CELETTE TRIO DIGITAL Operation instructions

ORIGINAL MANUAL
01/2023 - REV. 1.0
WWW.CELETTE.COM
TRIO DIGITAL
PRODUCT REF NO: CEL.1321-521-6

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TABLE OF CONTENTS
FOREWORD........................................................................................................................................Page 3
1 SAFETY PRECAUTIONS.............................................................................................................Page 4
- 1.1 SYMBOL USAGE..............................................................................................................Page 4
- 1.2 OPERATION HAZARDS .................................................................................................Page 4
- 1.3 ADDITIONAL SYMBOLS FOR INSTALLATION, OPERATION, AND MAINTENANCE......Page 7
- 1.4 EMF INFORMATION.........................................................................................................Page 8
2 PRODUCT FEATURES ................................................................................................................Page 9
3 DESCRIPTION OF TECHNICAL SPECIFICATIONS ................................................................Page 9
4 INSTALLATION ............................................................................................................................Page 10
- 4.1 SETUP................................................................................................................................Page 10
- 4.2 INPUT POWER CONNECTIONS....................................................................................Page 10
- 4.3 OUTPUT CONNECTIONS ...............................................................................................Page 10
- 4.3.1 WIRE FEEDER CONNECTION...........................................................................Page 10
- 4.3.2 CONNECTING THE WORK RETURN LEAD CLAMP..................................Page 10
- 4.3.3 CONNECTING THE GAS HOSE......................................................................Page 11
- 4.4 WELDING ..........................................................................................................................Page 11
- 4.4.1 INSTALLATION AND STARTER...................................................................Page 11
- 4.4.2 THE MACHINE IS READY TO WELD..........................................................Page 11
- 4.4.3 WELDING CARBON STEEL ............................................................................Page 12
- 4.4.4 WELDING STAINLESS STEEL......................................................................Page 12
- 4.4.5 WELDING ALUMINIUM .....................................................................................Page 12
- 4.5 WELDING DEFECTS .......................................................................................................Page 13
5 DESCRIPTION OF CONTROLS ..................................................................................................Page 14
6 MACHINE MAINTENANCE...........................................................................................................Page 15
7 TROUBLESHOOTING....................................................................................................................Page 16
8 WELDING MACHINE SERVICING...............................................................................................Page 17
- 8.1 PRESCRIPTIONS TO FOLLOW FOR SERVICING.....................................................Page 17
9 WIRE DRAWING ...........................................................................................................................Page 18
10 INVERTER COMBI 200 1PH/220V EUROPE/INDIA ..........................................................Page 19
11 INVERTER COMBI 200 1PH/220V USA...............................................................................Page 20

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FOREWORD:
IMPORTANT: Before starting the equipment, read the contents of this manual, which must be stored in a
place familiar to all users for the entire operative life-span of the machine. This equipment must be used
solely for welding operations.

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1. SAFETY PRECAUTIONS:
1.1 SYMBOL USAGE:
MEANS WARNING! WATCH OUT! THERE ARE POSSIBLE HAZARDS WITH THIS PROCEDURE!
THE POSSIBLE HAZARDS ARE SHOWN IN THE ADJOINING SYMBOLS.
MARKS A SPECIAL SAFETY MESSAGE.
Means “Note” not safety related.
This group of symbols mean WARNING! WATCH OUT! Possible ELECTRIC SHOCK, MOVING PARTS, and
HOT PARTS hazard.
Consult symbols and related instructions below for necessary actions to avoid the hazards.
1.2 OPERATION HAZARDS:
The symbolds shown below are used throughout this manual to call attention to and identify possible
hazards. When you see the symbol, watch out, and follow the related instructions to avoid the
hazard. The safety information to avoid the hazard. The safety information given below is only a
summary of the more complete safety information found in the safety standards listed in section
below. Read and follow all safety standards.
 Only qualied people should install, operate, maintain, and repair this unit.
During operation, keep everybody, especially children away.
ELECTRIC SHOCK CAN KILL:
Touching live electrical parts can cause fatal shocks or severe burns. The electrode
and work circuit is electrically live whenever the output is on. The input power circuit
and machine internal circuits are also live when power is on. In semiautomatic or
automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts
touching the welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent
any physical contact with the work or ground.
 Do not use AC output in damp areas, if movement is conned, or if there is a danger of falling.
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on unit.
Disconnect input power or stop engine before installing or servicing this equipment.
Properly install and ground this equipment according to it’s Owner’s Manual and national, state, and
local codes.
Always verify the supply ground - check and be sure that input power cord ground wire is properly
connected to ground terminal in disconnect box or that cord plug is conncted to a properly grounded
receptable outlet.

