TELWIN 955028 SUPERMIG 450i Instruction Manual

TELWIN 955028 SUPERMIG 450i

Product Information

• Product Name: Unknown
• Model Number: Cod.955028
• Available Languages : English, Italian, French, Spanish, German, Russian, Portuguese, Dutch, Greek, Romanian, Swedish, Croatian-Serbian, Polish, Finnish, Danish, Norwegian, Slovenian, Slovak, Hungarian, Lithuanian, Estonian, Latvian.

Product Usage Instructions

1. Ensure that you have read and understood the instructions for use and maintenance before operating the product.
2. The product is designed for a specific purpose. Do not use it for any other purpose.
3. Follow the safety instructions provided in the user manual to prevent accidents or injuries.
4. If there are any warning labels or symbols on the product, make sure to read and understand their meaning before use.
5. In case of fire or danger of fire, follow the instructions provided in the manual for appropriate actions to take.
6. If there is a risk of smoke or harmful fumes, take necessary precautions as mentioned in the user manual.
7. Use protective gloves when handling the product to ensure safety.
8. If there is a risk of ultraviolet radiation or any other hazardous situations mentioned in the manual, take necessary precautions.
9. Wear protective eyewear when required to prevent any eye injuries.
10. Do not enter restricted areas or use the product in prohibited locations as mentioned in the manual.
11. Use the product according to the instructions provided and avoid using it in combination with vital electrical and electronic apparatus.
12. Follow the maintenance instructions provided in the manual to ensure proper functioning and longevity of the product.
    Note: The actual product name and detailed usage instructions cannot be determined from the given text extract.

CONTINUOUS WIRE WELDING MACHINE FOR MIG-MAG AND FLUX, TIG, MMA WELDING FOR PROFESSIONAL AND INDUSTRIAL USE.
Note: The term “welding machine” will be used in the text that follows.

EXPLANATION OF DANGER, MANDATORY AND PROHIBITION SIGNS

• DANGER OF ELECTRIC SHOCK
• DANGER OF WELDING FUMES –
• DANGER OF EXPLOSION –
• WEARING PROTECTIVE CLOTHING IS COMPULSORY – (
• WEARING PROTECTIVE GLOVES IS COMPULSORY –
• DANGER OF ULTRAVIOLET RADIATION FROM WELDING –
• DANGER OF FIRE – (IT) PERICOLO INCENDIO –
• DANGER OF BURNS –
• DANGER OF NON-IONISING RADIATION
• GENERAL HAZARD
• DO NOT USE THE HANDLE TO HANG THE WELDING MACHINE. –
• WARNING: MOVING PARTS
• MIND YOUR HANDS, MOVING PARTS
• EYE PROTECTIONS MUST BE WORN
• NO ENTRY FOR UNAUTHORISED PERSONNEL
• WEARING A PROTECTIVE MASK IS COMPULSORY
• WEARING EAR PROTECTORS IS COMPULSORY –
• USERS OF VITAL ELECTRICAL AND ELECTRONIC APPARATUS MUST NEVER USE THE MACHINE – (
• PEOPLE WITH METAL PROSTHESES ARE NOT ALLOWED TO USE THE MACHINE –
• DO NOT WEAR OR CARRY METAL OBJECTS, WATCHES OR MAGNETISED CARDS –
• NOT TO BE USED BY UNAUTHORISED PERSONNEL
• Symbol indicating separation of electrical and electronic appliances for refuse collection.

GENERAL SAFETY CONSIDERATIONS FOR ARC WELDING

The operator should be properly trained to use the welding machine safely and should be informed about the risks related to arc welding procedures, the associated protection measures and emergency procedures.

• Avoid direct contact with the welding circuit: the no-load voltage supplied by the welding machine can be dangerous under certain circumstances.

• When the welding cables are being connected or checks and repairs are carried out the welding machine should be switched off and disconnected from the power supply outlet.

• Switch off the welding machine and disconnect it from the power supply outlet before replacing consumable torch parts.

• Make the electrical connections and installation according to the safety rules and legislation in force.

• The welding machine should be connected only and exclusively to a power source with the neutral lead connected to earth.

• Make sure that the power supply plug is correctly connected to the earth protection outlet.

• Do not use the welding machine in damp or wet places and do not weld in the rain.

• Do not use cables with worn insulation or loose connections.

• If a liquid cooling unit is present, filling operations must be carried out with the welding machine off and disconnected from the power supply.

• Do not weld on containers or piping that contains or has contained flammable liquid or gaseous products.

• Do not operate on materials cleaned with chlorinated solvents or near such substances.

• Do not weld on containers under pressure.

• Remove all flammable materials (e.g. wood, paper, rags etc.) from the working area.

• Provide adequate ventilation or facilities for the removal of welding fumes near the arc; a systematic approach is needed in evaluating the exposure limits for the welding fumes, which will depend on their composition, concentration and the length of exposure itself.

• Keep the gas bottle (if used) away from heat sources, including direct sunlight.

• Use electric insulation that is suitable for the torch, the workpiece and any metal parts that may be placed on the ground and nearby (accessible).
  This can normally be done by wearing gloves, footwear, head protection and clothing that are suitable for the purpose and by using insulating boards or mats.

• Always protect your eyes with the relative filters, which must comply with UNI EN 169 or UNI EN 379, mounted on masks or use helmets that comply with UNI EN 175. Use the relative fire-resistant clothing (compliant with UNI EN 11611) and welding gloves (compliant with UNI EN 12477) without exposing the skin to the ultraviolet and infrared rays produced by the arc; the protection must extend to other people who are near the arc by way of screens or non-reflective sheets.

• Noise: If the daily personal noise exposure (LEPd) is equal to or higher than 85 dB(A) because of particularly intensive welding operations, suitable personal protective means must be used.

ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS
Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). Welding current creates an EMF field around welding and welding equipment.
EMF fields may interfere with some medical implants (e.g. pacemakers, respiratory equipment, metallic prostheses etc.).
Protective measures for persons wearing medical implants have to be taken.
For example, access restrictions for passers-by or individual risk assessment for welders.
This welding machine complies with technical product standards for exclusive use in an industrial environment for occupational use. It does not assure compliance with the restrictions for use by layman.
All operators should follow the rules listed herebelow, in order to minimize exposure to EMF fields from the welding circuit:

• route the welding cables together. Secure them with tape when possible;
• place your trunk and head as far away as possible from the welding circuit;
• never coil welding cables around metal objects or your body;
• do not place your body between welding cables;
• keep welding cables on the same side of your body;
• connect the work clamp to the work piece as close as possible to the area being welded;
• do not work next to welding power sources;
• all operators should keep the required minimum distances as given in the EMF data sheet;
• distance from the EMF source to a point beyond which the exposure is less than 20%of the lowest permissible value: d= 15 cm.

Class A equipment:
This welding machine conforms to technical product standards for exclusive use in an industrial environment and for professional purposes. It does not assure compliance with electromagnetic compatibility in domestic dwellings and in premises directly connected to a low-voltage power supply system feeding buildings for domestic use.
EXTRA PRECAUTIONS

• WELDING OPERATIONS:

  • In environments with increased riskof electric shock;
  • In confined spaces;
  • n the presence of flammable or explosive materials;
    MUST BE evaluated in advance by an “Expert supervisor” and must always be carried out in the presence of other people trained to intervene in emergencies. All protective technical measures MUST be taken as provided in 7.10; A.8; A.10 of the applicable standard EN 60974-9: Arc welding equipment. Part 9: Installation and Use”.

• Welding MUST NOT be allowed if the welding machine or wire feeder is supported by the operator (e.g. using belts).

• The operator MUST NOT BE ALLOWED to weld in raised positions unless safety platforms are used.

• VOLTAGE BETWEEN ELECTRODE HOLDERS OR TORCHES: working with more than one welding machine on a single piece or on pieces that are connected electrically may generate a dangerous accumulation of no-load voltage between two different electrode holders or torches, the value of which may reach double the allowed limit. An expert coordinator must be designated to measuring the apparatus to determine if any risks subsist and suitable protection measures can be adopted, as foreseen by section 7.9 of the applicable standard ”EN 60974-9: Arc welding equipment. Part 9: Installation and Use”.

• The use of the machine must be limited to the operator only.

• The operator must disconnect the cable and the electrode holder from the machine once the MMA welding is over.

• The area around the welding machine must be forbidden to third parties. It also should not be left unattended.

• The torches not in use should be stored in their housing.

RESIDUAL RISKS

• OVERTURNING: position the welding machine on a horizontal surface that is able to support the weight: otherwise (e.g. inclined or uneven floors etc.) there is danger of overturning.
• It is forbidden to lift the trolley together with the welding machine, the wire feeder and the cooling unit (when present).
• IMPROPER USE: it is hazardous to use the welding machine for any work other than that for which it was designed (e.g. de-icing mains water pipes).

RISK OF BURNS
Some parts of the welding machine (torch, electrode-holder clamp) and the adjacent areas can reach temperatures over 65°C: adequate protective clothing must be worn.
Allow the just welded piece to cool before touching it!

• IMPROPER USE: the use the welding machine by more than one operator at the same time may be dangerous.
• MOVING THE WELDING MACHINE: Always secure the gas bottle, taking suitable precautions so that it cannot fall accidentally (if used).
• Do not use the handle to hang the welding machine.

The safety guards and moving parts of the covering of the welding machine and of the wire feeder should be in their proper positions before connecting the welding machine to the power supply.
WARNING! Any manual operation carried out on the moving parts of the wire feeder, for example:

• Replacing rollers and/or the wire guide;
• Inserting wire in the rollers;
• Loading the wire reel;
• Cleaning the rollers, the gears and the area underneath them;
• Lubricating the gears.
  SHOULD BE CARRIED OUT WITH THE WELDING MACHINE SWITCHED OFF AND DISCONNECTED FROM THE POWER SUPPLY OUTLET.

ENVIRONMENTAL CONDITIONS (EN 60974-1)

• Use the welding machine with the following environmental conditions only:
  • ambient temperature between -10°C and 40°C;
  • relative humidity of the air not exceeding 50% at 40°C;
  • relative humidity of the air not exceeding 90% at 20°C;
  • The surrounding air must be free of dust, acid, gas or corrosive substances, etc.

STORAGE

• Position the machine and its accessories (with or without packaging) in closed premises.
• The ambient temperature must be between -20°C and 55°C.
  If the machine is planned with liquid cooling and an ambient temperature under 0°C: use the anti-freeze liquid suggested by the manufacturer or completely empty the hydraulic circuit and the tank of liquid.
  Always use adequate measures to protect the machine from humidity, dirt and corrosion.

DISPOSAL
Do not dispose of this welding machine as normal household waste at the end of its life cycle.
The user is responsible for disposing of this electrical equipment in collection points designated for disposal and recycling of electrical equipment or contact the shop where you purchased the product. This provision only refers to disposal of the equipment within the European Union (WEEE).

INTRODUCTION AND GENERAL DESCRIPTION

This welding machine is a source of current for arc welding, made specifically for MAG welding carbon steel or weak alloys with CO2 protective gas or Argon/CO2 mixes, using full or core electrode wires (tubular).
It is also ideal for MIG welding stainless steel with Argon gas containing + 1-2% oxygen and aluminium and CuSi3, CuAl8 (brazing) with Argon gas, using electrode wires that are suitable for the workpiece to be welded.
It is particularly suitable for light metalwork fabrication and in body shops, for welding galvanized plates, high stress stainless steel and aluminium. SYNERGIC operation ensures fast and easy welding parameter setting, always guaranteeing high arc control and welding quality.
The welding machine can be used for TIG welding in direct current (DC), with arc striking upon contact (LIFT ARC mode). It welds all types of steel (carbon, low- and high-alloy) and heavy metals (copper, nickel, titanium and their alloys) with a gas shield of pure (99.9%) Ar or, for special uses, with an Argon/Helium mix. It can also be used for MMA electrode welding in direct current (DC) using coated electrodes (rutile, acid, basic).

MAIN CHARACTERISTICS MIG-MAG

• Operating modes:
  • manual;
  • synergic;
• Wire speed, welding current and voltage shown on the display.
• Operation selection 2T, 4T, Spot.

TIG

• Start LIFT.
• Welding voltage and current shown on an LCD screen.

MMA

• Operating modes:
  • Direct current MMA;
  • Pulse current MMA;
• Arc force settings, hot start.
• VRD device.
• Anti-stick protection.
• Welding voltage and current shown on an LCD screen.

GOUGING
Gouging voltage and current shown on an LCD screen.
OTHER

• Setting the metric or UK system.
• Possibility of connecting a semi-automatic type wire feeder unit (CV).

PROTECTION

• Thermostatic protection.
• Protection against accidental short-circuits caused by contact between torch and earth.
• Protection against irregular voltage (power supply voltage too high or too low).

STANDARD ACCESSORIES

• MIG torch
• Return cable complete with earth clamp.
• Torch holder stand.

OPTIONAL ACCESSORIES

• Argon bottle adapter.
• Self darkening mask.
• MIG/MAG welding kit.
• MMA welding kit.
• TIG welding kit.
• Trolley.
• Gouging Kit.

TECHNICAL SPECIFICATIONS

DATA PLATE
WELDING MACHINE
The main data on use and performance of the welding machine are summarised on the rating plate with the following meaning:

1. EUROPEAN reference standard for safety and construction of arc welding machines.

2. Manufacturer’s name and address.

3. Name of model.

4. Symbol of welding machine internal structure.

5. Symbol of planned welding procedure.

6. Symbol S : indicates cleaning operations can be carried out in an environment with increased risk of electric shock (e.g. in close proximity of large metal masses).

7. Symbol of the power supply:

   • 1~: single-phase alternating voltage;
   • 3~: three-phase alternating voltage.

8. Protection rating of the casing.

9. Characteristic data of the power supply:

   • U1 : Alternating voltage and power supply frequency to the welding machine (allowed limits ±10%).
   • I1 max : Absorbed maximum current from line.
   • I1 eff : Effective power supply current.

10. Welding circuit performance:

    • U0 : maximum no load voltage (welding circuit open).

    • I2/U2 : Normalized corresponding current and voltage which can occur supplied by the welding machine during welding.

    • X : Duty cycle ratio: indicates the time during which the welding machine can supply the corresponding current (same column). It is expressed as a %, based on a 10min cycle (e.g. 60% = 6 working minutes, 4 rest minutes; and so on).
      If the use factors (of plate, referring to 40°C ambient temperature) are surpassed, the thermal switch activates (the welding machine stays in stand-by until its temperature goes back within the permitted limits).

    • A/V-A/V : It indicates the settings range of the welding current (minimum- maximum) at the corresponding arc voltage.

11. Serial number to identify the welding machine (essential for technical assistance, spare part requests, tracing of product origin).

12.  : Value of delayed activation fuses to implement for line protection.

13. Symbols referring to safety standards whose meaning is outlined in chapter 1 “General safety for arc welding”.

WIRE FEEDER UNIT
The main information on use and performance of the wire feeder unit is summarised on the data plate and has the following meaning:

1. EUROPEAN reference standard for safety and construction of the wire feeder unit.

2. Symbol of the power supply:
   : direct voltage;

3. Protection rating of the casing.

4. U1 : Wire feeder unit power supply voltage.

5. I1 : Absorbed current with maximum load.

6. Welding circuit performance:

   • I 2: Current which can be supplied by the wire feeder unit during welding.
   • X : Duty cycle ratio: indicates the time during which the welding machine can supply the corresponding current (same column). It is expressed as a %, based on a 10min cycle (e.g. 60% = 6 working minutes, 4 rest minutes; and so on).

7.  Serial number to identify the welding machine (essential for technical assistance, spare part requests, tracing of product origin).
   NB: The rating plate shown is an example to explain the meanings of the symbols and figures; the exact technical specifications for the welding machine should be taken directly from the rating plate on the welding machine.

OTHER TECHNICAL DATA

1. WELDING MACHINE:
2. WIRE FEEDER UNIT:
3. AVERAGE CONSUMPTION OF WIRE AND WELDING GAS:
4. MIG TORCH:
5. TIG TORCH:
6. ELECTRODE-HOLDER CLAMP: The weight of the welding machine and wire feeder unit is outlined.
   

 DESCRIPTION OF THE WELDING MACHINE

CONTROL, ADJUSTMENT AND CONNECTION DEVICES.

WELDING MACHINE

At the front:

1. Control panel (see description);

2.  Positive (+) quick coupling for connecting the welding cable;

3. Negative (-) quick coupling for connecting the welding cable;

4. Earth return cable and clamp;

5. Welding cable and torch;
   At the back:

6.  Main ON/OFF switch;

7.  Power cable;

8. Positive quick coupling socket (+) for connection welding current cable with wire feeder unit;

9. Connector 14p for connection command cable with wire feeder unit;
   WIRE FEEDER UNIT

10. Control panel (see description);

11. Torch coupling;

12.  Positive quick coupling plug (+) for connection welding current cable with welding machine;

13. Connector 14p for connection command cable with welding machine;

14. Gas tube;

WELDING MACHINE CONTROL PANEL

1. Machine setting selector:

   • GOUGING                            : gouging mode.

   • MMA (PULSE) – TIG : MMA (PULSE) or TIG mode. Selection takes place using knob C- 2.
                       : MIG-MAG mode with synergic (automatic) or manual operation. This mode is only active if the connector (B2-13) coming from the wire feeder unit is correctly inserted in the machine connector (B1-9).

   • CV                                  : this allows operation of the semi-automatic type wire feeder  unit.

2.  Multi-function knob.
   If pressed for at least 3 seconds, it allows selection of the welding process: with C-1 in MMA (PULSE) – TIG : MMA (PULSE) or TIG selection; with C-1 in : MIG-MAG (SINERGIC or MANUAL) selection; Furthermore, rotation allows setting (in the following modes):
   MMA (PULSE) : of welding current;
   TIG : of welding current;
   GOUGING : of gouging current.
   Note: in and CV mode, current setting is disabled.

3. Multi-function knob.
   If pressed for at least 3 seconds, this allows access to preset machine programs. Note: enabled only with C-1 in and MIG-MAG in synergic mode (SYN). Furthermore, rotation allows setting (in the following modes):
   CV : of welding voltage.

4.  LCD display.
   WIRE FEEDER UNIT CONTROL PANEL

5. Knob, whose rotation allows:

   • setting of the welding seam (welding voltage) in MAN mode;
   • setting of the welding seam (arc length) in SYN mode;

6.  Manual wire jog button. This jogs the wire forward in the torch sheath without having to touch the torch button; this is a momentary action and the speed is set and fixed.

7. Knob, whose rotation allows:

   •  setting of the wire feeding speed in MAN mode;
   •  setting of the welding power in SYN mode;

INSTALLATION

ATTENTION: THE WELDING MACHINE MUST BE TURNED OFF AND DISCONNECTED FROM THE MAINS BEFORE COMMENCING ANY INSTALLATION AND POWER CONNECTION OPERATIONS.
THE ELECTRICAL CONNECTIONS MUST ONLY BE CARRIED OUT BY EXPERT OR QUALIFIED TECHNICIANS.

ASSEMBLY

Unpack the welding machine and assemble the separate parts included in the package.

Assembling the clamp-return cable

Assembling the welding cable electrode-holder clamp

POSITIONING THE WELDING MACHINE
Choose the place where the welding machine is to be installed so that there are no obstructions to the cooling air inlets and outlets; at the same time make sure that conductive dust, corrosive vapours, humidity etc. cannot be drawn into the machine. Leave at least 250 mm of free space all around the welding machine.
WARNING! Position the welding machine on a level surface with sufficient load- bearing capacity, so that it cannot be tipped over or shift dangerously.

 CONNECTION TO THE MAIN POWER SUPPLY

• Before making any electrical connection, check the rating plate data on the welding machine to make sure they correspond to the voltage and frequency of the available power supply where the machine is to be installed.
• The welding machine must be connected only and exclusively to a power supply with the neutral conductor connected to earth.
• To guarantee protection against indirect contact use the following types of residual current devices:
  • for single-phase machines.
  • for 3-phase machines.
• In order to satisfy the requirements of the EN 61000-3-11 (Flicker) standard we recommend connecting the welding machine to the interface points of the main power supply that have an impedance of less than Zmax = 0.10 ohm.
• The IEC/EN 61000-3-12 Standard does not apply to the welding machine.
  If the welding machine is connected to an electrical grid, the installer or user must make sure that the machine can indeed be connected (if necessary, consult the company that manages the electrical grid).

Plug and outlet
Connect a normalized plug (3P + P.E) – having sufficient capacity- to the power cable and prepare a mains outlet fitted with fuses or an automatic circuit-breaker; the special earth terminal should be connected to the earth conductor (yellow-green) of the power supply line.
Table (TAB. 1) shows the recommended delayed fuse sizes in amps, chosen according to the max. nominal current supplied by the welding machine, and the nominal voltage of the main power supply.
WARNING: Non-compliance with the above regulations renders the manufacturer’s safety system (class I) inefficient, with resulting serious risks to people (e.g. electric shock) and things (e.g. fire).

 WELDING CIRCUIT CONNECTION

Recommendations

• ATTENTION: BEFORE CARRYING OUT THE FOLLOWING CONNECTIONS, MAKE SURE THE WELDING MACHINE IS OFF AND DISCONNECTED FROM THE MAINS.

Table 1 (TAB. 1) gives the recommended values for welding cables (in mm2) according to the maximum energy supplied by the welding machine.

In addition:

• Fully rotate the welding cable connectors in the quick couplings (if present), to guarantee perfect electric contact; if this is not the case the connectors will overheat with consequent fast deterioration and loss of efficiency.
• Use the shortest welding cables possible.
• Do not use metal structures that are not part of the workpiece to replace the welding current return cable; this can endanger safety and give unsatisfactory welding results.

WELDING CIRCUIT CONNECTION IN MIG-MAG MODE
Connecting the gas bottle (if used)

• Gas bottle that can be loaded onto the supporting surface of the trolley: max. 60 kg.
• When using Argon gas or an Argon/CO2 mixture, screw the pressure reducer(*) onto the gas bottle valve, placing the relative pressure reducing valve supplied as an accessory.
• Connect the gas input hose to the pressure reducing valve and tighten the strip.
• Loosen the adjustment ring nut of the pressure reducing valve before opening the gas bottle valve.

(*) Accessory to be purchased separately if not supplied with the product.

Connecting the welding current return cable
Connect the cable to the piece to be welded or the metal bench on which the workpiece is placed, as close as possible to the joint being worked.

Torch
Insert the torch (B1-5) into the dedicated connector (B2-11), fully tightening the locking ring nut manually. Prepare the torch to receive the wire for the first time, removing the nozzle and the contact pipe, to make exiting easier.

WELDING CIRCUIT CONNECTIONS IN TIG MODE
Gas cylinder connection

• Screw the pressure reducer onto the cylinder gas valve, if necessary, inserting the specific reduction supplied as an accessory.
• Connect the input hose of the gas reducer and tighten with the supplied strip.
• Loosen the setting ring nut of the pressure reducer before opening the cylinder valve.
• Open the cylinder and adjust the quantity of gas (l/min) according to the illustrative use data, see table (TAB. 7); any adjustments in gas flow can be carried out during welding always using the pressure reducer ring nut. Check the tubing and fittings.

ATTENTION: Always close the gas cylinder valve at the end of work. 5.3.3.2 Connecting the welding current return cable

• Connect the cable to the piece to be welded or the metal bench on which the workpiece is placed, as close as possible to the joint being worked. Connect this cable to the clamp with the symbol (+) (Fig B1-2).
  5.3.3.3 Torch

• Insert the current cable in the specific fast clamp (-) (Fig. B1-3). Connect the gas hose of the torch to the cylinder.

WELDING CIRCUIT CONNECTIONS IN MMA MODE
Almost all the coated electrodes should be connected to the positive pole (+) of the generator; an exception is the negative pole (-) for electrodes with acid coating.

Connection of the electrode-holder clamp welding cable
Bring a special clamp on the clamp used to tighten the exposed part of the electrode. Connect this cable to the clamp with the symbol (+) (Fig B1-2).

Connecting the welding current return cable

• Connect the cable to the piece to be welded or the metal bench on which the workpiece is placed, as close as possible to the joint being worked. Connect this cable to the clamp with the symbol (-) (Fig B1-3).

 LOADING THE WIRE SPOOL

ATTENTION: BEFORE LOADING THE WIRE, MAKE SURE THE WELDING MACHINE IS OFF AND DISCONNECTED FROM THE MAINS.
MAKE SURE THE WIRE FEEDERS, THE WIRE GUIDE HOSE AND THE TORCH CONTACT PIPE CORRESPOND WITH THE DIAMETER AND NATURE OF THE WIRE TO BE USED AND THAT THEY ARE CORRECTLY MOUNTED. DO NOT WEAR PROTECTIVE GLOVES WHEN THREADING THE WIRE.

• Open the reel area door.
• Unscrew the spool lock nut.
• Position the wire spool on the reel; make sure the reel pulling pin is correctly housed in its hole (1b).
• Tighten the spool lock nut, using spacers as and where necessary (1b).
• Free the pressure counter-roller/s and distance it/them from the lower roller/s (2a);
• Make sure the pulling feeder/s is/are suitable for the wire being used (2b).
•  Free the wire end, cut off the misshaped end by cutting it cleanly and without leaving a burr; rotate the spool counter-clockwise and position the wire end into the wire feed input, pushing it by 50-100 mm into the torch connecting wire feed (2c).
• Reposition the counter-roller/s, adjusting the pressure at an intermediate value, make sure the wire is positioned correctly in the hollow of the lower feeder/s (3).
• Remove the nozzle and contact tube (4a).
• Insert the welding machine plug into the mains socket, switch on the welding machine, press the torch push-button or the wire forward push-button (Fig. C-6) and wait for the end of the wire which is running along the whole wire feed casing, to exit by 10-15 cm from the front of the torch, then release the push-button.

ATTENTION: During these operations the wire is being powered and is subject to mechanical force; if suitable precautions are not taken there is a danger of electric shock and wounds, and electric arcs striking:

• Do not direct the torch mouth against parts of the body.
• Do not approach the torch gas cylinder.
• Remount the contact tube and the nozzle onto the torch (4b).
• Make sure the wire exits regularly; set the roller pressure and reel braking (1a) to the lowest values possible, making sure the wire does not slide in the hollow and that when the drive stops the wire turns do not become loose because of too much spool inertia.
• Cut the end of the wire that exits from the nozzle by 10-15 mm.
• Close the reel area door.

REPLACING THE TORCH WIRE GUIDE SHEATH

Before replacing the sheath, straighten out the torch cable to make sure there are no loops.

Spiral sheath for steel wire

1. Remove the nozzle and contact tube from the torch head.

2. Unscrew the sheath lock nut on the central connector and slide out the existing sheath.

3. Slide the new sheath into the torch cable and gently push it until it comes out of the torch head.

4.  Hand tighten the sheath lock nut back in place.

5.  Cut the wire flush with the sheath and gently squeeze them together; remove it from the torch cable.

6.  Bevel the sheath cutting zone and reposition it in the torch-cable duct.

7.  Use a key to tighten the lock nut back in place.

8. Remount the contact tube and the nozzle.
   Synthetic sheath for aluminium wire
   Perform operations 1, 2 and 3 foreseen for steel sheaths (do not consider operations 4, 5, 6, 7 and 8).

9.  Screw the aluminium contact tube back in place checking that it comes into contact with the sheath.

10.  Insert the brass nipple, the OR ring onto the opposite end of the sheath (torch coupling side), maintain a light pressure on the sheath and tighten the sheath lock nut. The excess section of the sheath shall be removed later on (see (13)). Slide out the capillary tube for steel sheaths from the wire feeder torch coupling.

11. NO CAPILLARY TUBE IS FORESEEN for aluminium sheaths with diameters of 1.6-2.4 mm (yellow colour); the sheath will be inserted in the torch coupling without it.
    Cut the capillary tube for aluminium sheaths measuring 1-1.2 mm (red colour) to a length of 2 mm less than the one used for the steel tube and insert it on the free end of the sheath.

12. Insert and block the torch in the wire feeder coupling, mark the sheath at 1-2 mm from the rollers, now extract the torch again.

13. Cut the sheath to the foreseen measurement without deforming the inlet hole. Remount the torch in the wire feeder coupling and mount the gas nozzle.

MIG-MAG WELDING: PROCESS DESCRIPTION

 SHORT ARC

Wire welding and detachment of the drop takes place via subsequent short- circuits of the wire tip and weld pool (up to 200 times per second). The stick-out length of the wire is normally between 5 and 12mm.

Carbon, low-alloy steel

• Usable wire diameter: 0.6 – 0.8 – 0.9 – 1.0 – 1.2 mm (1.6 mm version 400A only)
• Usable gas: CO2 or Ar/CO2 mixtures

Stainless steel

• Usable wire diameter: 0.8 – 0.9 – 1.0 – 1.2 mm (1.6 mm version 400A only)
• Usable gas: Ar/O2 or Ar/CO2 mixtures (1 – 2%)

Aluminium and CuSi/CuAl

• Usable wire diameter: 0.8 – 1.0 – 1.2 mm
• Usable gas: Ar

PROTECTION GAS
AVERAGE WIRE ELECTRODE CONSUMPTION DURING MIG/MAG WELDING –

MIG-MAG OPERATION MODE

SYNERGIC operating mode

Defined by the user, the parameters such as material, wire diameter , gas type , the welding machine is automatically set in optimal operating conditions established by the various synergic curves saved. The user only has to select the material thickness to begin welding.

LCD display in SYNERGIC mode

N.B. All the values which be displayed and selected depend on the type of set welding.

1. Synergic operating mode ;
2.  Material to weld. Types available: Fe (steel), Ss (stainless steel), AlMg5 AlSi5 (aluminium), CuSi/CuAl (zinc-plated sheet metal – brazing);
3. Diameter of wire to use;
4. Recommended safety gas;
5.  Thickness of material to weld;
6.  Graphic indicator of thickness of material;
7. Graphic indicator of welding seam shape;
8. Welding values:
   • wire feed speed;
   • welding voltage;
   • welding current.
9. ATC (Advanced Thermal Control).

Parameters setting
Pressing knob C-3 for at least 1 second, you can access the preset programs on the machine. Turning the knob you can scroll all the programs (PRG 01, 02, etc.). Select the program chosen by pressing and releasing the same knob. The welding machine sets itself automatically in the best operation conditions established by the different synergy curves that are saved. The user only has to select the material thickness using knob C-7 to begin welding.

