Fimer TM230, TM260, TM320W, TM360W, TM420W Instruction Manual

TM 230 - TM 260 - TM 300 - TM 350 - TM 320W TM 360W - TM 420W - TM 500W - TM 650W

Instruction Manual

Istruzioni Originali Original instructions Übersetzung der Originalbetriebsanleitung Notice originale Manual original Подлинный инструкций

2

0

5

0 RONCO BRIANTINO (MI) Italy

V

ia Bri

gatti, 59

Tel. +3

9 03

9 6

0

79

3

26

- Fax. +39 039 6079334

www.fimer.com - info@fimer.com

TM 230 -TM 260 - TM 300 - TM 350 - TM 320W TM 360W - TM 420W - TM 500W - TM 650W

2006/42/CE 2006/95/CE 2004/108/CE 2002/95/CE

(RoHS)

1

2

3

4

14

7

5

15

6

16

17 18

19

108 12 139 11

NOMINAL DATA

WEIGHT: DIMENSIONS: STATIC CHARACTERISTIC: POWER SUPPLY PROTECTION:

INPUT LOAD: THERMAL PROTECTION: INTERVENTION TEMPERATURE: Overheating tests run at 40°C WIRE DIAMETER:

OTHER TECHNICAL CHARACTERISTICS

1. NAME, ADDRESS AND LOGO OF THE PRODUCER

2. MODEL

3. SERIAL NUMBER

4. BLOCKS SCHEME

5. WELDING OUTPUT

6. SUITABLE FOR USE IN HIGH-VOLTAGE AREAS

7. INPUT VOLTAGE

8. PROTECTION CLASS

9. TYPE OF WELDING OUTPUT CURRENT

10. INPUT VOLTAGE

11. NOMINAL INPUT TENSION

12. MAXIMUM NOMINAL INPUT CURRENT

13. MAXIMUM ACTUAL INPUT CURRENT

14. PRODUCT STANDARDS

15. RANGE OF WELDING VOLTAGE-CURRENT

16. DUTY CYCLE

17. NOMINAL WELDING CURRENT

18. CONVENTIONAL LOAD TENSION

19. YEAR OF MANUFACTURE

4

61 Kg.

330x900x820

constant

400V +/- 10%

thermostat bimetallic

16A Delay-Fuses Two-Pole 16A k- or C- Standard Switch

0,6 - 0,8 - 1,0 mm

TTMM 22330

0

Serial Numbe r :

6S4.230.152

Code :

Description :

Serial Number :

091079944

Fimer SpA

Via Brigatti, 59

20050 Ronco Briantino (MI)

Serial Number :

091079944

EN.60974-1

EN.60974-10

Model :

TM 230

V0=38V

da 25A / 15,25V a 220A / 25V X I

2

U

2

35%

220A

25V

60%

160A

22V

100% 115A

19,75V

MADE IN ITAL Y

3 - 50/60 Hz

V

1

=400V

I

1max

=12,1A

I

1ass

=7,2A

IP 21S 2009

1

2

3

4

14

7

5

15

6

16

17 18

19

108 12 139 11

NOMINAL DATA

WEIGHT: DIMENSIONS: STATIC CHARACTERISTIC: POWER SUPPLY PROTECTION:

INPUT LOAD: THERMAL PROTECTION: INTERVENTION TEMPERATURE: Overheating tests run at 40°C WIRE DIAMETER:

OTHER TECHNICAL CHARACTERISTICS

1. NAME, ADDRESS AND LOGO OF THE PRODUCER

2. MODEL

3. SERIAL NUMBER

4. BLOCKS SCHEME

5. WELDING OUTPUT

6. SUITABLE FOR USE IN HIGH-VOLTAGE AREAS

7. INPUT VOLTAGE

8. PROTECTION CLASS

9. TYPE OF WELDING OUTPUT CURRENT

10. INPUT VOLTAGE

11. NOMINAL INPUT TENSION

12. MAXIMUM NOMINAL INPUT CURRENT

13. MAXIMUM ACTUAL INPUT CURRENT

14. PRODUCT STANDARDS

15. RANGE OF WELDING VOLTAGE-CURRENT

16. DUTY CYCLE

17. NOMINAL WELDING CURRENT

18. CONVENTIONAL LOAD TENSION

19. YEAR OF MANUFACTURE

Serial Number :

6S4.260.152

Code :

Description :

Serial Number :

091079944

Fimer SpA

Via Brigatti, 59

20050 Ronco Briantino (MI)

Serial Number :

091079944

EN.60974-1

EN.60974-10

Model :

TM 260

V0=38V

da 25A / 15,25V a 250A / 26,5V X I

2

U

2

35%

250A

26,5V

60%

190A

23,5V

100% 130A 20,5V

MADE IN ITAL Y

3 - 50/60 Hz

V

1

=400V

I

1

max

=14,8A

I

1

ass

=8,7A

IP 21S 2009

TTMM 22660

0

5

67 Kg.

330x900x820

constant

400V +/- 10%

thermostat bimetallic

16A Delay-Fuses Two-Pole 16A k- or C- Standard Switch

0,6 - 0,8 - 1,0 mm

1

2

3

4

14

7

5

15

6

16

17 18

19

108 12 139 11

NOMINAL DATA

WEIGHT: DIMENSIONS: STATIC CHARACTERISTIC: POWER SUPPLY PROTECTION:

INPUT LOAD: THERMAL PROTECTION: INTERVENTION TEMPERATURE: Overheating tests run at 40°C WIRE DIAMETER:

OTHER TECHNICAL CHARACTERISTICS

1. NAME, ADDRESS AND LOGO OF THE PRODUCER

2. MODEL

3. SERIAL NUMBER

4. BLOCKS SCHEME

5. WELDING OUTPUT

6. SUITABLE FOR USE IN HIGH-VOLTAGE AREAS

7. INPUT VOLTAGE

8. PROTECTION CLASS

9. TYPE OF WELDING OUTPUT CURRENT

10. INPUT VOLTAGE

11. NOMINAL INPUT TENSION

12. MAXIMUM NOMINAL INPUT CURRENT

13. MAXIMUM ACTUAL INPUT CURRENT

14. PRODUCT STANDARDS

15. RANGE OF WELDING VOLTAGE-CURRENT

16. DUTY CYCLE

17. NOMINAL WELDING CURRENT

18. CONVENTIONAL LOAD TENSION

19. YEAR OF MANUFACTURE

6

Serial Numbe r :

6S4.300.152

Code :

Description :

Serial Number :

091079944

Fimer SpA

Via Brigatti, 59

20050 Ronco Briantino (MI)

Serial Number :

091079944

EN.60974-1

EN.60974-10

Model :

TM 300

V0=55V

da 30A / 15,25V a 300A / 29V X I

2

U

2

35%

300A

29V

60% 250A 26,5V

100% 170A

22,5V

MADE IN ITAL Y

3 - 50/60 Hz

V

1

=400V

I

1max

=19,4A

I

1ass

=8,5A

IP 21S 2009

100 Kg.

520x1070x850

400V +/- 10%

0,6 - 0,8 - 1,0 - 1,2 mm

TTMM 33000

0

constant

thermostat bimetallic

16A Delay-Fuses Two-Pole 16A k- or C- Standard Switch

1

2

3

4

14

7

5

15

6

16

17 18

19

108 12 139 11

NOMINAL DATA

WEIGHT: DIMENSIONS: STATIC CHARACTERISTIC: POWER SUPPLY PROTECTION:

INPUT LOAD: THERMAL PROTECTION: INTERVENTION TEMPERATURE: Overheating tests run at 40°C WIRE DIAMETER:

OTHER TECHNICAL CHARACTERISTICS

1. NAME, ADDRESS AND LOGO OF THE PRODUCER

2. MODEL

3. SERIAL NUMBER

4. BLOCKS SCHEME

5. WELDING OUTPUT

6. SUITABLE FOR USE IN HIGH-VOLTAGE AREAS

7. INPUT VOLTAGE

8. PROTECTION CLASS

9. TYPE OF WELDING OUTPUT CURRENT

10. INPUT VOLTAGE

11. NOMINAL INPUT TENSION

12. MAXIMUM NOMINAL INPUT CURRENT

13. MAXIMUM ACTUAL INPUT CURRENT

14. PRODUCT STANDARDS

15. RANGE OF WELDING VOLTAGE-CURRENT

16. DUTY CYCLE

17. NOMINAL WELDING CURRENT

18. CONVENTIONAL LOAD TENSION

19. YEAR OF MANUFACTURE

Serial Number :

6S4.350.152

Code :

Description :

Serial Number :

091079944

Fimer SpA

Via Brigatti, 59

20050 Ronco Briantino (MI)

Serial Number :

091079944

EN.60974-1

EN.60974-10

Model :

TM 350

V0=55V

da 30A / 15,5V a 330A / 30,5V X I

2

U

2

35%

330A

30,5V

60%

300A

29V

100% 210A 24,5V

MADE IN ITAL Y

3 - 50/60 Hz

V

1

=400V

I

1max

=22,4A

I

1ass

=14,9A

IP 21S 2009

TTMM 33550

0

7

110 Kg.

520x1070x850

400V +/- 10%

0,6 - 0,8 - 1,0 - 1,2 mm

constant

thermostat bimetallic

20A Delay-Fuses Two-Pole 20A k- or C- Standard Switch

1

2

3

4

14

7

5

15

6

16

17 18

19

108 12 139 11

NOMINAL DATA

WEIGHT: DIMENSIONS: STATIC CHARACTERISTIC: POWER SUPPLY PROTECTION:

INPUT LOAD: THERMAL PROTECTION: INTERVENTION TEMPERATURE: Overheating tests run at 40°C WIRE DIAMETER:

OTHER TECHNICAL CHARACTERISTICS

1. NAME, ADDRESS AND LOGO OF THE PRODUCER

2. MODEL

3. SERIAL NUMBER

4. BLOCKS SCHEME

5. WELDING OUTPUT

6. SUITABLE FOR USE IN HIGH-VOLTAGE AREAS

7. INPUT VOLTAGE

8. PROTECTION CLASS

9. TYPE OF WELDING OUTPUT CURRENT

10. INPUT VOLTAGE

11. NOMINAL INPUT TENSION

12. MAXIMUM NOMINAL INPUT CURRENT

13. MAXIMUM ACTUAL INPUT CURRENT

14. PRODUCT STANDARDS

15. RANGE OF WELDING VOLTAGE-CURRENT

16. DUTY CYCLE

17. NOMINAL WELDING CURRENT

18. CONVENTIONAL LOAD TENSION

19. YEAR OF MANUFACTURE

8

Serial Numbe r :

6S4.321.152

Code :

Description :

Serial Number :

091079944

Fimer SpA

Via Brigatti, 59

20050 Ronco Briantino (MI)

Serial Number :

091079944

EN.60974-1

EN.60974-10

Model :

TM 320 W

V0=55V

da 30A / 15,5V a 300A / 29V X I

2

U

2

35%

300A

29V

60%

260A

27V

100% 185A

23,25V

MADE IN ITAL Y

3 - 50/60 Hz

V

1

=400V

I

1max

=18,9A

I

1ass

=11,8A

IP 21S 2009

125 Kg.

520x1070x1400

400V +/- 10%

0,6 - 0,8 - 1,0 - 1,2 mm

TTMM 332200W

W

constant

thermostat bimetallic

16A Delay-Fuses Two-Pole 16A k- or C- Standard Switch

1

2

3

4

14

7

5

15

6

16

17 18

19

108 12 139 11

NOMINAL DATA

WEIGHT: DIMENSIONS: STATIC CHARACTERISTIC: POWER SUPPLY PROTECTION:

INPUT LOAD: THERMAL PROTECTION: INTERVENTION TEMPERATURE: Overheating tests run at 40°C WIRE DIAMETER:

