IMPORTANT: BEFORE STARTING THE EQUIPMENT,

IMPORTANT: BEFORE STARTING THE EQUIPMENT,
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.
1 SAFETY PRECAUTIONS
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
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.
This machine is manufactured in compliance with the instructions contained in the harmonized standard 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.
2 GENERAL TECHNICAL DESCRIPTIONS
2.1 SPECIFICATIONS
This manual has been prepared with the intent of instructing
the operator on how to install, operate, and properly maintain
this electric arc welding machine.
This machine is a constant voltage power source for
MIG/MAG and OPEN-ARC welding.
Upon receiving and unpacking the machine, make a careful
inspection to ensure that there are no damaged parts.
Should there be a claim for losses or damages it must be
made by the purchaser directly to the shipper who handled the goods.
When requesting information about this welding machine please state the machine's part number and serial
number to ensure receiving accurate information relating to your machine.
2.2 DESCRIPTION OF TECHNICAL SPECIFICATIONS
IEC 974.1. This machine is manufactured according to the
EN 60947.1 IEC 974 international standard.
N°.
Machine Serial Number which must appear on
requests or inquiries concerning the machine.
Three-phase transformer-rectifier.
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
Flat characteristic.
MIG/MAG. Continuous wire welding
U0.
Secondary no-load voltage
X.
Duty-Cycle Percentage
The duty-cycle is the number of minutes the
machine can operate (arc on) within a ten
minute period without overheating. The duty
cycle varies according to the output current.
I2.
Output welding current
U2.
Secondary voltage whith welding current I2
U1.
Nominal supply voltage
3~50/60Hz Three-phase input supply at 50 or 60 Hz
I1.
Input Amps absorbed corresponding to different output levels (I2).
IP21.
Protection class of the machine's case
The 1 in the singles digit place means that this
unit is not fit to work outdoors in the rain.
S
Fit to work in hazardous areas.
NOTE: This machine has also been designed to work
in class 3 pollution areas (see IEC 664)
3 INSTALLATION
3.1 SETUP
Place the machine in a ventilated area.
Dust, dirt, or any other foreign material that might enter the
machine may restrict the ventilation which could affect the
machine's performance.
Fasten the rotating support to the machine top and fix the
handle, the wheeles, the bottle support and, if any, the cooling unit.
Fig. 1
covers. This is both for obvious safety reasons and to avoid
interference with the machine's internal cooling system. The
warranty is to be considered null and void if this machine is
used without the protection of its top and side covers.
• Mount a plug on the power supply cable that corresponds
to the input power drawn by the machine.
3.3 OUTPUT CONNECTIONS
3.2 INPUT POWER CONNECTIONS
• All sections concerning the installation of this machine
must be read carefully.
• This machine must be installed by skilled personnel.
• Make sure that the input power plug has been disconnected before inspecting, maintaining, or servicing.
• Connect the yellow-green wire to a good electrical ground.
• Do not use water pipes as earth conductor.
• After a final inspection, the machine should be connected to the input supply voltage marked on the input
power cord.
• If you wish to change the input supply voltage, remove the right side panel (15), locate the voltage-changing
terminal board and arrange the connections as shown
in figure 1.
• After having changed the supply voltage, re-place the
upper cover.
• This machine must never be used without the top and side
2.3.1 Connecting the work return lead clamp.
• Connect the male end of the work return lead to one of the
impedance taps on the front panel of the machine. The impedance tap designated by the provides the maximum
amount of impedance which will produce nicely filleted weld
beads. This tap is recommended when welding aluminium,
stainless steel, and carbon steels of binary or ternary composition. The impedance tap designated by the provides the
least
amount of impedance and is recommended when
using carbon dioxide as a shielding gas to weld carbon
steels, in the upwards vertical position, of binary or ternary
composition.
It is generally advisable to use low impedance values for
small diameter wires and high values for big diameter wires.
• After having selected the proper impedance tap, attach the
work return clamp to the work to be welded.
