CEA Qubox 405W PULSE User manual

Qubox 405w - 505w
PULSE
EN ENGLISH
CEA COSTRUZIONI ELETTROMECCANICHE ANNETTONI S.p.A.
C.so E. Filiberto, 27 - 23900 Lecco - Italy
Tel. ++39.0341.22322 - Fax ++39.0341.422646
Cas. Post. (P.O.BOX) 205
E-mail: [email protected] - web: www.ceaweld.com
1020HC94D-EN-01/2020 SN - BO xxxxx

Thank you for buying our product. In order to get the best performance out of the plant and ensure the maximum lifes-
pan of its parts, the use and maintenance instructions contained in this manual must be read and strictly complied with,
as well as the safety instructions contained in the relevant folder.
The manual consists of the following sections:
QBW1 cooling unit manual
QF4 wire feeder manual
List of spare parts: QF4 wire feeder
QM/QP Series Control Panel Manual
Qubox pulse Generator Manual
List of spare parts: Qubox pulse
Generator / QBW1 cooling unit

Qubox 405w - 505w
PULSE
EN Operator’s manual READ
CAREFULLY
CEA COSTRUZIONI ELETTROMECCANICHE ANNETTONI S.p.A.
C.so E. Filiberto, 27 - 23900 Lecco - Italy
Tel. ++39.0341.22322 - Fax ++39.0341.422646
Cas. Post. (P.O.BOX) 205
E-mail: [email protected] - web: www.ceaweld.com

2
ENGLISH
EN
Introduction 2
Description 2
Operating features 2
Special processes for Qubox pulse 3
Technical data 3
Usage limits (IEC 60974-1) 3
Ambient conditions 4
How to lift up the system 4
Serial number 4
Opening the packaging 4
Installation and connections 4
Connection to the electrical supply 4
Usage norms 5
MIG-MAG welding / PULSE MIG 6
Spot welding 8
Interval welding 8
Aluminium welding 8
Electrode welding (MMA) 8
TIG welding with “Lift” 9
Maintenance 10
Optional 10
The pointing out of any difficulties and their
elimination 11
Replacing the digital interface PCB 11
Meaning of graphic symbols on machine 11
Wiring diagram 12
Introduction
Thank you for buying our product.
In order to get the best performance out of the plant and ensure
the maximum lifespan of its parts, the use and maintenance
instructions contained in this manual must be read and strictly
complied with, as well as the safety instructions contained
in the relevant folder. If repairs to the plant are required, we
recommend that our clients contact our service centre work-
shops, as they have the necessary equipment and personnel
that are specifically trained and constantly updated.
All our machines and equipment are constantly developed and
so changes may be made in terms of their construction and
features.
Description
MULTI-FUNCTION INVERTER GENERATOR FOR MIG-MAG,
PULSE MIG, MMA, and TIG WELDING
A practical, robust metal structure combined with the latest gen-
eration inverter technology with digital welding control, char-
acterise the multifunctional systems in the Qubox pulse series.
Innovative, technologically advanced, robust, and easy to use,
they can be used for very high quality MIG-MAG and Pulse MIG
welding for all materials and especially stainless steel and alu-
minium, reducing repeat work due to spray to a minimum, using
electrodes, and in TIG with “Lift” type ignition, and they repre-
sent the best solution for all industrial fields and all specialist
welding purposes that call for high precision and repeatable re-
sults. Qubox pulse equipments, fitted with an innovative syn-
ergic digital control and the extraordinary VISION-ARC meet
the needs of those that wish to combine synergy with complete
control of all welding parameters.
They come in a version with a separate feeder (QF4).
These are systems open to the future evolution of technology -
the control software can be kept up to date with the latest ver-
sions with the help of a personal computer.
Operating features
The main feature of the welding unit Qubox pulse are:
• Metallic main structure.
• Controls on the QF4 feeder protected by a visor.
• Exceptional MIG/MAG welding characteristics.
•
High welding performance in both MMA and TIG by “Lift”
mode striking.
•
Synergic digital control (QM) of all welding parameters fea-
turing the following functions:
-
Allows less expert operators to regulate all welding param-
eters in a user-friendly way and extremely easily, choos-
ing the type of program on the basis of the material, wire
diameter, and gas used.
- Innovative “VISION ARC” software for controlling all weld-
ing parameters.
-
With the special MIG torches you can adjust the welding
parameters at a distance straight from the torch.
- BURN BACK control. At the end of each weld, in any con-
dition and with any material, the digital control ensures a
perfect wire cut, prevents the typical “wire globule” from
forming and ensures correct arc restriking.
-
WSC Wire start control. This arc striking control device pre-
vents wire from sticking to the workpiece or torch nozzle
and ensures precise and smooth arc striking, particularly
when welding aluminium.
-
Welding parameters that are controlled digitally by a micro-
processor, are monitored and modified in just a few sec-
onds, maintaining a consistently precise and stable arc as
the welding conditions continue to vary due to the move-
ment of the torch and the irregularities of the parts to be
welded.
-
Exclusive SWS “Smart Welding Stop” system at the end of
TIG welding. Lifting up the torch without switching off the
arc will introduce a slope down and it will switch off auto-
matically.
-
“Energy Saving” function to operate the power source cool-
ing fan and the torch water cooling only when necessary.
- Auto-diagnostic feature for trouble shooting.
- Password-controlled total or partial equipment access.
• High electrical performance resulting in a reduction in ener-
gy consumption.
• Setting of all parameters on the QF4 feeder itself.

