8
IMPORTANT: BEFORE STARTING THE EQUIPMENT,
READ THE CONTENTS OF THIS MANUAL, WHICH MUST
BE STORED IN A PLACE FAMILIAR TO ALL USERS FOR
THE ENTIRE OPERATIVE LIFE-SPAN OF THE MACHINE.
THIS EQUIPMENT MUST BE USED SOLELY FOR WELDING OPERATIONS.
1 SAFETY PRECAUTIONS
WELDING AND ARC CUTTING CAN BE
HARMFUL TO YOURSELF AND OTHERS.
The user must therefore be educated
against the hazards, summarized below, deriving from welding operations. For more detailed information, order the manual code 3.300.758
NOISE
This machine does not directly produce noise
exceeding 80dB. The plasma cutting/welding proce-
dure may produce noise levels beyond said limit;
users must therefore implement all precautions required by
law.
ELECTRIC AND MAGNETIC FIELDS - May be dangerous.
· Electric current following through any conductor causes localized Electric and Magnetic
Fields (EMF). Welding/cutting current creates
EMF fields around cables and power sources.
· The magnetic fields created by high currents
may affect the operation of pacemakers. Wearers of vital
electronic equipment (pacemakers) shall consult their physician before beginning any arc welding, cutting, gouging or
spot welding operations.
· Exposure to EMF fields in welding/cutting may have other
health effects which are now not known.
· All operators should use the followingprocedures in order to
minimize exposure to EMF fields from the welding/cutting circuit:
- Route the electrode and work cables together - Secure
them with tape when possible.
- Never coil the electrode/torch lead around your body.
- Do not place your body between the electrode/torch
lead and work cables. If the electrode/torch lead cable is
on your right side, the work cable should also be on your
right side.
- Connect the work cable to the workpiece as close as
possible to the area being welded/cut.
- Do not work next to welding/cutting power source.
EXPLOSIONS
· Do not weld in the vicinity of containers under pressure, or in the presence of explosive dust, gases or
fumes. · All cylinders and pressure regulators used in
welding operations should be handled with care.
ELECTROMAGNETIC COMPATIBILITY
This machine is manufactured in compliance with the
instructions contained in the standard IEC 60974-10 (CL. A),
and must be used solely for professional purposes in an
industrial environment. There may be potential difficulties in ensuring electromagnetic compatibility in nonindustrial environments.
DISPOSAL OF ELECTRICAL AND ELECTRONIC
EQUIPMENT
Do not dispose of electrical equipment together
with normal waste!In observance of European
Directive 2002/96/EC on Waste Electrical and Electronic
Equipment and its implementation in accordance with
national law, electrical equipment that has reached the
end of its life must be collected separately and returned
to an environmentally compatible recycling facility. As the
owner of the equipment, you should get information on
approved collection systems from our local representative. By applying this European Directive you will improve
the environment and human health!
IN CASE OF MALFUNCTIONS, REQUEST ASSISTANCE
FROM QUALIFIED PERSONNEL.
1.1 WARNING LABEL
The following numbered text corresponds to the label
numbered boxes.
B. Drive rolls can injure fingers.
C. Welding wire and drive parts are at welding voltage
during operation — keep hands and metal objects
away.
1 Electric shock from welding electrode or wiring can
kill.
1.1 Wear dry insulating gloves. Do not touch electrode
with bare hand. Do not wear wet or damaged gloves.
1.2 Protect yourself from electric shock by insulating
INSTRUCTION MANUAL FOR ARC WELDING MACHINE
9
yourself from work and ground.
1.3 Disconnect input plug or power before working on
machine.
2 Breathing welding fumes can be hazardous to your
health.
2.1 Keep your head out of fumes.
2.2 Use forced ventilation or local exhaust to remove
fumes.
2.3 Use ventilating fan to remove fumes.
3 Welding sparks can cause explosion or fire.
3.1 Keep flammable materials away from welding.
3.2 Welding sparks can cause fires. Have a fire extinguisher nearby and have a watchperson ready to use
it.
3.3 Do not weld on drums or any closed containers.
4 Arc rays can burn eyes and injure skin.
4.1 Wear hat and safety glasses. Use ear protection and
button shirt collar. Use welding helmet with correct
shade of filter. Wear complete body protection.
