IMPORTANT: BEFORE STARTING THE EQUIPMENT, EN50199, and m must b

IMPORTANT: BEFORE STARTING THE EQUIPMENT, EN50199, and m must b
INSTRUCTION MANUAL FOR WIRE WELDING MACHINE
IMPORTANT: BEFORE STARTING THE EQUIPMENT,
READ THE CONTENTS OF THIS MANUAL, WHICH MUST
BE STORED IN A PLACE FAMILIAR TO ALL USERS FOR
THE ENTIRE OPERATIVE LIFE-SPAN OF THE MACHINE.
THIS EQUIPMENT MUST BE USED SOLELY FOR WELDING OPERATIONS.
EN50199, and must be used solely for professional purposes in an industrial environment. There may be potential difficulties in ensuring electromagnetic compatibility in nonindustrial environments.
IN CASE OF MALFUNCTIONS, REQUEST ASSISTANCE
FROM QUALIFIED PERSONNEL.
1 SAFETY PRECAUTIONS
2 GENERAL DESCRIPTION
WELDING AND ARC CUTTING CAN BE HARMFUL TO
YOURSELF AND OTHERS. The user must therefore be educated against the hazards, summarized below, deriving from
welding operations. For more detailed information, order the
manual code 3.300.758
2.1 SPECIFICATIONS
This manual has been prepared for the purpose of educating personnel assigned to install, operate and service
the welding machine.
This equipment is a constant-voltage power source, suitable for MIG/MAG and OPEN-ARC welding.
Upon receiving the machine, make sure there are no
broken or damaged parts.
The purchaser should address any complaints for losses
or damage to the vector. Please indicate the article and
serial number whenever requesting information about the
welding machine.
ELECTRIC SHOCK - May be fatal.
· Install and earth the welding machine according to
the applicable regulations.
· Do not touch live electrical parts or electrodes with
bare skin, gloves or wet clothing.
· Isolate yourselves from both the earth and the workpiece.
· Make sure your working position is safe.
FUMES AND GASES - May be hazardous to your health.
· Keep your head away from fumes.
· Work in the presence of adequate ventilation, and
use ventilators around the arc to prevent gases from
forming in the work area.
ARC RAYS - May injure the eyes and burn the skin.
· Protect your eyes with welding masks fitted with filtered lenses, and protect your body with appropriate safety garments.
· Protect others by installing adequate shields or curtains.
RISK OF FIRE AND BURNS
· Sparks (sprays) may cause fires and burn the skin;
you should therefore make sure there are no flammable materials in the area, and wear appropriate
protective garments.
NOISE
This machine does not directly produce noise exceeding 80dB. The plasma cutting/welding procedure
may produce noise levels beyond said limit; users
must therefore implement all precautions required by law.
PACEMAKERS
· The magnetic fields created by high currents may affect the
operation of pacemakers. Wearers of vital electronic equipment (pacemakers) should consult their physician before
beginning any arc welding, cutting, gouging or spot welding
operations.
EXPLOSIONS
· Do not weld in the vicinity of containers under pressure, or in the presence of explosive dust, gases or
fumes. · All cylinders and pressure regulators used in
welding operations should be handled with care.
ELECTROMAGNETIC COMPATIBILITY
This machine is manufactured in compliance with the
instructions contained in the harmonized standard
8
2.2 EXPLANATION OF TECHNICAL SPECIFICATIONS
EN 50199
EN60974.1
N°
3~
The welding machine is manufactured
according to these international standards.
serial number, which must always be indicated on any type of request regarding
the welding machine.
three-phase transformer-rectifier.
Flat characteristic.
Suitable for continuous electrode welding.
Unconventional welding current.
The values represent the minimum and
maximum levels attainable in welding.
U0.
Secondary open-circuit voltage.
X.
Duty cycle percentage.
The duty cycle expresses the percentage
of 10 minutes during which the welding
machine may run at a certain current
without
overheating.
