Blueweld GALAXY 300, Instruction Manual

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be carried out in the presence of other people trained to intervene in
emergencies.
All protective technical measures MUST be taken as provided in 7.10; A.8;
A.10 of the applicable standard EN 60974-9: Arc welding equipment. Part 9:
Installation and Use”.
- Welding MUST NOT be allowed if the welding machine or wire feeder is
supported by the operator (e.g. using belts).
- The operator MUST NOT BE ALLOWED to weld in raised positions unless
safety platforms are used.
- VOLTAGE BETWEEN ELECTRODE HOLDERS OR TORCHES: working with
more than one welding machine on a single piece or on pieces that are
connected electrically may generate a dangerous accumulation of no-load
voltage between two different electrode holders or torches, the value of which
may reach double the allowed limit.
An expert coordinator must be designated to measuring the apparatus to
determine if any risks subsist and suitable protection measures can be
adopted, as foreseen by section 7.9 of the applicable standard ”EN 60974-9:
Arc welding equipment. Part 9: Installation and Use”.
RESIDUAL RISKS
- OVERTURNING: position the welding machine on a horizontal surface that is
able to support the weight: otherwise (e.g. inclined or uneven floors etc.) there
is danger of overturning.
- IMPROPER USE: it is hazardous to use the welding machine for any work
other than that for which it was designed (e.g. de-icing mains water pipes).
- IMPROPER USE: the use the welding machine by more than one operator at
the same time may be dangerous.
- MOVING THE WELDING MACHINE: Always secure the gas bottle, taking
suitable precautions so that it cannot fall accidentally (if used).
- Do not use the handle to hang the welding machine.
The safety guards and moving parts of the covering of the welding machine
and of the wire feeder should be in their proper positions before connecting the
welding machine to the power supply.
WARNING! Any manual operation carried out on the moving parts of the wire
feeder, for example:
- Replacing rollers and/or the wire guide;
- Inserting wire in the rollers;
- Loading the wire reel;
- Cleaning the rollers, the gears and the area underneath them;
- Lubricating the gears.
SHOULD BE CARRIED OUT WITH THE WELDING MACHINE SWITCHED OFF
AND DISCONNECTED FROM THE POWER SUPPLY OUTLET.
2. INTRODUCTION AND GENERAL DESCRIPTION
This welding machine is a source of current for arc welding, made specifically for MAG
welding carbon steel or weak alloys with CO
2
protective gas or Argon/CO
2
mixes,
using tubular full or core electrode wires.
It is also ideal for MIG welding stainless steel with Argon gas cont 1-2%
oxygen and aluminium and CuSi3, CuAl8 (brazing) with Argon gas, using electrode
wires that are suitable for the workpiece to be welded.
Suitable core wires can be used without Flux protection gas, adapting torch polarity
according to the indications of the wire producer (versions 180A and 200A only).
It is particularly suitable for light metalwork fabrication and in body shops, for welding
galvanized plates, high stress stainless steel and aluminium. SYNERGIC operation
ensures fast and easy welding parameter setting, always guaranteeing high arc
control and welding quality (OneTouch Technology).
The welding machine can be used for TIG welding in direct current (DC), with arc
striking upon contact (LIFT ARC mode). It welds all types of steel (carbon, low- and
high-alloy) and heavy metals (copper, nickel, titanium and their alloys) with a gas
shield of pure (99.9%) Ar or, for special uses, with an Argon/Helium mix. It can also be
used for MMA electrode welding in direct current (DC) using coated electrodes (rutile,
acid, basic).
2.1 MAIN CHARACTERISTICS
MIG-MAG
- Synergic (automatic) or manual operation;
- Pre-set synergic curves;
- Wire speed, welding voltage and welding current shown on an LCD screen;
- 2T, 4T and spot operation selection;
- Adjustments: wire up slope, electronic reactance, wire burn-back time, post gas;
- Polarity change for GAS MIG-MAG/BRAZING welding or NO GAS/FLUX (versions
180A and 200A only).
TIG
- LIFT strike;
- Wire speed and welding current shown on an LCD screen.
MMA
- Pre-set arc force, hot start and anti-stick devices;
- Indication of the electrode diameter recommended according to the welding current;
- Wire speed and welding current shown on an LCD screen.
