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1. GENERAL SAFETY CONSIDERATIONS FOR ARC WELDING .......................................... 5
2. INTRODUCTION AND GENERAL DESCRIPTION ............................................................ 6
2.1 MAIN CHARACTERISTICS ....................................................................................................................6
2.2 STANDARD ACCESSORIES ..................................................................................................................6
2.3 OPTIONAL ACCESSORIES ...................................................................................................................6
3. TECHNICAL DATA ........................................................................................................... 6
3.1 DATA PLATE .............................................................................................................................................6
3.2 OTHER TECHNICAL DATA ...................................................................................................................6
4. WELDING MACHINE DESCRIPTION ............................................................................... 6
4.1 CONTROL, ADJUSTMENT AND CONNECTING DEVICES. .........................................................6
4.1.1 WELDING MACHINE (Fig. B, B1, B2, B3) ..............................................................................6
4.1.2 WELDING MACHINE CONTROL PANEL (Fig. C) ................................................................6
5. INSTALLATION ................................................................................................................ 7
5.1 POSITIONING THE WELDING MACHINE......................................................................................... 7
5.2 CONNECTION TO THE MAIN POWER SUPPLY ..............................................................................7
5.2.1 Plug and outlet ...........................................................................................................................7
5.3 WELDING CIRCUIT CONNECTION ....................................................................................................7
5.3.1 Recommendations ....................................................................................................................7
5.3.2 WELDING CIRCUIT CONNECTIONS IN MIG-MAG MODE .............................................. 7
5.3.2.1 Gas cylinder connection (if used) ..........................................................................7
5.3.2.2 Connecting the welding current return cable ..................................................7
5.3.2.3 Torch .................................................................................................................................7
5.3.2.4 Internal polarity change (where available) ........................................................7
5.3.2.5 External polarity change (where available) ........................................................7
5.3.3 WELDING CIRCUIT CONNECTION IN TIG MODE ..............................................................7
5.3.3.1 Connecting the gas bottle .......................................................................................7
5.3.3.2 Connecting the welding current return cable ..................................................7
5.3.3.3 Torch .................................................................................................................................7
5.3.4 WELDING CIRCUIT CONNECTIONS IN MMA MODE ....................................................... 7
5.3.4.1 Connection of the electrode-holder clamp welding cable ..........................7
5.3.4.2 Connecting the welding current return cable ..................................................7
5.4 LOADING THE WIRE SPOOL (Fig. H, H1, H2) .................................................................................7
5.5 LOADING THE WIRE SPOOL ONTO THE SPOOL GUN (Fig. I) ...................................................7
6. MIG-MAG WELDING: PROCESS DESCRIPTION ............................................................. 8
6.1 SHORT ARC ..............................................................................................................................................8
6.2 PROTECTION GAS .................................................................................................................................8
7. MIG-MAG OPERATION MODEE ...................................................................................... 8
CONTINUOUS WIRE WELDING MACHINE FOR MIG-MAG AND FLUX, TIG, MMA WELDING
FOR PROFESSIONAL AND INDUSTRIAL USE.
Note: The term "welding machine" will be used in the text that follows.
1. GENERAL SAFETY CONSIDERATIONS FOR ARC WELDING
The operator should be properly trained to use the welding machine safely and
should be informed about the risks related to arc welding procedures, the associated
protection measures and emergency procedures.
(Please refer to the applicable standard "EN 60974-9: Arc welding equipment. Part 9:
Installation and Use).
- Avoid direct contact with the welding circuit: the no-load voltage supplied by the
welding machine can be dangerous under certain circumstances.
- When the welding cables are being connected or checks and repairs are carried
out the welding machine should be switched off and disconnected from the power
supply outlet.
- Switch off the welding machine and disconnect it from the power supply outlet
before replacing consumable torch parts.
- Make the electrical connections and installation according to the safety rules and
legislation in force.
- The welding machine should be connected only and exclusively to a power source
with the neutral lead connected to earth.
- Make sure that the power supply plug is correctly connected to the earth protection
outlet.
- Do not use the welding machine in damp or wet places and do not weld in the rain.
- Do not use cables with worn insulation or loose connections.
- 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
substances.
- Do not weld on containers under pressure.
- Remove all flammable materials (e.g. wood, paper, rags etc.) from the working area.
- Provide adequate ventilation or facilities for the removal of welding fumes 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.
- Keep the gas bottle (if used) away from heat sources, including direct sunlight.
- Use electric insulation that is suitable for the torch, the workpiece and any metal
parts that may be placed on the ground and nearby (accessible).
This can normally be done by wearing gloves, footwear, head protection and
clothing that are suitable for the purpose and by using insulating boards or mats.
- Always protect your eyes with the relative filters, which must comply with UNI EN
169 or UNI EN 379, mounted on masks or use helmets that comply with UNI EN 175.