5 Become trained and read the instructions before
working on the machine or welding.
6 Do not remove or paint over (cover) label.
2 GENERAL DESCRIPTIONS
2.1 SPECIFICATIONS
This welding machine is a DC power source built using
INVERTER technology, engineered to weld with all types of
coated electrodes (cellulosic type not included) and with TIG
welding process with scratch starting and high frequency.
Must not be used to defrost pipes.
2.2 EXPLANATION OF THE TECHNICAL SPECIFICATIONS LISTED ON THE MACHINE PLATE.
This machine is manufactured according to the following
international standards: IEC 60974-1 - IEC 60974-3 -IEC
60974-10 CL. A - IEC 61000-3-12 - IEC 61000-3-11 (see
note 2).
N°. Serial number, which must be indicated on any
type of request regarding the welding machine.
Single-phase static transformer-rectifier
frequency converter.
Drooping characteristic.
SMAW. Suitable for welding with covered electrodes.
TIG Suitable for TIG welding.
U0. Secondary open-circuit voltage
X. Duty cycle percentage. % of 10 minutes during
which the welding machine may run at a certain
current without overheating.
I2. Welding current
U2. Secondary voltage with current I2
U1. Rated supply voltage
The machine has an automatic supply voltage selector.
1~ 50/60Hz 50- or 60-Hz single-phase power supply
I1 max. This is the maximum value of the absorbed current.
I1 eff. This is the maximum value of the actual current
absorbed, considering the duty cycle.
IP23S Protection rating for the housing.
Grade 3 as the second digit means that this
equipment may be stored, but it is not
suitable for use outdoors in the rain, unless
it is protected.
Suitable for hazardous environments.
Note:
1- The machine has also been designed for use in envi-
ronments with a pollution rating of 1. (See IEC 60664).
2- This equipment complies with IEC 61000-3-11 provided
that the maximum permissible system impedance Zmax
is less than or equal to 0,426 at the interface point
between the user's supply and the public system. It is the
responsibility of the installer or user of the equipment to
ensure, by consultation with the distribution network
operator if necessary, that the equipment is connected
only to a supply with maximum permissible system
impedance Zmax less than or equal to 0,426.
2.3 DESCRIPTION OF PROTECTIVE DEVICES
2.3.1. Thermal protection
This machine is protected by a temperature probe, which
prevents the machine from operating if the allowable temperatures are exceeded. Under these conditions the fan
keeps running and the LED M lights.
2.3.2. Block protections.
If the open-circuit voltage exceeds the allowable value,
the machine shuts off and the tripping of this protection
device is signalled by LED N flashing.
In this case shut the machine off and turn it back on. If the
situation persists, please contact technical service.
Another protection device is signalled by the wording E1
or E2 showing on display P. Also in this case please contact technical service.
2.3.3 Motor-driven generators
These must have a power equal to or greater than 6KVA,
and must not deliver a voltage greater than 260V.
3 INSTALLATION
Make sure that the supply voltage matches the voltage
indicated on the specifications plate of the welding
machine.
When mounting a plug, make sure it has an adequate
capacity, and that the yellow/green conductor of the
power supply cable is connected to the earth pin.
The capacity of the overload cutout switch or fuses
installed in series with the power supply must be equivalent to the absorbed current I1 of the machine.
3.1 START-UP
Only skilled personnel should install the machine. All connections must be carried out according to current regulations, and in full observance of safety laws (regulation CEI
26-10 - CENELEC HD 427).
3.2 DESCRIPTION OF THE EQUIPMENT
A - Procedure and mode selector switch
This push-button selects the welding procedure
(MMA or TIG) and mode.
In TIG mode there will always be two LEDs lit: one indicating HF or striking start mode, and the other indicating
continuous or pulse mode with 2- or 4-stage command.
S
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The selection changes each time the button is pressed.
The LEDs light alongside the various symbols to display
your choice.
B - LED. MMA welding (Manual Metal Arc)
This machine can weld all types of covered electrodes*
except for cellulosic.In this position, only the knob O is
enabled, to adjust the welding current.
C - LED. TIG welding with arc started with-
out high frequency.
To light the arc, press the torch trigger and touch the
tungsten electrode to the workpiece, then lift it. This
move must be quick and decisive.
D - LED. TIG welding with arc started with
high frequency.
To light the arc, press the torch trigger: a high voltage/frequency pilot spark will light the arc.
E - LED. Continuous 2-stage TIG welding
(manual).
When the torch trigger is pressed, the current begins to
increase over the previously set "slope up" time, until it
reaches the value set by means of the knob O. When the
trigger is released, the current begins to drop over the
previously set "SLOPE DOWN" time, until it returns to
zero.
In this position, you may connect the pedal control
accessory ART. 193.
F - LED. Continuous 4-stage TIG welding
(automatic).
This program differs from the previous one in that the arc
is both started and shut off by pressing and releasing the
torch trigger.
G - LED. Continuous TIG welding with dual
current level - 4 stages (automatic).
Set the two current levels before lighting the arc:
First level: press the R key until the LED X lights, and
adjust the main current using the knob O.
Second level: press the R key until the LED W lights, and
adjust the main current using the knob O.
When the torch trigger is pressed, the current begins to
increase over the previously set "slope up" time (led S lit),
until it reaches the value set by means of the knob O. The
LED X lights and appears on the display P.
Should it be necessary to reduce the current during welding, without shutting of the arc (for instance when changing the welding material or working position, moving from
horizontal to upright, etc.…), press and immediately
release the torch trigger: the current will switch to the
second value selected, the LED W will light and X will go
off.
To return to the previous main current, press and release
the torch trigger once again. The LED X will light, and the
LED W will go off. To stop welding at any time, simply
hold down the torch trigger for more than 0.7 seconds,
then release. The current begins to fall to zero within the
previously set "slope down" time interval (LED U lit).
If you press and immediately release the torch trigger during the "slope down" phase, you will return to "slope up"
if it is set to greater than zero, or to the lesser current
value of those set.
NOTE: The expression "PRESS AND IMMEDIATELY
RELEASE" refers to a maximum time of 0.5 seconds.
H - LED. Pulsed 2-stage TIG welding (manual).
From a pulse frequency of 0.16 to 1.1Hz, the display P
alternately shows the peak (main) current and the base
current. The LEDs X and W light alternately; beyond
1.1Hz the display P shows the mean of the two currents,
and the LEDs X and W both remain lit.
In this position, you may connect the pedal control
accessory ART. 193.
I - LED. Pulsed 4-stage TIG welding
(automatic).
This program differs from the previous one in that the arc
is both started and shut off by pressing and releasing the
torch trigger.
L - LED. Pulsed TIG welding with dual cur-
rent level - 4 stages (automatic).
The welding mode is the same as described for LED G.
After adjusting the peak and base currents for the first
level, the relationship between the two will also be upheld
in the second level.
M - LED - THERMAL PROTECTION
Lights when the operator exceeds the duty cycle or
percentage intermittence admissible for the machine,
and simultaneously blocks the current output.
NOTE: In this condition the fan continues cooling the
power source.
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N - BLOCK LED (see 2.3.2)
O - KNOB
Adjusts the welding current.
Also, in combination with the push-button R,
you may:
- adjust the second level of current W
-adjust the "slope up" S
-adjust the "slope down" U
- adjust the pulse frequency T
-adjust the post gas V
P - Display
It shows the welding current and the settings
selected with the button R and adjusted with the knob O,
as well as the block messages E1 and E2.
Q - SELECTOR
Selects and saves programs.
The welding machine can save nine welding programs
P01…..P09, and call them up using this button. A work-
ing program PL is also available.
Selecting
When this push-button is pressed briefly, the display P
shows the next program number after the one being
worked on. If it has not been saved the message will
flash, otherwise it will remain steady.
Saving
Once the program has been selected, hold for more than
3 seconds to save the data. In confirmation, the program
number on the display P will stop flashing
R - SELECTOR
When this button is pressed, the LEDs light in succession:
S - LED
Slope up. This is the time in which the current, starting from the minimum, reaches
the set current value. (0-10 sec.)
Warning: only those LEDs that refer to the chosen welding mode will light; i.e., in continuous TIG welding the LED
T, representing the pulse frequency, will not light.
Each LED indicates the parameter that may be adjusted
by means of the knob O while the LED itself is lit. Five
seconds after the last variation, the LED involved will shut
off; the main welding current will be displayed, and the
corresponding LED X lights.
X - LED
Main welding current.
W - LED
Second level of welding or base current.
This current is always a percentage of the
main current.
T - LED
Pulse frequency (0.16-250 Hz)
The peak and base times are equal
U - LED
Slope down. This is the time in which the
current reaches the minimum value and the
arc shuts off. (0-10 sec.)
V - LED
Post gas. Adjusts the time gas flows after welding
ends. (0-30 sec.)
Y - 10-PIN CONNECTOR
The following remote controls are connected to this connector:
a) foot control
b) torch with start button
c) torch with potentiometer
d) torch with up/down, etc…
Between pin 3 and 6 the “ARC ON” function is available
(clean contact 1A - 30V).
Z - 1/4 GAS FITTING
This is where the gas hose of the TIG welding
torch is to be connected.
AA - Negative output terminal (-)
AB -Positive output terminal (+)
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AC - switch
Turns the machine on and off
AD - gas intake fitting
3.3. GENERAL NOTES
Before using this welding machine, carefully read the
standards CEI 26/9 - CENELEC HD 407 and CEI 26.11 CENELEC HD 433. Also make sure the insulation of the
cables, electrode clamps, sockets and plugs are intact,
and that the size and length of the welding cables are
compatible with the current used.
3.4 MMA WELDING (MANUAL METAL ARC)
- This welding machine is suitable for welding all types of
electrodes, with the exception of cellulosic (AWS 6010)*.
- Make sure that the switch AC is in position 0, then connect the welding cables, observing the polarity required
by the manufacturer of the electrodes you will be using;
also connect the clamp of the ground cable to the workpiece, as close to the weld as possible, making sure that
there is good electrical contact.
- Do NOT touch the torch or electrode clamp simultaneously with the earth clamp.
- Turn the machine on using the switch AC.
- Select the MMA procedure by pressing the button A:
LED B lit.
- Adjust the current based on the diameter of the electrode, the welding position and the type of joint to be
made.
- Always remember to shut off the machine and
remove the electrode from the clamp after welding.
3.5 TIG WELDING
This welding machine is suitable for welding stainless
steel, iron, or copper using the TIG procedure.
Connect the earth cable connector to the positive pole (+)
of the welding machine, and the clamp to the workpiece
as close as possible to the welding point, making sure
there is good electrical contact.
Connect the power connector of the TIG torch to the negative pole (-) of the welding machine.
Connect the torch connector to the welding machine
connector Y.
Connect the torch gas hose fitting to the fitting Z on the
machine, and the gas hose from the cylinder pressure
regulator to the gas fitting AD on the rear panel.
Turn on the machine.
Do not touch live parts and output terminals while the
machine is powered.
The first time the machine is turned on, select the mode
using the push-button A and the welding parameters by
means of the key R and the knob O as described in paragraph 3.2.
The flow of inert gas must be set to a value (in liters per
minute) approximately 6 times the diameter of the electrode.
If you are using gas-lens type accessories, the gas
throughput may be reduced to approximately 3 times the
diameter of the electrode. The diameter of the ceramic
nozzle must be 4 to 6 times the diameter of the electrode.
The most commonly used gas is normally ARGON,
because it is less costly than other inert gases, but you
may also use blends of ARGON with a maximum of 2%
HYDROGEN for welding stainless steel, and HELIUM or
ARGON-HELIUM blends for welding copper. These
blends increase the heat of the arc while welding, but are
much more expensive.
If you are using HELIUM gas, increase the liters per
minute to 10 times the diameter of the electrode (Ex.
diameter 1.6 x10= 16 lt./min of Helium).
Use D.I.N. 10 protective glasses for up to 75A, and D.I.N.
11 from 75A up.
3.6. SAVING
You may save parameters only after welding.
Pressing the push-button Q briefly makes a selection;
held down for more than 3 seconds, it saves the data.
Each time it is turned on, the machine always shows
the last welding condition used.
