- 5 -
CONTINUOUS WIRE WELDING MACHINES FOR MIG-MAG AND FLUX TIG, MMA
ARC WELDING DESIGNED FOR PROFESSIONAL AND INDUSTRIAL USE.
Note: In the following text the term “welding machine” will be used.
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.
- If the welding machine has a liquid cooling unit the filling operations should
be carried out with the welding machine switched off and disconnected from
the power supply outlet.
- 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) because of particularly intensive welding operations, suitable personal
protective means must be used (Tab. 1).
- The flow of the welding current generates electromagnetic fields (EMF)
around the welding circuit.
Electromagnetic fields can interfere with certain medical equipment (e.g. Pace-
makers, respiratory equipment, metallic prostheses etc.).
Adequate protective measures must be adopted for persons with these types of
medical apparatus. For example, they must be forbidden access to the area in
which welding machines are in operation.
This welding machine conforms to technical product standards for exclusive
use in an industrial environment for professional purposes. It does not assure
compliance with the basic limits relative to human exposure to electromagnetic
fields in the domestic environment.
The operator must adopt the following procedures in order to reduce exposure
to electromagnetic fields:
- Fasten the two welding cables as close together as possible.
- Keep head and trunk as far away as possible from the welding circuit.
- Never wind welding cables around the body.
- Avoid welding with the body within the welding circuit. Keep both cables on
the same side of the body.
- Connect the welding current return cable to the piece being welded, as close
as possible to the welding joint.
- Do not weld while close to, sitting on or leaning against the welding machine
(keep at least 50 cm away from it).
- Do not leave objects in ferromagnetic material in proximity of the welding
circuit.
- Minimum distance d: 20 cm (Fig. N).
- 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
ENGLISH
INDEX
1. GENERAL SAFETY CONSIDERATIONS FOR ARC WELDING
....................................................................5
2. INTRODUCTION AND GENERAL DESCRIPTION
.........................................................................................
6
2.1 INTRODUCTION........................................................................................................................................6
2.2 METAL WELDABILITY ...............................................................................................................................6
2.3 STANDARD ACCESSORIES .....................................................................................................................6
2.4 OPTIONAL ACCESSORIES ......................................................................................................................6
3. TECHNICAL DATA...........................................................................................................................................
6
3.1 DATA PLATE (FIG. A).................................................................................................................................6
3.2 OTHER TECHNICAL DATA .......................................................................................................................6
4. DESCRIPTION OF THE WELDING MACHINE
..............................................................................................
6
4.1 CONTROL DEVICES, ADJUSTMENT AND CONNECTION (FIG. B)........................................................6
4.1.1 Welding machine with integrated wire feed ......................................................................................6
4.2 WELDING MACHINE CONTROL PANEL (FIG. C) ....................................................................................6
4.3 RECALLING AND STORING PROGRAMS ...............................................................................................8
4.3.1 RECALLING MANUFACTURER’S PRE-STORED PROGRAMS ....................................................8
4.3.1.1 MIG-MAG SYNERGIC programs .........................................................................................8
4.3.1.2 OPERATION IN MANUAL MODE (“PRG 0”) ........................................................................8
4.3.2 STORING AND RECALLING CUSTOMISED MIG-MAG PROGRAMS ...........................................8
4.3.2.1 Introduction ...........................................................................................................................8
4.3.2.2 Storage capacity for customised MIG-MAG programs .........................................................8
4.3.2.3 Storage procedure (SAVE) ...................................................................................................8
4.3.2.4 Procedure for recalling a customised program (RECALL) ...................................................8
5. INSTALLATION ................................................................................................................................................
8
5.1 PREPARATION ..........................................................................................................................................8
5.2 HOW TO LIFT THE WELDING MACHINE (FIG. E) ...................................................................................8
5.3 POSITION OF THE WELDING MACHINE ................................................................................................8
5.4 CONNECTION TO THE MAIN POWER SUPPLY .....................................................................................8
5.4.1 Note ..................................................................................................................................................8
5.4.2 Plug and outlet ..................................................................................................................................8
5.5 CONNECTION OF THE WELDING CABLES ...........................................................................................8
5.5.1 MIG-MAG WIRE WELDING (FIG.F) .................................................................................................8
5.5.1.1 Connecting the gas bottle .....................................................................................................8
5.5.1.2 Connecting the torch ............................................................................................................8
5.5.1.3 Connecting the welding current return cable ........................................................................8
5.5.2 TIG WELDING (FIG. G) ....................................................................................................................8
5.5.2.1 Connection to the gas bottle .................................................................................................8
5.5.2.2 Connecting the welding current return cable ........................................................................8
5.5.2.3 Connecting the torch ............................................................................................................8
5.5.3 MMA WELDING WITH COATED ELECTRODE (FIG. H) .................................................................8
5.5.3.1 Connecting the electrode-holder clamp ................................................................................8
5.5.3.2 Connecting the welding current return cable ........................................................................9
5.5.4 WARNINGS ......................................................................................................................................9
5.6 LOADING THE WIRE REEL (FIG. I) ..........................................................................................................9
5.7 REPLACING THE LINER IN THE TORCH (FIG. N) ..................................................................................9
5.7.1 Coiled hose for steel wires ...............................................................................................................9
5.7.2 Synthetic hose for aluminium wires ..................................................................................................9
6. WELDING: DESCRIPTION OF THE PROCEDURE
........................................................................................
9
6.1 MIG-MAG WELDING .................................................................................................................................9
6.1.1 SHORT ARC TRANSFER MODE .....................................................................................................9
6.1.1.1 ROOT MIG TRANSFER MODE ...........................................................................................9
6.1.2 SPRAY ARC TRANSFER MODE .....................................................................................................9
6.1.3 PULSE ARC TRANSFER MODE .....................................................................................................9
6.1.4 ADJUSTING THE WELDING PARAMETERS IN MIG-MAG ............................................................9
6.1.4.1 Protective gas ......................................................................................................................9
6.1.4.2 Welding current ..................................................................................................................10
6.1.4.3 Arc voltage and arc pinch-off ..............................................................................................10
6.1.5 BI-LEVEL AND PULSE ON PULSE OPERATION ..........................................................................10
6.2 TIG (DC) WELDING .................................................................................................................................10
6.2.1 LIFT strike .......................................................................................................................................10
6.3 MMA WELDING WITH COATED ELECTRODES ....................................................................................10
6.4 WELD QUALITY ......................................................................................................................................10
7. MAINTENANCE ............................................................................................................................................
10
7.1 ROUTINE MAINTENANCE ......................................................................................................................10
7.1.1 Torch ...............................................................................................................................................10
7.1.2 Wire feeder .....................................................................................................................................10
7.2 EXTRAORDINARY MAINTENANCE .......................................................................................................10
8. TROUBLESHOOTING (TAB.8)
.....................................................................................................................
10
page
page
