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INSTRUCTION MANUAL FOR WIRE WELDING MACHINE
IMPORTANT:
BEFORE USING THIS DEVICE ALL PEOPLE AUTHORIZED TO USE, REPAIR OR INSPECT IT, SHOULD READ
THE FOLLOWING INSTRUCTIONS ON ITS USE AND
SAFETY. PLESE CONTACT YOUR DISTRIBUTOR
SHOULD YOU NOT UNDERSTAND THESE INSTRUCTIONS.
available for each shift unless medical facilities are close by
for immediate treatment of flash burns of the eyes and skin
burns.
● Ear plugs should be worn when working on overhead or in
a confined space. A hard hat should be worn when others
work overhead.
● Flammable hair preparations should not be used by
persons intending to weld or cut.
1 SAFETY RULES FOR USING WELDING MACHINE
1.2.3
1.1
INTRODUCTION
Before using this device all people authorized to use, repair
or service it should read the following use and safety
instructions.
Remember: YOUR SAFETY DEPENDS ON YOU!!!
Follow all safety rules and instructions.
It is your job to protect yourselves and others against the
risks related to welding.
The operator is responsible for his own safety and the safety
of others in the work area. He must therefore know and obey
all safety rules.
NOTHING CAN REPLACE GOOD COMMON SENSE !!!
1.2
GENERAL PRECAUTIONS
1.2.1
Fire
● Avoid causing fire because of sparks, slag,
hot metal or pieces.
● Make sure that suitable fire-fighting equipment is available close to welding area.
● Remove all flammable and combustible material from the
welding area and its surrounding (32 fr minimum).
● Do not weld containers of combustible or flammable
material, even when empty. These must be carefully cleaned
before being welded.
● Allow the welded material to cool down before touching it or
putting it in contact with combustible or flammable material.
● Do not weld parts with hollow spaces, containing
flammables.
● Do not work under conditions with high concentrations of
combustible vapours, gases, or flammable dust.
● Always check the work area half an hour after welding so
as to make sure that no fire has started.
● Do not keep any combustible material such as lighters or
matches in your pockets.
1.2.2
Burns
● Wear fire-proof clothing all over your body in order to
protect your skin against burns caused by ultra- violet
radiation given off by the arc, and from weld metal sparks
and slag.
● Wear protective clothing-gauntlet gloves designed for use
in welding, hat and high safety-toe shoes. Button shirt collar
and pocket flaps, and wear cuff-less trousers to avoid entry
of sparks and slag.
● Wear helmet with safety goggles and glasses with side
shields underneath, appropriate filter lenses or plates (protected by clear cover glass). This is a MUST for welding to
protect the eyes from radiant energy and flying metal.
Replace cover glass when broken, pitted, or spattered.
● Avoid oil or greasy clothing. A spark may ignite them.
Hot metal such as electrode stubs and workpieces should
never be handled without gloves.
● First-aid facilities and a qualified first-aid person should be
88
8
Fumes
Welding operations give off harmful fumes and metal
dusts which may be hazardess to your health, therefore:
● Work in a well-ventilated area.
● Keep your head out of fumes.
● In closed areas, use suitable exhaust fans.
● If ventilation is not enough, use breathing sets approved
for this procedure.
● Clean the material to be welded of any solvents or halogen
degreasers giving rise to toxic gases. Some clorine solvents
may decompose with the radiation emitted by the arc, and
create phosgene gas.
● Do not weld plated metals or those containing lead,
graphite, cadmium, zink, chrome, mercury or beryllium,
unless you have the proper breathing set.
● The electric arc creates ozone. A long exposure to high
concentrations may cause headaches, nasal, throat and
eye irritation as well as serious congestions and chest pains.
IMPORTANT: DO NOT USE OXYGEN FOR VENTILATION.
● Gas leaks in a confined space should be avoided. Leaked
gas in large quantities can change oxygen concentration
dangerously. Do not bring gas cylinders into a confined space.
● DO NOT WELD where solvent vapors can be drawn into
the welding atmosphere or where the radiant energy can
penetrate to atmospheres containing even minute amounts
of trichloroethylene or perchloroethylene.
