Telwin MMA Welding Machines Instruction Manual

Telwin MMA Welding Machines

Product Specifications:

• Model: Cod.955202
• Features: TIG (AC/DC) HF/LIFT, MMA capabilities

Product Usage Instructions

Safety Warnings:
Ensure to follow all safety precautions mentioned in the user manual to prevent any accidents or injuries.

Power Connection:
Connect the power cord to a suitable power outlet following the voltage requirements specified in the manual.

Setting Up:
Adjust the machine settings according to the welding technique you intend to use (TIG, MMA).

Welding Process:
Start the welding process by striking an arc and moving the torch or electrode along the welding seam at a consistent pace.

Cooling System:
Monitor the machine’s cooling system to prevent overheating during prolonged use.

Frequently Asked Questions (FAQ):

1. Q: Can this machine be used for aluminum welding?
   A: Yes, this machine supports TIG welding with AC capabilities for aluminum welding.

2. Q: What is the recommended input voltage for this machine?
   A: The recommended input voltage is specified in the user manual; make sure to connect it to a compatible power source.

3. Q: How do I switch between TIG and MMA modes?
   A: Refer to the user manual for instructions on switching between TIG (HF/LIFT) and MMA modes.

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
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
DO NOT USE POWER WASHERS TO CLEAN THE MACHINE
DO NOT USE WATER TO CLEAN THE MACHINE
DO NOT USE VEHICLES TO TOW THE MACHINE
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

INVERTER WELDING MACHINES FOR TIG AND MMA WELDING DESIGNED FOR INDUSTRIAL AND PROFESSIONAL USE.
Note: In the following text the term “welding machine” will be used.

GENERAL SAFETY CONSIDERATIONS FOR ARC WELDING

The operator should be properly trained to use the welding machine safely and should be informed about the risks related to arc welding procedures, the associated protection measures and emergency procedures.
(Please refer to the applicable standard “EN 60974-9: Arc welding equipment. Part 9: Installation and Use).

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

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

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

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

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

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

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

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

• If 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 (Tab. 1).

WELDING MACHINE TECHNICAL DATA

• Idle state power consumption
  Power source efficiency

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 = 65 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;
• In 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 of adequate capacity for the weight; otherwise (e.g. tilted, disconnected flooring, etc.) there is an overturning hazard.

• It is forbidden to lift the trolley together with the welding machine and the cooling unit (when present).

• MISUSE: it is dangerous to use the welding machine for any work other than intended use (e.g. defrosting water mains piping).

• 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.
  Let the just welded workpiece cool before touching it!

• MISUSE: it is dangerous for more than one operator to simultaneously use the welding machine.

• WELDING MACHINE MOVEMENT: always secure the cylinder using suitable devices to prevent its accidental fall (if used).

• Do not use the handle to hang the welding machine.

ATTENTION! Any intervention on the torch or on the electrode holder or earth clamp, for example:

• Assembly of the torch;
• Replacement of consumables (nozzles, infusible electrode, etc.);
• Cleaning or maintenance.

MUST BE CARRIED OUT WITH THE WELDING MACHINE OFF AND DISCONNECTED FROM THE POWER MAINS.

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

INTRODUCTION
This welding machine is a source of current for arc welding, implemented specifically for TIG welding (AC/DC) with arc strike without contact (HF) or in contact (LIFT ARC).
This welding machine allows you to weld in alternating current (AC), aluminium and its alloys (AlSi, AlMg) but also all steel (carbon, stainless, low-alloys and high-alloys) in direct current (DC) and heavy metals (copper, nickel, titanium and their alloys), with pure Ar protection gas (99.9%) or, for particular uses, with Argon/Helium mixes.
It can also be used for MMA electrode welding in direct current (DC) using coated electrodes (rutile, acid, basic).
The specific characteristics of this welding machine (INVERTER), such as the high speed and adjustment precision give excellent welding quality.
Adjustment with the “inverter” system on the power line (primary) input also determines a drastic reduction in volume both of the transformer and the levelling reactance, allowing manufacture of a welding machine with extremely contained volume and weight, enhancing its manageability and movement.

MAIN CHARACTERISTICS
TIG

• AC/DC current.
• HF/LIFT strike.
• Continuous/pulsed operation.
• Operation selection 2T, 4T, 4T Bi-level, 2T Spot, 4T Spot (THIN SPOT).
• Automatic recognition of the type of torch (a button, button and UP/DW, button and potentiometer, water cooled).
• Automatic recognition of the water cooling unit (G.R.A.). (R.A. version only).
• Welding voltage and current shown on the TFT display.

MMA

• Arc force settings, Hot Start.
• VRD device.
• Anti-stick protection.
• Welding voltage and current shown on the TFT display.

OTHER

• Language setting.
• Metric or imperial system setting.
• Display mode setting (expert or easy, TIG only).
• Possibility of saving, referencing, importing and exporting customised programs (JOBS).
• Possibility of recording welding jobs (REC).
• Possibility of exporting a machine status report.
• Working hours counter.
• Alarms log (time-date and alarm type).

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).
• Anti-stick (MMA).
• Protection against overheating and insufficient pressure on the water cooling circuit of the torch (R.A. version only).

OPTIONAL ACCESSORIES

• Argon cylinder adapter.
• Trolley.
• TIG torch.
• Welding cable with electrode holder clamp.
• Welding cable with earth clamp.
• Manual remote command 2 potentiometers.
• Pedal remote command.
• G.R.A. water cooling unit.
• MMA welding kit.
• TIG welding kit.
• Various consumables kit.
• Coolant liquid for GRA water cooling unit.
• Auto-darkening mask: with fixed or adjustable filter.
• Gas fitting and gas tube for Argon cylinder connection.
• Pressure reducer with gauge.
• Various TIG welding type torches (4m, 8m, with torch button, with potentiometer , with Up/Down buttons, not cooled or water-cooled).

TECHNICAL SPECIFICATIONS

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

Fig. A

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:

   • U 1 : Alternating voltage and power supply frequency to the welding machine (allowed limits ±10%).
   • I 1 max : Absorbed maximum current from line.
   • I 1 eff : Effective power supply current.

10. Welding circuit performance:

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

    • I 2 / 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”.

Note: The data plate shown above is an example to give the meaning of the symbols and numbers; the exact values of technical data for the welding machine in your possession must be checked directly on the data plate of the welding machine itself.

OTHER TECHNICAL DATA
– WELDING MACHINE: see table 1 (TAB. 1).

• Idle state power consumption
  *Power source efficiency

TORCH TIG: see table 2 (TAB. 2).
TIG TORCH TECHNICAL DATA ACCORDING TO EN 60974-7

ELECTRODE HOLDER CLAMP: see table 3 (TAB. 3).
ELECTRODE HOLDER TECHNICAL DATA ACCORDING TO EN 60974-11

VOLTAGE CLASS: 113V

I max (A)| X (%)| Ø mm| Ø mm
300| 35| 3.25 ÷ 5| 35 ÷ 50
400| 35| 4.0 ÷ 6.3| 50 ÷ 70

AVERAGE CONSUMPTION OF WELDING GAS: see table 4 (TAB. 4).
SUGGESTED VALUES FOR WELDING

The weight is of the welding machine is outlined on table 1 (TAB. 1).

DESCRIPTION OF THE WELDING MACHINE

BLOCK DIAGRAM
The welding machine is essentially composed of power and control modules created on printed circuits optimised to obtain maximum reliability and less maintenance.
This welding machine is controlled by a microprocessor that allows setting a high number of parameters to enable optimal welding in every condition and on all material. It is however necessary, for its complete use, to know the operating potential.

Description (FIG. B)

1. Three-phase power line input, rectifier unit and levelling capacitors.
2. Switching bridge (IGBT) with transistors and drivers: it switches the voltage of the rectified line to alternating, high frequency voltage and adjusts power based on the required welding current/voltage.
3. High frequency transformer: primary winding is powered with the voltage converted by block 2; it has the function of adapting voltage and current to the values necessary for the arc welding procedure and, at the same time, galvanically isolate the welding circuit from the power line.
4. Secondary rectifier bridge with levelling inductance: it switches the alternating voltage / current provided by secondary winding to direct current / voltage with very low ripple.
5. Switching bridge to transistors (IGBT) and drivers; transforms output current to secondary from DC to AC for TIG AC welding (if planned).
6. Control and adjustment electronics; instantly controls the welding current value and compares it to the value set by the operator; it modulates control impulses of the drivers of the IGBT executing adjustment.
7. Welding machine operating control logic: sets the welding cycles, controls the actuators, supervises the safety systems.
8. Setting and display panel of the parameters and the operating modes.
9. HF strike generator (if planned).
10. EV gas protection solenoid valve.
11. Welding machine cooling fan.
12. Remote adjustment.

CONTROL, ADJUSTMENT AND CONNECTION DEVICES
Rear panel (FIG. C)

1. Main switch O/OFF – I/ON.
2. Supply cable (3P + E (Three-phase)).
3. Fitting for gas tube connection (cylinder-welding machine pressure reducer).
4. Auxiliary fuse box (ref. Wiring diagram).
5. Connector for CAD remote controls.
6. Connector for GRA water cooling unit.

Front panel FIG. D1

1. Quick coupling for connecting the welding current return cable.
2. Quick coupling for connecting electrode-holder clamp or TIG torch.
3. Fitting for connecting the gas tube of the TIG torch.
4. Connector for connecting the TIG torch control cable.
5. Control panel.

WELDING MACHINE CONTROL PANEL WITH TFT DISPLAY (FIG. D2)

1. TFT Display.
2. GAS TEST key: gas solenoid valve enabled (tubing bleeds, flow rate adjustment), without the need to use the torch button; once this button is pressed, the solenoid valve remains enabled for 10 seconds or until it is pressed again.
3. JOBS key: allows you to save, reference, export and import welding programs.
4. Multi-functional key, whose effect depends on the context and is referenced by an icon that appears on the display immediately above the key:
   • : access to settings menu;
   • : OK function or rather confirmation of the values chosen relating to the welding procedure (if you want to exit without saving press ESC);
   • : access the welding procedure selection menu (TIG/MMA/etc.).
5. Multi-functional key, whose effect depends on the context and is referenced by an icon that appears on the display immediately above the key:
   • : access the Easy Weld screen;
   • : access the Expert Weld (PRO) screen;
   • : ESC function or rather exit the current screen/parameter without saving any changes.
6. Multi-function knob:
   • rotate the knob to scroll through the various menu items;
   • if pressed, it allows you to access the selected item, rotation will change* the value, press again to confirm the value (if you want to exit without saving press ESC);
7. USB port.

• Setting of the parameters is generally free; however, there are combinations of values that have no practical meaning for welding. In this case, the relevant icon appears in grey and cannot be selected; in other cases, the variation range permitted for a parameter can depend on the other parameters previously selected.

WELDING MACHINE CONTROL PANEL WITH LCD DISPLAY (FIG. D3)

The LCD display (FIG. D3-1) allows you to display and set all the operating parameters of the welding machine, with the help of buttons (FIG. D3-2/3/4/5) and a knob (FIG. D3-6).
A detailed description of this panel and its functionality is found below (ref. section 4.4 and subsequent).

CONTROL PANEL WITH TFT DISPLAY (FIG. D2)
WELDING PROCEDURE SELECTION SCREEN
Pressing the Multi-Function key (FIG. D2-4), you access the screen that allows definition of the main characteristics of the procedure to use.

The first choice to make is the type of procedure (FIG. E-1):

• TIG HF (default): welding with infusible electrode and high frequency strike.
• TIG LIFT: welding with infusible electrode and contact strike.
• TIG HF PULSED.
• TIG LIFT PULSED.
• MMA: welding with coated electrode.
• MMA PULSE.

If the TIG procedure was selected in the previous step, you can then specify the sub-procedure which basically depends on the material to weld (FIG. E-2A/B):

• TIG AC (aluminium and its alloys, bronze).
• TIG DC (stainless steel or carbon steel, copper, bronze, titanium).
• MIX AC/DC (aluminium and its alloys, bronze).

Then, according to the specifications in the previous step, you can also specify:

• The type of waveform of the welding current for TIG AC (FIG. E-3):
  • Square.
  • Optimal (default).
  • Sinusoidal.
• the polarity of the welding current for TIG DC and MMA procedures (FIG. E-4):
  • DC- (Direct polarity).
  • DC+ (Reverse polarity).

In TIG DC, almost all applications require DC- polarity, while DC+ polarity can be used for particular processes.
In MMA, the polarity to use is specified by the manufacturer of the electrodes and normally given on the packaging (in general DC+ for basic electrodes and DC- for rutile electrodes).

For a TIG procedure, you can lastly select from the different welding profiles to manage by pressing the torch button (FIG. E-5):

• 2T.
• 4T.
• 4T Bilevel.
• 2T Spot / Thin Spot.
• 4T Spot / Thin Spot.

Once you have specified the procedure to use in detail, you can confirm the selections made by pressing the OK key or abandon the changes by pressing the ESC key.
The changes confirmed remain saved also after switching off the machine. Therefore, when the machine is switched back on it prepares to work according to the last procedure confirmed before previous switch-off.
After confirmation (or aborting) the changes, the TFT display will show the welding screen.

WELDING SCREEN (EXPERT WELD)
According to the type of procedure configured in the previous steps, the welding screen can appear differently.
In any case, the upper status bar will display a text referencing the main mnemonical procedure characteristics chosen (FIG. E-1).

For TIG procedures TIG (DC and AC), the welding screen will appear as in FIG. E-6, where you can configure the following parameters (also see FIG. N):

• Tungsten electrode diameter (AC only, FIG. E-7A): select based on the electrode actually being used; improves start (time and current of electrode pre-heating).
• Pre-gas: improves start (advance gas supply before arc strike).
• Start current Is: allows you to optimise the electric arc strike (passage from 0 to Is).
• Start time ts: optimises pre-heating of the workpiece (permanence time at Is).
• Initial ramp Sls: optimises pre-heating of the workpiece (passage from Is to I2).
• Main welding current I2, in amperes.
• End ramp Sle: avoid end crater in the welding bead (from I2 to Ie).
• End time te: allows optimised end of welding.
• End current le: allows optimised end of welding.
• Post-gas time: gas supply time after switching off the arc; protects the weld pool and electrode during cooling, avoiding its oxidation and rapid deterioration, optimising its duration and performance, in particular on strike.

CORRECT

EXCESSIVE CURRENT
CHECK OF THE ELECTRODE TIP
L= Ø IN DIRECT CURRENT

For TIG AC procedures, the AC sub-menu also appears (FIG. E-7B), where you can change, with reference to the current waveform:

• Frequency.
• Balancing: represents a ratio between time with the positive electrode and time with the negative electrode within a period of AC frequency; if the parameter value is positive, better surface cleaning and more heating of the electrode is obtained, if the parameter value is negative, you obtain more heating and penetration of the workpiece, if the parameter value is null, you obtain balance between cleaning and penetration (TAB. 5).

For TIG MIX AC/DC procedures, the MIX sub-menu also appears (FIG. E-7C), where you can change, with reference to the current waveform:

• the level of DC current as a % compared to the AC current.
• the period of time that passes between two subsequent AC pulses.
• the percentage of time in DC welding within the period.

For TIG 4T Bi-Level (DC and AC) procedures, the screen will appear as in FIG. E-17, where you can change, with reference to the current waveform:

• Base current I1: represents a second current level; % adjustment of the main current I2 For TIG PULSE (DC and AC) procedures, the screen will appear as in FIG. E-8, which in the PULSE sub-menu can vary, always with reference to the current waveform:
• Base current I1: represents a second level current; % adjustment of the main current I2; the welding current will change automatically between I1 and I2 with a defined frequency and balancing.
• Frequency: adjustment in Hz.
• Balancing, represents the ratio (in %) between the time in which the current is found at the welding main current level I2 and the total pulsation period.

For TIG SPOT (DC and AC) procedures, the screen will appear as in FIG. E-9, which in the SPOT sub-menu can vary, with reference to the current waveform:

• Time ON*.

• Time OFF.

• If the time ON is less or equal to 100ms, the procedure is defined “THIN SPOT” and the display TFT automatically displays the relevant text.
  Note that the 4T, 4T Bi-level, 2T SPOT and 4T SPOT functionalities can appear combined with the TIG DC and AC procedures, while they have no meaning for the MMA procedure. Also note the two panels with the voltage and current readings supplied by the welding machine.

For the MMA procedure, the welding screen will appear as in FIG. E-10a, where you can configure the following parameters:

• VRD on/off.
• Hot Start: this is the initial overcurrent (% adjustment) and the display shows the percentage increase as to the value of the selected welding current; this adjustment improves the start.
• Main welding current, in amperes.
• Arc Force: represents the dynamic overcurrent (% adjustment) and the display shows a percentage increase compared to the value of the welding current; this adjustment improves the fluidity of the welding, avoids sticking of the electrode on the workpiece and allows use of various types of electrodes.

For the MMA PULSE procedure, the welding screen will appear as in FIG. E-10b, where:

• I2: assumes the new meaning of the average current you wish to maintain, in amperes
• IPULSE: represents the ratio between the maximum value of the pulse current and the average current set (percentage value with adjustment 100-200%).

Note: the minimum value of the pulse is not set but calculated, in relation to the time function parameters, so that the average current is equal to that set.

• Freq: represents the number of pulses per second (value in Hertz with 0.2-99Hz adjustment).
• Bal: represents the ratio between the duration of the pulse compared to the total duration of the cycle (percentage value with 10-99% adjustment).

Also note the presence of a window with the voltage [V] and current [A] readings and also the diameter [mm] of the electrode recommended based on the current level set.

SETTINGS SCREEN
Pressing the JOBS key (FIG. D2-3), you can access the settings screen (FIG. E-11).

Selecting the SETUP (FIG. E-12) menu, you can set the following parameters:

• Language.
• Date/time.
• Measurement unit [metric or imperial].
• Machine name.

Selecting the SERVICE menu (FIG. E-13), you can access a series of sub- menus containing the relevant information on use and maintenance of the machine:

• Info: total start-up time of the machine, total welding activity time, alarms log and serial number.
• Firmware: upgrading, resetting the default values*, firmware version.
• Report: saving the USB key of a report with the alarms log and the current status of the welding machine (software installed, working life/hours, welding process set etc.).

Attention: resetting the default values will delete all the settings saved, however not the saved welding programs (JOBS), the alarms log and the working hours counter.

CALIBRATION
This generator allows you to calibrate current and voltage readings in compliance with standard EN 50504.
This procedure is reserved for specialist technicians. Contact your dealer for further information.

WATER COOLING UNIT (G.R.A.) MANAGEMENT
The welding machine recognises the presence of the original G.R.A. water cooling unit through appropriate polarisation of the GRA connector.
If the GRA water cooling unit is present and connected, selecting the AQUA menu (FIG. E-14), you can enable or disable it (if present, the GRA water cooling unit is enabled by default).
Attention! The GRA water cooling unit operation can be influenced by the type of torch used (see below).

• Solely and exclusively use the original GRA water cooling unit planned for this generator. With different models of GRA water cooling unit operation is not guaranteed and faults can occur on the generator or GRA water cooling unit or hazardous situations.

TIG TORCHES MANAGEMENT
The welding machine recognises the type of original torch connected through appropriate polarisation of the torch button connector.

According to the type of torch connected, the control panel can automatically propose different options in the settings menu (FIG. E-18):

• torch with potentiometer: the main welding current I2 is checked directly by the potentiometer of the torch; this function can be enabled or disabled manually by the settings menu, where you can also specify the working range of the potentiometer (FIG. E- 20).
• two-button torch with Up/Down: the main welding current I2 is checked directly by the second button of the torch; this function can be enabled or disabled manually by the settings menu, where you can also specify the working range of the Up/Down button (FIG. E- 20).
• air cooled torch: the G.R.A. water cooling unit, if present, is not enabled.
• water-cooled torch: pressing the torch button causes the automatic activation of the G.R.A. water cooling unit; when welding is complete, the GRA water cooling unit remains running for a few minutes to allow adequate cooling of the torch; if the GRA water cooling unit is not present or not connected, the display will show a warning on the possible damage of the torch due to overheating.

REMOTE CONTROL (C.A.D.) MANAGEMENT
The welding machine recognises the type of CAD original remote control connected through appropriate polarisation of the CAD connector.

According to the type of CAD remote control connected, the control panel can automatically propose different options in the settings menu (FIG. E-19):

• Remote control with two potentiometers: the first potentiometer adjusts the main current: the second potentiometer adjusts another parameter that depends on the enabled welding mode; turning one of the two potentiometers displays the parameter you are changing (which is no longer controllable with the handle of the panel); the meaning of the second potentiometer is: ARC FORCE if in MMA mode and END RAMP if in TIG mode.
• Pedal remote control: the current value is determined by the position of the pedal; it only works in 2-TIME TIG. Furthermore, pressing the pedal acts as a start command for the machine instead of the torch button.
• in the settings menu, it is also possible to specify the working range of the current potentiometer (FIG. E-20).
• When a CAD is combined with a torch with handle adjustment (potentiometer or UP/DOWN), the adjustment made on the torch prevails and the CAD is not considered.

WELDING PROGRAMS SCREEN (JOBS)
Pressing the JOBS key, you can directly access the welding programs screen (FIG. E-15):

• SAVE saves in the internal memory the current configuration by assigning them a chosen name (8 alphanumerical characters).
• RECALL recalls from the internal memory one of the previously saved configurations.
• DELETE deletes from the internal memory one of the previously saved configurations.
• IMPORT copies in the internal memory the configurations saved on a USB key.
• EXPORT copies on a USB key the configurations saved in the internal memory.
• REC saves on a USB type external memory the welding process in real time. For subsequent viewing with the PC “Welding Data Management” software.

EASY WELD SCREEN
For TIG procedures, when the TFT displays the EXPERT WELD screen, pressing the multi-function key (FIG. D2-5), you can enter the EASY WELD screen (FIG. E-16) and vice versa. On this screen, simply select the desired current level to automatically display the values recommended for the following parameters:

• Material thickness.
• Electrode diameter.
• Gas flow.

ALARMS
In the event of malfunctions, the display can show one or more of the following alarms (also see the next Troubleshooting section):

• Overheating (thermal protection).
• Overheating (I2 t).
• Undervoltage.
• Overvoltage.
• Primary overcurrent.
• TFT board power supply.
• Booster board power supply.
• Control board power supply.
• Torch button filter board power supply.
• Booster board communication error.
• Booster board communication loss.
• Control board communication error.
• Control board communication loss.
• Torch button filter board communication error.
• Torch button filter board communication loss.
• Current offset compensation error.
• G.R.A. water cooling unit. (if present, see the manual attached to the G.R.A. water cooling unit)*

Resetting is automatic when the reason for alarm activation stops.
On switching off the welding machine, one or more alarms may activate for a few seconds, however it should not be intended as a malfunction.
(*) In the event of a G.R.A. water cooling unit alarm, eliminate the cause of the alarm and then switch the welding machine off and on again.

USE OF CONTROL PANEL WITH LCD DISPLAY (FIG. D3)

1. LCD DISPLAY
   With the help of the buttons Fig. D3-2/3/4/5 and the knob Fig. D3-6, the LCD display allows you to display and set all the operating parameters of the welding machine.

2. Main setting button of welding process.
   Short press ( ):

   • welding with coated electrode (MMA).
   •  TIG welding with high frequency ark strike (TIG HF).
   • TIG welding with arc strike starting with contact (TIG HF).
   • in TIG mode, it indicates direct current welding (DC).
   • in TIG mode, it indicates alternating current welding (AC).
   • in TIG mode, it indicates alternating + direct current welding (MIX AC/ DC).
     Prolonged press (AQUA):
     In TIG mode and if G.R.A. (Water Cooling Unit) is present, it allows you to choose from 3 operating modes via the multifunction knob Fig. D3-6:
     AUTO: the GRA automatically activates only with the TIG torch water- cooled, otherwise it remains disabled.
     ON: the GRA enables during welding and switches off with a delay of a few minutes compared to the end of welding, independent of the type of TIG torch used.
     OFF: the GRA remains switched off.

3. Selection button of the operating mode.
   Short press (MODE), only for TIG procedures:

   • welding begins when the torch button is pressed and ends when the torch button is released.

   • welding begins when the torch button is pressed and released, and ends only when the torch button is pressed and released a second time.

   • welding begins when the torch button is pressed and released. On each short press/release the current passes from the value set  to the value and vice versa. Welding ends when the button is pressed for a set long time.
     enables spot welding (0.1-10s) with duration time control of the welding on a display (flashing icon).

   • enables short spot welding (0.01-0.09s) with duration time control of the welding on a display (flashing icon).
     Prolonged pressing (PULSE):

4. Save button of the welding programs (JOB SAVE) and test gas **.
   Short press  , only for TIG procedures:
   enables gas release for approximately 10 seconds (tube purging, flow rate adjustment); if the button is repressed during supply, the gas flow stops immediately.
   Prolonged press (JOB SAVE):**
   via the multifunction knob Fig. D3-6, it allows selection of the welding program where you can save the current configuration; saving with a prolonged press, exit without saving with a short press.

5. Retrieve button of the welding programs (JOB LOAD).
   Prolonged press (JOB LOAD):
   via the multifunction knob Fig. D3-6, it allows selection of a previously saved welding program; loading of the program with a prolonged press, exit without editing with a short press.

6. Multifunction knob with button and rotation.
   Based on the settings and the modes prepared, it enables selection and adjustment of the relevant parameters by displaying the value set on the display.
   In particular, for the MMA process, the parameters editable and shown on the display (Fig. D3-1) are:

   • VRD enabling/disabling the “Voltage Reduction Device” for a safe start at low voltage.

   • HOT START initial overcurrent to optimise welding arc strike (0-100% adjustment).

   • ARC FORCE dynamic overcurrent to optimise fluidity of the welding and avoid sticking of the electrode (0-100% adjustment).

   • main welding current in simple mode or in pulse mode, it is the average current value you want to maintain (output current in Amperes).

   • in pulse mode, it represents the ratio between the maximum value of the pulse current and the average current set (percentage value with adjustment 100-200%).
     Note: the minimum value of the pulse is not set but calculated, in relation to the time function parameters, so that the average current is equal to that set.

   • in pulse mode, it represents the number of pulses per second (value in Hertz with 0.2-99Hz adjustment).

   • in pulse mode, it represents the ratio between the duration of the pulse compared to the total duration of the cycle (percentage value with 10-99%adjustment).
     In particular, for the TIG process, the parameters editable and shown on the display (Fig. D3-1) are:

   • pre-gas time of safety gas flow before starting welding (0-10 seconds adjustment).

   • initial current maintained for a set time in 2T and for the time the button is pressed in 4T (adjustment in Amperes).

   • start ramp time of the current from value Is to I2 , in OFF ramp not present (0.1-10 seconds adjustment).
     N.B. : the parameters Is and TS can also be edited with the pedal remote command. Adjustment, however, must be made before activating the command itself.

   • main welding current (output current in Amperes).

   • in PULSE and Bi-Level mode, it represents the ratio between the maximum value of the pulse current and the main current (percentage value with adjustment 1-200%).

   • pulsation frequency, i.e. the parameter that adjusts the total time in which the current pulses on the two levels set and also, for AC/DC models in TIG AC, represents the repetition frequency of the entire current wave (positive and negative, adjustment in Hertz).

   • balance percentage, in PULSE (AC/DC) mode is the ratio between the time in which the current is at the highest level and the total pulsation period and also for AC/DC models in TIG AC it represents the ratio between the time with positive current and the time with negative current.

   • final ramp time of the current from value I2 to Iend , in OFF ramp not present (0.1-10 seconds adjustment).

   • final current, in 2T it is the current value of the arc after the final ramp if the ramp time is over zero, in 4T it is the current maintained after the final ramp for the entire time in which the torch button remains pressed (adjustment in Amperes).

   • post-gas time of safety gas flow starting from welding stoppage (0-10 seconds adjustment).

   • pre-heating energy in TIG AC, it adjusts pre-heating of the electrode to facilitate start-up. In OFF pre-heating not present (mm setting in relation to the diameter of the electrode used).
     Other explanatory icons on the display:

   • ALARM warning/alarm, in general combined with the code indicated on the display, drawing attention to possible anomalies/automatic protection activated on the welding machine.

   • thermal protection, combined with ALARM and the code on the display, warning  the condition of internal heating limits has been reached.

   • active output, indicates voltage is present in the output sockets of the welding machine.

   • remote command, indicates connection and control is active on the external commands or on the torch.

   • position pointer, in 4T with under a preset value, it indicates setting of a minimum initial current that makes the welding arc visible with button pressed. This allows precise selection of the starting point of the welding (if the initial current is set beyond a certain limit the function automatically disables).

   • PRG where planned, combined with the display indication of the active JOB number, it indicates the selected program whose parameters can be displayed, edited and saved.

   • when active, it indicates saving in progress of the welding program as set.

   • factory parameters, indicates setting of all the parameters at a preset value useful for wide-ranging operativity. The user can set the main current as wished to alter the other automatic settings.

DEFAULT reset procedure

It is possible to re-activate this condition at any time by switching off and back on the welding machine with the push-button on the multi-function knob (FIG. D3-6) pressed.

In the event of malfunctions, the display (Fig. D3-1) can show one or more of the following alarm codes (also see the next Troubleshooting section):

• AL.1 : thermal protection alarm.
• AL.3 : power line overvoltage protection has been triggered.
• AL.4 : power line undervoltage protection has been triggered.
• AL.8 : LCD panel auxiliary voltage out of range.
• AL.9 : malfunctioning of the G.R.A. water cooling unit (if present, see the manual attached to the G.R.A. water cooling unit)*
•  AL.13 : internal communication with Control board offline.
• AL.14 : internal communication with Control board error.
• AL.18 : auxiliary voltage Control board out of range.
• AL.20 : temperature monitoring sensor has been triggered (if planned).
• AL.22 : internal communication with Booster board offline.
• AL.23 : internal communication with Booster board error.
• AL.24 : auxiliary voltage Booster board out of range.
• AL.25 : internal communication with Torch Button Filter board.
• AL.26 : internal communication with Torch Button Filter error.
• AL.28 : intermittency ratio monitoring has been triggered.
• AL.29 : current sensor offset compensation monitoring has been triggered.
• AL.30 : primary overcurrent protection has been triggered.
• AL.31 : Control board software version incompatibility.
• AL.32 : Booster board software version incompatibility.
• AL.33 : Torch Button Filter board software version incompatibility.

Resetting is automatic when the reason for alarm activation stops.
(*) In the event of a G.R.A. water cooling unit alarm, eliminate the cause of the alarm and then switch the welding machine off and on again.
On switching off the welding machine, one or more alarms may activate for a few seconds, however it should not be intended as a malfunction.

INSTALLATION

WARNING! CARRY OUT ALL INSTALLATION OPERATIONS AND ELECTRICAL CONNECTIONS WITH THE WELDING MACHINE COMPLETELY SWITCHED OFF AND DISCONNECTED FROM THE POWER SUPPLY OUTLET.
THE ELECTRICAL CONNECTIONS MUST BE MADE ONLY AND EXCLUSIVELY BY AUTHORISED OR QUALIFIED PERSONNEL.

SET-UP
Unpack the welding machine, assemble the detached parts, contained in the packaging (if planned).

Assembling the clamp-return cable (Fig. F)

Assembling the welding cable electrode-holder clamp (Fig. G)

POSITION OF THE WELDING MACHINE
Choose the place to install the welding machine so that the cooling air inlets and outlets are not obstructed (forced circulation by fan, if present); at the same time make sure that conductive dusts, corrosive vapours, humidity etc. will not be sucked into the machine. Leave at least 250mm free space around the welding machine.
WARNING! Position the welding machine on a flat surface with sufficient carrying capacity for its weight, to prevent it from tipping or moving hazardously.

CONNECTION TO MAINS

• Before making any electrical connection, check the rating plate on the welding machine corresponds to the mains voltage and frequency available in the installation location.
• The welding machine must only be connected to a mains power supply with neutral conductor connected to earth.
• To guarantee protection against indirect contact, use the differential automatic switches type:
  • Type B ( ) for three-phase machines.
• To meet the requirements of the standard EN 61000-3-11 (Flicker), you are advised to connect the welding machine to the interface points of the power mains with an impedance under Zmax = 0.283 ohm (3~).
• The welding machine is within the requirements of standard IEC/EN 61000-3-12.

Plug and socket
Connect a standard plug (3P + E (3~)) to the power supply cable with adequate capacity and use a mains socket equipped with fuses or an automatic switch; the specific earth lug must be connected to the earth conductor (yellow-green) of the power supply line. Table 1 (TAB. 1) provides the recommended values in amperes of the line slow blow fuses chosen based on the max nominal current supplied by the welding machine and at the power supply nominal voltage.
ATTENTION! Failure to comply with the above rules renders the safety system (class I) ineffective, with resulting serious risks for people (e.g. electric shock) and for property (e.g. fire).

WELDING CIRCUIT CONNECTIONS
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 the welding cables (in mm2) according to the maximum energy supplied by the welding machine.

TIG welding
Connecting the torch (Fig. D1)

• Insert the current cable in the specific fast clamp. Connect the eight-pole connector (torch button) to the specific socket. Connect the gas tube of the torch to the specific connection.

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. This cable should be connected in the specific fast clamp.

Connecting the gas cylinder

• Screw the pressure reducer to the gas cylinder by imposing the specific reduction supplied as an accessory (when Argon gas is used).
• 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 4 (TAB. 4); 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.

MMA welding
Connecting the electrode-holder clamp welding cable (Fig. D1)
Bring a special clamp on the clamp used to tighten the exposed part of the electrode. This cable should be connected in the specific fast clamp.

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.
This cable should be connected in the specific fast clamp.

Recommendations:

• Fully rotate the welding cable connectors in the quick coupling (if present), to guarantee perfect electrical contact; on the contrary, the connectors will overheat causing their rapid wear and loss of efficiency.
• Use welding cables that are as short as possible.
• Do not use metal structures that are not part of the workpiece, when replacing the welding current return cable; this can endanger safety and give unsatisfactory cleaning results.

WELDING: PROCESS DESCRIPTION

TIG WELDING
TIG welding is a welding procedure that takes advantage of the heat produced by the electric arc which is struck, and maintained, between an infusible electrode (Tungsten) and the piece to weld. The Tungsten electrode is supported by a torch suitable for transmission of the welding current and protecting the electrode itself and the welding bath from atmospheric oxidation through an inert gas flow (normally Argon: Ar 99.5%) which exits the ceramic nozzle (FIG. H).

TORCH

THE ARGON, INERT GAS, PROTECTS THE WELDING PUDDLE FROM OXIDATION

1. FILLER ROD IF NEEDED –
2. NOZZLE
3. PUSHBUTTON
4. GAS
5. CURRENT
6. TORCH BUTTON CABLES
7. PIECE TO BE WELDED
8. ELECTROD

For the welding to be good, the exact diameter of the electrode must be used with the exact current, see table (TAB. 4).
The electrode normally projects from the ceramic nozzle by 2-3 mm, 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) (FIG. I).