Setting of the welding seam shape
Setting of the shape of the seam takes place using the knob (Fig. C-5) that regulates the arc length thereby establishing the greater or lesser welding temperature input. The settings scale varies from -10 ÷ 0 ÷ +10; in most cases, the knob in the intermediate position (0, ) has an optimal base setting (the value is shown on the LCD display on the left of the graphic symbol of the welding seam and disappears after a set time). Using the knob (Fig. C-5), the graphic indication on the display of the shape of the welding changes showing a more convex, flat or concave result. Convex shape. It means there is a low thermal load, therefore welding is “cold”, with little penetration; therefore, turning the knob clockwise you obtain more thermal load with the effect of welding with greater melting. Concave shape. It means there is a high thermal load, therefore welding is too “hot”, with excessive penetration; then, turn the knob anti-clockwise to obtain greater melting.

ATC Mode (Advanced Thermal Control)
This is enabled automatically when the thickness selected is less or equal to 1.5 mm. Description: the particular instantaneous control of the welding arc and the ultra rapid correcting of parameters minimize current spikes, something that is characteristic of Short Arc transfer procedures, to the advantage of a low thermal load on the piece to be welded. The result, on the one hand, is reduced deformation of materials and, on the other, a fluid and accurate transfer of the weld material and the creation of a welding seam that is easy to model.

Advantages:

• easy welding of thin materials;
• decreased deformation of material;
• stable arc even when working with low currents;
• rapid and accurate spot welding;
• easier coupling of spaced sheets.

7.1.5 Advanced parameter setting: MENU 1

****Simultaneously press the knobs (Fig. C-2) and (Fig. C-3) for at least 1 second and release to access the advanced parameter settings menu. When MENU 1 appears, again press. Each parameter can be set to the desired value by rotating/pressing the knob (Fig. C-3) until you exit the menu.

• Trailing wire ramp
  Use to adjust wire feed rate as welding starts, in order to optimise arc strike. Settings from 20 to 100% (start in % of full capacity speed).

• : electronic reactance correction
  A higher value determines a hotter welding bath. Settings from -50% (low reactance machines) to +50% (high reactance machines). Factory value: 0%

• : burn-back correction
  Use to adjust the wire burn-back time when welding is stopped. Settings from -10% to +10%. Factory value: 0%

• : Post gas
  Use to adapt the protective gas outflow starting from when welding is stopped. Settings from 0 to 10 seconds. Factory value: 1 sec.

• : Wire speed correction

It increases or decreases the wire feed speed according to the display. Settings from -5 to +5m/min. Factory value: 0 m/min.

 MANUAL operating mode

The user can customize all the welding parameters.

LCD display in MANUAL mode

1. MANUAL operating mode ;
2. Welding values:
   • wire feed speed;
   • welding voltage;
   • welding current.

Parameters setting
In manual mode, the wire feeding speed and the welding voltage are adjusted separately. The knob (Fig. C-7) adjusts the wire speed, the knob (Fig. C-5) adjusts the welding voltage (which determines the welding power and influences the seam shape). The welding current is shown on the display (Fig. M-2) only during welding.

Advanced parameter setting: MENU 1
Press the knobs (Fig. C2) and (Fig. C3) for at least 1 second and release to access the advanced parameter settings menu. When MENU 1 appears, again press. Each parameter can be set to the desired value by rotating/pressing the knob (Fig. C3) until you exit the menu.

• : Trailing wire ramp
  Use to adjust wire feed rate as welding starts, in order to optimise arc strike. Settings from 20 to 100% (start in % of full capacity speed). Factory value: 50%

• : Electronic reactance
  A higher value determines a hotter welding bath. Settings from 0% (low reactance machines) to 100% (high reactance machines). Factory value: 50%

• : Burn-back.
  Use to adjust the wire burn-back time when welding is stopped. Settings from 0 to 1 sec. Factory value: 0.08 sec.

• : Post gas.
  Use to adapt the protective gas outflow starting from when welding is stopped. Settings from 0 to 10 seconds. Factory value: 1 sec.

• : Wire speed correction

It increases or decreases the wire feed speed according to the display. Settings from -5 to +5m/min. Factory value: 0 m/min.

Semi-automatic type wire feeder unit setting
CV : Operating mode with semi-automatic type wire feeder unit.
This setting only allows operation in MAN mode. Rotation of the knob C-3 allows setting the welding voltage. To access the settings menu of the advanced parameters, simultaneously press the knobs (Fig. C-2) and (Fig. C-3) for at least 1 second and release them. In this different operating mode, the only settable parameter is (Electronic reactance).

CONTROLLING THE TORCH PUSH-BUTTON

Setting the torch push-button control mode

Both in manual and synergic mode to access the menu, simultaneously press the knobs (Fig. C-2) and (Fig. C-3) for at least 1 second and release them. Turn the knob (Fig. C-3) until menu 2 appears. Confirm selection by pressing the knob again.

Torch push-button control mode
It is possible to set 3 different torch push-button control modes:

• Mode 2T: 2t2t
  welding begins when the torch push-button is pressed and ends when the push- button is released.

• Mode 4T: 4t4t
  welding begins when the torch push-button is pressed and released, and ends only when the torch push-button is pressed and released a second time. This mode is useful for long welding operations.

• Spot welding mode:
  used for MIG/MAG spot welding with control of welding duration.

UNIT OF MEASUREMENT MENU
Both in manual and synergic mode to access the menu, simultaneously press the knobs (Fig. C-2) and (Fig. C-3) for at least 1 second and release them. Turn the knob (Fig. C-3) until menu 3 appears. Confirm selection by pressing the knob again. Now you can set the metric or imperial units of measurement. Pressing knob C-3 again, you return to manual (or synergic) mode.
INFO MENU
Both in manual and synergic mode to access the menu, simultaneously press the knobs (Fig. C-2) and (Fig. C-3) for at least 1 second and release them. Turn the knob (Fig. C-3) until menu 4 appears. Confirm selection by pressing the knob again; turning the knob C-3 you can obtain information on the software installed. Pressing knob C-3 again, you return to manual (or synergic) mode.

