Maxima 230 - Welding machine Telwin - Free user manual and instructions

USER MANUAL Maxima 230 Telwin

BEFORE USING THE WELDING MACHINE READ THE INSTRUCTION MANUAL CAREFULLY. CONTINUOUS WIRE WELDING MACHINE FOR MIG-MAG ARC AND FLUX, TIG, MMA WELDING FOR PROFESSIONAL AND INDUSTRIAL USE. NB: The following text uses the term "Welding machine" and "Multiprocess Welding Machine" for models prepared for MIG-MAG AND FLUX, TIG, MMA welding.

1. 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 o and disconnected from the power supply outlet. - Switch o 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. - Do not weld on containers or piping that contains or has contained ammable 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 ammable 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 lters, 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 re-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-reective 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). - The ow of the welding current generates electromagnetic elds (EMF) around the welding circuit. Electromagnetic elds can interfere with certain medical equipment (e.g. Pace-makers, respiratory equipment, metallic prostheses etc.). Adequate protective measures must be adopted for persons with these types of medical apparatus. For example, they must be forbidden access to the area in which welding machines are in operation. This welding machine conforms to technical product standards for exclusive use in an industrial environment for professional purposes. It does not assure compliance with the basic limits relative to human exposure to electromagnetic elds in the domestic environment. The operator must adopt the following procedures in order to reduce exposure to electromagnetic elds: - Fasten the two welding cables as close together as possible. - Keep head and trunk as far away as possible from the welding circuit. - Never wind welding cables around the body. - Avoid welding with the body within the welding circuit. Keep both cables on the same side of the body. - Connect the welding current return cable to the piece being welded, as close as possible to the welding joint. - Do not weld while close to, sitting on or leaning against the welding machine (keep at least 50 cm away from it). - Do not leave objects in ferromagnetic material in proximity of the welding circuit. - Minimum distance d= 20 cm (Fig. G). - 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 conned spaces; - In the presence of ammable 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 dierent 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”. RESIDUAL RISKS - OVERTURNING: position the welding machine on a horizontal surface that is able to support the weight: otherwise (e.g. inclined or uneven oors etc.) there is danger of overturning.- 6 - - 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). - 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.

2. INTRODUCTION AND GENERAL DESCRIPTION

This welding machine is a source of current for arc welding, made specically for MAG welding carbon steel or weak alloys with CO

protective gas or Argon/CO

mixes, using full or core electrode wires. It is also ideal for MIG welding stainless steel with Argon gas containing + 1-2% oxygen and aluminium and CuSi (brazing) with Argon gas, using electrode wires that are suitable for the workpiece to be welded. Suitable core wires can also be used without Flux protection gas, adapting torch polarity according to the indications of the wire producer. SYNERGIC operation ensures fast and easy welding parameter setting, always guaranteeing high arc control and welding quality. It is particularly suitable for light metalwork fabrication and in body shops, for welding galvanized plates, high stress stainless steel and aluminium. MULTIPROCESS VERSION: 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 - Synergic (automatic) operation; - Burn-back time based on wire speed; - Thermostatic safeguard; - Protection against accidental short-circuits caused by contact between torch and earth; - Protection against irregular power supplies (power supply voltage too high or too low); - Polarity reversal (Flux Welding) (where applicable); TIG (multiprocess version only) - Start LIFT; MMA (multiprocess version only) - Hot start and anti-stick devices preset; - Arc-force adjustment - Indication of recommended electrode diameter based on welding current; STANDARD ACCESSORIES - torch; - return cable complete with earth clamp; OPTIONAL ACCESSORIES - Argon bottle adapter; - Trolley (where applicable); - Self darkening helmet; - MIG/MAG welding kit; - MMA welding kit; - TIG welding kit.

DATA PLATE The most important data regarding use and performance of the welding machine are summarised on the rating plate and have the following meaning: Fig. A

1- EUROPEAN standard of reference, for safety and construction of arc

2- Symbol for internal structure of the welding machine.

3- Symbol for welding procedure provided.

4- Symbol S: indicates that welding operations may be carried out in

environments with heightened risk of electric shock (e.g. very close to large metallic volumes).

5- Symbol for power supply line:

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

6- Protection rating of the covering.

7- Technical specications for power supply line:

: Alternating voltage and power supply frequency of welding machine (allowed limit ±10%). - I 1 max : Maximum current absorbed by the line. - I

: eective current supplied.

8- Performance of the welding circuit:

: current and corresponding normalised voltage that the welding machine can supply during welding. - X : Duty cycle: indicates the time for which the welding machine can supply the corresponding current (same column). It is expressed as %, based on a 10 min. cycle (e.g. 60% = 6 minutes working, 4 minutes pause, and so on). If the usage factors (on the plate, referring to a 40°C environment) are exceeded, the thermal safeguard will trigger (the welding machine will remain in standby until its temperature returns within the allowed limits). - A/V-A/V : shows the range of adjustment for the welding current (minimum maximum) at the corresponding arc voltage.

9- Manufacturer’s serial number for welding machine identication

(indispensable for technical assistance, requesting spare parts, discovering product origin).

: Size of delayed action fuses to be used to protect the power line.

11- Symbols referring to safety regulations, whose meaning is given in

chapter 1 “General safety considerations 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) - MIG TORCH: see table 2 (TAB. 2) - TIG TORCH: see table 3 (TAB. 3) - ELECTRODE-HOLDER CLAMP: see table 4 (TAB. 4) The weight is of the welding machine is outlined on table 1 (TAB. 1).

4. DESCRIPTION OF THE WELDING MACHINE

CONTROL, ADJUSTMENT AND CONNECTION DEVICES. WELDING MACHINE (Fig. B1, B2) At the front:

1- Control panel (see description).

2- Welding cable and torch.

5- Positive (+) fast coupling for connecting the welding cable.

6- Negative (-) fast coupling for connecting the welding cable.

7- Fast coupling plug connected to the torch coupling.

8- Main ON/OFF switch.

1- Mains voltage present signalling led.

2- Alarm signalling led (activation of safety thermostat, short circuit

between torch and earth cable, over/undervoltage).

MIG-MAG MODE: Material thickness adjustment (welding power). MMA MODE (multiprocess version only): Adjustment of welding current indicating the recommended electrode diameter. TIG MODE (multiprocess version only): Adjustment of welding current.

: Adjustment of the welding seam (arc length); : default setting. : lower arc voltage. : upper arc voltage. MMA MODE (multiprocess version only): Adjustment of arc force (0-100%). TIG MODE (multiprocess version only): not enabled.

5- MIG-MAG, TIG or MMA welding process selector (multiprocess

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 sucient 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: - A type ( ) for single-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 = 0.24 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 the power supply plug to a mains socket tted with fuses or an automatic circuit-breaker; the corresponding earth terminal should be connected to the (yellow-green) earth conductor of the power supply. Table 1 (TAB. 1) shows the recommended delayed fuse sizes, in amps, for the main supply, which have been chosen according to the maximum rated current output from the welding machine, and to the nominal power supply voltage. WARNING! Non-compliance with the above regulations renders the manufacturer’s safety system (class I) inecient, with resulting serious risks to people (e.g. electric shock) and things (e.g. re).

CONNECTIONS MAKE SURE THAT THE WELDING MACHINE IS SWITCHED OFF AND DISCONNECTED FROM THE POWER SUPPLY. Table 1 (TAB. 1) shows the recommended sizes of the welding cables (in mm

), according to the maximum current output from the welding machine. Furthermore: - Fully rotate the welding cable connectors in the fast coupling (if present), to guarantee perfect electrical contact; on the contrary, the connectors will overheat causing their rapid wear and loss of eciency. - 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 CIRCUIT CONNECTIONS IN MIG-MAG MODE

Connecting to the gas bottle (if used) - The gas bottle that can be positioned on the trolley supporting surface: max 30kg. - Gas bottle can be loaded on welding machine bottle support platform: max 30kg (for 180A version only). - Screw the pressure reducer(*) onto the gas bottle, inserting the appropriate adapter supplied as an accessory when Argon or an Argon/

mixture is used. - Connect the gas input hose to the reducer and tighten the clamp. - Loosen the adjustment ring nut on 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 Must be connected to the workpiece or to the metal bench on which it is positioned, keeping it as close as possible to the joint being done. Torch Prepare the torch when loading the wire for the rst time, by dismantling the nozzle and the contact tip, to ease its exit. Internal polarity change Fig. B1 - Open the reel area door. - MIG/MAG welding (gas): - Connect the torch cable to the red clamp (+) (Fig. B-11) - Connect the clamp return cable to the negative fast coupling (-) (Fig. B-12). - FLUX welding (no gas): - Connect the torch cable to the black clamp (-) (Fig. B-12). - Connect the clamp return cable to the positive fast coupling (+) (Fig. B-11). - Close the reel area door. External polarity change (multiprocess version only) Fig. B1 - MIG/MAG welding (gas): - Connect the torch cable to the torch coupling (Fig. B-4). - Connect the fast coupling plug (Fig. B-7) to the positive coupling plug (+) (Fig. B-5).- 8 - - Connect the clamp return cable to the negative fast coupling (-) (Fig. B-6). - FLUX welding (no gas): - Connect the torch cable to the torch coupling (Fig. B-4). - Connect the fast coupling plug (Fig. B-7) to the negative coupling (-) (Fig. B-6). - Connect the clamp return cable to the positive fast coupling (+) (Fig. B-5).

WELDING CIRCUIT CONNECTIONS IN TIG MODE

Gas cylinder connection - Screw the pressure reducer onto the cylinder gas valve, if necessary, inserting the specic reduction supplied as an accessory. - Connect the input hose of the gas reducer and tighten with the supplied strip. - Loosen the adjustment 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. 5); any adjustments in gas ow can be carried out during welding always using the pressure reducer ring nut. Check the tubing and ttings. WARNING! Always close the gas cylinder valve at the end of work. 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. B-5). Torch - Insert the current cable in the specic fast clamp (-) (Fig. B-6). 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 (Fig. D2) 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. B-5). 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. B-6). LOADING THE WIRE REEL (Fig. E) WARNING! BEFORE STARTING THE OPERATIONS TO LOAD THE WIRE MAKE SURE THE WELDING MACHINE IS SWITCHED OFF AND DISCONNECTED FROM THE MAIN POWER SUPPLY OUTLET. MAKE SURE THAT THE WIRE FEEDER ROLLERS, THE WIRE GUIDE HOSE AND THE CONTACT TIP OF THE TORCH MATCH THE DIAMETER AND TYPE OF WIRE TO BE USED AND MAKE SURE THAT THESE ARE FITTED CORRECTLY. WHEN INSERTING AND THREADING THE WIRE DO NOT WEAR PROTECTIVE GLOVES. - Open the reel compartment door. - Position the wire reel on the spindle, holding the end of the wire upwards; make sure the tab for pulling the spindle is correctly seated in its hole (1a). - Release the pressure counter-roller(s) and move them away from the lower roller(s) (2a-b); - Make sure that the towing roller(s) is suited to the wire used (2c). - Free the end of the wire and remove the distorted end with a clean cut and no burr; turn the reel anti-clockwise and thread the end of the wire into the wire-guide infeed, pushing it 50-100mm into the wire guide of the torch tting (2d). - Re-position the counter-roller(s), adjusting the pressure to an intermediate value, and make sure that the wire is correctly positioned in the groove of the lower roller(s) (3) - Remove the nozzle and contact tip (4a). - Insert the welding machine plug in the power supply outlet, switch on the welding machine, press the torch button and wait for the end of the wire to pass through the whole of the wire guide hose and protrude by 10-15 cm from the front part of the torch, release the button. WARNING! During these operations the wire is live and subject to mechanical stress; therefore if adequate precautions are not taken the wire could cause hazardous electric shock, injury and striking of electric arcs: - Do not direct the mouthpiece of the torch towards parts of the body. - Keep the torch away from the gas bottle. - Re-t the contact tip and the nozzle onto the torch (4b). - Check that wire feed is regular; set the roller and spindle braking pressure to the minimum possible values making sure that the wire does not slide in the groove and when feed is halted the loops of wire are not loosened by excessive reel inertia. - Cut the end of the wire so that 10-15 mm protrude from the nozzle. - Close the reel compartment door.

6. WELDING: DESCRIPTION OF PROCEDURE

SHORT ARC The wire melts and the bead detaches as a result of the subsequent short- circuits in the wire tip positioned in the weld pool (up to 200 times per second). The wire stick-out is normally between 5 and 12 mm. Carbon steel and low-alloy steel - Usable wire diameter: 0.6 - 0.8 mm (1.0 mm - 180 A version) - Usable gas: CO

0.8 - 0.9 mm (115 A version)

The bead shape is adjusted using the knob (Fig. C-4) which adjusts the arc length and thus determines the greater or lesser intake of the sealing temperature. Referring to the table available in the machine (Fig. F), set the knob (Fig. C-4) depending on the material, wire and gas used. The points A, B, C, D represent good starting points for welding in dierent working conditions. Convex shape: it means that there is a low thermal transfer, therefore the welding, is “cold”, with little penetration; rotate the knob clockwise to obtain a higher thermal transfer with the eect of a weld with higher fusion. Concave shape: it means that there is a high thermal transfer, therefore the welding is too “hot”, with excessive penetration; turn the knob counterclockwise to obtain a lower melting. SETTING THICKNESS The setting of the thickness is carried out by adjusting the knob (Fig. C-3). This knob regulates the welding power according to sheet thickness and aects simultaneously the wire feeder speed as well as the amount of current transferred to the ller wire. Referring to the table provided in the machine (Fig. F), set the knob (Fig. C-3) depending on the material, wire, gas, and thickness that will be welded.

7. TIG DC WELDING: DESCRIPTION OF THE PROCEDURE (multiprocess

version only) 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. H). 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. I; 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- 9 - when the electrode itself has been accidentally contaminated, oxidised or used incorrectly. For the welding to be good, the exact diameter of the electrode must be used with the exact current, see table (TAB. 5). 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. L). 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. M). For welding to be successful, the pieces must be carefully cleaned and free from oxide, grease, oil, solvent, etc. PROCEDURE (LIFT STRIKE) - Adjust the welding current to the desired value using knob C-3; Adapt the current during welding to the real thermal load necessary. - Make sure the gas is owing 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÷3 mm 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.

8. MMA WELDING: DESCRIPTION OF THE PROCEDURE (multiprocess

version only) 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.

- One can see that for the same diameter electrode, high levels of current will be used for at 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).

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.

WARNING: DO NOT TAP the electrode against the workpiece, which

could damage the coating and make arc striking dicult. - 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 ll it, then quickly lift the electrode from the weld pool to switch o the arc (Aspects of the welding seam - Fig. N).

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; - Every time the wire reel is changed, blow out the wire-guide hose using dry compressed air (max. 5 bar) to make sure it is not damaged; - Before every use, check the wear and correct assembly of the parts at the end of the torch: nozzle, contact tip, gas diuser. 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 OUTLET. 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 rectier 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.

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.) - Check that the yellow led (ie. thermal protection interruption- either over or undervoltage or short circuit) is not lit. - 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.- 10 - (IT) MANUALE ISTRUZIONE ATTENZIONE: PRIMA DI UTILIZZARE LA SALDATRICE LEGGERE ATTENTAMENTE IL MANUALE DI ISTRUZIONE. SALDATRICE A FILO CONTINUO PER LA SALDATURA AD ARCO MIG-MAG E FLUX, TIG, MMA PREVISTE PER USO PROFESSIONALE E INDUSTRIALE. Nota: Nel testo che segue verrà impiegato il termine “Saldatrice” e “Saldatrice multiprocesso” per i modelli predisposti alla saldatura MIG- MAG E FLUX, TIG, MMA.

8- Interruptor general ON/OFF.

8- Interruptor geral ON/OFF.

8- Hovedbryter ON/OFF.

EKSTRAORDINÆRT VEDLIKEHOLD

anti-stick hot start -

max (A) I max (A) X (%)

I max (A) X (%) COOLING

I max (A) X (%) Ø mm Ø mm

WELDING POLARITY CHART

WELDING POLARITY CHART

WELDING POLARITY CHART

WELDING POLARITY CHART

BRAZING This set-up information is intended to act as a guide only. Please refer to operating manual for further information.

BRAZING This set-up information is intended to act as a guide only. Please refer to operating manual for further information. NO- GAS

WELDING POLARITY CHART

BRAZING This set-up information is intended to act as a guide only. Please refer to operating manual for further information.