I2.
Welding current
U2.
Secondary voltage with welding current I2.
U1.
Rated supply voltage
3~ 50/60Hz 50- or 60-Hz three-phase power supply.
I1 Max
Max. absorbed current at the corresponding
current I2 and voltage U2.
I1 eff
This is the maximum value of the actual
current absorbed, considering the duty
cycle.
This value usually corresponds to the
capacity of the fuse (delayed type) to be
used as a protection for the equipment.
IP21
Protection rating for the housing.
Grade 1 as the second digit means that this
equipment is suitable for use outdoors in
the
rain.
S
Suitable for use in high-risk environments.
NOTES: The welding machine has also been designed for
use in environments with a pollution rating of 3. (See IEC
664).
MIG/MAG.
I2 max.
3 INSTALLATION
• Only skilled personnel should install the machine .
• All connections must be carried out according to current regulations, and in full observance of safety laws.
3.1 PLACEMENT
Place the welding machine in a ventilated area.
Dust, dirt, and any other foreign matter entering the welding machine can interfere with ventilation and thus with
smooth operation.
Assemble the handle, the wheels, the cylinder support
and the cooling unit, if present.
3.2
INTERNAL CONNECTIONS
• Before working inside the welding machine, make sure
that the plug is disconnected from the power mains.
• After final inspection, the welding machine is connected
to the voltage indicated on the power supply cable.
• To change the supply voltage, remove the right side
panel and arrange the voltage change terminal board
connections as shown in the figure.
• Do not use the welding machine without its cover or
side panels for obvious safety reasons, and to avoid altering the cooling conditions for internal components.
• Connect a plug suitable for the absorbed current to the
power supply cable.
• Connect the yellow-green wire of the machine mains to
an efficient grounding socket.
3.3 EXTERNAL CONNECTIONS
3.3.1 Connecting the mass clip.
• Connect the terminal of the ground cable to one of the
impedance sockets of the machine, keeping in mind that
the "maximum impedance"
socket will give firmly
embedded welds, and is recommended for welding aluminum, stainless steel and carbon steel with binary or ternary blends.
The "minimum impedance" socket
is suitable for
welding carbon steels, with carbon dioxide gaseous protection, and in upright positions with binary or ternary
blends.
The minimum impedance socket also ensures prompt
starts under any conditions.
• After deciding on the appropriate impedance output,
connect the mass clip to the workpiece.
3.3.2 Connecting the gas hose.
• The gas cylinder must be equipped with a pressure
regulator and flow gauge.
• Connect the gas hose leaving the rear of the machine,
only after positioning the cylinder.
• Adjust the flow gauge to 8-10 liters/minute.
9
4 DESCRIPTION OF CONTROLS
4.1
CONTROLS ON THE FRONT PANEL OF THE
MACHINE
A - Selector switch
Turns the machine on and off, and serves to adjust the
welding voltage range.
B - Selector switch
Fine-tunes the welding voltage within the
range selected via the selector switch A.
C - Impedance sockets
Socket for connecting the mass terminal of the machine.
D - Central fitting
This is where the welding torch is to be connected.
E - Mode key.
G-H
H-II-L
L light in
When the key E is pressed, the LEDs F-G
sequence
F - LED - 2-sstage continuous manual mode
The machine begins welding when the trigger is pressed,
and stops when it is released.
G - LED - 4 -s
stage continuous automatic mode
To begin welding, press the torch trigger; you may release the trigger once the procedure has begun.
Press and release the trigger again to stop welding. This
setting is suitable for long-term welding, where the welder may tire of holding down the torch trigger.
H - LED - Signals that spot welding mode is activated
The machine begins welding when the trigger is pressed.
The spot execution time is adjusted by means of the knob
R; when this time has elapsed, the machine interrupts its
cycle even if the trigger is pressed. To restart the cycle
you must release the torch trigger, reposition the torch
and press the trigger again.
