific type of gas.
Check the regulator is appropriate for the protective
gas to be used.
4
Together with the previous instructions, the following pre-
cautions should be strictly observed to reduce the risk of
electric shock
ELECTRIC SHOCK INJURY
DO NOT touch a person suffering from electric shock if
he/she is still in contact with the cables. Switch the mains power
source off immediately THEN provide assistance.
CABLE CONTACT
Do not tamper with power cables if the mains power is still
switched on. Do not touch the welding circuitry. Welding circuitry is usually low voltage, however, as a precaution, do not touch the welder electrodes.
CABLE AND PLUG PRECAUTIONS
Check the power supply cable, plug and wall-socket regularly.
This is particularly important if the equipment is relocated often.
REPAIRS
Never attempt to repair the Welder yourself. The result would
not only cause warranty cancellation but also high danger risks.
MAINTENANCE PRECAUTIONS
Always check that the electric power supply has been disconnected before performing any of the maintenance operations listed in this manual ( e.g. before replacing any of the following: worn electrodes, welding wires, the wire feeder etc.)
Never point the welding gun or the electrode towards yourself
or others.
ELECTROMAGNETIC COMPATIBILITY
Check no power supply cables, telephone cables or other
electrical items (e.g. computer cables, control lines etc.) are
in the vicinity of the Welder.
Check there are no telephones, televisions, computers or other
transmission devices close to the Welder.
Make sure that people with pace-makers are not in the immediate vicinity of the Welder.
Do not use the Welder in hospitals or medical environments
(including veterinary surgeries). Make especially sure there
is no electrical medical equipment being used close to where welding is being done.
Should the Welder interfere with other apparatus, take the following precautionary measures:
1.
Check the Welder’s side panels are securely fastened.
2.
Shorten the power supply cables.
Place EMC filters between the Welder and the power source. (Contact Fimer Technical Dept. in this respect )
EMC compatibility : CISPR 11, Group 21, Class A.
7. GAS CYLINDER AND GAS PRESSURE
REGULATOR CONNECTIONS
Only for MIG welding: Skip this charter
entirely if the welder is to be used for MMA
6
1
5
1
2
2
3
8. WELDING METHODS
8.1 Manual MIG welding
To select this mode, turn knob 7 (Fig.1) to the
MIG MAN setting.
N.B.: These are guidelines only and are to be considered applicable solely to workpieces no thicker
than 4mm. The settings are selected according to
wire diameter, location and welding gas.
Step 1: Current selection
Convert the thickness of the
workpiece in to Amperes (A)
using the following formula:
0.025mm = 1A
i.e. 3mm = 125A
5
3
Step 2: Wire diameter selection
4
Fig.6
Carefully follow the procedure shown
in Fig. 6:
Connect the pressure regulator (2) to the gas
cylinder (3). Tighten the bolt (6) between the regulator (2) and the cylinder (3). Do not overtighten
to avoid damaging the cylinder valve (1).
Connect the gas hose of the torch (4) to the
pressare regulator (2) and clamp securely
using a clasp (5). (Alternatively use cylinder
and hose fast connectors).
Connect the other end of the gas hose (6) to the
socket on the rear panel of the welder unit
(Fig.2 – 23), securing it with a clasp.
Connect the gas hose from the torch to the
appropriate socket (7) on the front panel of the
unit (fig 1 - 33), tightening clockwise. Do not
over-tighten.
Open the gas cylinder valve (1). Press the torch
button and check that gas is flowing through
correctly.
WARNING: Cylinders contain high pressure
gas. Handle them with care. Inappropriate
treatment can cause serious accidents. Do not
pile gas cylinders up and never expose them to
excessive heat, flames or sparks. Do not bang
cylinders against each other. Contact your supplier for more information regarding the use and
maintenance of gas cylinders.
WARNING: Never use cylinders that are damaged or show signs of oil or grease leakage.
Contact your supplier immediately of any such
circumstances.
11
AMPERE (Min-Max)
40-90 A
60-140A
80-160A
100-200A
WIRE DIAMETER
0,6mm
0,8mm
1mm
1,2mm
Step 3: Wire diameter selection
0,6mm
recommended
wire speed
wire speed
1 amp ( 90mm/min) 90x120=11m/min
0,8mm
1 amp ( 50mm/min) 50x120=6m/min
1mm
1 amp ( 40mm/min) 40x120=5m/min
1,2mm
1 amp ( 30mm/min) 30x120=3,5m/min
wire diameter
Step 4: Electronic inductance selection
Material
Electronic inductance setting
Ferrous materials (SG2 SG3)
min <~> med
Stainless steel (NI-Cr)
med
Aluminium (Al)
med <~> max
Copper-silicon (Cu-SI3)
med <~> max
Copper-aluminium (CU-Al8)
med <~> max
Fig 7: Current reference values, wire diameter,
wire speed and electronic inductance.