3.6.1. Saving data from the PL program
Using the machine for the first time
When the machine is turned on, the display shows the
symbol PL; this disappears after 5 seconds, and a working current is displayed. Follow the instructions in paragraphs 3.2 and 3.5, then proceed as follows to save the
data in the program P01:
· Briefly press the push-button Q (mem+mem-) the message P01 will appear flashing.
· Press push-button Q for more than 3 seconds, until the
symbol P01 stops flashing: at this point, the data have
been saved.
· Obviously, if you wish to save in a program other than
P01, you should briefly press the push-button Q as many
times as necessary to display the desired program. P01
will be displayed the next time the machine is turned on.
PRESSING THE Q PUSH-BUTTON BRIEFLY MAKES A
SELECTION, WHILE HOLDING IT DOWN FOR MORE
THAN 3 SECONDS SAVES THE DATA.
3.6.2. Save from a free program
The operator may edit and save a selected program by
proceeding as follows:
· Press the push-button Q briefly and select the desired
program number.
· The symbol of free programs is flashing.
· Press the push-button A and select the welding procedure and mode (paragraph 3.1).
· Turn the knob O and set the welding current.
· If the TIG procedure has been selected, activate the LED
V (post gas) by means of the push-button R, and set the
desired value via the knob O (paragraph 3.1.)
· If you wish to adjust the "slope" times or other parameters, after making these adjustments which are neces-
sary in order to weld, follow the steps described in paragraph 3.1.
· Weld, even briefly, and decide where to save
· To save in the previously selected program, press the
button Q for more than 3 seconds, until the number stops
flashing.
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· To save in a different program, make your selection by
briefly pressing the push-button Q, then hold down the
push-button Q for more than 3 seconds.
3.6.3 Save from a saved program
Beginning with a previously saved program, the operator
may edit the data in memory to update the program itself,
or to find new parameters to save in another program.
3.6.3.1 Update
· After turning on the machine, select the parameters to
be edited and edit them.
· Weld, even briefly.
· Hold down the Q button for more than 3 seconds, until
the save is confirmed (program symbol changes from
flashing to steady).
3.6.3.2 Save in a new program
· After turning on the machine, select the parameters to
be edited and edit them.
· Weld, even briefly.
· Briefly press the selector Q until the desired program is
displayed.
· Hold down the Q button until the save is confirmed (program symbol changes from flashing to steady).
4 REMOTE CONTROLS
The following remote controls may be connected to
adjust the welding current for this welding machine:
Art. 193 Foot control (used in TIG welding)
Art (1262) TIG UP/DOWN Torch.
Art 1192+Art 187 (used in MMA welding)
ART. 1180 Connection to simultaneously connect the
torch and the pedal control.
ART. 193 may be used in any TIG welding mode with this
accessory.
Remote controls that include a potentiometer regulate the welding current from the minimum to the
maximum current set via the knob O.
Remote controls with UP/DOWN logic regulate the
welding current from the minimum to the maximum.
The remote control settings are always active in the PL
program, while they are not active in a saved program.
5 MAINTENANCE
Any maintenance operation must be carried out by qualified personnel in compliance with standard CEI 26-29
(IEC 60974-4).
5.1 GENERATOR MAINTENANCE
In the case of maintenance inside the machine, make
sure that the switch AC is in position "O" and that the
power cord is disconnected from the mains.
It is also necessary to periodically clean the interior of the
machine from the accumulated metal dust, using compressed air.
5.2 PRECAUTIONS AFTER REPAIRS.
After making repairs, take care to organize the wiring so that
there is secure insulation between the primary and secondary sides of the machine. Do not allow the wires to come
into contact with moving parts or those that heat up during
operation. Reassemble all clamps as they were on the original machine, to prevent a connection from occurring
between the primary and secondary circuits should a wire
accidentally break or be disconnected.
Also mount the screws with geared washers as on the original machine.
71
QUESTA PARTE È DESTINATA ESCLUSIVAMENTE AL PERSONALE QUALIFICATO.
THIS PART IS INTENDED SOLELY FOR QUALIFIED PERSONNEL.
DIESER TEIL IST AUSSCHLIEßLICH FÜR DAS FACHPERSONAL BESTIMMT.