I - LED. Indicates that 2-sstage manual dash welding
mode is activated
10
The machine begins welding when the torch trigger is
pressed, and continues for the welding time set on the
knob R, with a pause time set on the knob T. You must
release the trigger to stop welding.
L - LED. Indicates that 4-s
stage automatic dash welding
mode is activated
The machine begins welding when the torch trigger is
pressed; you may release the trigger once welding has
begun. The welding time and pause time are adjusted by
the knobs R and T, respectively.
To finish welding, press and release the torch trigger;
M - Yellow LED
Lights when the thermostat or safety button interrupt
operation of the welding machine.
N - Green LED
Indicates that the welding machine is on.
O - Display
This instrument displays the welding current, the welding
electrode speed in meters per minute, and the welding
time for 2-stage manual and 4-stage automatic spot and
dash welding functions.
The welding current remains in memory when you have
finished welding.
P - Display
This instrument displays the welding voltage and pause
time in the manual 2-stage and automatic 4-stage dash
welding function. The welding voltage remains in the
instrument's memory when you have finished welding.
Q - Setting knob
Adjusting this knob changes the welding wire speed. The
value in meters per minute is shown on the display O, and
remains saved there until welding begins.
R - Setting knob
This function is activated in the following modes: spot
welding, 2-stage manual and 4-stage automatic dash
welding.
This knob adjusts the spot welding time. The duration of
the spot welding time is displayed on the instrument O,
and may range from a minimum of 0.3 seconds to a maximum of 5 seconds. Once this time has been adjusted, the
instrument O continues to display it for 5 seconds.
S - Setting knob
This knob adjusts the length of the wire protruding from
the torch after welding ends :"BURN BACK".
T - Setting knob
This function is activated in the following modes: 2-stage
manual and 4-stage automatic dash welding. This knob
adjusts the pause time between spot welds.
The duration of the spot welding time is displayed on the
instrument P, and may range from a minimum of 0.3
seconds to a maximum of 5 seconds. Once this time has
been adjusted, the instrument P continues to display it for
5 seconds.
U - Quick-ffitting cocks.
To which are connected the hoses marked with the red
and blue adhesive strips of the torch.
Caution! Match the hose and cock colors correctly.
4.2
CONTROLS ON THE REAR PANEL. OF THE
POWER SOURCE
V - Gas hose fitting
Z - 230V socket.
To connect the cooling unit (do not connect other tools).
Max. power 440W.
W - Socket.
This socket connects to the safety device on the cooling
unit.
Note: the machine is equipped with a connector which, in
the absence of the cooling unit, must be connected to the
socket W.
X - Quick-ffitting cocks.
To connect the hoses on the extension marked with red
and blue adhesive strips.
Caution! Match the hose and cock colors correctly.
Z
W
U
X
5
WELDING
5.1
START-U
UP
• Make sure the wire diameter matches the diameter
marked on the roller, and mount the wire coil.
5.2
THE MACHINE IS READY TO WELD.
• Connect the mass cable clip to the workpiece.
• Set the switch A to 1.
• Remove the tapered gas nozzle by turning it clockwise.
• Unscrew the contact tip.
• Press the torch trigger to move the wire forward until it
comes out of the torch.
CAUTION: Keep your face away from the gun tube
assembly while the wire is coming out.
• Screw the contact tip back on, making sure that the
hole diameter is the same as that of the wire used.
Slide the tapered gas nozzle back on, again turning it
clockwise.
• Open the gas cylinder and adjust the flow gauge to
approximately 8/10 lt./min.
• Make sure that the gas used is compatible with the
material to be welded.
5.3
WELDING CARBON STEEL.
In order to weld these materials you must:
1) Use a welding gas with a binary composition, usually
AR/CO2 with percentages ranging from 75 to 80 % Argon
and 25 to 20 % CO2, or ternary compositions such as
AR/CO2 /O2 .
