2.3 OPTIONAL ACCESSORIES
5. INSTALLATION
- spool gun.
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WARNING!
3. TECHNICAL DATA
CARRY OUT ALL INSTALLATION OPERATIONS AND ELECTRICAL
3.1 DATA PLATE
CONNECTIONS WITH THE WELDING MACHINE COMPLETELY SWITCHED OFF
The most important data regarding use and performance of the welding machine are
AND DISCONNECTED FROM THE POWER SUPPLY OUTLET.
summarised on the rating plate and have the following meaning:
THE ELECTRICAL CONNECTIONS MUST BE MADE ONLY AND EXCLUSIVELY
Fig. A
BY AUTHORISED OR QUALIFIED PERSONNEL.
1-
EUROPEAN standard of reference, for safety and construction of arc welding
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machines.
2-
Symbol for internal structure of the welding machine.
5.1 PREPARATION (Fig. D)
3-
Symbol for welding procedure provided.
Unpack the welding machine, assemble the separate parts contained in the
4-
Symbol
S
: indicates that welding operations may be carried out in environments with
package.
heightened risk of electric shock (e.g. very close to large metallic volumes).
5-
Symbol for power supply line:
5.1.1 Assembling the return cable-clamp (Fig. E)
1~: single phase alternating voltage
3~: 3-phase alternating voltage
5.2 HOW TO LIFT THE WELDING MACHINE
6-
Protection rating of the covering.
None of the welding machines described in this manual is equipped with a lifting
7-
Technical specifications for power supply line:
device.
- U :
Alternating voltage and power supply frequency of welding machine (allowed
1
limit ±10%):
5.3 SITE
- I
:
Maximum current absorbed by the line.
Locate the welding machine in an area where openings for cooling air are not
1 max
obstructed (forced circulation with fan), leave at least 250mm free space around the
- I
:
: effective current supplied
1eff
welding machine; check that conductive dusts, corrosive vapours, humidity etc., will
8-
Performance of the welding circuit:
not enter welding machine.
- U :
maximum no-load voltage (open welding circuit).
0
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- I /U :
current and corresponding normalised voltage that the welding machine can
2
2
supply during welding
WARNING: Position the welding machine on a flat surface with sufficient
- X :
Duty cycle: indicates the time for which the welding machine can supply the
carrying capacity for the weight of the welding machine, to prevent tipping or
corresponding current (same column). It is expressed as %, based on a 10 min.
hazardous movement.
cycle (e.g. 60% = 6 minutes working, 4 minutes pause, and so on)
.
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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
5.4 CONNECTION TO THE MAIN POWER SUPPLY
until its temperature returns within the allowed limits).
5.4.1 Warning
- A/V-A/V:
shows the range of adjustment for the welding current (minimum maximum)
- Before making any electrical connection, make sure the rating data of the welding
at the corresponding arc voltage.
machine correspond to the mains voltage and frequency available at the place of
9-
Manufacturer's serial number for welding machine identification (indispensable for
installation..
technical assistance, requesting spare parts, discovering product origin).
- The welding machine should only be connected to a power supply system with the
10-
:
Size of delayed action fuses to be used to protect the power line
neutral conductor connected to earth.
11-
Symbols referring to safety regulations, whose meaning is given in chapter 1
“General safety considerations for arc welding”.
5.4.2 PLUG AND OUTLET
Connect a normalised plug
(2P + T for 1ph, 3P + T for 3ph)
having sufficient capacity-
Note: The data plate shown above is an example to give the meaning of the symbols
to the power cable and prepare a mains outlet fitted with fuses or an automatic circuit-
and numbers; the exact values of technical data for the welding machine in your
breaker; the special earth terminal should be connected to the earth conductor (yellow-
possession must be checked directly on the data plate of the welding machine itself.
green) of the power supply line. Table 1
(TAB.1)
shows the recommended delayed fuse
sizes in amps, chosen according to the max. nominal current supplied by the welding
3.2 OTHER TECHNICAL DATA
machine, and the nominal voltage of the main power supply.
- WELDING MACHINE: see table 1 (TAB.1)
- TORCH:
see table 2 (TAB.2)
5.4.3 VOLTAGE CHANGE
The welding machine weight is shown in table 1 (TAB. 1)
To carry out voltage change operations (only the 3-phase version), take off the panel
to gain access to the inside of the machine, and prepare the voltage change terminal
board so that the connection indicated on the special indicator plate corresponds to the
available power supply voltage.
