Helvi GLOBUS 201 User manual

INSTRUCTIONS MANUAL
MANUALE DI ISTRUZIONE
PLEASE READ THESE INSTRUCTIONS BEFORE INSTALLING, OPERATING,
OR SERVICING THIS PRODUCT. DO NOT DISTROY THIS MANUAL.
LEGGETE LE ISTRUZIONI PRIMA DI INSTALLARE, UTILIZZARE O
RIPARARE QUESTO IMPIANTO. CONSERVATE QUESTO MANUALE.
GLOBUS 201
GLOBUS 201C
GLOBUS 211

index
ENGLISH pag
1.0 Instruction 4
2.0 Safety worning 4
3.0 Overal features 10
4.0 Installation of the equipment 12
5.0 Globus 13
6.0 Stick welding 14
7.0 Quality of the weld 15
8.0 Tig welding 15
9.0 Tig welding by scratch arc 16
10.0 Tig welding by lift arc 17
11.0 Possible welding defects 18
12.0 Trouble shooting 18
13.0 Ordinary maintenance 19
14.0 Technical data information guide 20
ITALIANO pag
1.0 Introduzione 22
2.0 Precauzioni sulla sicurezza 22
3.0 Caratteristiche generali 28
4.0 Installazione dell’apparecchiatura 30
5.0 Globus 31
6.0 Saldatura ad arco 32
7.0 Qualità della saldatura 33
8.0 Saldatura a Tig 33
9.0 Saldatura a Tig con partenza a striscio 34
10.0 Saldatura a tig con partenza in lift arc 35
11.0 Possibili difetti in saldatura 36
12.0 Possibili inconvenienti di funzionamento 36
13.0 Manutenzione ordinaria 37
14.0 Guida alla lettura dei dati tecnici 38
indice

3
IMPORTANT
CAREFULLY READ THE FOLLOWING INSTRUCTIONS BEFORE INSTALLING
THE UNIT AND MAKE SURE THAT THE YELLOW/GREEN GROUNDING
CONDUCTOR IS DIRECTLY CONNECTED TO THE GROUND IN THE WELDING
LOCATION.
THE UNITMUST NEVERBE OPERATEDWITHOUT PANELSAS THISCOULD BE
DANGEROUS FOR THE OPERATOR AND COULD CAUSE SERIOUS DAMAGE
TO THE EQUIPMENT.
THE UNIT WORKS ONLY WITH INPUT VOLTAGE OF 230Vac -50 Hz-1Ph.
ALWAYS TURN THE POWER SWITCH OFFAND UNPLUG THE WELDER FROM
THE POWER SOURCE BEFORE SERVICING THE UNIT.
THIS WELDER CAN BE USED ONLY WITH DIESEL GENERATING
SETS WITH POWER HIGHER THAN 11 KVA AT 230 V 50 HZ.

4
1.0 INTRODUCTION
1.1 Equipment identification
Theunit’sidentificationnumber(specificationorpart number)model,and serialnumber
usually appear on a nameplate attached to the rear panel. Equipment which does
not have a control panel such as gun and cable assemblies is identified only by the
specification or part number printed on the shipping container. Record these numbers
for future reference.
1.2 Receipt of equipment
When you receive the equipment, compare it with the invoice to make sure it is
complete and inspect the equipment for possible damage due to shipping. All
machines dispatched have been scrupulously checked. However, should your
machine not work properly, consult the section on TROUBLE SHOOTING in this
manual. If the fault persists, consult your authorized dealer.
2.0 SAFETY WARNING
2.1 General instructions
This manual contains all the necessary instructions for:
- the installation of the equipment;
- a correct operating procedure;
- an adequate maintenance of the equipment.
Therefore,besure this manual iscarefullyreadand understood by themaintenance
and technical operators.
2.2 Location
Weldingprocessesofanykindcanbedangerousnotonlytotheoperatorbuttoanyperson
situated near the equipment if safety and operating rules are not strictly observed.
Therefore the owner and the operator must
be aware of all possible risks so that they may
takethe necessarysafetyprecautionstoavoid
any kind of accident at work.
The main precautions to be observed are:
-Operators should protect their body by
wearingnon flammable,close fittingprotective
clothing,withoutpocketsorturned-uptrousers.
Oilorgreaseshouldbecarefullyremovedfrom
all articles, before wearing. Operators should
also wear closed safety boots with steel toe
caps and with rubber soles ( Fig. 1).
1. Leather gloves
2. Leather aprons
3. Shoes cover
4. Security shoes
5. Face masks

