IMPORTANT!!! READ THIS MANUAL CAREFULLY BEFORE INSTALLING,

IMPORTANT!!! READ THIS MANUAL CAREFULLY BEFORE INSTALLING,
INSTRUCTION MANUAL FOR ARC WELDING MACHINE
IMPORTANT!!!
1~
READ THIS MANUAL CAREFULLY BEFORE INSTALLING,
USING, OR SERVICING THE WELDING MACHINE,
PAYING SPECIAL ATTENTION TO SAFETY RULES.
CONTACT YOUR DISTRIBUTOR IF YOU DO NOT FULLY
UNDERSTAND THESE INSTRUCTIONS.
1
PLACEMENT
Unpack the machine and place it in an adequately ventilated
area, dust-free if possible, taking care not to block the air
intake and outlet from the cooling slots.
CAUTION: REDUCED AIR CIRCULATION causes
overheating and could damage internal parts.
Keep at least 500 mm of free space around the device.
Never place any filtering device over the air intake points of
this welding machine.
The warranty shall become void if any type of filtering device
is used.
2.1 SPECIFICATIONS
This welding machine uses INVERTER technology to generate constant direct current and is designed to weld with coated
electrodes (excluding the cellulosic type) or using the TIG
process with both scratch and high frequency starting.
2.2 EXPLANATION OF TECHNICAL SPECIFICATIONS
IEC 974-1
EN 60974-1
Nº
f1
A
f2
U0
MMA
V
PEAK
U1 1x220V-50/60Hz
1~
f1
%
%
%
A
A
A
V
V
V
I1
A
A
A
A
U0
V
PEAK
U1 1x220V-50/60Hz
/ V - A / V
X
I2
U2
f2
TIG
/ V - A / V
X
I2
U2
%
%
%
A
A
A
V
V
V
I1
A
A
A
IP 23
IEC 974.1. The welder is manufactured according to this
EN 60947.1 international standard.
N°. .......... Serial number which must be stated for any
demands relating to the welding machine.
8
Single-phase static frequency converter-transformer-rectifier.
Drooping characteristic.
MMA Suitable for welding with coated electrodes.
U0. ........... Secondary no-load voltage (Peak value)
X. ............ Duty cycle percentage
The duty cycle expresses the percentage of
10 minutes in which the welding machine can
operate at a determined current,without over
heating.
I2. ............ Welding current
U2. ........... Secondary voltage with welding current I2
U1. ........... Rated supply voltage
1~50/60Hz Single-phase supply 50 or 60 Hz
I1. ............ Input current at the corresponding welding
current I2.
IP23. ....... Grade of protection of frame
Grade 3 as a second digit means that this
unit is fit to work outside under the rain.
S. ........... Fit to work in high-risk areas.
NOTES:. ... In addition, the welding machine has been
designed to work in areas with grade 3 of
pollution. (see IEC 664).
2.3 DESCRIPTION OF PROTECTIONS
2.3.1 Thermal protection
2 GENERAL DESCRIPTIONS
1~
f2
TIG Suitable for TIG welding.
INTRODUCTION
This machine must be used for welding only.
In any case, it is essential to pay special attention to the
chapter on SAFETY PRECAUTIONS.
The symbols next to certain paragraphs indicate points
requiring extra attention, practical advice or simple
information.
This manual must be kept carefully in a place familiar to
everyone involved in using the machine. It must be consulted
whenever doubts arise and be kept for the entire life-span of
the machine; it will also be used for ordering spare parts.
1.1
f1
This unit is protected by a normally closed thermostat
placed on the dissipator.
When the thermostat opens, the machine stops supplying
current, but the fan continues to work.
The intervention of the thermostat is indicated by the led
turning on (H) fig.2.
2.3.2 Block protections
This welding machine is equipped with two types of block
protections:
1) Red LED lit under the following conditions:
a) power voltage below 100 V
b) during warm-up
c) during cool-down
After turning the machine off, wait for this LED to go off
completely before turning it back on.
2) Red LED
lit and yellow LED
flashing under the
following conditions:
a) error in the microcontroller memory
b) incorrect signal on the current sensor during warm-up
c) short-circuit on the welding clamps when the welding
machine is turned on.
d) the machine is switched on while the torch trigger is
operated.
3 INSTALLATION
3.1 STARTUP
This unit must be installed by skilled personnel. All fittings
must be in conformity with the existing rules and in full
compliance with safety regulations.
