synergic programs (“PRG” from “1” to “36”).
It makes it possible to reduce the current gradually when the torch button is
released (adjustment 0-3 seconds and LED (15b) ON).
10h-
SPOT WELDING TIME.
This is enabled only and exclusively if “SPOT” mode is selected with key (8). It is
used for MIG/MAG spot welding with welding time control (adjustment 0.1-10
seconds and LED (15b) ON).
11- Key for manual activation of gas solenoid valve.
This button causes gas outflow (piping discharge flow rate adjustment) without
having to operate the torch button; the action of the button is momentary.
12- Key for manual wire feed.
This button is used to feed the wire along the torch hose without having to operate
the torch button; the action is momentary and feed rate is fixed.
13- Encoder knob for adjusting welding parameters (see 10a-10h).
14- Encoder knob.
Normally the knob regulates:
- Welding current (LED (16a) ON) in Pulse arc and MMA modes.
Before proceeding to recall a program, make sure the selected transfer mode (PULSE
- Wire feed rate (LED (16c) ON) in Short/Spray arc mode.
ARC,
PULSE ARC PULSE-ON-PULSE,
SHORT/SPRY ARC or "PRG=0") is actually
- The thickness of the piece being welded (LED (16b) on) if selected with key (17)
the one you intend to use.
for piece thickness in mm.
In welding modes using two current levels (bi-level, pulse-on-pulse Tstart) with
LED (10b) ON the knob regulates:
(
) - Welding current I2 (LED (16a) ON) for the secondary level in Pulse arc
mode.
(
) - Wire feed rate for the secondary welding level (LED (16c) ON) in
Short/Spray arc mode.
16a, 16b, 16c- LED indicating unit of measurement at the time (amps, thickness in
millimetres, metres/minute).
17-Key for selecting unit of measurement Amps/Thickness in mm (LED (16a)/LED
5. INSTALLATION
(16b)).
Activated in the synergic programmes from "1" to "36" for any type of MIG/MAG
WARNING! CARRY OUT ALL INSTALLATION OPERATIONS AND
welding. Selecting thickness in mm (LED (16b) lit up) allows regulation of the
ELECTRICAL CONNECTIONS WITH THE WELDING MACHINE COMPLETELY
thickness of the piece being welded using the encoder(14), the program
SWITCHED OFF AND DISCONNECTED FROM THE POWER SUPPLY OUTLET.
automatically calculates the current required to weld this thickness.
THE ELECTRICAL CONNECTIONS MUST BE MADE ONLY AND EXCLUSIVELY BY
In MIG/MAG short arc synergic programmes this key is used to pass from regulation
AUTHORISED OR QUALIFIED PERSONNEL.
of wire feed rate to thickness in mm (LED (16c)/LED (16b)).
5.1 PREPARATION (FIG. F)
Unpack the trolley and assemble it according to the instructions provided.
Unpack the welding machine, the wire feeder and the cooling unit (if present); install
them on the trolley.
5.2 LIFTING THE WELDING MACHINE
The individual components (welding machine, wire feeder and cooling system) should
only be lifted manually, after separation from the trolley.
5.3 POSITION OF THE WELDING MACHINE
Choose the place to install the welding machine so that the cooling air inlets and outlets
are not obstructed (forced circulation by fan, if present); at the same time make sure that
conductive dusts, corrosive vapours, humidity etc. will not be sucked into the machine.
Leave at least 250mm free space around the welding machine.
WARNING! Position the welding machine on a flat surface with sufficient
carrying capacity for its weight, to prevent it from tipping or moving hazardously.
5.4 CONNECTION TO THE MAIN POWER SUPPLY
5.4.1 Note
Before making any electrical connection, make sure the rating data of the welding
machine correspond to the mains voltage and frequency available at the place of
installation.
The welding machine should only be connected to a power supply system with the
neutral conductor connected to earth.
5.4.2 Plug and outlet
Connect a normalised plug
(3P + T)
having sufficient capacity to the power cable and
prepare a mains outlet fitted with fuses or an automatic circuit-breaker; the special earth
terminal should be connected to the earth conductor (yellow-green) of the power supply
line. The table
(TAB.1)
shows the recommended delayed fuse sizes in amps, chosen
according to the max. nominal current supplied by the welding machine, and the
nominal voltage of the main power supply.
The welding machine allows storage of customised programs in three groups that refer
5.5 CONNECTION OF THE WELDING CABLES
to the three synergic transfer modes (SHORT/SPRAY ARC Pulse arc and Pulse on
pulse) and to manual mode operation, with the following specifications:
-
SYNERGIC PULSE ARC PULSE ON PULSE: 10 programmes can be stored
WARNING! BEFORE MAKING THE FOLLOWING CONNECTIONS MAKE
(available numbers from "1" to "10"),
SURE THE WELDING MACHINE IS SWITCHED OFF AND DISCONNECTED FROM
THE POWER SUPPLY OUTLET.
2
Table
(TAB. 1)
gives the recommended values for the welding cables (in mm ) .
5.5.1.1 Connection to the gas bottle
The gas bottle can be loaded onto the supporting platform of the trolley
max. 60 kg.
- Screw the pressure reducing valve onto the gas bottle valve, inserting the appropriate
adapter supplied as an accessory, for when the gas used is Argon or an
select the desired transfer mode: PULSE ARC, PULSE
Argon /CO mixture.
2
ARC PULSE-ON- PULSE or SHORT/SPRAY ARC or select "PRG=0" if
- Connect the gas inlet pipe to the pressure-reducing valve and tighten the band
programmes have been pre-stored in manual mode.
supplied.