OTHER TECHNICAL CHARACTERISTICS

1. NAME, ADDRESS AND LOGO OF THE PRODUCER

2. MODEL

3. SERIAL NUMBER

4. BLOCKS SCHEME

5. WELDING OUTPUT

6. SUITABLE FOR USE IN HIGH-VOLTAGE AREAS

7. INPUT VOLTAGE

8. PROTECTION CLASS

9. TYPE OF WELDING OUTPUT CURRENT

10. INPUT VOLTAGE

11. NOMINAL INPUT TENSION

12. MAXIMUM NOMINAL INPUT CURRENT

13. MAXIMUM ACTUAL INPUT CURRENT

14. PRODUCT STANDARDS

15. RANGE OF WELDING VOLTAGE-CURRENT

16. DUTY CYCLE

17. NOMINAL WELDING CURRENT

18. CONVENTIONAL LOAD TENSION

19. YEAR OF MANUFACTURE

Serial Number :

6S4.361.152

Code :

Description :

Serial Number :

091079953

Fimer SpA

Via Brigatti, 59

20050 Ronco Briantino (MI)

Serial Number :

091079953

EN.60974-1

EN.60974-10

Model :

TM 360 W

V0=55V

da 30A / 15,5V a 330A / 30,5V X I

2

U

2

35%

330A

30,5V

60%

300A

29V

100% 210A 24,5V

MADE IN ITAL Y

3 - 50/60 Hz

V

1

=400V

I

1max

=22,4A

I

1ass

=14,9A

IP 21S 2009

TTMM 336600W

W

9

138 Kg.

520x1070x1400

costante

400V +/- 10%

termostato bimetallico

Fusibili 20A Ritardati Int. Bipolari: 20A Curva K o C

0,6 - 0,8 - 1,0 - 1,2 mm

1

2

3

4

14

7

5

15

6

16

17 18

19

108 12 139 11

NOMINAL DATA

WEIGHT: DIMENSIONS: STATIC CHARACTERISTIC: POWER SUPPLY PROTECTION:

INPUT LOAD: THERMAL PROTECTION: INTERVENTION TEMPERATURE: Overheating tests run at 40°C WIRE DIAMETER:

OTHER TECHNICAL CHARACTERISTICS

1. NAME, ADDRESS AND LOGO OF THE PRODUCER

2. MODEL

3. SERIAL NUMBER

4. BLOCKS SCHEME

5. WELDING OUTPUT

6. SUITABLE FOR USE IN HIGH-VOLTAGE AREAS

7. INPUT VOLTAGE

8. PROTECTION CLASS

9. TYPE OF WELDING OUTPUT CURRENT

10. INPUT VOLTAGE

11. NOMINAL INPUT TENSION

12. MAXIMUM NOMINAL INPUT CURRENT

13. MAXIMUM ACTUAL INPUT CURRENT

14. PRODUCT STANDARDS

15. RANGE OF WELDING VOLTAGE-CURRENT

16. DUTY CYCLE

17. NOMINAL WELDING CURRENT

18. CONVENTIONAL LOAD TENSION

19. YEAR OF MANUFACTURE

10

Serial Numbe r :

6S4.421.152

Code :

Description :

Serial Number :

091079953

Fimer SpA

Via Brigatti, 59

20050 Ronco Briantino (MI)

Serial Number :

091079953

EN.60974-1

EN.60974-10

Model :

TM 420 W

V0=55V

da 35A / 15,75V a 400A / 34V X I

2

U

2

35%

400A

34V

60%

360A

32V

100% 300A

29V

MADE IN ITAL Y

3 - 50/60 Hz

V

1

=400V

I

1max

=29,9A

I

1ass

=19,6A

IP 21S 2009

156 Kg.

520x1070x1400

400V +/- 10%

0,8 - 1,0 - 1,2 - 1,6 mm

TTMM 442200W

W

constant

thermostat bimetallic

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

1

2

3

4

14

7

5

15

6

16

17 18

19

108 12 139 11

NOMINAL DATA

WEIGHT: DIMENSIONS: STATIC CHARACTERISTIC: POWER SUPPLY PROTECTION:

INPUT LOAD: THERMAL PROTECTION: INTERVENTION TEMPERATURE: Overheating tests run at 40°C WIRE DIAMETER:

OTHER TECHNICAL CHARACTERISTICS

1. NAME, ADDRESS AND LOGO OF THE PRODUCER

2. MODEL

3. SERIAL NUMBER

4. BLOCKS SCHEME

5. WELDING OUTPUT

6. SUITABLE FOR USE IN HIGH-VOLTAGE AREAS

7. INPUT VOLTAGE

8. PROTECTION CLASS

9. TYPE OF WELDING OUTPUT CURRENT

10. INPUT VOLTAGE

11. NOMINAL INPUT TENSION

12. MAXIMUM NOMINAL INPUT CURRENT

13. MAXIMUM ACTUAL INPUT CURRENT

14. PRODUCT STANDARDS

15. RANGE OF WELDING VOLTAGE-CURRENT

16. DUTY CYCLE

17. NOMINAL WELDING CURRENT

18. CONVENTIONAL LOAD TENSION

19. YEAR OF MANUFACTURE

Serial Number :

6S4.501.152

Code :

Description :

Serial Number :

091079953

Fimer SpA

Via Brigatti, 59

20050 Ronco Briantino (MI)

Serial Number :

091079953

EN.60974-1

EN.60974-10

Model :

TM 500 W

V0=55V

da 35A / 15,75V a 500A / 39V X I

2

U

2

35%

500A

39V

60%

430A

35,5V

100% 320A

30V

MADE IN ITAL Y

3 - 50/60 Hz

V

1

=400V

I

1max

=42,5A

I

1ass

=25,8A

IP 21S 2009

TTMM 550000W

W

11

215 Kg.

520x1070x1400

400V +/- 10%

0,8 - 1,0 - 1,2 - 1,6 mm

constant

thermostat bimetallic

32A Delay-Fuses Two-Pole 32A k- or C- Standard Switch

1

2

3

4

14

7

5

15

6

16

17 18

19

108 12 139 11

NOMINAL DATA

WEIGHT: DIMENSIONS: STATIC CHARACTERISTIC: POWER SUPPLY PROTECTION:

INPUT LOAD: THERMAL PROTECTION: INTERVENTION TEMPERATURE: Overheating tests run at 40°C WIRE DIAMETER:

OTHER TECHNICAL CHARACTERISTICS

1. NAME, ADDRESS AND LOGO OF THE PRODUCER

2. MODEL

3. SERIAL NUMBER

4. BLOCKS SCHEME

5. WELDING OUTPUT

6. SUITABLE FOR USE IN HIGH-VOLTAGE AREAS

7. INPUT VOLTAGE

8. PROTECTION CLASS

9. TYPE OF WELDING OUTPUT CURRENT

10. INPUT VOLTAGE

11. NOMINAL INPUT TENSION

12. MAXIMUM NOMINAL INPUT CURRENT

13. MAXIMUM ACTUAL INPUT CURRENT

14. PRODUCT STANDARDS

15. RANGE OF WELDING VOLTAGE-CURRENT

16. DUTY CYCLE

17. NOMINAL WELDING CURRENT

18. CONVENTIONAL LOAD TENSION

19. YEAR OF MANUFACTURE

12

Serial Numbe r :

6S4.651.152

Code :

Description :

Serial Number :

091079953

Fimer SpA

Via Brigatti, 59

20050 Ronco Briantino (MI)

Serial Number :

091079953

EN.60974-1

EN.60974-10

Model :

TM 650 W

V0=63V

da 35A / 15,75V a 600A / 44V X I

2

U

2

35%

600A

44V

60%

500A

39V

100% 380A

33V

MADE IN ITAL Y

3 - 50/60 Hz

V

1

=400V

I

1max

=58A

I

1ass

=34,3A

IP 21S 2009

230 Kg.

520x1070x1400

400V +/- 10%

0,8 - 1,0 - 1,2 - 1,6 - 2,0 mm

TTMM 665500W

W

constant

thermostat bimetallic

40A Delay-Fuses Two-Pole 40A k- or C- Standard Switch

ITALIANO

USE AND MAINTENANCE MANUAL

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.

INDEX

• WARNING SYMBOLS .................................................................................................

...................................................................................................... pag. 14, 15, 16

1. MIG WELDING ...................................................................................... pag .17

2. POWER SUPPLY CONNECTION ......................................................... pa g.1 7

3. OUTPUT CONNECTIONS .................................................................... pag. 17

4. UNIT DESCRIPTION ............................................................................ pag .18

5. INSTALLATION OF THE WELDING WIRE .......................................... pag.2 1

6. CONNECTION BETWEEN THE SEPARATE TROLLEY AND BASE ............ pag.22

7. CONNECTION OF THE GAS CYLINDER AND REGULATOR. ..................... pag.23

8. MIG TORCH .......................................................................................... pag .23

9. PREPARING FOR THE WELDING ....................................................... pag.23

10. WELDING PROCESS ......................................................................... pag.24

11. HOW TO OBTAIN THE BEST WELDING RESULTS ......................... pag.2 4

12. REGULATING THE WELDING MACHINE ......................................... pag.2 4

13. TROUBLESHOOTING ........................................................................ pag.25

14. WIRE LINER REPLACEMENT ........................................................... pag. 26

15. INSTALLATION INSTRUCTIONS FOR

INDOOR WATER COOLING SYTEM ...................................................... pag. 27

16. SPARE PARTS ................................................................................... pag. 32

17. BLOCK DIAGRAM TM 230 - TM 260 ............................................... pag. 33

18. BLOCK DIAGRAM TM 300 .............................................................. pag. 34

19. BLOCK DIAGRAM TM 350 - TM 320W - TM 360W .......................... pag. 35

20. BLOCK DIAGRAM TM 420W - TM 500W - TM 650W ...................... pag. 36

ENGLISH

DEUTSCHFRANÇAIS

ESPAÑOLРУССКИЙ

13

WARNING SYMBOLS

CAUTION

D

ANGER

(Indicating a hazard that could cause injury or damage)

DANGER O

F FIRE OR EXPLOSION.

Indicating that eye protection is required to avoid b

urns and eye damage.

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

E

LECTRIC SHOCK

(Indicating the danger of electric shock)

DANGER COMPRESSED GAS

Indicating the risk of injury or death in the event of improper handl

ing or maintenance of compressed gas cylinders or regulators

IMPORTANT INFORMATION

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

D

ISPOSAL

INFORMATION

FIRE PRECAUTIONS

SAFETY WARNINGS

This equipment is designed solely for industrial or 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 kill 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.

INSTALLATION INSTRUCTIONS

OPERATING INSTRUCTIONS

UNPACKING INSTRUCTIONS

14

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

U

se 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 cons

equence of such action.

C

AUTION !

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

t

o 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, pocketless 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.

O

VERLOAD PROTECTION

Check that the power source supplying the Welder carries the correct voltage and is safety-protected. The power switch must open all the p

ower 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 p

oles 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 a

nything 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.

E

ARTHING

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 approp

riate for the wall-socket you intend using. Never tamper with

t

he power cable.

RELOCATION 1

Some Welders are extremely heavy therefore care should be t

aken 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

15

CLEAN ENVIRONMENT

Remove all flammable materials away from

the work environment.

S

ERIOUS DANGER ! 1

NEVER weld in confined spaces (e.g. in a con-

t

ainer 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) t

oxic, 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

W

ALL 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.

E

XTINGUISHER

Place an approved and appropriately-sized fire extinguisher in the work environment.

C

heck its working order regularly (carry out scheduled inspections)

and ensure that all parties involved know how to use one.

D

AMAGED 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.

16

17

ITALIANO

1. MIG WELDING

In MIG welding, a metal electrode consisting of a wire is melted in a weld pool. The wire electrode is continuously fed by a welding torch at a constant and controlled speed. The torch is connected to the positive pole, while the ground cable is connected to the negative pole. When the wire is fed and touches the workpiece, an electric arc is produced. The arc melts the wire which is then deposited on the workpiece. MIG welding uses a special metallic wire as an electrode and an inert gas (CO2, CO2/Argon mix or pure Argon) to protect the weld pool. Welding with continuous feeding of the wire allows using a higher current density than that used in welding with coated electrodes. This allows increasing the weld penetration and reducing the number of passes required to fill the joint.