• Make sure that the ground clamp is tightly fastened to the
work return cable and periodically check that this connection
remains well tightened. A loose connection can cause weld
current drops or overheating of the work return lead and
clamp which, in turn, creates the risk of burns from accidental contact with the work return lead.
• The weld circuit must not be placed deliberately in direct or
indirect contact with the ground conductor if it is not in the
work to be welded.
• If the work to be welded is attached deliberately to the
ground by a protection lead, then the connection must be the
most direct possible and it must be done using a lead that
has a cross section that is at least equal to the cross section
of the work return lead being used for the weld circuit. The
protection lead must also be attached to the work at the same
spot as the work return lead. To do so, a second ground
clamp, fitted to the protection lead, must be attached next to
the ground clamp of the work return lead.
2.3.2 Connecting the gas hose.
• 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.
• Keep the cylinder away from the welding area and uninsulated electric circuits.
• Cylinders containing inert gas have to be equipped with a
pressure reducer and a flowmeter.
• After having positioned the cylinder, connect the gas hose
that comes out from the rear of machine to the pressure reducer output.
• Regulate the gas flow to 8¸10 l/min.
4 DESCRIPTION OF CONTROLS
4.1 CONTROLS ON GENERATOR FRONT PANEL
The welding torch is attached to this terminal.
F/G - Ammeter/Voltmeter (optional)
The ammeter shows the welding current.
The Voltmerer shows the welding voltage.
N.B. When welding stops, the ammeter and voltmeter
continue to show the last reading until welding restarts.
H - Led (yellow color)
This led lights on when:
- that the thermostat has stopped welder operation.
- on machines fitted with a cooling unit, that the pressure switch indicates a low cooling liquid level or that the cooling unit
is off.
I - Led (green color)
This led signals that the machine is on.
L - Knob
This knob regulates the length of the wire that sticks
out of the torch after welding is finished: “BURN-BACK.”
M- Weld function selection switch
This switch selects among the following functions:
Manual welding cycle (2 step):
The machine begins welding when the torch trigger is
pushed and stops welding when the torch trigger is released.
Automatic welding cycle (4 step):
The machine begins welding when the torch trigger is
pushed. Once welding has begun, however, the torch trigger
can be released.To stop welding, the torch trigger must again
be pushed and then immediately released. This function is
useful when welding for long periods of time because it helps
reduce operator hand fatigue due to having to keep the torch
trigger constantly pushed during normal manual welding
operations.
N- Wire feed speed control.
This knob adjusts the wire feed speed.
O - Quick-fit hose connectors for connection to water
hoses of water-cooled torches.
Important: These connectors are colour-coded for safety.
Ensure that hose and connector colours match.
4.2 CONTROLS ON GENERATOR REAR PANEL
A- On/Off switch
This switch turns the machine on or off.
B- Rotary weld voltage switch
This switch selects the weld voltage setting. (Step adjustment)
C- Rotary weld voltage switch
This switch allows the fine tuning of the welding voltage
selected with switch B. (Step adjustment)
D - Impedance Taps
Connect the male end of the work return lead to one of
the three impedance taps.
E- Quick connect torch terminal
P - 230V power supply socket.
440 W max. power. For cooling unit only. (Warning: Do not
connect other equipment to this socket.).
R - Socket.
For connection to the safety device on the cooling unit.
N.B. If no cooling unit is used with the machine, plug the
connector supplied with the machine into the socket H.
S - Gas hose.
T - Quick-fit hose connectors for connection to extension
water hoses.
Important: These connectors are colour-coded for safety.
Ensure that hose and connector colours match.
5 ACCESSORIES
Art. 131 AMMETER + VOLTMETER
Plug the 3 connections coming out from the intermediate
panel to the Ammeter/Voltmeter and fix it to the front panel,
by means of the screws supplied, as shown in the drawing.
6 WELDING
6.1 INSTALLATION AND STARTER
• Machine installation must be done by a competent staff. All
connections must correspond to the rules in force (CEI 20-10
HD 427) and must respect laws concerning accidents.
• Check that the wire diameter corresponds to that indicated
on the roll and mount the wire coil.