These gases create heat during welding, and the bead
will be firmly embedded and attractive, while penetration
will be relatively low.
Using carbon dioxide as a protection gas will give a narrow, penetrated bead, but the ionization of the gas will
affect the stability of the arc.
2) Use a welding wire of the same quality as the steel to
be welded.
It is best to always use good quality wires, avoiding welding with rusted wires that could cause welding defects.
Generally, wires may be used within the following current
range: wire Ø x 100 = minimum Amp - wire Ø x 200 =
maximum Amp
example: wire Ø 1.2 = minimum Amp 120/maximum Amp
240. This with AR/CO2 binary blends and short-circuited
transfer.
3) Avoid welding rusted parts, or those with oil or grease
stains.
4) Use torches appropriate for the current being used.
5) Periodically check that the flaps of the mass clip have
not been damaged, and that the welding cables (torch
and mass) do not have any cuts or burns that would create a safety hazard.
5.4
WELDING STAINLESS STEEL
Series 300 stainless steels must be welded using a protection gas with a high Argon content, containing a small
percentage of O2 to stabilize the arc. The most widely
used blend is AR/O2 98/2.
Do not touch the wire with your hands.
The welding materials must be better quality than the
base material, and the welding area must be clean.
11
5.5
WELDING ALUMINUM
In order to weld aluminum you must use:
1) 100% Argon as the protection gas.
2) A welding wire with a composition suitable for the base
material to be welded.
To weld ALUMAN and ANTICORODAL, use wire with a
Silicon content of 3 to 5%.
To weld PERALUMAN and ERGAL, use wire containing
5% Magnesium.
3) A torch prepared for welding aluminum.
NOTE: If you only have a torch for steel wires, modify it as
follows:
- Make sure that the cable is not longer than 3 meters (it
is not recommended that you use longer torches).
-Remove the brass liner nut, the gas nozzle, and the contact tip, then remove the liner.
- Insert the Teflon liner for aluminum, making sure that it
protrudes from both ends.
- Screw the contact tip back on so that the liner adheres
tightly.
- In the free end of the liner, insert the liner nipples and the
OR gasket, and fasten in place with the nut; do not fasten
too tightly.
- Slide the brass tube onto the liner, and insert the entire
assembly into the adapter (after first removing the iron
tube inside the adapter).
- Cut the liner diagonally so that it is as close as possible
to the wire feeder roller.
The rollers must not be fully tightened.
5) Use contact tips suitable for aluminum, with the hole
corresponding to the wire diameter to be used for welding.
6) Use mills and brushing machines specifically designed
for aluminum, and never use them on other materials.
REMEMBER that clean equals quality
The wire coils must be stored in nylon bags containing a
dehumidifying agent.
7 MAINTAINING THE SYSTEM
Safety gas nozzle . This nozzle must be periodically cleaned to remove sprayed metal. Replace if distorted or
squashed.
Contact tip. Only a good contact between this contact tip
and the wire can ensure a stable arc and optimum current
output; you must therefore observe the following precautions:
A) The contact tip hole must be kept free of grime and
oxidation (rust).
B) Sprayed metal sticks more easily after long welding
sessions, blocking the wire flow. The tip must therefore
be cleaned more often, and replaced if necessary.
C) The contact tip must always be firmly screwed onto
the torch body. The thermal cycles to which the torch is
subjected can cause it to loosen, thus heating the torch
body and tip and causing the wire to advance unevenly.
Wire liner. This is an important part that must be checked
often, because the wire may deposit copper dust or tiny
shavings. Clean it periodically along with the gas lines,
using dry compressed air.
The liners are subjected to constant wear and tear, and
therefore must be replaced after a certain amount of time.
Gearmotor group. Periodically clean the set of feeder rollers, to remove any rust or metal residue left by the coils.
You must periodically check the entire wire feeder group:
hasp, wire guide rollers, liner and contact tip.
