Instructions manual

TM 215
 20050 RONCO B
RIANTINO (MB)
Via Brigatti, 59 Italy
Tel. +39 039 607
9326 - Fax. +39
039 6079334

www.fimer.com
- info@fimer.c
om

Istruzioni Originali
Original instructions
Übersetzung der Originalbetriebsanleitung
Notice originale
Manual original
 165A 130A
22,
25V 20,
5V

140A 120A
25,
6V 24,
9V

31,
1V 17,
2V
ALTRI DATI TECNICI
SPECIFICHE TECNICHE
PESO: 17 Kg.
DIMENSIONI: 200x450x480
CARATTERISTICA STATICA: cadente

ITALIANO
DISPOSITIVO DI PROTEZIONE DI RETE: Fusibili 25A Ritardati
Int. Bipolari: 25A Curva K o C
TENSIONE DI INGRESSO: 230V +/- 10%
PROTEZIONE TERMICA: termostato tipo “thermic SO1”
TEMP. INTERVENTO:
Le prove di riscaldamento sono state effettuate alla temperatura di 40°
FUNZIONE ARC FORCE E ANTI-STICKING: presente
DIAMETRI DEGLI ELETTRODI UTILIZZABILI: Ø 0,6; Ø 0,8; Ø 1,0 mm

ADDITIONALSPECIFICATION
TECHNICAL TECHNICAL INFORMATION
WEIGHT: 17 Kg.
DIMENSIONS: 200x450x480
STATIC CHARACTERISTIC: drooping

ENGLISH
POWER SUPPLY PROTECTION: 25A Delay-Fuses
Two-Pole 25A K- or C-Standard Switch
INPUT LOAD: 230V +/- 10%
THERMAL PROTECTION: Thermostat : “Thermic SO1”
INTERVENTION TEMPERATURE:
Overheating tests run at 40° C
ARC FORCE AND ANTI-STICKING FUNCTIONS: Present
MAX ELECTRODE DIAMETERS: Ø 0,6; Ø 0,8; Ø 1,0 mm

WEITERE TECHNISCHE
TECHNISCHE DATEN
SPEZIFIKATIONEN
GEWICHT: 17 Kg.
ABMESSUNGEN: 200x450x480
STATISCHE EIGENSCHAFTEN: fallend

DEUTSCH
NETZSCHUTZVORRICHTUNG: verzögerte 25A Sicherungen
Int. zweipolig: 25A K- oder C-Kurve
EINGANGSSPANNUNG : 230V +/- 10%
WÄRMESCHUTZ: Thermostat Typ „thermic SO1”
EINSATZTEMPERATUR:
Die Erhitzungsprüfungen wurden bei einer Temperatur in Höhe von 40° durchgeführt
ARC FORCE UND ANTISTICKING FUNKTION: vorhanden
VERWENDBARE ELEKTRODENDURCHMESSER: Ø 0,6; Ø 0,8; Ø 1,0 mm

AUTRES DONNEES
SPÉCIFICATIONS TECHNIQUES
TECHNIQUES
POIDS: 17 Kg.
DIMENSIONS: 200x450x480
CARACTÉRISTIQUE STATIQUE : cadente FRANÇAIS
DISPOSITIF DE PROTECTION DE RÉSEAU : Fusées Retardées 25A
Int. Bipolaires 25A Courbe K o C
TENSION D’ENTREE : 230V +/- 10%
PROTECTION THERMIQUE : Thermostat type “thermic SO1”
TEMP. INTERVENTION :
Les essais de chauffe ont été effectués à la température de 40°
FONCTION ARC FORCE ET ANTICOLLANT : present
DIAMETRES DES ELECTRODES UTILISABLES : Ø 0,6; Ø 0,8; Ø 1,0 mm

ESPECIFICACIONES TÉCNICAS
OTROS DATOS TÉCNICOS
PESO: 17 Kg.
DIMENSIONES: 200x450x480
CARACTERÍSTICA ESTÁTICA : cadente
ESPAÑOL

DISPOSITIVO DE PROTECCIÓN DE RED : Fusibles 25A Retardados

Int. Bipolares: 25A Curva K o C
TENSIÓN DE ENTRADA: 230V +/- 10%
PROTECCIÓN TÉRMICA : termostato tipo “thermic SO1”
TEMP. INTERVENCIÓN :
Las pruebas de calentamiento se han realizado con una temperatura de 40 ºC.
FUNCIÓN FUERZA ARC Y ANTISTICKING : presente
DIÁMETROS DE LOS ELECTRODOS UTILIZABLES : Ø 0,6; Ø 0,8; Ø 1,0 mm

VII
 USE AND MAINTENANCE MANUAL

ITALIANO
Fimer S.p.a. thanks you for selecting this unit, it will prove to be a useful, problem-free
tool for many years to come if the instructions contained in this manual are followed scru-
pulously.

This manual must be considered as an integral part of the unit and must accompany it
when it change location or is resold.
The user must assume responsability for maintaining this manual intact and legible at all

ENGLISH
times.

Fimer S.p.a. reserves the right to modify this manual at any time without notice.
All rights of translation and total or partial reproduction by any means whatsoever (inclu-
ding scanner, photocopy, film, and microfilm) are reserved and reproduction is prohibited
without the express written consent of Fimer S.p.a.

