period. It can take on values between 1% (lower average current) and 99%
ELECTRICAL CONNECTIONS WITH THE WELDING MACHINE COMPLETELY
(higher average current). In addition, for AC/DC models, in TIG AC mode (with
SWITCHED OFF AND DISCONNECTED FROM THE POWER SUPPLY OUTLET.
pulsation disabled), the parameter represents the time for which the current
THE ELECTRICAL CONNECTIONS MUST BE MADE ONLY AND EXCLUSIVELY BY
polarity is EN (electrode negative) as a percentage of the total alternating
AUTHORISED OR QUALIFIED PERSONNEL.
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current period
5.1 PREPARATION
Unpack the welding machine, assemble the separate parts contained in the package.
5.1.1 Assembling the return cable-clamp (FIG. E)
7g
POST-GAS.
5.1.2 Assembling the welding cable-electrode holder clamp (FIG. E)
In TIG is the post-gas time measured in seconds and it varies ranging from 0.1
to 25 seconds.
5.2 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.
7h
START SLOPE UP.
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This is the time for the initial current slope up in 4-stroke mode and varies from
WARNING! Position the welding machine on a flat surface with sufficient
0.1 to 10 sec.
carrying capacity for its weight, to prevent it from tipping or moving hazardously.
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5.3 CONNECTION TO THE MAIN POWER SUPPLY
- Before making any electrical connection, make sure the rating data of the welding
7i
FINAL SLOPE DOWN.
machine correspond to the mains voltage and frequency available at the place of
installation.
This is the time for the final current slope down and varies from 0.1 to 10 sec.
- The welding machine should only be connected to a power supply system with the
neutral conductor connected to earth.
- To ensure protection against indirect contact use residual current devices of the
following types:
7l
SPOT TIME.
- Type A (
) for single phase machines;
- Type B (
) for 3-phase machines.
Length of spot welding time in TIG and varies between 0.1 and 10 seconds.
- To comply with the requirements of the EN 61000-3-11 (Flicker) standard we
recommend connecting the welding machine to interface points of the power supply
that have an impedance of less than Zmax = 0.228ohm (1
~
), Zmax = 0.283ohm (3
~
).
8-
“LOAD”
and
“STORE”
keys
:
PROGRAMMING
5.3.1 Plug and outlet
A program consists of the welding mode with the setting of all parameters. The
Connect a normalised plug (2P + T (1
~
)), (3P + T (3
~
)) - having sufficient capacity- to
active program is stored and loaded automatically each time the machine is
the power cable and prepare a mains outlet fitted with fuses or an automatic circuit-
switched off.
breaker; the special earth terminal should be connected to the earth conductor (yellow-
In order to simplify the use of the machine, the operator can store the panel settings
green) of the power supply line. Table
(TAB.1)
shows the recommended delayed fuse
in 15 programs. Furthermore, the welder is supplied with 15 pre-set programs
sizes in amps, chosen according to the max. nominal current supplied by the welding
illustrating some of the typical operational possibilities of the machine.
machine, and the nominal voltage of the main power supply.
To load a program press the key LOAD;
the word "load" appears on the display
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and the led "PRG" will switch on. Immediately after, the word "P 01" will be
displayed indicating program 1. By rotating the knob you will shift onto other user's
WARNING! Failure to observe the above rules will make the (Class 1) safety
programs ranging from P 01 to P 15 and subsequently onto the pre-set programs
system installed by the manufacturer ineffective with consequent serious risks
ranging from PF 16 to PF 30.
to persons (e.g. electric shock) and objects (e.g. fire).
The mode LED's show the setting for the program on the display, while the
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particular parameters for the program can be displayed by pressing the selection
keys.
5.4 CONNECTION OF THE WELDING CABLES
To load a program, keep key "LOAD" pressed for a few seconds until the word
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"DONE" is displayed. At this time, the program is loaded and it is readily available
for use. Should you do not want to load the program but instead you would want to
WARNING! BEFORE MAKING THE FOLLOWING CONNECTIONS MAKE
exit from the programming mode and going back to the starting point, it is sufficient
SURE THE WELDING MACHINE IS SWITCHED OFF AND DISCONNECTED FROM
to briefly press the key "LOAD"; the word "NO" will be displayed and the panel will
THE POWER SUPPLY OUTLET.
go back to its original state.
2
Table
(TAB. 1)
gives the recommended values for the welding cables (in mm )
To store a program
, follow the same procedure: the desired parameters are set
depending on the maximum current supplied by the welding machine.
from the panel. We advise to run a welding test in order to ensure that the
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parameter settings meet indeed your work requirements. Then, press the key
"STORE": the word "stor" will be displayed, the led "PRG" will blink and the word "P
5.4.1 TIG welding
01" will appear indicating that the machine is on program 01. By rotating the knob
Connecting the torch
you will shift onto other user's programs ranging from P 01 to P 15. Should you do
- Insert the torch current cable into the appropriate quick terminal (-)/~. Connect the
not want to store the program but instead you want to exit from the programming
three-pin connector (torch button) to the appropriate socket. Connect the torch gas
mode and going back to the starting point, it is sufficient to briefly press the key
pipe to the appropriate connector.
