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Do not wrap the welding cables around your body.
Connect the earth cable to the workpiece as close as possible to the area to be
welded.
Do not work with the welder hanging from your body.
Keep your head and trunk as far as possible from the welding circuit. Do not work close
to the welder, or seated or leaning on it. Minimum distance: Fig 9 Da = cm 50; Db =
cm.20
Class A equipment
This equipment has been designed to be used in professional and industrial
environments.
If this equipment is used in domestic environments and those directly connected to a low
voltage power supply network which supplies buildings used for domestic purposes, it may
be difficult to ensure compliance to electromagnetic compatibility as the result of conducted
or radiated disturbances.
Welding in conditions of risk
If welding needs to be done in conditions of risk (electric discharges, suffocation, the
presence of inflammable or explosive materials), make sure that an authorised expert
evaluates the conditions beforehand. Make sure that trained people are present who can
intervene in the event of an emergency. Use the protective equipment described in 5.10;
A.7; A.9 of the IEC or CLC/TS 62081 technical specification.
If you are required to work in a position raised above ground level, always use a safety
platform.
If more than one welding machine has to be used on the same piece, or in any case on
pieces connected electrically, the sum of the no-load voltages on the electrode holders
or on the torches may exceed the safety levels. Make sure that an authorised expert
evaluates the conditions beforehand to see if such risk exists and adopt the protective
measures described in 5.9 of the IEC or CLC/TS 62081 technical specification if
required.
Additional warnings
Do not use the welding machine for purposes other than those described, for example
to thaw frozen water pipes.
Place the welding machine on a flat stable surface, and make sure that it cannot move.
It must be positioned in such a way as to allow it to be controlled during use but without
the risk of being covered with welding sparks.
Do not lift the welding machine. No lifting devices are fitted on the machine.
Do not use cables with damaged insulation or loose connections.
Description of the welding machine
The welding machine is a current generator for continuous wire welding, commonly known
as MIG / MAG, suited to welding carbon or light alloy steels, stainless steel and aluminium
using protective gas.
Some models can weld without the use of protective gas, using a special FLUX cored
wire.
The electrical characteristic of the transformer is flat (constant voltage).
This manual refers to a range of welding machines that differ in some of their characteristics.
Identify your model in Fig. 1.
Main parts Fig. 1
A) Spool compartment access door
B) Spool holder reel
C) Wire feeder
D) Power cable
E) Gas hose connection
F) ON/OFF switch
**
G) Torch polarity selector
H) Torch connector (Some models have directly connected cables)
I) Ground cable/inductor connector (Some models have directly connected cables)
** (This component may not be included with some models).
Technical data
A data plate is affixed to the welding machine. Fig. 2 shows an example of this plate.
A) Constructor name and address
B) European reference standard for the construction and safety of welding equipment
C) Symbol of the welding machine internal structure
D) Symbol of the foreseen welding process
E) Symbol of the continuous current delivered
F) Input power required:
1˜ alternate single phase voltage, frequency
3˜ alternate three-phase voltage, frequency
G) Level of protection from solids and liquids
H) Symbol indicating the possibility to use the welding machine in environments
potentially subject to electric discharges
I) Welding circuit performance
U0V
Minimum and maximum open circuit voltage (open welding circuit).
I2, U2 Current and corresponding normalised voltage delivered by the welding
machine.
X
Duty cycle. Indicate how long the welding machine can work for and how long
it must rest for in order to cool down. The time is expressed in % on the basis
of a 10 minute cycle (e.g. 60% means 6 min. work and 4 min. rest).
A / V
Current adjustment field and corresponding arc voltage.
J) Power supply data
U1
Input voltage (permitted tolerance: +/- 10%)
I1 eff Effective absorbed current
I1 max Maximum absorbed current
K) Serial number
L) Weight
M) Safety symbols: Refer to Safety Warnings
Technical data for torch and wire feeder Fig.4
950562-0 0/06/2
Connections to the mains must be made by expert or qualified personnel.