Preparation of the folded edges for welding without weld material
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 (FIG. L).

Preparation of the edges for butt weld joints to be welded with weld material
For welding to be successful, the workpieces must be carefully cleaned and be free of oxide, grease, oil, solvent, paint, etc.

START HF and LIFT
Start HF:
Electric arc ignition takes place without contact between the tungsten electrode and the workpiece to weld, using a spark generated by a high frequency device.
This strike mode does not involve tungsten inclusions in the welding bath or wear of the electrode and offers easy start-up of all welding positions.

Procedure:
Press the torch button by placing the tip of the electrode (2-3mm) close to the workpiece, wait for striking of the arc transferred to the HF impulses and, when the arc has ignited, form the weld pool on the workpiece and proceed along the joint.
If arc strike is difficult to achieve, despite ensuring gas is present and the HF discharges are visible, do not persist for long in subjecting the electrode to HF action, but check its surface intactness and the shape of the tip, if necessary implement grinding wheel truing.

Start LIFT:
The electric arc ignites by distancing the tungsten electrode from the workpiece to weld. Igniting in this manner causes less electric-irradiated disturbances and reduces tungsten inclusions and electrode wear to a minimum.

Procedure:
Place the tip of the electrode on the workpiece, pressing gently. Fully press the torch button and lift the electrode 2-3mm with a delay of a few seconds, thereby obtaining arc strike. Initially, the welding machine supplies ILIFT current and, after a few seconds, the welding current set will be supplied.

TIG DC Welding
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.
An electrode with 2% Thorium (red band) or an electrode with 2% Cerium (grey band) is normally used for TIG DC welding.
For good welding, it is advisable to refer to TAB. 4 which indicates the diameter of the electrode, current and gas flow based on the thickness you intend welding.
The tungsten electrode must be axially sharpened using a grinding wheel, see FIG. M; 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. In TIG DC mode, 2-time (2T) and 4-time (4T) operation is possible.

TIG AC Welding
This type of welding allows you to weld on metals such as aluminium and magnesium that form a protective oxide and insulation on their surface. By inverting Tungsten electrode polarity during welding, you can “break” the surface layer of oxide via a mechanism called “ionic sandblasting”.
Within the period of AC frequency, the Tungsten electrode is alternatively positive (EP = DC+) and negative (EN = DC-). During the EP time, the oxide is removed from the surface (“cleaning” or “pickling”) allowing bath formation. During the EN time, the maximum thermal contribution takes place on the workpiece allowing welding. The possibility of varying the balance parameter in AC allows you to reduce EP to the minimum for faster welding. Higher balance values enable better cleaning of the workpiece, but also more heating of the electrode.
Lower balance values allow faster welding, higher penetration, more concentrated arc, a narrower welding bath and limited heating of the electrode.
Using too high a balance value would widen the arc and the deoxidised part, heating of the electrode resulting in ball formation on the tip and more difficult striking and direction of the arc.
Using too low a balance value would cause a “dirty” welding bath with dark inclusions and instability of the electric arc.
The table (TAB. 5) summarises the effects of changing the AC welding balance.
In TIG AC mode, 2-time (2T) and 4-time (4T) operation is possible.
The instructions are also valid regarding the welding procedure.
The table (TAB. 4) outlines the guide data for welding on aluminium; the type of most suitable electrode is pure tungsten (green strip).

TIG MIX AC/DC welding
This type of welding allows you to increase the execution speed of the TIG AC procedure, periodically alternating a welding section in alternating current (AC) and a welding section in direct current with negative electrode (DC-). This mixed procedure is normally used with medium-high current levels and on very thick workpieces, where greater heat input speeds up welding without the risk of breaking the workpiece.
The typical parameters of this procedure are the DC current level expressed as a percentage compared to the AC current, the cycle time that represents the time interval between the two subsequent sections of DC welding, the ratio between the duration of DC welding and the cycle time.
Using excess values for the DC component can cause an insufficient deoxidising action and an unstable electric arc.

Procedure

• Use the knob to adjust the welding current to the required rate; adjust this value during welding to adapt to the actual heat transfer required.
• Press the torch button, checking correct flow of gas from the torch; if necessary, calibrate the pre-gas and post-gas time; these times should be adjusted based on the working conditions, in particular the post-gas delay must be such to allow cooling of the electrode and the bath when welding is complete without coming in contact with the atmosphere (oxidation and contamination).

TIG mode with 2T sequence:

• Fully press the torch button (P.T.) to strike the arc with current ISTART. Then, the current increases according the START RAMP up to the welding current value.
• To interrupt welding, release the torch button which would cause gradual current elimination (if END RAMP function inserted) or on immediate extinguishing of the arc with immediate post-gas.

TIG mode with 4T sequence (Fig. N):

• The first press of the button strikes the arc with current ISTART. On releasing the button, the current increases according to the START RAMP function up to the welding current value; this value is maintained also with the button released. When the button is pressed again, the current decreases according to the END RAMP function up to IEND. The latter is maintained up to release of the button which terminates the welding cycle starting with the post-gas period. Instead, if during the END RAMP function the button is released, the welding cycle immediately terminates and the post-gas period starts.

TIG mode with 4T sequence and BI-LEVEL (Fig. N):

• The first press of the button strikes the arc with current ISTART. On releasing the button, the current increases according to the START RAMP function up to the welding current value; this value is maintained also with the button released. On each subsequent press of the button (the time that passes between pressing and release must be short), the current will vary between the value set in the BI-LEVEL I1 parameter and the main current value I2.
• Keeping the button pressed for a long time, the current decreases according to the END RAMP function up to IEND. The latter is maintained up to release of the button which terminates the welding cycle starting with the post-gas period. Instead, if during the END RAMP function the button is released, the welding cycle immediately terminates and the post-gas period starts (FIG. N).

TIG SPOT mode:

• Welding takes place by keeping the torch button pressed on reaching the preset time (spot time).

MMA WELDING

• 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:

• 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 welding characteristics also depend on the ARC-FORCE value (dynamic behaviour) of the welding machine. This parameter is settable from the panel, or you can set with the 2- potentiometer remote control.

• Note that ARC-FORCE high values give better penetration and allow welding of any position typically with basic electrodes, low ARC-FORCE values allow a softer arc free of sprays typically with rutile electrodes.
  The welding machine is also equipped with HOT START and ANTI-STICK devices that guarantee easy start-up and no sticking of the electrode on the workpiece.

• 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.

MMA PULSE Welding
This type of welding allows you to reduce the heat input and more easily obtain an aesthetic weld typically used in vertical implementation with thin sheet metal and with gaps present. In this work mode, the parameter l2 assumes the meaning of average current you want to maintain, in amperes.

The other typical parameters of this procedure are:

• IPULSE which represents the ratio between the maximum value of the pulse current and the average current set (percentage value with adjustment 100-200%).
  Note: the minimum value of the pulse is not set but calculated, in relation to the time function parameters, so that the average current is equal to that set.

• Freq which represents the number of pulses per second (value in Hertz with 0.2-99Hz adjustment).

• Bal which represents the ratio between the duration of the pulse compared to the total duration of the cycle (percentage value with 10-99% adjustment).

Procedure

• Holding the mask IN FRONT OF THE FACE, strike the electrode tip on the workpiece as if you were striking a match. This is the correct strike-up method.
  WARNING: do not hit the electrode on the workpiece, this could damage the electrode and make strike-up difficult.

• As soon as arc is ignited, try to maintain a distance from the workpiece equal to the diameter of the electrode in use. Keep this distance as much constant as possible for the duration of the weld. Remember that the angle of the electrode as it advances should be of 20-30 grades.

• At the end of the weld bead, bring the end of the electrode backward, in order to fill the weld crater, quickly lift the electrode from the weld pool to extinguish the arc (CHARACTERISTICS OF THE WELD BEAD – FIG. O).

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.
• Carefully couple the electrode tightening clamp, clamp holder chuck and ceramic nozzle with the diameter of the electrode chosen to avoid overheating, poor gas dispensing and welding defects.
• At least once a day, check the wear status and correctness of the assembly of the torch terminal parts: electrode, electrode tightening clamp, clamp holder chuck and ceramic nozzle.

EXTRAORDINARY MAINTENANCE
EXTRAORDINARY MAINTENANCE OPERATIONS SHOULD BE CARRIED OUT ONLY AND EXCLUSIVELY BY SKILLED OR AUTHORISED ELECTRICAL-MECHANICAL TECHNICIANS AND IN COMPLIANCE WITH THE TECHNICAL STANDARD IEC/EN 60974-4.
ATTENTION! BEFORE REMOVING THE WELDING MACHINE PANELS AND GOING INSIDE, MAKE SURE THE WELDING MACHINE IS SWITCHED OFF AND DISCONNECTED FROM THE MAIN POWER SUPPLY.
If checks are carried out while the inside of the welding machine is live, this could cause a serious electric shock due to direct contact with live parts and/or injury due to direct contact with moving units.

• Periodically and however with a frequency based on use and the dust levels in the environment, inspect the inner welding machine and remove dust deposited on the electronic boards with a very soft brush and a vacuum cleaner. Avoid blowing compressed air, dispersing the dust.
• Also check the electrical connections are well-tightened and the cabling has no insulation damage.
• Having completed these operations, re-assemble the welding machine panels by tightening the fastening screws completely.
• Strictly avoid carrying out any welding operations with the welding machine open.
• Having carried out maintenance and repairs, restore the connections and wiring as they were originally, taking care they do not obstruct any moving parts or parts which can reach high temperatures. Wrap all the conductors as they were originally, taking care to keep the high voltage primary connections clearly separated from the secondary low voltage connections.
  Use all the washers and original screws to close the framework up again.

TROUBLESHOOTING

IN THE EVENT OF UNSATISFACTORY OPERATION AND BEFORE CARRYING OUT MORE SYSTEMATIC CHECKS OR CONTACTING YOUR SUPPORT CENTRE, CHECK THAT:

• The welding current is adequate for the diameter and type of electrode used.
• With the main switch “ON”, the relevant light is on; on the contrary, the defect normally lies on the power line (cables, socket and/or plug, fuses, etc.).
• The yellow led is not on, signalling intervention of the safety thermal switch for over or undervoltage or short circuit.
• Ensure you have observed the nominal duty cycle ratio; in the event of intervention of the thermostatic protection, wait for the machine to cool naturally, check the fan is working.
• Check the line voltage, if the value is too high or too low, the welding machine remains blocked.
• Check there is no short circuit on welding machine output: in this case, proceed to eliminate the problem.
• The welding circuit connections are carried out correctly, particularly the earth cable clamp is actually connected to the piece and without inter-positioning insulating materials (e.g. paint).
• The protection gas used is correct (Argon 99.5%) and the right amount.

GUARANTEE
The manufacturer guarantees proper operation of the machines and undertakes to replace free of charge any parts should they be damaged due to poor quality of materials or manufacturing defects within 12 months of the date of commissioning of the machine, when proven by certification. Returned machines, also under guarantee, should be dispatched CARRIAGE PAID and will be returned CARRIAGE FORWARD. This with the exception of, as decreed, machines considered as consumer goods according to European directive 1999/44/EC, only when sold in member states of the EU. The guarantee certificate is only valid when accompanied by an official receipt or delivery note. Problems arising from improper use, tampering or negligence are excluded from the guarantee. Furthermore, the manufacturer declines any liability for all direct or indirect damages.

CERTIFICATE OF GUARANTEE
MOD.
NR
Date of buying
Sales company (Name and Signature)
The product is in compliance with:

DIRECTIVES
LVD 2014/35/EU + Amdt.
EMC 2014/30/EU + Amdt.
RoHS 2011/65/EU + Amdt.
ErP 2009/125/EC + Amdt.
CR 2019/1784/EU + Amdt.

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