Weco Micro Mag 302 MFK User manual

Cod.006.0001.1360
31/01/2018 v2.9
ENGLISH
Micro Mag 302 MFK
GB
Instruction manual
Antwerpsesteenweg 949 9041 Gent - Oostakker
[email protected]
www.welda.be
T+32 (0)9 355 74 26
F+32 (0)9 355 92 01

Cod.006.0001.1360
31/01/2018 v2.9
ENGLISH
Micro Mag 302 MFK
2/34
Antwerpsesteenweg 949 9041 Gent - Oostakker
[email protected]
www.welda.be
T+32 (0)9 355 74 26
F+32 (0)9 355 92 01

Micro Mag 302 MFK
Cod.006.0001.1360
31/01/2018 v2.9
ENGLISH
3/34
CONTENTS
1INTRODUCTION............................................................................................................................................................................4
2INSTALLATION .............................................................................................................................................................................5
2.1 CONNECTIONS TO THE ELECTRICAL MAINS NETWORK ...........................................................................................................5
2.2 FRONT PANEL ..............................................................................................................................................................................5
2.3 REAR PANEL.................................................................................................................................................................................5
2.4 PREPARING FOR MMA WELDING ................................................................................................................................................6
2.5 PREPARING FOR TIG WELDING ..................................................................................................................................................7
2.6 PREPARING FOR MIG/MAG WELDING........................................................................................................................................8
2.6.1 WIRE SPOOL POSITIONING............................................................................................................................................................................... 8
2.6.2 POSITIONING THE WIRE IN THE WIRE FEEDER ............................................................................................................................................... 8
2.6.3 CONNECTIONS TO SOCKETS............................................................................................................................................................................ 9
3COMMISSIONING........................................................................................................................................................................11
3.1 USER INTERFACE ......................................................................................................................................................................11
3.2 UNIT POWER-UP.........................................................................................................................................................................13
3.3 RESET (LOAD FACTORY SETTINGS).........................................................................................................................................13
3.4 SET-UP (INITIAL SET-UP OF THE WELDING POWER SOURCE)................................................................................................14
3.5 LOCKING PROCEDURE ..............................................................................................................................................................15
3.6 GAS FLOW ADJUSTMENT ..........................................................................................................................................................15
3.7 ALARMS MANAGEMENT.............................................................................................................................................................16
4WELDING SETTINGS..................................................................................................................................................................17
4.1 TORCH TRIGGER MODES ..........................................................................................................................................................17
4.2 SELECTION OF THE WELDING MODE AND TORCH TRIGGER PROCEDURE...........................................................................18
4.3 PARAMETERS ACTIVATION .......................................................................................................................................................18
4.4 WELDING PARAMETERS............................................................................................................................................................19
5WELDING SETTINGS..................................................................................................................................................................20
5.1 ELECTRODE WELDING (MMA) ...................................................................................................................................................20
5.1.1 PARAMETERS SETTING................................................................................................................................................................................... 20
5.1.2 PARAMETERS SETTING: (1ST LEVEL)............................................................................................................................................................. 20
5.2 DC TIG WELDING........................................................................................................................................................................20
5.2.1 PARAMETERS SETTING................................................................................................................................................................................... 20
5.2.2 PARAMETERS SETTING: (GAS MENU) ............................................................................................................................................................ 20
