Fimer TM 215 Instruction Manual

Instructions manual

TM 215

Istruzioni Originali

Original instructions

Übersetzung der Originalbetriebsanleitung

Notice originale

Manual original

20050 RONCO BRIANTINO (MB) Italy

Via Brigatti, 59

Tel. +39 039 6079326 - Fax. +39 039 6079334

www.fimer.com - info@fimer.com

165A

22,25V

140A

25,6V

120A

24,9V

31,1V 17,2V

20,5V

130A

PESO: DIMENSIONI: CARATTERISTICA STATICA: DISPOSITIVO DI PROTEZIONE DI RETE:

TENSIONE DI INGRESSO: PROTEZIONE TERMICA: TEMP. INTERVENTO: Le prove di riscaldamento sono state effettuate alla temperatura di 40° FUNZIONE ARC FORCE E ANTI-STICKING: DIAMETRI DEGLI ELETTRODI UTILIZZABILI:

WEIGHT: DIMENSIONS: STATIC CHARACTERISTIC: POWER SUPPLY PROTECTION:

INPUT LOAD: THERMAL PROTECTION: INTERVENTION TEMPERATURE: Overheating tests run at 40° C ARC FORCE AND ANTI-STICKING FUNCTIONS:

MAX ELECTRODE DIAMETERS:

GEWICHT: ABMESSUNGEN: STATISCHE EIGENSCHAFTEN: NETZSCHUTZVORRICHTUNG:

EINGANGSSPANNUNG : WÄRMESCHUTZ: EINSATZTEMPERATUR: Die Erhitzungsprüfungen wurden bei einer Temperatur in Höhe von 40° durchgeführt ARC FORCE UND ANTISTICKING FUNKTION:

VERWENDBARE ELEKTRODENDURCHMESSER:

POIDS: DIMENSIONS: CARACTÉRISTIQUE STATIQUE : DISPOSITIF DE PROTECTION DE RÉSEAU :

TENSION D’ENTREE : PROTECTION THERMIQUE : TEMP. INTERVENTION : Les essais de chauffe ont été effectués à la température de 40° FONCTION ARC FORCE ET ANTICOLLANT :

DIAMETRES DES ELECTRODES UTILISABLES :

PESO: DIMENSIONES: CARACTERÍSTICA ESTÁTICA : DISPOSITIVO DE PROTECCIÓN DE RED :

TENSIÓN DE ENTRADA: PROTECCIÓN TÉRMICA : TEMP. INTERVENCIÓN : Las pruebas de calentamiento se han realizado con una temperatura de 40 ºC. FUNCIÓN FUERZA ARC Y ANTISTICKING :

DIÁMETROS DE LOS ELECTRODOS UTILIZABLES :

ITALIANO

ENGLISH

DEUTSCH

FRANÇAIS

ESPAÑOL

ALTRI DATI TECNICI

ADDITIONAL TECHNICAL INFORMATION

WEITERE TECHNISCHE DATEN

AUTRES DONNEES TECHNIQUES

OTROS DATOS TÉCNICOS

17 Kg.

200x450x480

cadente

230V + /- 10%

termostato tipo “t he rm ic S O1 ”

presente

Ø 0, 6; Ø 0, 8; Ø 1, 0 mm

Fusibili 2 5A Ritardati Int. B ip ol ar i: 25A C ur va K o C

17 Kg.

200x450x480

drooping

230V + /- 10%

Thermostat : “Thermic S O1 ”

Present

Ø 0, 6; Ø 0, 8; Ø 1, 0 mm

25A Delay-Fuses Two-Pole 25A K- or C-Standard Switch

17 Kg.

200x450x480

fallend

230V + /- 10%

Thermostat Typ „t he rm ic SO1”

vorhanden Ø 0, 6; Ø 0, 8; Ø 1, 0 mm

verzögerte 2 5A Sicherungen Int. z we ip ol ig : 25A K- oder C -K ur ve

17 Kg.

200x450x480

cadente

230V + /- 10%

Thermostat type “thermic SO1”

present Ø 0, 6; Ø 0, 8; Ø 1, 0 mm

Fusées R et ar dé es 25A Int. B ip ol ai re s 25A Co ur be K o C

17 Kg.

200x450x480

cadente

230V + /- 10% termostato tipo “t he rm ic S O1 ”

presente

Ø 0, 6; Ø 0, 8; Ø 1, 0 mm

Fusibles 2 5A Retardados Int. Bi po la re s: 2 5A Curva K o C

VII

TECHNICAL SPECIFICATION

TECHNISCHE SPEZIFIKATIONEN

SPÉCIFICATIONS TECHNIQUES

ESPECIFICACIONES TÉCNICAS

SPECIFICHE TECNICHE

1

ESPAÑOL

FRANÇAIS

DEUTSCH ENGLISH ITALIANO

USE A N D M A I N T E N A N C E M A N U A L

Fimer S.p.a. thanks you for selecting this unit, it will prove to be a useful, problem-free

tool for many years to come if the instructions contained in this manual are followed scrupulously.

This manual must be considered as an integral part of the unit and must accompany it when it change location or is resold. The user must assume responsability for maintaining this manual intact and legible at all times.

Fimer S.p.a. reserves the right to modify this manual at any time without notice. All rights of translation and total or partial reproduction by any means whatsoever (including scanner, photocopy, film, and microfilm) are reserved and reproduction is prohibited without the express written consent of Fimer S.p.a.

IN DEX

• WARNING ............................................

.............................................................

............................................................................................................... pag. 2, 3, 4

1. GENERAL INFORMATION........................................................................ pag. 5

2. DESCRIPTION OF WELDER ................................................................... pag. 6

3. WELDING METHODS ............................................................................... pag. 8

3.1 MIG/MAG WELDING ............................................................................. pag. 8

3.1.1 MANUAL MIG WELDING .................................................................... pag. 8

3.1.2 SYNERGIC SHORT ARC MIG WELDING ............................................... pag. 8

3.1.3 SYNERGIC PULSED MIG WELDING .................................................. pag. 9

3.2 MMA WELDING .................................................................................... pag. 9

4. CONNECTION TO POWER SUPPLY ....................................................... pag. 9

5. OUTPUT CONNECTIONS ...................................................................... pag. 10

5.1 MIG WELDING CONNECTIONS - with shielding gas and standard torch pag. 10

5.2 MIG WELDING CONNECTIONS - gasless and standard torch ............. pag. 10

5.3 MIG WELDING CONNECTIONS - with shielding gas and Spool torch........ pag. 10

5.4 MIG WELDING CONNECTIONS - with shielding gas and Spool torch ........ pag. 10

5.5 MMA WELDING CONNECTIONS ........................................................... pag. 10

6. WELDING WIRE INSTALLATION ............................................................. pag. 11

6.1 WELDING WIRE INSTALLATION ......................................................... pag. 11

7. GAS CYLINDER AND GAS PRESSURE REGULATOR CONNECTIONS..... pag. 12

8. WELDING METHODS ........................................................................... pag. 12

8.1 MANUAL MIG WELDING .................................................................... pag. 12

8.2 SYNERGIC MIG WELDING.................................................................. pag. 13

8.3 MMA WELDING .................................................................................. pag. 14

8.3.1 DESCRIPTION ................................................................................ pag. 14

8.3.2 MMA WELDING FEATURES.................................................................... pag. 14

8.3.3 MMA WELDING ....................................................................................... pag. 14

9. WIRE LINER REPLACEMENT ............................................................... pag. 15

10. DEFAULT PARAMETER ADJUSTMENT ................................................. pag. 15

11.TROUBLE SHOOTING .......................................................................... pag. 16

12. BLOCK DIAGRAM ............................................................................... pag. 16

WARNINg SYMBOLS

CA UTI ON

DA Ng ER

(Indicating a hazard that could cause injury or damage)

DANgER OF FIRE OR EXpLOSI ON.

In d icat ing t h at ey e prot e cti o n is r e quir e d to a v oid burn s and eye d amage.

TOXIC gAS

Indicating the risk of toxic gas hazards

HOT SLAg

Indicating the risk of being burned by hot slag

EYE pROTECTION

Indicating that eye protection is required to avoid flying debris

ELECTRIC SHOCK

(Ind ic ating t he danger o f elect ri c shock )

DANgER COMpRESSED gAS

Indicating the risk of injury or death in the event of improper handling or maintenance of compressed gas cylinders or regulators

IMpORTANT INFORMATION

Indicating the precautions to be taken when installing and using the unit.

DISpOSAL INFORMATION

FIRE pRECAUTIONS

SAFETY WARNINgS

This equipment is designed solely for industrial o r professional use. As such, only experienced or ful-

ly-trained people should use the equipment. The user and/or owner is responsible for ensuring inexperienced personnel does not have access to the equipment.

The safety information contained in this manual is a guide to ensure you are not subjected to unnecessary risks. However, the operator must be competent and careful at all times.

Fimer SpA declines all responsibility for injury or dama-

ge caused by inexperienced, improper or neglectful use

of its equipment.

A workman must look after his tools carefully ! Remember that any tool or equipment can become a hazard if it is not looked after properly.

Equipment in a state of disrepair or neglect can be dangerous. If it does not operate properly or overheats, the electricity supply should be removed immediately and the unit should be returned to the supplier for repair.

All equipment connected to electric power supplies can be dangerous if the manufacturers instructions are not read and obser-

ved. Read, understand and observe these safety instructions to reduce the risk of death or injury from electric shock. Ensure that even bystanders are aware of, and understand, the dangers that exist in the welding area.

Read this manual carefully before using your Welder. You can then do a better and safer job.

By reading this manual you will learn more about the possibilities, limitations and potential dangers of welding. Retain this manual for the entire life of the equipment. It should be kept within the operator’s reach at all times.

Fires and explosions can seriously injure or cause dama-

ge ! Read, understand and observe all safety warnings

to reduce the risk of death or injury from fire or explosion. Pay particular attention to the fact that even bystanders should be aware of, and understand, the dangers existing in the welding area. Remember that welding, by nature, produces sparks, hot spatter, molten metal drops, hot slag and hot metal parts that can cause fires, can burn skin and damage eyes.

Arc rays can damage your eyes and burn your skin ! Read, understand and observe all safety warnings to avoid dama-

ge from arc rays. Pay particular attention to the fact that even bystanders should be aware of, and understand, the dangers existing in the welding area. Wear a protective mask and make sure bystanders do the same.

