1. GENERAL SAFETY CONSIDERATIONS
FOR ARC WELDING ................................................. 05
5.5.5 Warnings....................................................................................... 07
2. INTRODUCTION AND GENERAL DESCRIPTION... 06
5.5.6 Connecting the water cooling unit (G.R.A). (only for
2.1 INTRODUCTION
the R.A. version) ............................................................................ 07
2.2 MAIN FEATURES................................................................................... 06
5.6 LOADING THE WIRE REEL................................................................... 07
2.3 WELDABILITY OF MATERIALS............................................................. 06
5.7 REPLACING THE LINER IN THE TORCH ............................................. 07
5.7.1 Coiled hose for steel wires ............................................................ 07
5.7.2 Synthetic hose for aluminium wires ............................................... 08
3. TECHNICAL DATA .................................................... 06
.. 08
3.1 DATA PLATE ........................................................................................... 06
3.2 OTHER TECHNICAL DATA .................................................................... 06
06
6.1.2 Spray arc ...................................................................................... 08
6.2 ADJUSTING THE WELDING PARAMETERS ........................................ 08
6.2.1 Shielding gas ................................................................................. 08
6.2.2
4.2 THERMAL RELAY.................................................................................. 07
6.2.3 Arc voltage..................................................................................... 08
4.3 SAFEGUARD FOR INSUFFICIENT PRESSURE IN THE WATER
COOLING CIRCUIT ............................................................................... 07
08
5. INSTALLATION ......................................................... 07
5.1 PREPARATION....................................................................................... 07
5.2 HOW TO LIFT THE WELDING MACHINE............................................ 07
5.3 POSITION OF THE WELDING MACHINE ............................................. 07
5.4 CONNECTION TO THE MAIN POWER SUPPLY ................................. 07
08
5.4.1 Note ............................................................................................... 07
5.4.2 Plug and outlet............................................................................... 07
5.4.3 Voltage change ............................................................................. 07
5.5 CONNECTION OF THE WELDING CABLES ....................................... 07
5.5.1 Connection to the gas bottle.......................................................... 07
.................................................................................... 06
7. MAINTENANCE ........................................................
7.1 ROUTINE MAINTENANCE ................................................................... 08
7.1.1.Torch.............................................................................................. 08
7.1.2 Wire feeder ................................................................................... 08
7.2 EXTRAORDINARY MAINTENANCE...................................................... 08
8. TROUBLESHOOTING...............................................
5.5.2 Connection to the wire feeder........................................................ 07
5.5.3 Connecting the welding current return cable ................................. 07
5.5.4 Connecting the torch ..................................................................... 07
2.4 STANDARD ACCESSORIES ................................................................. 06
2.5 OPTIONAL ACCESSORIES .................................................................. 06
6. WELDING: DESCRIPTION OF THE PROCEDURE
6.1 METHODS OF METAL TRANSFER...................................................... 08
6.1.1 Short arc....................................................................................... 08
4. DESCRIPTION OF THE WELDING MACHINE .........
4.1 CONTROL, ADJUSTMENT AND CONNECTION DEVICES ................. 06
4.1.1 Welding machine .......................................................................... 06
4.1.2 Wire feeder ................................................................................... 06
Welding current............................................................................. 08
6.2.4 Weld quality ................................................................................... 08
INDEX
ENGLISH
page
page
CONTINUOUS WIRE WELDING MACHINES FOR MIG/MAG AND FLUX ARC
clothing designed for this purpose and by using insulating platforms or mats.
WELDING DESIGNED FOR PROFESSIONAL AND INDUSTRIAL USE.
- Always protect your eyes using masks or helmets fitted with appropriate
Note: In the following text the term welding machine" will be used.
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
1. GENERAL SAFETY CONSIDERATIONS FOR ARC
in the vicinity of the arc should be protected by shields of non-reflecting
WELDING
curtains.
The operator should be properly trained to use the welding machine safely and
- Noise level: If particularly intensive welding operations cause a personal daily
should be informed about the risks related to arc welding procedures, the
exposure level (LEPd) that is greater than or equal to 85db(A), the use of
associated protection measures and emergency procedures.
suitable personal protectors is compulsory.
(Refer also to the IEC TECHNICAL SPECIFICATION or CLC/TS 62081 :
INSTALLATION AND USE OF EQUIPMENT FOR ARC WELDING).
- The flow of the welding current generates electromagnetic fields (EMF)
- Avoid direct contact with the welding circuit: the no-load voltage supplied by
around the welding circuit.
the welding machine can be dangerous under certain circumstances.
Electromagnetic fields can interfere with certain medical equipment (e.g. Pace-
- When the welding cables are being connected or checks and repairs are
makers, respiratory equipment, metallic prostheses etc.).
carried out the welding machine should be switched off and disconnected
Adequate protective measures must be adopted for persons with these types of
from the power supply outlet.
medical apparatus. For example, they must be forbidden access to the area in
- Switch off the welding machine and disconnect it from the power supply outlet
which welding machines are in operation.
This welding machine conforms to technical product standards for exclusive use
before replacing consumable torch parts.
in an industrial environment for professional purposes. It does not assure
- Make the electrical connections and installation according to the safety rules
compliance with the basic limits relative to human exposure to electromagnetic
and legislation in force.
fields in the domestic environment.
- The welding machine should be connected only and exclusively to a power
source with the neutral lead connected to earth.
The operator must adopt the following procedures in order to reduce exposure to
- Make sure that the power supply plug is correctly connected to the earth
electromagnetic fields:
protection outlet.
- Fasten the two welding cables as close together as possible.
- Do not use the welding machine in damp or wet places and do not weld in the
- Keep head and trunk as far away as possible from the welding circuit.
- Never wind welding cables around the body.
rain.
- Avoid welding with the body within the welding circuit. Keep both cables on
- Do not use cables with worn insulation or loose connections.
the same side of the body.
- If the welding machine has a liquid cooling unit the filling operations should be
- Connect the welding current return cable to the piece being welded, as close
carried out with the welding machine switched off and disconnected from the
as possible to the welding joint.
power supply outlet.
- Do not weld while close to, sitting on or leaning against the welding machine
(keep at least 50 cm away from it).
- Do not leave objects in ferromagnetic material in proximity of the welding
circuit.
- Minimum distance d: 20 cm (Fig. N).
- 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
- Class A equipment:
substances.
This welding machine conforms to technical product standards for exclusive use
- Do not weld on containers under pressure.
in an industrial environment and for professional purposes. It does not assure
- Remove all flammable materials (e.g. wood, paper, rags etc.) from the working
compliance with electromagnetic compatibility in domestic dwellings and in
area.
premises directly connected to a low-voltage power supply system feeding
- Provide adequate ventilation or facilities for the removal of welding fumes
buildings for domestic use.
near the arc; a systematic approach is needed in evaluating the exposure
limits for the welding fumes, which will depend on their composition,
concentration and the length of exposure itself.
EXTRA PRECAUTIONS
- Keep the gas bottle (if used) away from heat sources, including direct
sunlight.
- WELDING OPERATIONS:
- In environments with increased riskof electric shock
- In confined spaces
- In the presence of flammable or explosive materials
MUST BE evaluated in advance by an Expert supervisor and must always be
carried out in the presence of other people trained to intervene in
,
*
)
emergencies.
- Use adequate electrical insulation with regard to the electrode, the work piece
Technical protection measures MUST BE taken as described in 5.10; A.7; A.9.
and any (accessible) earthed metal parts in the vicinity.
of the IEC TECHNICAL SPECIFICATION or CLC/TS 62081 .
This is normally achieved by wearing gloves, shoes, head coverings and
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