3
Special processes for Qubox pulse
The specific utilization of special welding processes is an ide-
al choice for automation and allows to optimize specific weld-
ing applications, by granting far better performances in terms
of quality and welding speed.
Special processes (optional)
vision.ARC, available on Qubox pulse equipment, is the sup-
port basis in order to weld by means of the special processes
shown in table 1.
Table 1
MIG/MAG
vision.PIPE for a more accurate welding in pipe first
root pass.
vision.COLD to weld thin thickness laminations with
low heat transfer.
vision.ULTRASPEED for high speed welding.
vision.POWER for a more concentrated arc and
deeper penetration on medium and thick thickness.
Extended Curve Package (E.C.P.)
This is a package of additional curves, dedicated to
highly specialised machining and procedures.
Table 2
Model Qubox 405w pulse Qubox 505w pulse
MIG-MAG welding
Three-phase input 50/60 Hz V400 ± 20% 400 ± 20%
Mains supply: Zmax Ω0,030 0,020
Input power @ I2Max kVA 22,5 29,5
Delayed fuse (I eff) A32 40
Power factor / cosφ 0,7 / 0,99 0,75 / 0,99
Efficiency degree η0,88 0,89
Open circuit voltage V62 62
Current range A10 ÷ 400 10 ÷ 500
Duty cycle @ 100% (40°C) A350 420
Duty cycle @ 60% (40°C) A400 500
Wires diameter (*) mm 0,6 ÷ 1,6 (*) 0,6 ÷ 1,6 (*)
N° rollers (*) 4 (*) 4 (*)
Power output of feeder motor (*) W100 (*) 100 (*)
Rated wire feeding speed (*) m/min 1,5 ÷ 25 (*) 1,5 ÷ 25 (*)
Spool (*)
Diameter
Weight
mm
kg
Ø300 (*)
15 (*)
Ø300 (*)
15 (*)
Standards IEC 60974-1 - IEC 60974-5 (*) - IEC 60974-10
Protection class IP 23 S IP 23 S
Insulation class H H
Dimensions mm 1030 - 515 - 950 1030 - 515 - 950
Weight kg 82 85
(*) On the QF4 feeder, fitted separately.
WARNING: This equipment complies with EN//IEC 61000-3-12 provided that the maximum permissible system impedance Zmax is less than or
 505w pulse at the interface point between the user’s supply and the public system. It is
the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the
equipment is connected only to a supply with maximum permissible system impedance Zmax 405w pulse -
 505w pulse.
This system, tested according to EN/IEC 61000-3-3, meets the requirements of EN/IEC 61000-3-11.
Technical data
The general technical data of the system are summarized in
table 2.
Usage limits (IEC 60974-1)
The use of a welder is typically discontinuous, in that it is made
up of effective work periods (welding) and rest periods (for the
positioning of parts, the replacement of wire and underflush -
ing operations etc. This welder is dimensioned to supply a I
2
max nominal current in complete safety for a period of work of
60% of the total usage time. The regulations in force establish
the total usage time to be 10 minutes. The work cycle is con-
sidered to be 60% of this period of time. Exceeding the work
cycle allowed could cause a trip switch to trip (for further infor-
mation see the QM control panel manual), which protects the
components inside the welding machine against dangerous
overheating. After several minutes the overheat cut-off rearms
automatically and the welder is ready for use again.

4
Ambient conditions
The manufacturer does not accept any responsibility for dam-
age that may result from the plant being used or stored in am-
bient conditions that do not conform.
• The ambient air temperature range must be as follows:
-
When in use: from -10 °C to +40 °C (from 14 °F to 104 °F).
- When being transported and stored: from -20 °C to +55 °C
(from -4 °F to 131 °F).
• The relative humidity of the air must be as follows:
- Up to 50% at 40 °C (104 °F).
- Up to 90% at 20 °C (68 °F).
• Altitude (above sea level): up to 2000 m (6561 feet 8.16 in.).
•
Ambient air: free of dust, acids, corrosive substances or gas-
es, etc.
How to lift up the system
Before lifting the unit, open the bag containing the eyebolts (at-
tached to machine), remove the two eyebolts complete with fi-
bre washers and mount them on the upper part of the cover.
Only lift the unit using the two eyebolts.
These lifting and conveying devices conform to the require-
ments laid down by the international standard. Do not use oth-
er hoisting and transportation systems.
The angle of incidence on the chains or cables must be as
small as possible.
Always remove the gas cylinder and feeder.
Serial number
The welding machine’s serial number is shown on the unit’s
data plate.
The serial number provides the key to tracing the production lot
applicable to the product. The serial number may be essential
with ordering spare parts or planning maintenance.
Opening the packaging
The system essentially consists of:
• Qubox pulse weld unit.
• Separately:
- QF4 wire-feeder unit (supplied separately).
- MIG-MAG welding torch (optional).
-
Wire-feeder/generator interconnection cable (supplied sep-
arately).
Perform the following operations on receiving the apparatus:
•
Remove the welding generator and all accessories and com-
ponents from the packaging.
•
Check that the welding apparatus is in good condition; other-
wise immediately inform the retailer or distributor.
• Check that all the ventilation grilles are open and that there
is nothing to obstruct the correct air flow.
Installation and connections
The installation site for the system must be carefully chosen
in order to ensure its satisfactory and safe use. The user is re-
sponsible for the installation and use of the system in accord-
ance with the producer’s instructions contained in this manual.
Before installing the system the user must take into consider-
ation the potential electromagnetic problems in the work area.
In particular, we suggest that you should avoid installing the
system close to:
• Signalling, control and telephone cables.
• Radio and television transmitters and receivers.
• Computers and control and measurement instruments.
• Security and protection instruments.
Persons fitted with pace-makers, hearing aids and similar
equipment must consult their doctor before going near a ma-
chine in operation. The equipment’s installation environment
must comply to the protection level of the frame.
The welding unit is characterized by the following classes:
• IP 23 S protection class indicates that the generator can be
used in both interior and exterior environments.
•
The “S” usage class indicates that the generator can be em-
ployed in environments with a high risk of electrical shocks.
This system is cooled by means of the forced circulation of air,
and must therefore be placed in such a way that the air may
be easily sucked in and expelled through the apertures made
in the frame.
Assemble the system in the following way:
• Fitting the feeder unit to the generator.
• Connect up the welder to the mains.
•
Connect up the wire-feeder/generator interconnection cable.
• Connect up the welding cables.
Instructions for fitting the individual components / optional ex-
tras are contained in the relevant packaging.
Connection to the electrical supply
Connection of the machine to the user line (electrical cur-
rent) must be performed by qualified personnel.
Before connecting the welding machine to the mains pow-
er supply, make sure that rated voltage and frequency cor-
respond to those provided by the mains power supply and
that the welding machine’s power switch is turned to “O”.
Use the welder’s own plug to connect it up to the main pow-
er supply. Proceed as follows if you have to replace the plug:
•
3 conducting wires are needed for connecting the machine
to the supply.
•
The fourth, which is YELLOW GREEN in colour is used for
making the “GROUND” connection.
Connect a suitable load of normalised plug (3P+T) to the
power cable and provide for an electrical socket complete
with fuses or an automatic switch. The ground terminal
must be connected to the ground conducting wire (YEL-
LOW-GREEN) of the supply.
Table 3 shows the capacity values that are recommended for
fuses in the line with delays.
NOTE: Any extensions to the power cable must be of a suita-
ble diameter, and absolutely not of a smaller diameter than the
special cable supplied with the machine.
Table 3
Model
Qubox 405w
pulse
Qubox 505w
pulse
MIG-MAG welding
Input power @ I2Max kVA 23,5 29,5
Delayed fuse (I eff) A32 40
Duty cycle @ 60% (40°C) A400 500
Mains cable
Length / Section m
mm2
4,5
4 × 6
4,5
4 × 6
Ground cable mm250 70

5
Usage norms
CONTROL APPARATUS (Fig. A)
Pos. 1 Front panel.
Pos. 2 Fast coupling positive polarity.
Pos. 3 Fast coupling negative polarity.
Pos. 4 Cooling system tank cap.
Pos. 5 Mains switch. In the “O” position the welder is off.
Pos. 6 Mains cable.
Pos. 7 Cooling system fuse.
Pos. 8 Quick water couplings.
111 12
2
3
4
5
6
7
8
9
10
FIG. A
Pos. 9 Quick positive pole connection on the connecting ca-
ble.
Pos. 10 Connector for connecting the interconnection cable.
Pos. 11 White LED: signals power supply presence. When it
is switched on, the system is powered up and ready
for operation.
Pos. 12 Yellow LED: signals intervention of overheat cutoff.
This LED shines to indicate that the overheating pro-
tection has cut in because the work cycle is not being
followed. After several minutes the overheat cut-off
rearms automatically (and the yellow LED turns itself
off) and the welder is ready for use again.

6
MIG-MAG welding / PULSE MIG
To begin MIG-MAG / PULSE MIG welding, carry out the follow-
ing tasks (with the machine switched off).
1 - Connecting the gas hose and torch (Fig. B1-B2)
• Connect the gas hose to the pressure reducer fitted on the
cylinder beforehand.
• Screw the torch onto the centralised connection on the front
panel of the feeder and connect the feed (blue) and return
(red) water hoses for cooling the torch to the respective (blue
and red) rapid couplings on the front panel of the feeder.
2A - Connecting the cables - Welding with a POSITIVE
POLE TORCH (Fig. B1)
1) The feeder - generator connecting cable is used to connect
the welding machine to the feeder.
WARNING: Do not disconnect the wire-feeder until the ma-
chine has been switched off.
Connect up the interconnection cables (power cable, an-
cillary wiring and gas tube) to the special attachments and
couplings shown in Fig. B1.
The delivery (blue coloured) and return (red coloured) wa-
ter tubes, used for cooling the torch of the welding machine,
are part of the interconnection cable and should be con-
nected as follows:
•
Interconnection cable on generator side: connect up
tubes to their rapid couplings (blue and red coloured) at
the back of the coolant system.
• Wire feeder side connecting cable: connect the red and
blue pipes to their respective bulkhead grommets on the
rear panel of the feeder.
2) Connect up the earthing system cable to the rapid cou-
pling marked by a - (negative) symbol and then the rel-
evant ground clamps to the piece being welded or to its
support in an area free from rust, paint and grease. Using
particularly long earthing cables reduces the voltage and
causes some problems from increased resistance and in-
ductance of the cables that could cause faulty welding. Fol-
low instructions to avoid these problems:
•
Use earthing and extension cables with appropriate sec-
tion.
• Lay out the cables as a flat as possible to prevent them
from coiling up.
BLACKBLACK
RED
RED
BLUE
BLUE
RED
RED
BLUE
BLUE
BLUEBLUE
RED
RED
BLACKBLACK
FIG. B1

7
2B - Connecting the cables - Welding with a
NEGATIVE POLE TORCH (Fig. B2)
1) Connect the generator - feeder connection cable using the
extension cable in addition to invert the polarity (optional).
WARNING: Do not disconnect the wire-feeder until the ma-
chine has been switched off.
Connect up the interconnection cables (power cable, an-
cillary wiring and gas tube) to the special attachments and
couplings shown in Fig. B2.
The delivery (blue coloured) and return (red coloured) wa-
ter tubes, used for cooling the torch of the welding machine,
are part of the interconnection cable and should be con-
nected as follows:
•
Interconnection cable on generator side: connect up
tubes to their rapid couplings (blue and red coloured) at
the back of the coolant system.
• Wire feeder side connecting cable: connect the red and
blue pipes to their respective bulkhead grommets on the
rear panel of the feeder.
2) Connect up the earthing system cable to the rapid cou-
pling marked by a + (positive) symbol and then the relevant
ground clamps to the piece being welded or to its support in
an area free from rust, paint and grease. Using particularly
long earthing cables reduces the voltage and causes some
problems from increased resistance and inductance of the
cables that could cause faulty welding. Follow instructions
to avoid these problems:
•
Use earthing and extension cables with appropriate sec-
tion.
• Lay out the cables as a flat as possible to prevent them
from coiling up.
3 - Welding
1) Switch the welding machine on by moving the power sup-
ply switch to I(Pos. 4, Fig. A).
2) Make the adjustments and do the parameter settings on
the control panel (for further information see the QM/QP
control panel manual).
3) Load the wire (see the relevant paragraph in the feeder
manual) using the motor test button, after having removed
the wire guide nozzle from the torch to allow the wire to
come out freely during loading (remember that the wire
guide nozzle must correspond to the diameter of the wire
used).
BLACKBLACK
RED
RED
BLUE
BLUE
RED
RED
BLUE
BLUE
BLUEBLUE
RED
RED
BLACKBLACK
FIG. B2

8
4) Open the tap on the cylinder slowly and adjust the reduc-
er knob to obtain a pressure of about 1,3 to 1,7 bar, and
then activate the gas test button and regulate the flow to
a value between 14 and 20 lit/min to suit the current used
for welding.
5) The welding machine is ready to weld. Make the adjust-
ments and select the parameters for the feeder or, if select-
ed, on the control panel (for further information see the QM/
QP control panel manual). Start welding by moving close
to the welding point and press the torch button.
6) Once welding has been completed remove any slag, switch
off the machine (which is only to be done when the fan is
not running), and close the gas cylinder.
Spot welding
The substantial difference with MIG-MAG welding is essentially
related to the torch and the settings that must be done on the
QF4 feeder’s control panel.
•
The gas guide nozzle specifically for spot welding must be
fitted on the torch.
• On the QF4 feeder’s control panel, select spot welding mode
and set the time.
To begin spot welding:
•
Press the torch button to start the welding current and wire
feed.
• When the spot welding time expires, the wire feed stops au-
tomatically.
•
When the torch button is pushed again a new welding cy-
cle starts.
• Release the torch button.
Interval welding
The basic difference from spot welding is the addition of an ad-
ditional time known as the “stitch pause”.
On the QF4 feeder’s control panel, select intermittent welding
mode and then set the following times for it:
• Stitch time.
• Stitch pause.
To begin interval welding:
•
Press the torch button to start the welding current and wire
feed.
•
At this point the welding machine automatically carries out a
succession of welded portions followed by a pause, accord-
ing to the times entered previously. This procedure stops au-
tomatically only when the torch button is released.
•
When the torch button is pushed again the torch begins a
new interval welding cycle.
Aluminium welding
To weld with aluminum wire proceed as follows:
• Replace the drive rolls with special ones for aluminium wire.
• Use a torch with a 3M cable and a carbon Teflon sheath.
•
Set the pressure between the drive rollers at the minimum,
by turning the screw provided.
•
Use argon gas at a pressure of 1,3 - 1,7 bar and regulate
the flow to a value between 14 and 20 lit/min to suit the cur-
rent used for welding.
Electrode welding (MMA)
On the Qubox pulse machine, electrode welding is used to weld
most metals (different types of steel, etc.) using coated rutilic
and basic electrodes with diameters ranging from Ø 1.6 mm to
Ø 6 mm, and devices that the user can adjust for “Arc Force”,
“Hot Start”, and Anti-sticking functions to avoid the electrodes
sticking.
1) Connecting the welding cables (Fig. C):
Disconnect the machine from the mains power supply and
connect the welding cables to the output terminals (Posi-
tive and Negative) of the welding machine, attaching them
to the clamp and ground with the polarity specified for the
type of electrode being used (Fig. C). Always follow the
electrode manufacturer’s instructions. The welding cables
must be as short as possible, they must be near to one
another, positioned at or near floor level. Do not touch the
electrode clamp and the ground clamp simultaneously.
2) Switch the welding machine on by moving the power sup-
ply switch to I(Pos. 5, Fig. A).
3) Set up the parameter selections / settings on the QF4 feed-
er’s control panel (for more information see the QM opera-
tor software manual).
4) Carry out welding by moving the torch to the workpiece.
Strike the arc (press the electrode quickly against the met-
al and then lift it) to melt the electrode, the coating of which
forms a protective residue. Then continue welding at an in-
clination of about 60° compared with the metal in relation
to the direction of welding.
FIG. C

9
PART TO BE WELDED
The part to be welded must always be connected to ground
in order to reduce electromagnetic emission. Much attention
must be afforded so that the ground connection of the part to
be welded does not increase the risk of accident to the user or
the risk of damage to other electric equipment. When it is nec-
essary to connect the part to be welded to ground, you should
make a direct connection between the part and the ground
shaft. In those countries in which such a connection is not al-
lowed, connect the part to be welded to ground using suitable
capacitors, in compliance with the national regulations.
WELDING PARAMETERS
Table 4 shows some general indications for the choice of elec-
trode, based on the thickness of the parts to be welded. The
values of current to use are shown in the table 5 with the re-
spective electrodes for the welding of common steels and
low-grade alloys. These data have no absolute value and are
indicative data only. For a precise choice follow the instructions
provided by the electrode manufacturer.
Table 4
Welding thickness (mm) Ø electrode (mm)
1,2 ÷ 2
1,5 ÷ 3
3 ÷ 5
5 ÷ 12
≥ 12
≥ 20
1,6
2
2,5
3,25
4
≥ 5
Table 5
Ø electrode (mm) Current (A)
1,6
2
2,5
3,25
4
5
6
30 ÷ 60
40 ÷ 75
60 ÷ 110
95 ÷ 140
140 ÷ 190
190 ÷ 240
220 ÷ 330
The current to be used depends on the welding positions and
the type of joint, and it increases according to the thickness and
dimensions of the part.
The current intensity to be used for the different types of weld-
ing, within the field of regulation shown in table 4 is:
• High for plane, frontal plane and vertical upwards welding.
• Medium for overhead welding.
•
Low for vertical downwards welding and for joining small pre-
heated pieces.
A fairly approximate indication of the average current to use in
the welding of electrodes for ordinary steel is given by the fol-
lowing formula:
I = 50 × (Øe - 1)
Where:
I = intensity of the welding current
Øe = electrode diameter
Example:
For electrode diameter 4 mm
I = 50 × (4 - 1) = 50 × 3 = 150A
TIG welding with “Lift”
In the TIG process welding is achieved by melting the two met-
al pieces to be joined, with the possible addition of material
from the outside, using an arc ignited by a tungsten electrode.
The “Lift” type ignition used in Qubox pulse equipments makes
it possible to reduce tungsten inclusions on ignition to a mini-
mum. The molten bath and the electrode are protected by and
inert gas (for example, Argon). This type of welding is used
to weld thin sheet metal or when elevated quality is required.
1) Connecting the welding cables (Fig. D):
•
Connect one end of the gas hose to the gas connecter on
the TIG torch and the other end to the pressure reducer
on the inert gas cylinder (Argon or similar).
• With the machine switched off:
-
Connect the ground cable to the snap-on connector
marked + (positive).
-
Connect the relative ground clamp to the workpiece or
to the workpiece support in an area free of rust, paint,
grease, etc..
-
Connect the TIG torch power cable to the snap-on con -
nector marked - (negative).
2) Switch the welding machine on by moving the power sup-
ply switch to I(Pos. 5, Fig. A).
3) Set up the parameter selections / settings on the QF4 feed-
er’s control panel (for more information see the QM opera-
tor software manual).
4) Open the gas cylinder and regulate the flow by adjusting
the valve on the TIG torch by hand.
5) Ignite the electric arc by contact, using a decisive, quick
movement without dragging the tungsten electrode on the
piece to be welded (“Lift” type ignition).
6) The welder has a SWS “Smart Welding Stop” system for
the end of TIG welding. Lifting up the torch without switch-
ing off the arc will introduce a slope down and it will switch
off automatically.
7) When you have finished welding remember to shut the
valve on the gas cylinder.
FIG. D

10
Table 6 shows the currents to use with the respective elec-
trodes for TIG DC welding. This input is not absolute but is for
your guidance only; read the electrode manufacturers’ instruc-
tions for a specific choice. The diameter of the electrode to use
is directly proportional to the current being used for welding.
Table 6
Ø ELECTRODE
(mm)
ELECTRODE TYPE
Current adjustment field (A)
TIG DC
Tungsten
Ce 1%
Grey
Tungsten
Rare ground 2%
Turchoise
110-50 10-50
1,6 50-80 50-80
2,4 80-150 80-150
3,2 150-250 150-250
4200-400 200-400
Maintenance
ATTENTION: Cut off the power supply to the equipment be-
fore effecting any internal inspection.
Qubox pulse
IMPORTANT: For fully electronic welding machines, remov-
ing the dust by sucking it into the machine by the fans, is of ut-
most importance.
In order to achieve correct functioning of the machine, pro-
ceed as described:
•
Periodic removal of accumulations of dirt and dust inside the
equipment using compressed air. Do not point the jet of air
directly at the electrical parts as this could damage them.
•
Periodical inspection for worn cables or loose connections
that could cause overheating.
TORCH
The torch is subjected to high temperatures and is also stressed
by traction and torsion. We recommend not to twist the wire and
not to use the torch to pull the welder. As a result of the above
the torch will require frequent maintenance such as:
• Cleaning welding splashes from the gas diffuser so that the
gas flows freely.
• Substitution of the contact point when the hole is deformed.
•
Cleaning of the wire guide liner using trichloroethylene or
specific solvents.
• Check of the insulation and connections of the power cable;
the connections must be in good electrical and mechanical
condition.
SPARE PARTS
Original spares have been specifically designed for our equip-
ment. The use of spares that are not original may cause vari-
ations in the performance and reduce the safety level of the
equipment. We are not liable for damage due to use of spare
parts that are not original.
Optional
NOTE: The digital control unit of the generator is fitted with a
control recognition device which allows it to identify which de-
vice is connected and take action accordingly.
REMOTE CONTROL ANALOGIC RC
(must be plugged into the relevant connector on the front pan-
el of the QF4 drawing unit)
This command works as an alternative to:
•
Completely replaces the ENCODER - A knob on the QF4
feeder’s front panel.
•
Partially (depending on the welding process selected) replac-
es the ENCODER - V knob on the QF4 feeder’s front panel
(for further information see the QM/QP control panel manual).
AIR AND/OR WATER COOLED UP/DOWN TORCH
(must be plugged into the relevant connector on the front pan-
el of the QF4 drawing unit)
This command works as an alternative to:
• The ENCODER - A knob on the QF4 feeder’s front panel. In
“synergic” MIG MAG and “manual” MIG MAG welding pro-
cesses, by pressing the two right (+) and left (-) buttons you
can regulate the values for the synergic welding parameters.
• The ENCODER - V knob on the QF4 feeder’s front panel. In
the JOB welding process, by pressing the two right (+) and
left (-) buttons you can scroll the welding points set previ-
ously.
PUSH-PULL TORCH
(must be plugged into the relevant connector on the front pan-
el of the QF4 drawing unit)
The push-pull torch makes it possible to improve the alumini-
um wire feed, using the motor on the torch itself. The param-
eters normally regulated using the ENCODER - A knob on the
QF4 feeder’s front panel, when this torch is on, are now regu-
lated using the potentiometer on the torch itself.
TORCH WITH DISPLAY (DIGITORCH)
(must be plugged into the relevant connector on the front pan-
el of the QF4 drawing unit)
The new Digitorch keep all information within easy reach. The
innovative microcontroller with display integrated into the grip
allows the main welding parameters to be displayed and ad-
justed:
• Current
• Thickness of material
• Wire speed
• Arc length
• Electronic inductance
• Memorised programme number
Press the up/down buttons, depending on the selected oper-
ating method, to move from one programme to another or in-
crease and decreases the parameters on the synergic curves
in use.