5
-Operators should wear a non- flammable welding helmet or face shield
designed so as to shield the neck and the face, also on the sides. The helmet
or the face shield should be fitted with protective glasses adequate to the
welding process and current used. Glass screens must always be kept clean,
and immediately replaced if they are broken or cracked (Fig.2). It is good
practice to install a pane of transparent glass on top of the adiactinic glass,
between it and the welding area. This pane can be frequently replaced when
incandescent spatters and deposits greatly reduce visibility. When working
with coated plates that emit toxic fumes when heated, use an air-supplied
respirator.
- Welding should be done in a closed area that does not open onto other working
areas, in order to protect all workers against radiation and fumes. If such an area
cannotbe provided,the weldingarea mustbe delimitedbyprotectivescreenspainted
in opaque black large enough to restrain the visibility of any person situated near
the area (Fig. 3).
- Remove all chlorinated solvents from the welding area before welding. Certain
chlorinated solvents decompose when exposed to ultraviolet radiation to form
phosgene gas.
- Never, under any circumstances, look at an electric arc without suitable eye
protection (Fig. 4).
FIG.2
FIG.3
FIG.4

6
- Always wear protective goggles with transparent lenses to prevent splinters or
other foreign particles from harming the eyes (Fig. 5).
- Adequate local exhaust ventilation must be used in the area. It should be provided
through a mobile hood or through a built-in system on the workbench that provides
exhaust ventilation from the sides, the front and below, but not from above the bench
so as to avoid raising dust and fumes. Local exhaust ventilation must be provided
together with adequate general ventilation and air virculation, particularly when work
is done in a confined space. (Fig.6). Any symptom of stain or soreness to the eyes,
the nose or the throat may be cause by inadequate ventilation; work must be stopped
immediately and all necessary steps must be taken to rpovide adequate ventilation.
- Welding process must be performed on metal coatings thoroughly cleaned from
layers of rust or paint, to avoid production of harmful fumes. The parts degreased
with a solvent must be dried before welding.
- Do not weld metal or painted metal containing zinc, lead, cadmiun or beryllium
unless the operator, or anyone else subjected to the fumes, is wearing respiratory
equipment or an air-supplied helmet.
- Technical and sanitary protection of all welding operators-directly or indirectly
involved in welding processes is provided by the regulations in force for sanitation
and prevention of employment related injuries.
FIG.5
FIG.6

7
- do not use damaged welding or input cables (Fig. 8); FIG.7
FIG.8
2.3 Safety instructions
For your safety, before connecting the source to the line, closely follow these instructions:
- an adequate two-pole switch must be inserted before the two-pole main outlet; this
switch must be equipped with time-delay fuses and it must match the data specified
in the chapter “Technical Specification”;
- the mono-phase connection with ground must be made with a two-pole plug
compatible with the above mentioned socket;
- two wires of the two-pole input cable are used for the connection with the mono-
phase line and the yellow-green wire for the compulsory connection to the ground
in the welding location;
-connectall themetal partswhich arenear theoperator inthe weldinglocation byusing
cables bigger or of the same cross section of the welding cable to a ground terminal;
- when working in a confined space, the power source must be kept outside the
welding area and the ground cable should be welded to the workpiece; do not work
in a damp or wet area in these conditions (Fig. 7).

8
2.4 Fire prevention
The working area should conform to the Safety Regulations, and therefore, fire
extinguishers should be provided in the area and walls, ceiling and floor should be
non-flammable.All combustible material must be moved from the welding area (Fig.
10). If combustibles cannot be moved, they must be protected with fire-resistant
cover. Ventilate potentially flammable atmospheres before welding. Never operate
in an atmosphere which contains heavy concentrations of dust, flammable gas or
combustibleliquidvapor.The powersourcemust belocatedin asafearea witha firm
andflatfloor; itshouldnot be putagainsta wall. Donotweldcontainers inwhichfuel,
lubricant or any other flammable material have been stored.After having completed
your work, always check that the area is free of glowing or smouldering material.
FIG.10
- the operator should never touch, with any part of his body, high temperature or
electrically hot metal parts (Fig. 9);
- the operator should never wind the welding cables around his body;
- the welding gun should never be pointed at the operator or at another person. The
power source has a protection level IP 22; therefore, it prevents:
- any manual contact with hot or moving internal parts;
- the insertion of any solid body with more than 12mm diameter;
- protected against vertically falling drops of water (condensation).
The source must never be operated without its panels; this could cause serious
injury to the operator and could damage the equipment itself.
FIG.9

9
5- Check the immunity of any other equipment operating in the same environment.
In certain cases additional protective measures may be required.
Interference can be reduced in the following ways:
1- If there is interference in the power supply line, an E.M.C. filter should be
inserted between the mains and the unit.
2- The output cables of the unit should be shortened; these should be kept close
together and stretched along the ground.
3- All the panels of the unit should be correctly closed after carrying out
maintenance.
2.8 Medical and first aid treatment
First aid facilities and a qualified first aid person should be available for each shift
forimmediatetreatment of electricalshockvictims.Amedical facilityshouldbe close
by for immediate treatment of flash burns of the eye and skin burns.
EMERGENCY FIRST AID:
Call physician and ambulance immediately.
Use First Aid techniques recommended by The Red Cross.
DANGER: ELECTRIC SHOCK CAN BE FATAL
If person is unconscious and electric shock is suspected , do not touch the
person if he or she is in contact with welding equipment, or other live electrical
parts. Disconnect (open) power at wall switch and then use FirstAid. Dry wood,
wooden broom, or other insulating material can be used to move
cables, if necessary, away from the person.
2.5 Shielding gas
Use the correct shielding gas for the welding process. Be sure that the regulator/
flowmeter mounted on the cylinder is working well.
Remember to keep away the cylinder from any source of heat.
2.6 Permitted noise levels 86/188/EEC Rule.
Under normal circumstances the equipment used for electric arc welding does
not exceed the permitted 80 dBA. However in certain conditions eg. high welding
parameters in confined spaces, noise levels may exceed the permitted level. For this
reason it is strongly recommended that operatives wear appropriate ear protection.
2.7 Electromagnetic compatibility.
Before installing the STICK/TIG welding unit, carry out an inspection of the
surrounding area, observing the following guidelines:
1- Make sure that there are no other power supply cables, control lines, telephone
leads or other equipment near the unit.
2- Make sure that there are no radio receivers or television appliances.
3- Make sure there are no computers or other control systems.
4- Make sure that there is no-one with a pacemaker or hearing aid in the area
around the unit.

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3. OVERALL FEATURES
The new inverters GLOBUS 201/201C and Globus 211 have been designed
to work with unstable input voltages. The use of power components and of
electrolytic capacitors with higher voltage and a special control circuit grant a
high welding current stability in spite of the mains voltage fluctuations. These
units allow coated electrode (MMA) welding by scratch starting tungsten inert
gas (TIG) welding. GLOBUS 201C allows also cellulosic electrode welding.
The technology used to manufacture the generator, combined to both MMA
and TIG functions, make it particularly easy to be used since the beginning.
The generator is composed by a control and power p.c. board, by a switching
transformer and a levelling inductance. In the p.c.board are included different
electronic functions in order to improve the arc striking and the dynamic of the
welding, so that we can achieve an optimum weld with any type of electrode
and top simplicity of performance.
An IGBT bridge guarantees a fast speed of response and greater precision,
together witha drastic reductionof allmagnetic componentswith aconsequent
great reduction of the generator weight.All the above characteristics, including
a handle that enable the unit to be carried easily, and the low electricity
consumption, make this generator ideal for all types of welding applications.
In order to obtain satisfactory results, in conformity with all safety standards,
the operator should have a good knowledge of the following:
Stick/Tig process.
Welding parameter adjustments .
Welding performance.

11
GLOBUS 201 GLOBUS 201CGLOBUS 211
POWER SUPPLY V 230 230 230
PHASES 1 1 1
FREQUENCY Hz 50/60 50/60 50/60
OUTPUT CURRENT A 200 155 200
@ 60% V 28 26,2 28
OUTPUT CURRENT A 155 120 155
@ 100% V 26,2 24,8 26,2
NO LOAD VOLTAGE V 80 80 80
PROTEC. DEGREE IP22 IP22 IP22
INSULATION CLASS H H H
3.1 MAINS FEATURES AND TECHNICAL DATA

12
- Plug the inverter to the mains.
These units may be connected only to diesel generating sets with power
higher than 11KVA 220V 50Hz. If you connect other units to the same
generator, first verify that the generator power is the same or higher than the
sum of the maximum powers of the connected units.
DO NOT USE THE GENERATOR WITH INPUT CABLES’ EXTENSIONS
LONGER THAN 10 m AND THINNER THAN 4.0 sqmm. REMEMBER TO
KEEPTHEM LAYEDAND NOT WOUND OR ENTANGLED. DO NOT USE THE
WELDER WITHTHE SIDE PANELS PARTIALLY ORCOMPLETELY REMOVED
IN ORDER TO AVOID ACCIDENTAL CONTACTS WITH INNER LIVE PARTS.
- the green light must be on and the yellow one must be off. If the green led
blinks, check the voltage supplied by the mains or by the generator, until it sets
within the limit values and the green led is on.
- The inverter is now ready for use. Make sure you are welding in a properly
ventilatedarea andthat theventilation openingsof themachine arenot obstructed
(poor air ventilation may reduce the duty cycle of the unit and cuase damages).
Now you may choose the welding process by connecting the accessories as
showed in the following pages.
4.0 INSTALLATION OF THE EQUIPMENT
Proper operation of the generator is ensured by adequate installation. The
assembly of the inverter must be done by expert people, following the
instructions and in full respect of the safety standards.
- Remove the welder from the carton box.
BEFORE ATTEMPTING ANY ELECTRICAL CONNECTION CHECK THE
DATA PLATE AND MAKE SURE THAT THE INPUT VOLTAGE AND THE
FREQUENCY ARE THE SAME OF THE MAINS OUTLET TO BE USED.
EARTHING
- Toprotectuserstheweldingmachinesmustbeconnectedproperlytothe
earth (ground) system (INTERNATIONAL SAFETY REGULATIONS).
- It is indispensable to earth (ground) the machine properly with the
yellow-green conductor of the power supply cable, in order to avoid
discharges due to accidental contacts with earthed objects.
- The chassis (that is conductive) is electrically connected to the earth
conductor. Failure to earth the equipment correclty can cause electric
shocks dangerous to the users.

13
5.0 GLOBUS 201/201C
1 Green Led - it glows if power is on, unit is ready for operation
- it blinks if there are input voltage anomalies (overvoltage-undervoltage)
- after turning the unit off it blinks for a few seconds and then it stops.
2 Yellow Led - it glows indicating overtemperature cutout. Let the unit to cool
down. Thermostat will automatically reset and you can continue
welding.
3 Tig/Stick Selector
4 Welding Current Setting
5 Down Slope Time Setting
6 Post Gas Time Setting
7 50mm² dinse positive socket
8 50mm² dinse negative socket
9 Torch Trigger Connector
10 Gas Output Connector
11 Gas Input Connector
GLOBUS 211

14
- Switch the Inverter on. The two leds on the front panel will be respectively
the green = lit and the yellow = off. The green led will glow if the input voltage
is beyond the nominal values. The yellow led will blink in case of thermostatic
protection intervention. Select the stick welding through the switch placed on the
front panel (in the units fitted with).
- Protecting your face with a mask or a helmet. Touch, with the elctrode fastened,
in the electrode holder, the work piece until the arc will be struck.
Avoid hammering the work piece with the electrode since it may loose the
coating and increase the arc stricking difficulties.
- Afterstrickingthearckeepfeedingthe electrodeinto theweldpoolwithanangleof
about 60° and moving left to right so that you may control visually the welding.The
length of the arc can laso be controlled by lifting or lowering slightly the electrode.
Also a variation of the welding angle may increase the size of the weld pool
- Connect the earth cable to the negative pole of the Inverter and the earth clamp
to the workpiece.
- Connect the welding cable to the positive pole of the Inverter.
- Select the welding current using the potentiometer on the front panel. the welding
current should be choosen following the instruction given by the electrodes
manufacturer on the elctrode box, but the following indications may be useful as
general information:
RETEMAIDEDORTCELETNERRUCGNIDLEW
mm5.1A04-A03
mm0.2A56-A05
mm5.2A001-A07
mm52.3A041-A001
mm0.4A061-A041
6.0 STICK WELDING
General informations
The electric arc may be described as a source of bright light and strong heat;
in fact, the flow of electric current in the gas atmosphere which surrounds the
electrode and the workpiece determines the radiation of electromagnetic waves
that can be peceived as light and/or heat depending on their wave length. At an
unperceivable level, the arc also produces ultra-violet and infra-red light; ionizing
rays have never been noted. The heat produced by the arc is used in the welding
process to melt and join metal parts. The necessary electric current is supplied by
special equipment commonly called welding machine.
12 ON/OFF Switch
13 Input Cable

15
7.0 QUALITY OF THE WELD
Thequalityoftheweldwilldependmainlyontheabilityofthewelder,onthetypeofweld
and on the quality of the electrode: Choose the proper electrode before attempting to
weld, paying attention to the thickness and composition of the metal to be welded.
Correct welding current. If the current is too high the elctrode will burn fast and
the weld pool will be wide irregularand difficult to be controlled. If the current is too
low you will lack power and the weld pool will be narrow and irregular.
Correct arc length. If the arc is too long it will cause spatters and small fusion of
the welding piece. If the arc is too short the arc heta will insufficient causing the
elctrode to stick to the work piece.
Correct welding speed. The correct welding speed will consent to achieve a weld
of proper width, without waves or craters.
8.0 TIG WELDING
The TIG process uses the electrical arc struck between the tungsten electrode of
the torch and the work piece surface.
In TIG welding the torch is always connected to the negative pole of the
welder.
Welder preparation:
- Connect the earth cable to the positive pole of the welder and the earth clamp
to the work piece.
- Connect the tig torch to the negative pole of the welder and the gas hose to th
pressure regulator of the gas cylinder.
CAUTION:
Protect your eyes when hitting the slag with the chip hammer to avoid
damages.
CAUTION:
A bad start can be due to the dirty workpiece, a bad connection
between earth cable and work piece, or the bad fastening of the
electrode in the electrode holder.
improving the capacity of surfacing of the slag.
- At the end of the weld let the slag cool off before removing it, using the brush-
hammer.

16
The flow of the gas is manually controlled using the knob on the torch handle.
Use inhert gas (argon ) only.
- Switch the inverter on.
In order to avoid damages to the generator, we suggest only expert people
to proceed with the SCRATCH ARC welding.
NOTES:
a) The arc length generally varies between 3 and 6mm. depending on the type of
joint, type and thickness of material, and so on.
b) The torch is advanced in the direction of welding, without lateral movement,
maintaining the torch angle of 45° to the workpiece.
FIG.a
FIG.b
9.0 TIG WELDING BY SCRATCH ARC
- Ensure the electrode at the torch nozzle, protrudes by 4 - 5mm., also ensure that
the electrode is sharply pointed with an angle of 40°-60°.
- Set the welding current considering the thickness of the material to be welded and
of the diameter of the tungsten electrode to be used.
- Open the gas valve on the torch handle, allowing gas to flow from the torch nozzle.
Cover your face with the head shield, bring the torch to within 3-4mm of the work,
and at an angle of 45 °, so that the ceramic nozzle gently touches the work surface.
(fig.b). Scratch the tip of the electrode until an arc develops, quickly withdraw the
electrodeandmaintaning agapofapprox. 3-4mmproceed to weld.Tostopwelding,
simply remove the torch from the work piece.
REMEMBER to turn OFF the gas immediately you finish welding.
Gas valve

17
10.0 TIG WELDING BY LIFT ARC
FIG.b FIG.c FIG.d
-Connect the earth cable to the positive pole of the welder and the earth clamp to
thework piece.
-Connect the tig torch to the negative pole of the welder and the gas hose to
thepressure regulator of the gas cylinder.
Globus 201/201C: The gas flow is manually controlled by using the knob on
the torch handle.
Globus 211: The gas flow is automatically controlled using the post gas
potentiometeron the front panel.Use inhert gas (argon) only.
- Set the slope down time considerating the value of the weld current and the
thicknessof the material (low current=low slope down time ; high current = high
slope downtime (Globus 211 only).
- Set the welding current considering the thickness of the material to be welded
andof the diameter of the tungsten electrode to be used.
- Switch the inverter on.
-Covering yourfacewith amaskor ahelmet, bringthetungsten electrodeofthetorch
within3or 4mmof the workpiecekeeping itatan angle of45°, pushthetorchtrigger
(fig. a) and touching it with the ceramic nozzle (fig. b).
- With a rapid movement short - circuit the tungsten electrode (fig. c) and go back
to a distance of 3-4 mm (fig. d). The arc will be struck developing a hot and intense
light.Advance the torch maintaining the same distance from the work piece and
proceeding right to left.
- To stop the weld release the torch trigger or lift the torch from the work piece. In the
first case the output current decreases to zero in a slope down time before adjusted
(Globus 211), in the second case the current stops immediately (Globus 201/201C).

18
12.0 TROUBLE SHOOTING
11.0 POSSIBLE WELDING DEFECTS

19
13.0 ORDINARY MAINTENANCE
CAUTION!!!
BEFORE CARRY OUT ANY MAINTENANCE, UNPLUG THE MACHINE FROM
THE MAINS POWER SUPPLY.
The efficiency of the welding system over time is directly related to the frequency
of maintenance jobs, such as:
For welding machines only need to be taken care inside. The dustier the working
environment is, the more often this should be done.
- Take off the lid.
- Remove all traces of dust in the inner parts of the generator with a jet of
compressed air at a pressure under 3Kg/cm.
Check all electrical connections, making sure that nuts and screws have been
firmly tightened. Do not delay in replacing worn-out parts.
- Put the lid back on.
- After completing the above operations, the generator is ready to be restarted
following the instructions given in this manual.

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14.0 TECHNICAL DATA INFORMATION GUIDE
1 Serial number
2 Welding power source symbol
3 Kind of characteristic
4 Min. and max. rated no load voltage
5 Welding process symbol
6 Input supply and no. of phases
7 Rated supply voltage
8 Code letter for degree of insulation
9 Degree of protection
10 Input Power
11 Size of the necessary main fuse
12 Rated supply current
13 Rated welding current
14 Conventional load voltage
15 Duty cycle
16 Range of output
17 Referring standard
2
3
4
5
6
7
11
8
1
17
16
15
13
14
12
10
9