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USER MANUAL TM 236 PULSE SYNERGIC/GEN

1. vraies B NecTHO HATODI M ra ESPANOL ENGLISH ITALIANO DEUTSCH FRANCAIS 43 of 44
2. 30 3 2 CONNECTION FOR TIG WELDING seed e petuo i See denen eode ee oda e eie 31 5 4 CONNECTION FOR WELDING dietis ER YES oU SEN CIE dietus 3l O INSTALLATION OF THE WELDING WIRE 1122 2 a E 22 7 CONNECTION OF THE GAS CYLINDER AND REGULATOR rnm 33 5 WEEDING PROCESSES tutus a ese a dete ost ats tease dod bout ob 35 SEL Manua MIG SV e sot iier ott peo aoe t sette A 35 oy merece EES dort ae 36 WELDING 37 S4 TIO WECDING M 38 9 REPLACEMENT OF SHEATH INSIDE THE TORCH CABLE 39 LOZREVMOTE CONNECTION SR SARS OAS 40 11 1 MIG WELDING WITH STANDARD TORCH eene eene 40 11 2 MIG WELDING WITH SPOOL OR PUSH PULL TORCH mmm 40 IEF Ho WELDING cena tini ena um as 40 EE S PEE SIBI 40 HIROUBLESHOOTING carice iesu hina cee eee Riles dearth Goll acco DG 41 I2 BEOCK DIAGRAM ase tu toad Ras 42 13 MEMORISATION OF THE WORKING POINT Sa ta enr Soa cR rends 42 910 100 335GB REVOI 3 of 44 DECLARATION OF CONFORMITY Uffici Via Brigatti 59 20050 Ronco Briantino Ml Italy Tel 39 039 6079326 Fax 39 039 6079334 website www fimer com YOUR BRAND YOU
3. 23 2 0 560 480 IP 215 1000 10 40 20 55 40 EN 60974 1 EN 60974 10 Group 2 Class A Built in thermostat INPUT ELECTRICAL DATA Line voltage No of phases Frequency Hz Effective line current A Maximum line current A Input power kVA Power supply protections OUTPUT DATA Static Characteristics Wire diameter First welding method Welding range No load voltage V Output currents and voltages Duty I2 A U2 V Second welding method Welding range No load voltage V Output currents and voltages Duty I2 A U2 V Third welding method Welding range No load voltage V Duty I2 A U2 V 910 100 335GB REVOI 230 1 50 60 21 6 40 3 5 Delayed 25A fuses or Co K Curve 25A magneto thermal switches Drop 0 6 0 8 1 0 1 2 MIG MAG from 15A 14 75V to 235A 25 75V 55 35 60 100 220 160 130 25 22 20 5 TIG from 15A 10 6V to 235A 19 4V 55 35 60 100 220 160 130 18 8 16 4 15 2 MMA from 15A 10 6V to 185A 17 4V 55 35 60 100 185 138 109 27 4 25 52 24 36 6 of 44 IMPORTANT INSTRUCTIONS DANGER Indicating a hazard that could cause injury or damage AN A ELECTRIC SHOCK Indicating the danger of electric shock DANGER OF FIRE OR EXPLOSION Indicating that eye protection is required to avoid burns and eye damage gt A TOXIC GAS Indicating the risk of toxic gas hazards HOT SLAG Indicat
4. ge from arc rays Pay particular attention to the fact that even bystanders should be aware of and understand the dangers exi sting in the welding area Wear a protective mask and make sure bystan ders do the same 4 A Fumes toxic gases and vapours can be harmful Read p understand and observe all safety warnings to avoid ham from toxic welding gases Pay particular attention to the fact that even bystanders should be aware of and understand the dangers 4 A Carelessness while using or maintaining the compres sed gas cylinders or regulators can injure or kill the operator and or bystanders Read understand and observe all safety warnings to avoid the dangers of compressed gas Pay particular attention to the fact that even bystanders should be aware of and understand the dangers HIGH VOLTAGE The unit carries potentially lethal voltage 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 All maintenance or repair operations requiring access to such areas may only be performed by Fimer trained technicians FOREIGN OBJECTS A A Never block the air vents with foreign objects and avoid any contact with liquids Clean using just a dry cloth The e safety precautions apply even when the unit is switched off A The upper part of the Welder was not designed to with stand heavy loads Never stand on the unit A AN A Check that al
5. stroke mode final 1 setting of the final value of the current after the current downslope t of the torch button only active in 4 stroke mode 910 100 335GB REVOI 25 of 44 downslope t setting of the time in which upon release of the torch button the current decreases by the set value until reaching the final value only in 4 stroke mode Water pump if ON the water pump is enabled if OFF the cooling water pump is disabled 3 2 2 PULSED TIG WELDING To access this operating method turn knob 10 to make the selection shown in the figure Select TIG procedure Lift arc Lift arc pul CHE ERO DIS Once the selection has been made the following welding screen opens Ready to weld gt 150 A 16 0 v 2M PU Pre gas LLELE ARGC POSE GAS P1 2 Menu 2 2 can be accessed by pressing knob 10 for 3 seconds and turning it back groune 1 inicial I final I current downslope Ee total period t pulse period t Water pump Timer Eur During welding knob 9 shown in figure 1 regulates the welding current whose value appears on the display the display also shows the relative arc voltage The other parameters shown in the figure can also be regulated via knob 10 2 4 strokes setting of the 2 stroke or 4 stroke operating mode 2t In the 2 stroke operating mode the torch button welds for the entire time it is pressed 4t In the 4 stroke operating mode the first pressin
6. this decrease allows removing the electrode from the holder without creating sparks which can damage the electrode holder 910 100 335GB REVOI 27 of 44 The correct connection of the electrode holder and the ground cable is shown in line 1 of figure 5 in this way the electrode holder is connected to the positive pole and the ground cable to the negative pole Always check the correct connection on the electrode packet and if necessary invert them 3 3 1 MANUAL MMA WELDING To access this operating mode turn knob 10 to make the selection shown in the figure Select MMA procedure Manual synergic CEA Tels Once the selection has been made the following welding screen opens Ready to weld gt 151 A 26 0 v Arc Force MMA HOUT STALT 9 Manual EOE SE ys WIGHT Knob 9 shown in figure 1 allows regulating the welding current thicker welding pieces require higher currents The other parameters shown in the figure can also be regulated via knob 10 Arc Force allows increasing the percentage of the current proportional to the set current that the welding machine can force in order to keep the arc well established Hot Start allows increasing the percentage of the welding current proportional to the set current that the welding machine can force once the arc has been established Hot start T allows setting the time in which the hot start current can be forced 910 100 335GB REVOI 28 of 44 3 3 2 SYNERGIC MMA WELD
7. 3 Pulsed manual 4 Pulsed Synergic Turn knob 10 to select one of the different MIG MAG welding methods press to confirm the selection Ses onerum C Short arc ma Short arc si Are Arc puls S wrc wac Mig mag 01 Mig mag 02 The MIG MAG 01 MIG MAG 02 etc welding methods can be saved by the user up to 32 different settings can be saved using button 4 of fig 1 3 1 1 MANUAL SHORT ARC MIG WELDING To access this operating mode turn knob 10 to make the selection shown in the figure Select MIG MAG procedure Short arc ma Short arc si Arc puls m operons Arc puls s Mig mag 01 Mig mag 02 Once the selection has been made this screen is displayed Ready to weld Inductance MIG MAG 2 4 strokes S A Me E172 910 100 335GB REVOI 16 of 44 Menu 2 2 can be accessed by pressing knob 10 for 3 seconds and turning tt Ore gas T post gas t downslope t burn back t Timer Water pump P2 2 During manual welding the welding current whose value is always shown on the display can be regulated via knob 9 shown in fig 1 the display also shows the relative arc voltage and wire speed To regulate the wire speed turn knob 10 to select the wire speed parameter press the knob to confirm the value selected turn the knob again to set the desired speed and press again to confirm The welding current and wire speed must be regulated according to the thickness of the piece to be wel
8. MAG TIG Cr Eos Arc welding with inert gas Argon and infusible tungsten electrode often shortened to TIG welding Tungsten Inert Gas is a welding procedure where the heat is produced by an arc that strikes against a non consumable electrode and the piece to be welded The welding is executed by melting the edges of the workpiece and inserting other materials coming from filler irons thus creating the join The arc is established by touching the workpiece with the electrode The TIG procedure is suitable for any type of working position and can be applied on very thin metal sheets TIG welding is characterised by its high level of arc control powerful and concentrated heat source and greater control of the quality of the filling material This makes the TIG procedure particularly suitable for precision welding on a wide range of thicknesses for welding in difficult positions and on pipes that require high welding penetration This procedure allows using a variety of different materials such as iron nickel alloy copper titanium magnesium etc However this type of welding is not suitable for aluminium During welding the potentiometer 11 in figure 1 regulates the welding current The correct connection of the torch and ground cable is shown in line 2 of figure 5 The machine does not include the TIG torch necessary for welding this can be purchased separately 910 100 335GB REVOI 24 of 44 3 2 1 TRADITIONAL TIG WELDING To
9. Manual MMA welding Power supply connection Power supply connection Output connections Output connections Connection for MIG welding with traditional torch and Connection for MMA welding gas Welding process Connection for MIG welding with Spool or Push pull Manual MMA welding torch and gas Installation of the welding wire Connection of the gas cylinder and regulator Welding process Synergic MIG welding with gas G Welding pulsed synergic ere MMA welding General features General features Description of the machine Description of the machine Description of the various types of welding 9 Description of the various types of welding MIG MAG welding 3 MMA Welding Synergic pulsed MIG welding 3 3 2 Synergic MMA welding Power supply connection 4 Power supply connection 5 5 8 8 3 amp ed eia Qua gt N o os WC Output connections Output connections Connection for MIG welding with traditional torch and Connection for MMA welding gas Welding process Connection for MIG welding with Spool or Push pull Synergic MMA welding torch and gas Installation of the welding wire Connection of the gas cylinder and regulator Welding process Synergic MIG welding with gas QUOI D Go 4 3 e Attention The machine can only be u
10. Too much spatter 1 Current too high 1 the current ororen too angled 2 Straighten the torch display no SD card The SD card was removed Insert the SD card display low water pressure fie ceca un 910 100 335GB REVOI 41 of 44 12 BLOCK DIAGRAM AC Input Input switch Input and control power board Power module Solenoid valve Wire feeder motor Display Auxiliary transformer Fans Current sensor mounted on block 2 O O N 13 MEMORISATION OF THE WORKING POINT As illustrated in the previous sections the welding machine allows significantly personalising the working point in both manual operation and synergic operation The best working point for a workpiece can be saved in the memory and quickly retrieved later Follow these instructions to save a new working point 1 Press the MEM key 4 in figure 1 2 urn knob 10 figure 1 to select the first letter of the name in which you want to save the working point 3 Press knob 10 to confirm the selection of the letter 4 Repeat steps 2 and 3 until the entire name has been spelled out 5 Confirm the name by pressing the OK key From this moment onwards the working point is Save with name ABCD Wire speed MIG MAG Iced i ES i Mec Ee memorised with its own name and is displayed together P272 with the other welding procedures Meaning of th
11. again to set the desired speed and press to confirm The other parameters shown in the figure can also be regulated via knob 10 back ground I setting of the base current i e the current that is maintained continually for the entire duration of the welding and that is increased during the pulse peak peak setting of the peak current i e the value that the welding current is increased during the pulse peak burn back I setting of the burn back current burn back t setting of the burn back time expressed as a percentage continuous i e limits the time that can be welded with the torch button pressed 2 4 strokes setting of the 2 stroke or 4 stroke operating mode 2t In the 2 stroke operating mode the torch button welds for the entire time it is pressed 910 100 335GB REVOI 20 of 44 4t In the 4 stroke operating mode the first pressing of the torch button starts the welding process and a second pressing stops the welding process The Crater Filler function is active in this mode when the torch button is pressed for the second time at the end of welding the current decreases from the set value until it reaches zero in a time set between zero and ten seconds by the current downslope t Menu 2 2 can be accessed by pressing knob 10 for 3 seconds and turning it pre gas t setting of the time in which upon the pressing of the torch button the gas flows without the arc being established post gas