Fumes, toxic gases and vapours can be harmful ! Read,

understand and observe all safety warnings to avoid harm from toxic welding gases. Pay particular attention to the fact that even bystanders should be aware of, and understand, the dangers.

Carelessness while using or maintaining the compres-

sed gas cylinders or regulators can injure or k ill the operator and/or bystanders ! Read, understand and observe all safety warnings to avoid the dangers of compressed gas. Pay particular attention to the fact that even bystanders should be aware of, and understand, the dangers.

HIgH VOLTAgE

The unit carries potentially lethal voltage.

The high voltage areas of the equipment have been segregated and can be reached only by using tools that are not provided with the Welder. All maintenance or repair operations requiring access to such areas may only be performed by Fimer-trained technicians.

FOREIgN OBjECTS

Never block the air vents with foreign objects and avoid any contact with liquids. Clean using just a dry cloth. The-

se safety precautions apply even when the unit is switched off.

CABLE gAUgES

Check that all cables are appropriately gauged for

the input power required by your specific Welder. This precaution applies also to extension cables, if used. All extension cables must be straight. Coiled cables can overheat, becoming dangerous. Twisted or coiled cables can also cause Welder malfunction.

WEIgHT LOADS

The upper part of the Welder was not designed to withstand heavy loads. Never stand on the unit.

IN STA LL ATI ON IN ST RU CTI ON S

OpERATINg INSTRUCTIONS

UNpACKINg INSTRUCTIONS

READ THE INSTRUCTION MANUAL

SUITABLE FOR ENVIRONMENT WITH INCREASED HAZARD OF ELECTRIC SHOCK

3

WELDING OPERATION

SAFETY INSTRUCTIONS

PERSONNEL PROTECTION

LOCATION

Place the Welder well away from heat sources. Place the

Welder in a well-ventilated environment. Place the Welder in a safe, protected area. It must not be installed outdoors. Do not install the Welder in dusty environments. Dust can get into the inner parts of the unit and inhibit cooling. The Welder must be positioned on a flat, stable surface that extends further than the units own dimensions in all directions.

CLEAN LOCATIONS

The installation area must be kept clean and dry to be sure the Welder fans do not draw in small objects or liquids. Not only could the equipment malfunction but a serious risk of fire outbreak could be created.

REPAIRS

Never attempt to repair the Welder yourself. Always

refer to the manufacturer or an authorized repairer. All warranty provisions will immediately become null and void if any repair, or attempt to repair, not specifically authorized in writing or handled by Fimer S.p.A. is carried out. Furthermore, Fimer S.p.A. will accept no responsibility for any malfunction or damage resulting as a consequence of such unauthorized action.

SPARE PARTS

Use only manufacturer-recommended spare parts.

Other spare parts could cause equipment malfunction. The use of non-original spare parts will also result in the warranty provisions becoming null and void, releasing the manufacturer from any responsibility for malfunction or damage resulting as a consequence of such action.

CAUTION !

Welding processes can be dangerous for the operator and bystanders if the safety warnings and instructions are not heeded.

WORK-AREA FLOORING

The work-area flooring MUST be fireproof.

WORK-AREA SURFACES

Work benches or tables used during welding MUST have fireproof surfaces.

PROTECTION MASK

Wear a protective non-flammable welding mask

to protect your neck, your face and the sides of your head. Keep the front lens clean and replace it if it is broken or cracked. Place a transparent protection glass between the mask and the welding area.

CLOTHING

Wear close-fitting, closed, non-flammable, pocke-

tless clothing.

EXTINGUISHER

Always place an approved fire extinguisher in the immediate vicinity of the work area. Fire extinguishers should be checked regularly.

EYE PROTECTION

NEVER look at the arc without appropriate eye protection.

FUMES AND GASES 1

Clean away paint, rust or any other dirt from the item to be welded to avoid the creation of dangerous fumes.

FUMES AND GASES 2

NEVER weld on metals containing zinc, mercury, chromium, graphite, heavy metals, cadmium or beryllium unless

the operator and the bystanders use appropriate air-supplied respirators.

CONFINED SPACES

When welding in small environments, leave the power source outside the area where welding will take place and

attach the grounding clamp to the part to be welded.

HUMIDITY

Never weld in wet or humid environments.

DAMAGED CABLES

Never use damaged cables. (This applies to both

the power and the welding cables.)

DAMAGED CABLES

Never remove the unit side panels. If the side panels can be opened, always checked they are closed

tightly before starting any work.

HIGH VOLTAGE PROTECTION

Together with the previous instructions, the following precautions should be strictly observed

FIRE PREVENTION

Together with the previous instructions, the following precautions should be strictly observed. Welding operations require high temperatures therefore the risk of fire is great.

TECHNICAL ASSISTANCE

The Welder must be taken to an authorized Technical Assi-

stance Centre if the equipment has been damaged in any way or if any one of the following events occurs : liquid infiltration; damage caused by falling objects; exposure to rain or humidity (exceeding the specified limits); malfunction; performance failure or if the equipment has been dropped.