4.DESCRIPTION OF THE WELDING MACHINE
Fig. F
4.1 Control, adjustment and connection devices (Fig. B)
Reassemble the panel carefully using the appropriate screws.
4.2 Control panel (Fig. C)
Warning!
In the factory the machine is set at the highest voltage of the available range, e.g.
LED showing thermostatic protection. Indicates welding cutout due to
U 400V
Ü
Voltage setting at the factory.
1
overheating.
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LED's showing power supply voltage.
WARNING!
Failure to observe the above rules will make the (Class 1) safety system installed
-
- low main supply voltage (welder underpowered);
by the manufacturer ineffective with consequent serious risks to persons (e.g.
electric shock) and objects (e.g. fire).
.
- normal main supply voltage (welder powered correctly);
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/
- high main supply voltage (welder overpowered).
5.5 CONNECTION OF THE WELDING CABLES
WARNING:
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Under faulty power supply conditions, the following conditions will occur:
- over- or under- voltage LED will light up;
WARNING! BEFORE MAKING THE FOLLOWING CONNECTIONS MAKE
- intermittent buzzer;
SURE THE WELDING MACHINE IS SWITCHED OFF AND DISCONNECTED FROM
- the display will show
ALL UPP or ALL LOW.
THE POWER SUPPLY OUTLET.
We recommend switching the welder off to prevent it being damaged.
2
Table 1
(TAB. 1)
gives the recommended values for the welding cables (in mm )
depending on the maximum current supplied by the welding machine.
A
:
LED on: the display shows the welding current.
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Intermittent LED: Wire feed rate up slope programming mode
5.5.1 Connection to the gas bottle
- Gas bottle can be loaded on welding machine bottle support platform: max 20 Kg.
m/min
LED on: the display shows wire feed rate.
- Screw the gas regulator onto the gas bottle valve, inserting the appropriate
adapter supplied as an accessory, when the gas used is Argon or an Argon /CO
2
Intermittent LED: Wire burn back time programming mode
mixture.
- Connect the gas inlet pipe to the gas regulator and tighten the band supplied.
sec
LED on: the display shows spot welding time
- Loosen the adjustment ring nut on the gas regulator before opening the bottle valve.
Intermittent LED: Post-gas time programming mode
5.5.2 Connecting the welding current return cable (Fig. G1)
Dual function button: if pressed and released it will show the welding
Connect the welding current return cable to the piece to be welded or to the metal
bench on which it rests, as close as possible to the join being made.
current, wire feed rate and spot welding time (only if spot welding
operation is selected!)
If the button is pressed for at least 3 seconds, this gives access to welding
5.5.3 Connecting the torch (Fig. G1)
parameter programming mode.
Engage the torch (1) with its dedicated connector (2) by tightening the locking ring
To exit programming mode press the button again for at least 3 seconds.
manually as far down as it will go. Prepare the wire for loading the first time by
dismantling the nozzle and the contact tube to ease its exit.
Knob for adjusting wire feed rate and for setting accessory welding
parameters (in programming mode).
5.5.4 Connecting the spool gun (Fig. G2)
Connect the spool gun
(3)
to the centralised torch connection
(4)
screwing the ring nut
DEFAULT
LED on: indicates that wire feed is at recommended rate (pre-set default
right down to fasten it. Then insert the control cable connector
(5)
in the special socket
value).
(6)
. The welding machine will recognise the spool gun automatically.
Button for selecting 2/4-stroke, spot welding.
5.6 LOADING THE WIRE REEL (Fig. H1,H2, H3)
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Wire diameter selection button.
WARNING! BEFORE STARTING THE OPERATIONS TO LOAD THE WIRE
MAKE SURE THE WELDING MACHINE IS SWITCHED OFF AND DISCONNECTED
Welding gas selection button.
FROM THE MAIN POWER SUPPLY OUTLET.
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Welding material selection button (steel, stainless steel, aluminium,
MAKE SURE THAT THE WIRE FEEDER ROLLERS, THE WIRE GUIDE HOSE AND
coppersilicon or copper-aluminium alloys for MIG brazing).
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)
.
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