The welding unit consists of a DC power source, a wire feeder, a torch and a ground clamp. Each welder has two switches (13 and 14 of Fig. 1) used to regulate the welding current (the TM 230 and TM 260 models only have Switch 13 for this purpose) and two potentiometers (1 and 9 of Fig. 1) to respectively regulate the welding time and wire speed. The welding current and wire speed must be regulated taking into consideration the thickness of the workpiece to be welded. Thicker pieces require a higher welding current and higher wire speed. The wire speed can be adjusted during welding to obtain better results.

IMPORTANT: The welding machine must only be used by trained personnel.

All the TM welding machines are wire welders produced with advanced technology that makes them extremely reliable. In fact, minimal maintenance is required to

ensure long life of the equipment without any problems.

The user-friendliness of the welding machine allows for rapid interchangeability of operators.

For an excellent welding performance, it is recommended to use a welding spray. This will increase the sealing capacity and reduce weld spatter.

2. POWER SUPPLY CONNECTION

Before connecting the machine, check the voltage, number of phases and power frequency. The admissible power supply voltage is reported in the “Technical Specifications” section of this manual and in the machine’s rating label. Make sure there is sufficient power to run the machine. The “Technical Specifications” section of this manual contains information on the type of line protection devices to use. The machine comes with a specific power cord which should not be extended. If an extension cord is necessary, use one that has the same or a larger cross section than the machine’s cord depending on the length of the cord.

3. OUTPUT CONNECTIONS

The welding cables are connected with a quick coupling system that uses special connectors. The ground cable must first be connected to its connector (15 or 16 of Fig.1) and then the torch cable (19 di Fig. 1). This connector also allows connecting the electrical contacts of the torch and the hose that carries the welding gas to the torch. Refer to the following sections for more information on the connections to be carried out before proceeding with the welding.

ESPAÑOL

FRANÇAIS DEUTSCH

ENGLISH

РУССКИЙ

19

12

13

14

18 17

16

19

18

17

15b

15a

20

12

13

14

20

TM 320W - TM 360W

TM 420W TM 500W TM 650W

9

19

18 17

14

13

10

1

11

8

6

7

2

5

TM 3 50

TM 3 00

1

9

6

8

7

11 10

15b

15a

14

15c

20

Fig. 1: FRONT VIEW

4. UNIT DESCRIPTION

TM 230 - TM 260

8 9

1

11

TM 320W - TM 360W - TM 420W - TM 500W - TM 650W

10,12

13

19

16

3

4

20

15b

15a

7

12

18

19

ITALIANO

FIGURE 1

1. TIMER SPOT: Sets the maximum welding

time from 0 to 20 seconds (if the torch button is kept pressed for a longer period, the welding duration is automatically interrupted)

2. DISPLAY FOR VISUALISING the value of the welding current or voltage: Press button 3

to switch-over between the current and voltage value.

3. VOLTAGE/CURRENT SWITCH: see point 2

4. WIRE FEED BUTTON: Allows the welding

wire to be fed without pressing the torch button.

5. 4T LED: this light turns on when the machine is operating in 4T mode.

6. 2T/4T OPERATING MODE SELECTOR:

When the 2T (two-stroke) mode is selected, press the torch button to start the welding process and wire feed. When the 4T (4-stroke) mode is selected, press the torch button to start the welding process and wire feed, and press this button again to stop the welding process.

7. BURN BACK: Accurately adjusts the time during which the current is maintained in the welding circuit after the torch button has been released (this allows safely separating the electrode from the workpiece). This adjustment must be made using a screwdriver, preferably in plastic (turn in a clockwise direction to increase the time).

8. SOFT START: Sets the departure ramp of the wire speed: use a screwdriver (preferably in plastic) to set the time of the ramp (turn in a clockwise direction to increase the time).

9. WIRE SPEED CONTROL: Regulates the outgoing speed of the wire by controlling the motor speed.

10. MACHINE IN OPERATION INDICATING LIGHT

11. THERMAL PROTECTION INDICATING LIGHT: Turns on when the machine is overheat-

ing and the exit is interrupted. This usually occurs if the intermittence factor of the machine is exceeded. Make sure the air grills positioned on the back and front of the machine are not obstructed and leave the machine running to allow the internal components to cool down; normal welding operations can be resumed when this LED turns off. If the welding machine is equipped with a cooling unit, the LED may also turn on if the cooling liquid does not circulate correctly (see paragraph 14).

12. ON-OFF SWITCH: Turns the machine on a

nd off

13. WELDING LEVEL SWITCH: Allows selecting the welding current according to the thickness of the material to be welded.

14. SWITCH FOR CHANGING THE WELDING CURRENT RANGES: TM 230, 260: not present TM 300, 350, 320W, 360W:

- in the MIN position, turn switch 13 to move the welding current from the minimum value to the value halfway between the minimum and maximum values.

- in the MAX position, turn switch 13 to move the welding current from the halfway value to the maximum value. The combination of the 10 positions of switch 13 and 2 positions of switch 14 allows selecting from 20 possible welding currents.

TM 420W, 550W, 650W:

- in the MIN position, turn switch 13 to move the welding current from the minimum value to onethird of the maximum value.

- in the MED position, turn switch 13 to move the welding current from one-third of the maximum value to two-thirds of the maximum value.

- in the MAX position, turn switch 13 to move the welding current from two-thirds of the maximum value to the maximum value. The combination of the 10 positions of switch 13 and the 3 positions of switch 14 allows selecting from 30 possible welding currents. 15a. GROUND CONNECTOR: The minimum inductance value is inserted when the negative welding cable is connected to this connector. Only use this connector (which guarantees the best performances) during spray-arc welding (see paragraph 10). 15b. GROUND CONNECTOR: A higher inductance value is inserted when the negative welding cable is connected to this connector. Only use this connector when the machine is operating in short-arc mode (see par. 10).

15c. GROUND CONNECTOR (only for TM 420W, 500W, 650W): The highest inductance

value is inserted when the negative welding cable is connected to this connector. Only use this connector when the machine is operating in short-arc mode (see par.10).

16. GROUND CONNECTOR: Allows connecting the negative cable to the workpiece (TM230,

TM260 and TM300).

РУССКИЙ

ESPAÑOL

FRANÇAIS DEUTSCH

ENGLISH

21

23 24

Fig.2A

28

27

29

26

TM 230 - TM 260

23

24

22

33, 34

25

21

F

ig.2A

28

27

29

26

TM 300- TM 350

Fig.2A

28

27

29

26

20

TM 320W TM 360W - TM 420W TM 500W - TM 650W

17. H²O out: Only to be used with the “liquid

cooling” option

18. H²O in: Only to be used with the “liquid cooling” option

19. TORCH QUICK CONNECTOR: Output connection (positive) for the welding circuit, electrical contacts and torch gas.

FIGURE 2

20. AIR INLET

21. GAS PIPE CONNECTOR: to be connected

to the pressure reducer of the cylinder

22. INPUT CABLE: connect this cable to the mains power supply.

23. WIRE SPOOL

24. WIRE FEED UNIT: for more details refer to Figure 2A.

25. SUPPORT FOR WELDING GAS CYLINDER.

26. WIRE ENTRANCE OF THE WIRE-FEED MOTOR

27. WIRE PRESSURE REGULATOR: Allows

regulating the tension of the welding wire

28. WIRE-FEED MOTOR

29. WIRE-FEED ROLLERS

30. ELECTRICAL CONNECTOR FOR THE SIGNALS (cable bundle) (separate trolley)

Fig. 2: SIDE VIEW

22

20 25

30

23 24

31 32

33, 34

22

21

35 36

20

37, 38

25

20

21

ITALIANO

31. POWER ELECTRICAL CONNECTOR

(cable bundle) (separate trolley)

32. GASE TUBE CONNECTION (cable bundle) (separate trolley) (Black)

33. CONNECTION FOR LIQUID COOLING

(separate trolley) (Red)

34. CONNECTION FOR LIQUID COOLING

(separate trolley) (Blue)

35. ELECTRICAL CONNECTOR FOR THE SIGNALS (cable bundle) (Base)

36. ELECTRICAL CONNECTOR FOR THE POWER (cable bundle) (Base)

37. CONNECTION FOR LIQUID COOLING

(Base) (Blue)

38. CONNECTION FOR LIQUID COOLING

(Base) (Red)

5. INSTALLATION OF THE WELDING WIRE

Follow the instructions below to install the welding wire (refer to Figure 2A).

Attention: before installing the welding wire, always remove the gas nozzle (Fig. 3A) and wire-guide tip (Fig. 3B) from the welding torch.

1. Disconnect the power cord from the mains outlet (22 of Fig. 2 and 4C).

2. Unscrew the knurled knob positioned in the

middle of the welding wire spool (23 of Fig. 2) and, if necessary, remove the used spool.

3. Remove the plastic wrapper from the new spool and place the spool on the special spool holder (23 of Fig. 2). Reassemble the knurled knob. The allen screw (M8) positioned underneath the knurled knob forms the braking system of the wire spool. Tighten the allen screw in order to obtain the best braking result. Too much pressure may cause excessive braking which in turn may block the wire-feed motor. Too little pressure may not allow the wire spool to immediately stop at the end of the welding.

4. TM 230, TM 260: Unscrew the knob of the wire-feed unit (27 of Fig.2A) and lift the upper feed roll (29 of Fig. 2A). TM 300, TM 350: Unscrew the knob of the wirefeed unit (27 of Fig.2A) and turn outwards. This will lift the upper feed rolls (29 of Fig. 2A).

TM 360W, TM 420W, TM 500W, TM 650W:

Unscrew the knobs of the wire-feed unit and turn. This will lift the upper feed roll (29 of Fig. 2A) Remove any wire left over from the previous welding.

5. Insert the wire into the little in-feed tube (26 di Fig. 2A) of the wire-feed motor and let it slide

under the wire-feed rolls.

6. Lower the upper rolls(29 of Fig. 2A) and tight- en the plastic knob (27 of Fig. 2A) of the wire pressure regulator. Tighten slightly. If tightened too much, the wire

Fig.3A

Fig.3B

GA S NOZZL E

WIRE-FEEDER GUIDE

Fig.3

TORCH CABLE

ENGLISHESPAÑOL

РУССКИЙ FRANÇAIS

DEUTSCH

may get blocked which could cause motor damage. If not tightened enough, the rolls may not be able to feed the wire. For the TM 360W, TM 420W, TM 500W, TM 650W machines, repeat this operation for the second knurled knob.

N.B. When changing the diameter of the wire, make sure the correct groove of the wire-feed roll is facing towards the inside of the machine. To do this, check that the value corresponding to the wire diameter and wire type being used is legible (facing towards the outside of the machine). Remember that the rolls with a “V-shaped” slot are suitable for feeding iron or steel wires. Rolls with a “U-shaped” slot are suitable for aluminium wires.

Attention: Before proceeding with the next steps, make sure the torch cable (Fig. 3) is tight and that no angles or burrs are present on the welding wire. Please follow these precautions to ensure the correct operation of the wire guide.

6. CONNECTION BETWEEN THE SEPARATE TROLLEY AND BASE

Before carrying out the operations described in the following paragraphs, connect the separable trolley and the machine base for the TM

360W - TM 420W - TM 500W -TM 650W

machines.

N.B. The red and blue tubes (33 and 34 of Fig 4A) are only supplied with some machines.

1. Find the connection side as shown in Figure 4B.

2. Connect the power electrical connector (36 of Fig 4B) to the appropriate coupler (36 of Fig 4C).

3. Connect the signal connector (35 of Fig 4B) to the appropriate coupler (35 of Fig 4C).

Wiew Feeder

Base

32 (black)

34 (blue)

33 (red)

38 (red)

37 (blue)

35 36

gas

30

31

Fig. 4C

Fig. 4A

Fig. 4B

36

38

37

35

22

21

30 31

34 33

32

22

23

ITALIANO

4. Connect(if present) the quick connector (38 of Fig 4B) of the red tube to the quick coupler (38 of Fig 4C).

5. Connect(if present) the quick connector (37 of Fig 4B) of the blue tube to the quick coupler (37 of fig 4C).

6. Connect the gas hose (Fig 4B) to the cylinder (Fig 5) by carefully following the instructions out- lined in Paragraph 7.

7. Take hold of the other end of the cable bundle (Fig 4A).

8. Connect the power electrical connector (31 of Fig 4A) to the appropriate coupler (31 of Fig 4C).

9. Connect the signal connector (30 of fig 4A) to the appropriate coupler (30 of Fig 4c).

10. Connect the quick connector of the black gas hose (32 of Fig 4A) to the appropriate coupler (32 of Fig 4C).

11. Connect the quick connector of the red tube (33 of Fig 4A) to the appropriate coupler (33 di Fig 4C).

12. Connect the quick connector of the blue tube (34 of Fig 4A) to the appropriate coupler (34 of Fig 4C.

7. CONNECTION OF THE GAS CYLINDER AND REGULATOR (see Fig 5)

1. Connect the pressure regulator (2) to the gas

cylinder (3). Tighten the connecting nut (6) of the regulator (2) to the cylinder (3). Do not over-tighten because this may damage the valve (1) of the cylinder (3).

2. Connect the gas hose (4) to the regulator (2) by securing it with a tube clamp (5).

3. Make sure the gas hose is correctly connected to the welding machine.

4. Open the valve (1) of the gas cylinder (3). Press the torch button and make sure the gas flows correctly.

Attention: The cylinders contain highly pressurized gas. Handle with care. Improper handling could lead to serious accidents. Do not place the cylinders on top of each other and do not expose to excessive heat, flames or sparks. Do not allow the cylinders to strike against each other. Contact your gas supplier for more information on the use and handling of the cylinders.

Attention: Do not use the cylinder if you find oil leaks, grease or damaged parts. Immediately contact your gas supplier if these conditions exist.

8. MIG TORCH

It is recommended to periodically check the condition of the welding torch. In particular, check the gas nozzle (Fig 3A) and wire-guide tip (Fig 3B). These parts must be kept clean and intact. Replace the wire-guide when the wire does not run smoothly.

9. PREPARING FOR THE WELDING

1. Connect the welding machine to the mains

power.

2. Make sure the polarity of the torch and ground cables are positioned correctly.

3. Connect the ground terminal to the workpiece, making sure the contact is good.

Fig. 5

2

5

3

4

5

4

3

1

2

6

1

РУССКИЙ

ESPAÑOL

FRANÇAIS DEUTSCH

ENGLISH

10. WEL D ING PR O CESS

The TM230 and 260 welding machines have 11 regulating positions (13 of Fig. 1), the TM300, 350, 320W and 360W machines have 20 regulating positions (13 and 14 of Fig. 1) and the TM420W, 500W

and 650W welding machines have 30 regulating positions (13 and 14 of Fig. 1). The choice of the best current is determined by the thickness of the material to weld. Refer to the following table for setting the correct welding current.

11. HOW TO OBTAIN THE BEST WELDING RESULTS

1. During welding, keep the torch at a 45° angle from the workpiece. Keep the gas nozzle (Fig. 3A) at around 6 mm from the workpiece.

2. Continuously move the torch.

3. Do not weld in the presence of strong wind. Strong wind could carry away the gas from the weld pool and lead to porous welding.

4. Keep the wire clean: never use rusty wires.

5. Do not fold or twist the torch cable.

6. When changing the wire spool, clean the wireguide tube with compressed air.

7. Periodically remove any dust from the air inlets using low-pressure compressed air. Always direct the jet of air from the inside of the machine towards the outside in order to prevent dirt from being pushed inside the welding machine.

12. REGULATING THE WELDING MACHINE

Once the welding current has been set according to the instructions in paragraph 9, keep the length of the electrical arc between 5 and 10 mm and adjust the wire speed to obtain the best welding result. Carry out some test welds on a metallic

sheet that has been cleaned of any coating, rust or paint.

NOTE: When the torch button is pressed, the following three functions are performed:

- gas flow;

- wire feed;

- welding current.

Start welding at a high wire speed and then gradually reduce the speed via the potentiometer (9 of Fig. 1). Continue to reduce the wire speed and listen to the sound produced. The sound will go from a crackling noise to a strong and regular buzzing noise (similar to the sound of oil being fried). This buzzing sound indicates that the correct wire speed has been reached for the workpiece. Each time the current is adjusted, reset the wire speed. Always start from the highest wire speed. This operation prevents damaging the tip of the torch during welding.

SPESSORE DEL PEZZO DIAMETRO FILO CORRENTE DI SALDATURA ARCO

mm mm A

0.8 - 1.0 0.6 - 0.8 60 - 100

Short - Arc

1.5 - 2.0 0.8 - 1.0 80 - 120

Short - Arc

2.0 - 3.0 1.0 - 1.2 100 - 130

Short - Arc

3.0 - 4.0 1.2 - 1.6 120 - 200

Short - Arc

> 4.0 1 150 ÷ 200

Spray - Arc

> 4.0 1.2 200 ÷ 300

Spray - Arc

> 4.0 1.6 300 ÷ 400

Spray - Arc

24

25

ITALIANO

The most common problems you may encounter and the relative solutions are listed below:

13. TROUBLESHOOTING

РУССКИЙ

ESPAÑOL

FRANÇAIS DEUTSCH

ENGLISH

DEFECT CAUSE SOLUTION

Welder does not start. 1) Make sure that there is vol-

tage 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 wirefeeder

1) Blow with compressed air, replace nozzle

2) Excessive spool torque. 2) Loose

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

Jerky or intermittent wire-feed. 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 con-

tent 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

• Gun side: remove the gas nozzle (A)

• Unscrew the wire liner tip and the gas diffuser (B)

• Connector side (C): grab the end of wire liner using a plier and start to extract the wire liner

• Complete the extraction of the wire liner (G)

A

B

C

D

E

F

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

• Now rescrew the diffusor on the gun (B)

G

H

14. WIRE LINER REPLACEMENT

26

27

1. Using a screwdriver, remove the eyebolt on

the back of the appliance.

2. Remove the 14 black cross-head screws which fasten the back wall.

3. Slide off the back wall.

4. Remove the MATE-N-LOCK connector posi-

tioned on the back.

