SincoSald NOVATIG 503 AC/DC User manual

Original instructions in Italian.
Please keep for future use.
1.995.217 EN - Rev. 1.1
INSTRUCTION MANUAL
for installation,
use and maintenance
of welding
machines.
MODEL
NOVATIG 503 AC/DC
G.R.3

Contents
1. PREFACE 4
1.1. PURPOSE OF THE INSTRUCTION MANUAL FOR USE AND MAINTENANCE 4
1.2. RECIPIENTS 4
1.3. STORAGE OF THE INSTRUCTION MANUAL 5
1.4. UPDATING THE INSTRUCTION MANUAL 5
1.5. HOW TO READ THE INSTRUCTION MANUAL 5
1.6. TERMS, SYMBOLS AND PICTOGRAMS 5
2. GENERAL INFORMATION 6
2.1. MANUFACTURER IDENTIFICATION DATA 6
2.2. MACHINE IDENTIFICATION DATA AND PLATES 6
2.3. DECLARATIONS OF CONFORMITY 7
2.4. SAFETY STANDARDS 7
2.5. INFORMATION ON TECHNICAL ASSISTANCE 7
2.6. PREPARATION BY THE CUSTOMER 8
3. SAFETY 8
3.1. GENERAL SAFETY WARNINGS 8
3.2. INTENDED USE 13
3.3. CONTRAINDICATIONS FOR USE 13
3.4. HAZARDOUS AREAS 13
3.5. SAFETY DEVICES 13
3.6. SIGNS 14
3.7. RESIDUAL RISKS 15
4. INSTALLATION 16
4.1. SHIPPING 16
4.2. PACKAGING 16
4.3. MACHINE RECEIPT 16
4.4. HANDLING AND LIFTING 16
4.5. UNPACKING 17
4.6. STORAGE 18
4.7. PREPARATIONS 18
4.8. ASSEMBLY/POSITIONING 18
4.9. CONNECTIONS 18
4.10. PRELIMINARY CHECKS 19
5. OVERVIEW 20
5.1. OPERATING PRINCIPLE 20
5.2. FEATURES 20
5.3. ENVIRONMENTAL CONDITIONS 20
5.4. LIGHTING 20
5.5. VIBRATIONS 21
5.6. NOISE 21
5.7. TECHNICAL SPECIFICATIONS 21
1.995.217 EN - Rev. 1.1
NOVATIG 503 AC/DC
G.R.3
2

6. MACHINE USE 22
6.1. MACHINE LAYOUT DESCRIPTION 22
6.1.1. Layout for the front and rear panel 22
6.1.2. Further Controls Explained 23
6.2. POWER SUPPLY INPUT CONNECTION 28
6.3. INSTALLATION & OPERATION FOR MMA WELDING 28
6.3.1. Set up installation for MMA Welding 28
6.3.2. Operation for MMA Welding 29
6.4. INSTALLATION & OPERATION FOR TIG WELDING 30
6.4.1. Set up installation for TIG Welding 30
6.4.2. Operation for TIG Welding 31
6.4.3. Remote current control 31
6.5. REMOTE CONTROL CONFIGURATION 32
6.5.1. Wireless remote control Configuration 32
6.5.2. Wire foot pedal Configuration 33
6.6. STARTUP 34
6.7. NORMAL STOP 34
6.8. DECOMMISSIONING 34
7. MAINTENANCE 35
7.1. MACHINE ISOLATION 35
7.2. SPECIAL PRECAUTIONS 35
7.3. CLEANING 35
7.4. ROUTINE MAINTENANCE 35
7.5. WELDING MACHINE REPAIRS 36
7.6. DIAGNOSTICS AND TROUBLESHOOTING 37
8. ACCESSORIES AND SPARE PARTS 38
8.1. CUSTOMER SERVICE 38
8.2. SPARE PARTS 38
9. ADDITIONAL INSTRUCTIONS 38
9.1. WASTE DISPOSAL 38
9.2. DECOMMISSIONING AND DISMANTLING 38
10. ANNEXES 40
10.1. WIRING DIAGRAMS 40
10.2. SPARE PARTS 41
1.995.217 EN - Rev. 1.1
NOVATIG 503 AC/DC
G.R.3
3

THE OFFICIAL LANGUAGE CHOSEN BY THE MANU-
FACTURER IS ITALIAN. The manufacturer cannot be
held liable for translations in other languages that do
not conform to the original meaning (ORIGINAL IN-
STRUCTIONS).
1.2. RECIPIENTS
This Instruction Manual is intended for the installer,
the operator/user, the system manager, the system
safety manager and the qualified or qualified and au-
thorised technician authorised to maintain the ma-
chine.
INSTALLER: Technician authorised by the manufac-
turer and expert in handling, installation, connection
and adjustment of the machine.
OPERATOR/USER: This is the person in charge of us-
ing the machine and cleaning it.
PLANT MANAGER: The individual who makes the
adjustments and the programming.
PLANT SAFETY MANAGER: Person responsible for
verifying that all applicable safety regulations and
the provisions set out in this manual are observed.
QUALIFIED TECHNICIAN: Qualified person who, by
virtue of an accurate technical knowledge of the ma-
chine and all the safety procedures, performs ordi-
nary maintenance and minor repairs.
QUALIFIED AND AUTHORISED TECHNICIAN: High-
ly qualified person, trained and authorised by the
manufacturer to make significant adjustments and
extraordinary maintenance or repairs during the war-
ranty period.
EXPOSED PERSON: Any person who is wholly or
partly in a dangerous area (near the machine and ex-
posed to risk due to his or her safety).
The machine is intended for industrial use, so its use
is strictly for qualified, skilled technical personnel, in
particular those:
•over 18 years of age;
•physically and psychologically capable of per-
forming particularly difficult technical work;
•sufficiently trained to use the machine and carry
out maintenance work on it;
•deemed suitable for carrying out the task entrust-
ed to them by their employer;
1. PREFACE
1.1. PURPOSE OF THE INSTRUCTION
MANUAL FOR USE AND MAINTENANCE
This manual has been designed to provide the user
with general knowledge of the machine and to allow
it to be used safely.
This instruction manual is an integral part of the ma-
chine and has the purpose of providing all the infor-
mation necessary to ensure:
1. safe handling of the machine, either packaged
and unpackaged;
2. correct machine installation;
3. knowledge of the technical specifications of the
machine;
4. thorough understanding of machine operations
and limitations;
5. indication of the qualifications and specific train-
ing required of those operating and carrying out
maintenance work on the machine
6. in-depth knowledge of its intended, unforeseen
and prohibited uses;
7. its proper and safe use;
8. how to carry out correct and safe maintenance
and repair operations;
9. technical assistance and management of spare
parts;
10. disposal of waste produced by the machine;
11. the safe dismantling of the machine in accord-
ance with applicable regulations to protect work-
ers’health and the environment.
This document assumes that the applicable occu-
pational health & safety and hygiene regulations
are complied with at the site where the machine
will be used.
IMPORTANT: Those in charge have the respon-
sibility, in accordance with current legislation,
to carefully read the contents of this Instruction
Manual and ensure that operators and mainte-
nance personnel read the parts relevant to them.
The customer has the responsibility to make sure
that, if this document is modified by the Manufactur-
er, only the updated versions of the manual are actu-
ally present at the workplace.
The instructions, documentation and drawings
found in this Manual are of a confidential technical
nature and strictly the property of the Manufactur-
er, therefore, aside from the purpose for which it was
produced, any reproduction in whole or in part of the
contents and/or format must have the prior consent
of the Manufacturer.
1.995.217 EN - Rev. 1.1
NOVATIG 503 AC/DC
G.R.3
4