12. all times All equipment connected to electric power supplies can be dan gerous if the manufacturers instructions are not read and obser ved Read understand and observe these safety instructions to reduce the risk of death or injury from electric shock Ensure that even bystanders are aware of and understand the dangers that exi st in the welding area Fires and explosions can senously injure or cause dama A A ge Read understand and observe all safety wamings to reduce the nsk of death or injury from fire or explo sion Pay particular attention to the fact that even bystanders should be aware of and understand the dangers existing in the welding area Remember that welding by nature produces sparks hot spatter mol ten metal drops hot slag and hot metal parts that can cause fires can bum skin and damage eyes 910 100 335GB REVOI WARNING SYMBOLS DANGER COMPRESSED GAS Indicating the risk of injury or death in the event of improper hand ling or maintenance of compressed gas cylinders or regulators FIRE PRECAUTIONS A A IMPORTANT INFORMATION Indicating the precautions to be taken when installing and DISPOSAL INFORMATION INSTALLATION INSTRUCTIONS OPERATING gt INSTRUCTIONS UNPACKING INSTRUCTIONS SUITABLE FOR USE IN HIGH VOLTAGE AREAS S Arc rays can damage your eyes and bum your skin Read A understand and observe all safety wamings to avoid dama
13. allowable is indicated in the Technical Specifications section of this manual and on the machine s nominal data label Check that the welding machine has been correctly connected to the ground terminal Also check that the plug supplied with the machine is compatible with the local mains power outlet Make sure there is sufficient power to run the machine The Technical Specifications section of this manual contains information on the type of power supply protection devices to use The machine comes with a special power cord 18 of Figure 2 which should not be extended If an extension cord is necessary use one that has the same or a larger cross section than the machine s power cord depending on the length of the cord Use a bipolar ground cord with a cross section equal to or greater than 2 5 mm 5 OUTPUT CONNECTIONS The welding cables are connected by means of a quick coupling system that uses special connectors 5 1 CONNECTION FOR MIG WELDING WITH TRADITIONAL TORCH 1 Connect the ground cable to the appropriate connector positioned on the front panel 12 of Fig 1 Align the key with the groove and insert tighten the connector by turning it in a clockwise direction until it stops Do not over tighten 2 Connect the torch to the connector positioned on the front panel 15 of fig 1 by turning it in a clockwise direction until it stops Do not over tighten Attention The machine comes with a standard MIG
14. at the end of welding the current decreases from the set value until it reaches zero in a time set between zero and ten seconds by the current downslope t Menu 2 2 can be accessed by pressing knob 10 for 3 seconds and turning it back ground I setting of the base current i e the current that is maintained continually for the entire duration of the welding process and which is increased during the pulse peak a variation of 20 can be made in relation to the value automatically set pre gas t setting of the time in which upon the pressing of the torch button the gas flows without the arc being established post gas t setting of the time in which upon release of the torch button the gas continues to flow after the arc has been turned off current downslope t setting of the time in which upon release of the torch button the current decreases by the set value until reaching zero only in 4 stroke mode burn back t setting of the burn back time expressed as a percentage Timer timer setting the timer sets the maximum time for continuous welding i e limits the time spent welding with the torch button pressed Water pump if ON the water pump is enabled if OFF the cooling water pump is disabled 910 100 335GB REVOI 23 of 44 3 2 TIG WELDING To select this welding method go to the selection menu if necessary press button 2 start Select TIG using knob 10 and press to confirm Ready to weld MMA MIG