OVERLOAD PROTECTION

Check that the power source supplying the Welder carries the correct voltage and is safety-protected. The power switch must open all the power supply circuits. (If a single-phase connection is used, both the live and the neutral poles must be open. If a three-wire connection is used , all three poles must be open. Four-wire circuits require all poles and neutral open). Time-delayed fuses or K-standard circuit breakers should be used.

CABLE COLOURS

The green-yellow wire is for earthing. (Don’t use it for

anything else !)

INSTALLATION ENVIRONMENT

The equipment is not suitable for use in washrooms,

shower cubicles, pool areas or similar environments. If you are obliged to use the unit in such areas, turn off all water supplies and check the area has been evacuated.

OPERATING AND/OR INSTALLATION ENVIRONMENT 3

Never use the Welder in an explosive, corrosive, abra-

sive or saline environment.

VENTILATION

Weld in a well-ventilated environment that does not have direct access to other work areas.

EARTHING

If the Welder was not already supplied with a plug, connect the earth wire first. When removing the plug, disconnect the earth wire last.

PLUG AND POWER SUPPLY

If the Welder already has a plug attached, check that it is appropriate for the wall-socket you intend using. Never tamper with the power cable.

RELOCATION 1

Some Welders are extremely heavy therefore care should be

taken when relocating the unit. Check the floor or platform weight load limitations before relocating the unit if the Welder is to be used, even only temporarily, in a non-industrial environment

OPERATING AND/OR INSTALLATION ENVIRONMENT 1

The Welder was not designed for installation or use in areas where it

could be subject to blows or vibration, such as road-vehicles, railway carriages, cable-cars, aircraft, ships or boats or similar environments (including cranes, conveyor-carriers or any other mobile equipment prone to vibration)

OPERATING AND/OR INSTALLATION ENVIRONMENT 2

The Welder should never be used or stored in the rain or in snow.

RELOCATION 2

Never store or move the Welder in an inclined position or on its

side.

Together with the previous instructions, the following

precautions should be strictly observed

4

CLEAN ENVIRONMENT

Remove all flammable materials away from

the work environment.

SERIOUS DANGER ! 1

NEVER weld in confined spaces (e.g. in a container vehicle, a cistern or a storeroom etc.) where toxic, inflammable or explosive materials are, or have been, located or stored. Cisterns, in particular, may still contain toxic, flammable or explosive gases and vapours years after they have been emptied.

SERIOUS DANGER! 3

NEVER use the Welder to melt frozen water

pipes.

SERIOUS DANGER ! 2

NEVER weld a cistern that contains (or has stored)

toxic, inflammable or explosive materials. They could still contain toxic, flammable or explosive gases and vapours years after they have been emptied. If you are obliged to weld a cistern, ALWAYS passivate it by filling it with sand or a similar inert substance before starting any work.

WELDING ENVIRONMENT VENTILATION

Ventilate the welding environment carefully. Maintain sufficient air-flow to avoid toxic or explosive gas accumulation. Welding processes on certain kinds or combinations of metals can generate toxic fumes. In the event of this happening, use air-supply respirators. BEFORE welding, read and understand the welding alloy safety provisions.

GAS TYPES

These welders use only inert (non-flammable) gases for welding arc protection. It is important that the appropriate type of gas is chosen for the type of welding being performed.

UNIDENTIFIED GAS CYLINDERS

NEVER use unidentified gas cylinders.

PRESSURE REGULATOR 1

NEVER connect the cylinder directly to the Welder. Always use a pressure regulator.

PRESSURE REGULATOR 2

Check the regulator is performing its function properly. Read the regulator instructions carefully.

PRESSURE REGULATOR 3

Never lubricate any part of the regulator.

PRESSURE REGULATOR 4

All regulators are designed for a specific type of gas. Check the regulator is appropriate for the protective

gas to be used.

VENTILATION

Together with the previous instructions, the following pre-

cautions should be strictly observed

PROTECTIVE WELDING GASES

Together with the previous instructions, the following precautions should be strictly observed when welding with protective gases

WALL AND FLOOR PROTECTION

The walls and flooring surrounding the welding environment must be shielded using non-flammable materials. This not only reduces the risk of fire but also avoids damage to the walls and floors during welding processes.

EXTINGUISHER

Place an approved and appropriately-sized fire extinguisher in

the work environment. Check its working order regularly (carry out scheduled inspections) and ensure that all parties involved know how to use one.

DAMAGED GAS CYLINDERS

NEVER use damaged or faulty cylinders.

CYLINDER RELOCATION

NEVER lift a gas cylinder by holding the regulator.

GAS CYLINDERS

Do not expose gas cylinders to excessive heat sources, sparks, hot slag or flames.

GAS HOSE 1

Check the gas hose is not damaged.

GAS HOSE 2

Always keep the gas hose well away from the work area.

ELECTRIC SHOCK

Together with the previous instructions, the following pre-

cautions should be strictly observed to reduce the risk of

electric shock

ELECTRIC SHOCK INJURY

DO NOT touch a person suffering from electric shock if

he/she is still in contact with the cables. Switch the mains power

source off immediately THEN provide assistance.

CABLE CONTACT

Do not tamper with power cables if the mains power is still

switched on. Do not touch the welding circuitry. Welding circuitry is usually low voltage, however, as a precaution, do not touch the welder electrodes.