• Connect the pipe with the cylinder flowmeter.
• Position the welding machine so as to allow free air circulation inside it and avoid that metal or any other.
6.2 THE MACHINE IS READY TO WELD
• Connect the ground terminal to the part to be welded.
• Put the switch A on I.
• Extract the conic gas nozzle by rotating it clockwise.
• Unscrew the current nozzle.
• Press the torch trigger to feed the wire until it comes out
from the torch.
WARNING: Keep your face away from the terminal nozzle
while the wire comes out.
• Screw the current nozzle again, making sure that the hole
diameter be the same as that the wire used.
• Insert the welding conic gas nozzle by rotating it clockwise.
• Open the gas cylinder and adjust flowmeter at 8¸10 l/min.
WARNING: Check that the gas used is compatible with the
material to be welded.
6.3 WELDING CARBON STEELS.
To weld carbon steels the following things are necessary:
1) The use of a binary shielding gas which is most commonly
Argon and Carbon dioxide, in a ratio of 75¸80 % Argon and
25¸20% Carbon dioxide. Some applications, however, may
require a mix of three gases: Argon, Carbon dioxide (CO2),
and dioxide (O2). These gas mixtures generate heat during
welding and as a result the weld bead will be well filleted and
neat in appearance. The penetration, however, will not be
deep.
The use of Carbon dioxide as the shield gas results in a narrow weld bead with deep penetration but the ionization of the
gas will have an influence on arc stability.
2) The use of a filler wire of the same quality as the steel to
be welded. It is recommended that high quality wires be used
and that welding with rusted wires be avoided because they
can give rise to defects in the weld bead. Generally, the current range within which a wire can be used is calculated in
the following manner:
Ø of wire x 100= minimum number of Amperes.
Ø of wire x 200= maximum number of Amperes.
Practical example: 1.2 Ø wire= 120 Amps minimum and 240
Amps maximum. These amperages are based on the use of
an Argon/CO2mixture as the shield gas and welding in the
Short Arc transfer mode.
3) Avoid welding on rusted work pieces or work having spots
of oil and grease present on the surface.
4) The use of a welding torch suitable to the welding currents
that are going to be used.
5) Periodically check that the two handles making up the
ground clamp are not damaged and that the welding cables
(torch cable and the work return lead) do not have any cuts
or burn marks that would reduce their efficiency.
6.4 WELDING STAINLESS STEEL
Welding stainless steels in the 300 series (the austenitic
series) must be done using a shield gas mixture of predominantly Argon with a small percentage of O2 added to stabilize the arc. The recommended mixture is AR/O2 in the ratio
of 98/2. Do not use CO2 or AR/CO2mixtures as the shield
gas.
Do not touch the welding wire with your bare hands.
The filler metal (the wire) must be of a higher quality than the
work to be welded and the weld area must be clean.
6.5 WELDING ALUMINIUM
The following is required for aluminium welding:
1) 100% Argon as welding protection gas.
2) A torch wire of composition suitable for the basic 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.
3) A torch prepared for aluminium welding.
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 cur-
rent nozzles, then slip the sheath off.
- Insert the teflon sheath for aluminium and ensure it protrudesfrom both ends.
- Screw the current nozzle so that the sheath adheres to it.
- Insert the sheath holding nipple, 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 slide roller.
4) Use drive rolls that are suitable for aluminium wire. The
drive rolls, when being installed, must be tightened as tight
as possible.
5) Use contact tips that are suitable for aluminium wire and
make sure that the diameter of the contact tip hole corresponds to the wire diameter that is going to be used.
6) 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.
7 WELDING DEFECTS
1- DEFECTCAUSES
2- DEFECTCAUSES
3- DEFECTCAUSES
4- DEFECT
CAUSES
Porosity (in, or on the surface of the weld
bead)
• Bad wire (rust on the surface).
• Insufficient gas shielding due to:
- Inadequate gas flow due to a block in the
gas line.
- Defective flowmeter.
- Gas regulator covered with frost because
a gas heater was not used to heat the CO2
shielding gas.