1.5. HOW TO READ
THE INSTRUCTION MANUAL
The Manual is split into chapters, each one dedicated
to a specific category of information addressed to the
personnel for whom the relevant qualifications have
been defined.
To facilitate immediate comprehension of the text,
terms, abbreviations and pictograms are used, the
meanings of which can be found in Paragraph 1.6.
1.6. TERMS, SYMBOLS AND
PICTOGRAMS
To highlight parts of text of significant importance
the following symbols were adopted:
ATTENTION: Indicates the need to adopt appropri-
ate behaviours so as not to put people's health and
safety at risk and not to cause damage to the ma-
chine or the environment.
HAZARD: Indicates situations of serious danger that
can seriously endanger the health and safety of peo-
ple.
IMPORTANT: Indicates technical information of par-
ticular importance which should not be neglected.
The following pictogram stickers are affixed to the
machine, depending on the version:
The product complies with the safety
requirements provided by the applica-
ble EU directives or regulations.
Carefully read the instructions listed in
the manual.
Machine subjected to general danger
(see instruction manual).
Machine used in environments with a
high risk of electric shock.
WARNING!
Moving mechanical parts.
(For MIG generators only)
•capable of comprehending and interpreting the
operator manual and the safety instructions;
•familiar with the emergency procedures and how
to implement them;
•have understood the operational procedures es-
tablished by the machine's Manufacturer.
1.3. STORAGE
OF THE INSTRUCTION MANUAL
The Instruction Manual must be carefully stored and
must accompany the machine each time it changes
hands throughout its life cycle.
It should be kept in good condition by handling it
with care, with clean hands, and not placing it on
dirty surfaces.
Parts of the manual must not be removed, torn or
changed.
The Manual should be kept close to the machine to
which it refers in an environment free from humidity
and heat.
1.4. UPDATING
THE INSTRUCTION MANUAL
The Manufacturer is only liable for the Instructions
issued and validated by itself (Original Instructions);
any translations MUST always be accompanied by
the Original Instructions to verify the correctness of
the translation. In any case, the Manufacturer is not
liable for translations that have not been approved
by the Manufacturer himself, thus if an inconsisten-
cy is detected, attention must be paid to the origi-
nal language and, if necessary, the manufacturer's
sales office should be contacted, which will make the
changes deemed appropriate.
The Manufacturer reserves the right to make chang-
es to the project, changes/improvements to the ma-
chine and updates to the Instruction Manual without
previously informing Customers. However, should
changes be made to the machine installed at the
Customer's site, in agreement with the Manufacturer
and involving the adaptation of one or more chap-
ters of the Instruction Manual, the Manufacturer shall
provide the Customer with the parts of the Instruc-
tion Manual that concern the change, with the new
global revision model. The Customer shall be respon-
sible, following the instructions that accompany the
updated documentation, for replacing any parts that
are no longer valid with the new ones.
1.995.217 EN - Rev. 1.1
NOVATIG 503 AC/DC
G.R.3
5

NOVATIG 503 AC/DC plate explanation
Pos. 1 Name and address of the manufacturer
and trademark
Pos. 2 Identification of the welding machine
model
Pos. 3 Welding machine serial number
Pos. 4 Welding machine type symbol: Transform-
er - Rectifier for arch welding
Pos. 5 Reference to the legislation followed for
welding machine construction: EN 60974-1
Pos. 6a Welding with TIG procedure
Pos. 6b Welding with MMA procedure
Pos. 7 Symbol indicating that the welding ma-
chine can be used in environments with
an increased risk of electric shock
Pos. 8 Welding current symbol: Direct/Alternat-
ing Current
Pos. 9 Rated no-load voltage U0 in V
Pos. 10 Electric adjustment range of the welding
machine: minimum and maximum rated
welding current, with the relevant charged
voltages
Pos. 11 Welding machine service factor (X): this
figure indicates the welding machine ser-
vice factor as a percentage of a 10-minute
work cycle. Example X = 60% - I2 350 A,
these data indicate that the welding ma-
chine on a work cycle can weld with a cur-
rent I2 = 350 A for a time of 6 minutes out
of 10, that is 60%.
Pos. 11a Service factor: 60 %
2. GENERAL INFORMATION
2.1. MANUFACTURER
IDENTIFICATION DATA
MANUFACTURER: SINCOSALD S.r.l
HEADQUARTERS - OFFICES
via della Fisica, 26/28
20864 Agrate Brianza (MB) Italy
Tel: [phone]
Fax: [phone]
CONTACTS:
[email protected] www.sincosald.it
2.2. MACHINE IDENTIFICATION
DATA AND PLATES
Each machine is identified by a CE plate on which its
reference data is indelibly marked. For any commu-
nication with the manufacturer or service centre al-
ways quote these references.
IMPORTANT: The plate must not be removed for
any reason, under penalty of forfeiture of the
guarantee and the unavailability of spare parts
due to failure to be identified. The position of the
nameplate on the Machine can vary from machine
to machine.
NOVATIG 503 AC/DC Plate
U1 = 400V
IP 23 IP 23
U1 = 400V
EN 60974 - 1
Imax=37AIeff=29A Imax=41AIeff=32A
EN 60974 - 1
3 50/60 Hz. 3 50/60 Hz.
1
2 3
4 5
6a
7
7
6b
9
9
8
8
11
11
12
12
13
13
11a
11a
12a
12a
13a
13a
11b
11b
12b
12b
13b
13b
10
10
14
15 16 1920 20
17 18
2 3
4 5
6a
7
7
6b
9
9
8
8
11
11
12
12
13
13
11a
11a
12a
12a
13a
13a
11b
11b
12b
12b
13b
13b
10
10
14
15 16 19
17 18
1.995.217 EN - Rev. 1.1
NOVATIG 503 AC/DC
G.R.3
6

2.3. DECLARATIONS OF CONFORMITY
The machine is constructed in compliance with the
relevant EU Directives, applicable at the time of its
entering onto the market.
2.4. SAFETY STANDARDS
The machine was built in accordance with the follow-
ing standards and directives:
Harmonised standards
IEC 60974-1 - IEC 60974-5 - IEC 60974-10
Directives
EN 60204-1 - 2014-35-EV - 9231 EEC - 9368 EEC
Standards
EN/IEC 61000-3-12 - EN/IEC 61000-3-11 - EN/IEC
61000-3-3
2.5. INFORMATION
ON TECHNICAL ASSISTANCE
The machines are covered by a warranty, as provided
for in the general conditions of sale.
If during the warranty period you experience a mal-
function or failure of the machine parts, which fall un-
der the cases covered by the warranty, the manufac-
turer, after the necessary machine checks, will repair
or replace defective parts.
The goods travel at the customer's risk; product dam-
age caused by transportation or unloading is not
covered by the warranty. All equipment and consum-
ables supplied with the product are also excluded
from the warranty.
It is reminded that any modifications carried out by
the user, without the express written consent of the
manufacturer, will void the warranty and free the
manufacturer from any liability for damage caused
by a defective product.
This applies in particular to alterations made to safety
devices that reduce their effectiveness.
The same considerations apply when using non-orig-
inal spare parts or those different to the ones explicit-
ly specified by the manufacturer.
For these reasons, we recommend our customers to
always contact our Customer Service.
Pos. 11b Service factor: 100 %
Pos. 12 Rated welding current (I2)
Pos. 12a Value of the rated welding current at 60 %
Pos. 12b Value of rated welding current at 100 %
Pos. 13 Conventional load voltage (U2)
Pos. 13a Voltage at 60 % load
Pos. 13b Voltage at 100 % load
Pos. 14 Symbol for the welding machine power
supply and number of phases (3) followed
by the direct/alternating current symbol
Pos. 15 Rated power voltage
Pos. 16 Indicates the degree of welding machine
protection: IP 23
Pos. 17 Maximum current in TIG welding
Pos. 18 Actual current in TIG welding
Pos. 19 See chapter 9. ADDITIONAL INSTRUC
TIONS
Pos. 20 Product complies with the safety require-
ments established by the applicable EU
directives or regulations
G.R.3 plate
Explanation of the G.R.3 plate
Pos. 1 Name and address of the manufacturer
and trademark
Pos. 2 Cooling unit model identification
Pos. 3 Reference to the regulation followed for
cooling unit construction: IEC 60974-2
Pos. 4 Cooling unit power voltage
Pos. 5 Maximum current
Pos. 6 Cooling unit protection grade: IP 23
Pos. 7 See chapter 9.
ADDITIONAL INSTRUCTIONS
Pos. 8 Maximum flow (LT/min)
Pos. 9 Absorbed power
1.995.217 EN - Rev. 1.1
NOVATIG 503 AC/DC
G.R.3
7

3. SAFETY
3.1. GENERAL
SAFETY WARNINGS
WARNING: your safety depends on you!!!
- Follow all safety rules carefully.
- It is your duty to protect yourself and others from the
risks of welding operations.
- The operator is responsible for his own safety and
that of those in the work area. He must therefore
know all the safety rules and observe them.
Nothing can replace common sense!!!
IMPORTANT: Before operating the machine, care-
fully read the instructions contained in this man-
ual and follow them thoroughly.
The manufacturer has made every effort to design
this machine and to make it as INTRINSICALLY SAFE
as possible.
The manufacturer has also equipped the machine
with all the protective and safety devices considered
necessary. Finally, it has provided enough informa-
tion for it to be used safely and correctly.
IMPORTANT: This information must be scrupu-
lously followed..
The user may chose to appropriately add to the infor-
mation provided by the manufacturer with addition-
al processing instructions, which, obviously, do not
contradict that contained in this Instruction Manual,
in order contribute to safe machine use.
For example, you must pay close attention to the
clothing that anyone working on the machine is
wearing:
•Avoid using clothes with hooks that can remain
attached to parts of the machine;
•Avoid using ties or other fluttering clothing parts;
•Avoid wearing bulky rings or bracelets that may
get caught in parts of the machine.
Whenever necessary, further recommendations for
use will be provided in the Manual for the user re-
lated to preventive measures, personal protective
equipment, information to prevent human error and
any reasonably foreseeable prohibited behaviour.
2.6. PREPARATION BY THE CUSTOMER
Unless otherwise agreed in the contract, the follow-
ing are normally the Customer's responsibility:
•Room preparations, including any building work
and/or ducting systems required;
•Electrical supply of the equipment, in compli-
ance with the standards in force in the country
of use. Particular care must be given to the pro-
tective conductor commonly known as "earth-
ing" and to the efficiency of the circuit breaker
installed to protect the power outlet. It is the pur-
chaser's responsibility to keep the above system
adequately efficient, in compliance with current
accident prevention regulations.
•Consumables or material normally subject to
wear;
•Equipment unloading at delivery and the conse-
quent liabilities.
1.995.217 EN - Rev. 1.1
NOVATIG 503 AC/DC
G.R.3
8

All safety features placed on moving parts to prevent
accidents and safeguard safety can not be modified
or removed, but must be adequately safeguarded.
The user must promptly inform the employer or his
direct superior of any defects or anomalies presented
on the mobile parts.
A) Electric shock
ELECTRIC SHOCK CAN BE FATAL!!!
- All electric shocks are potentially fatal.
- Do not touch live parts.
- Insulate yourself from the piece to be welded and
from the earth, wearing insulating gloves and
clothes.
- Keep clothing (gloves, shoes, headgear, clothes)
and body dry.
- Do not work in damp or wet environments. Do not
lean on the piece to be welded.
- If you have to work near or in an area at risk, use all
possible precautions.
- If you also feel a little electric shock, stop welding
immediately; do not use the device until the prob-
lem is identified and resolved.
- Provide an automatic wall switch, of adequate ca-
pacity and possibly in the vicinity of the machine,
to immediately cut off the device in the event of
an emergency situation.
- Frequently inspect the power cord.
- Disconnect the power cord from the mains before
working on the cables or before opening the ma-
chine.
- Do not use the machine without the protective
bulkheads.
- Always replace any damaged parts of the machine
with original materials.
- Never bypass machine safety devices.
- Make sure that the power supply line is equipped
with an efficient earth socket.
- Make sure that the work bench and the work piece
are connected to an efficient earth socket.
- Never electrically and simultaneously touch "hot"
parts of pliers connected to two welders because
the voltage between the two can be the total of
the no-load voltage of both welding machines.
- Any maintenance must be performed only by
expert personnel, aware of the risks due to the
voltages necessary for the operation of the equip-
ment.
It is, however, essential to diligently follow the follow-
ing indications:
•It is absolutely forbidden to operate the machine
automatically with the fixed and/or mobile guards
removed;
•It is strictly prohibited to disable the safety mech-
anisms installed on the machine;
•Operations at reduced safety levels must be car-
ried out in strict accordance with the instructions
given in the relevant descriptions;
•After any operation with reduced safety levels,
guards/safety devices should be replaced on the
machine as soon as possible;
•Any cleaning must be carried out with the electri-
cal and pneumatic separation devices sectioned.
•Do not alter parts of the machine for any reason;
in the event of malfunction, due to non-compli-
ance with the above, the manufacturer cannot be
held liable for the consequences. We recommend
that you request any changes to be made directly
to the manufacturer;
•Clean the casing of the machines, the panels and
the controls with soft cloths that are dry or have
been lightly soaked in a mild detergent solution;
do not use any type of solvent, such as alcohol or
petrol, as the surfaces may be damaged;
•Position the machines as determined at the time
of order according to the diagrams provided by
the manufacturer, otherwise it cannot be held li-
able for any problems.
ATTENTION:
The Manufacturer cannot be held liable for dam-
age caused by the machine to persons, animals or
property in the event of:
•use of the machine by personnel who are not
adequately trained;
•improper use of the machine;
•electrical, hydraulic or pneumatic power supply
faults;
•incorrect installation;
•failure to perform scheduled maintenance;
•unauthorised modifications or operations;
•the use of spare parts that are not original or
not specific to the model;
•total or partial failure to follow the instructions;
•use contrary to the specific national regulations;
•calamities and exceptional events.
General requirements
The moving parts must always be used according to
the manufacturer's instructions, as indicated in this
manual, which must always be available at the work-
place.
1.995.217 EN - Rev. 1.1
NOVATIG 503 AC/DC
G.R.3
9

- Do not expose cylinders to excessive heat, sparks,
molten slag or flames.
- Do not tamper with the cylinder valves.
- Do not attempt to unlock blocked valves with
hammers, keys, tools or other systems.
- Never delete or alter the name, number or other
markings on the cylinders. It is illegal and dangerous.
- Do not lift the cylinders from the ground by hold-
ing them by the valve or by the cap, or by using
chains, slings or magnets.
- Do not attempt to mix any gas inside the cylinders.
- Never refill the cylinders, but have them refilled by
specialised companies.
- Do not modify or exchange the cylinder fittings.
2) Pressure regulators:
- Keep pressure regulators in good condition. Dam-
aged regulators can cause damage or serious ac-
cidents; they must be repaired only by qualified
personnel.
- Do not use regulators for gases other than those
for which they were manufactured.
- Never use a regulator that leaks or appears physi-
cally damaged.
- Never lubricate a regulator with oil or grease.
3) Hoses:
- Replace hoses that appear damaged.
- Keep hoses taut to avoid accidental creases.
- Keep the excess hose collected and keep it out of
the work area to prevent damage.
E) Fire
- Avoid igniting fire due to sparks and hot slag or
incandescent parts.
- Ensure that appropriate fire protection devices are
available near the welding area.
- Remove flammable and combustible materials
from the welding area and the surrounding area
(minimum 10 metres).
- Do not weld on fuel and lubricant containers, even
if empty; these must be carefully cleaned before
being welded.
- Allow the welded piece to cool before touching it
or putting it in contact with combustible or flam-
mable materials.
- Do not weld on parts with cavities containing
flammable materials.
- Do not operate in atmospheres with high concen-
trations of combustible vapours, flammable gases
or dust.
- Always check the work area thirty minutes af-
ter the end of welding operations to ensure that
there are no fires.
B) Radiation
Ultraviolet radiation, emitted from the electric arc,
can damage the eyes and burn the skin.
Follow the instructions below:
- Wear appropriate clothing and protective masks.
- DO NOT use CONTACT LENSES!!! The intense heat
emanating from the electric arc could stick them
to the cornea.
- Use masks with lenses, with a minimum DIN 10 or
DIN 11 protection grade.
- Protect people near the welding area.
- REMEMBER: The arc can blind or damage your
eyes. The arc is dangerous up to a distance of 15
metres. Never look at the arc with the naked eye!
- Prepare the welding area so as to reduce reflection
and transmission of ultraviolet radiation: paint
walls and exposed surfaces black to reduce reflec-
tion, installing protective screens or curtains, to
reduce ultraviolet transmissions.
- Replace the mask lenses when they are damaged
or broken.
C) Welding wire
Attention: the welding wire can cause perforated
wounds.
- Do not press the button on the welding torch be-
fore carefully reading the instructions for use.
- Do not point the torch towards parts of the body,
other people or metals, when mounting the weld-
ing wire on the welding machine.
D) Explosions
- Do not weld above or near pressurised containers.
- Do not weld in an atmosphere containing explo-
sive powders, gases or vapours.
This welder uses inert gases such as CO2, ARGON, or
ARGON + CO2 mixtures to protect the arc, therefore it
is necessary to pay the utmost attention to:
1) Cylinders:
- Handle or use pressurised cylinders in accordance
with the regulations in force.
- Do not connect the cylinder directly to the ma-
chine's gas pipe, without using a pressure regulator.
- Do not use cylinders that leak or are physically
damaged.
- Do not use cylinders that are not well secured to
the welding machine or to suitable supports.
- Do not transport cylinders without the valve pro-
tection fitted.
- Do not use cylinders whose contents have not
been clearly identified.
- Do not put the cylinder in electrical contact with
the arc.
1.995.217 EN - Rev. 1.1
NOVATIG 503 AC/DC
G.R.3
10

DO NOT WELD or cut where solvent vapours can
be drawn into the welding atmosphere or if radiant
energy can penetrate into atmospheres containing
even tiny amounts of trichloroethylene and perchlo-
rethylene.
H) Moving parts can cause damage
Moving parts, such as the fan, can cut fingers and
hands and catch clothes.
Keep all doors, covers and guards closed and securely
in place.
Protections and coverings can be removed, for pos-
sible maintenance and checks, only by qualified per-
sonnel.
Keep hands, hair, loose clothing and tools away from
moving parts.
Refit the covers and guards and close the doors when
the operation is completed and before restarting the
machine.
I) Noise
These welders do not in themselves produce any
noise exceeding 70 dB. Arc welding processes can
produce noise levels above this limit. Therefore, users
must implement the precautions required by law.
Ear plugs should be used when working overhead or
in a small space.
A rigid helmet should be used when others work in
the area above.
Welders should not use flammable hair products.
WARNINGS ABOUT ELECTROMAGNETIC COMPAT-
IBILITY
Although these welding machines have been built
according to the regulations, they can generate elec-
tromagnetic disturbances, that is disturbances to the
telecommunication systems (telephone, radio, televi-
sion) or to the control and safety systems. Read the
instructions carefully to eliminate or minimise inter-
ference.
ATTENTION: the welding machine has been de-
signed to work in an industrial environment, there-
fore, to operate in domestic environments it may be
necessary to observe special precautions in order to
avoid possible electromagnetic interference.
You must install and use the welding machine accord-
ing to the manufacturer's instructions. If electromag-
netic interference is detected, countermeasures must
be taken to eliminate the problem, possibly using the
manufacturer's technical assistance. In any case, do
not modify the welding machine without the manu-
facturer's approval.
- Do not keep combustible materials such as light-
ers or matches in your pocket.
F) Burns
Protect the skin against burns caused by ultraviolet
radiation emitted by the electric arc, by sparks and
slag from molten metal, using fireproof clothing,
which covers all exposed surfaces of the body.
Wear protective clothing and welder gloves, head-
gear and high shoes with safety tip. Button the shirt
collars and pocket flaps and wear trousers without
cuff to avoid the entry of sparks and slag.
Wear a mask with protective glass on the outside and
adiactinic glass filter inside. This is MANDATORY for
welding operations, in order to protect the eyes from
radiant energy and volatile metals. Replace the pro-
tective glass if it is broken, pitted or spotted. Avoid
oily or greasy clothes; a spark could ignite them. In-
candescent metal parts, such as work pieces, should
always be handled with gloves.
First aid equipment and a qualified person should be
available for each shift, unless there are health facili-
ties nearby for immediate treatment of eye and skin
burns.
G) Fumes
Welding operations produce harmful fumes and met-
al dust, which can damage health:
- Do not work in spaces without adequate ventila-
tion. Keep your head out of the fumes.
- In closed environments, use suitable exhaust fans.
If ventilation is not adequate, use suitable respi-
rators.
- Clean the material to be welded if there are sol-
vents or halogen degreasers, which give rise to
toxic gases. During welding, some chlorinated sol-
vents can decompose in the presence of radiation
emitted by the electric arc and produce phosgene
gas.
- Do not weld coated metals or those containing lead,
graphite, cadmium, zinc, chromium, mercury or be-
ryllium, unless a suitable respirator is available.
The electric arc generates ozone. Prolonged expo-
sure, in environments with high concentrations of
ozone, can cause headaches, irritation of the nose,
throat and eyes and severe congestion and chest
pain.
IMPORTANT: DO NOT USE OXYGEN FOR VENTILA-
TION!!!
Gas leaks must be avoided in small spaces. Large gas
leaks can dangerously change the oxygen concentration.
Do not place cylinders in small spaces.
1.995.217 EN - Rev. 1.1
NOVATIG 503 AC/DC
G.R.3
11

which may have been deposited on the transformer
or on the diodes of the rectifier unit; to do this use a
jet of dry, clean air.
The mantle and all the possible accesses inside the
welding machine must be correctly closed during
the welding and cutting operations. The welding ma-
chine must never be modified in any part except for
modifications planned and authorised by the manu-
facturer and carried out by persons authorised by the
manufacturer.
In particular, the distance of the arc from the work
piece and the stabilisation devices must be adjusted
and maintained according to the manufacturer's rec-
ommendations.
C) Welding cables
Welding cables must be kept as short as possible and
must be placed close to each other and passed on
the floor or as low as possible.
D) Work piece earthing
The earth connection of the work piece can reduce
electromagnetic emissions in some cases.
The operator must pay attention to avoid that the
earthing of the piece is not a source of danger for
people and damage to the equipment. Where nec-
essary, earthing must be carried out with a direct
connection between the work piece and the ground,
while in countries where this is not permitted, the
connection must be made using a capacitor in ac-
cordance with the regulations of the country.
E) Shielding
Cable and equipment shielding in the work area can
reduce interference. Shielding of the entire welding
or cutting installation can be considered for special
applications.
F) Equipotential connections
The equipotential connections of all metal compo-
nents in and near welding installations should be
considered.
In any case the metal components connected to the
piece to be welded will increase the risk for the op-
erator to receive an electric shock from the simulta-
neous contact with these metal components and the
electrode. The operator should be isolated from all
these metal components rendered equipotential.
Checks and inspections
Checks must be carried out by a qualified technician
or a qualified and authorised technician; they must
be visual and functional, with the aim of guarantee-
ing the safety of the machine.
Work area control to prevent E.M. interference
Before installing the welding machine it is necessary
to check the work area to detect the existence of ser-
vices that could malfunction in the event of electro-
magnetic disturbances.
Below is a list of services to consider:
a) Power cables, control cables, transmission system and
telephone cables that pass near the welding machine.
b) Radio or television transmitters and receivers.
c) Computer or control equipment.
d) Safety and industrial process control equipment.
e) Calibration and measurement instruments.
f) Check the level of electromagnetic immunity of
the equipment operating in the work area.
g) The health of people in the vicinity, for example
people who use pacemakers and earphones for
hearing.
h) The daily duration of welding operations or other
activities.
The other devices must be electromagnetically com-
patible. This operation may require additional protec-
tive measures.
The dimensions of the area to be considered depend
on the structure of the building and the type of activ-
ity in progress.
PACEMAKERS AND HEARING AIDS
Magnetic fields deriving from high currents can af-
fect the correct functioning of pacemakers and hear-
ing aids. Wearers of electronic equipment should
consult a physician before approaching arc welding
operations.
METHODS FOR REDUCING EMISSIONS
A) Power supply
The welding or cutting device must be connected to
the power supply following the manufacturer's rec-
ommendations.
When interference problems arise, it may be neces-
sary to take measures to solve the problem, such as
the addition of filters on the power supply.
In the case of permanent installation of the equip-
ment, the metal shielding of the power cables can be
taken into consideration. The shielding must be con-
nected to the welding machine so that there is good
electrical contact between it and the mantle of the
welding machine itself.
B) Welding machine maintenance
The welding machine must be periodically subjected
to maintenance, according to the manufacturer's in-
structions.
Remove dust or foreign materials every 6 months,
1.995.217 EN - Rev. 1.1
NOVATIG 503 AC/DC
G.R.3
12

ATTENTION: It cannot therefore be used as a de-
vice tor thaw pipes; any improper use automati-
cally voids the warranty and excludes the man-
ufacturer from any liability in case of damage to
persons and property.
3.3. CONTRAINDICATIONS FOR USE
The machine must not be used:
•For uses other than those specified by the man-
ufacturer, for different uses or not mentioned in
this manual;
•In explosive, corrosive atmospheres or with a high
concentration of dust or oily substances suspend-
ed in the air;
•In atmospheres with high fire risks;
•Exposed to adverse weather conditions;
•With safety devices bypassed or out of order;
•With electrical bridges and/or other means that
exclude power/parts of the machine.
3.4. HAZARDOUS AREAS
The work area pertaining to the operator which is
substantially the entire perimeter of the machine is
considered hazardous.
It is the responsibility of the operator to keep the
work area clear of persons or objects while using the
machine and to avoid damage to persons, things or
animals.
The use of the machine near other equipment or
machines introduces additional risks. The operator is
asked to evaluate these risks in order to prevent ac-
cidents.
3.5. SAFETY DEVICES
Welding machines are equipped with safety devices
designed to prevent damage to the operator or to the
welding machine itself. A safety device is any object
or system that can reduce the risk of such damage.
Do not tamper with active safety devices or their con-
nections.
Do not operate with the welding machine without
the metal covers or with non-insulated connections.
If necessary, during installation and connection, they
must be integrated with others in order to guarantee
compliance with the laws in force.
IMPORTANT: Daily check that the safety devices
are functioning properly and efficient.
They include:
•inspection of all supporting structures, which
must not show any signs of cracking, breakage,
damage, deformation, corrosion, wear or altera-
tion to the original characteristics;
•checking all mechanical parts;
•inspection of all the safety devices installed on the
machine;
•ll connections with pins and screws;
•inspection of the machine operations;
•inspection of the machine status;
•verification of the correct operation and efficiency
of the electrical system;
•checking the seal and efficiency of the pneumatic
and/or hydraulic system.
The results of these checks must be reported on a
specific sheet.
ATTENTION: If worn or faulty parts are not
promptly replaced, the manufacturer cannot be
held in any way liable for the damage caused by
accidents that may result.
If faults or anomalies are detected, they must be
eliminated before the machine is put into opera-
tion, and the expert carrying out the inspection
will have to certify that the repair has been made,
thus allowing the machine to be used.
If the person performing the inspection detects haz-
ardous faults, they must promptly inform the ma-
chine manufacturer.
Place the machine out of service if operating faults
are found while performing the appropriate checks/
inspections and/or repairs. Check that no objects are
left between the moving parts after any maintenance
work.
In order to guarantee maximum safety of the ma-
chine it is, nonetheless, PROHIBITED to:
•Tamper with any part of the machine;
•Leave moving parts unattended;
•Use the machine when not operating at full effi-
ciency;
•Modify the machine to change the originally es-
tablished use, without explicit authorisation from
the Manufacturer;
•Run moving parts with manual operations in case
of power failure.
3.2. INTENDED USE
The welding system should only be used for the pur-
pose for which it was manufactured meaning to gen-
erate an electrical arch for MIG/MAG, TIG, MMA weld-
ing accordingly.
1.995.217 EN - Rev. 1.1
NOVATIG 503 AC/DC
G.R.3
13

General warning:
This symbol indicates a hazard of any
nature that may cause personal and
property damages.
Explosion hazard:
This symbol indicates the presence of
explosive substances or explosion hazard.
Warning:
Contact injuries may occur
in this point (i.e. Electrical shock).
3.6. SIGNS
The safety signs must always be clearly visible and it
is absolutely forbidden to remove or hide them.
Generally there are signals or signs on the machine
or in the work environment that indicate dangerous
situations, prohibitions or instructions during use or
operations connected to it, as in the following exam-
ples:
Emission of optical radiation:
The risk of optical radiation exists
where the sign is affixed. Cat. 2 (EN 12198).
Fire hazard:
Fire hazards exist
where the sign is affixed.
1.995.217 EN - Rev. 1.1
NOVATIG 503 AC/DC
G.R.3
14

3.7. RESIDUAL RISKS
Careful use of the machine minimises the probability
of accidents; however, during the use of the machine
it is necessary to strictly observe the safety rules de-
scribed in this manual.
Blinding:
Protection goggles or mask
must be worn near this symbol.
Fatal hazard:
Pay the utmost attention near this
indication!!! Never touch the area indicated by this
symbol since it indicates
a fatal hazard.
Noise:
Protection goggles or mask
near this symbol.
1.995.217 EN - Rev. 1.1
NOVATIG 503 AC/DC
G.R.3
15

the packaging during the unloading phase and, in
suspicious cases, open the packaging and to ver-
ify the safety of the machine and any loose units.
4.4. HANDLING AND
LIFTING
ATTENTION: handling and lifting must be carried
out by trained and qualified operators, using
appropriate means and methods, to avoid risks
to personal health and damage to the machine.
Before carrying out handling and lifting, check
the position of the centre of gravity of the load;
always check the correct weight balance of the
machine when it is transported, so as to prevent
unexpected machine movements or falls. It is
recommended to always use vehicles capable of
supporting the weight and dimensions of the ma-
chine ("TECHNICAL SPECIFICATIONS" paragraph
of this manual), so as to avoid damage to the ma-
chine or to persons or things around it.
IMPORTANT: the customer is always exclusively
liable during the equipment loading and unload-
ing phases.
For transport to the final installation site, it is prefera-
ble to use a forklift or pallet truck, taking care that the
lifting forks support the entire crate.
For movements within the plant, the machine may
be transported with a crane by properly harnessing
it using cables with the appropriate resistance char-
acteristics, depending on the weight of the machine
itself.
If the supply includes only the welding machine,
4. INSTALLATION
4.1. SHIPPING
The shipment, also depending on the destination,
can be carried out by different means.
The packed machine must be properly anchored to
the means of transport in order to avoid uncontrolled
movements.
The shipment is always carried out under the respon-
sibility of the purchaser who assumes all charges
for accidents and thefts that could occur during the
transport itself.
4.2. PACKAGING
The machine is shipped packed in a special container
and, if necessary, it is suitably stabilised with shock-
proof material to ensure its integrity.
The packaging is made, with containment of the
overall dimensions, also depending on the type of
transport adopted.
To facilitate transport, the shipment can be per-
formed with some components disassembled and
properly protected and packaged.
THE PACKAGING CONTAINS:
No. 1 NOVATIG 503 AC/DC welding machine
No. 1 G.R.3. cooling unit
No. 1 Instruction manual
OPTIONAL ACCESSORIES:
No. 1 Earth cable
No. 1 Clamp cable
No. 1 Welding torch
4.3. MACHINE
RECEIPT
Upon receipt of the machine, check that the informa-
tion in the shipping document actually corresponds
to the material received and check that the packag-
ing is perfectly intact.
IMPORTANT: in case of damage or absence of
some parts, immediately report the anomaly to
the carrier, making any descriptive notes of the
damage on the transport document before sign-
ing.
Do not use the machine, but contact the seller to
agree on the procedure to be adopted.
To this end, it is advisable to carry out a check of
1.995.217 EN - Rev. 1.1
NOVATIG 503 AC/DC
G.R.3
16

If only the welding machine is present, this must
be handled using the convenient handle on the
upper part of the welding machine itself.
ATTENTION: risk of overturning when unloading
the machine from the pallet equipped with de-
scent ramps.
ATTENTION: when carrying out unpacking op-
erations, it may be necessary to have two per-
sons equipped with suitable personal protective
equipment.
IMPORTANT: in addition to handling the machine
using the special trolley, it can be lifted from the
ground after having wrapped it with lifting straps,
by slinging it from the bottom in a stable and safe
way.
Alternatively, if present, use the appropriate lift-
ing eye bolts.
The welder has a sturdy handle integrated in the
frame for handling.
N.B. These lifting and handling devices com-
ply with the provisions prescribed by European
standards. Do not use other devices such as lifting
and handling equipment.
generally weighing less than 25 kg, the packaging
consists of a cardboard box without lifting pallets. It
can be easily lifted by two operators and taken to the
place of use.
ATTENTION: The machine must remain packed
during unloading from the means of transport
and until it is transferred to its destination.
IMPORTANT: The Manufacturer cannot be held
liable for damage caused to persons or property
due to utilising lifting systems other than those
described above.
4.5. UNPACKING
IMPORTANT: Consult the "Handling and lifting"
paragraph to correctly handle the machine.
ATTENTION: To remove the machine from the
packaging, use appropriate means and methods
to avoid risks to human health.The packaging ma-
terial must be properly disposed of in compliance
with the laws in force.
•Remove the protective covers such as straps, box-
es, etc. using appropriate tools so as not to ruin
the content.
•Remove the protective covers such as straps, box-
es, etc. using appropriate tools so as not to ruin
the content.
•Position appropriate descent ramps from the pal-
let verifying that the slides are well hooked to the
pallet.
•Complete the unloading operations by carefully
lowering the machine from the pallet.
1.995.217 EN - Rev. 1.1
NOVATIG 503 AC/DC
G.R.3
17

To achieve an adequate level of safety, the electri-
cal system to which the machine is connected must
provide, at the user's full charge, an earthing system
according to the provisions of the user's country, a
circuit breaker to protect the power supply socket
with value I (current variation) not less than 30mA
and anything else for a correct execution in a work-
manlike manner, according to Laws and/or Technical
standards in matters of safety in the workplace and
electrical systems. Prepare connections for earthing
the machine casing.
ATTENTION: These preparations are always the
sole liability of the user and nothing can be attrib-
uted to the manufacturer for damage to proper-
ty, persons and/or animals due to poor electrical
connections.
4.8. ASSEMBLY/POSITIONING
WARNING: the assembly of any detached units
and the installation of the machine must be car-
ried out exclusively by technicians authorised by
the manufacturer.
To allow for correct operations, the machine must
always be positioned in places that comply with the
environmental conditions described in this manual.
The machine must always be positioned in a per-
fectly levelled area; levelling can also be carried
out using any adjustment systems present on the
machine.
ATTENTION: The machine must be positioned so
as not to obstruct the entry and exit of the air
from the cooling slots. REDUCED FLOW OF AIR
causes overheating and possible damage to in-
ternal parts. Keep at least 500 mm of free space
around the device.
IMPORTANT: Do not place any filtering device on
the air intake passages of this welding machine.
The warranty is void if any type of filtering device
is used.
4.9. CONNECTIONS
Electrical connections
The machine's internal connections are carried out
by qualified personnel sent by the manufacturer. The
electrical connection between the machine panel
and the customer's power distribution supply line
must be carried out by qualified personnel from the
Customer.
4.6. STORAGE
In the case of inactivity, the machine must be stored
in compliance with the following precautions:
•Store the machine in an enclosed area accessible
only to employees; the storage area must have a
stable support surface with an adequate load co-
efficient and must be free of fire and/or explosion
risk; it must have adequate humidity and temper-
ature and sufficient lighting.
•Protect the machine from any impact and stresses;
•Protect the machine from humidity and high tem-
peratures;
•Ensure the machine does not come into contact
with corrosive substances;
•In the event of prolonged storage, periodically
check that there are no variations in the condition
of the packages.
4.7. PREPARATIONS
Installation preparations
For the installation, it is necessary to prepare a ma-
noeuvring area suited to the machine dimensions
and selected lifting means. The machine must be
positioned so that it is ideally ergonomic and pro-
vides maximum safety in the work place: leave an
area around it large enough to allow easy operations
and handling of the material to be processed and for
maintenance and adjustment operations to be car-
ried out.
Before installing the machine, check that the selected
area is suitable and has the necessary authorisations
to carry out the activity, sufficiently ventilated and il-
luminated, with a stable and levelled support surface.
For installations on a raised floor, check that the slab
can withstand the load.
Electrical system preparation
Connection to the electrical system which powers
and combines the synchronisation with other ma-
chines should be done by specialised and qualified
staff following the wiring diagram and arrangements
set out in Laws and/or Technical Standards currently
in force for safety in workplaces and electrical instal-
lations.
Appropriate safety devices must be provided for its
operation in line with those required in the area of
safety in the workplace.
IMPORTANT: The manufacturer cannot held liable
for any damage to property, persons and/or ani-
mals caused by non-compliance with this provi-
sion.
1.995.217 EN - Rev. 1.1
NOVATIG 503 AC/DC
G.R.3
18

Gas hose connection
ATTENTION: Cylinders can explode if damaged!!!
- Keep the cylinders upright and chained to the ap-
propriate support.
- Keep the cylinders in a place where they cannot
be damaged accidentally.
- Do not lift the machine with the cylinder attached.
- Never touch the cylinder with the welding wire.
- Keep the cylinder away from the welding area or
from non-insulated electrical circuits.
The inert gas cylinder must be equipped with a pres-
sure reducer and possibly also a flow meter. Only af-
ter having correctly positioned the cylinder, connect
the gas hose, exiting from the rear of the machine, to
the pressure reducer. Next you can open the cylinder
and adjust the pressure reducer.
4.10. PRELIMINARY CHECKS
It is necessary to carry out the following operations
before each machine start-up:
•Check all the safety systems;
•Check protection and signs.
Before putting the machine into operation, a number
of checks and controls must be carried out in order to
prevent errors or accidents during the Start-up phase:
•Check that the machine has not been damaged
during assembly;
•Verify, with particular care, the integrity of the
electrical panels, control panels, electrical wiring
and tubing;
•Check the exact connection of all external power
sources;
•Check the free movement and free rotation of all
moving parts;
•Check that hydraulic and pneumatic connections
are tight so that they do not cause dangerous
leakage.
IMPORTANT: The personnel qualified to carry out
the electrical connection must make sure of the
perfect efficiency of the earthing of the electrical
system and must check that the line voltage and
the frequency correspond to the data shown on
the identification plate. Incorrect supply voltages
can cause serious damage to the system.
If the system is set to operate at single-phase 230 V at
50-60 Hz, wire the end of the power cable to an EEC
plug with the same capacity as the socket on the line
switch as per the following diagram:
SINGLE-PHASE connections
Wire colour Connection
Brown "S" phase
Blue "T" phase
Yellow/Green Earth
If the system is set to operate at three-phase 400 V at
50-60 Hz, wire the end of the power cable to an EEC
plug with the same capacity as the socket on the line
switch as per the following diagram:
THREE-PHASE connections
Wire colour Connection
Black "R" phase
Brown "S" phase
Blue "T" phase
Yellow/Green Earth
ATTENTION: Make sure the system line switch is
in the "0" position before connecting the power
cable.
ATTENTION: It is mandatory to install a circuit
breaker with interlocked CEE socket, of adequate
capacity and verifying that the earth socket is ef-
ficient and separate from the rest of the electrical
system of the working environment.
ATTENTION: the yellow-green wire of the welding
machine power cable must always be connected
to the protection conductor (system earth). The
yellow-green wire should NEVER be combined
with another phase wire for a voltage withdrawal.
Do not touch live parts.
1.995.217 EN - Rev. 1.1
NOVATIG 503 AC/DC
G.R.3
19

•2T/4T trigger control.
•AC waveforms include square wave, sine wave,
triangular wave.
•AC balance control monitors the oxide and helps
better cleaning during aluminum welding
•Dual digital display meters for accurate pre-setting
and feedback of welding parameters & output.
•Up/ Down Button Remote Control torch and
•Roller wheel amps control on torch. (optional)
•Wireless Remote Control and Wire / Wireless
•Foot Pedal. (optional)
5.3. ENVIRONMENTAL CONDITIONS
The machine does not require particular environ-
mental conditions. The machine must be installed in-
doors in a well-lit, ventilated industrial building with
solid and level flooring.
The machine is suitable for operating in environ-
ments that:
•have an altitude not exceeding 2000 m a.s.l.;
•temperature between + 5 ° and + 35 ° C;
•relative humidity not higher than 80%.
It is forbidden to use the machine in environments
that are:
•dusty;
•in corrosive atmosphere;
•at fire risk;
•in an explosive atmosphere.
ATTENTION: The welding machine has an IP 23
protection grade, therefore its use is precluded
in certain environmental situations, such as rain,
excessive presence of metallic dust, presence of
acids and corrosive atmospheres.
5.4. LIGHTING
The lighting of the area of installation must comply
with the laws in force in the country where the ma-
chine is installed and must, however, ensure good
visibility at all points, not create hazardous reflec-
tions and allow clear reading of the control panels as
well as identification of emergency buttons.
As the machine does not have its own light, it is nec-
essary for the working environment to be equipped
with general lighting to guarantee the machine has a
value of 200 and 300 lux at all points of the machine.
5. OVERVIEW
5.1. OPERATING PRINCIPLE
The NOVATIG series welding systems were designed
for TIG welding.
The NOVATIG.series welding system composition is
shown below.
5.2. FEATURES
•IGBT module inverter technology for smooth & stable
output, increased reliability and high duty cycle.
•Phase loss protection for automatic shut down
if power supply phase loss occurs, to prevent
damage.
•Integrated heavy duty industrial trolley and water
cooler (optional).
•Lift TIG and HF start modes for versatility when
welding around sensitive electronic equipment
•Adjustable arc force, hot start & anti stick control
for greater control and ease of use when MMA
welding.
•Electronic HF TIG arc ignition system for
contamination free and easy arc starting with low
EMF interference.
1.995.217 EN - Rev. 1.1
NOVATIG 503 AC/DC
G.R.3
20