CABLE AND PLUG PRECAUTIONS

Check the power supply cable, plug and wall-socket regularly.

This is particularly important if the equipment is relocated often.

REPAIRS

Never attempt to repair the Welder yourself. The result would

not only cause warranty cancellation but also high danger risks.

MAINTENANCE PRECAUTIONS

Always check that the electric power supply has been discon-

nected before performing any of the maintenance operations listed in this manual ( e.g. before replacing any of the following: worn electrodes, welding wires, the wire feeder etc.)

Never point the welding gun or the electrode towards yourself

or others.

Check no power supply cables, telephone cables or other

electrical items (e.g. computer cables, control lines etc.) are

in the vicinity of the Welder.

Check there are no telephones, televisions, computers or other

transmission devices close to the Welder.

ELECTROMAGNETIC COMPATIBILITY

Make sure that people with pace-makers are not in the immediate vicinity of the Welder.

Do not use the Welder in hospitals or medical environments (including veterinary surgeries). Make especially sure there is no electrical medical equipment being used close to where welding is being done.

Should the Welder interfere with other apparatus, take the fol-

lowing precautionary measures:

1. Check the Welder’s side panels are securely fastened.

2. Shorten the power supply cables. Place EMC filters between the Welder and the power source. (Contact Fimer Technical Dept. in this respect )

EMC compatibility : CISPR 11, Group 1, Class A.

2

11

7. GAS CYLINDER AND GAS PRESSURE REGULATOR CONNECTIONS Only for MIG welding: Skip this charter

entirely if the welder is to be used for MMA

Carefully follow the procedure shown in Fig. 6: Connect the pressure regulator (2) to the gas cylinder (3). Tighten the bolt (6) between the regulator (2) and the cylinder (3). Do not overtighten to avoid damaging the cylinder valve (1). Connect the gas hose of the torch (4) to the pressare regulator (2) and clamp securely using a clasp (5). (Alternatively use cylinder and hose fast connectors). Connect the other end of the gas hose (6) to the socket on the rear panel of the welder unit (Fig.2 – 23), securing it with a clasp. Connect the gas hose from the torch to the appropriate socket (7) on the front panel of the unit (fig 1 - 33), tightening clockwise. Do not over-tighten. Open the gas cylinder valve (1). Press the torch button and check that gas is flowing through correctly. WARNING: Cylinders contain high pressure gas. Handle them with care. Inappropriate treatment can cause serious accidents. Do not pile gas cylinders up and never expose them to excessive heat, flames or sparks. Do not bang cylinders against each other. Contact your supplier for more information regarding the use and maintenance of gas cylinders. WARNING: Never use cylinders that are damaged or show signs of oil or grease leakage. Contact your supplier immediately of any such circumstances.

8. WELDING METHODS

8.1 Manual MIG welding

To select this mode, turn knob 7 (Fig.1) to the MIG MAN setting. N.B.: These are guidelines only and are to be considered applicable solely to workpieces no thicker than 4mm. The settings are selected according to wire diameter, location and welding gas.

Fig 7: Current reference values, wire diameter

,

wire speed and electronic inductance.

Proceed as follows for manual MIG welding:

1. Set the welding current, according to the

thickness of the workpiece and the diameter of the wire to be used, using the knob 10, Figure 1 (S

tep 1, Fig8). The display panel (Fig. 1 – 1)

shows the value selected.

2. According to the diameter of the wire, set the wire speed using knob 9 of Figure 1. (Step 3, Fig.8)

3. According to the kind of material, regulate the electronic inductance (Fig. 1 – 8). (Step 4, Fig8)

4

3

2

1

6

2

5

1

3

5

Fig.6

Step 1: Current selection

Convert the thickness of the workpiece in to Amperes (A)

using the following formula:

0.025mm = 1A

i.e. 3mm = 125A

Step 2: Wire diameter selection

Step 3: Wire diameter selection

AMPERE (Min-Max) WIRE DIAMETER

40-90 A 0,6mm 60-140A 0,8mm 80-160A 1mm

100-200A 1,2mm

wire diameter

recommended wire speed

wire speed

0,6mm 1 amp ( 90mm/min) 90x120=11m/min

0,8mm 1 amp ( 50mm/min) 50x120=6m/min

1mm 1 amp ( 40mm/min) 40x120=5m/min

1,2mm 1 amp ( 30mm/min) 30x120=3,5m/min

Step 4: Electronic inductance selection

Material Electronic inductance setting

Ferrous materials (SG2 SG3) min <~> med Stainless steel (NI-Cr) med Aluminium (Al) med <~> max Copper-silicon (Cu-SI3) med <~> max Copper-aluminium (CU-Al8) med <~> max

12

4. Connect the earth clamp to the workpiece.

5. Start to weld maintaining an arc length of

between 5 to 10 mm.

6. Regulate the wire speed (Knob Fig. 1 –

9).For best results regulate the speed (Knob 9) until a loud, regular sizzling sound is heard (similar to that of frying bacon). Always perform a trial run using a metal sheet that is free of grease, rust or paint.

For best results heed the following advice:

1. Keep the torch at a 45° angle to the work-

piece. Keep the gas nozzle (Fig.4A) app. 6 mm away from the workpiece.