"STORE"; the word "NO" will be displayed for a few seconds and the panel will go
Connecting the welding current return cable
back to its original state. Once you have chosen the program on which you will want
- This is connected to the piece to be welded or to the metal bench on which it rests, as
to store the information, press for a few seconds the key "STORE" and the word
close as possible to the joint being made.
"sure?" will appear on the display. Press briefly the key “STORE" to confirm the
This cable is connected to the terminal with the (+) symbol (~ for TIG machines
programming. If instead you do not want to confirm, wait for a few seconds until the
designed for AC welding).
machine will exit from the programming mode immediately after the word "no" has
Connecting the gas bottle
appeared on the display.
- Screw the pressure reducing valve to the gas bottle valve, first inserting the special
TABLE 3A - 3B - 3C - 13D
reduction accessory supplied when argon gas is used.
- Connect the gas inflow hose to the pressure reducing valve and tighten the hose
RESET
clamp supplied.
CAREFUL! This procedure cancelles all user's programs
- Loosen the ringnut for adjusting the pressure reducing valve before opening the valve
A reset procedure which stores the 15 programs provided into the user's 15
on the bottle.
programs is available. Turn the machine on by pressing simultaneously keys LOAD
- Open the valve on the bottle and adjust the quantity of gas (l/min) according to the
and STORE; the word "RES" will appear on the display. If you press keys LOAD and
suggestions for use given in the table
(TAB. 4)
; if it is necessary to adjust the gas flow
STORE simultaneously for a second time all user's programs will be stored and the
during welding this should always be done by adjusting the ring nut on the pressure
word "DONE" will appear on the diplay whereas if you press the two keys one at the
reduction valve. Make sure there are no leaks in the piping and connectors.
time, the machine will go back to its normal state.
WARNING! Always close the gas bottle valve at the end of the job.
STORING AND DISPLAYING THE ALARMS
5.4.2 MMA WELDING
When there is an alarm event the machine memory stores its current operating
Almost all coated electrodes are connected to the positive pole (+) of the power source;
status. It is possible to recall the machine status for the 10 most recent alarm
as an exception to the negative pole (-) for acid coated electrodes.
events, using the following procedure: when the LOAD and STORE keys are
Connecting the electrode-holder clamp welding cable
pressed simultaneously the message "A0-X" is displayed, where X stands for the
On the end take a special terminal that is used to close the uncovered part of the
type of alarm record ( 1,2,etc.) . Turning the knob will shift through the alarms from
electrode.
A0 (the most recent) to A9. The mode LED's show the machine settings at the time
This cable is connected to the terminal with the symbol (+)
when the alarm shown on the display occurred, while the operating parameters can
Connecting the welding current return cable
be shown by just pressing the selection keys. Pressing one of the two keys briefly
This is connected to the piece being welded or to the metal bench supporting it, as close
will return to normal mode.
as possible to the join being made.
9-
Encoder knob for setting welding parameters that can be selected with key (7)
.
This cable is connected to the terminal with the symbol (-)
10-
Alphanumeric display.
Warnings:
11-
Red LED, indicating measuring unit.
- Turn the welding cable connectors right down into the quick connections (if present),
12-
Green LED, power on.
to ensure a perfect electrical contact; otherwise the connectors themselves will
13-
Yellow LED, normally off. When on it indicates one of the following faults:
overheat, resulting in their rapid deterioration and loss of efficiency.
“AL. 1”:
fault in primary power supply: the power supply voltage is 15% above or
- The welding cables should be as short as possible.
below the rating plate value.
- Do not use metal structures which are not part of the workpiece to substitute the
WARNING: Exceeding the upper voltage limit, as above, will cause serious
return cable of the welding current: this could jeopardise safety and result in poor
damage to the device.
welding.
“AL. 2”:
one of the safety thermostats has triggered because the machine is
overheated.
6. WELDING: DESCRIPTION OF THE PROCEDURE
“AL. 3”:
phase failure (present on 3-phase power supply versions).
6.1 TIG WELDING
14-
Red LED, programming.
TIG welding is a welding procedure that exploits the heat produced by the electric arc
that is struck, and maintained, between a non-consumable electrode (tungsten) and the
5. INSTALLATION
piece to be welded. The tungsten electrode is supported by a torch suitable for
_____________________________________________________________________________________________________________________
transmitting the welding current to it and protecting the electrode itself and the weld pool
from atmospheric oxidation, by the flow of an inert gas (usually argon: Ar 99.5) which
WARNING! CARRY OUT ALL INSTALLATION OPERATIONS AND
- 6 -
