the clip supplied.
4.2 THERMAL SAFEGUARD (Fig. B-5, C-2)
The thermostatic safeguard pilot lamp switches on under overheating conditions,
interrupting the power supply; resetting takes place automatically after a few minutes
5.5.3 Connecting the welding current return cable
cooling off.
- This is connected to the piece being welded or to the metal bench supporting it, as
close as possible to the join being made.
4.3 PROTECTION FOR INSUFFICIENT PRESSURE OF THE WATER COOLING
- This cable is connected to the terminal with the symbol (-).
CIRCUIT (FIG. B-6)
The pilot lamp switches on under conditions of insufficient pressure of the water
5.5.4 Connecting the torch
cooling circuit. Under this condition, the welding machine does not provide power.
-
Engage the torch with its dedicated connector by tightening the locking ring
manually as far down as it will go.
5. INSTALLATION
-
Prepare the wire for loading the first time by dismantling the nozzle and the contact
_____________________________________________________________________________________________________________________
tip to ease its exit.
WARNING! CARRY OUT ALL INSTALLATION OPERATIONS AND
5.5.5 Warnings
ELECTRICAL CONNECTIONS WITH THE WELDING MACHINE COMPLETELY
-
Turn the welding cable connectors right down into the quick connections (if present),
SWITCHED OFF AND DISCONNECTED FROM THE POWER SUPPLY OUTLET.
to ensure a perfect electrical contact; otherwise the connectors themselves will
THE ELECTRICAL CONNECTIONS MUST BE MADE ONLY AND EXCLUSIVELY BY
overheat, resulting in their rapid deterioration and loss of efficiency.
AUTHORISED OR QUALIFIED PERSONNEL.
-
The welding cables should be as short as possible.
_____________________________________________________________________________________________________________________
-
Do not use metal structures which are not part of the workpiece to substitute the
return cable of the welding current: this could jeopardise safety and result in poor
5.1 PREPARATION (FIG. D)
welding.
Unpack the welding machine, assemble the separate parts contained in the package.
5.5.6 Connecting the water cooling unit (G.R.A). (only for the R.A. version) (FIG.
5.2 HOW TO LIFT THE WELDING MACHINE
G1)
None of the welding machines described in this manual are equipped with a lifting
-
Remove the top cover from the welding machine (1).
device.
-
Insert the G.R.A. (2).
-
Attach the G.R.A. to the back using the screws supplied.
5.3 POSITION OF THE WELDING MACHINE
-
Close the top cover on the welding machine (3).
Choose the place to install the welding machine so that the cooling air inlets and outlets
-
Connect the G.R.A. to the welding machine using the cable supplied.
are not obstructed (forced circulation by fan, if present); at the same time make sure that
-
Connect the water pipes to the quick-release couplings.
conductive dusts, corrosive vapours, humidity etc. will not be sucked into the machine.
-
Switch on the G.R.A. following the procedure described in the handbook supplied
Leave at least 250mm free space around the welding machine.
with the cooling unit.
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WARNING: when the power supply outlet for the cooling unit is not used it is
necessary to insert the corresponding plug supplied with the welding machine
WARNING! Position the welding machine on a flat surface with sufficient
(excluding the version with I max=350A) (FIG. G2).
2
carrying capacity for its weight, to prevent it from tipping or moving hazardously.
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5.6 LOADING THE WIRE REEL (FIG. H1, H2)
5.4 CONNECTION TO THE MAIN POWER SUPPLY
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5.4.1 Note
- Before making any electrical connection, make sure the rating data of the welding
WARNING! BEFORE STARTING THE OPERATIONS TO LOAD THE WIRE
machine correspond to the mains voltage and frequency available at the place of
MAKE SURE THE WELDING MACHINE IS SWITCHED OFF AND DISCONNECTED
installation.
FROM THE MAIN POWER SUPPLY OUTLET.
- The welding machine should only be connected to a power supply system with the
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neutral conductor connected to earth.
MAKE SURE THAT THE WIRE FEEDER ROLLERS, THE WIRE GUIDE HOSE AND
- To comply with the requirements of the EN 61000-3-11 (Flicker) standard we
THE CONTACT TIP OF THE TORCH MATCH THE DIAMETER AND TYPE OF WIRE
recommend connecting the welding machine to interface points of the power supply
TO BE USED AND MAKE SURE THAT THESE ARE FITTED CORRECTLY. WHEN
that have an impedance of less than Zmax = 0.02ohm.
INSERTING AND THREADING THE WIRE DO NOT WEAR PROTECTIVE GLOVES.
-
The welding machine falls within the requisites of IEC/EN 61000-3-12 standard.
- 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)
.
5.4.2 Plug and outlet
- Release the pressure counter-rollers and move them away from the lower rollers
Connect a normalised plug
(3P + T)
having sufficient capacity to the power cable and
(2a)
;
prepare a mains outlet fitted with fuses or an automatic circuit-breaker; the special earth
- Make sure that the towing rollers is suited to the wire used
(2b)
.
terminal should be connected to the earth conductor (yellow-green) of the power supply
- Free the end of the wire and remove the distorted end with a clean cut and no burr;
line. The table
(TAB.1)
shows the recommended delayed fuse sizes in amps, chosen
turn the reel anti-clockwise and thread the end of the wire into the wire-guide infeed,
according to the max. nominal current supplied by the welding machine, and the
pushing it 50-100mm into the wire guide of the torch fitting
(2c)
.
nominal voltage of the main power supply.
- Re-position the counter-rollers, adjusting the pressure to an intermediate value, and
make sure that the wire is correctly positioned in the groove of the lower rollers
(3)
5.4.3 Voltage change (FIG. E)
- Use the adjustment screw located at the centre of the spindle to apply a slight braking
To carry out voltage change operations(only the three phase version), take off the panel
pressure on the spindle itself
(1b)
.
to gain access to the inside of the machine, and prepare the voltage change terminal
- Remove the nozzle and contact tip
(4a)
.
board so that the connection indicated on the special indicator plate corresponds to the
available power supply voltage.
- Insert the welding machine plug in the power supply outlet, switch on the welding
Reassemble the panel carefully using the appropriate screws.
machine, press the torch button and wait for the end of the wire to pass through the
Warning! In the factory the machine is set at the highest voltage of the available
whole of the wire guide hose and protrude by 10-15 cm from the front part of the
range, e.g.
torch, release the button.
U 400V
Ü
Voltage setting at the factory.
1
__________________________________________________________________
_____________________________________________________________________________________________________________________
WARNING! During these operations the wire is live and subject to mechanical
WARNING! Failure to observe the above rules will make the (Class 1) safety
stress; therefore if adequate precautions are not taken the wire could cause
system installed by the manufacturer ineffective with consequent serious risks
hazardous electric shock, injury and striking of electric arcs:
to persons (e.g. electric shock) and objects (e.g. fire).
__________________________________________________________________
_____________________________________________________________________________________________________________________
5.5 CONNECTION OF THE WELDING CABLES (FIG. F)
- Do not direct the mouthpiece of the torch towards parts of the body.
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- Keep the torch away from the gas bottle.
- Re-fit the contact tip and the nozzle onto the torch
(4b)
.
WARNING! BEFORE MAKING THE FOLLOWING CONNECTIONS MAKE
- Check that wire feed is regular; set the roller and spindle braking pressure to the
SURE THE WELDING MACHINE IS SWITCHED OFF AND DISCONNECTED FROM
minimum possible values making sure that the wire does not slide in the groove and
THE POWER SUPPLY OUTLET.
when feed is halted the loops of wire are not loosened by excessive reel inertia.
2
Table
(TAB. 1)
gives the recommended values for the welding cables (in mm )
- Cut the end of the wire so that 10-15 mm protrude from the nozzle.
depending on the maximum current supplied by the welding machine.
- Close the wire feeder door.
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5.5.1 Connection to the gas bottle
5.7 REPLACING THE LINER IN THE TORCH (FIG. I)
Gas bottle can be loaded on welding machine bottle support platform: max 60 kg.
Before proceeding to replace the hose, lay out the torch cable straight without any
- Screw the pressure reducing valve onto the gas bottle valve, inserting the appropriate
bends.
adapter supplied as an accessory, for when the gas used is Argon or an
Argon /CO mixture.
2
5.7.1 Coiled hose for steel wires
- Connect the gas inlet pipe to the pressure-reducing valve and tighten the band
1-
Unscrew the nozzle and contact tip on the torch head.
supplied.
2-
Unscrew the hose locking nut on the central connector and remove the old hose.
- Loosen the adjustment ring nut on the pressure-reducing valve before opening the
3-
Insert the new hose into the cable-torch duct and push it gently until it comes out of
bottle valve.
the torch head.
4-
Tighten up the hose locking nut by hand.
5.5.2 Connection to the wire feeder
5-
Trim off all the excess protruding hose pressing it slightly; remove it from the torch
-
Carry out the connections to the wire feeder (rear panel):
cable again.
- welding current cable to quick connection (+);
6-
Smooth the part where the hose was cut and reinsert it into the cable-torch duct.
- control cable to appropriate connector.
7-
Tighten up the nut again using a spanner.
- Make sure the connectors are firmly tightened in order to prevent overheating and
8-
Reassemble the contact tip and nozzle.
loss of efficiency.
- Connect the gas pipe from the pressure-reducing valve on the bottle and lock it with
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