2. Move the torch smoothly.

3. Weld using small zigzag movements so as to be

able to regulate the size of the weld as desired.

4. Do not weld in windy surroundings. Draughts can disperse the gas from the welding pool causing porous welding results.

5. Ensure the wire is clean: never use rusty welding wire.

6. Keep the torch cable straight.

7. Clean the wire-feed guide with compressed

air when changing spools.

8. Remove dust from the air intake grills regularly, using low-pressure compressed air. Always point the jet of air outwards to avoid dirt being forced into the unit.

Pulsed mode:

Pressing button 12 of Fig.1 will set the unit in manual pulsed MIG welding mode. LED 6 of Figure 1 will be on. This mode is for experienced operators only. In fact it is mainly used as an alternative to synergic pulsed MIG welding under rare circumstances, e.g. for special materials and when satisfactory results cannot be achieved using the predefined settings. In this mode the potentiometer knob (Fig. 1 – 10) regulates the welding current, knob 9 (Fig.1) sets the wire speed and knob 8 (Fig.1) regulates the pulsing frequency.

8.2 SYNERGIC MIG WELDING

In synergic MIG welding (with gas) mode the welder tunes itself automatically to suit the type of material to be welded and the thickness of the workpiece. Contrary to manual mode, a series of predefined programmes to suit all requirements are available. It should be noted, however, that certain parameters can be set manually. More information in this respect will be provided in later sections. A choice of Short-Arc (Fig. 1, LED 6 off) or Pulsed (Fig. 1, LED 6 on) synergic MIG welding is available. Press the Pulse button (Fig.1 – 12) lightly to switch mode. To select this mode, turn knob 7 (Fig.1) to one of

the SYNERGIC settings.

Proceed as follows for synergic MIG welding:

1. Select one of the following programmes

according to the type of material to be welded (Selector knob 7, Fig1)

• Al-Mg 0.8: The permissible thickness range is 0.8 to 4 mm.

• Al-Mg 5 1.0: The permissible thickness range is 0.9 mm to 5 mm.

• Al-Si 12 1.0: The permissibile thickness range is 0.8mm to 5 mm (Spool Gun welding is recommended for this type of wire).

• ideal for welding stainless steel (Ni-Cr)

0.8mm in diameter. The permissible thickness range is 0.8 mm to 5 mm.

• ideal for welding SG2 or SG3 materials

0.8mm in diameter. The permissible thickness range is 0.8 mm to 3.2 mm.

• Cu-Si 3 0.8: Ideal for Cu-Si3 having a diameter of 0.8 mm. Such materials can be braze welded, particularly zinc-plates iron sheets to be used by car manufacturers The permissible thickness range is 0.8 to 4 mm.

2. Select the workpiece thickness using Knob 2 of Figure 10. The display panel (Fig. 1 – 1) will display the selected thickness parameter (in mm) for a few seconds.

3. Turn knobs 8 and 9 to a mid-way position.

4. Connect the earth clamp to the workpiece.

5. Start to weld maintaining an arc length of

between 5 to 10 mm.

A high-quality result is usually achieved in this mode. However, the following instructions may help you achieve even better results depending upon whether Short-Arc or Pulsed mode is being used.

Short-Arc Mode: 6- If during welding the arc tends to decrease

excessively, turn knob 9 of Figure fig1 anti clockwise to reduce the wire speed, which will also decrease the weld pool. If, on the other hand, the arc tends to over-lengthen, turn the knob clockwise.

7. If there is too much splatter while welding, the electronic inductance parameter needs to be increased. Do so turning knob 8 of Figure 1 clockwise. If maintaining an arc is difficult, turn the knob anti-clockwise.

Pulsed mode:

8. To vary the length of the arc fine-tune

knob 9 of Figure 1.

14

8.3 MMA WELDING

8.3.1 Description

Electric MMA (Metal Manual Arc) and SMAW (Shielded Metal Arc Welding) are both manual procedures exploiting the heat generated by an electric arc that is produced when covered welding electrodes make contact with the workpiece. It is commonly used due to its versatility. In fact, welding jobs can be performed anywhere: in a workshop, in the open, in confined spaces or hard to reach areas. A wide range of electrodes are available, suiting all requirements. The arc is generated touching the electrode to the workpiece. The potentiometer knob (Fig. 1 –10) regulates the welding current (thicker workpieces require higher current settings).

8.3.2 MMA Welding Features

While welding the following features come into effect:

Arc Force: Whenever the arc tends to drop the microprocessor automatically increases the welding current in order to maintain and stabilise the arc.

Hot Start: The arc is generated touching the electrode to the workpiece. To ensure the arc is generated efficiently, the microprocessor increases the welding current for app. one second, guaranteeing fast, safe arc generation.

Antisticking: Decreases the welding current up to minimum, when the operator makes a mistake causing the electrode to stick to the workpiece. The electrode can be removed from its clamp without causing damaging sparks.

8.3.3 MMA Welding

Fig 8 Welding current at the electrode

diameter.

Proceed as follows for MMA welding:

1. Using knob 10 (Fig.1) select the welding

current according to the type of electrode and the thickness of the workpiece. The welding current value is shown on display panel 13. The knobs 8 and 9 (fig.1) are disabled. Guidance values suitable for various electrode diameters are provided in Fig 9.

