- Welding MUST NOT be allowed if the welding machine or wire feeder is
- Connection cables kit 4m and 10m.
- Reel cover kit.
supported by the operator (e.g. using belts).
- Double timing electronic board (version with I max = 350A).
- The operator MUST NOT BE ALLOWED to weld in raised positions unless
2
- Voltmeter ammeter board (optional for version with I max = 420A, 550A).
safety platforms are used.
2
- Wire feeder wheel kit.
- VOLTAGE BETWEEN ELECTRODE HOLDERS OR TORCHES: working with
- Aluminium welding kit.
more than one welding machine on a single piece or on pieces that are
- 5m MIG torch 350A, 500A.
connected electrically may generate a dangerous accumulation of no-load
- 3m MIG torch 500A R.A.
voltage between two different electrode holders or torches, the value of which
(standard accessory on the R.A. models).
may reach double the allowed limit.
- 5m MIG torch 500A R.A.
An expert coordinator must use measuring instruments to determine the
existence of a risk and should take suitable protection measures as detailed in
5.9 of the IEC TECHNICAL SPECIFICATION or CLC/TS 62081 .
3. TECHNICAL DATA
3.1 DATA PLATE (FIG. A)
The most important data regarding use and performance of the welding machine are
RESIDUAL RISKS
summarised on the rating plate and have the following meaning:
1-
Protection rating of the covering.
- OVERTURNING: position the welding machine on a horizontal surface that is
2-
Symbol for power supply line:
able to support the weight: otherwise (e.g. inclined or uneven floors etc.) there
1~: single phase alternating voltage;
is danger of overturning.
3~: three phase alternating voltage.
3-
Symbol
S
: indicates that welding operations may be carried out in environments with
- IMPROPER USE: it is hazardous to use the welding machine for any work other
heightened risk of electric shock (e.g. very close to large metallic volumes).
than that for which it was designed (e.g. de-icing mains water pipes).
4-
Symbol for welding procedure provided.
5-
Symbol for internal structure of the welding machine.
- MOVING THE WELDING MACHINE: Always secure the gas bottle, taking
6-
EUROPEAN standard of reference, for safety and construction of arc welding
suitable precautions so that it cannot fall accidentally.
machines.
7-
Manufacturer's serial number for welding machine identification (indispensable for
technical assistance, requesting spare parts, discovering product origin).
8-
Performance of the welding circuit:
- U :
maximum no-load voltage (open welding circuit).
0
- I /U :
current and corresponding normalised voltage that the welding machine can
2
2
The safety guards and moving parts covers of the welding machine and of the
supply during welding.
wire feeder should be in their proper positions before connecting the welding
- X :
Duty cycle: indicates the time for which the welding machine can supply the
machine to the power supply.
corresponding current (same column). It is expressed as %, based on a 10 minutes
cycle (e.g. 60% = 6 minutes working, 4 minutes pause, and so on).
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 until its
temperature returns within the allowed limits).
- A/V-A/V:
shows the range of adjustment for the welding current (minimum
WARNING! Any manual operation carried out on the moving parts of the wire
maximum) at the corresponding arc voltage.
feeder, for example:
9-
Technical specifications for power supply line:
- Replacing rollers and/or the wire guide
- U :
Alternating voltage and power supply frequency of welding machine (allowed
1
- Inserting wire in the rollers
limit 10%).
- Loading the wire reel
- I
: Maximum current absorbed by the line.
1 max
- Cleaning the rollers, the gears and the area underneath them
- I
:
: Effective current supplied.
- Lubricating the gears
1eff
SHOULD BE CARRIED OUT WITH THE WELDING MACHINE SWITCHED OFF AND
10-
:
Size of delayed action fuses to be used to protect the power line.
DISCONNECTED FROM THE POWER SUPPLY OUTLET.
11-
Symbols referring to safety regulations, whose meaning is given in chapter 1
General safety considerations for arc welding .
Note: The data plate shown above is an example to give the meaning of the symbols and
Never lift the welding machine.
numbers; the exact values of technical data for the welding machine in your possession
must be checked directly on the data plate of the welding machine itself.
2. INTRODUCTION AND GENERAL DESCRIPTION
2.1 INTRODUCTION
3.2 OTHER TECHNICAL DATA
This welding machine is made up by a current power supply and by a separate wire
- WELDING MACHINE: see table 1 (TAB.1)
feeder that is connected to it by a cable bundle. The power source consists of three-
- TORCH:
see table 2 (TAB.2)
phase, constant voltage power supply rectifier with step adjustment and with reactance
- WIRE FEEDER:
see table 3 (TAB.3)
multi-sockets. The wire feeder is equipped with a 4-roller feeding unit.
The welding machine's weight is specified in table 1 (TAB.1)
In the R.A. version, the wire feeder is equipped with piping and fittings for connecting
the water-cooled torch to the cooling unit.
4. WELDING MACHINE DESCRIPTION
2.2 MAIN CHARACTERISTICS
4.1 CONTROL, ADJUSTMENT AND CONNECTION DEVICES
- Spot-welding timing adjustment.
4.1.1 Welding machine (FIG. B)
- 2T/4T operation, Spot (version with I max = 420A, 550A).
2
front side:
- Wire up-slope adjustment, final wire burn-back (version with I max = 420A, 550A).
2
1-
Main switch with pilot lamp.
- Thermostatic safeguard.
2-
Arc voltage step adjustment.
- Protection for insufficient water pressure (only for R.A. version).
3-
Fuse.
4-
Negative polarity quick-latches, corresponding to different reactance levels, for
2.3 WELDABILITY OF MATERIALS
connecting the earth cable.
5-
Thermostat-tripping pilot lamp.
The welding machine is suitable for MAG welding of carbon or mild steels using CO
2
6-
Pilot lamp for the tripping of the torch cooling circuit's insufficient pressure
shielding gas and Ar/CO or Ar/CO /O mixtures (Ar-Argon generally >80%) with both
2
2
2
protection.
flux core and tubular wire.
rear side:
It is possible to use tubular wire without shielding gas (self-shielding gas) by adjusting
7-
Welding current cable exit.
torch polarity according to the wire manufacturer's instructions.
8-
Control cable exit.
For MAG welding of stainless steel, similar methods are use to those for carbon steel,
9-
Water cooling unit fuse.
while it is necessary to use flux core or tubular wire identical to or compatible with the
10-
Entry of power supply cable with cable clamp.
base material and mixtures of Ar/O or Ar/CO shielding gas (Ar generally > 98%).
2
2
11-
5p connector for water cooling unit.
MIG welding of aluminium and its alloys should be carried out using wires with a
composition that is compatible with the material to be welded using pure Ar (99.9%) as
4.1.2 Wire feeder (FIG. C)
shielding gas.
front side:
MIG brazing, typically, can be carried out on galvanised plate with copper alloy wires
1-
Wire feeding speed.
(e.g. copper-silicon or copper-aluminium) with pure Ar (99.9%) shielding gas.
2-
Thermostat tripping pilot lamp.
3-
Welding time.
2.4 STANDARD ACCESSORIES
4-
Torch function selector pushbutton (2T-4T).
- ARGON cylinder adapter.
5-
Solenoid valve active pilot light.
- Cable and earth clamp.
6-
Torch quick latch connector.
- Gas regulator 2 manometers.
7-
Quick latch fittings for torch water piping (only R.A. version).
- G.R.A. water cooling unit
rear side:
(just for the R.A. version).
- MIG torch
8-
Low voltage fuse.
(water-cooled in the R.A. version).
9-
Gas pipe fitting.
10-
Positive polarity quick latch.
- Wire feeder.
11-
14-pole connector for control cable
2.5 OPTIONAL ACCESSORIES
inner side:
(only versions with I max = 420A, 550A)
- G.R.A. water cooling unit
2
12-
Wire speed up slope adjustment.
(standard accessory on the R.A. models).
13-
Final wire burn back adjustment.
- Torch holder mobile arm kit.
- Connection cables kit for the R.A. models 4m, 10m and 30m.
- 6 -
