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platforms are used.
- VOLTAGE BETWEEN ELECTRODE HOLDERS OR TORCHES: working with more than
one welding machine on a single piece or on pieces that are connected electrically
may generate a dangerous accumulation of no-load voltage between two different
electrode holders or torches, the value of which may reach double the allowed limit.
An expert coordinator must be designated to measuring the apparatus to determine
if any risks subsist and suitable protection measures can be adopted, as foreseen by
section 7.9 of the applicable standard "EN 60974-9: Arc welding equipment. Part 9:
Installation and Use".
RESIDUAL RISKS
- OVERTURNING: position the welding machine on a horizontal surface that is able to
support the weight: otherwise (e.g. inclined or uneven floors etc.) there is danger of
overturning.
- IMPROPER USE: it is hazardous to use the welding machine for any work other than
that for which it was designed (e.g. de-icing mains water pipes).
- IMPROPER USE: the use the welding machine by more than one operator at the same
time may be dangerous.
- MOVING THE WELDING MACHINE: Always secure the gas bottle, taking suitable
precautions so that it cannot fall accidentally (if used).
- Do not use the handle to hang the welding machine.
The safety guards and moving parts of the covering of the welding machine and of
the wire feeder should be in their proper positions before connecting the welding
machine to the power supply.
WARNING! Any manual operation carried out on the moving parts of the wire feeder,
for example:
- Replacing rollers and/or the wire guide;
- Inserting wire in the rollers;
- Loading the wire reel;
- Cleaning the rollers, the gears and the area underneath them;
- Lubricating the gears.
SHOULD BE CARRIED OUT WITH THE WELDING MACHINE SWITCHED OFF AND
DISCONNECTED FROM THE POWER SUPPLY OUTLET.
2. INTRODUCTION AND GENERAL DESCRIPTION
This welding machine is a source of current for arc welding, made specifically for MAG
welding carbon steel or weak alloys with CO
tubular full or core electrode wires.
It is also ideal for MIG welding stainless steel with Argon gas containing + 1-2% oxygen
and aluminium and CuSi3, CuAl8 (brazing) with Argon gas, using electrode wires that are
suitable for the workpiece to be welded.
Suitable core wires can be used without Flux protection gas, adapting torch polarity
according to the indications of the wire producer (versions 180A and 200A only).
It is particularly suitable for light metalwork fabrication and in body shops, for welding
galvanized plates, high stress stainless steel and aluminium. SYNERGIC operation ensures
fast and easy welding parameter setting, always guaranteeing high arc control and welding
quality (OneTouch Technology).
The welding machine, where available (see Tab. 1), can be used for TIG welding in direct
current (DC), with arc striking upon contact (LIFT ARC mode). It welds all types of steel
(carbon, low- and high-alloy) and heavy metals (copper, nickel, titanium and their alloys)
with a gas shield of pure (99.9%) Ar or, for special uses, with an Argon/Helium mix. It can also
be used for MMA electrode welding in direct current (DC) using coated electrodes (rutile,
acid, basic).
2.1 MAIN CHARACTERISTICS
MIG-MAG
- Synergic (automatic) or manual operation;
- Pre-set synergic curves;
- Wire speed, welding voltage and welding current shown on an LCD screen;
- 2T, 4T and spot operation selection;
- Adjustments: wire up slope, electronic reactance, wire burn-back time, post gas;
- Polarity change for GAS MIG-MAG/BRAZING welding or NO GAS/FLUX (versions 180A and
200A only).
- Setting the metric or UK system.
TIG (see table 1)
- Start LIFT;
- Wire speed and welding current shown on an LCD screen.
MMA (see table 1)
- Arc force adjustment, hot start.
- VRD device.
- Anti-stick protection.
- Indication of recommended electrode diameter based on welding current;
- Wire speed and welding current shown on an LCD screen.
PROTECTION
- Thermostatic safeguard;
- Protection against accidental short-circuits caused by contact between torch and earth;
- Protection against irregular voltage (power supply voltage too high or too low);
- Anti-stick (MMA).