2. Connect the earth clamp to the workpiece.

3. Place the electrode in the clamp.

4. During the entire welding process main-

tain a 3-4mm distance from the welding pool that has been created. Weld using small zigzag movements so as to be able to regulate the size of the weld as desired.

5. Remove the electrode from the workpiece to stop welding.

WARNING: When “Basic” electrodes are being used, remove any residue left on the electrode before welding. To do that, gently tap the electrode on a metallic surface. (If residue is left on an arc cannot be generated).

Diameter (mm)

Current (A)

1.6

35-50

2.0

40-70

2.5

60-100

3.25

80-140

4.0

120-170

5.0

180-250

15

9. WIRE LINER REPLACEMENT

In case of wire liner replacement please follow carefully this instructions.

10. DEFAULT PARAMETER ADJUSTMENT

The information contained in this paragraph is not essential for normal use of the welder and the operations described herein should, in fact, only be carried out by experienced welders. For instance, the default wire speed controlled by the synergic programmes (P.CV) can be adjusted, as can the measurement units (P.PU) used to specify the workpiece thickness. None of the other default parameters (P.PR e P.PO) should ever be adjusted. The default P.CV value is 140 but is adjustable within a range of 0 to 250. When the P.PU is set to 0, the units displayed are in mm. When it is set to 1, the units are expressed in inches.

To access the programming menu, press button 12 (Fig.1) for at least 8 seconds or until “P.CV” (wire speed setting) is displayed. To change the speed, press the same button again. The current value will be displayed. Button 13 (Fig.1) (Wire Load) increases the speed. Button 11 (Fig.1) (ON/OFF Spool) decreases the speed. Button 12 (Fig.1) (MIG Pulse) confirms the selection and the programme returns to the initial “P.CV” position.

To change settings controlling how the measurment units are expressed, press button 13 (Fig.1, Wire Load) until “P.PU” is displayed Buttons 13 and 11 alternate between mm and inches. Button 12 (Fig.1. MIG Pulse) confirms the selection and the programme returns to the initial “P.PU” position.

To exit the programming menu, scroll down the menu list using buttons 13 and 11 (Fig.1) until “End” is displayed. Press button 12 (Fig.1) to confirm.

• Gun side: remove the gas nozzle (A).

• Unscrew the wire liner tip (B).

• Connector side (C): unscrew the terminal

nut (D, E) and grab the end of wire liner

using a pliers and start to extract the wire

liner (F).

• Complete the liner substitution rescrewing

the covering nozzle (A).

Figure 9: wire liner replacement

• Complete the extraction of the wire liner (G)

• Insert the new liner and push up to end (H).

• Now rescrew the liner tip (B) on the gun.

C

D

E

F

A

B

G

H

16

11. TROUBLE SHOOTING

The most common problems and their solutions are listed below:

DEFECT CAUSE SOLUTION

Welder does not start. 1) Make sure that there is voltage in

the supply mains

1) Switch-on the supply mains

The wire does not feed when the wire-feeder roller rotates

1) Dirt on the tip of the wire-feeder 1) Blow with compressed air, replace nozzle

2) Excessive spool torque. 2) Loose

3) Faulty torch. 3) Check wire-feeder liner.

Jerky or intermittent wirefeed.

1) Faulty gas nozzle.

2) Replace

2) Scorched gas nozzle. 2) Replace

3) Dirt in wire-feeder roller groove. 3) Clean

4) Worn wire-feeder roller groove 2) Replace

Arc cut-out 1) Loose earth clamp grip. 1) Tighten clamp grip

2) Short circuit between contact nozzle and gas hose.

2) Clean or replace contact nozzle and wire-feed nozzle

Welder cuts out after prolonged use

1) Unit overheated and thermal protection device has set in

1) Leave the unit to cool down for at least 1-20 minutes.

Porous welds 1) Lack of shielding gas caused by

build-up in gas nozzle

1) Clean away build-up

2) Incorrect torch angle

2) The air gap between the torch and the workpiece must be 5-10 mm. Ensure 60° torch angle.

3) Gas shortage

3) Increase gas flow

4) Damp workpieces 4) Dry workpieces with hot-air gun or suchlike

5) Welding Arc too long 5) Shorten the arc

Hot cracks 1) Damp workpieces 1) Clean

2) Welding with very high heat supply 2) Decrease the welding current

3) Impure welding wire 3) Change the welding wire

4) Base material with high content of

carbon, sulphur and other imputities

Insufficient penetration

1) current too low 1) increase the current

2) Inconstant wire feeding 2) See the above paragraph

3) Edges too apart from each other

4) Bevel too small

Insufficient melting 1) Abrupt movements of the torch

1) Move the torch smoothly.

2) Non-optimized inductance value 2) Change the inductance value.

3) Oxidized workpieces 3) Clean

Lateral indentations 1) Excessive welding speed 1) Decrease the welding speed

Breakages 1) Unsuitable wire 1) Change the type of wire

2) Bad quality of the workpieces

Excessive splashes 1) current too high 1) Decrease the current value

2) Non-optimized inductance value

2) Increase the inductance value

3) torch too inclined 3) Straighten the torch

17

12. BLOCK DIAGRAM

1. Input Switch

2. Control and power card

3. Solenoid Valve

4. Wire-feeder motor

5. FAN

6. Display panel

7. Current sensor (installed on block 2)

......................................................................................