CETTE PARTIE EST DESTINEE EXCLUSIVEMENT AU PERSONNEL QUALIFIE.
ESTA PARTE ESTÁ DESTINADA EXCLUSIVAMENTE AL PERSONAL CUALIFICADO.
ESTA PARTE È DEDICADA EXCLUSIVAMENTE AO PESSOAL QUALIFICADO.
TÄMÄ OSA ON TARKOITETTU AINOASTAAN AMMATTITAITOISELLE HENKILÖKUNNALLE.
DETTE AFSNIT HENVENDER SIG UDELUKKENDE TIL KVALIFICERET PERSONALE.
DIT DEEL IS UITSLUITEND BESTEMD VOOR BEVOEGD PERSONEEL.
DENNA DEL ÄR ENDAST AVSEDD FÖR KVALIFICERAD PERSONAL.
AUTOV TO TMHVMA PROORIVZETAI APOKLEISTIKAV GIA TO EIDIKEUMEVNO PROSWPIKO.V
72
Art. 265
73
pos DESCRIZIONE DESCRIPTION
01 FASCIONE HOUSING
02 SUPPORTO MANICO HANDLE SUPPORT
03 MANICO HANDLE
04 PANNELLO POSTERIORE BACK PANEL
05 PRESSACAVO STRAIN RELIEF
06 COPERTURA COVER
07 INTERRUTTORE SWITCH
08 CAVO RETE POWER CORD
09 RACCORDO FITTING
10 RACCORDO FITTING
11 ELETTROVALVOLA SOLENOID VALVE
12 RACCORDO FITTING
13 PIEDE IN GOMMA RUBBER FOOT
14 FONDO BOTTOM
15 IMPEDENZA PFC PFC CHOKE
16 TRASFORMATORE H.F. H.F. TRANSFORMER
17 RACCORDO FITTING
pos DESCRIZIONE DESCRIPTION
18 PRESA GIFAS GIFAS SOCKET
19 RACCORDO FITTING
20 SUPPORTO CIRCUITO CIRCUIT BOARD SUPPORT
21 CIRCUITO FILTRO FILTER CIRCUIT
22 PANNELLO ANTERIORE FRONT PANEL
23 MANOPOLA KNOB
24 SUPPORTO CIRCUITO CIRCUIT BOARD SUPPORT
25 CIRCUITO DISPLAY DISPLAY CIRCUIT
26 MOTORE CON VENTOLA MOTOR WITH FAN
27 CIRCUITO CONNETTORE CONNECTOR CIRCUIT
28 PIANO INTERMEDIO INSIDE BAFFLE
29 COPERTURA COVER
30 CIRCUITO DI POTENZA POWER CIRCUIT
31 RACCORDO FITTING
32 TAPPO CAP
33 CORNICE FRAME
When ordering spare parts please always state the machine item
and serial number and its purchase data, the spare part position
and the quantity.
La richiesta di pezzi di ricambio deve indicare sempre: numero di
articolo, matricola e data di acquisto della macchina, posizione e
quantità del ricambio.
Art. 265
74
Art. 265
75
CODIFICA COLORI WIRING DIAGRAM
CABLAGGIO ELETTRICO COLOUR CODE
A NERO BLACK
B ROSSO RED
C GRIGIO GREY
D BIANCO WHITE
E VERDE GREEN
F VIOLA PURPLE
G GIALLO YELLOW
H BLU BLUE
K MARRONE BROWN
J ARANCIO ORANGE
I ROSA PINK
CODIFICA COLORI WIRING DIAGRAM
CABLAGGIO ELETTRICO COLOUR CODE
L ROSA-NERO PINK-BLACK
M GRIGIO-VIOLA GREY-PURPLE
N BIANCO-VIOLA WHITE-PURPLE
O BIANCO-NERO WHITE-BLACK
P GRIGIO-BLU GREY-BLUE
Q BIANCO-ROSSO WHITE-RED
R GRIGIO-ROSSO GREY-RED
S BIANCO-BLU WHITE-BLUE
T NERO-BLU BLACK-BLUE
U GIALLO-VERDE YELLOW-GREEN
V AZZURRO BLUE
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