2.2 STANDARD ACCESSORIES
- Torch;
- Return cable complete with earth clamp;
- Torch holder support (where available).
2.3 OPTIONAL ACCESSORIES
- Argon bottle adapter;
- Trolley (versions 180A and 200A only);
protective gas or Argon/CO
mixes, using
2
2
- Self darkening helmet;
- MIG MAG welding kit;
- MMA welding kit;
- TIG welding kit.
3. TECHNICAL DATA
3.1 DATA PLATE
The most important data regarding use and performance of the welding machine are
summarised on the rating plate and have the following meaning:
1- EUROPEAN standard of reference, for safety and construction of arc welding machines.
2- manufacturer's name and address.
3- product model.
4- Symbol for internal structure of the welding machine.
5- Symbol for welding procedure provided.
6- Symbol S: indicates that welding operations may be carried out in environments with
heightened risk of electric shock (e.g. very close to large metallic volumes).
7- Symbol for power supply line:
1~ : single phase alternating voltage;
3~ : 3-phase alternating voltage.
8- Protection rating of the covering.
9- Technical specifications for power supply line:
- U
: Alternating voltage and power supply frequency of welding machine (allowed
1
limit ±10%).
- I
: Maximum current absorbed by the line.
1 max
- I
: effective current supplied.
1eff
10- 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
supply during welding.
- X : Duty cycle: indicates the time for which the welding machine can supply the
corresponding current (same column). It is expressed as %, based on a 10 min. 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
maximum) at the corresponding arc voltage.
11- Manufacturer's serial number for welding machine identification (indispensable for
technical assistance, requesting spare parts, discovering product origin).
12-
: Size of delayed action fuses to be used to protect the power line.
13- 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
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.
3.2 OTHER TECHNICAL DATA
- WELDING MACHINE: see table 1 (TAB. 1)
- MIG TORCH: see table 2 (TAB. 2)
- TIG TORCH: see table 3 (TAB. 3)
- ELECTRODE-HOLDER CLAMP: see table 4 (TAB. 4)
The weight of the welding machine is given in table 1 (TAB. 1).
4. WELDING MACHINE DESCRIPTION
4.1 CONTROL, ADJUSTMENT AND CONNECTING DEVICES.
4.1.1 WELDING MACHINE (Fig. B, B1, B2, B3)
At the front:
1- Control panel.
2- Welding cable and torch.
3- Earth return cable and clamp.
4- Torch coupling.
5- Positive (+) fast coupling for connecting the welding cable.
6- Negative (-) fast coupling for connecting the welding cable.
7- Fast coupling plug connected to the torch coupling.
8- Touch coupling (T2).
9- SPOOL GUN torch coupling.
10- SPOOL GUN control cable connector.
11- Welding cable and torch (T2).
12- SPOOL GUN (optional).
At the back:
13- Main ON/OFF switch.
14- Hose connector for protective gas.
15- Power cable.
16- Hose connector for torch T2 protective gas.
17- Hose connector for SPOOL GUN torch protective gas.
On the reel area (where available):
18- Positive clamp (+).
19- Negative clamp (-).
NB: Polarity inversion for FLUX welding (no gas).
4.1.2 WELDING MACHINE CONTROL PANEL (Fig. C)
1- selection, if pressed, of MIG-MAG welding (SYNERGIC or MANUAL), TIG or MMA
SYNERGIC MIG-MAG:
- Adjustment of welding power.
MANUAL MIG-MAG:
- Adjustment of wire feed speed.
TIG (where available):
- Adjustment of welding current.
MMA (where available):
- Adjustment of welding current.
2- If pressed
it allows access to preset machine programs.
SYNERGIC MIG-MAG:
- Adjustment of the welding seam (arc length)
MANUAL MIG-MAG:
- Adjustment of the welding seam (welding voltage)
TIG:
- Not enabled.
MMA:
- 6 -
Fig. A
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