DEUTSCH
INDEX
• WARNING .........................................................................................................
............................................................................................................... pag. 2, 3, 4

1. GENERAL INFORMATION........................................................................ pag. 5

2. DESCRIPTION OF WELDER ................................................................... pag. 6
3. WELDING METHODS ............................................................................... pag. 8
3.1 MIG/MAG WELDING ............................................................................. pag. 8
3.1.1 MANUAL MIG WELDING .................................................................... pag. 8

FRANÇAIS
3.1.2 SYNERGIC SHORT ARC MIG WELDING ............................................... pag. 8
3.1.3 SYNERGIC PULSED MIG WELDING .................................................. pag. 9
3.2 MMA WELDING .................................................................................... pag. 9
4. CONNECTION TO POWER SUPPLY ....................................................... pag. 9
5. OUTPUT CONNECTIONS ...................................................................... pag. 10
5.1 MIG WELDING CONNECTIONS - with shielding gas and standard torch pag. 10
5.2 MIG WELDING CONNECTIONS - gasless and standard torch ............. pag. 10
5.3 MIG WELDING CONNECTIONS - with shielding gas and Spool torch........ pag. 10
5.4 MIG WELDING CONNECTIONS - with shielding gas and Spool torch ........ pag. 10
ESPAÑOL
5.5 MMA WELDING CONNECTIONS ........................................................... pag. 10
6. WELDING WIRE INSTALLATION ............................................................. pag. 11
6.1 WELDING WIRE INSTALLATION ......................................................... pag. 11
7. GAS CYLINDER AND GAS PRESSURE REGULATOR CONNECTIONS..... pag. 12
8. WELDING METHODS ........................................................................... pag. 12
8.1 MANUAL MIG WELDING .................................................................... pag. 12
8.2 SYNERGIC MIG WELDING.................................................................. pag. 13
8.3 MMA WELDING .................................................................................. pag. 14
8.3.1 DESCRIPTION ................................................................................ pag. 14
8.3.2 MMA WELDING FEATURES.................................................................... pag. 14
8.3.3 MMA WELDING ....................................................................................... pag. 14
9. WIRE LINER REPLACEMENT ............................................................... pag. 15
10. DEFAULT PARAMETER ADJUSTMENT ................................................. pag. 15
11.TROUBLE SHOOTING .......................................................................... pag. 16
12. BLOCK DIAGRAM ............................................................................... pag. 16
1
 WARNINg SYMBOLS
DANgER DANgER COMpRESSED gAS
Indicating the risk of injury or death in the event of improper hand-
(Indicating a hazard that could cause injury or damage) ling or maintenance of compressed gas cylinders or regulators
ELECTRIC SHOCK FIRE
(Indicating the danger of electric shock) pRECAUTIONS

DANgER IMpORTANT INFORMATION

OF FIRE OR EXpLOSION. Indicating the precautions to be taken when installing and
using the unit.

Indicating that eye protection is required to avoid DISpOSAL

burns and eye damage. INFORMATION

TOXIC gAS INSTALLATION

Indicating the risk of toxic gas hazards INSTRUCTIONS

HOT SLAg OpERATINg

Indicating the risk of being burned by hot slag INSTRUCTIONS

EYE pROTECTION UNpACKINg

Indicating that eye protection is required to avoid flying debris INSTRUCTIONS

SUITABLE FOR ENVIRONMENT WITH INCREASED

READ THE INSTRUCTION MANUAL
HAZARD OF ELECTRIC SHOCK

CAUTION
SAFETY WARNINgS Arc rays can damage your eyes and burn your skin ! Read,
understand and observe all safety warnings to avoid dama-
This equipment is designed solely for industrial or ge from arc rays. Pay particular attention to the fact that
professional use. As such, only experienced or ful- even bystanders should be aware of, and understand, the dangers exi-
ly-trained people should use the equipment. The user sting in the welding area. Wear a protective mask and make sure bystan-
and/or owner is responsible for ensuring inexperienced person- ders do the same.
nel does not have access to the equipment.

Fimer SpA declines all responsibility for injury or dama- Fumes, toxic gases and vapours can be harmful ! Read,
ge caused by inexperienced, improper or neglectful use understand and observe all safety warnings to avoid harm
of its equipment. from toxic welding gases. Pay particular attention to the fact that even
bystanders should be aware of, and understand, the dangers.
A workman must look after his tools carefully ! Remember that
any tool or equipment can become a hazard if it is not looked
after properly. Carelessness while using or maintaining the compres-
Equipment in a state of disrepair or neglect can be dangerous. If it sed gas cylinders or regulators can injure or kill the
does not operate properly or overheats, the electricity supply should operator and/or bystanders ! Read, understand and observe all safety
be removed immediately and the unit should be returned to the sup-
plier for repair. warnings to avoid the dangers of compressed gas. Pay particular
attention to the fact that even bystanders should be aware of, and
Read this manual carefully before using your Welder. understand, the dangers.
You can then do a better and safer job.
By reading this manual you will learn more about the HIgH VOLTAgE
possibilities, limitations and potential dangers of welding.
Retain this manual for the entire life of the equipment. It should be The unit carries potentially lethal voltage.
kept within the operator’s reach at all times. The high voltage areas of the equipment have been segregated
and can be reached only by using tools that are not provided with the
Welder.
The safety information contained in this manual is a guide to All maintenance or repair operations requiring access to such areas may
ensure you are not subjected to unnecessary risks. However, only be performed by Fimer-trained technicians.
the operator must be competent and careful at all times.

