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An expert coordinator must use measuring instruments to
determine whether a risk exists and should take suitable
protective measures as indicated in section 5.9 of the "IEC
TECHNICAL SPECIFICATION or CLC/TS 62081".
RESIDUAL RISKS
- IMPROPER USE: it is dangerous to use the engine-driven
welder for any work other than that for which it is intended (e.g.
defrosting frozen water pipes).
- Never lift the machine without first disconnecting and
removing all interconnection and power supply cables and
piping.
The only permitted way to lift the machine is that described in
the "INSTALLATION" section of this handbook.
- It is forbidden to drag the engine-driven machine on streets.
2. INTRODUCTION AND GENERAL DESCRIPTION
This engine-driven welder is a power source for arc welding, built
specifically for direct current (DC) MMA welding.
The properties of this (INVERTER) adjustment system, such as high-
speed precise adjustment, mean that the engine-driven welder
produces excellent quality welds with coated electrodes (rutile, acid,
basic, cellulose).
The machine also has an auxiliary outlet for a direct current power
supply to tools with universal motors (brushes) such as angle
grinders and drills.
OPTIONAL ACCESSORIES:
- MMA welding kit.
- TIG welding kit.
- Argon bottle adapter.
- Pressure reduction valve.
- TIG torch.
- Wheels kit (Standard for the model with I max=200A).
- AC power supply kit (only model with I max = 160A, I max = 200A).
3. TECHNICAL DATA
RATING PLATE
The most important information regarding use and performance of the
engine-driven welder are summarised on the rating plate and have the
following meanings:
1- Symbol S: means that it is possible to carry out welding operations
in environments with a heightened risk of electric shock (e.g. close
to large metal objects).
2- Symbol for intended welding procedure.
3- Symbol indicating the internal structure of the welding machine.
4- Serial number identifying the welding machine (essential for
servicing and repairs, when ordering spare parts and identifying
the origin of the product).
5- EUROPEAN standard of reference for the construction and safety
of arc welding machines.
6- Performance of welding circuit:
- U : maximum no-load voltage.
0
- I /U : Normalised current and corresponding voltage that may be
2
2
supplied by the welding machine during welding.
- X : Duty cycle: indicates the time for which the welding machine is
able to supply the corresponding current (same column). It is
expressed as %, based on a cycle of 10 minutes (e.g. 60% = 6
minutes work, 4 minutes pause; and so on).
If the utilisation factors (referred to a surrounding temperature of
40°C) are exceeded, the thermal relay will trigger (the engine-
driven welder will go into standby mode until the temperature
returns within the accepted limits).
- A/V-A/V: Indicates the adjustment range of the welding current
(minimum-maximum) for the corresponding arc voltage.
7- Protection rating of case.
8- Symbol for engine.
9- Specifications for engine:
- n: Rated load speed.
- n : Rated idling speed.
0
- P
: Maximum power of engine
1max
10-Auxiliary power outlet:
- Symbol for direct current.
- Rated output voltage.
- Rated output current.
- Duty cycle.
11-Size of delayed action fuse to be used to protect the auxiliary
outlet.
12-Symbols referring to safety standards, the meanings of which are
given in section 1 "General safety rules".
13-Guaranteed sound power level for the engine-driven welder.
Note: The rating plate shown is just an example to show the meanings
of the symbols and figures; the exact technical specifications for your
welding machine should be read directly from the rating plate on the
engine-driven welder itself
OTHER TECHNICAL DATA:
- ENGINE-DRIVEN WELDER: see table 1 (TAB.1)
- ELECTRODE-HOLDER CLAMP: see table 2 (TAB.2)
- AC POWER SUPPLY KIT: see table 3 (TAB.3).
The weight of the engine-driven welder is shown in table 1
2
2
2
Fig. A
(TAB.1)
4. DESCRIPTION OF THE ENGINE-DRIVEN WELDER
The engine-driven welder consists of an engine that drives a
permanent magnet high frequency alternator which is used to supply
power to a power module from which the welding current and auxiliary
current are taken.
1- Engine.
2- High frequency alternator.
3- Rectifier.
4- Direct current auxiliary power outlet.
5- Input for 3-phase generator, rectifier unit and levelling capacitors.
6- Transistor switching bridge (IGBT's) and drivers; commutes the
rectified voltage into high frequency alternating voltage and
adjusts the power according to the required welding
current/voltage.
7- High frequency transformer: the primary winding is powered with
the voltage converted by block 6; its function is to adapt the voltage
and current to the values needed for the arc welding procedure and
at the same time to form galvanic isolation of the welding circuit
from the power supply line
8- Secondary rectifier bridge with levelling inductance: commutes the
alternating voltage/current supplied by the secondary winding to
very low ripple direct voltage/current.
9- Control and adjustment electronics: for instantaneous monitoring
of transitory welding current values and comparison with setting
made by the operator; modulates the control impulses from the
IGBT drivers used for adjustments.
Determines the dynamic response of the current while the
electrode is melting (instantaneous short circuits) and supervises
the safety systems.
CONTROL AND ADJUSTMENT DEVICES AND CONNECTION TO
THE ENGINE-DRIVEN WELDER
1- Auxiliary power outlet 230V DC (direct current).
2- Auxiliary outlet fuse.
3- GREEN LED: when lit this indicates operation in direct current
generator mode.
4- GREEN LED: when lit this indicates operation in alternating
current (AC) generator mode. The AC power supply kit is supplied
as an optional accessory.
5- GREEN LED: when lit indicates operation in welding machine
mode.
6- Selector switch for DIRECT CURRENT GENERATOR
GENERATOR WELDING MACHINE. Used to select the desired
operating mode:
Direct current generator;
Alternating current generator;
Welding machine.
7- RED LED: normally off, when on indicates overheating in the
alternator which shuts down both the welding current and the
auxiliary current. The machine remains switched on but does not
supply any current until a normal temperature is reached. Reset is
automatic.
8- Welding current adjustment potentiometer with graduated scale in
Amps.; used for adjustment, also while welding.
9 - YELLOW LED: normally off, when on it indicates a fault that has
shut down the welding current due to triggering of the following
safeguards:
- Thermal relay: the temperature inside the engine-driven welder
is too high. The machine stays on but does not supply any
current until a normal temperature is reached. Reset is
automatic.
- ANTI STICK safeguard: automatically shuts down the welding
current if the electrode sticks to the material being welded, so
that it can be removed manually without ruining the electrode-
holder clamp.
- Engine overspeed safeguard: shuts down the welding current
supply until the engine speed returns to the rated values.
10- Function selector potentiometer and arc-force adjustment:
(
TIG welding). In this position the potentiometer enables TIG
welding with scratch strike. HOT START and ARC-FORCE are
disabled.
(
MMA welding). Positioning the potentiometer between 0
and 100% gives an easy start (HOT START) and it is possibile to
adjust the ARC-FORCE for all types of electrodes. At very low
values an optimal welding dynamic is obtained for "soft"
electrodes (e.g. rutile, stainless steel), at high values an optimal
welding dynamic is obtained for "hard" electrodes (e.g. acid, basic,
cellulose).
11- Positive quick connection (+) for connecting the welding cable.
12- Negative quick connection (-) for connecting the welding cable.
13- Terminal for earth connection.
5. INSTALLATION
________________________________________________________________________________
WARNING!
ALL
- 4 -
Fig. B
Fig. C
INSTALLATION
OPERATIONS
AC
AND
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