PROTECTIONS
- Thermostatic safeguard;
- Protection against accidental short-circuits caused by contact between torch and
earth;
- Protection against irregular voltage (power supply voltage too high or too low);
- Anti-stick (MMA).
2.2 STANDARD ACCESSORIES
- torch;
- return cable complete with earth clamp.
- Torch holder stand.
2.3 OPTIONAL ACCESSORIES
- Argon bottle adapter;
- Trolley (versions 180A and 200A only);
- Self darkening helmet;
- MIG MAG welding kit;
- MMA welding kit;
- TIG welding kit.
3. TECHNICAL DATA
3.1 DATA PLATE
The most important data regarding use and performance of the welding machine are
summarised on the rating plate and have the following meaning:
Fig. A
1- EUROPEAN standard of reference, for safety and construction of arc welding
machines.
2- Symbol for internal structure of the welding machine.
3- Symbol for welding procedure provided.
4-
Symbol
S
: indicates that welding operations may be carried out in environments
with heightened risk of electric shock (e.g. very close to large metallic volumes).
5- Symbol for power supply line:
1~ : single phase alternating voltage;
3~ : 3-phase alternating voltage.
6- Protection rating of the covering.
7- Technical specifications for power supply line:
- U
1
: Alternating voltage and power supply frequency of welding machine (allowed
limit ±10%).
- I
1 max
: Maximum current absorbed by the line.
- I
1eff
: effective current supplied.
8-
Performance of the welding circuit:
- U
0
: maximum no-load voltage (open welding circuit).
- I
2
/U
2
: current and corresponding normalised voltage that the welding machine
can supply during welding.
- X : Duty cycle: indicates the time for which the welding machine can supply the
corresponding current (same column). It is expressed as %, based on a 10 min.
cycle (e.g. 60% = 6 minutes working, 4 minutes pause, and so on) .
If the usage factors (on the plate, referring to a 40°C environment) are exceeded,
the thermal safeguard will trigger (the welding machine will remain in standby
until its temperature returns within the allowed limits).
- A/V-A/V : shows the range of adjustment for the welding current (minimum
maximum) at the corresponding arc voltage.
9- Manufacturer’s serial number for welding machine identification (indispensable for
technical assistance, requesting spare parts, discovering product origin).
10- : Size of delayed action fuses to be used to protect the power line.
11- Symbols referring to safety regulations, whose meaning is given in chapter 1
“General safety considerations for arc welding”.
Note: The data plate shown above is an example to give the meaning of the symbols
and numbers; the exact values of technical data for the welding machine in your
possession must be checked directly on the data plate of the welding machine itself.
3.2 OTHER TECHNICAL DATA:
- WELDING MACHINE: see table 1 (TAB. 1)
- MIG TORCH: see table 2 (TAB. 2)
- TIG TORCH: see table 3 (TAB. 3)
- ELECTRODE-HOLDER CLAMP: see table 4 (TAB. 4)
The weight of the welding machine is given in table 1 (TAB. 1).
4. WELDING MACHINE DESCRIPTION
4.1 CONTROL, ADJUSTMENT AND CONNECTING DEVICES.
4.1.1 WELDING MACHINE (Fig. B, B1)
At the front:
1- Control panel (see description).
2- Welding cable and torch.
3- Earth return cable and clamp.
4- Positive (+) fast coupling for connecting the welding cable.
5- Negative (-) fast coupling for connecting the welding cable.
At the back:
6- Main switch ON/OFF.
7- Hose connector for protective gas.
8- Power cable.
In the reel section (versions 180A and 200A only):
9- Positive clamp (+).
10- Negative clamp (-).
N.B.: Polarity inversion for FLUX welding (no gas).
4.1.2 WELDING MACHINE CONTROL PANEL (Fig. C)
1- if pressed, it selects the MIG-MAG (SYNERGY or MANUAL), TIG or MMA welding
mode
SYNERGIC MIG-MAG
- Adjusts the welding power.
MANUAL MIG-MAG
- Adjusts the wire feeding speed.
TIG:
- Adjusts the welding current.
MMA:
- Adjusts the welding current.
2- if pressed, it allows accessing the setting menus of MIG-MAG (SYNERGY or
MANUAL), TIG or MMA welding processes.
SYNERGIC MIG-MAG
- Welding seam adjustment (arc length)
MANUAL MIG-MAG
- Welding seam adjustment (welding current)
TIG:
- Not active.
MMA:
- Not active.
3- LCD display