widmer Easymig 188 User manual

THREE-PHASE MIG WELDER
DREIPHASIGE SCHWEISSGERAETE
POSTE A SOUDER TRIFASÉ
BEDIENUNGSANLEITUNG
MANUEL D’INSTRUCTIONS
FRD
GB
OPERATING MANUAL

SMALTIMENTO DI APPARECCHI DA ROTTAMARE DA PARTE DI PRIVATI NELL’UNIONE EUROPEA
Questo simbolo che appare sul prodotto o sulla confezione indica che il prodotto non deve essere smaltito assieme agli altri rifiuti domesti-
ci. Gli utenti devono provvedere allo smaltimento delle apparecchiature da rottamare portandole al luogo di raccolta indicato per il riciclag-
gio delle apparecchiature elettriche ed elettroniche. La raccolta ed il riciclaggio separati delle apparecchiature da rottamare in fase di smal-
timento favoriscono la conservazione delle risorse naturali e garantiscono che tali apparecchiature vengano rottamate nel rispetto dell’am-
biente e della tutela della salute. Per ulteriori informazioni sui punti di raccolta delle apparecchiature da rottamare, contattare il proprio comu-
ne di residenza, il servizio di smaltimento dei rifiuti locale o il negozio presso il quale è stato acquistato il prodotto.
DISPOSAL OF WASTE EQUIPMENT BY USERS IN PRIVATE HOUSEHOLDS IN THE EUROPEAN UNION
This symbol on the product or on its packaging indicates that this product must not be disposed of with your other household waste. Instead,
it is yr responsibility to dispose of yr waste equipment by handing it over to a designated collection point for the recycling of waste electri-
cal and electronic equipment. The separate collection and recycling of yr waste equipment at the time of disposal will help to conserve natu-
ral resources and ensure that it is recycled in a manner that protects human health and the environment. For more information about where
you can drop off yr waste equipment for recycling, please contact yr local city office, yr household waste disposal service or the shop where
you purchased the product.
EVACUATION DES ÉQUIPEMENTS USAGÉS PAR LES UTILISATEURS DANS LES FOYERS PRIVÉS AU
SEIN DE L’UNION EUROPÉENNE
La présence de ce symbole sur le produit ou sur son emballage indique que vous ne pouvez pas vous débarrasser de ce produit de la même
façon que vos déchets courants. Au contraire, vous êtes responsable de l’évacuation de vos équipements usagés et à cet effet, vous êtes tenu
de les remettre à un point de collecte agréé pour le recyclage des équipements électriques et électroniques usagés. Le tri, l’évacuation et le
recyclage séparés de vos équipements usagés permettent de préserver les ressources naturelles et de s’assurer que ces équipements sont recy-
clés dans le respect de la santé humaine et de l’environnement. Pour plus d’informations sur les lieux de collecte des équipements usagés,
veuillez contacter votre mairie, votre service de traitement des déchets ménagers ou le magasin où vous avez acheté le produit.
ENTSORGUNG VON ELEKTROGERÄTEN DURCH BENUTZER IN PRIVATEN HAUSHALTEN IN DER EU
Dieses Symbol auf dem Produkt oder dessen Verpackung gibt an, dass das Produkt nicht zusammen mit dem Restmüll entsorgt werden darf.
Es obliegt daher Ihrer Verantwortung, das Gerät an einer entsprechenden Stelle für die Entsorgung oder Wiederverwertung von
Elektrogeräten aller Art abzugeben (z.B. ein Wertstoffhof). Die separate Sammlung und das Recyceln Ihrer alten Elektrogeräte zum
Zeitpunkt ihrer Entsorgung trägt zum Schutz der Umwelt bei und gewährleistet, dass sie auf eine Art und Weise recycelt werden, die keine
Gefährdung für die Gesundheit des Menschen und der Umwelt darstellt. Weitere Informationen darüber, wo Sie alte Elektrogeräte zum
Recyceln abgeben können, erhalten Sie bei den örtlichen Behörden, Wertstoffhöfen oder dort, wo Sie das Gerät erworben haben.
ELIMINACIÓN DE RESIDUOS DE APARATOS ELÉCTRICOS Y ELECTRÓNICOS POR PARTE DE
USUARIOS DOMÉSTICOS EN LA UNIÓN EUROPEA
Este símbolo en el producto o en el embalaje indica que no se puede desechar el producto junto con los residuos domésticos. Por el contra-
rio, si debe eliminar este tipo de residuo, es responsabilidad de usuario entregarlo en un punto de recolección designado de reciclado de apa-
ratos electrónicos y eléctricos. El reciclaje y la recolección por separado de estos residuos en el momento de la eliminación ayudarán a pre-
servar recursos naturales y a garantizar que el reciclaje proteja la salud y el medio ambiente. Si desea información adicional sobre los luga-
res donde puede dejar estos residuos para su reciclado, póngase en contacto con las autoridades locales de su ciudad, con el servicio de
gestión de residuos domésticos o con la tienda donde adquirió el producto.
DESCARTE DE EQUIPAMENTOS POR USUÁRIOS EM RESIDÊNCIAS DA UNIÃO EUROPEIA
Este símbolo no produto ou na embalagem indica que o produto não pode ser descartado junto com o lixo doméstico. No entanto, é sua respon-
sabilidade levar os equipamentos a serem descartados a um ponto de colecta designado para a reciclagem de equipamentos eletro-eletrônicos.
A colecta separada e a reciclagem dos equipamentos no momento do descarte ajudam na conservação dos recursos naturais e garantem que os
equipamentos serão reciclados de forma a proteger a saúde das pessoas e o meio ambiente. Para obter mais informações sobre onde descartar
equipamentos para reciclagem, entre em contacto com o escritório local de sua cidade, o serviço de limpeza pública de seu bairro ou a loja em
que adquiriu o produto.

