- 4 -
5.5.1 MIG/MAG FLUX WELDING.............................................. 08
1. GENERAL SAFETY CONSIDERATIONS
5.5.1.1 Connection to the gas bottle.................................. 08
FOR ARC WELDING
...............................................
04
5.5.1.2 Connection to the wire feeder ............................... 08
5.5.1.3 Connecting the welding current return cable ......... 08
2. INTRODUCTION AND GENERAL DESCRIPTION..
05
5.5.1.4 Connecting the torch ........................................... 08
2.1 INTRODUCTION .................................................................... 05
5.5.2 TIG WELDING ............................................................... 08
2.2 WELDABILITY OF MATERIALS ............................................. 05
5.5.2.1 Connection to the gas bottle.................................. 08
2.3 STANDARD ACCESSORIES .................................................. 05
5.5.2.2 Connecting the welding current return cable ......... 08
2.4 OPTIONAL ACCESSORIES ................................................... 05
5.5.2.3 Connecting the torch ............................................ 08
5.5.3 MMA WELDING WITH COATED ELECTRODE ............. 08
5.5.3.1 Connecting the electrode holder clamp................. 08
3. TECHNICAL DATA ...................................................
05
5.5.3.2 Connecting the welding current return cable ......... 08
3.1 DATA PLATE............................................................................ 05
5.5.4 WARNINGS .................................................................... 08
3.2 OTHER TECHNICAL DATA ..................................................... 05
5.6 LOADING THE WIRE REEL ..................................................... 08
5.7 REPLACING THE LINER IN THE TORCH ................................. 08
4. DESCRIPTION OF THE WELDING MACHINE ........
05
5.7.1 Coiled hose for steel wires ................................................ 08
4.1 CONTROL, ADJUSTMENT AND CONNECTION DEVICES.. 05
5.7.2 Synthetic hose for aluminium wires................................... 08
4.1.1 Welding machine .......................................................... 05
4.1.2 Wire feeder ................................................................... 05
6. WELDING: DESCRIPTION OF THE PROCEDURE ..
08
4.2 WELDING MACHINE CONTROL PANEL............................... 06
6.1 MIG/MAG WELDING .............................................................. 08
4.3 WIRE FEEDER CONTROL PANEL........................................ 07
6.1.1 SHORT ARC TRANSFER MODE................................... 08
4.4 RECALLING AND STORING PROGRAMS ............................ 07
6.1.2 SPRAY ARC TRANSFER MODE ................................... 08
4.4.1RECALLING MANUFACTURER'S
6.1.3 PULSE ARC TRANSFER MODE ................................... 09
PRE-STORED PROGRAMS ......................................... 07
6.1.4 ADJUSTING THE WELDING PARAMETERS
4.4.1.1 MIG/MAG SYNERGIC programs ......................... 07
IN MIG/MAG .... .............................................................. 09
4.4.1.2 Operation in MANUAL mode (“PRG 0”) ................ 07
6.1.4.1 Protective gas...................................................... 09
4.4.2 STORING AND RECALLING CUSTOMISED MIG/MAG
6.1.4.2 Welding current................................................... 09
PROGRAMS....... ........................................................... 07
6.1.4.3 Arc voltage.......................................................... 09
4.4.2.1 Introduction ......................................................... 07
6.1.5 BI-LEVEL AND PULSE ON PULSE OPERATION ......... 09
4.4.2.2 Storage capacity for customised
MIG/MAG programs ............................................ 07
6.2 TIG WELDING (DC)................................................................. 09
4.4.2.3 Storage procedure (STORE) ............................... 07
6.3 MMA WELDING WITH COATED ELECTRODES..................... 09
4.4.2.4 Procedure for recalling a customised
6.4 Weld quality ............................................................................ 09
program (LOAD).................................................. 07
7. MAINTENANCE ........................................................
09
5. INSTALLATION
.................................................................... 07
7.1 ROUTINE MAINTENANCE ...................................................... 09
5.1 PREPARATION ..................................................................... 07
7.1.1.Torch .............................................................................. 09
5.2 HOW TO LIFT THE WELDING MACHINE .............................. 07
7.1.2 Wire feeder..................................................................... 09
