(indispensable for technical assistance, requesting spare par ts, For welders with double voltage supply , it is necessary to set the
discovering product origin). blocking screw of the voltage-re verse s witch in the position corre
7- Perf ormance of the welding circuit:
sponding to the voltage really availab le (see example below).
- U : maximum no-load voltage (open welding circuit).
Fig. G
0
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- I /U : current and corresponding nor malised voltage that the
2 2
welding machine can supply during welding.
WARNING! Failure to observe the above rules will make the
- X : Duty cycle: indicates the time for which the welding machine
(Class 1) safety system installed by the manufacturer ineffective
can supply the corresponding current (same column). It is
with consequent serious risks to persons (e.g. electric shock) and
expressed as %, based on a 10 min. cycle (e.g. 60% = 6 minutes
objects (e .g. fire).
working, 4 minutes pause, and so on).
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If the usage factors (on the plate, referring to a 40°C
environment) are exceeded, the thermal safeguard will trigger
CONNECTION OF THE WELDING CABLES
(the welding machine will remain in stand-by until its temperature
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returns within the allowed limits).
- A/V -A/V: sho ws the range of adjustment for the welding current
W ARNING! BEFORE MAKING THE FOLLOWING
(minimum-maximum) at the corresponding arc voltage.
8- T echnical specifications for pow er supply line:
CONNEC TION S MA KE SURE THE WELD ING MACHINE IS
- U : Alternating voltage and power supply frequency of welding
1
SWITCHED OFF AND DISCONNECTED FROM THE PO WER
machine (allowed limit ±10%):
SUPPL Y OUTLET .
- I : Maximum current absorbed by the line.
1 max
T able (T AB. 1) gives the recommended values for the welding cab les (in
2
- I : Effectiv e current supplied.
mm ) depending on the maximum current supplied by the welding
1eff
9- :
machine.
Size of delayed action fuses to be used to protect the
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power line.
10- Symbols referring to saf ety regulations, whose meaning is given in
AC Versions:
chapter 1 “General safety considerations for arc welding”.
Connecting the electrode-holder clamp welding cable
On the end take a special terminal that is used to close the uncovered
Note: The data plate shown above is an e xample to give the meaning of
part of the electrode.
the symbols and numbers; the exact values of technical data for the
For welding machines supplied with a ter minal, this cable is connected
welding machine in your possession must be checked directly on the
data plate of the welding machine itself.
to the terminal with the symbol .
OTHER TECHNICAL DA T A
Connecting the welding current return cable
This is connected to the piece being welded or to the metal bench
- WELDING MA CHINE: see table (T AB.1)
supporting it, as close as possible to the join being made. For w elding
- ELECTRODE HOLDER CLAMP: see table (T AB. 2)
machines supplied with a terminal, the cable is connected to the
terminal with the symbol .
4. DESCRIPTION OF THE WELDING MACHINE
Control, regulation and connection devices
AC/DC Versions:
Fig. B
Almost all coated electrodes are connected to the positive pole (+) of
the pow er source; as an exception to the negative pole (-) f or acid
5. INST ALLA TION
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coated electrodes.
WELDING OPERA TIONS WITH DIRECT CURRENT
W ARNING! CARRY OUT ALL INST ALLA TION OPERA TIONS
AND ELECTRICAL CONNECTIONS WITH THE WELDING MACHINE
Connecting the electrode-holder clamp welding cable
COMPLETEL Y SWITCHED OFF AND DISCONNECTED FR OM THE
On the end take a special terminal that is used to close the uncovered
PO WER SUPPL Y OUTLET .
part of the electrode.
THE ELECTRICAL CONNECTIONS MUST BE MADE ONL Y AND
This cable is connected to the terminal with the symbol (+).
EXCLUSIVEL Y BY AUTHORISED OR QU ALIFIED PERSONNEL.
__________________________________________________________________________________
Connecting the welding current return cable
This is connected to the piece being welded or to the metal bench
PREP ARA TION
supporting it, as close as possible to the join being made.
Fig. C
This cable is connected to the terminal with the symbol (-).
Unpack the welding machine, assemble the separate parts contained in
the package.
WELDING OPERA TIONS WITH AL TERNA TING CURRENT :
Assembling the return cable-clamp
Fig. D
Electrode-holder clamp cable and earth cable to either of the related
terminals ( ~ / ~ ).
Assembling the welding cable-electrode holder c lamp
T AKE THE GREA TEST CARE TO CONNECT THE WELDING CABLES
Fig. E
CORRECTL Y e.g. ( - ) / ~ or (+) / ~ ).
HO W T O LIFT THE WELDING MA CHINE
Warnings:
The welding machine MUST be lifted as shown in Fig. F (only for the
- T urn the welding cable connectors right down into the quick
model I = 350A). For all other welding machines never use the
2 max
connections (if present), to ensure a perfect electrical contact;
handle for lifting.
otherwise the connectors themselves will overheat, resulting in
This holds for the first time the welding machine is installed and
their rapid deterioration and loss of efficiency .
throughout its entire working life.
- The welding cab les should be as shor t as possible.
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- Do not use metal structures which are not part of the w orkpiece to
substitute the return cable of the welding current: this could
WARNING! Position the welding machine on a flat surface
jeopardise safety and result in poor welding.
with sufficient carrying capacity for its weight, to prevent it from
tipping or moving hazardously .
6. WELDING: DESCRIPTION OF THE PROCEDURE
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AC Versions:
These welding machines consist of a single phase drooping-type
CONNECTION TO THE MAIN POWER SUPPL Y
transformer and are suitable for welding in alternating current with
- Before making any electrical connection, make sure the rating data
coated electrodes (E43R type).
of the welding machine correspond to the mains voltage and
AC/DC Versions:
frequency available at the place of installation.
These welding machines are power sources for mixed current (direct
- The welding machine should only be connected to a power supply
and alter nating), which can be selected using the welding terminals,
system with the neutral conductor connected to ear th.
and are suitable f or arc welding using electrodes with various types of
- T o comply with the requirements of the EN 61000-3-11 (Flicker)
coating (rutile, acid, basic).
standard we recommend connecting the welding machine to
T o switch on the welding machine operate the main switch (Fig. B (1)).
interface points of the power supply that have an impedance of less
The intensity of the supplied welding current can be adjusted
than Zmax =0.06 ohm.
continuously , by means of a manually operated magnetic shunt (Fig. B
- the welding machine falls within the requisites of IEC/EN 61000-3-12
(4)). The value for the current setting, (I ) can be read in amps on the
2
standard.
graduated scale (Fig.B (2)) on the top or front panel. The
corresponding arc voltage (U ) f or the current shown is given according
2
PLUG AND OUTLET
to the following relationship: U = (20 + 0,04 I ) V (EN 60974).
2 2
Connect a nor malised plug (2P + T , 3P + T) having sufficient capacity- to
the pow er cable and prepare a mains outlet fitted with fuses or an
THERMOST A TIC PRO TECTION
automatic circuit-breaker; the special ear th terminal should be
This welder is automatically protected from thermic overheating
connected to the ear th conductor (yellow-green) of the power supply
(thermostat automatic re-start). When the windings reach performance
line. T able (T AB.1) shows the recommended delayed fuse sizes in
temperature, the protections cut off the supply circuit, igniting the yellow
amps, chosen according to the max. nominal current supplied by the
lamp on the front panel (Fig. B (3)). After a few minutes’ cooling the
welding machine, and the nominal voltage of the main power supply .
protection will reopen the supply line and turn off the y ellow lamp. The