11
Meaning of graphic symbols on machine
Power supply switch
System for use in environments with in-
creased risk of electroshock
Product suitable for free circulation in the
European Community
Danger! high voltage
Grounding
Positive pole snap-in connector
Negative pole snap-in connector
Warning!
Before using the equipment you should
carefully read the instructions included in
this manual
Special disposal
The pointing out of any difficulties
and their elimination
The supply line is attributed with the cause of the most com-
mon difficulties. In the case of breakdown, proceed as follows:
1) Check the value of the supply voltage.
2) Check that the power cable is perfectly connected to the
plug and the supply switch.
3) Check that the power fuses are not burned out or loose.
4) Check whether the following are defective:
• The switch that supplies the machine
• The plug socket in the wall
• The generator switch
NOTE: Given the required technical skills necessary for the re-
pair of the generator, in case of breakdown we advise you to
contact skilled personnel or our technical service department.
Replacing the digital interface PCB
Proceed as follows:
• Unscrew the 4 screws fastening the front rack panel.
• Extract wiring connectors from the digital interface PCB.
•
Remove the digital interface PCB by lifting it out of its sup-
ports.
•
Proceed vice versa to assemble the new digital interface
PCB.

12
Wiring diagram
Key to the electrical diagram
C-LINK Capacitor
CCI Interconnection cable connector
CHR Power supply connector for the cooling system
CN Connectors on PCB
D2 Secondary diode
FFuse
F-EMC EMC filter
IL Power supply switch
L2 Secondary inductor
MElectric pump
MI-L Primary left IGBT
MI-R Primary destroy IGBT
MKB Membrane keyboard
MV1-2 Fan motor
P1-P2 Primary circuit connectors
QBW1 Integrated cooling unit (when fitted)
RP Primary rectifier
RS Secondary rectifier
S-DF Digital interface PCB
S-F Secondary filter PCB
S-IL In Rush Limiter PCB
S-INV Inverter PCB
S-PS Power Source PCB
SB Spikes Blocker
TAUX Auxiliary transformer
TH1 Primary inverter thermistor
TH2 Main transformer thermistor
TH3 Secondary rectifier thermostat
THA Hall effect transformer
TP Main transformer
VR Output diodes snubber varistor
WPressure switch
X1 In Rush Limiter PCB connector
Colour key
AN Orange-Black
Ar Orange
Az Sky Blue
Bc White
Bl Blue
Gg Grey
Gl Yellow
GV Yellow-Green
Mr Brown
NA Black-Sky Blue
Nr Black
RN Red-Black
Ro Pink
Rs Red
Vd Green
Vl Violet

2101EC91

QBW1 COOLING UNIT
EN Operator’s manual READ CAREFULLY
CEA COSTRUZIONI ELETTROMECCANICHE ANNETTONI S.p.A.
C.so E. Filiberto, 27 - 23900 Lecco - Italy
Tel. ++39.0341.22322 - Fax ++39.0341.422646
Cas. Post. (P.O.BOX) 205
E-mail: [email protected] - web: www.ceaweld.com