MMA WELDING: PROCESS DESCRIPTION

 GENERAL PRINCIPLES

• It is essential to follow the recommendations provided by the manufacturer on the electrode packaging which indicates the correct electrode polarity and relative rated current.
•  Welding current is regulated to suit the diameter of the electrode being used and the type of soldering to be performed; an example of the currents used for the various electrode diameters can be seen below:
  Ø Electrode (mm)| Welding current (A)
  ---|---
  Min.| Max.
  1.6| 30| 50
  2.0| 40| 80
  2.5| 60| 110
  3.2| 90| 140
  4.0| 120| 180
  5.0| 170| 250
  6.0| 230| 350
  8.0| 320| 500
•  One can see that for the same diameter electrode, high levels of current will be used for flat welding, whilst lower current levels will be used for vertical or overhead welding.
• The mechanical characteristics of the welded joint are determined by the intensity of the selected current and also other welding parameters such as the length of the arc, the operating speed and position, the diameter and quality of the electrodes (to ensure correct conservation, use special packaging or containers to store and protect the electrodes against humidity).

ATTENTION:
Instability of the arc due to the composition of the electrode can occur, depending on the brand, type and thickness of the electrode coatings.

PROCEDURE

• Keeping the mask IN FRONT OF YOUR FACE, rub the tip of the electrode on the piece to be welded, moving as if striking a match; this is the most correct method for igniting the arc.
  ATTENTION: DO NOT TAP the electrode against the workpiece, which could damage the coating and make arc striking difficult.

• As soon as the arc has struck, try to keep the electrode at a distance from the workpiece that is equivalent to the diameter of the electrode being used, and keep this distance as constant as possible while welding; remember that the electrode angle while moving forward must be approx. 20-30 degrees.

• At the end of the welding seam, take the electrode end slightly back as to the forward direction, above the crater to fill it, then quickly lift the electrode from the weld pool toswitch off the arc (Aspects of the welding seam)

LCD DISPLAY IN MMA MODE

• MMA operating mode;

• Welding values: Simultaneously press the knobs (Fig. C-2) and (Fig. C-3) for at least 1 second and release to access the advanced parameter settings menu. Each parameter can be set to the desired value by rotating/pressing the knob (Fig. C-3) until you exit the menu.

• Hot : this is the initial “HOT START” overcurrent, the display shows the percentage increase as to the value of the selected welding current. Settings from 0 to 100%. Factory value: 50%.

• Arc : this is the dynamic “ARC-FORCE” overcurrent, the display shows the percentage increase as to the value of the pre-selected welding current. This setting improves welding fluidity, prevents the electrode from adhering to the workpiece and makes it possible to use different types of electrodes.
  Settings from 0 to 100%. Factory value: 50%.

• Urd : ON/OFF; this enables or disables the device that reduces the loadless output voltage (ON or OFF setting). Factory value: OFF. With the VRD enabled, operator safety increases when the welding machine is on but not in the welding mode.

LCD DISPLAY IN MMA PULSE MODE

• PLS5: MMA PULSE operating mode;

• Welding values:

• recommended diameter of the electrode.

• To access the settings menu of the advanced parameters, simultaneously press

• the knobs (Fig. C-2) and (Fig. C-3) for at least 1 second and release them. Each parameter can be set to the desired value by rotating/pressing the knob (Fig. C-3) until you exit the menu.

• Hot : this is the initial “HOT START” overcurrent, the display shows the percentage increase as to the value of the selected welding current.

• Settings from 0 to 100%. Factory value: 50%

• Arc : this is the dynamic “ARC-FORCE” overcurrent, the display shows the percentage increase as to the value of the pre-selected welding current.
  This setting improves welding fluidity, prevents the electrode from adhering to the workpiece and makes it possible to use different types of electrodes.

• Settings from 0 to 100%. Factory value: 50%

• Urd  : ON/OFF; this enables or disables the device that reduces the loadless output voltage (ON or OFF setting). Factory value: OFF.

• With the VRD enabled, operator safety increases when the welding machine is on but not in the welding mode.

• PLS : ON/OFF; enables or disables the MMA PULSE mode. With MMA PLS a current pulse is added to facilitate vertical up welding.

• FrE : this represents the number of pulsations per second (Hz)

• Settings from 0,2 to 99,9. Factory value: 1.2

• bAL : this represents the ratio between the duration of the pulse and the total duration of the cycle. Value expressed as a percentage.

• Settings from 10 to 99%. Factory value: 30%

• iPL : this represents the ratio between the current of the pulse and the average current set.

• Value expressed as a percentage.

• Settings from 100 to 200%. Factory value: 142%
  Note: the minimum value of the pulse is not set, but calculated so that the average current is equal to that set.

TIG DC WELDING: PROCESS DESCRIPTION

GENERAL PRINCIPLES

TIG DC welding is suitable for all types of low-alloy and high carbon steel, and heavy metals such as copper, nickel, titanium and their alloys (FIG. P). An electrode with 2% Cerium (grey band) is normally used for TIG DC welding with electrode at the (-) pole. The tungsten electrode must be axially sharpened using a grinding wheel, see FIG. Q; make sure the tip is perfectly concentric to prevent arc deviation. The electrode must be ground along its length. This operation must be repeated periodically according to the use and wear state of the electrode, or when the electrode itself has been accidentally contaminated, oxidised or used incorrectly. For good welding, it is indispensable to refer to TAB. 7 which indicates the diameter of the electrode, current and gas flow based on the thickness you intend welding. The electrode normally projects from the ceramic nozzle by 2 – 3mm, but can reach 8 mm for welding edges.
The weld is created by the edges that melt. Filler metal is not needed when welding suitably prepared thin material (up to about 1 mm). A greater thickness requires rods made from the same material as the basic material and with a suitable diameter, with edges that have been suitably prepared .For welding to be successful, the pieces must be carefully cleaned and free from oxide, grease, oil, solvent, etc.

PROCEDURE (LIFT STRIKE)

• Use the knob C-2 to adjust the welding current to the required rate; adjust this value during welding processes to adapt to the actual heat transfer required.

• Make sure the gas is flowing correctly.
  The arc ignites through contact, distancing the tungsten electrode from the workpiece. Igniting in this manner causes less electric-irradiated disturbances and reduces tungsten inclusions and electrode wear to a minimum.

• Place the tip of the electrode on the workpiece, pressing gently.

• Immediately lift the electrode by 2 – 3mm to obtain the arc strike.
  The welding machine initially supplies reduced current. After a few seconds, the set welding current is issued.

• Quickly lift the electrode from the workpiece to interrupt welding.

12.3 LCD DISPLAY IN TIG MODE

• TIG operating mode;
• Welding values:
• welding voltage;
  welding current.
  The actual welding settings (welding current and voltage) are shown in the top section of the display.

GOUGING PROCESS

GENERAL PRINCIPLES

This procedure consists of using carbon gouging electrodes, covered with a copper film for current transfer. The metal is fused by the electric arc between the end of the electrode and the workpiece. The molten metal is blown by compressed air.
The oxygen contained in the compressed air oxidises the molten metal and limits it adherence to the workpiece.
The gouging current should be adjusted based on the diameter of the electrode used. By way of example, the currents used for the various electrode diameters are:

PROCEDURE

• Adjust the gouging current to the desired value using knob C-2
• Check the correct outflow of compressed air.
• Rest the tip of the electrode on the workpiece
• Quickly lift the electrode from the workpiece to interrupt gouging.

13.3 LCD DISPLAY IN GOUGING MODE

• : Gouging operating mode;
• Welding values:
  Note: The gouging process in the 270A version with U1 = 230V is disabled.

RESET FACTORY SETTINGS
The welding machine can be brought to the factory default settings by keeping the two knobs (Fig.C-2) and (Fig.C-3) pressed during the start-up operation.

ALARM WARNINGS

Reset is automatic when the reason for alarm activation stops.
Alarm messages that can appear on the display:

• : Welding thermal switch has tripped. Operations come to a halt until the machine has cooled down sufficiently.
• : overvoltage switch has tripped. Check the power supply voltage.
• : overvoltage switch has tripped. Check the power supply voltage.
• : welding circuit overcurrent switch has tripped. Make sure the feeder speed and/or welding current are not too high.
• : torch and earthing short-circuit switch has tripped. Make sure the welding circuit has not short-circuited.
• : no internal communication switch has tripped. If the alarm continues, contact an authorised repair centre.
• : auxiliary voltage alarm switch has tripped. If the alarm continues, contact an authorised repair centre.
• FEEDER FAULT: check the wire feeder and the fuse on the machine.

When the welding machine is switched off, for a few seconds, signal may appear.

MAINTENANCE

WARNING! BEFORE CARRYING OUT MAINTENANCE OPERATIONS MAKE SURE THE WELDING MACHINE IS SWITCHED OFF AND DISCONNECTED FROM THE MAIN POWER SUPPLY.

ROUTINE MAINTENANCE:

ROUTINE MAINTENANCE OPERATIONS CAN BE CARRIED OUT BY THE OPERATOR.
Torch

• Do not put the torch or its cable on hot pieces; this would cause the insulating materials to melt, making the torch unusable after a very short time.
• Make regular checks on the gas pipe and connector seals.
• Accurately match collet and collet body with the selected electrode diameter in order to avoid overheating, bad gas diffusion and poor performance.
• At least once a day check the terminal parts of the torch for wear and make sure they are assembled correctly: nozzle, electrode, electrode-holder clamp, gas diffuser.
• Before using the welding machine, always check the terminal parts of the torch for wear and make sure they are assembled correctly: nozzle, electrode, electrode-holder clamp, gas diffuser.

Wire feeder

• Make frequent checks on the state of wear of the wire feeder rollers, regularly remove the metal dust deposited in the feeder area (rollers and wire-guide infeed and outfeed).

EXTRAORDINARY MAINTENANCE

EXTRAORDINARY MAINTENANCE MUST ONLY BE CARRIED OUT BY TECHNICIANS WHO ARE EXPERT OR QUALIFIED IN THE ELECTRIC-MECHANICAL FIELD, AND IN FULL RESPECT OF THE IEC/EN 60974-4 TECHNICAL DIRECTIVE.
WARNING! BEFORE REMOVING THE WELDING MACHINE PANELS AND WORKING INSIDE THE MACHINE MAKE SURE THE WELDING MACHINE IS SWITCHED OFF AND DISCONNECTED FROM THE MAIN POWER SUPPLY OULET.
If checks are made inside the welding machine while it is live, this may cause serious electric shock due to direct contact with live parts and/or injury due to direct contact with moving parts.

• Inspect the welding machine regularly, with a frequency depending on use and the dustiness of the environment, and remove the dust deposited on the transformer, reactance and rectifier using a jet of dry compressed air (max. 10 bar).
• Do not direct the jet of compressed air on the electronic boards; these can be cleaned with a very soft brush or suitable solvents.
• At the same time make sure the electrical connections are tight and check the wiring for damage to the insulation.
• At the end of these operations re-assemble the panels of the welding machine and screw the fastening screws right down.
• Never, ever carry out welding operations while the welding machine is open.
• After having carried out maintenance or repairs, restore the connections and wiring as they were before, making sure they do not come into contact with moving parts or parts that can reach high temperatures. Tie all the wires as they were before, being careful to keep the high voltage connections of the primary transformer separate from the low voltage ones of the secondary transformer.
  Use all the original washers and screws when closing the casing.

TROUBLESHOOTING

IN CASE OF UNSATISFACTORY FUNCTIONING, BEFORE SERVICING MACHINE OR REQUESTING ASSISTANCE, CARRY OUT THE FOLLOWING CHECK:

• Check that when general switch is ON the relative lamp is ON. If this is not the case then the problem is located on the mains (cables, plugs, outlets, fuses, etc.)
• There is no alarm signalling intervention of the thermostat safeguard, over or undervoltage or short-circuit.
• Check that the nominal intermittance ratio is correct. In case there is a thermal protection interruption, wait for the machine to cool down, check that the fan is working properly.
• Check the mains voltage: if the value is too high or too low the welding machine will be stopped.
• Check that there is no short-circuit at the output of the machine: if this is the case eliminate the incovenience.
• Check that all connections of the welding circuit are correct, particularly that the work clamp is well attached to the workpiece, with no interferring material or surface-coverings (ie. Paint).
• Protective gas must be of appropriate type and quantity.

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