1.2.4
Explosions
Do not weld above or near containers under pressure.
● Do not weld in environments containing explosive
dusts, gases or vapours.
This welding machine uses inert gases such as CO2, ARGON, or a mixture of ARGON + CO2 for the protection of the
arc, thus you should take special precautions:
A) CYLINDERS
● Do not directly connect cylinder to the machine gas hose
without a pressure regulator.
● Handle or use pressure cylinders in conformity with the
existing rules.
● Do not use leaking or damaged cylinders.
● Do not use cylinders which are not well secured.
● Do not carry cylinders without the protection of the
installed valve.
● Do not use cylinders whose content has not been clearly
identified.
● Never lubricate cylinder valves with oil or grease.
● Do not put the cylinder in electrical contact with the arc.
● Do not expose cylinders to excessive heat, sparks, molten
slags or flame.
● Do not tamper with the cylinder valves.
● Do not try to loosen tight valves by means of hammers,
keys, or any other object.
● NEVER DEFACE or alter name, number, or other markings on a cylinder. It is illegal and hazardous.
● Do not lift cylinders off the ground by their valves or caps,
or by chains, slings or magnets.
● Never try to mix any gases in a cylinder.
● Never refill any cylinder.
● Cylinder fittings should never be modified or exchanged.
● Make sure that the power supply line is equipped with an
efficient earth plug.
● Make sure that the work bench and the workpiece are
connected to an efficient earth plug.
● Any maintenance should only be carried out by qualified
personnel aware of the risks due to dangerous voltages
necessary for the operation of the unit.
B)
PRESSURE REGULATORS
● Keep pressure regulators in good condition. Damaged
regulators may cause damages or accidents, they should
only be repaired by skilled personnel.
● Do not use regulators for gases other than those for which
they are manufactured.
● Never use a leaking or damaged regulator.
● Never lubricate regulators with oil or grease.
1.2.7
Pace maker
● Magnetic fields from high currents can affect pacemaker
operation. Persons wearing electronic life support equipment (pacemaker) should consult their doctor before going
near arc welding, gouging or spot welding operations.
C)
HOSES
● Replace hoses which appear damaged.
● Keep hoses unwound in order to avoid bending.
● Keep the excess hose wound and out of the working area
in order to avoid any damage.
1.2.5
Radiations
Ultra-violet radiation created by the arc may damage your eyes and burn your skin. Therefore:
● Wear proper clothing and helmet.
● Do not use contact lenses!! The intense heat coming from
the arc may cause them to stick to the cornea.
● Use masks with grade DIN 10 or DIN 11 safety lenses at
the least.
● Protect people in the surrounding welding area.
Remember: the arc may dazzle or damage the eyes. It is
considered dangerous up to a distance of 15 meters (50
feet). Never look at the arc with the naked eye.
● Prepare the welding area so as to reduce reflection and
transmission of ultra-violet radiation. Paint walls and exposed surfaces in black to reduce reflection, install sheathings
or curtains to reduce ultra-violet transmissions.
● Replace mask lenses whenever damaged or broken.
Electric shock
Electric shock can kill.
All electric shocks are potentially fatal.
● Do not touch live parts.
● Insulate yourself from the piece to be cut and from the
ground by wearing insulated gloves and clothing.
● Keep garments (gloves, shoes, hats, clothing) and body
dry.
● Do not work in humid or wet areas.
● Avoid touching the piece to be welded.
● Should you work close to or in a dangerous area, use all
possible precautions.
● If you should feel even the slightest electric shock sensation, stop welding immediately. Do not use the machine until
the problem is identified and solved.
● Always fit an automatic wall switch with adequate power,
possibly close to the machine, allowing you to immediately
switch the machine off in case of an emergency.
● Frequently inspect the power supply cable.
● Disconnect power supply cable from mains before replacing cables or before removing unit covers.
● Do not use the unit without protection covers.
● Always replace any damaged parts of the unit, with original
material.
● Never disconnect unit safety devices.
1.2.8.
Caution!
Welding wire can cause puncture wounds.
● Do not press gun trigger until instructed to do so.
● Do not point gun toward any part of the body, other people,
or any metal when threading welding wire.
