Installation; Connection To The Electrical Supply; Gas Connection; Instructions For Use - CEA MAXI 405 Manual De Instrucciones

Installation

Select the location of the machine to ensure satisfactory and
reliable service. Before installing the welding set the user must
take into account possible electromagnetic problems of the
working area. In particular, we suggest installing the equip-
ment away from:
• Signalling, control and telephone cables.
• Radiotelevision transmitters and receivers.
• Computers or controlling and measuring instrument.
• Safety and protection devices.
The welder must not be rested on a slant of more than 10°.
These welding machines are cooled through air forced-circula-
tion. That is why they must be disposed to facilitate the suction
and the emission of air through the slots of the frame.
The welding unit is characterized by the following classes:
• IP 23 S protection class indicates that the generator can be
used in both interior and exterior environments.
• The "S" usage class indicates that the generator can be em-
ployed in environments with a high risk of electrical shocks.

Connection to the electrical supply

Connection of the machine to the user line (electrical cur-
rent) must be performed by qualified personnel.
All connections must be made in conformity with existing regu-
lations while fully respecting the accident-prevention laws (see
CEI 26-10 CENELEC HD 427 regulations).
Before connecting the welding equipment to the mains
supply check that the data on the machine plate corre-
spond to the supply voltage and frequency and that its
main switch is on the "O" position.
These welders can work at different voltages and are normal-
ly supplied to work at the highest voltage shown on the data
plate. Make sure this voltage corresponds to the mains; if not
remove the right hand side panel and connect up the red or blue
connector corresponding to the mains voltage, as described in
Fig. B. Connection to the mains supply must be carried out us-
ing a quadrupole wire supplied with the welder, of which:
• Three wires the supply.
• The fourth one, yellow-green, to earth.
Connect a suitable plug to the primary cable and fix to a
socket fitted with fuses or automatic switch; the proper
earth terminal must be connected to the earth connector
(yellow-green) of the main supply.
Model
Power input @ I Max
2
Delayed fuse (I @ 60%)
2
U1=220V-230V-240V
U1=380V-400V-415V
Duty cycle @ 35% (40°C)
Supply connection cable
Length
Section

Gas connection

The units are supplied with a pressure reducer complete with
pressure gauge for adjustment of the pressure of the gas used
in welding. The gas cylinders (optional) must be placed on the
rear cylinder-support platform of the welding machine and se-
cured with the chain supplied. They must be installed in a way
that does not interfere with the stability of the welding machine.
For connections between cylinder, reducer and gas tube, com-
ing from the interconnecting generator/wire feeder cable, pro-
ceed as follows:
• Connect the gas tube to the corresponding attachment on the
pressure reducer (if installed) or directly onto the gas cylinder.
• Open the gas cyclinder and regulate the flowmeter to about
8/12 l/min.
ATTENTION:
Table 2
MAXI 405 MAXI 505
kVA 19,0 24,2
A 35 40
A 20 25
A 400 500
m 4,5 4,5
mm 2 4 × 6 4 × 6
• Check that the gas used is compatible with the material to
be welded.
• There is a 48VAC preheating outlet (Pos. 8, Fig. C) on the
back panel of the generator for supplying the heat required
to avoid the "frosted" effect on the pressure reducer, when
using a great quantity of carbon dioxide for welding.

Instructions for use

COMMAND AND CONTROL UNITS (Fig. C)
Pos. 1 Fuse of auxiliary circuit.
Pos. 2 Digital ammeter + voltmeter (not supplied)
Pos. 3 Indicator light. When this light is on it means the weld-
er is powered and ready to work.
Pos. 4 Orange pilot light. When this light is on it means the
overheat cutoff has tripped as you are working out-
side the processing cycle. Wait for a few minutes be-
fore continuing to weld.
Pos. 5 Line switch / Scale switch. In position "O" the welder
is off.
Pos. 6 Snap-in connector for ground line. These welders of-
fer the possibility of selecting two inductance values
so as to modify the welding bath by altering the dy-
namic characteristics of the generator. The selection
is made in function of the welding current (pass from
position
rent).
Pos. 7 Change over switch with 10 positions for finely regu-
lating the weld voltage.
Pos. 8 48 Vac preheater plug.
Pos. 9
Snap-in connector for power supply cable of exten-
sion (+ pole).
Pos. 10 Connector (48Vac) for connection to the power sup-
ply cable of the entrainer.
Pos. 11 Opening to wire up the cooling system.

Connection for welding cables to welder

Connect the earth cable and extension as shown in figures C.
• Insert the ground cable in the snap-in connector (Pos. 6,
Fig. C).
• The generator-wirefeeder extension consists of a power ca-
ble, a wire for the auxiliary power supply and a gas pipe that
are coupled to the generator as follows:
- Insert the power cable in the snap-in connector (Pos. 9,
Fig. C).
- Insert the wire in its connector (Pos. 10, Fig. C).
When it is necessary to weld with direct polarity, invert the
connections of the power cable and ground cable. The use of
ground cables and excessively long extensions causes drops
in voltage and problems due to the greater resistance and in-
ductance of the cables that may cause welding defects. To pre-
vent these problems follow these rules:
• Use ground cables and extensions of suitable section.
• Straighten the cables as much as possible avoiding the for-
mation of loops.
Connection of extension
cable to wirefeeder
WF series (Fig. D)
The extension between the generator and wire feeder con-
sists of a power cable, a multipolar cable for auxiliary power
supply and a gas hose which are to be connected to the rear
of the wire feeder.
• The auxiliary cable must be fixed to the special connector
(Pos. 1, Fig. D).
• The gas tube must be connected to the quickfit connector
(Pos. 2, Fig. D).
• The power cable must be fixed to the quick-fit connector
(Pos. 3, Fig. D).
TR series (Fig. E)
The extension between the generator and wire feeder con-
sists of a power cable, a multipolar cable for auxiliary power
10
to on increasing the cur-