3

1.0 SAFETY INFORMATION
1.1 INTRODUCTION
Make sure this manual is carefully read and understood by the welder, and by the maintenance and
technical workers.
1.2 PERSONAL PROTECTION
Welding processes of any kind can be dangerous not only to the operator but to any person situated
near the equipment, if safety and operating rules are not strictly observed.
Arc rays can injure your eyes and burn your skin. The welding arc produces very
bright ultra violet and infra red light. These arc rays will damage your eyes and
burn your skin if you are not properly protected.
• Wear closed, non-flammable protective clothing, without pockets or turned up trousers, gloves
and shoes with insulating sole and steel toe. Avoid oily greasy clothing.
• Wear a non-flammable welding helmet with appropriate filter lenses designed so as to shield the
neck and the face, also on the sides. Keep protective lens clean and replace them when broken,
cracked or spattered. Position a transparent glass between lens and welding area.
• Weld in a closed area that does not open into other working areas.
• Never look at the arc without correct protection to the eyes. Wear safety glasses with the side shiel-
ds to protect from flying particles.
Gases and fumes produced during the welding process can be dangerous and ha-
zardous to your health.
• Adequate local exhaust ventilation must be used in the area. It should be provided through a mo-
bile hood or through a built-in system on the workbench that provides exhaust ventilation from the
sides, the front and below, but not from above the bench so as to avoid raising dust and fumes.
Local exhaust ventilation must be provided together with adequate general ventilation and air
circulation, particularly when work is done in a confined space.
• Welding process must be performed on metal surfaces thoroughly cleaned from rust or paint,
to avoid production of harmful fumes. The parts degreased with a solvent must be dried before
welding.
• Be very carefull when welding any metals which may contain one or more of the follwing:
Antimony Beryllium Cobalt Manganese Selenium Arsenic Cadmium
Copper Mercury Silver Barium Chromium Lead Nickel
Vanadium
• Remove all chlorinated solvents from the welding area before welding. Certain chlorinated sol-
vents decompose when exposed to ultraviolet radiation to form phosgene gas (nerve gas).
1.3 FIRE PREVENTION
Fire and explosion can be caused by hot slag, sparks or the welding arc.
• Keep an approved fire extinguisher of the proper size and type in the working area. Inspect it re-
gularly to ensure that it is in proper working order;
• Remove all combustible materials from the working area. If you can not remove them, protect
them with fire-proof covers;
• Ventilate welding work areas adequately. Maintain sufficient air flow to prevent accumulation of
explosive or toxic concentrations of gases;
• Do not weld on containers that may have held combustibles;
• Always check welding area to make sure it is free of sparks, slag or glowing metal and flames;
• The work area must have a fireproof floor;
1.4 ELECTRIC SHOCK
WARNING: ELECTRIC SHOCK CAN KILL!
• A person qualified in First Aid techniques should always be present in the working area; If a per-
son is found unconscious and electric shock is suspected, do not touch the person if she or he is
in contact with cable or electric wires. Disconnect power from the machine, then use First Aid. Use
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4

dry wood or other insulating materials to move cables, if necessary away from the person.
• Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit.
• Make sure the main line is properly grounded.
• Do not coil the torch or the ground cables around your body.
• Never touch or come in physical contact with any part of the input current circuit and welding
current circuit.
Electric warning:
• Repair or replace all worn or damaged parts.
• Extra care must be taken when working in moist or damp areas.
• Install and maintain equipment according to local regulations.
• Disconnect power supply before performing any service or repair.
• Should you feel the slightest electrical shock, stop any welding immediately and do not use the
welder until the fault has been found and corrected.
1.5 NOISE
Noise can cause permanent hearing loss. Welding processes can cause noise levels that exceed safe
limits. You must protect your ears from loud moise to prevent permanent loss of hearing.
• To protect your hearing from loud noise, wear protective ear plugs and/or ear muffs.
• Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.
1.6 ELECTROMAGNETIC COMPATIBILITY
Before installing your welder, carry out an inspection of the surrounding area, observing the following
guidelines:
• Make sure that there are no other power supply cables, control lines, telephone leads or other
equipment near the unit.
• Make sure that there are no radio receivers, television appliances, computers or other control
systems near the unit.
• People with pace-maker or hearing-prosthesis should keep far from the power source.
! In particular cases special protection measures may be required.
Interference can be reduced by following these suggestions:
• If there is interference in the power source line, an E.M.T. filter can be mounted between the power
supply and the power source;
• The output cables of the power source should be not too uch long, kept together and connected
to ground;
• After the maintenance all the panels of the power source must be securely fastened in place.
1.7 PROTECTIVE WELDING GASES
Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can
explode. Treat them carefully.
• These welders use only inert or non-flammable gases for welding arc protection. It is important to
choose the appropriate gas for the type of welding being performed;
• Do not use gas from unidentified cylinders or damaged cylinders;
• Do not connnect the cylinder directly to the welder, use a pressure regulator;
• Make sure the pressure regulator and the gauges function properly;
• Do not lubrificate the regulator with oil or grease;
• Each regulator is designed for use with a specific gas. Make sure the regulator is designed for the
protective gas being used;
• Make sure that the cylinder is safely secured tightly to the welder with the chain provided.
• Never expose cylinders to excessive heat, sparks, slag or flame;
• Make sure that the gas hose is in good condition;
• Keep the gas hose away from the working area.
5
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2.0 INSTALLATION RECOMMENDATIONS
2.1 LOCATION
Be sure to locate the welder according to the following guidelines:
• In areas, free from moisture and dust;
• Ambient temperature between 0° to 40°C;
• In areas, free from oil, steam and corrosive gases;
• In areas, not subjected to abnormal vibration or shock;
• In areas, not exposed to direct sunlight or rain;
• Place at a distance of 300mm or more from walls or similar that could restrict natural air flow for
cooling.
2.2 VENTILATION
Since the inhalation of welding fumes can be harmful, ensure that the welding area is effectively ventilated.
2.3 MAIN SUPPLY VOLTAGE REQUIREMENTS
Before you make any electrical connection, check that supply voltage and frequency available at site are
those stated in the ratings label of your generator.
The main supply voltage should be within ±10% of the rated main supply voltage. Too low a voltage
may cause poor welding performance. Too high a supply voltage will cause components to overheat and
possibly fail. The welder Power Source must be:
• Correctly installed, if necessary, by a qualified electrician;
• Correctly grounded (electrically) in accordance with local regulations;
• Connected to the correct size electric circuit.
In case the supply cable is not fitted with a plug, connect a standardized plug (3P+T) to the supply cable
(in some models the supply cable is supplied with plug).
To connect the plug to the supply cable, follow these instructions:
• the brown (phase) wire must be connected to the terminal identified by the letter L1
• the blue or grey wire must be connected to the terminal identified by the letter L2
• the black or grey wire must be connected to the terminal identified by the letter L3
• the yellow/green (ground) wire must be connected to the terminal identified by the letter PE or by
the symbol .
In any case, the connection of the yellow/green wire to the PE terminal must be done in order that
in the event of tearing of the power supply cable from the plug, the yellow/green wire should be the last
one to be disconnected.
The outlet should be protected by the proper protection fuses or automatic switches.
Notes:
• Periodically inspect supply cable for any cracks or exposed wires. If it is not in good conditions,
have it repaired by a Service Centre.
• Do not pull violently the input power cable to disconnect it from supply.
• Do not squash the supply cable with other machines, it could be damaged and cause electric shock.
• Keep the supply cable away from heat sorces, oils, solvents or sharp edges.
• In case you are using an extension cord, try to keep it well straight and avoid its heating up.
2.4 SAFETY INSTRUCTIONS
For your safety, before connecting the power source to the line, closely follow these instructions:
• An adequate two-pole switch must be inserted before the main outlet; this switch must be equip-
ped with time-delay fuses;
• The connection with ground must be made with a two-pole plug compatible with the above men-
tioned socket;
• When working in a confined space, the power source must be kept outside the welding area and
the ground cable should be fixed to the workpiece. Never work in a damp or wet area, in these
conditions.
• Do not use damaged input or welding cables
• The welding torch should never be pointed at the operator’s or at other persons’ body;
• The power source must never be operated without its panels; this could cause serious injury to the
operator and could damage the equipment.
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6

3.0 VOLTAGE CHANGE
Your generator can be connected at 230/400V three-phase.
The generator is set at the factory for a 400V three-phase voltage.
For safety double check the sticker placed at the end of the input
cable.
Should it became necessary to use an input current at 230V simply
follow these instructions (only on models with this option):
• Put the main switch in the “OFF” position, disconnect the sup-
ply cable from the mains.
• Remove the right side panel
• Change the connections on the voltage change board, fol-
lowing the instructions on the label (see Fig. 1)
• Make sure that the nuts holding the bridges are securely ti-
ghtened.
• Re-assemble the right side panel.
For safety reasons and to avoid affecting the cooling conditions, do not
work with the side panels partially opened or completely removed. FIG. 1
4.0 ASSEMBLY
4.1 HANDLE AND WHEELS ASSEMBLY (FIG. 2-3)
FIG. 2
A
B
C
D
E
F
G
HF
I
L
M
N
O
P
Q
FIG. 3
FIG. 2
• Unpack the welder;
• Screw the two casters (D) to the machine;
• nsert the axle (A) through the holes at the rear of the welder and slide a wheel (B) on to each end
followed by the retaining washers (C);
• Assemble the plastic handle (E) using the screws provided (F);
FIG. 3GENERATOR
• Insert the axle (B) through the holes at the rear of the welder, slide the washers (D) and the wheels
(A) as shown in picture 3 and fix the wheels (A) using the supplied rings;
• Mount the handle (E) on the supports (F) e fix the together with the spacers (H) to the front panel
using the provided screws (G);
SEPARATE WIRE FEEDER
• Mount the handle (L) on the supports (M) and fix them using the provided screws (N);
• Screw the four casters (I) to the wire feeder bottom;
• Assemble the rotating support (O) on the top of the generator using the provided washers (Q) and
screws (P) and place the wire feeder on it.
• Place the gas cylinder on the cylinder support and fix it with the chain provided: the cylinder must
be equipped with pressure regulator. For the connection between the generator and the separate
7
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5.0 COOLING UNIT AND INTERCONNECTION CABLE
Water cooling unit is a device used to cool the welding torch, if required by the welding you are perfor-
ming. Using a pump, a water recirculation system between the torch and the cooling unit is created.
5.1 ASSEMBLY
Fix the cooling unit support to the generator upper panel, place the cooling unit on the support and fix
it. Then, fasten the wire feeder rotating support to the cooling unit cover. (see Fig. 6)
These connections must be done by qualified workers, making sure that the generator is
not connected to the mains.
5.2 CONNECTIONS
• Remove the right top panel of generator: next to the generator rear there is a terminal board to
which the cooling unit must be connected.
•
4.3 TORCH LEAD ASSEMBLY – DIRECT CONNECTION (FIG. 5)
• Before fitting the torch hose assembly (7) on the machine remove the nut (1) and the washer (2). Then,
measure the length of the liner from the brass nut (10). This measurement should be a maximum of
20mm, and should be carefully trimmed to this length using a good pair of side cutters, or similar,
ensuring there are no burrs or sharp edges which may impede the progress of the wire when fitted.
• Carefully feed the hose assembly (7) through the hole in the front face of the welder, taking care to
feed the electrical connector (14) through at the same time. Then connect them to the wire feeder.
Then insert also the threaded terminal ring (3), the power cable terminal, the washer (2) and screw
on the nut (1) tightly.
• Fit the plastic cover (15) over the bracket assembly (4) securing with the two self-tapping screws
provided.
• Connect the gas hose (12) to the gas hose nipple (6) securing with the hose clamps supplied (13).
4.2 TORCH LEAD ASSEBLY – EURO
CONNECTION (FIG.4)
• Plug the torch hose into the socket on the front of the
welder and secure by hand screwing in the threaded
connection.
FIG. 4
20 mm
FIG. 5
2/3mm
• Make the electrical connec-
tions by joining connectors
(11-14)
Note: when correctly
assembled the wire liner
(9) must be at 2-3 mm
distance from the point
of contact between the
upper and lower roll.
wire feeder use the interconnection cables provided.
• Place the power source in a well ventilated area: dust, grit or any other thing that may obstruct the
air intake and output vents can prevent the ventilation and good operation of the welder.
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8

• Make the cooling unit connection cables go through the
cable clamps placed on the generator rear. Remove the bri-
dge between PS-PS contacts, then connect the cooling unit
safety device (pressure switch) cable to them (this cable is
easy to recognize, since it has just two wires).
• Then, carefully connect the cooling unit power cable (three
wires cable) to the terminal board.
• Extra care must be taken, since both 230V and 400V coo-
ling units can be connected to it.
• Before connecting the power cable, check the cooling unit
voltage on the rating plate. After having connected the ca-
bles, tighten the cable clamps.
• Reassemble the right top panel
• Interconnect the wire feeder to the generator and the coo-
ling unit, following cooling fluid input and output instructions
(Fig.6A).
• Before switching on the water cooler, check on the notch
scale that tank is filled with coolant. Fill it up with distilled
water adding ethylene antifreeze.
Important: Do NOT use the water cooler without
coolant, this may cause damages to the glands.
Use only ethylenic anti-freeze liquid, do NOT use
liquids with polypropylenic base.
• Connect the torch to the euro connector, and torch cooling
pipes to the fast connectors placed on the cooling unit front,
following cooling fluid input and output instructions.
• Now connect the generator to the mains and check if coo-
ling unit is working correctly.
On the cooling unit front there are the following devices:
• Unit power switch
• Protection fuse
FIG. 6
• Orange pilot light: when it is on, it indicates that there is a lack of pressure in the cooling circuit
and welding is not allowed.
Please note that if cooling fluid doesn’t circulate welding is not allowed: this may happen if there is not
enough fluid in the system, or if you are using a torch that is not water cooled.
FIG. 6A
9
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Ensure the gas and electrical supplies are disconnected. Before proceeding, remove
the nozzle and the contact tip from the torch.
7.0 LOADING WIRE
Your Mig welder is designed to accept either 5kg or 15kg wire spools.
Wire spools aren’t supplied with the unit and must be purchased separately.
• Remove the wire spool (B) from the spool holder (C).
• Loosen the nut (A), remove the spring and the washer;
remove the spool holder (C) from the pivot.
• Insert on the pivot the 100mm diameter wire spool;
Mount the washer, the spacer (G) and the spring.
• Tighten the lock nut (A).
Tighten nut (A) to appropriate tightness. Exces-
sive pressure strains the wire feeding motor.
Too little pressure does not allow the immediate
stop of the wire spool at the end of the welding.
SPOOL HOLDER AS FIG. 7 - 7A
• Open the side panel. Loosen the nut (A) of the spool holder
(position 1) (brake drum).Remove the spacer (E, if present). In
the case you are replacing the wire spool, extract it by pushing
the snap tongue (D) (Fig 7).
• Remove the plastic protection from the spool. Place it on the
spool holder. Mountthe spacers again (E/F, only for 5kg spools;
the smaller spacer E must be mounted between the spool and
the spool holder). Then tighten the lock nut (A) turning it to
position 2. (Fig. 7).
Your Mig welder can also accept 100 mm diameter wire
spools. For the mounting follow these instructions:
FIG. 7
FIG. 7A
SPOOL HOLDER AS FIG. 8
• Open the side panel. Loosen the nut of the spool holder.
• Remove the plastic protection from the spool. Place it
on the spool holder and fix it tightening the nut.
Tighten nut to appropriate tightness. Excessive
pressure strains the wire feeding motor. Too lit-
tle pressure does not allow the immediate stop
of the wire spool at the end of the welding. FIG. 8
The bottle (not supplied) should be located at the
rear of the welder, securely held in position by the
chain provided.
For safety, and economy, ensure that the regulator is fully
closed, (turned counter-clockwise) when not welding
and when fitting or removing the gas cylinder.
• Turn the regulator adjustment knob counter-
clock wise to ensure the valve is fully closed.
• Screw the gas regulator fully down on the gas
bottle valve, and fully tighten.
• Connect the gas hose to the regulator secu-
ring with clip/nut provided.
• Open the cylinder valve, then set the gas flow
to approx. 8l/min. on the regulator.
• Operate the torch trigger to ensure that the
gas is flowing through the torch.
MATERIAL
TO WELD GAS CYLINDER WIRE
Mild steel
Argon +
CO2 cylinder
or CO2
cylinder
Copper coated
mild steel wire
spool.
For no gas
welding use flux-
cored wire spool
Stainless steel Argon
cylinder Stainless steel wire spool.
Aluminium Argon
cylinder Aluminium wire spool
6.0 GAS CYLINDER AND REGULATOR CONNECTION
WARNING: Cylinders are highly pressurized. Handle with care. Serious accidents
can result from improper handling or misuse of compresses gas cylinders. Do not
drop the cylinder, knock it over, expose it to excessive heat, flames or sparks. Do not
strike it against other cylinders.
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10

8.0 REPLACING THE WIRE LINER
Before performing this procedure, ensure the gas and electrical supplies are di-
sconnected.
• Open the side panel. Loo-
sen and lower the plastic
knob (A) and release the
pressure arm (B) (Fig. 9).
Cut the wire (in the case it is
installed) grasp it with pliers
so that it cannot exit from
the spool and fix it on the
suitable hole in the reel. Re-
move the nozzle and con-
tact tip. Remove with pliers
the wire from the hose and
torch assembly.
WARNING: When changing the wire diameter
being used, or replacing the wire feed roll, be sure
that the correct groove for the wire diameter selec-
ted is inside, closest to the machine. The wire is dri-
ven by the inside groove. Feed rolls are marked on
the side identifying the groove nearest that side.
• Close the side panel of the machine. Connect the power
supply cable to the power output line. Turn on the switch.
Press the torch switch. The wire fed by the wire feeding mo-
tor at variable speed must slide through the liner. When it
exits from the torch neck, release the torch switch. Turn off
the machine. Mount the contact tip and the nozzle.
When checking the correct exit of the wire from the torch do not bring your face
near the torch, you may run the risk to be wounded by the outgoing wire. Do not
bring your fingers close to the feeding mechanism when working! The rolls, when
moving, may crush the fingers. Periodically, check the rolls. Replace them when
they are worn and compromise the regular feeding of the wire.
The procedure to follow for
replacing the wire liner depends
upon the torch connection type of
your welder.
• Loosen and lower the plastic knob (A) (Fig.9). Open the
pressure arm (B) of the feeder. Extract the wire from the
torch liner (E).
• When the wire is disconnected, grasp it with pliers so that it
cannot exit from the spool. If necessary, straighten it before
inserting it in the wire input guide (C). Insert the wire on the
lower roll (D) and in the torch liner (E).
WARNING: keep the torch straight. When feeding a
new wire through the liner, make sure the wire is cut
cleanly (no burrs or angles) and that at least 2 cm
from the end is straight (no curves). Failure to follow
these instructions could cause damage to the liner.
• Lower the pressure arm (B) and place the knob (A). Tighten
slightly. If tightened too much, the wire gets locked and
could cause motor damage. If not tighten enough, the rolls
will not feed the wire.
ALUMINIUM WIRE FEEDER
PLASTIC/ALUMINIUM WIRE FEEDER
PLASTIC WIRE FEEDER
FIG. 9
12
3
4
56
7
FIG. 10
If the torch is already mounted connected and has a gas valve on the handle (Fig. 10):
• Remove the screws (1-2) securing the torch support bracket (3).
11
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Colour BLUE RED YELLOW
Diameter Ø 0,6-0,9 Ø 1,0-1,2 Ø 1,2-1,6
12
3
4
5
In case of direct connection (Fig.11) :
• Remove the screws (1) securing the torch support bracket (2).
• Unscrew the brass nut (3) from the torch hose end and remo-
ve the torch from its place.
• Remove the nozzle and the contact tip.
• Pull the liner (4) out of the hose.
• Thread the new liner into the hose to the torch neck.
• Replace the torch were it was.
• Mount the brass nut (3) and the plastic support bracket (2)
again.
• Measure the wire liner and trim it back, using a good pair of
side cutters, so that there is no more of 2mm gap between
the end of the liner and the feed roller. Take care to ensure
there are no burrs or sharp edges which may impede the
progress of thewire when fitted.
• Install the wire into the feeding system, mount the nozzle and
the contact tip again and close the side panel.
FIG. 11
Euro Connection (Fig.12):
• Disconnect the torch from the machine.
• Place it on a flat surface and carefully remove the
brass nut (1).
• Pull the liner out of the hose.
• Install the new liner and mount the brass nut (1)
again.
• In case you are replacing a Teflon wire liner, follow
these instructions:
• Install the new liner and take care to insert also the
O ring (3) on the wire liner collet (4).
• Install the collet on the wire liner and replace the
brass nut (1).
• Cut the wire liner close to the brass nut
Warning: the length of the new wire liner must be the same of the liner you have
just pulled out of the hose.
• Connect the torch to the machine and install the wire into the feeding system.
8.1 HOW TO CHOOSE THE WIRE LINER FOR DIRECT AND EURO CONNECTION
TORCHES
Mainly we can have 2 types of wire liners: Steel wire liners and Teflon wire liners.
• The steel wire liners can be coated or not coated: the coated wire liners are used for air cooled torches;
the wire liners which are not coated are used for water cooled torches.
• The Teflon wire liners are suggested for the welding of Aluminium, as they allow a smooth feeding
of the wire.
• Hold the torch on its side, on a flat surface and carefully remove the upper cover by unscrewing
the securing screws (4). Take care not to disturb the components within, so that you can take note
of their exact position.
• Lift out the gas valve (5) and disconnect the liner from its quick fit coupling (7) by pushing in.
• Straighten the torch hose and pull the liner completely out of the hose.
• Thread the new liner into the hose from the torch. Push the end of the liner firmly into the quick fit
coupling on the gas valve (5).
• Re-assemble the torch, taking care to ensure that all the components are correctly seated. Do not force
the two halves of the handle together, ensure that the dowel is lined up before tightening the screws.
• Replace the torch in the torch support bracket (3).
• Mount the upper cover (3) of the torch by fixing the screws (1-2).
• Measure the wire liner and trim it back, using a good pair of side cutters, so that there is no more
of 2mm gap (7) between the end of the liner and the feed roller. Take care to ensure there are no
burrs or sharp edges which may impede the progress of the wire when fitted.
• Install the wire into the feeding system and close the side panel.
STEEL
FIG. 12
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12

9.0 WELDER CONTROLS
13
14
6
5
7
11
10
23
12
914
6
5
3
11
10
2
7
914
6
5
7
11
10
2
9
1
4
8
5
3
11
10
2
7
12
13
20 19
16
22
17
15
23
16
22
24
15 18
9
1
4
6
5
3
11
10
2
7
12
13
FIG. 13 FIG. 14 FIG. 15
FIG. 16 FIG. 17
9
11
4
7
5
1
10
2
9
7
4
2
10
1
5
FIG. 18 FIG. 19
13
-ENGLISH-

1 Main ON/OFF switch. Generator main switch. In some models, this green led lights up when the
machine is switched on.
2 Welding voltage selector switch. 6-7-8 positions (fine selector switch for models with 2
switches)
3 Welding voltage selector switch. 2-3-4-6 positions (coarse selector switch)
4 Wire speed control knob. Turn it to increase or decrease the wire speed.
5 Timer for spot welding.
This potentiometer permits the adjustment of the spot welding time; you can produce welding spots or
beads, which will automatically stop according to the time you have set. To activate the timer, turn it
clockwise; to deactivate it turn it counter-clockwise, until you hear a “click”.
6 B.B.T. (Burn Back Time)
When releasing the torch trigger the machine will work for a very short time. This function allows avoiding
the burning of the wire and the consequent sticking of this to the contact tip. By turning the B.B.T. potentio-
meter clockwise/counter-clockwise, the wire which is exiting from the torch at the end of the welding will
become shorter or longer. In some models with separate wire feeder the B.B.T. potentiometer is placed
in the spool holder compartment of the wire feeder (above the wire feeder motor).
7 Over temperature pilot lamp (orange).
This pilot lamp will light if the over temperature thermostat operates. During an over temperature
condition, the output of the power source will be disabled, but the fan should continue to operate to cool
the machine. The pilot lamp will automatically extinguish after the machine has cooled sufficiently. Then,
you will be able to work again.
8 Power on led (green). It lights on when the generator is powered.
9 Auxiliary circuits protection fuses.
In some models with internal wire feeder the fuses are placed in the spool holder compartment, above the
wire feeder motor. In some models with separate wire feeder the fuses are placed inside the generator.
10 Torch connection (Euro connection or direct connection)
11 Negative terminal ( ) low impedance.
connection point for the ground cable: low impedance is suggested for thin welding wires.
12 Negative terminal ( ) high impedance.
connection point for the ground cable: low impedance is suggested for thick welding wires.
13 Digital instrument.
Some models just have the ammeter, while some others have both ammeter and voltmeter. In some models
with separate wire feeder, after welding, the display will show (for a few seconds) the real welding current.
14 Manual / automatic selector.
- manual= 2 times welding: the welding process starts when we press the torch trigger and
stops when we release it.
- automatic= 4 times welding: the welding process starts when we press the torch trigger (after
a pre-gas time) and continues even if we release the torch trigger; the process stops when you press and
release again the torch trigger (after a post gas time).
15 Positive terminal. Connection point for the power cable of the interconnection cable.
16 Six poles connection. Connection point for cable interconnection 6 poles connector.
17 Gas hose connection. Connection point for the gas hose of the interconnection cable.
18 Generator power cable
19 ON/OFF switch. Cooling unit main switch. This green lamp lights on when the cooling unit is
powered.
20 Missing cooling fluid.
-ENGLISH-
14

If this lamp lights up, it means that you have to add cooling fluid to the system
21 Fast connections.
They are placed on the front of the wire feeder. The torch cooling pipes are connected to these fast
connections.
22 Fast connections.
They are placed on the rear of the wire feeder and on the rear of the cooling unit; the interconnection
pipes are connected to these fast connections.
23 Cooling unit power cable.
24 Cable for the connection of the cooling unit safety device (pressure switch).
It is possible to spot weld two sheets of up to 0,8mm thickness mild steel by replacing the torch gas
nozzle with a spot welding nozzle (not supplied). Select the spot welding function by adjusting the timer .
Place two sheets one upon another; place the nozzle on the upper sheet and then press the torch trigger
ensuring that the sheets are in contact. Press the trigger to spot weld the first sheet to the second one. The
spot welding will automatically stop when the adjusted time has passed. For spot welding, the machine
must be set at maximum current and maximum wire speed. It is advisable to use 0,8mm ø wire.
10.0 SPOT WELDING
Only for models fitted with timer for spot welding.
The machine will be set up as for mild steel except for the following changes:
• 100% ARGON as welding protective gas.
• Ensure that your torch is set up for aluminium welding:
1. The lenght of the torch cable should not exceed 3m (it is advisable not to use longer torches).
2. Install a teflon wire liner (follow the instructions for the renewing of the wire liner at paragraph 8).
3. Ensure that drive rolls are suitable for aluminium wire.
• Use contact tips that are suitable for aluminium wire and make sure that the diameter of the con-
tact tip hole corresponds to the wire diameter that is going to be used.
11.0 ALUMINIUM WELDING
12.0 PREPARATION FOR WELDING
WARNING: make sure the polarity is correctly set. For GAS welding the torch must be
connected to the positive terminal (+), while the ground cable must be connected to the
negative terminal (-).
For NO GAS welding the torch must be connected to the negative terminal (-), while the
ground cable must be connected to the positive terminal (+).
In GAS welding, to avoid the oxidation of the weld puddle, we need a shielding gas. In
NO GAS welding the protection is given by the flux cored wire.
N
O GAS
GAS
• Connect the ground cable to the proper
female outlet on the bottom right-hand
corner of the welder (on some models the
ground cable is already connected).
• Attach the ground clamp to the bare metal
to be welded, making sure of good con-
tact;
• Make sure that the wire-roller groove in the
roller corresponds to the diameter of the
wire being used. Refer to paragraph 7.
• Plug the machine to a suitable outlet.
• Open the gas valve on the gas cylinder re-
gulator, (turn knob counter-clockwise) and
adjust the flow rate using the regulator
knob (turn it counter-clock wise to decrea-
se the gas flow; turn it clockwise to increa- FIG. 20
se the gas flow). Note: The gas flow may need adjustments in order to obtain a better welding,
this depends on the type and thickness of the metal and on the welding current.
15
-ENGLISH-

14.0 TECHNICAL DATA INFORMATION GUIDE
1 Serial Number of the unit
2 Power source model
3 Type of characteristic
4 Min. - Max rated No Load Voltage
5 Type of welding
6 Symbol for the main supply and no. of phases
7 Rated value of the supply voltage
8 Code letter for degree of insulation
9 Protection degree
10 Power
11 Size of the necessary main fuse
12 Supply current
13 Welding supply and voltage
14 Power Factor
15 Control range (current / voltage)
16 Reference standard
FIG. 21
13.0 OPERATION
A certain experience is required to adjust and use a Mig power source. In Mig welding two parameters
are fundamental: the welding voltage and the wire speed. The resulting welding current is a result of these
two settings.
• Set the voltage and wire feed controls to positions suitable for the thicknesses of the material to be welded.
• Welding current varies in relationship to wire speed. For low welding current output, the wire speed
control knob should be set at the low end of the wire feed speed scale.
• Turning the wire speed control knob clockwise, will result in increased wire feed speed and welding
current. Welding voltage must be adjusted to match the wire feed speed (welding current).
• Progressively select higher voltage positions, while increasing the wire speed.
Increase of the welding voltage, at the same wire speed, leads to a longer arc (without substantially affecting
the current). Conversely, a decreased welding voltage results in a shorter arc (the current again is not su-
bstancially changed).
A change in wire diameter results in changed parameters. A smaller diameter wire requires an increase
in wire feed speed to reach the same current. But be careful: If certain limits are exceeded, a satisfactory
weld cannot be obtained:
• A) A too high wire feed speed (too high with regard to the welding voltage) results in pulsing within
the torch. This is because the wire dips into the puddle and cannot be melted off fast enough. This
will cause excessive spatter,
• B) A too high welding voltage (too high with regard to the wire feed speed), will result in excessive
and unstable arc. By increasing still further the voltage, the contact tip will burn.
• C) In any case, an excessive wire speed can be corrected through the arc voltage increase. The li-
mit of this operation depends on the thickness of the material to weld (a certain limit exceeded will
result in the perforation).Place the torch over the seam to be welded holding it at approximately
a 45° angle, with the nozzle at 5 mm distance from the piece to be welded. Lower the shielding
helmet and press the welding torch trigger to initiate an arc. As the arc has struck, move the torch
from a left to right direction, slowly along the seam at a constant speed.
• Using the wire speed control knob, adjust for a “crisp” sounding arc: experience will help to reco-
gnize the right “sound” of the arc.
-ENGLISH-
16

15.0 PROTECTION GASES GUIDE
METALLO
Mild steel
Aluminium
Stainless steel
Copper, Nickel and
Alloys
GAS
CO2
Argon + CO2
Argon + CO2 + Oxygen
Argon
Argon + Helium
Argon + CO2 + Oxygen
Argon + Oxygen
Argon
Argon + Helium
NOTE
Argon controls spatters
Oxygen improves arc stability
Arc stability, good fusion and minimum
spatter.
Higher heat input suitable for heavy
sections. Minimum porosity.
Arc stability.
Minimum spatter.
Suitable for light gauges because of low
flowability of the weld pool.
Higher heat input suitable for heavy
sections.
Contact the technical service of your gas supplier to know the percentages of the different
gases which are the most suitable to your application.
16.0 WELDING HINTS AND MAINTENANCE
• Always weld clean, dry and well prepared material.
• Hold gun at a 45° angle to the workpiece with nozzle about 5 mm from the surface.
• Move the gun smoothly and steadily as you weld.
• Avoid welding in very drafty areas. A weak pitted and porous weld will result due to air blowing
away the protective welding gas.
• Keep wire and wire liner clean. Do not use rusty wire.
• Sharp bends or kinks on the welding cable should be avoided.
• Always try to avoid getting particles of metal inside the machine since they could cause short cir-
cuits.
• If available, use compressed air to periodically clean the hose liner when changing wire spools
IMPORTANT: Disconnect from power source when carrying out this operation.
• Using low pressure air (3/5 Bar=20-30 PSI), occasionally blow the dust from the inside of the wel-
der. This keeps the machine running cooler. Note: do not blow air over the printed circuit board
and electronic components.
• The wire feed roller will eventually wear during normal use. With the correct tension the pressure
roller must feed the wire without slipping. If the pressure roller and the wire feed roller make con-
tact (when the wire is in place between them), the wire feed roller must be replaced.
• Check all cables periodically. They must be in good condition and not cracked.
17
-ENGLISH-

17.0 TROUBLESHOOTING
This chart will assist you in resolving common problems you may encounter. These are
not all the possible solutions.
PROBLEM POSSIBLE SOLUTION
POSSIBLE CAUSE
No “life” from welder
Fan operates normally, but
when gun trigger pulled,
there is no wire feed, weld
output or gas flow
Feed motor operates but
wire will not feed
Lack of penetration
Wire is birdnesting at the
drive roller
Wire burns back to contact
tip
Workpiece clamp and/or
cable gets hot.
Check for proper input cable connec-
tion
Check fuse and replace as necessary
Replace torch trigger
Allow welder to cool. The extinguishing of
the pilot lamp / switch on the front panel
indicates the thermostat has closed.
Replace wire feeding motor
Increase roller pressure
Re-cut wire square with no burr
Clear with compressed air or replace
liner
Re-adjust the welding parameters.
Clear with compressed air and tighten
all connections.
Replace the contact tip.
Tighten or replace torch.
Use correct size welding wire.
Move the gun smoothly and not too
fast.
Adjust pressure on drive roller.
Replace wire liner
Replace contact tip
Cut wire liner at the right lenght
Replace the contact tip
Increase wire speed
Use correct size contact tip.
Tighten connection or replace cable.
Clean or replace nozzle.
Decrease wire feed speed
Input cable or plug malfunction.
Wrong size fuse.
Faulty trigger on gun
Thermostat intervention
Faulty wire feeding motor (rare)
Insufficient feed roller pressure
Burr on end of wire
Liner blocked or damaged
Voltage or wire feed speed too
low.
Loose connection inside the
machine (rare).
Worn or wrong size contact tip.
Loose gun connection or faulty
gun assembly
Wrong size wire.
Torch moved too fast.
Eccessive pressure on drive roller
Gun liner worn or damaged
Contact tip clogged or damaged
Liner stretched or too long
Contact tip clogged or damaged
Wire feed speed to slow
Wrong size contact tip
Bad connection from cable to
clamp
Slag buildup inside nozzle or
nozzle is shorted.
Wire feed speed too fast
-ENGLISH-
18

Gun nozzle arcs to work
surface.
Wire pushes torch back
from the workpiece
Poor quality welds
Weld deposit “stringy” and
incomplete
Weld deposit too thick
Nozzle clogged
Torch held too far from the
workpiece
Insufficient gas at weld area
Rusty, painted, damp, oil or greasy
workpiece
Rusty or dirty wire
Poor ground contact
Incorrect gas / wire combination
Torch moved over workpiece too
quickly
Gas mixture incorrect
Torch moved over workpiece too
slowly
Welding voltage too low
Clean or replace nozzle
Hold the torch at the right distance
Check that the gas is not being blown
away by drafts and if so move to more
sheltered weld area. If not check gas
cylinder contents gauge, regulator setting
and operation of gas valve.
Ensure workpiece is clean and dry.
Ensure wire is clean and dry.
Check ground clamp/workpiece con-
nection
Check on the manual for the correct
combination
Move the torch slower
See shielding gas table
Move the torch faster
Increase welding voltage
19
-ENGLISH-

Die beim Schweißvorgang erzeugte Ultraviolett- und Infrarotstrahlung kann die
Augen beschädigen und die Haut verbrennen, wenn keine geeigneten Schutzmaß-
nahmen getroffen werden.
• Die Bediener müssen den eigenen Körper schützen, indem sie geschlossene und nicht brennbare
Schutzanzüge tragen, sowie eine Schweißmaske aus nicht brennbarem Material, mit der Gesicht
und Hals auch seitlich geschützt werden. Die Schutzgläser sind stets sauberzuhalten und auszu-
wechseln, falls sie beschädigt werden. Es empfiehlt sich, das inaktinische Glas mit transparentem
Glas vor Spritzern zu schützen.
• Die Schweißarbeiten sind in einem Bereich durchzuführen, der von den anderen Arbeitsbereichen
abgeschirmt ist.
• Die Bediener dürfen niemals, egal aus welchem Grund, ohne geeigneten Augenschutz in einen Licht-
bogen schauen. Personen, die in der Nähe des Schweißortes arbeiten, müssen mit besonderer Vor-
sicht vorgehen. Sie müssen immer Schutzbrillen tragen, deren Linsen für den Schutz vor ultravioletter
Strahlung, Spritzern und anderen Fremdpartikeln, die den Augen schaden können, geeignet sind.
1.1 INTRODUZIONE
Sicherstellen, dass das vorliegende Handbuch sowohl vom Bediener, als auch von den für die Wartung
zuständigen Technikern gelesen und verstanden wird.
1.2 SICUREZZA PERSONALE
Falls die Bedienungs- und Sicherheitsvorschriften nicht genau beachtet werden, können die Schweißarbeiten für
den Bediener und auch für Personen, die sich in der Nähe des Schweißortes befinden, gefährlich werden.
1.0 SICHERHEITSVORSCHRIFTEN
Gase und Rauch, die während des Schweißvorgangs erzeugt werden, können die
Gesundheit gefährden
• Der Schweißbereich muss mit einem geeigneten Absaugsystem ausgestattet sein. Hierbei kann es
sich sowohl um eine Absaughaube handeln, als auch um eine geeignete Arbeitsstation, an der
eine seitliche und frontale Absaugung, sowie eine Absaugung unterhalb des Arbeitstisches vorge-
sehen ist, damit Staub und Rauch umgehend entfernt werden. Das Absaugsystem vor Ort muss
durch ein allgemeines Lüftungs – und Luftaustauschsystem ergänzt werden, vor allem, wenn in
beengten Räumlichkeiten gearbeitet wird.
• Der Schweißvorgang ist auf Metalloberflächen durchzuführen, die von allen Rost- oder Lackschi-
chten befreit wurden, damit keine gesundheitsschädlichen Dämpfe entstehen können. Vor dem
Schweißen die mit Lösungsmitteln entfetteten Teile trocknen.
• Besondere Vorsicht ist geboten beim Schweißen von Materialien, die eine oder mehrere der fol-
genden Komponenten enthalten: Antimon Beryllium Kobalt Magnesium
Arsenikselen Kadmium Kupfer Quecksilber Silber Barium Chrom
Blei Nickelvanadium.
• Vor dem Schweißen alle Lösungsmittel mit Chlorgehalt aus dem Schweißbereich entfernen. Einige
Lösungsmittel auf Chlorbasis zersetzen sich, wenn sie ultravioletter Strahlung ausgesetzt werden
und bilden Phosgengase - Phosgengase sind hochgiftig!
1.3 BRANDSCHUTZ
Glühende Schlacken, Funken und der Lichtbogen können Brände und Explosionen erzeugen.
• Ein Feuerlöscher von angemessener Größe und entsprechenden Eigenschaften muss stets griffbe-
reit sein. Von Zeit zu Zeit dessen Funktionstüchtigkeit überprüfen;
• Alles brennbare Material aus dem Schweißbereich und den umliegenden Bereichen entfernen. Mate-
rial, das nicht entfernt werden kann, ist mit geeigneten, feuerhemmenden Abdeckungen zu schützen;
• Die Umgebung ausreichend lüften. Die Lüftung dient dazu, die Ansammlung giftiger oder explo-
siver Gase zu verhindern;
• Keine Behälter schweißen, die brennbares Material enthalten (auch wenn diese entleert wurden)
oder unter Druck stehen;
• Nach dem Schweißen sicherstellen, dass kein glühendes Material oder Flammen vorhanden sind;
• Die Decke, der Boden und die Wände im Schweißbereich müssen aus brandsicherem Material
bestehen.
1.4 ELEKTRISCHER SCHOCK
ACHTUNG: EIN ELEKTRISCHER SCHOCK KANN TÖDLICH SEIN!
• In jedem Arbeitsbereich muss eine Person anwesend sein, die in der Lage ist, Erste Hilfe zu leisten.
Falls Verdacht auf einen elektrischen Schock besteht, darf der Verletzte niemals berührt werden,
-DEUTSCH-
20