15. INSTALLATION INSTRUCTIONS FOR INDOOR WATER COOLING SYTEM

РУССКИЙ

ESPAÑOL

FRANÇAIS DEUTSCH

ENGLISH

ITALIANO

5. Free the hexagonal hole.

6. Take the control unit of the cooling system.

7. Position the control unit so that its resting sur-

face lines up with the outer most side of the machine. Refer to the figure.

8. Connect the MATE-N-LOCK connector of the control unit to the special connector located on the back of the appliance.

28

29

9. Slide through the power cord.

10. Position the top part of the control unit

against the upper side of the machine wall. Refer to the figure. In this operation, carefully check that none of the tubes are crushed against the wall of the control unit and the inside walls of the apparatus.

11. Free the second window located on the back of the control unit.

12. Position the wall of the control unit so that it rests perfectly against the back part of the machine.

РУССКИЙ

ESPAÑOL

FRANÇAIS DEUTSCH

ENGLISH

ITALIANO

13. Replace the eyebolt.

14. Reinsert the 14 screws that were removed.

15. Fill the cooling circuit with cooling liquid.

16. Use a cable band to connect all the cables to

the back wall as shown in the figure.

17. Attach the trolley separated from the machine and connect the five cables wrapped up in the band.

30

31

18. Connect the torch supplied with the

unit. Make sure the cooling tubes are closed correctly.

19. Turn on the appliance via the switch positioned on the front of the machine. “0” indicates that the machine is OFF, and “1” indicates that the machine is ON.

20. Turn on the control unit by turning the switch from “STOP” to “START”.

21. Wait for the tubes to be filled with the cooling liquid, check the tank level, if necessary, add more liquid.

22. Wait for the yellow LED located on the front of the trolley to turn off.

If the yellow LED does not turn off:

- Check the level of the cooling liquid inside the tank

- Make sure the cable band is not tangled, thereby preventing the liquid from circulating.

- Make sure the internal tubes are not crushed. If so, repeat the operations described in point 10.

N.B. If the problem persists, contact an Authorised Service Centre.

РУССКИЙ

ESPAÑOL

FRANÇAIS DEUTSCH

ENGLISH

ITALIANO

11

1. unit control card

2. auxiliary transformer

3. on/off switch

4. fan

5. rectifier

6. power transformer

7. 2/3 position switch

8. 7 position switch

9. inductance

10. wire-feeder motor

11. wire-feeder

1

8 7

10

11

TM 230,260

TM300, 350

2

3

6

9

5

4

11

8

2

3

6

5

9

10 11

4

7

1

2

3

4

5

6

8

16. SPARE PARTS

1

32

TM 320W - TM 360W - TM 420W TM 500W - TM 650W

33

ENGLISH

DEUTSCHFRANÇAIS

ESPAÑOL

РУССКИЙ

ITALIANO

17. BLOCK DIAGRAM TM230-TM260

1. Contactor

2. Current switch

3. Current transformer

4. Rectifier bridge

5. Output connectors

6. Control board 6a Wire speed regulation 6b Soft Start selection 6c Burn Buck selection 6d Welding duration regulation

7. Wire feeder motor

8. Gas solenoid valve

9. Thermostat

10. Overheating warning

11. Fan

12. Auxiliary transformer

13. ON/OFF switch

14. ON welding machine lamp

1. Contactor 2a. Current switch 2b. Current range selector

3. Power transformer

4. Rectifier bridge

5. Output connectors

6. Control board 6a Wire speed regulation 6b Soft Start selection 6c Burn Buck selection 6d Welding duration regulation

7. Wire feeder motor

8. Gas solenoid valve

9. Thermostat

10. Overheating warning

11. Fan

12. Auxiliary transformer

13. ON/OFF switch

14. ON welding machine lamp

18. BLOCK DIAGRAM TM300

34

35

ENGLISH

DEUTSCHFRANÇAIS

ESPAÑOL

РУССКИЙ

ITALIANO

19. BLOCK DIAGRAM TM350 - TM320W - TM360W

1. Contactor 2a. Current switch 2b. Current range selector

3. Power transformer

4. Rectifier bridge

5. Smoothing inductance output

6. Output connectors

7. Control board 7a Wire speed regulation 7b Soft Start selection 7c Burn Buck selection 7d Welding duration regulation

8. Wire feeder motor

9. Gas solenoid valve

10. Thermostat

11. Overheating warning

12. Fan

13. Auxiliary transformer

14. ON/OFF switch

15. ON welding machine lamp

36

20. BLOCK DIAGRAM TM420 - TM500W - TM650W

1. Contactor 2a. Current switch 2b. Current range selector

3. Power transformer

4. Rectifier bridge

5. Smoothing inductance output

6. Output connectors

7. Control board 7a Wire speed regulation 7b Soft Start selection 7c Burn Buck selection 7d Welding duration regulation

8. Wire feeder motor

9. Gas solenoid valve

10. Thermostat

11. Overheating warning

12. Fan

13. Auxiliary transformer

14. ON/OFF switch

15. ON welding machine lamp

37

ENGLISH

DEUTSCHFRANÇAIS

ESPAÑOL

РУССКИЙ

ITALIANO

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

NNOOTTEE

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

38

NNOOTTEE

ESPAÑOL FRANÇAIS

ENGLISH

ITALIANO

DEUTSCH

P

er 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. L

a 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 c

on i loro accessori.

P

er 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.

A

LLA DATA DELLA REDAZIONE DEL PRESENTE MANUALE D’ISTRUZIONI QUESTE INFORMAZIONI SONO DA RITENERSI NON DEFINITIVE IN QUANTO SUSCETTIBILI DI POSSIBILI MODIFICHE SECONDO GLI OBBLIGHI L

EGATI 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!

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 pret- tamente 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/coun- cil 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 Umset- zung 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 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!

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. L

a Legislazione prevede la suddivisione in 2 categorie principali chiamate RAEE PROFESSIONALI o RAEE DOMESTICI.

P

er RAEE PROFESSIONALI s’intendono tutti i rifiuti di apparecchiature elettriche ed elettroniche destinate ad uso pret-

tamente industriale.

P

er 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”. P

er 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 s

maltimento.

ALLA DATA DELLA REDAZIONE DEL PRESENTE MANUALE D’ISTRUZIONI QUESTE INFORMAZIONI SONO DA R

ITENERSI 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.