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 When making input connections, attach proper grounding conductor rst - double-check
connections.
Frequently inspect input power cord for damage or bare wiring - replace cord immediately if
damaged - bare wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly with a separate cable.
Do not touch electrode if you are in contact with the work, ground, or another electrode from a
different machine.
Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit
according to manual.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as
practical.
Insulate work clamp when not connected to workpiece to prevent contact with any single weld output
terminal.
Do not connect more than one electrode or work cable to any single weld output terminal.
SINGNIFICANT DC VOLTAGE EXISTS AFTER REMOVAL OF INPUT POWER ON INVERTERS:
Turn OFF inverter, disconnect input power, and discharge input capacitors according to instructions
in Maintenance Section before touching any parts.
FUMES AND GASES CAN BE HAZARDOUS:
Welding produces fumes and gases. Breathing these fumes and gases can be
hazardous to your health.
Keep your head out of the fumes. Do not breathe fumes.
If inside, ventilate the area and/or use exhaust at the arc to remove welding
fumes and gases.
If ventilation is poor, use an approved air-supplied respirator.
Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instructions for metals,
consumables, coatings, cleaners, and degreasers.
 Work in a conned space only if it is well ventilated, or while wearing an air-supplied respirator.
Always have a trained watch-person nearby. Welding fumes and gases can displace air and lower the
oxygen level causing injury or death. Be sure the breathing air is safe.
Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the
arc can react with vapors to form highly toxic and irritating gases.
Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating
is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-
supplied respirator. The coatings and any metals containing these elements can give off toxic fumes
if welded.
ARC RAYS CAN BURN EYES AND SKIN:
Arc rays from the welding process produce intense visible and invisible (ultraviolet
and infrared) rays that can burn eyes and skin Sparks fly off from the weld.
 Wear a welding helmet tted with a proper shade of lter to protect your face and
eyes when welding or watching.

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Wear approved safety glasses with side shields under your helmet.
Use protective screens or barriers to protect others from flash and glare; warn others not to watch
the arc.
Wear protective clothing made from durable, flame resistant material (leather and wool) and foot
protection.
WELDING CAN CAUSE FIRE OR EXPLOSION:
Welding on closed containers, such as tanks, drums or pipes, can cause them to
blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece,
and hot equipment can cause re and burns. Accidental contact of electrode to
metal objects can cause sparks, explosion, overheating, or re. Check and be sure
the area is safe before doing any welding.
Protect yourself and others from flying sparks and hot metal.
Do not weld where flying sparks can strike flammable material.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover
them with approved covers.
Be alert that welding sparks and hot materials from welding can easily go through small cracks and
openings to adjacent areas.
 Watch for re, and keep a re extinguisher nearby.
 Be aware that welding on a ceiling, floor, bulkhead, or partition can cause re on the hidden side.
Do not weld on closed containers such as tanks, drums, or pipes unless they are properly prepared
accoring to AWS F4.1 (see Safety Standards).
Connect work cable to the work as close to the welding area as practical to prevent welding current
from travelling long, possibly unknown paths and causing electric shock and re hazards.
Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at contact tip when not in use.
Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes,
and a cap.
Remove any combustibles, such as a butane lighter or matches, from your person before doing any
welding.
FLYING METAL CAN INJURE EYES:
Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As
welds cool, they can throw off slag.
Wear approved safety glasses with side shields even under your welding helmet.
BUILDUP OF GAS CAN INJURE OR KILL:
Shut off shielding gas supply when not in use.
 Always ventilate conned spaces or use approved air-supplied respirator.
HOT PARTS CAN CAUSE SEVERE BURNS:
Do not touch hot parts bare handed.
Allow cooling period before working on gun or torch.
MAGNETIC FIELDS CAN AFFECT PEACEMAKERS:
Pacemaker wearers keep away.
Wearers should consult their doctor before going near arc welding, gouging, or
spot welding operations.

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NOISE CAN DAMAGE HEARING:
Noise from some processes or equipment can damage hearing.
Wear approved ear protection if noise level is high.
CYLINDERS CAN EXPLODE IF DAMAGED:
Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can
explode. Since gas cylinders are normally part of the welding process, be sure to
treat them carefully.
Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames,
sparks, and arcs.
Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent
falling or tipping.
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder - explosion will result.
 Use only correct shielding gas cylinders, regulators, hoses, and ttings designed for the specic
application; maintain them and associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is in use or connected for use.
Read and follow instructions on compressed gas cylinders, associated equipment, and CGA
publication P-1 listed in safety standards.
1.3 ADDITIONAL SYMBOLS FOR INSTALLATION, OPERATION, AND MAINTENANCE:
FIRE OR EXPLOSION HAZARD:
Do not install or place unit on, over, or near combustible surfaces.
Do not install unit near flammables.
Do not overload building wiring - be sure power supply system is properly sized,
rated, and protected to handle this unit.
FALLING UNIT CAN CAUSE INJURY:
Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.
Use equipment of adequate capacity to lift and support unit.
If using lift forks to move unit, be sure forks are long enough to extend beyond
opposite side of unit.
OVERUSE CAN CAUSE OVERHEATING:
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before starting to weld again.
 Do not block or lter airflow to unit.
STATIC (ESD) CAN DAMAGE PC BOARDS:
Put on grounded wrist strap BEFORE handling boards or parts.
Use proper static-proof bags and boxes to store, move, or ship PC boards.

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MOVING PARTS CAN CAUSE INJURY:
Do not press gun trigger until instructed to do so.
Do not point gun toward any part of the body, other people, or any metal when
threading welding wire.
WELDING WIRE CAN CAUSE INJURY:
Keep away from moving parts.
Keep away from pinch points such as drive rolls.
MOVING PARTS CAN CAUSE INJURY:
Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards closed and securely in place.
H.F. RADIATION CAN CAUSE INTERFERENCE:
High-frequency (H.F.) can interfere with radio navigation, safety services, computers,
and communications equipment.
 Have only qualied persons familiar with electronic equipment perform this installation.
 The user is responsible for having a qualied electrician promptly correct any interference problem
resulting from the installation.
 If notied by the FCC about interference, stop using the equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and
use grounding and shielding to minimize the possibility of interference.
ARC WELDING CAN CAUSE INTERFERENCE:
Electromagnetic energy can interfere with sensitive electronic equipment such as
computers and computer-driven equipment such as robots.
Be sure all equipment in the welding area is electromagnetically compatible.
To reduce possible interference, keep weld cables as short as possible, close together, and down
low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine in installed and grounded according to this manual.
If interference still occurs, the user must take extra measures such as moving the welding machine,
using shielded cables, using line lters, or shielding the work area.
1.4 EMF INFORMATION:
This machine is manufactured in compliance with the instructions contained in the harmonized standard,
and must be used solely for professional purposes in an industrial environment. There may be potential
difculties in ensuring electromagnetic compatibility in non-industrial environments. IN CASE OF
MALFUNCTIONS, REQUEST ASSISTANCE FROM QUALIFIED PERSONNEL.

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2. GENERAL TECHNICAL DESCRIPTIONS:
2.1 SPECIFICATIONS:
This manual has been prepared with the intent of instructing the operator on how to install, operate, and
properly maintain this electric arc welding machine.
This machine is a constant voltage power source for MIG/MAG and OPEN-ARC welding. Upon receiving
and unpacking the machine, make a careful inspection to ensure that there are no damaged parts.
Should there be a claim for losses or damages it must be made by the purchaser directly to the shipper
who handled the goods.
When requesting information about this welding machine please state the machine’s part number and
serial number to ensure receiving accurate information relating to your machine.
MODEL SN
ENXXXX
-A/-V---A/-V
X -% -%
U0 =
I2 -A -A
U2 -V -V
U1= I1max= I1eff=
IP21S
2.2 DESCRIPTION OF TECHNICAL SPECIFICATIONS:
MODEL: The model of the machine
EN XXXXX: International Standards
SN: Machine Serial Number which must appear on requests or inquiries concerning the machine
Three-phase transformer-rectier
3-50/60Hz: Three-phase input supply at 50 or 60 Hz
Uo: Secondary no-load voltage (peak value)
X: Duty-Cycle Percentage
The duty-cycle is the number of minutes, expressed as a percentage, the machine can
operate (arc on) within a ten minute period without overheating. The duty cycle varies
according to the output current.
I2: Output welding current
I1: Input Amps absorbed corresponding to different output levels (I2)
U2: Secondary voltage with welding current I2
U1: Nominal supply voltage
IP21S: Machine case protection class. The 1 in the second digit place means that this unit is not t
to work outdoors in the rain.
NOTE: This machine has also been designed to work in class 3 pollution areas.

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3. INSTALLATION:
3.1 SETUP:
Place the machine in a ventilated area.
Dust, dirt, or any other foreign material that might enter the machine may restrict the ventilation which
could affect the machine’s performance. Fasten the rotating support to the machine top and x the handle,
the wheels, the bottle support and, if any, the cooling unit.
3.2 INPUT POWER CONNECTIONS:
All sections concerning the installation of this machine must be read carefully.
This machine must be installed by skilled personnel.
Make sure that the input power plug has been disconnected before inspecting, maintaining, or servicing.
Connect the yellow-green wire to a good electrical ground.
Do not use water pipes as earth conductor.
After a nal inspection, the machine should be connected to the input supply voltage marked on the
input power cord.
If you wish to change the input supply voltage, remove the right side panel , locate the voltage-
changing terminal board and arrange the connections as shown in ILLUSTRATION OF WORKING
PRINCIPLE.
After having changed the supply voltage, re-place the upper cover.
This machine must never be used without the top and side covers. This is both for obvious safety reasons
and to avoid interference with the machine’s internal cooling system. The warranty is to be considered
null and void it this machine is used without the protection of its top and side covers.
Mount a plug on the power supply cable that corresponds to the input power drawn by the machine.
3.3 OUTPUT CONNECTIONS:
3.3.1 Wire feeder connection:
This power source is compatible with the wire feeders. To connect the power source to the wire feeder
units use the extension art. Performances and operating features of the wire feeder are described in the
operating manuals supplied with the wire feeder itself.
3.3.2 Connecting the work return lead clamp:
Some versions have one impedance socket only.
Connect the male end of the work return lead to one of the impedance taps on the front panel of the
machine. The impedance tap designated by the provides the maximum amount of impedance
which will produce nicely lleted weld beads. This tap is recommended when welding aluminum, stainless
steel, and carbon steels of binary or ternary composition. The impedance tap designated by the
provides the least amount of impedance and is recommended when using carbon dioxide as a shielding
gas to weld carbon steels, in the upwards vertical position, of binary or ternary composition.
It is generally advisable to use low impedance values for small diameter wires and high values for big
diameter wires.
After having selected the proper impedance tap, attach the work return clamp to the work to be welded.
Make sure that the ground clamp is tightly fastened to the work return cable and periodically check that
this connection remains well tightened. A loose connection can cause weld current drops or overheating
of the work return lead and clamp which, in turn, creates the risk of burns from accidental contact with
the work return lead. The weld circuit must not be placed deliberately in direct or indirect contact with the
ground conductor if it is not in the work to be welded.

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4. WELDING:
If the work to be welded is attached deliberately to the ground by a protection lead, then the connection
must be the most direct possible and it must be done using a lead that has a cross section that is at least
equal to the cross section of the work return lead being used for the weld circuit. The protection lead
must also be attached to the work at the same spot as the work return lead. To do so, a second ground
clamp, tted to the protection lead, must be attached next to the ground clamp of the work return lead.
3.3.3 Connecting the gas hose:
Keep the cylinders in an upright position by chaining them to their support.
Keep the cylinders in a place where they cannot be damaged.
Do not lift the machine with the cylinder on its support.
Keep the cylinder away from the welding area and uninsulated electric circuits.
Cylinders containing inert gas have to be equipped with a pressure reducer and a flow meter.
After having positioned the cylinder, connect the gas hose that comes out from the rear of machine to the
pressure reducer output.
Regulate the gas flow to 8-10 L/min.
4.1 INSTALLATION AND STARTER:
Machine installation must be done by a competent staff. All connections must correspond to the rules in
force and must respect laws concerning accidents.
Check that the wire diameter corresponds to that indicated on the roll and mount the wire coil.
Connect the pipe coming out of the extension with the cylinder flow meter.
Position the welding machine so as to allow free air circulation inside it and avoid that metal or any other.
4.2 THE MACHINE IS READY TO WELD:
Connect the ground terminal to the part to be welded.
Turn the machine on.
Extract the conic gas nozzle by rotating it clockwise.
Unscrew the current nozzle.
Press the torch trigger to feed the wire until it comes out from the torch.
WARNING: Keep your face away from the terminal nozzle while the wire comes out.
Screw the current nozzle again, making sure that the hole diameter be the same as that the wire used.
Insert the welding conic gas nozzle by rotating it clockwise. Open the gas cylinder and adjust flowmeter at
8-10L/min.
WARNING: Check that the gas used is compatible with the material to be welded.

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4.3 WELDING CARBON STEEL:
To weld carbon steels the following things are necessary:
1. The use of a binary shielding gas which is most commonly Argon and Carbon dioxide, in a ratio of
75-80 % Argon and 20-25% Carbon dioxide. Some applications, however, may require a mix of three
gases: Argon, Carbon dioxide (CO2), and dioxide (O2). These gas mixtures generate heat during
welding and as a result the weld bead will be well lleted and neat in appearance. The penetration,
however, will not be deep.
The use of Carbon dioxide as the shield gas results in a narrow weld bead with deep penetration but
the ionization of the gas will have an influence on arc stability.
2. The use of a ller wire of the same quality as the steel to be welded. It is recommended that high
quality wires be used and that welding with rusted wires be avoided because they can give rise to
defects in the weld bead. Generally, the current range within which a wire can be used is calculated in
the following manner:
Ø of wire x 100= minimum number of Amperes.
Ø of wire x 200= maximum number of Amperes.
Practical example: 1.20 Ø wire= 120 Amps minimum and 240 Amps maximum. These amperages are
based on the use of an Argon/CO2mixture as the shield gas and welding in the Short Arc transfer mode.
3. Avoid welding on rusted work pieces or work having spots of oil and grease present on the surface.
4. The use of a welding torch suitable to the welding currents that are going to be used.
5. Periodically check that the two handles making up the ground clamp are not damaged and that the
welding cables (torch cable and the work return lead) do not have any cuts or burn marks that would
reduce their efciency.
4.4 WELDING STAINLESS STEEL:
Welding stainless steels in the 300 series (the austenitic series) must be done using a shield gas mixture
of predominantly Argon with a small percentage of O2 added to stabilize the arc. The recommended
mixture is AR/O2 in the ratio of 98/2. Do not use CO2 or AR/CO2 mixtures as the shield gas.
Do not touch the welding wire with your bare hands.
The ller metal (the wire) must be of a higher quality than the work to be welded and the weld area must
be clean.
4.5 WELDING ALUMINIUM:
The following is required for aluminum welding:
1. 100% Argon as welding protection gas.
2. A torch wire of composition suitable for the basic material to be welded.
For ALUMAN welding wire 3.5% silicon.
For ANTICORODAL welding wire 3.5% silicon.
For PERALUMAN welding wire 5% magnesium.
For ERGAL welding wire 5% magnesium.
3. A torch prepared for aluminum welding.
If you only have a torch for steel wires, the same shall be modied in the following way:
Make sure that length of torch cable does not exceed 118 inches (it is advisable not to use longer torches).
Remove the brass sheath-holding nut, the gas and the current nozzles, then slip the sheath off.
Insert the teflon sheath for aluminum and ensure it protrudes from both ends.
Screw the current nozzle so that the sheath adheres to it.
Insert the sheath holding nipple, the O-Ring in the free end of the sheath and secure with the nut
without tightening too much.

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Slip the brass tube on the sheath and insert both into the adapter (after removing the iron tube which
was tted inside the adaptor).
Cut the sheath diagonally so that it stays as close as possible to the wire slide roller.
4. Use drive rolls that are suitable for aluminum wire. The drive rolls, when being installed, must be
tightened as tight as possible.
5. Use contact tips that are suitable for aluminum wire and make sure that the diameter of the contact tip
hole corresponds to the wire diameter that is going to be used.
6. Use abrasive grinders and tool brushes specically designed for aluminum. Never use these tools on
other materials. REMEMBER that cleanliness equals quality.
The wire spools must be stored in plastic bags with a dehumidier.
DEFECT 1: Porosity (In, or on the surface of the weld bead)
CAUSES: Bad wire (rust on the surface)
Insufcient gas shielding due to:
Inadequate gas flow due to a block in gas line
Defective flow meter
Gas regulator covered with frost because a gas heater was not used to heat the CO2
shielding gas
Failure of gas valve solenoid
Gas nozzle plugged up with splatter
Gas flow holes plugged up
Air drafts in the welding area
DEFECT 2: Shrinkage Cracks
CAUSES: Welding wire or work to be welded dirty or rusty
Weld bead too smal
Weld bead too concave
Too much weld bead penetration
DEFECT 3: Lateral Cracking
CAUSES: Welding speed too fast
Low current and high arc voltages
DEFECT 4: Too much Spatter
CAUSES: Voltage too high
Insufcient impedance
No gas heater used for CO2 shielding gas
5. WELDING DEFECTS:

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6. MACHINE MAINTENANCE:
GAS NOZZLE: Periodically clean the nozzle of all weld spatter that may have accumulated during
welding operations If the nozzle should become distorted or oval in shape then it
must be replaced.
CONTACT TIP: A good contact between the contact tip and the wire ensures a stable arc and optimal
current output. Therefore, following steps must be followed:
1. The contact tip hole must be kept free of dirt or oxidation.
2. After lengthy welds, spatter can easily accumulate on the contact tip and prevent the
wire from being fed. The contact tip must be cleaned regularly and if necessary it
must be replaced.
3. The contact tip must always be screwed tightly on to the body of the torch. The
thermal cycles which the torch undergoes during operation may loosen the contact
tip which, in turn, may cause the torch body and nozzle to overheat or cause
unsteady wire feed.
THE WIRE LINER: It is an important part that must often be checked since, during normal operations,
the wire can deposit copper dust or tiny metal shavings in the lining. Periodically clean
the liner and the gas line with a jet of dry, compressed air. Wire liners are exposed to
continual wear and therefore they must be replaced after a certain period of time.
WIRE FEED MOTOR: Periodically clean the wire feed assembly and the drive rolls from any rust or metal
shavings due to the feeding of the wire. A periodic check of all the components of
the wire feed assembly, spool holder, drive rolls, wire liner and the contact tip is
recommended.

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7. TROUBLESHOOTING:
TROUBLE PROBABLE CAUSE REMEDY
Limited electric output
A phase missing Check the phase of the feed line and/or
the remove control switch contacts
A line fuse is burnt Replace it
Wrong connection on the voltage
changer terminal board
Check the terminal board connections
by following the plate scheme
The rectier diode are burnt Replace the rectier
Loosened torch or ground connections Tighten all connections
Welding regulation commutator has an
uncertain contact Replace the commutator
Transformer wire interrupted on the
commutator
Unscrew the commutator contact
remove the wire insulation and put it
under the contact
Welding with a lot of
metal spatter
Wrong adjustment of the welding
parameters
Select the correct parameters through
the welding voltage switch and the
wire-speed adjustment potentiometer
Wire advancing unproperly Uncorrected sheath diam
Insufcient grounding Check grounding connections
Wire not advancing Wire roller with too wide groove Replace roller
Wire advancing
unproperly
Obstructed or clogged liner Extract it and clean
Loose wire pressing roller Tighten it
Coil reel friction too tight Loosen and adjust it
Current nozzle clogged Replace it
The wire jams or
entangles between
the drive rolls and the
torch infeed wire guide
Wrong current nozzle diameter Replace it
Wrong roller groove alignment Align it
Obstructed or clogged sheath Remove and clean
NOTE: All repair work must be done by qualied personnel.
Disconnect the power input cable from the mains supply before replacing cables or before removing the
unit covers. The machine is equipped with a thermostat that shuts the machine down when the power
source overheats. After the thermostat intervenes, let the power source cool down for several minutes
before resuming welding operations.
The troubleshooting table lists troubles, causes and remedies for those troubles that occur most
commonly.

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8. WELDING MACHINE SERVICING:
Experience has shown that many fatal accidents originated from servicing improperly executed. For this
reason, a careful and thorough inspection on a serviced welding machine is just as important as one
carried out on a new welding machine.
Furthermore, in this way producers can be protected from being held responsible for defects stemming
from repairs not carried out by the manufacturer.
8.1 Prescriptions to follow for servicing:
After rewinding the transformer or the inductance, the welding machine must pass the applied-voltage
test in accordance with indications of the international standard.
If the servicing is not done by the manufacturers, the repaired welding machines which underwent
replacements or modications of any component shall be marked in a way such that the identity of the
person having serviced it is clear.
After making repairs, take care to re-order the cables so that there is sure to be insulation between the
primary and secondary sides of the machine. Make sure that the wires cannot come into contact with
moving parts or parts that heat during operation. Replace all clamps in their original positions on the
machine, to prevent a connection between the primary and secondary circuits if a conductor accidentally
breaks or disconnects.

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9. DESCRIPTION OF CONTROLS:
9.1 CONTROLS ON GENERATOR FRONT PANEL:
A: Connecter of torch
B: toggle switch (torch selection)
B1: toggle switch (torch selection)
C: control socket
J: Adjustable feeding wire knob: Adjust the speed of feeding wire (the larger the number, the faster the
feeding wire)
L2: Rotary weld voltage switch:
This switch allows the ne tuning of the welding voltage selected with switch G. (Step adjustment)
some model without the function
M: Power switch
N: Connecter of pull-push torch (spool on gun)
O: Quick connecter of ground cable
B1: Toggle switch (torch selection) up - for normal torch down - for spool on gun
9.2 CONTROLS ON GENERATOR REAR PANEL:
A: Power fuse
B2: Gas pipe connecter for torch(I)
B3: Gas pipe connecter for torch(III)
C: Gas pipe connecter for torch pull-push torch (spool on gun)
D: Socket for heater of regulator
E: Input power cable (conrm the power voltage before use)
F: Ground connector
H: Support for cylinder
DIGITAL CONTROL DESCRIPTION
B1
9.29.1
A
M
L2
J
B
C
N
OF
E
A
D
H
B3
B2
C

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9.3 DIGITAL CONTROL DESCRIPTION:
B
C
D
A E F
A: Trigger Function Selection: Three modes to select
B: Normal welding mode:
- Normal welding 2T mode (non-latching)
- Normal welding 4T mode (latching)
C: Spot welding mode
D: Stitch welding mode
- Stitch welding 2T mode
- Stitch welding 4T mode
E: Parameter setting. Please note the wire frame on the panel:
RED frame for normal MIG welding modes
BLACK frame for Spot welding modes
GREEN frame for Stitch welding modes
t1: Welding time for “spot” or “stitch ON” operation
t2: Welding time for “stitch OFF” operation
F: Welding time setting
The higher the number, the longer the time for function selected
- burn back
- Overheat warning. Machine will auto-reset after cooling period and light will go off.
- Power test. Conrms machine is wired correctly to line power supply.
- Fast wire feeding test. Conrms wire feed motor is functional and used for set-up.
- Gas test. Conrms shield gas input system is functional.
- wire start- gas after flow

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10. WIRE DIAGRAM:
10.1 I321-521-6 3PH 380V:

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10.2 I321-521-5 3PH 220V/380V: