Cea Maxiq 400 User manual

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

1020HE03A-EN-03/2021 SN - CR xxxxx

MAXIQ 400 - 400w - 500 - 500w

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

List of spare parts: MAXIQ Generator /

QBW1 cooling unit

MF4 wire feeder manual

List of spare parts: MF4 wire feeder

MAXIQ Generator Manual

MF Series Control Panel Manual

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

MAXIQ 400 - 400w - 500 - 500w

ENGLISH

Introduction 2

Description 2

Operating features 2

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 6

Aluminium welding 8

Maintenance 8

Optional 8

The pointing out of any difficulties and their elimination 8

Replacing the digital interface PCB 8

Meaning of graphic symbols on machine 9

Wiring diagram 10

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

INVERTER GENERATOR FOR MIG-MAG WELDING

A practical, robust metal structure combined with the latest

generation inverter technology with digital welding control,

characterise the multifunctional systems in the MAXIQ series.

Innovative, technologically advanced, robust, and easy to use,

they can be used for very high quality MIG-MAG welding for

all materials, reducing repeat work due to spray to a minimum,

and they represent the best solution for all industrial fields and

all specialist welding purposes that call for high precision and

repeatable results.

They come in a version with a separate feeder (MF4).

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 MAXIQ are:

• Metallic main structure.

• Controls on the MF4 feeder.

• Exceptional MIG/MAG welding characteristics.

•

MF digital control panel fitted on the feeder equipped with the

HYBRID SYNERGIC function:

Allows less experienced operators to set all welding pa-

rameters in a user-friendly and simple way after choosing

the material and the diameter of the wire used.

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.

“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.

• High electrical performance resulting in a reduction in ener-

gy consumption.

• Setting of all parameters on the MF4 feeder itself.

Technical data

The general technical data of the system are summarized in

table 1.

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

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 MF 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.

Table 1

Model MAXIQ 400 MAXIQ 400w MAXIQ 500 MAXIQ 500w

MIG-MAG welding

Three-phase input 50/60 Hz V400 ± 20% 400 ± 20% 400 ± 20% 400 ± 20%

Mains supply: Zmax Ω0,030 0,030 0,020 0,020

Input power @ I2Max kVA 19 19,5 25,5 26

Delayed fuse (I eff) A32 32 32 32

Power factor / cosφ 0,82 / 0,99 0,82 / 0,99 0,87 / 0,99 0,87 / 0,99

Efficiency degree η0,85 0,85 0,86 0,86

Input power at IDLE state W30 30 30 30

Open circuit voltage V62 62 62 62

Current range A10 ÷ 400 10 ÷ 400 10 ÷ 500 10 ÷ 500

Duty cycle @ 100% (40°C) A300 300 390 390

Duty cycle @ 60% (40°C) A350 350 430 430

Duty cycle @ 35% (40°C) A400 400 500 500

Wires diameter (*) mm 0,6 ÷ 1,6 (*) 0,6 ÷ 1,6 (*) 0,6 ÷ 1,6 (*) 0,6 ÷ 1,6 (*)

N° rollers (*) 4 (*) 4 (*) 4 (*) 4 (*)

Power output of feeder motor (*) W100 (*) 100 (*) 100 (*) 100 (*)

Rated wire feeding speed (*) m/min 1,5 ÷ 25 (*) 1,5 ÷ 25 (*) 1,5 ÷ 25 (*) 1,5 ÷ 25 (*)

Spool (*)

Diameter

Weight

Ø300 (*)

15 (*)

Ø300 (*)

15 (*)

Ø300 (*)

15 (*)

Ø300 (*)

15 (*)

Standards IEC 60974-1 - IEC 60974-5 (*) - IEC 60974-10

Protection class IP 23 S IP 23 S IP 23 S IP 23 S

Insulation class HHHH

Dimensions mm 1040 - 495 - 950 1040 - 495 - 950 1040 - 495 - 950 1040 - 495 - 950

Weight kg 66 78 68 80

(*) On the MF4 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

equal to 0,030 Ω MAXIQ 400 - 0,030 Ω MAXIQ 400w - 0,020 Ω MAXIQ 500 - 0,020 Ω MAXIQ 500w. 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 net-

work operator if necessary, that the equipment is connected only to a supply with maximum permissible system impedance Z

max

less than or

equal to 0,030 Ω MAXIQ 400 - 0,030 Ω MAXIQ 400w - 0,020 Ω MAXIQ 500 - 0,020 Ω MAXIQ 500w.

This system, tested according to EN/IEC 61000-3-3, meets the requirements of EN/IEC 61000-3-11.

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:

• MAXIQ weld unit.

• Separately:

- MF4 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 2

Model

MAXIQ

400

MAXIQ

400w

MAXIQ

500

MAXIQ

500w

MIG-MAG welding

Input power @ I2Max kVA 19 19,5 25,5 26

Delayed fuse (I eff) A32 32 32 32

Duty cycle @ 35% (40°C) A400 400 500 500

Mains cable

Length / Section m

mm2

4,5

4 × 6

4,5

4 × 6

4,5

4 × 6

4,5

4 × 6

Ground cable mm250 50 70 70

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 (Qubox w).

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 (Qubox w).

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.

111 12

MIG-MAG welding

To begin MIG-MAG welding, carry out the following 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.

FIG. B1

BLACKBLACK

RED

BLUE

RED

BLUE

BLUEBLUE

RED

BLACKBLACK

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. 5, Fig. A).

2) Make the adjustments and do the parameter settings on

the control panel (for further information see the MFcon-

trol 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).

FIG. B2

BLACKBLACK

RED

BLUE

RED

BLUE

BLUEBLUE

RED

BLACKBLACK

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 from the

control panel MF (for further information see the MF con-

trol 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.

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.

Maintenance

ATTENTION: Cut off the power supply to the equipment be-

fore effecting any internal inspection.

MAXIQ

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 appropriate connector on the MF4

feeder front panel).

This command replaces:

•

Completely the ENCODER-A and ENCODER-V knobs on

the MF4 feeder front panel.

AIR AND/OR WATER COOLED UP/DOWN TORCH

(must be plugged into the appropriate connector located on the

MF4 feeder front panel).

Once plugged in, the torch is automatically recognised.

Pressing the buttons adjusts the speed of the welding wire and

in particular: the right button increases the speed, the left but-

ton decreases it.

PUSH-PULL TORCH

(must be plugged into the relevant connector on the front pan-

el of the MF4 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

MF4 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 MF4 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:

• Wire speed

• Welding voltage

• Electronic inductance

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.

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

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

L-F Filter inductance

MElectric pump

MI-H Upper primary IGBT

MI-L Lower primary 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-F Secondary filter PCB

S-IL In Rush Limiter PCB

S-DF Digital interface 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

2101EE08

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

ENGLISH

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 MAXIQ 400w

- MAXIQ 500w welding machines.

Technical data

The general technical data of the system are summarized in

table 1.

Table 1

Model QBW1

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

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.

FIG. A

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

Blu

Blue

OFF

Blu

Blue

Maintenance

WARNING: Prior to undertaking any kind of inspection within

the machine, unplug the device from feed.

• Periodically check the level of the cooling fluid.

•

Add fluid whenever it drops below the minimum level indi-

cated.

•

Add antifreeze when the room temperature is below 2°C (ta-

ble 2).

• Make sure all joints are tight and that there areno leaks

• Periodically clean the radiator with compressed air to elimi-

nate the dust that reduces the cooling capacity.

IMPORTANT: Original spare parts have been specially de-

signed for our equipment. The use of non-original spare parts

may cause variations in performance or reduce the foreseen

level of safety. We decline all responsibility for the use of non-

original spare parts.

Table 2

Distilled

water Antifreeze External temperature

0°C -10°C -15°C -20°C

80% 20%

75% 25%

70% 30%

65% 35%

Hydraulic diagram

Meaning of graphic symbols on machine

4 5 6 72 31

•1 Fuse •2 Cold water outlet •3 Hot water intake for cooling in the unit •4 Grounding •5 Warning! •6 Before using the equipment you should carefully read