FOREIgN OBjECTS
All equipment connected to electric power supplies can be dan-
gerous if the manufacturers instructions are not read and obser- Never block the air vents with foreign objects and avoid
ved. Read, understand and observe these safety instructions any contact with liquids. Clean using just a dry cloth. The-
to reduce the risk of death or injury from electric shock. Ensure that se safety precautions apply even when the unit is switched off.
even bystanders are aware of, and understand, the dangers that exi-
st in the welding area. WEIgHT LOADS
The upper part of the Welder was not designed to with-
Fires and explosions can seriously injure or cause dama- stand heavy loads. Never stand on the unit.
ge ! Read, understand and observe all safety warnings
to reduce the risk of death or injury from fire or explo- CABLE gAUgES
sion. Pay particular attention to the fact that even bystanders should Check that all cables are appropriately gauged for
be aware of, and understand, the dangers existing in the welding area. the input power required by your specific Welder.
Remember that welding, by nature, produces sparks, hot spatter, mol- This precaution applies also to extension cables, if used. All extension
ten metal drops, hot slag and hot metal parts that can cause fires, can cables must be straight. Coiled cables can overheat, becoming dange-
burn skin and damage eyes. rous. Twisted or coiled cables can also cause Welder malfunction.
 OVERLOAD PROTECTION SPARE PARTS
Check that the power source supplying the Welder carries the Use only manufacturer-recommended spare parts.
Other spare parts could cause equipment mal-
correct voltage and is safety-protected. The power switch must open all the function. The use of non-original spare parts will also result in the war-
power supply circuits. (If a single-phase connection is used, both the live and ranty provisions becoming null and void, releasing the manufacturer
from any responsibility for malfunction or damage resulting as a con-
the neutral poles must be open. If a three-wire connection is used , all three sequence of such action.
poles must be open. Four-wire circuits require all poles and neutral open).
Time-delayed fuses or K-standard circuit breakers should be used. WELDING OPERATION
EARTHING SAFETY INSTRUCTIONS
If the Welder was not already supplied with a plug, connect the
earth wire first. When removing the plug, disconnect the earth
wire last. CAUTION !
Welding processes can be dangerous for the operator and bystanders
PLUG AND POWER SUPPLY if the safety warnings and instructions are not heeded.
If the Welder already has a plug attached, check that it is appro-
priate for the wall-socket you intend using. Never tamper with
the power cable. PERSONNEL PROTECTION
Together with the previous instructions, the following
CABLE COLOURS
The green-yellow wire is for earthing. (Don’t use it for precautions should be strictly observed
anything else !)
PROTECTION MASK
RELOCATION 1 Wear a protective non-flammable welding mask
Some Welders are extremely heavy therefore care should be to protect your neck, your face and the sides of
taken when relocating the unit. Check the floor or platform wei- your head. Keep the front lens clean and replace it if it is broken
ght load limitations before relocating the unit if the Welder is to be used, or cracked. Place a transparent protection glass between the mask
even only temporarily, in a non-industrial environment and the welding area.
RELOCATION 2 CLOTHING
Never store or move the Welder in an inclined position or on its Wear close-fitting, closed, non-flammable, pocke-
side. tless clothing.
INSTALLATION ENVIRONMENT VENTILATION
The equipment is not suitable for use in washrooms, Weld in a well-ventilated environment that does not have
shower cubicles, pool areas or similar environments. If direct access to other work areas.
you are obliged to use the unit in such areas, turn off all water sup-
plies and check the area has been evacuated. EYE PROTECTION
OPERATING AND/OR INSTALLATION ENVIRONMENT 1 NEVER look at the arc without appropriate eye protection.
The Welder was not designed for installation or use in areas where it
could be subject to blows or vibration, such as road-vehicles, railway FUMES AND GASES 1
carriages, cable-cars, aircraft, ships or boats or similar environments (including Clean away paint, rust or any other dirt from the item to
cranes, conveyor-carriers or any other mobile equipment prone to vibration) be welded to avoid the creation of dangerous fumes.
FUMES AND GASES 2
OPERATING AND/OR INSTALLATION ENVIRONMENT 2 NEVER weld on metals containing zinc, mercury, chro-
The Welder should never be used or stored in the rain or in snow. mium, graphite, heavy metals, cadmium or beryllium unless
the operator and the bystanders use appropriate air-supplied respirators.
OPERATING AND/OR INSTALLATION ENVIRONMENT 3
Never use the Welder in an explosive, corrosive, abra- HIGH VOLTAGE PROTECTION
sive or saline environment. Together with the previous instructions, the following pre-
cautions should be strictly observed
EXTINGUISHER
Always place an approved fire extinguisher in the immediate vicinity CONFINED SPACES
of the work area. Fire extinguishers should be checked regularly. When welding in small environments, leave the power
source outside the area where welding will take place and
LOCATION attach the grounding clamp to the part to be welded.
Place the Welder well away from heat sources. Place the
Welder in a well-ventilated environment. Place the Welder in HUMIDITY
a safe, protected area. It must not be installed outdoors. Do not install the
Welder in dusty environments. Dust can get into the inner parts of the unit Never weld in wet or humid environments.
and inhibit cooling. The Welder must be positioned on a flat, stable surfa-
ce that extends further than the units own dimensions in all directions. DAMAGED CABLES
Never use damaged cables. (This applies to both
CLEAN LOCATIONS the power and the welding cables.)
The installation area must be kept clean and dry to be sure the Welder DAMAGED CABLES
fans do not draw in small objects or liquids. Not only could the equip- Never remove the unit side panels. If the side panels
ment malfunction but a serious risk of fire outbreak could be created. can be opened, always checked they are closed
tightly before starting any work.
REPAIRS
Never attempt to repair the Welder yourself. Always
refer to the manufacturer or an authorized repairer. FIRE PREVENTION
All warranty provisions will immediately become null and void if any repair, Together with the previous instructions, the following pre-
or attempt to repair, not specifically authorized in writing or handled by cautions should be strictly observed.
Fimer S.p.A. is carried out. Furthermore, Fimer S.p.A. will accept no Welding operations require high temperatures therefore
responsibility for any malfunction or damage resulting as a consequen- the risk of fire is great.
ce of such unauthorized action.
WORK-AREA FLOORING
TECHNICAL ASSISTANCE
The Welder must be taken to an authorized Technical Assi- The work-area flooring MUST be fireproof.
stance Centre if the equipment has been damaged in any way
or if any one of the following events occurs : liquid infiltration; dama- WORK-AREA SURFACES
ge caused by falling objects; exposure to rain or humidity (exceeding
the specified limits); malfunction; performance failure or if the equip- Work benches or tables used during welding
ment has been dropped. MUST have fireproof surfaces.

3
 DAMAGED GAS CYLINDERS
WALL AND FLOOR PROTECTION NEVER use damaged or faulty cylinders.
The walls and flooring surrounding the welding
environment must be shielded using non-flammable materials. This CYLINDER RELOCATION
not only reduces the risk of fire but also avoids damage to the wal-
ls and floors during welding processes. NEVER lift a gas cylinder by holding the regulator.

GAS CYLINDERS
EXTINGUISHER Do not expose gas cylinders to excessive heat sour-
Place an approved and appropriately-sized fire extinguisher in ces, sparks, hot slag or flames.
the work environment.
Check its working order regularly (carry out scheduled inspections)
and ensure that all parties involved know how to use one. GAS HOSE 1
Check the gas hose is not damaged.
CLEAN ENVIRONMENT
Remove all flammable materials away from GAS HOSE 2
Always keep the gas hose well away from the work
the work environment. area.
SERIOUS DANGER ! 1 ELECTRIC SHOCK
NEVER weld in confined spaces (e.g. in a con- Together with the previous instructions, the following pre-
tainer vehicle, a cistern or a storeroom etc.) where toxic, inflamma-
ble or explosive materials are, or have been, located or stored. cautions should be strictly observed to reduce the risk of
Cisterns, in particular, may still contain toxic, flammable or explosi-
ve gases and vapours years after they have been emptied. electric shock
SERIOUS DANGER ! 2 ELECTRIC SHOCK INJURY
NEVER weld a cistern that contains (or has stored) DO NOT touch a person suffering from electric shock if
toxic, inflammable or explosive materials. They could
still contain toxic, flammable or explosive gases and vapours years he/she is still in contact with the cables. Switch the mains power
after they have been emptied. If you are obliged to weld a cistern, source off immediately THEN provide assistance.
ALWAYS passivate it by filling it with sand or a similar inert sub-
stance before starting any work. CABLE CONTACT
Do not tamper with power cables if the mains power is still
switched on. Do not touch the welding circuitry. Welding cir-
SERIOUS DANGER! 3 cuitry is usually low voltage, however, as a precaution, do not tou-
NEVER use the Welder to melt frozen water ch the welder electrodes.
pipes.
CABLE AND PLUG PRECAUTIONS
VENTILATION Check the power supply cable, plug and wall-socket regularly.
Together with the previous instructions, the following pre- This is particularly important if the equipment is relocated often.
cautions should be strictly observed REPAIRS
Never attempt to repair the Welder yourself. The result would
WELDING ENVIRONMENT VENTILATION not only cause warranty cancellation but also high danger risks.
Ventilate the welding environment carefully. Maintain
sufficient air-flow to avoid toxic or explosive gas accumulation. MAINTENANCE PRECAUTIONS
Welding processes on certain kinds or combinations of metals can Always check that the electric power supply has been discon-
generate toxic fumes. In the event of this happening, use air-sup- nected before performing any of the maintenance opera-
ply respirators. BEFORE welding, read and understand the wel- tions listed in this manual ( e.g. before replacing any of the fol-
ding alloy safety provisions. lowing: worn electrodes, welding wires, the wire feeder etc.)

Never point the welding gun or the electrode towards yourself

PROTECTIVE WELDING GASES or others.
Together with the previous instructions, the following
ELECTROMAGNETIC COMPATIBILITY
precautions should be strictly observed when welding
with protective gases Check no power supply cables, telephone cables or other
electrical items (e.g. computer cables, control lines etc.) are
in the vicinity of the Welder.
GAS TYPES
These welders use only inert (non-flammable) gases for welding Check there are no telephones, televisions, computers or other
arc protection. It is important that the appropriate type of gas is transmission devices close to the Welder.
chosen for the type of welding being performed.
Make sure that people with pace-makers are not in the imme-
UNIDENTIFIED GAS CYLINDERS diate vicinity of the Welder.
NEVER use unidentified gas cylinders.
Do not use the Welder in hospitals or medical environments
PRESSURE REGULATOR 1 (including veterinary surgeries). Make especially sure there
NEVER connect the cylinder directly to the Welder. is no electrical medical equipment being used close to whe-
Always use a pressure regulator. re welding is being done.

PRESSURE REGULATOR 2
Check the regulator is performing its function properly. Should the Welder interfere with other apparatus, take the fol-
Read the regulator instructions carefully. lowing precautionary measures:
1. Check the Welder’s side panels are securely fastened.
PRESSURE REGULATOR 3 2. Shorten the power supply cables.
Never lubricate any part of the regulator.
Place EMC filters between the Welder and the power source. (Con-
tact Fimer Technical Dept. in this respect )
PRESSURE REGULATOR 4
All regulators are designed for a specific type of gas.
Check the regulator is appropriate for the protective EMC compatibility : CISPR 11, Group 21, Class A.
gas to be used.

4
 7. GAS CYLINDER AND GAS PRESSURE 8. WELDING METHODS
REGULATOR CONNECTIONS
Only for MIG welding: Skip this charter 8.1 Manual MIG welding
entirely if the welder is to be used for MMA To select this mode, turn knob 7 (Fig.1) to the
MIG MAN setting.
N.B.: These are guidelines only and are to be con-
6
sidered applicable solely to workpieces no thicker
than 4mm. The settings are selected according to
1 wire diameter, location and welding gas.
5
1
2 Step 1: Current selection
2
3
Convert the thickness of the
5 workpiece in to Amperes (A)
using the following formula:
0.025mm = 1A
3
i.e. 3mm = 125A

Step 2: Wire diameter selection

AMPERE (Min-Max) WIRE DIAMETER
4
40-90 A 0,6mm
Fig.6 60-140A 0,8mm
Carefully follow the procedure shown 80-160A 1mm
in Fig. 6: 100-200A 1,2mm
Connect the pressure regulator (2) to the gas
Step 3: Wire diameter selection
cylinder (3). Tighten the bolt (6) between the reg-
ulator (2) and the cylinder (3). Do not overtighten wire diameter
recommended
wire speed
to avoid damaging the cylinder valve (1). wire speed
Connect the gas hose of the torch (4) to the 0,6mm 1 amp ( 90mm/min) 90x120=11m/min
pressare regulator (2) and clamp securely 0,8mm 1 amp ( 50mm/min) 50x120=6m/min
using a clasp (5). (Alternatively use cylinder 1mm 1 amp ( 40mm/min) 40x120=5m/min
and hose fast connectors). 1,2mm 1 amp ( 30mm/min) 30x120=3,5m/min
Connect the other end of the gas hose (6) to the
socket on the rear panel of the welder unit Step 4: Electronic inductance selection
(Fig.2 – 23), securing it with a clasp. Material Electronic inductance setting
Connect the gas hose from the torch to the Ferrous materials (SG2 SG3) min <~> med
appropriate socket (7) on the front panel of the Stainless steel (NI-Cr) med
unit (fig 1 - 33), tightening clockwise. Do not Aluminium (Al) med <~> max
over-tighten. Copper-silicon (Cu-SI3) med <~> max
Open the gas cylinder valve (1). Press the torch Copper-aluminium (CU-Al8) med <~> max
button and check that gas is flowing through
correctly. Fig 7: Current reference values, wire diameter,
WARNING: Cylinders contain high pressure wire speed and electronic inductance.
gas. Handle them with care. Inappropriate
treatment can cause serious accidents. Do not Proceed as follows for manual MIG welding:
pile gas cylinders up and never expose them to 1. Set the welding current, according to the
excessive heat, flames or sparks. Do not bang thickness of the workpiece and the diameter of
cylinders against each other. Contact your sup- the wire to be used, using the knob 10, Figure 1
plier for more information regarding the use and (Step 1, Fig8). The display panel (Fig. 1 – 1)
maintenance of gas cylinders. shows the value selected.
WARNING: Never use cylinders that are dam- 2. According to the diameter of the wire, set
aged or show signs of oil or grease leakage. the wire speed using knob 9 of Figure 1.
Contact your supplier immediately of any such (Step 3, Fig.8)
circumstances. 3. According to the kind of material, regulate the
electronic inductance (Fig. 1 – 8). (Step 4, Fig8)

11
4. Connect the earth clamp to the workpiece. the SYNERGIC settings.
5. Start to weld maintaining an arc length of
between 5 to 10 mm. Proceed as follows for synergic MIG welding:
6. Regulate the wire speed (Knob Fig. 1 – 1. Select one of the following programmes
9).For best results regulate the speed (Knob 9) according to the type of material to be welded
until a loud, regular sizzling sound is heard (sim- (Selector knob 7, Fig1)
ilar to that of frying bacon). Always perform a • Al-Mg 0.8: The permissible thickness range
trial run using a metal sheet that is free of is 0.8 to 4 mm.
grease, rust or paint. • Al-Mg 5 1.0: The permissible thickness
For best results heed the following advice: range is 0.9 mm to 5 mm.
1. Keep the torch at a 45° angle to the work- • Al-Si 12 1.0: The permissibile thickness
piece. Keep the gas nozzle (Fig.4A) app. 6 mm range is 0.8mm to 5 mm (Spool Gun welding is
away from the workpiece. recommended for this type of wire).
2. Move the torch smoothly.
3. Weld using small zigzag movements so as to be • ideal for welding stainless steel (Ni-Cr)
able to regulate the size of the weld as desired. 0.8mm in diameter. The permissible thickness
4. Do not weld in windy surroundings. Draughts range is 0.8 mm to 5 mm.
can disperse the gas from the welding pool • ideal for welding SG2 or SG3 materials
causing porous welding results. 0.8mm in diameter. The permissible thickness
5. Ensure the wire is clean: never use rusty range is 0.8 mm to 3.2 mm.
welding wire. • Cu-Si 3 0.8: Ideal for Cu-Si3 having a diam-
6. Keep the torch cable straight. eter of 0.8 mm. Such materials can be braze
7. Clean the wire-feed guide with compressed welded, particularly zinc-plates iron sheets to be
air when changing spools.
used by car manufacturers The permissible
8. Remove dust from the air intake grills regu-
larly, using low-pressure compressed air. Always thickness range is 0.8 to 4 mm.
point the jet of air outwards to avoid dirt being 2. Select the workpiece thickness using Knob
forced into the unit. 2 of Figure 10. The display panel (Fig. 1 – 1) will
display the selected thickness parameter (in
Pulsed mode: mm) for a few seconds.
Pressing button 12 of Fig.1 will set the unit in man- 3. Turn knobs 8 and 9 to a mid-way position.
ual pulsed MIG welding mode. LED 6 of Figure 1 4. Connect the earth clamp to the workpiece.
will be on. This mode is for experienced operators
5. Start to weld maintaining an arc length of
only. In fact it is mainly used as an alternative to syn-
ergic pulsed MIG welding under rare circum- between 5 to 10 mm.
stances, e.g. for special materials and when satis-
factory results cannot be achieved using the prede- A high-quality result is usually achieved in this
fined settings. In this mode the potentiometer knob mode. However, the following instructions may help
(Fig. 1 – 10) regulates the welding current, knob 9 you achieve even better results depending upon
(Fig.1) sets the wire speed and knob 8 (Fig.1) regu- whether Short-Arc or Pulsed mode is being used.
lates the pulsing frequency.

8.2 SYNERGIC MIG WELDING Short-Arc Mode:

In synergic MIG welding (with gas) mode the 6- If during welding the arc tends to decrease
welder tunes itself automatically to suit the type excessively, turn knob 9 of Figure fig1 anti clockwise
of material to be welded and the thickness of the to reduce the wire speed, which will also decrease
workpiece. Contrary to manual mode, a series of the weld pool. If, on the other hand, the arc tends to
predefined programmes to suit all requirements over-lengthen, turn the knob clockwise.
are available. 7. If there is too much splatter while welding,
It should be noted, however, that certain param- the electronic
eters can be set manually. More information in
inductance parameter needs to be increased. Do so
this respect will be provided in later sections. A
choice of Short-Arc (Fig. 1, LED 6 off) or Pulsed turning knob 8 of Figure 1 clockwise. If maintaining
(Fig. 1, LED 6 on) synergic MIG welding is avail- an arc is difficult, turn the knob anti-clockwise.
able. Press the Pulsed mode:
Pulse button (Fig.1 – 12) lightly to switch mode. 8. To vary the length of the arc fine-tune
To select this mode, turn knob 7 (Fig.1) to one of knob 9 of Figure 1.

12
 8.3 MMA WELDING 8.3.3 MMA Welding

8.3.1 Description Diameter (mm) Current (A)

Electric MMA (Metal Manual Arc) and
SMAW (Shielded Metal Arc Welding) are 1.6 35-50
both manual procedures exploiting the heat 2.0 40-70
generated by an electric arc that is pro-
2.5 60-100
duced when covered welding electrodes
make contact with the workpiece. It is com- 3.25 80-140
monly used due to its versatility. In fact, 4.0 120-170
welding jobs can be performed anywhere:
in a workshop, in the open, in confined 5.0 180-250
spaces or hard to reach areas. A wide
range of electrodes are available, suiting Fig 8 Welding current at the electrode
all requirements. The arc is generated diameter.
touching the electrode to the workpiece.
The potentiometer knob (Fig. 1 –10) regu- Proceed as follows for MMA welding:
lates the welding current (thicker work- 1. Using knob 10 (Fig.1) select the welding
pieces require higher current settings). current according to the type of electrode
and the thickness of the workpiece. The
welding current value is shown on display
8.3.2 MMA Welding Features panel 13. The knobs 8 and 9 (fig.1) are dis-
While welding the following features come abled. Guidance values suitable for vari-
into effect: ous electrode diameters are provided in
Fig 9.
Arc Force: Whenever the arc tends to drop 2. Connect the earth clamp to the work-
the microprocessor automatically increases piece.
the welding current in order to maintain and 3. Place the electrode in the clamp.
stabilise the arc. 4. During the entire welding process main-
tain a 3-4mm distance from the welding
Hot Start: The arc is generated touching pool that has been created. Weld using
the electrode to the workpiece. To ensure small zigzag movements so as to be able
the arc is generated efficiently, the micro- to regulate the size of the weld as desired.
processor increases the welding current for 5. Remove the electrode from the work-
app. one second, guaranteeing fast, safe piece to stop welding.
arc generation.

Antisticking: Decreases the welding cur- WARNING: When “Basic” electrodes are
rent up to minimum, when the operator being used, remove any residue left on the
makes a mistake causing the electrode to electrode before welding. To do that, gen-
stick to the workpiece. The electrode can tly tap the electrode on a metallic surface.
be removed from its clamp without causing (If residue is left on an arc cannot be gen-
damaging sparks. erated).

14
9. WIRE LINER REPLACEMENT 10. DEFAULT PARAMETER ADJUSTMENT
In case of wire liner replacement please fol- The information contained in this paragraph is
low carefully this instructions. not essential for normal use of the welder and
the operations described herein should, in fact,
• Gun side: remove the gas nozzle (A). only be carried out by experienced welders.
For instance, the default wire speed controlled
• Unscrew the wire liner tip (B). by the synergic programmes (P.CV) can be
adjusted, as can the measurement units (P.PU)
used to specify the workpiece thickness. None
of the other default parameters (P.PR e P.PO)
should ever be adjusted.
The default P.CV value is 140 but is adjustable
A B within a range of 0 to 250. When the P.PU is set
• Connector side (C): unscrew the terminal to 0, the units displayed are in mm. When it is
set to 1, the units are expressed in inches.
nut (D, E) and grab the end of wire liner
using a pliers and start to extract the wire To access the programming menu, press button
liner (F). 12 (Fig.1) for at least 8 seconds or until “P.CV”
(wire speed setting) is displayed. To change the
speed, press the same button again. The cur-
rent value will be displayed. Button 13 (Fig.1)
(Wire Load) increases the speed.
Button 11 (Fig.1) (ON/OFF Spool) decreases
the speed. Button 12 (Fig.1) (MIG Pulse) con-
firms the selection and the programme returns
C D to the initial “P.CV” position.
• Complete the extraction of the wire liner (G) To change settings controlling how the measur-
ment units are expressed, press button 13
(Fig.1, Wire Load) until “P.PU” is displayed
Buttons 13 and 11 alternate between mm and
inches.
Button 12 (Fig.1. MIG Pulse) confirms the
E F selection and the programme returns to the ini-
tial “P.PU” position.
• Insert the new liner and push up to end To exit the programming menu, scroll down the
(H). menu list using buttons 13 and 11 (Fig.1) until
• Now rescrew the liner tip (B) on the gun. “End” is displayed. Press button 12 (Fig.1) to
confirm.

G H

• Complete the liner substitution rescrewing

the covering nozzle (A).

Figure 9: wire liner replacement

15
 11. TROUBLE SHOOTING
The most common problems and their solutions are listed below:

DEFECT CAUSE SOLUTION

Welder does not start. 1) Make sure that there is voltage in 1) Switch-on the supply mains
the supply mains
The wire does not feed 1) Dirt on the tip of the wire-feeder 1) Blow with compressed air, replace nozzle
when the wire-feeder rol-
ler rotates

2) Excessive spool torque. 2) Loose

3) Faulty torch. 3) Check wire-feeder liner.

Jerky or intermittent wire- 1) Faulty gas nozzle. 2) Replace

feed.
2) Scorched gas nozzle. 2) Replace

3) Dirt in wire-feeder roller groove. 3) Clean

4) Worn wire-feeder roller groove 2) Replace

Arc cut-out 1) Loose earth clamp grip. 1) Tighten clamp grip

2) Short circuit between contact nozz- 2) Clean or replace contact nozzle and
le and gas hose. wire-feed nozzle
Welder cuts out after pro- 1) Unit overheated and thermal protec- 1) Leave the unit to cool down for at least
longed use tion device has set in 1-20 minutes.

Porous welds 1) Lack of shielding gas caused by 1) Clean away build-up

build-up in gas nozzle
2) Incorrect torch angle 2) The air gap between the torch and the
workpiece must be 5-10 mm. Ensure 60° torch
angle.
3) Gas shortage 3) Increase gas flow

4) Damp workpieces 4) Dry workpieces with hot-air gun or such-

like
5) Welding Arc too long 5) Shorten the arc

Hot cracks 1) Damp workpieces 1) Clean

2) Welding with very high heat supply 2) Decrease the welding current

3) Impure welding wire 3) Change the welding wire

4) Base material with high content of

carbon, sulphur and other imputities

Insufficient penetration 1) current too low 1) increase the current

2) Inconstant wire feeding 2) See the above paragraph

3) Edges too apart from each other

4) Bevel too small

Insufficient melting 1) Abrupt movements of the torch 1) Move the torch smoothly.

2) Non-optimized inductance value 2) Change the inductance value.

3) Oxidized workpieces 3) Clean

Lateral indentations 1) Excessive welding speed 1) Decrease the welding speed

Breakages 1) Unsuitable wire 1) Change the type of wire

2) Bad quality of the workpieces

Excessive splashes 1) current too high 1) Decrease the current value

2) Non-optimized inductance value 2) Increase the inductance value

3) torch too inclined 3) Straighten the torch

16
12. BLOCK DIAGRAM

1. Input Switch
2. Control and power card 5. FAN
3. Solenoid Valve 6. Display panel
4. Wire-feeder motor 7. Current sensor (installed on block 2)

17
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 Per RAEE s’intendono i rifiuti di Apparecchiature Elettriche ed Elettroniche (AEE) incluse di tutti i componenti,i sottoinsiemi
ed i materiali di consumo che sono parte integrante del prodotto nel momento in cui si assume la decisione di disfarsene.
La Legislazione prevede la suddivisione in 2 categorie principali chiamate RAEE PROFESSIONALI o RAEE DOMESTICI.

Per RAEE PROFESSIONALI s’intendono tutti i rifiuti di apparecchiature elettriche ed elettroniche destinate ad uso pret-
tamente industriale.
ITALIANO

ITALIANO
Per RAEE DOMESTICO s’intendono tutti i generatori ad alimentazione monofase con corrente di uscita MAX <= 200A
con i loro accessori.

Per lo smaltimento di un RAEE DOMESTICO si avranno 2 possibilita’:

a)Nel caso si decidesse di comprare una nuova apparecchiatura equivalente l’utilizzatore potrà consegnarlo al distribu-
tore il quale dovrà ritirarlo gratuitamente.
b)Dovrà depositarlo nella piazzola Comunale, nel contenitore o apposita area identificata come “RAGGRUPPAMENTO 4”.
Per lo smaltimento di un RAEE PROFESSIONALE alla data di redazione del Manuale di istruzioni non essendo ancora
definitiva l’applicazione della Normativa si prega di contattare il distributore e/o Il costruttore per informazioni in merito allo
smaltimento.
ALLA DATA DELLA REDAZIONE DEL PRESENTE MANUALE D’ISTRUZIONI QUESTE INFORMAZIONI SONO DA
RITENERSI NON DEFINITIVE IN QUANTO SUSCETTIBILI DI POSSIBILI MODIFICHE SECONDO GLI OBBLIGHI
LEGATI AL DECRETO LEGISLATIVO N° 151/2005 CHE OTTEMPERA LA DIRETTIVA 2002/96/CE.

This product contains electrical or electronic materials.

ENGLISH

The presence of these materials may, if not disposed of properly, have potential adverse affects

ENGLISH
on the environment. Presence of this label on the product means it must not be disposed of in
normal household waste and must be disposed of separately.

As a consumer you are responsible for ensuring that this product is disposed of properly. If your
supplier offers a disposal facility please use it or alternatively contact your local authority/coun-
cil to find out how to properly dispose of this product.

Nur für EU-Länder

DEUTSCH

DEUTSCH
Werfen Sie Elektrogeräte nicht in den Hausmüll

Gemäß Europäischer Richtlinie 2002/96/EG über Elektro- und Elektronik-Altgeräte und Umset-
zung in nationales Recht müssen verbrauchte Elektrowerkzeuge getrennt gesammelt und einer
umweltgerechten Wiederverwertung zugeführt werden.

Ne pas jeter les appareils électriques avec les déchets ordinaires!

No tirar nuncalos aparatos eléctricos junto con los residuos en general!
FRANÇAIS

Conformément à la Directive Européenne 2002/96/EC relative aux Déchets d’Équipements

ESPAÑOL

De conformidad a la Directiva Europea

(DEEE), 2002/96/EC relativa a los Residuos de Equipos Eléc-

FRANÇAIS
Électriques ou Électroniques et à sa transposition dans la législation nationale,
tricos o Electrònicos (RAEE) y al acuerdo de la legislaciòn nacional, los equipos
les appareils électriques doivent être collectés à part et être soumis à un recyclage eléctricos
deberàn
respectuexser de
recogidos y reciclados respetando el medioambiente.
l’environnement.

Como propietario
En tant del equipo,
que propriétaire dedeberà informar de
l’équipement, los devriez
vous sistemasvous
y lugares apropiados
informer para
sur les la reco-
systèmes
gida de los mismos.
de collecte approuvés auprès nos représentants locaux.

Aplicar estacette
Appliquer Directiva Europea
Directive protegeràaméliorera
Européenne el medioambiente y su salud!et la santé!
l’environnement

Ne pas nuncalos
No tirar jeter les appareils électriques
aparatos eléctricos avec
junto les
con losdéchets ordinaires!
residuos en general!
FRANÇAIS
ESPAÑOL

Conformément
De conformidadàalalaDirective
Directiva Européenne 2002/96/EC
Europea 2002/96/EC relative
relativa a losaux Déchets
Residuos ded’Équipements
Equipos Eléc-
ESPAÑOL

Électriques
tricos o Electrònicos (RAEE) y al acuerdo de la legislaciòn nacional, los equiposnationale,
ou Électroniques (DEEE), et à sa transposition dans la législation eléctricos
les appareils
deberàn électriques
ser recogidos doivent respetando
y reciclados être collectés à part et être soumis à un recyclage
el medioambiente.
respectuex de l’environnement.
Como propietario del equipo, deberà informar de los sistemas y lugares apropiados para la reco-
En
gidatant quemismos.
de los propriétaire de l’équipement, vous devriez vous informer sur les systèmes
de collecte approuvés auprès nos représentants locaux.
Aplicar esta Directiva Europea protegerà el medioambiente y su salud!
Appliquer cette Directive Européenne améliorera l’environnement et la santé!
AIS