Use the relative fire-resistant clothing (compliant with UNI EN 11611) and welding
gloves (compliant with UNI EN 12477) without exposing the skin to the ultraviolet
and infrared rays produced by the arc; the protection must extend to other people
who are near the arc by way of screens or non-reflective sheets.
- Noise: If the daily personal noise exposure (LEPd) is equal to or higher than 85 dB(A)
INDEX
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7.1 SYNERGIC operating mode ...............................................................................................................8
7.1.1 LCD display in SYNERGIC mode (Fig. L) ............................................................................. 8
7.1.2 Parameters setting .................................................................................................................... 8
7.1.3 Adjustment of the welding seam shape ........................................................................... 8
7.1.4 ATC Mode (Advanced Thermal Control) ............................................................................ 8
7.1.5 Using the spool gun (where available) .............................................................................. 8
7.1.6 Advanced parameter setting: MENU 1 (Fig. M)............................................................... 8
7.2 MANUAL operating mode .................................................................................................................8
7.2.1 LCD display in MANUAL mode (Fig. N) .............................................................................. 8
7.2.2 Parameters setting .................................................................................................................... 8
7.2.3 Setting of spool gun parameters (where available) ..................................................... 8
7.2.4 Advanced parameter setting: MENU 1 (Fig. M)............................................................... 8
7.2.5 T1, T2 and SPOOL GUN torch settings (where available) ............................................ 8
8. CONTROLLING THE TORCH PUSH-BUTTON ................................................................. 8
8.1 Setting the torch push-button control mode (Fig. O) ............................................................. 8
8.2 Torch push-button control mode ...................................................................................................8
9. UNIT OF MEASUREMENT MENU (Fig. O) ...................................................................... 9
10. INFO MENU (Fig. O) ...................................................................................................... 9
11. TIG DC WELDING: PROCESS DESCRIPTION ................................................................ 9
11.1 GENERAL PRINCIPLES .......................................................................................................................9
11.2 PROCEDURE (LIFT STRIKE) ...............................................................................................................9
11.3 LCD DISPLAY IN TIG MODE (Fig. C) ...............................................................................................9
12. MMA WELDING: PROCESS DESCRIPTION ................................................................... 9
12.1 GENERAL PRINCIPLES .......................................................................................................................9
12.2 Procedure ..............................................................................................................................................9
12.3 LCD DISPLAY IN MMA MODE (Fig. C) ...........................................................................................9
13. RESET FACTORY SETTINGS .......................................................................................... 9
14. ALARM WARNINGS ...................................................................................................... 9
15. MAINTENANCE ............................................................................................................ 9
15.1 ROUTINE MAINTENANCE: ................................................................................................................9
15.1.1 Torch ............................................................................................................................................ 9
15.1.2 Wire feeder ................................................................................................................................ 9
15.2 EXTRAORDINARY MAINTENANCE ................................................................................................9
16. TROUBLESHOOTING .................................................................................................. 10
because of particularly intensive welding operations, suitable personal protective
means must be used (Tab. 1).
ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS
Electric current flowing through any conductor causes localized electric and magnetic
fields (EMF). Welding current creates an EMF field around welding and welding
equipment.
EMF fields may interfere with some medical implants (e.g. pacemakers, respiratory
equipment, metallic prostheses etc.).
Protective measures for persons wearing medical implants have to be taken.
For example, access restrictions for passers-by or individual risk assessment for
welders.
This welding machine complies with technical product standards for exclusive use in
an industrial environment for occupational use. It does not assure compliance with
the restrictions for use by layman.
All operators should follow the rules listed herebelow, in order to minimize exposure
to EMF fields from the welding circuit:
- route the welding cables together. Secure them with tape when possible;
- place your trunk and head as far away as possible from the welding circuit;
- never coil welding cables around metal objects or your body;
- do not place your body between welding cables;
- keep welding cables on the same side of your body;
- connect the work clamp to the work piece as close as possible to the area being
welded;
- do not work next to welding power sources;
- all operators should keep the required minimum distances as given in the EMF data
sheet;
- distance from the EMF source to a point beyond which the exposure is less than 20%
of the lowest permissible value: d= 15 cm.
- Class A equipment:
This welding machine conforms to technical product standards for exclusive use in an
industrial environment and for professional purposes. It does not assure compliance
with electromagnetic compatibility in domestic dwellings and in premises directly
connected to a low-voltage power supply system feeding buildings for domestic use.
EXTRA PRECAUTIONS
- 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.
All protective technical measures MUST be taken as provided in 7.10; A.8; A.10 of
the applicable standard EN 60974-9: Arc welding equipment. Part 9: Installation
and Use".
- Welding MUST NOT be allowed if the welding machine or wire feeder is supported
by the operator (e.g. using belts).
- The operator MUST NOT BE ALLOWED to weld in raised positions unless safety
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