Make sure that the welding machine is switched off and the plug is not in the power socket
before carrying out this procedure.
Make sure that the power socket that the welding machine is plugged into is protected
by safety devices (fuses or automatic switch) and grounded.
Assembly and electrical connections
Assembly the detached parts found in the packaging. Fig.8.
Check that the electrical supply delivers the voltage and frequency corresponding to the
welding machine and that it is fitted with a delayed fuse suited to the maximum delivered
rated current (I2 max) Fig. 3,1
(Only for three-phase models) The requirements set out in the IEC/EN6000--2
standard do not apply to this equipment. If this equipment is connected to low voltage
power supply network, either the installer or the user is responsible for checking that
this can be done (consult the distribution system operator if required).
Plug. If the welding machine is not fitted with a plug, fit a normalised plug (2P + T for
1Ph and 3P + T for 3Ph) of suitable capacity to the power cable Fig.3,2
Preparing the welding circuit
Connect the ground lead to the welding machine and to the piece to be welded, as close
as possible to the point to be welded.
**
Connect the torch
to the welding machine socket.
Select the polarity of the torch**.
The torch polarity must be negative "-" for cored wire and positive "+" for all other types
of wire. For selection follow the instructions in Fig.5 .
The recommended sections (mm2) of the welding cable, based on the maximum
delivered rated current (I2 max), are shown in Fig. 3,3.
Installing the continuous wire
For installation, follow the instructions in Fig. 6.
The material and diameter of the wire must correspond to the wire feeder roller Fig. 6,5,a,
the contact tip Fig. 6,9,b and the torch liner. If the measurements do not match, there may
be problems with the smooth running of the wire.
Cored wire requires a special roller with a knurled groove to ensure drawing.
The pressure of the wire pressing knob Fig. 6,5,c is important for correct operation. If
the wire slips, there will be problems with the welding; if on the other hand it is too tight,
it may be deformed and will not run smoothly through the torch. It can be adjusted as
follows: screw the wire pressing knob until it starts to draw the wire, then, if the wire is
soft (aluminium, cored wire) turn the screw once more; if the wire is hard (steel, stainless
steel, etc.) turn the screw three more times.
To remove the continuous wire easily from the welding machine, cut the wire between
the spool and the wire feeder, keeping it taut, and then tie it to the spool. The open the
wire guider arm and, using a pair of pliers, pull the piece of wire out of the torch.
Installing the protective gas cylinder** and pressure
reducer**
Place the protective gas cylinder in an upright position, far away from the welding area.
Use the welding machine support or some other fixed part so that there is no risk of it
falling or being damaged.
For installation, follow the instructions in Fig. 7.
Gas
Application
Argon
All non-ferrous metals (aluminium)
Argon + 1-3%O
Stainless steel
2
Argon + 20%CO
Low carbon steel
2
CO
Low carbon steel
2
Non-refillable cylinders are equipped with a pin valve that opens automatically when
the pressure reducer is screwed onto the cylinder.
Argon/CO2 is preferable to CO2 as it guarantees better results.
Cored wire does not need protective gas.
Close the gas valve on the cylinder and zero-set the pressure reducer once you have
finished work.
** (This component may not be included with some models).
Welding process: description of controls and signals
Once you have put the welding machine into operation, switch it on, open the protective
gas valve and carry out the adjustments following the order shown in the description of the
controls, Fig. 1.
1) Adjusting the welding current
Select the welding current according to the work to be carried out. Start with a low current
if the metal is thin. Then increase the current until the best position is found.
Do not adjust the welding current while welding, as the current could damage the
switches.
2) Adjusting the wire speed
To start welding, press the trigger on the torch and adjust the continuous wire speed. The
speed is correct when the noise of the welding arc is regular and constant. If the speed is
too fast, the wire presses against the piece, and if it is too slow the welding arc stretches
and the wire melts in drops. If you cannot find the correct speed, adjust the welding current
instead.
Starting up
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