- 7 -
: default settings.
: arc lower voltage.
: arc higher voltage.
5. INSTALLATION
WARNING! ALL INSTALLATION OPERATIONS AND
ELECTRICAL CONNECTIONS MUST ALWAYS BE CARRIED
OUT WITH THE WELDING MACHINE SWITCHED OFF AND
DISCONNECTED FROM THE POWER SUPPLY.
THE ELECTRIC CONNECTIONS MUST ONLY BE CARRIED OUT
BY EXPERT OR QUALIFIED TECHNICIANS.
Return cable-clamp assembly
Fig. D
POSITIONING THE WELDING MACHINE
Choose the place where the welding machine is to be installed so
that there are no obstructions to the cooling air inlets and outlets; at
the same time make sure that conductive dust, corrosive vapours,
humidity etc. cannot be drawn into the machine.
Leave at least 250 mm of free space all around the welding machine.
WARNING! Position the welding machine on a level
surface with sufficient load-bearing capacity, so that it cannot
be tipped over or shift dangerously.
CONNECTION TO THE MAIN POWER SUPPLY
- Before making any electrical connection, check the rating plate
data on the welding machine to make sure they correspond to the
voltage and frequency of the available power supply where the
machine is to be installed.
- The welding machine must be connected only and exclusively to a
power supply with the neutral conductor connected to earth.
- To guarantee protection against indirect contact use the following
types of residual current devices:
- A type (
) for single-phase machines.
- In order to satisfy the requirements of the EN 61000-3-11 (Flicker)
standard we recommend connecting the welding machine to the
interface points of the main power supply that have an impedance
of less than Zmax = 0.15 ohm.
- The IEC/EN 61000-3-12 Standard does not apply to the welding
machine.
If the welding machine is connected to an electrical grid, the
installer or user must make sure that the machine can indeed be
connected (if necessary, consult the company that manages the
electrical grid).
Plug and outlet
Connect the power supply plug to a mains socket fitted with fuses or
an automatic circuit-breaker; the corresponding earth terminal should
be connected to the (yellow-green) earth conductor of the power
supply. Table 1 (TAB. 1) shows the recommended delayed fuse sizes,
in amps, for the main supply, which have been chosen according to
the maximum rated current output from the welding machine, and to
the nominal power supply voltage.
WARNING! Non-compliance with the above regulations
renders the manufacturer’s safety system (class I) inefficient,
with resulting serious risks to people (e.g. electric shock) and
things (e.g. fire).
WELDING CIRCUIT CONNECTIONS
WARNING! BEFORE CARRYING OUT THE FOLLOWING
CONNECTIONS MAKE SURE THAT THE WELDING MACHINE
IS SWITCHED OFF AND DISCONNECTED FROM THE POWER
SUPPLY.
Table 1
(TAB. 1)
shows the recommended sizes of the welding
cables (in mm
2
), according to the maximum current output from the
welding machine.
Connecting to the gas bottle (if used)
- The gas bottle that can be positioned on the trolley supporting
surface: max 30kg.
- Screw the pressure reducer(*) onto the gas bottle, inserting the
appropriate adapter supplied as an accessory when Argon or an
Argon/CO
2
mixture is used.
- Connect the gas input hose to the reducer and tighten the clamp.
- Loosen the adjustment ring nut on the pressure reducing valve
before opening the gas bottle valve.
(*) Accessory to be purchased separately if not supplied with the
product.
Connecting the welding current return cable
Must be connected to the workpiece or to the metal bench on which it
is positioned, keeping it as close as possible to the joint being done.
Torch
Prepare the torch when loading the wire for the first time, by
dismantling the nozzle and the contact tip, to ease its exit.
Polarity change
Fig. B
- Open the door of the reel space.
- MIG/MAG welding (gas):
- Connect the torch cable coming from the wire feeder to the red
terminal (+).
- Connect the return cable clamp to the black terminal (-).
- FLUX welding (no gas):
- Connect the torch cable coming from the wire feeder to the black
terminal (-).
- Connect the return cable clamp to the red terminal (+).
- Close the door of the reel space.
Recommendations:
- Screw the welding cable connectors right down into the quick
couplings (if present), so as to ensure perfect electrical contact;
otherwise, the connectors will overheat, wear rapidly and become
inefficient.
- Use welding cables that are as short as possible.
- Do not use metal structures that are not part of the workpiece to
substitute the welding current return cable; this could endanger
safety and produce an unsatisfactory weld.
LOADING THE WIRE REEL (Fig. E)
WARNING! BEFORE STARTING THE OPERATIONS
TO LOAD THE WIRE MAKE SURE THE WELDING MACHINE
IS SWITCHED OFF AND DISCONNECTED FROM THE MAIN
POWER SUPPLY OUTLET.
MAKE SURE THAT THE WIRE FEEDER ROLLERS, THE WIRE
GUIDE HOSE AND THE CONTACT TIP OF THE TORCH MATCH
THE DIAMETER AND TYPE OF WIRE TO BE USED AND MAKE
SURE THAT THESE ARE FITTED CORRECTLY. WHEN INSERTING
AND THREADING THE WIRE DO NOT WEAR PROTECTIVE
GLOVES.
- Open the reel compartment door.
- Position the wire reel on the spindle, holding the end of the wire
upwards; make sure the tab for pulling the spindle is correctly
seated in its hole
(1a)
.
- Release the pressure counter-roller(s) and move them away from
the lower roller(s)
(2a-b)
;
- Make sure that the towing roller(s) is suited to the wire used
(2c)
.
- Free the end of the wire and remove the distorted end with a clean
cut and no burr; turn the reel anti-clockwise and thread the end of
the wire into the wire-guide infeed, pushing it 50-100mm into the
wire guide of the torch fitting
(2d)
.
- Re-position the counter-roller(s), adjusting the pressure to an
intermediate value, and make sure that the wire is correctly
positioned in the groove of the lower roller(s)
(3)
- Remove the nozzle and contact tip
(4a)
.
- Insert the welding machine plug in the power supply outlet, switch
on the welding machine, press the torch button and wait for the end
of the wire to pass through the whole of the wire guide hose and
protrude by 10-15 cm from the front part of the torch, release the
button.