5.3 MIG/MAG WELDING ....................................................................................................................................................................21
5.3.1 PARAMETERS SETTING................................................................................................................................................................................... 21
5.3.2 PARAMETERS SETTING: (1ST LEVEL)............................................................................................................................................................. 21
5.3.3 PARAMETERS SETTING: (2ND LEVEL) ............................................................................................................................................................ 22
5.3.4 PARAMETERS SETTING: (GAS MENU) ............................................................................................................................................................ 22
5.4 JOBS MANAGEMENT..................................................................................................................................................................23
5.4.1 SAVING A JOB .................................................................................................................................................................................................. 23
5.4.2 LOADING A USER JOB ..................................................................................................................................................................................... 23
5.4.3 DELETING A JOB .............................................................................................................................................................................................. 23
6TECHNICAL DATA......................................................................................................................................................................24
7SPARE PARTS............................................................................................................................................................................26
7.1 WIRE FEED MOTOR....................................................................................................................................................................28
7.2 WIRE FEEDER ROLLS ................................................................................................................................................................29
8ELECTRICAL DIAGRAM .............................................................................................................................................................30
8.1 MICRO MAG 302 MFK .................................................................................................................................................................30
8.2 REMOTE CONTROLLER .............................................................................................................................................................32
8.2.1 RC03: ELECTRICAL DIAGRAM.......................................................................................................................................................................... 32
8.2.2 RC04: ELECTRICAL DIAGRAM.......................................................................................................................................................................... 32
8.2.3 RC05: ELECTRICAL DIAGRAM.......................................................................................................................................................................... 33
8.2.4 RC06: ELECTRICAL DIAGRAM.......................................................................................................................................................................... 33
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1INTRODUCTION
IMPORTANT!
This handbook must be consigned to the user prior to
installation and commissioning of the unit.
Read the "General prescriptions for use" handbook supplied
separately from this handbook before installing and
commissioning the unit.
The meaning of the symbols in this manual and the associated
precautionary information are given in the "General
prescriptions for use”.
If the "General prescriptions for use" are not present, it is
mandatory to request a replacement copy from the
manufacturer or from your dealer.
Retain these documents for future consultation.
KEY
DANGER!
This pictogram warns of danger of death or serious injury.
WARNING!
This pictogram warns of a risk of injury or damage to property.
CAUTION!
This pictogram warns of a potentially hazardous situation.
INFORMATION
This pictogram gives important information concerning the execution
of the relevant operations.
This symbol identifies an action that occurs automatically as a
result of a previous action.
This symbol identifies additional information or a reference to a
different section of the manual containing the associated
information.
§
This symbol identifies a reference to a chapter of the manual.
NOTES
The figures in this manual are purely guideline and the images may
contain differences with respect to the actual equipment to which they
refer.
INTRODUCTION
Micro Mag 302 MFK is a compact and rugged three-phase, synergic
inverter power source for MIG/MAG, MMA and TIG Lift welding.
Easy to transport, only 22 kg , it is the best option for maintenance
and repair on fi eld, shipyard and off -shore operations.
Polarity change allows welding with self shielded wires.
Innovative unique HAC (Hybrid Arc Control) supplies a soft and very
stable MIG/MAG arc with excellent weld bead quality and minimal
spattering in any working conditions.
3T Mode allows both Hot Start and Crater Filler current setting, for
optimal penetration at start and crater fi lling at bead’s end.
Additional parameters, Motor Slope, Soft Start, Burn Back and Post
Gas are included for perfect arc ignition and optimum wire cutting at
the end of welding.
Microprocessor, inverter technology, digital displays, synergic curves
and memory locations for customized welding parameters assure