- Failure of gas valve solenoid.
- Gas nozzle plugged up with spatter.
- Gas flow holes plugged up.
- Air drafts in the welding area.
Shrinkage Cracks
• Welding wire or work to be welded dirty or
rusty.
• Weld bead too small.
• Weld bead too concave.
• Too much weld bead penetration.
Lateral cracking
• Welding speed too fast.
• Low current and high arc voltages.
Too much Spatter
• Voltage too high
• Insufficient impedance
• No gas heater used for CO2 shielding gas.
8 MACHINE MAINTENANCE
Gas nozzle . Periodically clean the nozzle of all weld spatter
that may have accumulated during welding operations. If the
nozzle should become distorted or oval in shape then it must
be replaced.
Contact tip . A good contact between the contact tip and the
wire ensures a stable arc and optimal current output.
Therefore, following steps must be followed:
A) The contact tip hole must be kept free of dirt or oxidation.
B) After lengthy welds, spatter can easily accumulate on the
contact tip and prevent the wire from being fed. The contact
tip must be cleaned regularly and if necessary it must be
replaced.
C) The contact tip must always be screwed tightly on to the
body of the torch. The thermal cycles which the torch undergoes during operation may loosen the contact tip which, in
turn, may cause the torch body and nozzle to overheat or
cause unsteady wire feed.
The Wire Liner is an important part that must often be
checked since, during normal operations, the wire can deposit copper dust or tiny metal shavings in the lining. Periodically
clean the liner and the gas line with a jet of dry, compressed
air. Wire liners are exposed to continual wear and therefore
they must be replaced after a certain period of time.
Wire feed motor. Periodically clean the wire feed assembly
and the drive rolls from any rust or metal shavings due to the
feeding of the wire. A periodic check of all the components of
the wire feed assembly, spool holder, drive rolls, wire liner and
the contact tip is recommended.
9 TROUBLESHOOTING
TROUBLE
Limited electric
output
PROBABLE CAUSE
A phase is missing
REMEDY
Check the phase of the
feed line and/or the remove control switch contacts
A line fuse is burnt
Replace it
Wrong connection on the Check the terminal board
voltage changer terminal connections by following
the plate scheme
board
Welding with a lot
of metal spatter
Wire not
advancyng or
advancyng unproperly
The wire jams or
entangles between
the drive rolls and
the torch infeed
wire guide
The rectifier diode are burnt
Replace the rectifier
Loosened torch or
ground connections
Tighten all connections
Welding regulation commutator has an uncertain contact
Replace the commutator
Trasformer wire interrupted on the commutator
Unscrew the commutator
contact, remove the wire
insulation and put it under
the contact
Wrong adjustment of the
welding parameters
Select the correct parame
ters through the weldingvoltage switch and the
wire-speed adjustment
potentiometer
Wire advancing unproperly
Uncorrect sheath diam.
Insufficient grounding
Check grounding connections
Wire roller with too wide
groove
Replace roller
Obstructed or clogged liner
Extract it and clean
Loose wire pressing roller Tighten it
Coil reel friction too tight
Loosen and adjust it
Current nozzle clogged
Replace it
Wrong current nozzle dia- Replace it
meter
Wrong roller groove align- Align it
ment
Obstructed or clogged
sheath
Remove and clean
Note: All repair work must be done by qualified personnel.
Disconnect the power input cable from the mains supply
before replacing cables or before removing the unit covers.
The machine is equipped with a thermostat that shuts the
machine down when the power source overheats. After the
thermostat intervenes, let the power source cool down for
several minutes before resuming welding operations.
The troubleshooting table lists troubles, causes and remedies
for those troubles that occur most commonly.
10 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.
10.1 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.
• 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.
• After making repairs, take care to re-order the cables so that
there is sure to be insulation between the primary and secondary sides of the machine. Make sure that the wires cannot
come into contact with moving parts or parts that heat during
operation. Replace all clamps in their original positions on the
machine, to prevent a connection between the primary and
secondary circuits if a conductor accidentally breaks or
disconnects.
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