8 ERRORS DURING USE
MALFUNCTION PROBABLE CAUSE
Limited
current
delivery
Line fuse burnt
Incorrect connection on the
voltage change terminal board
6 WELDING DEFECTS
1- DEFECTCAUSES
of
2- DEFECTCAUSES
3- DEFECTCAUSES
4- DEFECTCAUSES
12
Porosity (within or outside the bead)
•Electrode defective (rusted surface)
• Missing safety gas due to:
- low gas flow
- flow gauge defective
- regulator frosted due to no preheating
the CO2 protection gas
- defective solenoid valve
- contact tip clogged with sprays
- gas outlet holes clogged
- air drafts in welding area.
Shrinkage cracks
• Wire or workpiece dirty or rusted.
• Bead too small.
• Bead too concave.
• Bead too deeply penetrated.
Side cuts
• Welding pass done too quickly
• Low current and high arc voltages.
Excessive spraying
• Voltage too high.
• Insufficient inductance.
• No preheating of the CO2 protection gas
Phase missing
Rectifier diode(s) burnt
Loose ekectrical torch power
or mass connections
Unever contact in the voltage
regulator selector switch
Transformer wire broken on the
selector switch
Welding
metal
splatters
while welding
The wire
does not
advance,
or advance
jerkily
The wire
jams and
twists
around the
rollers and
torch wire
intake
guide
Welding parameters incorrectly
set
Insufficient grouding connections
Wire moves forward irregularly
Wire feeder roller groove too
wide
Liner jammed or clogged
Wire press roller is not tight
Coil support clutch too tight
Contact tip clogged
Incorrect contact tip diameter
Roller groove incorrectly aligned
Liner jammed or clogged
SOLUTION
Check the three phases of the
line and/or the remote switch
contacts
Replace the fuse
Check the terminal board connections following the plate diagram
Replace the rectifier
Tighten all connections
Change the selector switch
Unscrew the selector switch
contact and peel the wire,
being careful to remove only
the insulation; then return it
under the contact.
Use the welding voltage and
wire speed potentiometers to
adjust
Check their efficiency
Incorrect liner diameter
Replace the roller
Remove and clean
Tighten
Loosen the clutch by adjusting
the setting screw
Replace
Replace
Align
Remove and clean
NOTE: All tasks should be carried out only by skilled personnel.
Disconnect the power supply cable from the mains before working on the cables
or opening the machine.
The machine is equipped with a safety thermostat that trips in case of overload.
You must wait a few minutes after this intervention to allow the source to cool.
The table below lists the most common errors, causes and solutions.
9 REPAIRING THE WELDING MACHINES
Experience has shown that many fatal accidents are caused by poor repairs. That is why it is just as important to
fully check a repaired welding machine as a new one.
This also protects manufacturers from being held liable
for defects for which others are to blame.
9.1
Rules to follow for repairs
• After rewinding the transformer or inductances, the welding machine must pass the applied voltage tests described in table 2 of paragraph 6.1.3 of the standard EN
60974.1 (CEI 26.13). Compliance must be verified as specified in 6.1.3.
• If no rewinding has been carried out, a welding machine that has been cleaned and/or refurbished must pass
an applied voltage test with test voltage values at 50% of
those given in table 2 of 6.1.3. Compliance must be verified as specified in 6.1.3.
• After rewinding and/or replacing parts, the open-circuit
voltage must not exceed the values listed in 10.1 of EN
60974.1.
• If the repairs are not performed by the manufacturer,
repaired welding machine in which any components have
been replaced or altered must be marked in such a way
as to identify who carried out the repairs.
• After making a repair, make sure to rearrange the wiring
so that there is secure insulation between the primary and
secondary sides of the machine. Do not allow wires to
come into contact with moving parts or those that heat up
during operation. Reassemble all of the clamps as they
were on the original machine, to prevent an accidental
connection between the primary and secondary circuits if
a conductor should break or disconnect.
13
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement