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TEAMWELDER MIG drive Synergic puls, Operating Instructions Manual

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TEAMWELDER MIG drive Synergic puls Operating Instructions Manual Download Page 71

 

Technical data 

MIG-DRIVE SYNERGIC PULS 

 

299-031000-TWD01 

18.10.2016

 

71

 

 

 

8 

Technical data

 

8.1 

MIG-DRIVE SYNERGIC PULS 

 

 

Performance specifications and guarantee only in connection with original spare and 
replacement parts! 

 

Supply voltage 

42 VAC 

Maximum welding current at 60% DC 

550 A 

Maximum welding current at 100% DC 

420 A 

EMC class 

A 

Safety identification 

 

/ 

 

/ 

 

Harmonised standards used 

IEC 60974-1, -5, -10

 

Wire feed speed 

0.5 m/min. to 25 m/min 

Factory-installed roll equipment 

1.0 mm + 1.2 mm (for steel wire) 

Drive 

4-roll (37 mm) 

Wire spool diameter 

Standardised wire spools up to 300 mm 

Torch connector 

Euro torch connector 

Protection classification 

IP 23 

Ambient temperature* 

-25 °C to +40 °C 

Dimensions L x W x H 

690 x 300 x 410 mm 

27.2 x 11.8 x 16.1 inch 

Weight 

15.1 kg 

33.3 lb 

 

 

*Ambient temperature depends on coolant! Observe the coolant temperature range for the 
welding torch cooling! 

 

Summary of Contents for MIG drive Synergic puls

Page 1: ...Operating instructions EN Wire feed unit MIG DRIVE SYNERGIC PULS 299 031000 TWD01 18 10 2016 Observe additional system documents...

Page 2: ...on 49 2623 9276400 A list of authorised sales partners can be found at www teamwelder com Liability relating to the operation of this equipment is restricted solely to the function of the equipment No...

Page 3: ...welding current leads 22 5 1 2 1 Stray welding currents 23 5 1 3 Intermediate hose package connection 24 5 1 4 Intermediate hose package strain relief 25 5 1 5 Shielding gas supply shielding gas cyli...

Page 4: ...settings 58 5 7 1 Selecting changing and saving parameters 59 5 7 1 1 Reset to factory settings 60 5 7 1 2 Special parameters in detail 61 5 8 Machine configuration menu 62 5 8 1 Selecting changing a...

Page 5: ...eable parts 73 10 1 Wire feed rollers 73 10 1 1 Wire feed rollers for steel wire 73 10 1 2 Wire feed rollers for aluminium wire 73 10 1 3 Wire feed rollers for cored wire 73 10 1 4 Conversion kit 74 1...

Page 6: ...erved to prevent serious and even fatal injuries Safety notes include the WARNING keyword in the heading with a general warning symbol The hazard is also highlighted using a symbol in the page margin...

Page 7: ...off machine Release Switch on machine Press and keep pressed Switch Wrong Turn Correct Numerical value adjustable Menu entry Signal light lights up in green Navigating the menu Signal light flashes gr...

Page 8: ...combination with all other parts of these instructions Read and observe the operating instructions for all system components especially the safety instructions The illustration shows a general example...

Page 9: ...equipment depending on the application The machine may only be opened by qualified personnel Hazard when interconnecting multiple power sources If a number of power sources are to be connected in par...

Page 10: ...arks results in burns Use welding shield or welding helmet with the appropriate safety level depending on the application Wear dry protective clothing e g welding shield gloves etc according to the re...

Page 11: ...workers at work The regulations applicable to occupational safety and accident prevention in the country concerned Setting up and operating the machine as per IEC 60974 9 Brief the user on safety cons...

Page 12: ...reas connected to the low voltage public mains network Setting up and operating When operating arc welding systems in some cases electro magnetic interference can occur although all of the welding mac...

Page 13: ...amaged itself during movement and set up Tilt resistance is guaranteed up to an angle of 10 according to IEC 60974 1 Set up and transport the machine on level solid ground Secure add on parts using su...

Page 14: ...e equipment is not used correctly No liability is accepted for any damages arising from improper usage The equipment must only be used in line with its designated purpose and by trained or expert pers...

Page 15: ...ginal document of the specific declaration of conformity is included with every product 3 3 3 Service documents spare parts and circuit diagrams WARNING Do not carry out any unauthorised repairs or mo...

Page 16: ...additional stickers with information on the replacement parts and JOB lists will be located on the inside 4 Welding torch connection Euro or Dinse torch connector Welding current shielding gas and to...

Page 17: ...s connection 3 Quick connect coupling red coolant return 4 Connector plug welding current Welding current connection on wire feed unit 5 Quick connect coupling blue coolant supply 6 Machine feet 7 Int...

Page 18: ...ort to enable horizontal pivoting of the machine 4 Wire feed unit 5 Push button gas test rinse hose package see 5 1 5 3 chapter 6 Wire inching push button For potential and gas free inching of the wir...

Page 19: ...it Displays the welding parameters and the corresponding values see 5 2 chapter 2 Signal light JOB List Illuminates upon display or selection of the JOB number 3 JOB LIST Welding task push button JOB...

Page 20: ...5 8 2 chapter 9 Welding type push button for machine versions with pulsed arc welding procedures only standard MIG MAG welding pulsed MIG MAG welding 10 Push button gas test rinse hose package see 5...

Page 21: ...ets are suitable for transport by hand only The machine must not be suspended or lifted using a crane Read and observe the documentation to all system and accessory components 5 1 1 Ambient conditions...

Page 22: ...and as close as possible in parallel Lay the workpiece lead and hose package of power sources with HF igniter TIG for as long as possible in parallel with a distance of 20 cm to avoid HF sparkover Alw...

Page 23: ...ors damage machines and electronic devices and cause overheating of components leading to fire Check that all welding current connections are firmly secured and electrical connections are in perfect c...

Page 24: ...connection on wire feed unit 7 Quick connect coupling blue coolant supply 8 Intermediate hose package strain relief see 5 1 4 chapter Insert the end of the hose package through the strain relief of t...

Page 25: ...Connection sockets or connection plugs on the machine or the intermediate tube package may be damaged if the strain relief is missing or incorrectly fitted The strain relief takes the strain from cab...

Page 26: ...supply from the shielding gas cylinder to the welding torch is a fundamental requirement for optimum welding results In addition a blocked shielding gas supply may result in the welding torch being d...

Page 27: ...Open the pressure regulator Switch on the power source at the main switch Trigger gas test see 5 1 5 3 chapter function welding voltage and wire feed motor remain switched off no accidental arc ignit...

Page 28: ...erview of coolants Do not mix different coolants When changing the coolant the entire volume of liquid must be changed Dispose of the coolant in accordance with local regulations and the material safe...

Page 29: ...after welding MIG MAG Parameter Nominal values Actual values Hold values Welding current 1 Material thickness Wire feed speed Welding voltage 1 traditional MIG MAG TIG MMA Parameter Nominal values Ac...

Page 30: ...either a steel liner or liner with the correct inner diameter must be inserted in the torch Recommendation Use a steel liner when welding hard unalloyed wire electrodes steel Use a chrome nickel liner...

Page 31: ...h control lead etc 5 Quick connect coupling blue coolant supply 6 Quick connect coupling red coolant return Insert the central plug for the welding torch into the central connector and screw together...

Page 32: ...in an unpredictable manner Welding wire can be conveyed at very high speeds and if conveyed incorrectly may escape in an uncontrolled manner and injure persons Before mains connection set up the comp...

Page 33: ...ly fasten the wire spool to the wire spool support Before you start working always check the wire spool is securely fastened Standard D300 wire spool holder can be used Adapters see 9 chapter are requ...

Page 34: ...electrode CAUTION Risk of injury due to welding wire escaping from the welding torch The welding wire can escape from the welding torch at high speed and cause bodily injury including injuries to the...

Page 35: ...wire carefully from the wire spool and insert through the wire inlet nipple over the drive roller grooves and the guide pipe into the capillary tube and Teflon core using guide pipe Press the clamping...

Page 36: ...ol Description 0 1 Allen screw Securing the wire spool retainer and adjustment of the spool brake Tighten the Allen screw 8 mm in the clockwise direction to increase the braking effect Tighten the spo...

Page 37: ...s sticker on the machine The required process parameters are calculated by the system depending on the operating point specified single dial operation via wire speed rotary dial Conventional welding t...

Page 38: ...rmined quickly with the JOB list see 11 1 chapter 2 4 3s 1 3 Figure 5 15 Item Symbol Description 0 1 JOB LIST Welding task push button JOB Select the welding task from the welding task list JOB LIST T...

Page 39: ...amics 2 1 Figure 5 16 Item Symbol Description 0 1 Push button throttling effect arc dynamics Arc is harder and more narrow Arc is softer and wider 2 Welding parameter setting dial For setting the weld...

Page 40: ...setting the operating point by means of the panel thickness parameter is described as an example below Plate thickness details in welding programs generally refer to fillet welds in the PB welding pos...

Page 41: ...hrottling effect dynamics gas post flow time gas pre flow time and wire burn back correction are stored for each JOB individually Changes are stored permanently in the JOB that is currently selected I...

Page 42: ...ional sequences operating modes 5 3 7 1 Explanation of signs and functions Symbol Meaning Press torch trigger Release torch trigger Shielding gas flowing I Welding output Wire electrode is being conve...

Page 43: ...g gas is expelled gas pre flows Wire feed motor runs at creep speed Arc ignites after the wire electrode makes contact with the workpiece welding current flows Change over to pre selected wire speed S...

Page 44: ...ns at creep speed Arc ignites when the wire electrode makes contact with the workpiece Welding current flows Wire feed speed increases to the set nominal value 2 cycle Release torch trigger no effect...

Page 45: ...ons 2 Welding parameter setting dial For setting the welding performance for selecting the JOB welding task and for setting other welding parameters 3 Select operating mode button Non latched Latched...

Page 46: ...e operating point welding output Figure 5 24 5 3 9 MIG MAG automatic cut out The welding machine ends the ignition process or the welding process with an ignition fault no welding current flows within...

Page 47: ...d to the Euro torch connector of the wire feeder only To do so the welding current lead of the intermediate hose package must be connected to the welding current connection at the rear of the unit Fig...

Page 48: ...bol Description 0 1 JOB LIST Welding task push button JOB Select the welding task from the welding task list JOB LIST The list can be found inside the protective cap on the wire feeder and in the appe...

Page 49: ...2016 49 5 4 3 Further welding parameters Preselection Select TIG JOB 127 see 5 4 2 chapter ENTER EXIT NAVIGATION 5s 3s Figure 5 28 Display Setting selection Gas pre flow time Ignition current Up slop...

Page 50: ...gger liftarc current flowing regardless of the main current set b Incline the torch over the torch gas nozzle to produce a gap of approx 2 3 mm between the electrode tip and the workpiece The arc igni...

Page 51: ...Function sequences operating modes 5 4 5 1 Legend Symbol Meaning Press torch trigger Release torch trigger I Welding current Gas pre flows Gas post flows Non latched Latched t Time tUp Upslope time t...

Page 52: ...alue set for the starting current Istart Welding current increases to the main current in the set upslope time 2nd cycle Release torch trigger The main current falls in the set downslope time to the e...

Page 53: ...s and hold torch trigger The main current falls in the set downslope time to the end crater current Iend 4th cycle Release torch trigger arc is extinguished Gas post flow time elapses The welding proc...

Page 54: ...connection G connecting nipple Place yellow insulating cap on the G connection nipple protects against electrical voltage and dirt 5 5 1 Welding task selection Select MMA JOB 128 see 11 1 chapter You...

Page 55: ...ive values cellulose electrode types 2 Welding parameter setting rotary transducer Setting of welding current and other welding parameter and their values 5 5 3 Hotstart The hotstart device improves t...

Page 56: ...ng selection Hotstart current Hotstart time 5 5 4 Antistick Anti stick prevents the electrode from annealing If the electrode sticks in spite of the Arcforce device the machine automatically switches...

Page 57: ...r sources welding torches electrode holders remote controls spare parts and replacement parts etc from our range of products Only insert and lock accessory components into the relevant connection sock...

Page 58: ...s the user maximum flexibility in optimising their requirements These settings are not configured directly on the machine control since a regular setting of the parameters is generally not required Th...

Page 59: ...rameters by turning the welding parameter setting rotary dial Set or change the parameters by turning the arc length correction select welding program rotary dial EXIT Exit the menu Press the right pa...

Page 60: ...ll special parameters saved by the user will be overwritten by the factory settings RESET l 0 Hard Soft Figure 5 39 Display Setting selection Initialising Keep the push button pressed until InI is sho...

Page 61: ...in The ramp time can be set between two ranges During wire inching the speed can be changed by means of the welding parameter setting rotary dial Changing the speed has no effect on the ramp time Latc...

Page 62: ...esistance 1 Lead resistance for the first welding circuit 0 m 60 m 8 m ex works Time controlled power saving mode see 5 8 2 chapter 5 min 60 min time until activation of power saving mode when inactiv...

Page 63: ...who is able to implement the required safety procedures In the event of failure of any one of the following tests the machine must not be operated again until it has been repaired and a new test has b...

Page 64: ...Wheels and their securing elements Transport elements strap lifting lugs handle Other general condition 6 3 1 2 Functional test Operating message safety and adjustment devices Functional test Welding...

Page 65: ...f Juli 4th 2021 used electric and electronic equipment may no longer be placed in unsorted municipal waste It must be collected separately The symbol depicting a waste container on wheels indicates th...

Page 66: ...pray and replace if necessary Setting the spool brake see 5 3 2 5 chapter Check settings and correct if necessary Setting pressure units see 5 3 2 4 chapter Check settings and correct if necessary Wor...

Page 67: ...the wire feeder Speedometer is not emitting a signal M3 51 defective inform Service 6 x Shielding gas error Check shielding gas supply for machines with shielding gas monitoring 7 x Secondary overvol...

Page 68: ...r once the error has been rectified b The error message can be reset by pressing a key button Welding machine control Key button MIG 300 D3 Synergic not possible c The error message can only be reset...

Page 69: ...when no changes are done after 3 sec 7 3 2 Resetting all JOBs All customised welding parameters that are stored will be replaced by the factory settings EXIT 3s RESET ENTER 3s 3s Figure 7 2 Display S...

Page 70: ...nt circuit Coolant tank and quick connect coupling of coolant supply and return are only fitted in machines with water cooling To vent the cooling system always use the blue coolant connection which i...

Page 71: ...ty identification Harmonised standards used IEC 60974 1 5 10 Wire feed speed 0 5 m min to 25 m min Factory installed roll equipment 1 0 mm 1 2 mm for steel wire Drive 4 roll 37 mm Wire spool diameter...

Page 72: ...Accessories Internet 72 299 031000 TWD01 18 10 2016 9 Accessories 9 1 Internet For the accessories available for your product go to www teamwelder com Figure 9 1...

Page 73: ...1 0 1 2 Drive rollers 37 mm steel 092 000842 00000 FE 2DR4R 1 2 1 6 Drive rollers 37 mm steel 092 000843 00000 FE AL 2GR4R Pressure rollers smooth 37mm 092 000844 00000 10 1 2 Wire feed rollers for al...

Page 74: ...092 000846 00000 URUE AL 4ZR4R 1 2 1 6 Conversion kit 37mm 4 roller drive for aluminium 092 000847 00000 URUE AL 4ZR4R 2 4 3 2 Conversion kit 37mm 4 roller drive for aluminium 092 000868 00000 URUE R...

Page 75: ...chine versions with pulsed arc welding procedures only MIG MAG pulse arc welding can be selected with JOBs 6 8 9 10 11 13 14 15 34 35 36 37 74 75 76 77 237 238 and 239 If an attempt is made to set ano...

Page 76: ...correction 0 40 40 Gas post flow time 0 5 0 0 20 0 s Wire burn back 0 50 50 TIG Gas pre flow time 0 5 0 0 5 0 s Ignition current 1 200 Up slope time 1 0 0 0 20 0 s Down slope time 0 0 20 0 s End curre...

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