(CENELEC HD 427).
3.2 DESCRIPTION OF THE MACHINE
TIG
4
TIG
5
6
7
8
3
MMA
9
2
10
1
80
4
3
5
6
60
7
8
120
40
140
9
2
1
10
4
3
160
20
5
6
7
8
B)
C)
9
2
5
t
100
1
10
180
t
D)
E)
F)
G)
Fig, 2
A) Mode selector.
This selector must be set according to the
TIG
TIG task to be performed, based on the following
MMA
guidelines:
1) MMA
2)
3)
4)
5)
6)
Welding of all covered electrodes except cellulosic. In this position, only knob C is enabled, to
adjust the welding current.
CONTINUOUS TIG welding, with manual strike
(scratch) start.
To light the arc, press the torch trigger and touch
the part briefly. To end welding, release the
trigger.
CONTINUOUS TIG welding with automatic
strike (scratch) start.
To light the arc, press and release the torch
trigger and touch the part briefly. To end welding,
press and release the trigger.
CONTINUOUS TIG welding, started by means
of a high voltage/frequency device and automa
tic command.To light the arc, press and release
the torch trigger. To end welding, press and
release the trigger.
CONTINUOUS TIG welding, started by means
of a high voltage/frequency device and manual
command.
To light the arc, press the torch trigger. Release
the trigger to end welding.
CONTINUOUS TIG welding, started by means
of a high voltage/frequency device with manual
program. To light the arc, press the torch trigger;
the current begins to slope up at fixed increments
(regardless of the position of knob B). If the
trigger is released, the current instantly rises to
the maximum value set on knob C. To end
welding, press the trigger; the current begins to
slope down at fixed decrements (regardless of
the position of knob D). If the trigger is released,
the current immediately returns to zero.
Knob to set current slope up time (0-10 sec.)
Knob to adjust the welding current. The current is
adjusted up to 140A in MMA mode, up to 180A in all
other TIG modes.
Knob to set current slope down time (0-10 sec.)
“Gas-delay” knob
Adjusts the gas outlet time when welding is
finished. The setting field ranges from 0.3 sec. to
30 sec.
Connector for TIG torch trigger
The torch trigger wires (normally open) must
correspond to pins 1 and 5.
Block LED (see 2.3.2)
H) Thermostat LED.
This lights when the operator exceeds the service
or intermittent percentage factor allowed for the
machine, and simultaneously cuts off all current
distribution.
NOTE: In this condition, the fan continues to cool the
generator.
I) Fitting (1/4 GAS).
Used to connect the gas hose of the TIG welding torch.
L) Negative outlet clamp (-).
M) Positive outlet clamp (+).
3.3 GENERAL NOTES
Before using this welding machine, carefully read the
CENELEC standards HD 407 and HD 433 also check
insulation of cables, electrode holder clamp, sockets and
plugs and that the section and length of welding cables are
compatible with current used.
3.4 COATED ELECTRODE WELDING
• This welding machine is fit to weld all types of electrodes
except the cellulose type (AWS 6010)
• Use electrode holder clamps in compliance with the safety
standards and without projecting tightening screws.
• Make sure that switch located on the back panel is in 0 (off)
position, then connect welding cables in accordance with
polarity demanded by the electrode manufacturer which
you will be using.
Connect the earth cable clamp to the workpiece.
• Welding circuit should not be deliberately placed in direct
or indirect contact with protection wire if not in the workpiece.
• If earthing is deliberately made on the workpiece by means
of protection wire, the connection must be as direct as
possible, with the wire having a section at least equal to the
welding return current wire and connected to the piece being
worked on, in the same place as the return wire, using the
return wire terminal or a second earth terminal
closeby.
• All possible precautions must be taken in order to avoid
stray currents.
9
• This welding machine is fit for welding with TIG
procedure: stainless steel, iron, and copper.
• Connect ground cable wire to positive (+) pole of welding
machine and connect clamp to work piece as close as
possible to welding machine, making sure there is a good
electrical contact.
• The welding machine circuit should not be deliberately in
direct or indirect contact with protection conductor if not in
the workpiece.
• If earthing is deliberately made on the workpiece by means
of protection wire, the connection must be as direct as
possible, with the wire having a section at least equal to the
welding return current wire and connected to the piece
being worked on, in the same place as the return wire, using
the return wire terminal or a second earth terminal closeby.
• All possible precautions must be taken in order to avoid
stray currents.
• Use TIG torch suitable for the welding current and connect
power wire to negative pole (-) of welding machine.
• Connect torch connector to welding machine connector F.
•Connect the torch gas tube fitting to the welder fitting I, and
the gas hose from the cylinder pressure reducer to the gas
fitting located on the rear panel.
Using knob A select scratch start
direct current
negative electrode
( Argon )
0.5mm (0.020")
15¸40 A
1mm (0.040")
25¸85 A
1,6mm (0.060")
70¸150 A
2.4mm (0.095")
150¸250 A
3.2mm (0.130")
200¸350 A
• Check to see that power supply voltage corresponds
to
voltage indicated on the welding machine technical
specification tag.
• Connect the power cord to a plug with a sufficient capacity,
making sure that the yellow/green conductor of the power
cord is connected to the grounding pin.
• The capacity of magnetothermic switch or fuses in series
with mains supply should be more than or equal to current
I1 absorbed by the unit.
• Any extensions should have adequate sections for
absorbed current I1.
• Turn machine on with the main switch.
• Do not touch live electric parts.
• Do not touch weld output terminals when unit is energized.
• Do not touch torch and earth clamp at the same time.
• Once welding is finished, remember to turn machine
off and to close the gas cylinder valve.
3.6.1 Electrode preparation
It is necessary to pay special attention to the preparation
of the electrode point, grinding it so as to obtain vertical
markings as shown in fig. 3.
NO
YES
or high frequency start
and the manual mode
or the automatic mode
.
• Inert gas flow must be regulated to a value ( l/min.)
approximately 6 times the diameter of the electrode.
• If accessories such as gas lenses are used, the gas flow can
be reduced to approx. 3 times the diameter of the electrode.
• The diameter of the ceramic nozzle must be 4 to 6 times
larger than diameter of the electrode.
• The most commonly used shielding gas is ARGON
,however, ARGON mixtures with a max. of 2% HYDROGEN
can also be used for welding stainless steel, and HELIUM
or ARGON/HELIUM mixtures can be used for welding
copper. These mixtures increase the heat generated by the
arc.
10
electrode ø
2% thoriated tungsten
( red band )
1,5÷2 d
3.5 TIG WELDING
If you are using helium gas, increase the flow rate (l/min) so
as to obtain a ratio 10 times the size of the electrode
(example: diam. 1.6x10 = 16 l./min. helium).
• Use protection lenses with shades D.I.N. 10 for up to 75A
and D.I.N. 11 for 75A and above.
• Use a 2% thoriated tungsten electrode chosen according to
table 2 and prepared according to that indicated in point 3.6.1.
↔
• Check to see that power supply voltage corresponds to
voltage indicated on the welding machine technical
specification tag.
• Connect the power cord to a plug with a sufficient capacity,
making sure that the yellow/green conductor of the power
cord is connected to the grounding pin.
• The capacity of magnetothermic switch or fuses in series
with mains supply should be more than or equal to current
I1 absorbed by the unit.
• Input current I1 is determined by reading the techinical
specifications on unit i.e. power supply voltage U1
available.
• Any extensions should have adequate sections for input
current I1.
• Turn the machine on with the main switch.
• Do not touch live electric parts.
• Do not touch weld output terminals when unit is
energized.
• Do not touch torch or electrode holder and ground clamp
at the same time.
• Regulate current based on the diameter of the electrode,
welding position and type of joint to be carried out.
When finished welding, always remember to turn unit
off, and to remove electrode from electrode holder.
fig.3
d
↔
CAUTION. HOT FLYING METAL PARTICLES can
injure personnel, start fires, and damage equipment:
TUNGSTEN CONTAMINATION can lower weld quality.
• Shape tungsten electrode only on grinder with proper
guards in a safe location wearing proper face, hand, and
body protection.
• Shape tungsten electrodes on a fine grit, hard abrasive
wheel used only for tungsten shaping.
• Grind the end of the tungsten electrode to a taper for a
length of 1,5¸2 electrode diameters as shown in fig. 3.
3.6.2 Recommended welding positions.
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.
5 GENERAL PRECAUTIONS
40˚
5.1 Fire
30˚
➠
70˚÷80˚
70˚÷8
0˚
➠
20˚
20˚
20˚
90˚
0˚
10˚
➠
➠
70˚÷8
70˚÷8
0˚
➠
➠
20˚
• Avoid causing fire because of sparks,
slag, hot metal or pieces.
• Make sure that suitable fire-proof
devices are available close to welding
90˚
20˚
4 MAINTENANCE AND SERVICE
4.1 GENERAL NOTES
• Do not touch live electrical parts.
• Turn off welding power source and remove input
power
plug from socket before, maintenace, servicing.
MOVING PARTS can cause serious injury.
• Keep away from moving parts.
HOT SURFACES can cause severe burns
• Allow cooling the unit before servicing.
4.2 WELDING MACHINE MAINTENANCE
All servicing and repair must be done by qualified
personnel.
4.2.1 Precautions to take while servicing:
• EXCESSIVE PRESSURE can break circuit board.
• Use only minimal pressure and gentle movements when
disconnecting or connecting board plugs and removing or
installing board.
• INCORRECT INSTALLATION OR MISALIGNED PLUGS
CAN DAMAGE CIRCUIT BOARD.
• Be sure that plugs are properly installed and aligned before
replaceing cover.
• 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
area.
• Remove all flammable and combustible material from
welding area and its surrounding (min. 30 feet).
• 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.
5.2 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 colthing-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
or cutting, (and chipping) to protect the eyes from radiant
energy and flying metal. Replace cover glass when broken,
pitted, or spattered.
• Avoid oil or greasy clothing. A spark may ignite them.
Hot metal such as electrode stubs and workpieces should
never be handled without gloves.
• First-aid facilities and a qualified first-aid person should
be available for each shift unless medical facilities are close
by for immediate treatment of flash burns of the eyes and
skin burns.
• Ear plugs should be worn when working on overhead or
in a confined space. A hard hat should be worn when
others work overhead.
• Flammable hair preparations should not be used by
persons intending to weld.
5.3 Fumes
Welding operations give off harmful fumes and
metal dusts which may be hazardous to your
health, therefore:
• Work in a well-ventilated area.
• Keep your head out of fumes.
• In closed areas, use suitable exhaust fans, placed under
the welding area if possible.
• If ventilation is not enough, use breathing sets approved
for this procedure.
11
• 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, quicksilver or mercury,
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.
5.4 Explosions
• Do not weld above or near containers under
pressure.
• Do not weld in environments containing
explosive dusts, gases or vapours.
This welding machine is used for TIG welding and uses
ARGON gas for the protection of the arc, thus you should
take special precautions:
A) CYLINDERS
• NEVER DEFACE or alter name, number, or other markings on a cylinder. It is illegal and hazardess.
• Do not use cylinders whose contents have not been
clearly identified.
• Do not directly connect cylinder to reducing unit 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 lift cylinders off the ground by ther valves or caps,
or by chains, slings or magnets.
• Never try to mix any gases in the cylinder.
• Never refill any cylinder.
• 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 flames.
• Do not tamper with cylinder valves.
• Do not try to loosen tight valves by means of hammers,
keys, or any other object.
B) PRESSURE REGULATORS
• Keep pressure regulators in good condition. Damaged
regulators may cause damages or accidents, they should
only be repaired by skilled personnel.
• Do not use regulators for gases other than those for which
they are manufactured.
• Never use a leaking or damaged regulator.
• Never lubricate regulators with oil or grease.
C) HOSES
• Replace hoses which appear damaged.
• Keep hoses unwound in order to avoid bending.
12
• Keep the excess hose wound and out of the working area
in order to avoid any damage.
• Cylinder fittings should never be modified or exchanged.
5.5 Radiation
Ultra-violet radiation created by the arc may
damage your eyes and burn you 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 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.
5.6 Electric shock
Electric shock can kill.All electric shocks are potentially fatal.
• Do not touch live parts.
• Insulate yourself from the piece to be welded 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 that the unit can fall into water.
• Avoid touching or holding the piece to be welded by hand.
• 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.
• Often inspect the mains 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 remove unit safety devices.
• Make sure that the power supply line is equipped with an
efficient earth plug.
• Make sure that bench and the workpiece are connected to
efficient earth point.
• 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.
5.7 Pacemaker
Magnetic fields from high currents can affect pacemaker
operation. Persons wearing electronic life support equipment (pacemaker) should consult with their doctor before
going near arc welding, gouging, cutting or spot welding
operations.
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