Proceed as follows for manual MIG welding:
1. Set the welding current, according to the
thickness of the workpiece and the diameter of
the wire to be used, using the knob 10, Figure 1
(Step 1, Fig8). The display panel (Fig. 1 – 1)
shows the value selected.
2. According to the diameter of the wire, set
the wire speed using knob 9 of Figure 1.
(Step 3, Fig.8)
3. According to the kind of material, regulate the
electronic inductance (Fig. 1 – 8). (Step 4, Fig8)
4. Connect the earth clamp to the workpiece.
5. Start to weld maintaining an arc length of
between 5 to 10 mm.
6. Regulate the wire speed (Knob Fig. 1 –
9).For best results regulate the speed (Knob 9)
until a loud, regular sizzling sound is heard (similar to that of frying bacon). Always perform a
trial run using a metal sheet that is free of
grease, rust or paint.
For best results heed the following advice:
1. Keep the torch at a 45° angle to the workpiece. Keep the gas nozzle (Fig.4A) app. 6 mm
away from the workpiece.
2. Move the torch smoothly.
3. Weld using small zigzag movements so as to be
able to regulate the size of the weld as desired.
4. Do not weld in windy surroundings. Draughts
can disperse the gas from the welding pool
causing porous welding results.
5. Ensure the wire is clean: never use rusty
welding wire.
6. Keep the torch cable straight.
7. Clean the wire-feed guide with compressed
air when changing spools.
8. Remove dust from the air intake grills regularly, using low-pressure compressed air. Always
point the jet of air outwards to avoid dirt being
forced into the unit.
Pulsed mode:
Pressing button 12 of Fig.1 will set the unit in manual pulsed MIG welding mode. LED 6 of Figure 1
will be on. This mode is for experienced operators
only. In fact it is mainly used as an alternative to synergic pulsed MIG welding under rare circumstances, e.g. for special materials and when satisfactory results cannot be achieved using the predefined settings. In this mode the potentiometer knob
(Fig. 1 – 10) regulates the welding current, knob 9
(Fig.1) sets the wire speed and knob 8 (Fig.1) regulates the pulsing frequency.
8.2 SYNERGIC MIG WELDING
In synergic MIG welding (with gas) mode the
welder tunes itself automatically to suit the type
of material to be welded and the thickness of the
workpiece. Contrary to manual mode, a series of
predefined programmes to suit all requirements
are available.
It should be noted, however, that certain parameters can be set manually. More information in
this respect will be provided in later sections. A
choice of Short-Arc (Fig. 1, LED 6 off) or Pulsed
(Fig. 1, LED 6 on) synergic MIG welding is available. Press the
Pulse button (Fig.1 – 12) lightly to switch mode.
To select this mode, turn knob 7 (Fig.1) to one of
the SYNERGIC settings.
Proceed as follows for synergic MIG welding:
1. Select one of the following programmes
according to the type of material to be welded
(Selector knob 7, Fig1)
•
Al-Mg 0.8: The permissible thickness range
is 0.8 to 4 mm.
•
Al-Mg 5 1.0: The permissible thickness
range is 0.9 mm to 5 mm.
•
Al-Si 12 1.0: The permissibile thickness
range is 0.8mm to 5 mm (Spool Gun welding is
recommended for this type of wire).
•
ideal for welding stainless steel (Ni-Cr)
0.8mm in diameter. The permissible thickness
range is 0.8 mm to 5 mm.
•
ideal for welding SG2 or SG3 materials
0.8mm in diameter. The permissible thickness
range is 0.8 mm to 3.2 mm.
•
Cu-Si 3 0.8: Ideal for Cu-Si3 having a diameter of 0.8 mm. Such materials can be braze
welded, particularly zinc-plates iron sheets to be
used by car manufacturers The permissible
thickness range is 0.8 to 4 mm.
2. Select the workpiece thickness using Knob
2 of Figure 10. The display panel (Fig. 1 – 1) will
display the selected thickness parameter (in
mm) for a few seconds.
3. Turn knobs 8 and 9 to a mid-way position.
4. Connect the earth clamp to the workpiece.
5. Start to weld maintaining an arc length of
between 5 to 10 mm.
A high-quality result is usually achieved in this
mode. However, the following instructions may help
you achieve even better results depending upon
whether Short-Arc or Pulsed mode is being used.
Short-Arc Mode:
6- If during welding the arc tends to decrease
excessively, turn knob 9 of Figure fig1 anti clockwise
to reduce the wire speed, which will also decrease
the weld pool. If, on the other hand, the arc tends to
over-lengthen, turn the knob clockwise.
7.
If there is too much splatter while welding,
the electronic
inductance parameter needs to be increased. Do so
turning knob 8 of Figure 1 clockwise. If maintaining
an arc is difficult, turn the knob anti-clockwise.
Pulsed mode:
8. To vary the length of the arc fine-tune
knob 9 of Figure 1.
12
8.3 MMA WELDING
8.3.1 Description
Electric MMA (Metal Manual Arc) and
SMAW (Shielded Metal Arc Welding) are
both manual procedures exploiting the heat
generated by an electric arc that is produced when covered welding electrodes
make contact with the workpiece. It is commonly used due to its versatility. In fact,
welding jobs can be performed anywhere:
in a workshop, in the open, in confined
spaces or hard to reach areas. A wide
range of electrodes are available, suiting
all requirements. The arc is generated
touching the electrode to the workpiece.
The potentiometer knob (Fig. 1 –10) regulates the welding current (thicker workpieces require higher current settings).
8.3.2 MMA Welding Features
While welding the following features come
into effect:
Arc Force: Whenever the arc tends to drop
the microprocessor automatically increases
the welding current in order to maintain and
stabilise the arc.
Hot Start: The arc is generated touching
the electrode to the workpiece. To ensure
the arc is generated efficiently, the microprocessor increases the welding current for
app. one second, guaranteeing fast, safe
arc generation.
Antisticking: Decreases the welding current up to minimum, when the operator
makes a mistake causing the electrode to
stick to the workpiece. The electrode can
be removed from its clamp without causing
damaging sparks.
14
8.3.3 MMA Welding
Diameter (mm)
Current (A)
1.6
35-50
2.0
40-70
2.5
60-100
3.25
80-140
4.0
120-170
5.0
180-250
Fig 8 Welding current at the electrode
diameter.
Proceed as follows for MMA welding:
1. Using knob 10 (Fig.1) select the welding
current according to the type of electrode
and the thickness of the workpiece. The
welding current value is shown on display
panel 13. The knobs 8 and 9 (fig.1) are disabled. Guidance values suitable for various electrode diameters are provided in
Fig 9.
2. Connect the earth clamp to the workpiece.
3. Place the electrode in the clamp.
4. During the entire welding process maintain a 3-4mm distance from the welding
pool that has been created. Weld using
small zigzag movements so as to be able
to regulate the size of the weld as desired.
5. Remove the electrode from the workpiece to stop welding.
WARNING: When “Basic” electrodes are
being used, remove any residue left on the
electrode before welding. To do that, gently tap the electrode on a metallic surface.
(If residue is left on an arc cannot be generated).
9. WIRE LINER REPLACEMENT
In case of wire liner replacement please follow carefully this instructions.
• Gun side: remove the gas nozzle (A).
• Unscrew the wire liner tip (B).
A
B
• Connector side (C): unscrew the terminal
nut (D, E) and grab the end of wire liner
using a pliers and start to extract the wire
liner (F).
C
D
• Complete the extraction of the wire liner (G)
E
F
• Insert the new liner and push up to end
(H).
• Now rescrew the liner tip (B) on the gun.
G
10. DEFAULT PARAMETER ADJUSTMENT
The information contained in this paragraph is
not essential for normal use of the welder and
the operations described herein should, in fact,
only be carried out by experienced welders.
For instance, the default wire speed controlled
by the synergic programmes (P.CV) can be
adjusted, as can the measurement units (P.PU)
used to specify the workpiece thickness. None
of the other default parameters (P.PR e P.PO)
should ever be adjusted.
The default P.CV value is 140 but is adjustable
within a range of 0 to 250. When the P.PU is set
to 0, the units displayed are in mm. When it is
set to 1, the units are expressed in inches.
To access the programming menu, press button
12 (Fig.1) for at least 8 seconds or until “P.CV”
(wire speed setting) is displayed. To change the
speed, press the same button again. The current value will be displayed. Button 13 (Fig.1)
(Wire Load) increases the speed.
Button 11 (Fig.1) (ON/OFF Spool) decreases
the speed. Button 12 (Fig.1) (MIG Pulse) confirms the selection and the programme returns
to the initial “P.CV” position.
To change settings controlling how the measurment units are expressed, press button 13
(Fig.1, Wire Load) until “P.PU” is displayed
Buttons 13 and 11 alternate between mm and
inches.
Button 12 (Fig.1. MIG Pulse) confirms the
selection and the programme returns to the initial “P.PU” position.
To exit the programming menu, scroll down the
menu list using buttons 13 and 11 (Fig.1) until
“End” is displayed. Press button 12 (Fig.1) to
confirm.
H
• Complete the liner substitution rescrewing
the covering nozzle (A).
Figure 9: wire liner replacement
15
11. TROUBLE SHOOTING
The most common problems and their solutions are listed below:
DEFECT
Welder does not start.
The wire does not feed
when the wire-feeder roller rotates
CAUSE
SOLUTION
1) Make sure that there is voltage in 1) Switch-on the supply mains
the supply mains
1) Dirt on the tip of the wire-feeder
1) Blow with compressed air, replace nozzle
2) Excessive spool torque.
2) Loose
3) Faulty torch.
3) Check wire-feeder liner.
1) Faulty gas nozzle.
2) Replace
2) Scorched gas nozzle.
2) Replace
3) Dirt in wire-feeder roller groove.
3) Clean
4) Worn wire-feeder roller groove
2) Replace
Arc cut-out
1) Loose earth clamp grip.
1) Tighten clamp grip
Welder cuts out after prolonged use
2) Short circuit between contact nozzle and gas hose.
1) Unit overheated and thermal protection device has set in
2) Clean or replace contact nozzle and
wire-feed nozzle
1) Leave the unit to cool down for at least
1-20 minutes.
1) Lack of shielding gas caused by
build-up in gas nozzle
1) Clean away build-up
2) Incorrect torch angle
2) The air gap between the torch and the
workpiece must be 5-10 mm. Ensure 60° torch
angle.
3) Gas shortage
3) Increase gas flow
4) Damp workpieces
5) Welding Arc too long
4) Dry workpieces with hot-air gun or suchlike
5) Shorten the arc
1) Damp workpieces
1) Clean
2) Welding with very high heat supply
2) Decrease the welding current
3) Impure welding wire
3) Change the welding wire
Jerky or intermittent wirefeed.
Porous welds
Hot cracks
4) Base material with high content of
carbon, sulphur and other imputities
Insufficient penetration
1) current too low
1) increase the current
2)
2) See the above paragraph
Inconstant wire feeding
3) Edges too apart from each other
4) Bevel too small
Insufficient melting
1) Abrupt movements of the torch
1) Move the torch smoothly.
2) Non-optimized inductance value
2) Change the inductance value.
3) Oxidized workpieces
3) Clean
Lateral indentations
1) Excessive welding speed
1) Decrease the welding speed
Breakages
1) Unsuitable wire
1) Change the type of wire
2) Bad quality of the workpieces
Excessive splashes
16
1) current too high
1) Decrease the current value
2) Non-optimized inductance value
2) Increase the inductance value
3) torch too inclined
3)
Straighten the torch
12. BLOCK DIAGRAM
1.
2.
3.
4.
Input Switch
Control and power card
Solenoid Valve
Wire-feeder motor
5.
6.
7.
FAN
Display panel
Current sensor (installed on block 2)
17
NOTE:
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Per RAEE PROFESSIONALI s’intendono tutti i rifiuti di apparecchiature elettriche ed elettroniche destinate ad uso prettamente industriale.
Per RAEE DOMESTICO s’intendono tutti i generatori ad alimentazione monofase con corrente di uscita MAX <= 200A
con i loro accessori.
ITALIANO
ITALIANO
Per RAEE s’intendono i rifiuti di Apparecchiature Elettriche ed Elettroniche (AEE) incluse di tutti i componenti,i sottoinsiemi
ed i materiali di consumo che sono parte integrante del prodotto nel momento in cui si assume la decisione di disfarsene.
La Legislazione prevede la suddivisione in 2 categorie principali chiamate RAEE PROFESSIONALI o RAEE DOMESTICI.
Per lo smaltimento di un RAEE DOMESTICO si avranno 2 possibilita’:
a)Nel caso si decidesse di comprare una nuova apparecchiatura equivalente l’utilizzatore potrà consegnarlo al distributore il quale dovrà ritirarlo gratuitamente.
b)Dovrà depositarlo nella piazzola Comunale, nel contenitore o apposita area identificata come “RAGGRUPPAMENTO 4”.
Per lo smaltimento di un RAEE PROFESSIONALE alla data di redazione del Manuale di istruzioni non essendo ancora
definitiva l’applicazione della Normativa si prega di contattare il distributore e/o Il costruttore per informazioni in merito allo
smaltimento.
ALLA DATA DELLA REDAZIONE DEL PRESENTE MANUALE D’ISTRUZIONI QUESTE INFORMAZIONI SONO DA
RITENERSI NON DEFINITIVE IN QUANTO SUSCETTIBILI DI POSSIBILI MODIFICHE SECONDO GLI OBBLIGHI
LEGATI AL DECRETO LEGISLATIVO N° 151/2005 CHE OTTEMPERA LA DIRETTIVA 2002/96/CE.
AIS
ENGLISH
The presence of these materials may, if not disposed of properly, have potential adverse affects
on the environment. Presence of this label on the product means it must not be disposed of in
normal household waste and must be disposed of separately.
Nur für EU-Länder
Werfen Sie Elektrogeräte nicht in den Hausmüll
DEUTSCH
As a consumer you are responsible for ensuring that this product is disposed of properly. If your
supplier offers a disposal facility please use it or alternatively contact your local authority/council to find out how to properly dispose of this product.
Gemäß Europäischer Richtlinie 2002/96/EG über Elektro- und Elektronik-Altgeräte und Umset-
zung in nationales Recht müssen verbrauchte Elektrowerkzeuge getrennt gesammelt und einer
umweltgerechten Wiederverwertung zugeführt werden.
Ne pas jeter les appareils électriques avec les déchets ordinaires!
No tirar nuncalos aparatos eléctricos junto con los residuos en general!
FRANÇAIS
Conformément à la Directive Européenne 2002/96/EC relative aux Déchets d’Équipements
De
conformidad
a la Directiva Europea
relativa a los
Residuos
de Equipos
ElécÉlectriques
ou Électroniques
(DEEE), 2002/96/EC
et à sa transposition
dans
la législation
nationale,
tricos
o
Electrònicos
(RAEE)
y
al
acuerdo
de
la
legislaciòn
nacional,
los
equipos
eléctricos
les appareils électriques doivent être collectés à part et être soumis à un recyclage
deberàn
ser de
recogidos
y reciclados respetando el medioambiente.
respectuex
l’environnement.
Como
propietario
del equipo,
informar de
los devriez
sistemasvous
y lugares
apropiados
para
la recoEn tant
que propriétaire
dedeberà
l’équipement,
vous
informer
sur les
systèmes
gida
de
los
mismos.
de collecte approuvés auprès nos représentants locaux.
Aplicar
estacette
Directiva
Europea
protegeràaméliorera
el medioambiente
y su salud!et la santé!
Appliquer
Directive
Européenne
l’environnement
Ne
pas nuncalos
jeter les appareils
électriques
avec
les
ordinaires!
No tirar
aparatos eléctricos
junto
con
losdéchets
residuos
en general!
Conformément
2002/96/EC
relative
Déchets
De conformidadàalalaDirective
Directiva Européenne
Europea 2002/96/EC
relativa
a losaux
Residuos
ded’Équipements
Equipos ElécÉlectriques
ou
Électroniques
(DEEE),
et
à
sa
transposition
dans
la
législation
tricos o Electrònicos (RAEE) y al acuerdo de la legislaciòn nacional, los equiposnationale,
eléctricos
les
appareils
électriques
doivent respetando
être collectés
à part et être soumis à un recyclage
deberàn
ser recogidos
y reciclados
el medioambiente.
respectuex de l’environnement.
ESPAÑOL
FRANÇAIS
ESPAÑOL
ESPAÑOL
FRANÇAIS
DEUTSCH
ENGLISH
This product contains electrical or electronic materials.
Como propietario del equipo, deberà informar de los sistemas y lugares apropiados para la recoEn
quemismos.
propriétaire de l’équipement, vous devriez vous informer sur les systèmes
gidatant
de los
de collecte approuvés auprès nos représentants locaux.
Aplicar esta Directiva Europea protegerà el medioambiente y su salud!
Appliquer cette Directive Européenne améliorera l’environnement et la santé!
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