1.2.9.
Moving parts can cause injury.
Moving parts, such as fans, can cut fingers and hands and
catch loose clothing.
● Keep all doors, panels, covers, and guards closed and
securely in place.
● Have only qualified people remove guards or covers for
maintenance and troubleshooting as necessary.
● Keep hands, hair, loose clothing, and tools away from
moving parts.
● Reinstall panels or guards and close doors when servicing
is finished and before starting the machine.
2 GENERAL DESCRIPTION
2.1
SPECIFICATIONS
This welding machine is a semiautomatic, constant voltage
generator. It is possible to weld mild steel, stainless steel,
and aluminium.
2.2
EXPLANATION OF
TECHNICAL SPECIFICATIONS
N°
Serial number which must be stated when asking
for information or servicing related to this machine.
Single-phase Transformer - Rectifier
Three-phase Transformer - Rectifier
1.2.6
1
3
Uo
X
I2
U2
U1
I1
IP 21
S
External characteristic of the unit.
Secondary no-load voltage (peak value).
The duty-cycle expresses the percentage of 10
minutes during which the welding machine can
operate at a determined current level without
overheating:
e.g. X = 60% at I2 = 100 A.
This means that the welding machine can weld with
a current I2 = 100A for 6 minutes out of 10, i.e. 60%.
Welding current
Secondary voltage with welding current I2
Nominal supply voltage at the rated frequency.
Input current at the corresponding welding current I2
Grade of protection of the case.
Grade 1 as a second digit means that this unit is
not fit for working in the rain.
Fit for working in high-risk areas.
9
1
Nº
U0
-
-
U1
-
-~-/-Hz
CLASSE DI ISOLAMENTO
CLASS OF INSULATION
CLASSE DES ISOLANTS
ISOLIERSTOFFKLASSE
CLASE DE AISLAMIENTO
PROTEZIONE TERMICA
THERMAL PROTECTION
PROTECTION THERMIQUE
TERMISCH GESCHÜTZ
PROTECCION TERMICA
2.3
X
- /-
I2
-
U2
-
I1
-
-
- / -
-
-
-
VENTILAZIONE FORZATA
FORCED VENTILATION
VENTILE
KUHLART F
VENTILACION
-
-
IP
21
Before connecting the power supply cable (40) ensure that
mains voltage corresponds to the machine voltage, then:
a) for permanent connection to the power mains without a
plug, you must insert a main switch having a suitable
capacity in compliance with the rated specifications.
b) for a plug-socket connection, use a plug having a suitable capacity in compliance with the rated specifications. In this case the plug must be used to completely
disconnect the machine from the mains, after setting
the switch 56 to “O” (off).
The yellow-green wire must be connected to the earth
terminal.
The connection voltage can be changed on the threephase
machine by following the instructions in figure.
MADE
IN
ITALY
DESCRIPTION OF PROTECTION
This unit is protected by a normally closed thermostat placed
on the power transformer.
When the thermostat intervenes, the machine stops welding, while the motor-driven fan continues to work.
Wait a few minutes to allow the generator to cool down.
3 INSTALLATION
3.1
PRECAUTIONS
WARNING!!
ELECTRIC SHOCK CAN KILL
●
●
This machine must be installed by skilled personnel.
Make sure that the input power plug has been disconnected before inspecting, repairing, or servicing.
3.2
SETUP
Unpack the machine and place it in a properly ventilated
area, possibly not dusty, making sure that air flow on the
cooling vents is not obstructed.
WARNING: RESTRICTED AIR FLOW causes overheating
and possible damage to internal parts.
● Maintain at least 20 inches (500 mm) of free space on all
sides of the unit.
● Do not place any filtering device over the intake air vents
of this power source. The warranty is void if any type of
filtering device is used.
3.3
STARTUP
This unit must be installed by skilled personnel. All fittings
must be in conformity with the existing safety standards.
(See CEI standards 26-10 -CENELEC HD 427).
Install the components supplied with the welding machine.
Connect the welding torch (70).
Check that the wire diameter corresponds to that shown on
the drive roll and mount the wire spool.
Make sure that the wire goes into the groove of the drive roll
(11) and that wire and groove are perfectly aligned.
1010
10
N.B. TO REACH THE VOLTAGE CHANGER REMOVE
THE FIXED HOUSING (44).
IMPORTANT: BEFORE CHANGING VOLTAGE MAKE
SURE THAT THE MACHINE IS NO MORE CONNECTED
TO THE MAINS.
Connect the ground clamp (60) to the workpiece.
The welding circuit must not be deliberately placed in
direct or indirect contact with the protection wire except in
the workpiece.
If the workpiece is deliberately grounded using the protection wire, the connection must be as direct as possible,
using a wire at least as large as the welding current
return wire, and connected to the workpiece at the same
point as the return wire, using the return wire clamp or a
second grounding clamp placed next to it.
All precautions must be taken to avoid stray welding
currents.
Turn the machine on by means of the switch (56).
Remove the taper gas nozzle (71) by rotating it clockwise.
Unscrew the contact tip (72).
● Do not point gun toward any part of the body, other
people, or any metal when threading welding wire.
Welding wire can cause puncture wounds.
Press the torch push button (70) and release it only when the
wire comes out.
Tighten the contact tip (72) and make sure that the hole
diameter corresponds to the wire being used.
Reinstall the taper gas welding nozzle (71), rotating it clockwise.
WARNING!!
ELECTRIC SHOCK CAN KILL.
● Do not touch live electrical parts.
● Do not touch the weld output terminals when the unit is
energized.
● Do not touch the torch or electrode holder and the work
clamp at the same time.
ATTENTION: The green/yellow wire of the input power
cable must always be connected to the protection lead
(ground of the system). The yellow/green wire must NEVER
be combined with another phase wire for drawing voltage.
3.4
CONNECTING THE GAS HOSE
WARNING!!
CYLINDERS CAN EXPLODE IF DAMAGED
● Keep the cylinders in an upright position by chaining them
to their support.
● Keep the cylinders in a place where they cannot be
damaged.
● Do not lift the machine with the cylinder on its support.
● Never touch the cylinder with the welding wire.
● Keep the cylinder away from the welding area and
uninsulated electric circuits.
● Cylinders containing inert gas have to be equipped with a
regulator and a flowmeter.
● After having positioned the cylinder, connect the gas hose
that comes out from the rear of machine to the pressure
regulator. The gas hose shall be chosen according to the
process in use (see 3.5 E).
Turn the gas cylinder on and adjust the flowmeter to approx.
8-10 litre/min.
3.5
UNIT DESCRIPTION
A) On/Off switch.
Switches the welder on and off. On some versions this
switch is also used to select the welding voltage range.
B) Wire speed adjuster knob.
Use this knob to set the wire feed speed. This knob is
only enabled when the welding torch connector (G) is
selected on the mode selector switch (E).
C) Spot time adjuster knob.
Use this knob to set the spot welding duration time.
When the button on the welding gun is pressed, the
machine will start spot welding and continue for the time
set on this knob. To start the next welding cycle, release
and press the welding torch button.
D) Welding voltage selector switch.
Use this selector switch to set the welding voltage.
E) Mode selector switch.
This switch is used to select one of the following
operating modes:
1) Selector switch (E) in position
. This enables the
welding torch connector (G); the MIG torch (supplied)
must be connected to the connector. Use the knob (B)
on the front control panel to set the wire feed speed.
When selecting this process, you have to connect the
bottle to its corresponding gas hose. See back panel.
2) Selector switch (E) in position
. This enables the
F)
G)
H)
I)
L)
M)
extension cable connector (H); the extension cable (art.
1324 supplied as an optional) must be connected to the
connector. The extension cable also has a plug which
must be connected to the remote connector (F) on the
front control panel.
The extension cable (art. 1324) can either be plugged
into the spool gun (art. 1562) or into the separate wire
feeder (art. 1424) fitted with optional accessories.
For instructions on the fitting and use of these
accessories, see the manuals supplied with these units.
When selecting this process, you have to connect the
bottle to its corresponding gas hose. See back panel.
Remote connector.
Connector for the extension cable (art. 1324).
Welding torch connector.
Connector for the welding torch (supplied).
Extension cable connector.
Connector for the extension cable (art.1324).
Fe and Al earth socket.
Connect the earth cable clamp to these sockets.
The socket shall be chosen according to the used
material. (see paragraph 4).
Ammeter.
The ammeter displays the welding current.
Green led.
This lights up when the mode selector switch (E) is in
the
position.
N) Green led.
This lights up when the mode selector switch (E) is in
the
position.
11
O) Green led.
This lights up when the torch button is pressed and
indicates that the two solenoid valves are operating
correctly.
P) Yellow led.
This lights up when the thermostat interrupts welder
operation.
Q) Green led.
This lights up when the selector switch (C) is on.
R) Warning light.
This lights up to indicate that the machine is switched on.
3.6
GENERAL NOTES
Before using this welding machine, carefully read the CEI
Standards 26/9 or CENELEC HD 407 and CEI 26/11 or
CENELEC HD 433, also check for insulation of cables, torch
and earth cable.
When you have finished welding, switch off the welder
and shut off the gas cylinder.
current nozzles, then slip the sheath off.
— Insert the teflon sheath for aluminium and ensure it
protrudes from both ends.
— Screw the current nozzle so that the sheath adheres to it.
— Insert the sheath holding nipple and the O-Ring in the free end
of the sheath and secure with the nut without tightening too much.
— Slip the brass tube on the sheath and insert both into the
adapter (after removing the iron tube which was fitted inside
the adaptor).
— Cut the sheath diagonally so that it stays as close as
possible to the wire drive roller.
Use drive rolls that are suitable for aluminium wire. The wire
pressing roll must be properly tightened.
Make sure that the diameter of the contact tip hole
corresponds to the wire diameter that is going to be used.
Use abrasive grinders and tool brushes specifically designed
for aluminium. Never use these tools on other materials.
REMEMBER that cleanliness equals quality.
The wire spools must be stored in plastic bags with a
dehumidifier.
See the figure for correct torch inclination.
4 WELDING GUIDELINES
4.4
STAINLESS STEEL WELDING
4.1 SPOT WELDING
For spot welding, replace the gas-weld nozzle with the
special spot-weld nozzle. Exert enough pressure with the
torch to achieve a good junction of metal sheets.
This can be obtained by positioning the knob (C) on "spot-time"
and adjusting the spot-welding time through the knob.
ATTENTION: Metal sheets will have to be perfectly clean.
4.2
MILD-STEEL WELDING
75% ARGON + 25% CO2 or 100% CO2 can be used for mild
steel welding.
Adjust the welding voltage with switch (55) (56), the gas hose
corresponding to the process in use and connect the earth
cable to the socket (I) marked with the symbol Fe.
— Approach the point to be welded and press the torch push
button (70).
— Adjust the potentiometer until the welding noise is constant and continuous.
If the speed is too high, the wire tends to get stuck on the
workpiece which makes the torch bounce back. If speed is
too low, the wire melts irregularly or else the arc switches off.
When you have finished welding, switch off the welder and
shut off the gas cylinder.
See the figure for correct torch inclination.
4.3 ALUMINIUM WELDING
The machine will be set up as for mild steel except for the
following changes:
- 100% ARGON as welding protection gas.
- Connect the earth cable to the socket (I) marked Al.
- Wire of composition suitable for the material to be welded.
— For ALUMAN welding wire 3÷5% silicon.
— For ANTICORODAL welding wire 3÷5% silicon.
— For PERALUMAN welding wire 5% magnesium.
— For ERGAL welding wire 5% magnesium.
If you only have a torch for steel wires, the same shall be
modified in the following way:
— Make sure that lenght of torch cable does not exceed
118 inches (it is advisable not to use longer torches).
— Remove the brass sheath-holding nut, the gas and the
1212
12
The machine will be set-up as for mild-steel welding except
for following changes:
— Stainless steel wire compatible with the composition of
steel to be welded.
— Cylinder containing a mixture of 98% ARGON + 2% O2
(recommended mixture).
NOTE: Recommended torch inclination and welding direction are shown in the figure.
5 MAINTENANCE AND CHECK UP
Maintenance must only be carried out by suitably qualified
personnel.
5.1
GENERAL NOTES
WARNING: ELECTRIC SHOCK CAN KILL
● Do not touch live electrical parts.
● Turn off the power source, and remove input power plug from
receptacle before inspection, maintenance, or servicing.
MOVING PARTS can cause serious injury.
● Keep away from moving parts.
HOT SURFACES can cause severe burns.
● Allow cooling period before servicing.
Periodically clean the transformer or diodes from any dust or
foreign bodies; for this purpose, use a dry and clean air jet.
When reinstalling the drive roll, ensure that the groove is
aligned with the wire and that it corresponds to the diameter
of the wire used.
Keep the inside of the gas nozzle constantly clean so as to
avoid metal bridges formed by welding spatter between the
gas nozzle and the contact tip.
Make sure that the contact tip outlet has not widened, if so,
replace it.
The torch must not be banged or violently knocked.
5.2 WELDING MACHINE SERVICING
Experience has shown that many fatal accidents originated
from servicing improperly executed. For this reason, a
careful and thorough inspection on a serviced welding
machine is just as important as one carried out on a new
welding machine.
Furthermore, in this way producers can be protected from
being held responsible for defects stemming from repairs
not carried out by the manufacturer.
5.2.1 Prescriptions to follow for servicing
● After rewinding the transformer or the inductance, the
welding machine must pass the applied-voltage test in
accordance with indications in table 2 of 6.1.3 of the EN
60974.1 (standard CEI 26.13).
Conformity must be checked as specified in 6.1.3.
5.3
● If no rewinding is done, a welding machine which has
been cleaned and/or reconditioned must pass an
applied-voltage test with voltage values equal to 50% of
the values given in table 2 of 6.1.3. Conformity must be
checked as specified in 6.1.3.
● After rewinding and/or the replacement the no-load
voltage shall not exceed the values given given in 10.1
of EN 60974.1.
● If the servicing is not done by the manufacturers, the
repaired welding machines which underwent replacements
or modifications of any component, shall be marked in a
way such that the identity of the person having serviced
it is clear.
5.2.2
Instructions to be followed after all repair
work.
Following any repair work, great care must be taken when
refitting cables and wires to ensure safe and proper insulation between the primary and secondary sides of the machine. When refitting wires and cables, ensure that wires
cannot come into contact with moving parts or those parts
which heat up during operation. Refit clips and straps in their
original position and in such a way that any accidental cable
breakage or disconnection will not lead to a dangerous
contact between the primary and secondary circuits.
TROUBLESHOOTING GUIDE
TROUBLE
PROBABLE CAUSE
REMEDY
TROUBLE
PROBABLE CAUSE
REMEDY
The welding machine
supplies limited current
Line fuse blown
Replace line fuse
No wire feed or irregular
wire feed
Drive roll with too large a
groove
Replace the drive roll
Obstructed or clogged
liner
Remove and clean
Burnt out diode or diodes
Replace
Wire holding roller not
completely tightened
Tighten all the way
Burnt out electronic board
Replace
Spool holder clutch too
tight
Loosen the clutch through
the adjustment
Clogged contact tip
Replace
Contact tip with wrong
diameter
Replace
Loosened torch or earth
Tighten all connections
connections or any other
electrical power connections
Welding with a lot of
metal spatter
Voltage adjustment switch
has a loose contact
Replace the switch
Improper adjustment of
welding parameters
Select the correct parameters
through the welding-voltage
potentiometer and the wirespeed adjustment potentiometer
Misalignment of the drive
roll groove
Realign
Inlet wire guide out of
position
Position it as close as
possible to the drive roll.
Check grounding connections
Obstructed or clogged
liner
Remove and clean
Insufficient shielding gas
Increase gas delivery
Excess oxidation of the
edges to be welded
Thoroughly clean the
edges with a metal brush
Gas nozzle partially or
completely clogged by
spatter
Remove and clean or
replace being careful not
to clog the gas outlets
Insufficient grounding
The wire jams or entangles
between the drive rolls and
the torch infeed wire guide
Porosity in the welding
seam
13
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