- Loosen the adjustment ring nut on the pressure-reducing valve before opening the
4.4.2.3 Storage procedure (STORE).
After adjusting the welding machine to carry out a particular weld perfectly, proceed as
follows
(see FIG.E)
:
a) Press key
(5)
“STORE”.
b) “
Pr
” will appear on display
(16)
and a number (between “1” and “10”) on display
(15)
.
c) Turn the encoder knob (either
(13)
or
(14)
) to select the number where the program is
to be stored (see also 4.4.2 ).
d) Press the “STORE” key again.
e) Displays
(15)
and
(16)
will flash.
f) Within two seconds, press the “STORE” key again.
g) The displays will show “
St Pr
”, indicating that the program has been stored; after 2
seconds the displays will automatically switch to the values relating to the
parameters that have just been saved.
Note. If the “STORE” key is not pressed again within 2 seconds while the displays are
flashing, they will show “
No St
” and the program will not be stored; the displays
automatically return to what they were showing initially.
4.4.2.4 Procedure for recalling a customised program (LOAD)
Then proceed as follows
(see FIG.E)
:
a) Press the “LOAD” key.
b) “
Pr
” appears on display
(16)
and a number (between “1” and “10”) on display
(15)
.
c) Turn the encoder knob (either
(13)
or
(14)
) to select the number used to store the
program that is to be used.
d) Press the “LOAD” key again for more than 2 seconds.
e) The displays will show “
Ld Pr
” indicating that the program has been loaded; after 2
seconds the displays will automatically switch to the values relating to the program
that has just been recalled.
Note. If the “LOAD” key is not pressed again for longer than 2 seconds, the displays
15- Alphanumeric display with 3 digits. Shows:
will show “
No Ld
” and the program will not be loaded; the displays automatically
- welding parameter values (see from
(10a)
to
(10h)
) in loadless operation.
return to what they were showing initially.
- actual arc voltage, while welding.
NOTE: when welding stops, the display automatically switches to the setting
NOTES:
value.
- DURING OPERATIONS WITH THE “STORE” AND “LOAD” KEYS THE “PRG”
- an alarm signal (see point 1).
LED IS ON.
15a, 15b, 15c- LED's indicating present unit of measurement (volts, seconds,
- A RECALLED PROGRAM CAN BE MODIFIED AS THE OPERATOR WISHES,
percentage).
BUT THE MODIFIED VALUES ARE NOT AUTOMATICALLY SAVED. TO STORE
16- Alphanumeric display with 3 digits.
Shows:
THE NEW VALUES IN THE SAME PROGRAM IT IS NECESSARY TO FOLLOW
- the value of the setting made using the encoder knob
(14)
.
THE STORAGE PROCEDURE (see 4.4.2.3).
- the actual current, while welding.
- THE USER IS RESPONSIBLE FOR RECORDING CUSTOMISED PROGRAMS
NOTE: when welding stops, the display automatically switches to the setting
AND THE RELATED MANAGING OF THE ASSOCIATED PARAMETERS.
value.
- CUSTOMISED PROGRAMS CANNOT BE SAVED IN TIG OR MMA ELECTRODE
- an alarm signal (see point 1).
MODE.
4.4 RECALLING AND STORING PROGRAMS
4.4.1 RECALLING MANUFACTURER'S PRE-STORED PROGRAMS
4.4.1.1 MIG/MAG SYNERGIC programs
The welding machine is designed with 36
stored synergic programs,
as specified in
the table
(TAB.4), which must be consulted when selecting a suitable program for
the type of welding to be carried out.
A particular program is selected by pressing the “PRG” program repeatedly and the
corresponding number, between “0” and “36” will be shown on the display (the number
“0” does not have a corresponding synergic program but is for operating in manual
mode, as described in the next paragraph).
Note: In a synergic program, it is essential to first select the desired transfer
mode, PULSE ARC or SHORT/SPRAY ARC, using the appropriate key (see FIG.E
(7)).
Note:
All types of wire that are not shown in the table can be used in manual mode
“PRG 0”.
4.4.1.2 OPERATION IN MANUAL MODE (“PRG 0”)
Operation in manual mode corresponds to the number “0” on the display and is only
active if the SHORT/SPRAY ARC transfer mode has been selected previously
(see
FIG.E (7)).
In this mode, as there will be no synergy, the operator should set all welding parameters
manually.
Warning!
The operator can set all the parameters freely therefore it is possible to set
values that are incompatible with a correct welding procedure.
Note: it is NOT possible to use PULSE ARC transfer mode when manual is
selected.
4.4.2 STORING AND RECALLING CUSTOMISED MIG/MAG PROGRAMS
4.4.2.1 Introduction
The welding machine can be used to (STORE) customised work programs relating to a
set of valid parameters for a particular welding job. Each stored program can be recalled
(LOAD) at any time so that the user finds the welding machine “ready-to-use” for a
specific job that has been optimised previously.
4.4.2.2 Storage capacity for customised MIG/MAG programs
-
SYNERGIC PULSE ARC: able to store 10 programs (available numbers from “1” to
“10”),
-
SYNERGIC SHORT/SPRAY ARC: able to store 10 programs (available numbers
5.5.1 MIG/MAG-FLUX WELDING (FIG. H)
from “1” to “10”),
-
MANUAL SHORT/SPRAY ARC (“PRG=0”): able to store 10 programs (available
numbers from “1” to “10”), for a total of 40 customised programs.
To actually recall the program to be used, before selecting the number (as
described in parag. 4.4.1),
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