complete welding process repeatability.
The inductance can be adjusted electronically by means of the user
interface in order to optimize the arc.
A perfect wire feeding is guaranteed thanks to a 4-rolls motor drive
included in Micro Mag 302 MFK.
Fan. The fan is turned on only during welding, at the end of the
welding process it remains on for a fixed period of time according to
welding conditions. The fan is nonetheless controlled by specific
thermal sensors that guarantee a correct cooling of the machine.
Accessories that can be connected to the unit:
-Manual remote controller for remote adjustment of the welding
current.
-Push-Pull torch(purchasing and installing the relative kit).
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2INSTALLATION
DANGER!
Lifting and positioning
Read the warnings highlighted by the following symbols in the
“General prescriptions for use”.
2.1 CONNECTIONS TO THE ELECTRICAL MAINS
NETWORK
The characteristics of the mains power supply to which the equipment
shall be connected are given in the section entitled “Technical data”
on page 24.
The machine can be connected to motorgenerators provided their
voltage is stabilised.
Connect/disconnect the various devices with the machine switched
off.
2.2 FRONT PANEL
1.
Remote controller connector.
2.
Negative pole welding socket.
3.
Positive pole welding socket.
4.
Polarity selector cable.
5.
EURO TORCH welding socket.
2.3 REAR PANEL
1.
Wire feed motor power transformer fuse.
Type: Delayed acting (T)
Amperage: 630 mA
Voltage: 500 V
2.
Welding power source ON/OFF switch.
3.
Mains protection ON LED.
4.
Connector for gas feed hose:
cylinder power source
5.
Power cable.
Total length (including internal part): 3,5 m
Number and cross section of wires: 4 x 2,5 mm2
Power plug type: not supplied
5
1
3
2
4
1
2
5
3
4
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2.4 PREPARING FOR MMA WELDING
1.
Set the welding power source ON/OFF switch to “O” (unit de-
energized).
2.
Plug the power cable plug into a mains socket outlet.
3.
Choose the electrode based on the type of material and thickness
of the workpiece to be welded.
4.
Insert the electrode in the electrode holder.
5.
Connect the electrode holder cable to the welding socket based on
the polarity requested by the type of electrode used.
6.
Connect the plug of the ground clamp to the welding socket on the
basis of the polarity required.
7.
Connect the earth clamp to the workpiece being processed.
DANGER!
Electric shock hazard!
Read the warnings highlighted by the following symbols in the
“General prescriptions for use”.
8.
Set the welding power source ON/OFF switch to “I” (unit
powered).
9.
Select the following welding mode on the selector located in the
spool compartment: MMA
10.
Set the required welding parameter values on the user interface.
When the remote controller [RC] is connected and the relative
locking screw is tightened, welding current can be adjusted using
the remote controller.
The system is ready to start welding.
Preparing for MMA (polarity to basic electrode)
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2.5 PREPARING FOR TIG WELDING
1.
Set the welding power source ON/OFF switch to “O” (unit de-
energized).
2.
Plug the power cable plug into a mains socket outlet.
3.
Connect the gas hose from the welding gas cylinder to the rear
gas socket.
4.
Open the cylinder gas valve.
5.
Connect the TIG torch plug to the EURO TORCH welding socket.
6.
Choose the electrode based on the type of material and
thickness of the workpiece to be welded.
7.
Insert the electrode in the TIG torch.
8.
Connect the plug of the polarity selector cable to the welding
socket on the basis of the polarity required.
9.
Connect the plug of the ground clamp to the welding socket on
the basis of the polarity required.
10.
Connect the earth clamp to the workpiece being processed.
11.
Set the welding power source ON/OFF switch to “I” (unit
powered).
12.
Select the following welding mode on the selector located in the
spool compartment: DC TIG
13.
Open the gas solenoid valve by pressing and releasing the button
.
14.
Use the flow control valve to adjust the flow of gas as required
while the gas is flowing out.
15.
Close the gas solenoid valve by pressing and releasing the
button .
16.
Set the required welding parameter values on the user interface.
When the remote control pedal is connected and the relative
locking screw is tightened the welding current will vary in relation
to the pressure exerted on the pedal.
The system is ready to start welding.
Preparing for TIG (polarity for tungsten electrode)
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2.6 PREPARING FOR MIG/MAG WELDING
2.6.1 WIRE SPOOL POSITIONING
1.
Open the unit side door to gain access to the spool compartment.
2.
Unscrew the cap of the spool holder.
3.
If necessary, fit an adapter for the wire spool.
4.
Choose the wire on the basis of the workpiece thickness and
material type.
5.
Fit the spool in the spool holder, ensuring it is located correctly.
6.
Adjust the spool holder braking system by tightening/loosening the
screw in such a way that the wire feed force is not excessive and
when the spool stops rotating no excess wire is released.
7.
Refit the plug.
2.6.2 POSITIONING THE WIRE IN THE WIRE FEEDER
1.
Lower the wire feeder pressure devices.
2.
Raise the wire feeder pressure arms.
3.
Remove the protective cover.
4.
Check that the feed rolls are suitable for the wire gauge.
(See § 7.2 page 29.)
The diameter of the roll groovemust be compatible with the
diameter of the welding wire.
The roll must be of suitable shape in relation to the composition of
the wire material.
The groove must feature a "U" profile for soft materials
(Aluminium and its alloys, CuSi3).
The groove must be "V" shaped for harder materials (SG2-SG3,
stainless steels).
Rolls with a knurled groove profile are available for flux-cored
wire.
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5.
Feed the wire between the wire feeder rolls and insert it into the
MIG/MAG TORCH connector plug.
6.
Make sure the wire is located correctly in the roll grooves.
7.
Close the wire feeder pressure arms.
8.
Adjust the pressure system so that the arms press the wire with a
force that does not deform it while also ensuring constant feed rate
without slipping.
9.
Refit the protective cover.
10.
Close the spool compartment door in the side of the unit.
2.6.3 CONNECTIONS TO SOCKETS
1.
Set the welding power source ON/OFF switch to “O” (unit de-
energized).
2.
Plug the power cable plug into a mains socket outlet.
3.
Connect the gas hose from the welding gas cylinder to the
relative socket.
4.
Open the cylinder gas valve.
5.
Connect the MIG/MAG torch plug to the EURO TORCH welding
socket.
6.
Connect the plug of the ground clamp to the welding socket on
the basis of the polarity required.
7.
Connect the plug of the polarity selector cable to the welding
socket on the basis of the polarity required.
8.
Connect the earth clamp to the workpiece being processed.
9.
Set the welding power source ON/OFF switch to “I” (unit
powered).
10.
Select the following welding mode on the selector located in the
spool compartment: MIG/MAG
11.
Feed the wire through the torch until it protrudes from the tip,
pressing button on the unit's user interface.
The insertion speed is 1.2 m/min for 3 seconds, subsequently
increasing to 10 m/min. When the button is released wire feed is
interrupted.
This function produces a slower feed rate and hence greater
precision when inserting the wire when it enters the torch nozzle.
12.
Select the torch trigger procedure on the user interface.
13.
Open the gas solenoid valve by pressing and releasing the button
.
14.
Use the flow control valve to adjust the flow of gas as required
while the gas is flowing out.
15.
Close the gas solenoid valve by pressing and releasing the
button .
16.
Set the required welding parameter values on the user interface.
On connecting and enabling a remote controller [RC] certain
settings can be modified from said controller without having to
take action on the user interface of the welding power source.
The system is ready to start welding.
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Preparing for MIG/MAG
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3COMMISSIONING
3.1 USER INTERFACE
CODE
SYMBOL
DESCRIPTION
L1
This LED illuminates to show an anomaly in the operating conditions.
See § 3.7 ALARMS MANAGEMENT page 16.
L2
Illumination of this LED indicates the display of the average voltage and current value measured during the final moments of
welding.
The value appears on the following displays: D1-D2
L3
This LED illuminates to confirm the presence of power on the output sockets.
L4
Illuminates to show a value in the following unit of measurement: METRES PER MINUTE
L5
Illuminates to show a value in the following unit of measurement: AMPERES
L6
Illuminates to show a value in the following unit of measurement: MILLIMETRES
L7
Illuminates to show a value in the following unit of measurement: SECONDS
L8
Illuminates to show a value in the following unit of measurement: VOLTS
L9
Illuminates to show a value in the following unit of measurement: PERCENTAGE
L10
When this LED illuminates the following parameter can be set: WIRE FEED RATE
L11
When this LED illuminates the following parameter can be set: WELDING CURRENT
L12
When this LED illuminates the following parameter can be set: THICKNESS
L13
Illuminates to show that the required Synergic welding program can be set.
L10
Illumination shows that the following function has been activated: 2 stroke procedure.
L11
Illumination shows that the following function has been activated: 4 stroke procedure.
L12
Illumination shows that the following function has been activated: 3 stroke Special procedure.
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CODE
SYMBOL
DESCRIPTION
D1
Parameters/functions setting
Manual MIG/MAG mode: the display shows the programmed wire feed rate.
Synergic MIG/MAG mode: the display shows the value of the selected main welding parameter.
Welding
MIG/MAG mode: The display shows the modification of the main welding parameter.
MMA mode: The display shows the effective amperes value during welding.
TIG Mode: The display shows the effective amperes value during welding.
Menu function
The display shows the acronym of the parameter or function to be adjusted.
Programs setting
The display shows the message P “program no.”.
D2
Parameters/functions setting
Manual MIG/MAG mode: the display shows the programmed voltage.
Synergic MIG/MAG mode: the display shows the arc correction value imposed by the operator with respect to the default
value of the synergic curve.
Welding
MIG/MAG mode: The display shows the effective voltage value during welding.
Menu function
The display shows the value of the parameter or function to be adjusted.
Programs setting
The display shows the acronym of the material to be welded on the basis of the selected synergic curve.
S1
MIG/MAG mode: this button activates wire feed to insert it through the MIG/MAG torch.
S2
Parameters/functions setting
Manual MIG/MAG mode:
the button selects one of the following settings: WIRE FEED RATE - SYNERGIC PROGRAM
Synergic MIG/MAG mode:
the button selects one of the following settings: WIRE FEED RATE - WELDING CURRENT - THICKNESS - SYNERGIC PROGRAM
In all welding modes
This button provides the facility to gain access to the secondary parameters adjustment menu.
Powering up the unit
This button opens the initial setup menu.
S3
This button opens the gas solenoid valve to fill the circuit and calibrate the pressure with the regulator on the gas cylinder.
Gas menu function
Hold down the button for 3 seconds to open the menu.
S4
Press and release: the button opens the JOBs upload menu.
Hold down for 3 seconds: the button opens the JOBs save and delete menu.
S5
MIG/MAG mode: this button selects the torch trigger procedure.
E1
Parameters/functions setting
Manual MIG/MAG mode: the encoder sets the wire feed rate.
Synergic MIG/MAG mode: the encoder sets the main adjustment value.
Welding
The encoder selects the main welding parameter to be set.
Menu function
The encoder selects the function or parameter to be adjusted.
Programs setting
The encoder selects the synergic program to be uploaded.
E2
Parameters/functions setting
Manual MIG/MAG mode: the encoder sets the welding voltage.
Synergic MIG/MAG mode: the encoder sets the arc correction.
Menu function
The encoder sets the value of the selected function or parameter.
Programs setting
The encoder selects the MIG/MAG welding program.
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CODE
SYMBOL
DESCRIPTION
POT1
Manual MIG/MAG mode: the potentiometer sets the inductance value.
Synergic MIG/MAG mode: the potentiometer sets the inductance value from the minimum to the maximum permissible value
in accordance with the selected synergic curve.
SEL1
The selector sets the welding mode.
3.2 UNIT POWER-UP
Set the welding power source ON/OFF switch to “I” to switch on the unit.
F x.x
The message appears for a few seconds on the following displays: D1-D2
x.x= software version.
First power-up or power-ups following a RESET procedure
The welding power source sets up for welding with the factory presets.
Subsequent power-ups
The welding power source sets up for welding in the latest stable welding configuration that was active at the time of power-off.
3.3 RESET (LOAD FACTORY SETTINGS)
The reset procedure involves complete restoration of the default values, parameters and memory settings set in the factory.
All memory locations will be reset and hence all your personal welding settings will be lost!
The reset procedure is useful in the following cases:
-Too many changes made to the welding parameters so user finds it difficult to restore defaults.
-Unidentified software problems that prevent the welding power source from functioning correctly.
Set the welding power source ON/OFF switch to “O” to switch the unit off.
S3
S5
Hold down both buttons simultaneously.
Set the welding power source ON/OFF switch to “I” to switch on the unit.
SIMULTANEOUS ACTIONS
rEC FAC
The message appears on the following displays: D1-D2
Wait for the memory clear procedure to terminate.
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3.4 SET-UP (INITIAL SET-UP OF THE WELDING POWER SOURCE)
Set the welding power source ON/OFF switch to “O” to switch the unit off.
SEL1
Use this selector to select one of the following welding modes:
MMA
MIG/MAG
TIG
S2
Hold down the button.
Set the welding power source ON/OFF switch to “I” to switch on the unit.
SIMULTANEOUS ACTIONS
Set UP
The message appears for a few seconds on the following displays: D1-D2
The acronym relative to the setting to be edited appears on the following displays: D1
The value relative to the selected setting appears on the following displays: D2
E1
Using the encoder, select the setting to be changed.
E2
Using the encoder, edit the value of the selected setting.
E1
Use the encoder to select the following setting: ESC
S2
Press any button to save the setting and quit the menu.
Tab. 1 - Setup settings MMA, TIG
ACRONYM
SETTING
MIN
DEFAULT
MAX
rC
REMOTE CONTROLLER SELECTION
oFF
oFF
3
OFF
3
Tab. 2 - Setup settings MIG/MAG
ACRONYM
SETTING
MIN
DEFAULT
MAX
rC
REMOTE CONTROLLER SELECTION
oFF
oFF
6
OFF
3
4
5
6
LoC
LOCK STATUS ACTIVATION
oFF
oFF
3
OFF
1
2
3
PP
PUSH PULL ACTIVATION
(purchasing and installing the relative kit)
oFF
oFF
oN
bb.
SELECTION OF BURN TYPE
SPc
Std
Std
ESC
QUITTING THE MENU
REMOTE CONTROLLER SELECTION
OFF=
No remote controller enabled.
3=
The unit is enabled to receive commands from a remote control equipped with 1 potentiometer.
4=
The unit is enabled to receive commands from a remote control equipped with 2 potentiometers.
5=
The unit is enabled to receive commands from a remote control equipped with 1 UP/DOWN lever.
6=
The unit is enabled to receive commands from a remote control equipped with 2 UP/DOWN levers.
LOCK STATUS ACTIVATION
OFF=
All adjustments enabled.
1 - 2 - 3=
All adjustments are disabled with the exceptions shown in Tab. 3 page 15.
SELECTION OF BURN TYPE
SPc=
The setting activates Special burning.
Std=
The setting activates Standard burning.
QUITTING THE MENU
To quit the menu select this setting and press button S2.
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3.5 LOCKING PROCEDURE
The locks are enabled only in MIG/MAG welding mode.
The procedure inhibits unit adjustments, allowing the user to modify only certain settings depending on the selected lock status.
The procedure is used to prevent accidental alteration of the unit settings and welding settings by the operator.
Enabling
If no locking status is selected (LOC = oFF) and if you wish to set up a limitation on use of the power source, display the LOC function in the
SETUP menu.
Open the Setup menu.
The acronym relative to the setting to be edited appears on the following displays: D1
The value relative to the selected setting appears on the following displays: D2
E1
Use the encoder to select the following setting: LoC
E2
Use the encoder to select the required lock status.
Depending on the selected Lock, certain functions will remain enabled.
E1
Use the encoder to select the following setting: ESC
S2
Press any button to save the setting and quit the menu.
Tab. 3 - Functions not disabled by Locks
LOCK
STATUS
USER INTERFACE
RC03
RC04
RC05
RC06
OFF
All adjustments enabled.
All adjustments enabled.
All adjustments enabled.
All adjustments enabled.
All adjustments enabled.
1
Selection of torch trigger procedure (button S5)
Display of main welding parameters (button S2)
Arc correction (encoder E2)
Wire insertion (button S1)
Gas test (button S3)
Arc correction
(Potentiometer Pot2)
Arc correction (UP/DOWN
lever 2)
2
Selection of torch trigger procedure (button S5)
Display of main welding parameters (button S2)
Arc correction (encoder E2)
Synergy (encoder E1)
Wire insertion (button S1)
Gas test (button S3)
All adjustments enabled.
All adjustments enabled.
All adjustments enabled.
All adjustments enabled.
3 (*1)
Selection of torch trigger procedure (button S5)
Display of main welding parameters (button S2)
JOB selection (encoder E2)
Wire insertion (button S1)
Gas test (button S3)
Scroll JOBS (UP/DOWN
lever 1)
Scroll JOBS (UP/DOWN
lever 1)
Disabling
If a lock status is selected, you can only edit parameters permitted by the currently active lock status.
Open the Setup menu.
The acronym relative to the setting to be edited appears on the following displays: D1
The value relative to the selected setting appears on the following displays: D2
E1
Use the encoder to select the following setting: LoC
E2
Use the encoder to select the following setting: oFF
E1
Use the encoder to select the following setting: ESC
S2
Press any button to save the setting and quit the menu.
3.6 GAS FLOW ADJUSTMENT
When the unit is powered on the solenoid valve opens for 1 second.
This serves to fill the gas circuit.
S3
Open the gas solenoid valve by pressing and releasing the button.
Adjust the pressure of gas flowing from the torch by means of the flow meter connected to the gas cylinder.
S3
Close the gas solenoid valve by pressing and releasing the button.
The solenoid valve closes automatically after 30 seconds.
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3.7 ALARMS MANAGEMENT
This LED illuminates if an incorrect operating condition occurs.
An alarm message appears on the following display: D3
Tab. 4 - Alarm messages
MESSAGE
MEANING
EVENT
CHECKS
AL. HEA.
Overheating alarm
Indicates tripping of the welding power
source thermal protection.
All functions disabled.
Exceptions:
-cooling fan.
Leave the unit running so that the
overheated components cool as rapidly
as possible.
When the unit has cooled, the welding
power source will reset automatically.
-Make sure that the power required by
the welding process is lower than the
maximum rated power output.
-Check that the operating conditions
are in compliance with the welding
power source data plate
specifications.
-Check for the presence of adequate
air circulation around the welding
power source.
AL. Cur.
Overcurrent alarm
Indicates tripping of the welding power
source current surge protection.
All functions disabled.
Exceptions:
-cooling fan.
An audible signal will sound (buzzer).
Muting the audible signal:
-in torch trigger procedure 2T, release
the torch trigger.
-In torch trigger procedure 4T or 3TS
the alarm mutes automatically after 5
seconds.
Exit the alarm state by performing one of
the following actions:
-press any button.
-switch the power source off.
-Check that the programmed arc
voltage value is not too high in relation
to the thickness of the work to be
welded.
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4WELDING SETTINGS
4.1 TORCH TRIGGER MODES
2 STROKE LIFT-ARC TIG WELDING (2T)
1.
Touch the workpiece with the torch electrode.
2.
Press (1T) and keep the torch trigger pressed.
3.
Slowly lift the torch to strike the arc.
The welding current reaches the preset value, by way of a up slope time, if programmed.
4.
Release (2T) the trigger to start the weld completion procedure.
The current reaches the end current value in the time set in the down slope time parameter.
The arc is extinguished.
Gas delivery continues for the time set in the post gas parameter.
4 STROKE LIFT-ARC TIG WELDING (4T)
1.
Touch the workpiece with the torch electrode.
2.
Press (1T) and release (2T) the torch trigger.
3.
Slowly lift the torch to strike the arc.
The welding current reaches the preset value, by way of a up slope time, if programmed.
4.
Press (3T) the trigger and keep it pressed to start the weld completion procedure.
The current reaches the end current value in the time set in the down slope time parameter.
The arc continues and the current output will be the value set in the end current parameter.
In these conditions the weld pool can be closed (crater filler current).
5.
Release (4T) the trigger to extinguish the arc.
Gas delivery continues for the time set in the post gas parameter.
2 STROKE MIG/MAG WELDING (2T)
1.
Bring the torch up to the workpiece.
2.
Press (1T) and keep the torch trigger pressed.
The wire advances at the approach speed until making contact with the work.
The arc strikes and the wire feeder accelerates to the set feed rate value.
3.
Release (2T) the trigger to start the weld completion procedure.
Gas flow continues for the time set in the post gas parameter (adjustable time).
4 STROKE MIG/MAG WELDING (4T)
1.
Bring the torch up to the workpiece.
2.
Press (1T) and release (2T) the torch trigger.
The wire advances at the approach speed until making contact with the work.
The arc strikes and the wire feeder accelerates to the set feed rate value.
3.
Press (3T) the trigger to start the weld completion procedure.
Gas flow continues until the torch trigger is released.
4.
Release (4T) the torch trigger to start the post gas procedure (adjustable time).
3 STROKE SPECIAL MIG/MAG WELDING (3TS)
1.
Bring the torch up to the workpiece.
2.
Press (1T) the torch trigger.
The wire advances at the approach speed until making contact with the work.
The welding arc strikes and the wire feed rate changes to the first welding level (hot start), which is set as a percentage of the normal
welding feed rate.
This first level is used to create the weld pool: for example, when welding aluminium a value of 130 % is recommended.
3.
Release (2T) the trigger to switch to normal welding speed; the switch to normal welding speed is performed in accordance with the start
ramp, which can be set in seconds.
4.
Press the torch trigger again (Level 3) to switch to the third welding level (crater filler), which is set as a percentage of the normal welding
feed rate.
The switch of welding current level in terms of crater filling is performed in accordance with the crater ramp, which can be set in seconds.
This third level is used to complete the weld and fill the final crater (crater filler) in the weld pool: for example, when welding aluminium a
value of 80 % is recommended.
5.
Release the torch trigger a second time (4T) to close the weld and run the post gas procedure.
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4.2 SELECTION OF THE WELDING MODE AND TORCH TRIGGER PROCEDURE
Specific torch trigger procedures are available in accordance with the selecting welding mode.
The availability of certain procedures depends on whether or not certain parameters or functions of the unit are enabled or set in the associated
menus.
The table shows the settings to be made to enable each procedure.
KEY
2T:
2 STROKE
4T:
4 STROKE
3TS:
3 STROKE SPECIAL
1:
Not enabled with manual program P0.
:
Always available.
SEL1
Use this selector to select one of the following welding modes.
S5
Use this button to select one of the following torch trigger procedures.
PROCEDURE
MODE
2T
4T
3TS
MMA


TIG DC CONTINUOUS


1
MIG/MAG
4.3 PARAMETERS ACTIVATION
The welding parameters are available in accordance with the selected welding mode and procedure.
The table shows the settings required to enable each parameter.
KEY
1:
Not enabled with manual program P0.
:
Always available.
MENU
MODE 

PROCEDURE 
PARAMETER 
1°
WELDING CURRENT



1
1
1
1°
ARC CORRECTION



1°
INDUCTANCE



1°
WIRE FEED RATE



1°
THICKNESS
1
1
1
1°
PROGRAMS



2°
HOT-START


2°
ARC FORCE

2°
CRATER FILLER

2°
3 LEVELS SLOPE

2°
SOFT START



2°
MOTOR SLOPE



2°
BURN BACK



GAS
POST GAS TIME





GAS
PRE-GAS TIME



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4.4 WELDING PARAMETERS
WELDING CURRENT
Output current value during welding.
HOT-START (MMA)
This parameter aids electrode melting at the time of arc striking.
Consequences of a higher value:
-Easier arc strike.
-Increased spatter at welding start.
-Increase of strike area.
Consequences of a lower value:
-More difficult arc strike.
-Less spatter at welding start.
-Smaller strike area.
HOT-START (MIG/MAG)
This function is useful when using aluminium alloy welding wire.
Consequences of a higher value:
-Greater heat output.
-Greater penetration.
Consequences of a lower value:
-"Cold" weld bead.
ARC FORCE
This parameter helps to avoid electrode sticking during welding.
During electrode fusion low conductivity parts of the coating become
detached and tend to become interposed between the electrode tip as
it is fusing and the workpiece. This condition results in an interruption
of the arc. In addition, it may occur that the electrode comes into
contact with the workpiece creating a short circuit and consequent
quenching of the arc. To avoid arc quenching the power source
therefore delivers instantaneous peak currents in correspondence
with preset arc voltage thresholds.
Consequences of a higher value:
-Fluidity during welding.
-Welding arc stability.
-Greater electrode fusion in workpiece.
-More welding spatter.
Consequences of a lower value:
-The arc is extinguished more easily.
-Less welding spatter.
MOTOR SLOPE
Time required to switch from SOFT START speed to welding speed.
ARC CORRECTION IN VOLTS
This parameter corrects the synergic voltage value relative to the
synergic point of the MIG/MAG processes.
The default value for horizontal and frontal welding is 0.0 V.
NOTE: A value >0 produces an increase in the length of the welding
arc, while a value <0 produces a shorter arc.
INDUCTANCE
Consequences of a higher value:
-"Softer welding".
-Less spatter.
-Less positive starting.
Consequences of a lower value:
-"Harder welding".
-More spatter.
-More reliable starting.
PRE GAS
Time of gas delivery before the arc strike.
CAUTION: an excessively long value will slow the welding procedure.
Other than in the presence of special requirements the value should
generally be kept at 0.0 s or anyway very low.
Consequences of a higher value:
-This parameter allows a shielded environment to be created,
thereby eliminating contaminants at the start of the welding pass.
SOFT START
The soft start is the wire approach speed to the workpiece.
The value is expressed as a percentage of the set feed rate.
Consequences of a lower value:
-The start of welding is "softer".
Consequences of a higher value:
-The welding start may prove difficult.
BURN BACK
The burn back value is associated with the quantity of wire that is
burnt at the end of the welding procedure.
Consequences of a higher value:
-Wire significantly retracted into the torch nozzle.
Consequences of a lower value:
-Stick-out at welding start is longer.
POST GAS
Time of post gas delivery when the welding arc is extinguished.
This is useful when welding at high current values or with materials
that oxidise readily to cool the weld pool in an uncontaminated
atmosphere.
In the absence of specific requirements the value should generally be
kept low.
Consequences of a higher value:
-More effective pickling (improved appearance of workpiece at the
end of the welding pass).
-Higher gas consumption.
Consequences of a lower value:
-Lower gas consumption.
-Oxidation of electrode tip (more difficult arc strike).
CRATER FILLER
This parameter serves to obtain a uniform deposit at the end of the
welding process to fill the crater with a reduced wire feed rate to
facilitate the deposition of filler material.
By keeping the torch trigger pressed during the 3rd time, the wire feed
rate is reduced (crater filler speed) thereby ensuring optimal crater
filling, until the POST GAS time is started by releasing the torch
trigger (4Th time).
Consequences of a higher value:
-Difficult crater filling (values greater than 100%).
Consequences of a lower value:
-Cold welding (values close to 1%).
3 LEVELS SLOPE
Establishes the duration of the slope between the 1st and 2nd time
and between the 3rd and 4th time.
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5WELDING SETTINGS
5.1 ELECTRODE WELDING (MMA)
SEL1
Select the following welding mode on the selector located in the spool compartment: MMA
MMA
The message appears on the following displays: D2
5.1.1 PARAMETERS SETTING
E1
Using the encoder, edit the value of the parameter.
The value appears on the following display: D1
The value is saved automatically.
Tab. 5 - Main welding parameters: MMA mode
PARAMETER
MIN
DEFAULT
MAX
WELDING CURRENT
10 A
80 A
250 A
5.1.2 PARAMETERS SETTING: (1ST LEVEL)
S2
Hold down the button for 3 seconds to gain access to the 1st level menu.
The acronym relative to the setting to be edited appears on the following displays: D1
The value relative to the selected setting appears on the following displays: D2
E1
Use the encoder to scroll the list of settings to edit.
E2
Using the encoder, edit the value of the selected setting.
Press any button to save the setting and quit the menu.
Tab. 6 - Parameters of the 1st level menu: MMA mode
ACRONYM
PARAMETER
MIN
DEFAULT
MAX
H.S.
HOT-START
0 %
50 %
100 %
A.F.
ARC FORCE
0 %
30 %
100 %
5.2 DC TIG WELDING
SEL1
Select the following welding mode on the selector located in the spool compartment: DC TIG
tIG
The message appears on the following displays: D2
5.2.1 PARAMETERS SETTING
E1
Using the encoder, edit the value of the parameter.
The value appears on the following display: D1
The value is saved automatically.
Tab. 7 - Main welding parameters: DC TIG mode
PARAMETER
MIN
DEFAULT
MAX
WELDING CURRENT
10 A
80 A
250 A
5.2.2 PARAMETERS SETTING: (GAS MENU)
S3
Hold down the button for 3 seconds to open the menu.
The acronym relative to the setting to be edited appears on the following displays: D1
The value relative to the selected setting appears on the following displays: D2
E2
Using the encoder, edit the value of the selected setting.
Press any button to save the setting and quit the menu.
Tab. 8 - GAS menu parameters: DC TIG mode
ACRONYM
PARAMETER
MIN
DEFAULT
MAX
Po.G.
POST GAS TIME
0.0 s
3.0 s
10.0 s
*1
*1:
When a synergic program is loaded the default value of the parameter is defined automatically by the software and the message "SYN" will
be shown on the display.
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