2
ENGLISH
EN
Introduction 2
Description 2
Technical data 2
Usage limits (IEC 60974-1) 3
Installation 3
Usage norms 3
Start-up / drainage 4
Meaning of graphic symbols on machine 6
Hydraulic diagram 6
Maintenance 6
Wiring diagram 6
Introduction
Thank you for buying our product.
In order to get the best performance out of the plant and ensure
the maximum lifespan of its parts, the use and maintenance
instructions contained in this manual must be read and strictly
complied with, as well as the safety instructions contained
in the relevant folder. If repairs to the plant are required, we
recommend that our clients contact our service centre work-
shops, as they have the necessary equipment and personnel
that are specifically trained and constantly updated.
All our machines and equipment are constantly developed and
so changes may be made in terms of their construction and
features.
Description
The device, particularly suited for cooling by means of water
circulation utilised in particularly heavy welding operations, is
composed in its essential parts of:
• A single-phase electric pump.
• A plastic tank.
• A radiator.
• A pressure switch.
• A protection fuse.
Compact and lightweight, this is an integral part of Q ubox 400w
- Qubox 500w welding machines.
Technical data
The general technical data of the system are summarized in
table 1.
Table 1
Model WR 35
Single-phase input V400
Frequency Hz 50/60
Max power supply kW 0,3
Max current absorbed A0,9
Delayed fuse A1,6
Coolant
• 20%-30% antifreeze
• 70%-80% distilled
water
Cooling power Φ1kW 0,95
Capacity with 4 m TIG torch l/min 1,6
Capacity with 4 m MIG/MAG
torch l/min 1,4
Capacity with 4 m MIG/MAG
torch + 10 m extension cable l/min 1,15
Max pressure bar 4,3
Standards IEC 60974-2
Protection class IP 23
Insulation class F
Tank capacity l 5
Dimensions mm 460-205-520
Weight kg 11
Weight with liquid kg 16

3
Usage limits (IEC 60974-1)
The cooling device is sized for cooling by means of water cir-
culation in the welder in a continuous manner. As a work cycle,
it is considered at 100%.
Installation
WARNING: The cooling device may only be installed horizon-
tally.
The installation site for the system must be carefully chosen in
order to ensure its satisfactory and safe use.
The user is responsible for the installation and use of the sys-
tem in accordance with the producer’s instructions contained
in this manual.
Before installing the system the user must take into consider-
ation the potential electromagnetic problems in the work area.
In particular, we suggest that you should avoid installing the
system close to:
• Signalling, control and telephone cables.
• Radio and television transmitters and receivers.
• Computers and control and measurement instruments.
• Security and protection instruments.
Persons fitted with pace-makers, hearing aids and similar
equipment must consult their doctor before going near a ma-
chine in operation. The installation environment of the device
has to be in conformance with the protection degree of the
carcass, which is equivalent to IP 23 (publication IEC 60529),
which means that the device may be used in closed environ-
ments as well as outdoors. This system is cooled by means of
the forced circulation of air, and must therefore be placed in
such a way that the air may be easily sucked in and expelled
through the apertures made in the frame.
Usage norms
CONTROL APPARATUS (Fig. A)
Pos. 1 Red snap-in connector for water intake.
Pos. 2 Blue snap-in connector for water outlet.
Pos. 3 Cap for filling of the tank with coolant.
Pos. 4 Level indicator for presence of coolant in the tank (the
level of the liquid must never be inferior to the notch
indicated).
Pos. 5 Protection fuse.
Pos. 6 Cable for electric connection of the device to the gen-
erator cooling device.
1
23
4
5
6
FIG. A

4
Start-up / drainage
Before connecting the equipment to the utilities check the rating plate to make sure the voltage and frequency of the
mains correspond and check that the main circuit breaker on the equipment is turnedto “O”.
Upon the first usage following a period of extended inactivity of the device or in the case in which the electropump does not go
under pressure (slight whistle), it is necessary to undertake drainage in order to eliminate all the air bubbles present within the
hydraulic circuit.
Carry out the following operations following the assembly instructions indicated here (Fig. B) and also contained in the acces-
sories packet:
1) Unscrew the tank’s cap and, using a funnel, fill it with distilled water. In case of particularly rigid climates with air temperature
near to 0° C it is necessary to add antifreeze to the cooling distilled water. Do not use antifreeze containing propylene be-
cause it could provoke blockage of the electropump. Screw the tank cap back on.
2) Connect the hose supplied to the blue quick coupling and insert the other end of the hose into a receptacle that contains wa-
ter.
3) Switch on the welding machine, turn the main switch to position 1, and wait for the time required for the cooling plant to cir-
culate the liquid. Wait for the exit of the liquid. The operation will be terminated when the liquid exits in a constant way and
without any traces of air bubbles.
4) Upon the completion of the operation, turn the welder off.
5) Connect the water pipes before beginning work.
FIG. B
Acqua distillata
Distilled water
Blu
Blue
1x
1
2

5
ON
Blu
Blue
1x
OFF
Blu
Blue
1x
3
4
5