NOTE:

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NOTE:

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NOTE:

ESPAÑOL FRANÇAIS ENGLISH

ITALIANO

DEUTSCH

Per RAEE s’intendono i rifiuti di Apparecchiature Elettriche ed Elettroniche (AEE) incluse di tutti i componenti,i sottoinsiemi ed i materiali di consumo che sono parte integrante del prodotto nel momento in cui si assume la decisione di disfarsene. La Legislazione prevede la suddivisione in 2 categorie principali chiamate RAEE PROFESSIONALI o RAEE DOMESTICI.

Per RAEE PROFESSIONALI s’intendono tutti i rifiuti di apparecchiature elettriche ed elettroniche destinate ad uso prettamente industriale. Per RAEE DOMESTICO s’intendono tutti i generatori ad alimentazione monofase con corrente di uscita MAX <= 200A con i loro accessori.

Per lo smaltimento di un RAEE DOMESTICO si avranno 2 possibilita’: a)Nel caso si decidesse di comprare una nuova apparecchiatura equivalente l’utilizzatore potrà consegnarlo al distribu-

tore il quale dovrà ritirarlo gratuitamente. b)Dovrà depositarlo nella piazzola Comunale, nel contenitore o apposita area identificata come “RAGGRUPPAMENTO 4”. Per lo smaltimento di un RAEE PROFESSIONALE alla data di redazione del Manuale di istruzioni non essendo ancora definitiva l’applicazione della Normativa si prega di contattare il distributore e/o Il costruttore per informazioni in merito allo smaltimento.

ALLA DATA DELLA REDAZIONE DEL PRESENTE MANUALE D’ISTRUZIONI QUESTE INFORMAZIONI SONO DA RITENERSI NON DEFINITIVE IN QUANTO SUSCETTIBILI DI POSSIBILI MODIFICHE SECONDO GLI OBBLIGHI LEGATI AL DECRETO LEGISLATIVO N° 151/2005 CHE OTTEMPERA LA DIRETTIVA 2002/96/CE.

This product contains electrical or electronic materials.

The presence of these materials may, if not disposed of properly, have potential adverse affects on the environment. Presence of this label on the product means it must not be disposed of in normal household waste and must be disposed of separately.

As a consumer you are responsible for ensuring that this product is disposed of properly. If your supplier offers a disposal facility please use it or alternatively contact your local authority/council to find out how to properly dispose of this product.

Nur für EU-Länder

Werfen Sie Elektrogeräte nicht in den Hausmüll

Gemäß Europäischer Richtlinie 2002/96/EG über Elektro- und Elektronik-Altgeräte und Umsetzung in nationales Recht müssen verbrauchte Elektrowerkzeuge getrennt gesammelt und einer umweltgerechten Wiederverwertung zugeführt werden.

No tirar nuncalos aparatos eléctricos junto con los residuos en general!

De conformidad a la Directiva Europea 2002/96/EC relativa a los Residuos de Equipos Eléc- tricos o Electrònicos (RAEE) y al acuerdo de la legislaciòn nacional, los equipos eléctricos deberàn ser recogidos y reciclados respetando el medioambiente.

Como propietario del equipo, deberà informar de los sistemas y lugares apropiados para la reco- gida de los mismos.

Aplicar esta Directiva Europea protegerà el medioambiente y su salud!

Ne pas jeter les appareils électriques avec les déchets ordinaires!

Conformément à la Directive Européenne 2002/96/EC relative aux Déchets d’Équipements Électriques ou Électroniques (DEEE), et à sa transposition dans la législation nationale, les appareils électriques doivent être collectés à part et être soumis à un recyclage respectuex de l’environnement.

En tant que propriétaire de l’équipement, vous devriez vous informer sur les systèmes de collecte approuvés auprès nos représentants locaux.

Appliquer cette Directive Européenne améliorera l’environnement et la santé!

No tirar nuncalos aparatos eléctricos junto con los residuos en general!

De conformidad a la Directiva Europea 2002/96/EC relativa a los Residuos de Equipos Eléctricos o Electrònicos (RAEE) y al acuerdo de la legislaciòn nacional, los equipos eléctricos deberàn ser recogidos y reciclados respetando el medioambiente.

Como propietario del equipo, deberà informar de los sistemas y lugares apropiados para la recogida de los mismos.

Aplicar esta Directiva Europea protegerà el medioambiente y su salud!

Ne pas jeter les appareils électriques avec les déchets ordinaires!

Conformément à la Directive Européenne 2002/96/EC relative aux Déchets d’Équipements Électriques ou Électroniques (DEEE), et à sa transposition dans la législation nationale, les appareils électriques doivent être collectés à part et être soumis à un recyclage respectuex de l’environnement.

En tant que propriétaire de l’équipement, vous devriez vous informer sur les systèmes de collecte approuvés auprès nos représentants locaux.

Appliquer cette Directive Européenne améliorera l’environnement et la santé!

Fimer TM 215 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual