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ELECTRICAL CONNECTIONS MUST BE MADE WITH THE
ENGINE-DRIVEN WELDER SWITCHED OFF COMPLETELY THE
ELECTRICAL CONNECTIONS MUST BE MADE ONLY AND
EXCLUSIVELY BY EXPERT OR SKILLED PERSONNEL.
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SETTING UP THE ENGINE-DRIVEN WELDER
Unpack the engine-driven welder and assemble the separate parts
contained in the package.
Assembling the clamp-return cable
Assembling the electrode-holder clamp-welding cable
HOW TO LIFT THE MACHINE
The machine should be lifted as shown in Fig. S. This holds for both
initial installation and for the entire life of the machine.
POSITIONING THE ENGINE-DRIVEN WELDER
Choose a position to install the engine-driven welder so that there are
no obstructions to the cooling air inlets and outlets; at the same time
make sure there is no intake of conductive powders, corrosive
vapours, humidity etc.
Keep at least 1m free space all around the engine-driven welder.
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WARNING! Position the engine-driven welder on a flat
surface that will support its weight so that it cannot tipp or shift
dangerously.
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EARTHING THE MACHINE
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To prevent electric shock from faulty user apparatus the
machine must be connected to a fixed earth installation using the
terminal supplied for this purpose.
ELECTRICAL CONNECTIONS MUST BE CARRIED OUT ONLY
AND EXCLUSIVELY BY EXPERT OR SKILLED PERSONNEL.
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ENGINE
MODEL with I max = 160A
2
As regards:
- checks before use;
- starting the engine;
- using the engine;
- stopping the engine;
refer to the USER'S HANDBOOK supplied by the engine
manufacturer.
Note: For a correct operation of the engine-driven welder, turn the
lever of the accelerator to the right.
Otherwise, the yellow led (Fig. C-9) on the control panel (Fig. C) may
turn on.
MODEL with I max = 200A
2
As regards:
- checks before use;
- starting the engine;
- using the engine;
- stopping the engine;
refer to the USER'S HANDBOOK supplied by the engine
manufacturer.
Furthermore:
Electrical connections
- Connect the negative terminal of the batteries (Fig. G).
Electrical start
- Check that the lever of the electrovalve is positioned downwards
(Fig H).
- The accelerator lever is at 50% (Fig. I).
- Fit the key into the motor starting panel (Fig. L).
- Rotate the key clockwise by one step. Check that the red leds 2 and
3 turn on (Fig. L).
- Rotate the key by a further step. Once the starting is done, release
the key. Check that the green led 1 turns on and leds 2 and 3 turn off
(Fig. L).
- After a few minutes, rotate the accelerator lever to the MAX (Fig. I).
WARNING: operate the starting motor for not more that 20
consecutive seconds. If the motor does not start wait for a further
minute before repeating the starting operation.
Shutoff
- Before shutoff, rotate the accelerator lever to the MIN for a few
minutes.
- Rotate the key by one step anti-clockwise.
Starting by recoil
- Position the electrovalve lever upwards (Fig H).
- Accelerator lever to 50% (Fig. I).
- Hold the handgrip of the starting cord.
Fig. D
Fig. E
Fig. F
- Slowly pull the handgrip until a strong resistance is felt.
- Slowly follow the handgrip of the cord into the starting position .
- Pull the handgrip to the end with a definite and uniform movement.
- Slowly follow the starting cord handgrip into the initial position.
- After a few seconds rotate the accelerator lever to the MAX (Fig. I)
Shutoff (manual)
- Before shutoff, rotate the accelerator lever to the MIN for a few
seconds.
- Push the STOP lever as in Fig. M.
CONNECTIONS FOR THE WELDING CIRCUIT
________________________________________________________________________________
WARNING!
BEFORE
CONNECTIONS MAKE SURE THE ENGINE-DRIVEN WELDER IS
SWITCHED OFF.
The table (TAB. 1) shows the recommended values for the welding
2
cables (in mm ) based on the maximum current supplied by the
engine-driven welder.
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Almost all coated electrodes should be connected to the positive
terminal (+) of the engine-driven welder; exceptionally, connection is
to the negative terminal (-) for acid coated electrodes.
Connecting the electrode-holder-clamp welding cable
On the terminal attach a special clamp to close the exposed part of the
electrode.
This cable should be connected to the terminal with the symbol (+)
Connecting the welding current return cable
On the terminal attach a clamp that should be connected to the piece
being welded or to the metal bench on which it is placed, as close as
possible to the join being made.
This cable should be connected to the terminal with the symbol (-)
Advice:
- Screw the welding cable connectors right into the quick connections,
to ensure a perfect electrical contact; otherwise an imperfect contact
will cause overheating in the connectors and they will quickly
become damaged and inefficient.
- The welding cables used should be as short as possible.
- Do not use metal structures that are not part of the piece being
welded, to replace the welding current return cable; this could be a
safety hazard and give an unsatisfactory result for the weld.
6. WELDING: DESCRIPTION OF THE PROCEDURE
- It is essential to follow the electrode manufacturer's instructions as
regards the correct polarity and optimal welding current (these
instructions are usually printed on the package containing the
electrodes).
- The welding current should be adjusted according to the diameter of
the electrode being used and the type of join to be made; indicatively,
the currents used for the different electrode diameters are:
ø Electrode (mm)
1,6
2
2,5
3,2
4,0
5,0
- Bear in mind that for the same electrode diameter high current
values will be used for horizontal welding, while lower values should
be used for vertical or overhead welding.
- As well as being determined by the chosen current intensity, the
mechanical properties of the welded join are also determined by
other welding parameters such as arc length, working speed and
position, electrode diameter and quality (to store the electrodes
correctly keep them in a dry place in their original package or in
suitable containers).
Procedure:
Position the selector to the correct position
- Keeping the mask IN FRONT OF THE FACE, scratch the tip of the
electrode along the piece to be welded as though you were striking a
match; this is the most correct way to strike the arc.
WARNING: DO NOT TAP the electrode on the piece; this could
damage the coating, making it difficult to strike the arc.
- As soon as the arc has struck, try to keep at a distance from the
piece equivalent to the diameter of the electrode in use and keep this
distance as constant as possible while carrying out the weld;
remember that the electrode should be inclined at about 20-30
degrees in the direction of progress (Fig. N).
- At the end of the weld seam take the electrode slightly backwards
with respect to the direction of progress, above the crater so that it is
filled, then lift the electrode quickly from the weld pool so that the arc
is extinguished.
APPEARANCE OF THE WELD SEAM
7. USING THE ENGINE-DRIVEN WELDER AS A DIRECT
CURRENT GENERATOR
- Make sure the machine is connected to an earth stake as described
- 5 -
MAKING
THE
FOLLOWING
Welding current (A)
min.
25
-
40
-
60
-
80
-
120
-
170
-
Fig. O
max.
50
80
110
160
200
250
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