5.3 POSITION THE WELDING MACHINE ................................... 07
7.2 EXTRAORDINARY MAINTENANCE....................................... 09
5.4 CONNECTION TO THE MAIN POWER SUPPLY .................. 07
5.4.1 Note .............................................................................. 07
5.4.2 Plug and outlet .............................................................. 07
8. TROUBLESHOOTING ..............................................
09
5.5 CONNECTION OF THE WELDING CABLES ........................ 07
INDEX
ENGLISH
page
page
CONTINUOUS WIRE WELDING MACHINES FOR MIG/MAG AND FLUX TIG, MMA
-
Keep the gas bottle (if used) away from heat sources, including direct
ARC WELDING DESIGNED FOR PROFESSIONAL AND INDUSTRIAL USE.
sunlight.
Note: In the following text the term “welding machine" will be used.
1.
GENERAL SAFETY CONSIDERATIONS FOR ARC
WELDING
,
*
)
- Use adequate electrical insulation with regard to the electrode, the work piece
The operator should be properly trained to use the welding machine safely and
and any (accessible) earthed metal parts in the vicinity.
should be informed about the risks related to arc welding procedures, the
This is normally achieved by wearing gloves, shoes, head coverings and
associated protection measures and emergency procedures.
clothing designed for this purpose and by using insulating platforms or mats.
(Refer also to the “IEC TECHNICAL SPECIFICATION or CLC/TS 62081”:
- Always protect your eyes using masks or helmets fitted with appropriate
INSTALLATION AND USE OF EQUIPMENT FOR ARC WELDING).
lenses.
Use special fire-resistant protective clothing and do not allow the skin to be
exposed to the ultraviolet and infrared rays produced by the arc; other people
in the vicinity of the arc should be protected by shields of non-reflecting
curtains.
-
Avoid direct contact with the welding circuit: the no-load voltage supplied by
- Noise level: If particularly intensive welding operations cause a personal daily
the welding machine can be dangerous under certain circumstances.
exposure level (LEPd) that is greater than or equal to 85db(A), the use of
-
When the welding cables are being connected or checks and repairs are
suitable personal protectors is compulsory.
carried out the welding machine should be switched off and disconnected
from the power supply outlet.
-
Switch off the welding machine and disconnect it from the power supply outlet
before replacing consumable torch parts.
-
Make the electrical connections and installation according to the safety rules
- The electromagnetic fields generated by the welding process may interfere
and legislation in force.
with the operation of electrical and electronic equipment.
-
The welding machine should be connected only and exclusively to a power
Users of vital electrical or electronic devices (e.g. pace-makers, respirators
source with the neutral lead connected to earth.
etc.) should consult a doctor before stopping in the vicinity of areas where this
-
Make sure that the power supply plug is correctly connected to the earth
welding machine is used.
protection outlet.
Users of vital electrical or electronic devices should not use the welding
-
Do not use the welding machine in damp or wet places and do not weld in the
machine.
rain.
-
Do not use cables with worn insulation or loose connections.
-
If the welding machine has a liquid cooling unit the filling operations should be
carried out with the welding machine switched off and disconnected from the
power supply outlet.
- This welding machine complies with the requirements of the technical
standard for the product for use only and exclusively in industrial
environments and for professional purposes. It is not guaranteed to meet
electromagnetic compatibility requirements in the home.
-
Do not weld on containers or piping that contains or has contained flammable
liquid or gaseous products.
-
Do not operate on materials cleaned with chlorinated solvents or near such
EXTRA PRECAUTIONS
substances.
-
Do not weld on containers under pressure.
- WELDING OPERATIONS:
-
Remove all flammable materials (e.g. wood, paper, rags etc.) from the working
- In environments with increased riskof electric shock
area.
- In confined spaces
-
Provide adequate ventilation or facilities for the removal of welding fumes
- In the presence of flammable or explosive materials
near the arc; a systematic approach is needed in evaluating the exposure
MUST BE evaluated in advance by an “Expert supervisor” and must always be
limits for the welding fumes, which will depend on their composition,
carried out in the presence of other people trained to intervene in
concentration and the length of exposure itself.
emergencies.