15. display also shows At start up the Fimer logo and the Firmware revision are displayed 2 Command button Its meaning is reported in the first line of Part 2 of the display normally the pressing of this button returns to the main screen 3 Command button Its meaning is reported in the second line of Part 2 of the display normally the pressing of this button returns to the previous screen 4 Command button Its meaning is reported in the third line of Part 2 of the display when this button is pressed it memorises the current machine settings up to a maximum of 32 9 Command button Its meaning is reported in the fourth line of Part 2 of the display this button allows the gas to flow without the need to press the torch button 6 Wire feed button When active the wire MIG can be advanced T SD slot This slot covered by a special plastic cover must contain the SD Card supplied with the machine without this card the machine remains inactive and a special signal is reported on the display 8 USB port only for technical assistance 9 Knob for setting the main welding parameter the main welding parameter can be set with this knob MMA Welding sets the welding current TIG Welding sets the welding current Manual MIG welding sets the welding voltage Synergic MIG welding sets the thickness of the piece to be welded 910 100 335GB REVOI 13 of 44 10 Knob for setting the other welding parameters The remaining w
16. industrial environment RELOCATION 2 Never store or move the Welder in an inclined position or on its side INSTALLATION ENVIRONMENT A A The equipment is not suitable for use in washrooms shower cubicles pool areas or similar environments If you are obliged to use the unit in such areas tum off all water sup plies and check the area has been evacuated OPERATING AND OR INSTALLATION ENVIRONMENT 1 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 carriages cable cars aircraft ships or boats or similar environments induding cranes conveyor carriers or any other mobile equipment prone to vibration A OPERATING AND OR INSTALLATION ENVIRONMENT 2 A The Welder should never be used or stored in the rain or in snow OPERATING AND OR INSTALLATION ENVIRONMENT 3 Never use the Welder an explosive corrosive abra sive or saline environment r EXTINGUISHER a Always place an approved fire extinguisher in the immediate vicinity of the work area Fire extinguishers should be checked regularly LOCATION A Place the Welder well away from heat sources Place the Welder in a well ventilated environment Place the Welder in a safe protected area It must not be installed outdoors Do notinstall the Welder in dusty environments Dust can get into the inner parts of the unit and inhibit cooling The Welder must be position
17. power cables if the mains power is still switched on Do not touch the welding circuitry Welding cir cuitry is usually low voltage however as a precaution do not tou ch the welder electrodes CABLE AND PLUG PRECAUTIONS Check the power supply cable plug and wall socket regularly This is particularly important if the equipment is relocated often REPAIRS Never attempt to repair the Welder yourself The result would not only cause warranty cancellation but also high danger nsks MAINTENANCE PRECAUTIONS AS Always check that the electric power supply has been discon nected before performing any of the maintenance opera tions listed in this manual e g before replacing any of the fol lowing worn electrodes welding wires the wire feeder etc Never point the welding gun or the electrode towards yourself or others ELECTROMAGNETIC COMPATIBILITY 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 Check there are no telephones televisions computers or other transmission devices close to the Welder Make sure that people with pace makers are the imme diate vicinity of the Welder Do not use the Welder in hospitals or medical environments including veterinary surgeries Make especially sure there is no electrical medical equipment being used close to whe re welding is being done A Should the Welder
18. t setting of the time in which upon release of the torch button the gas continues to flow after the arc has been turned off current downslope t setting of the time in which upon release of the torch button the current decreases by the set value until reaching zero only in 4 stroke mode Timer timer setting the timer sets the maximum welding time Water pump if ON the water pump is enabled if OFF the cooling water pump is disabled Arc length setting this parameter variable from 100 up to 100 allows shortening negative values or lengthening positive values the welding arc 3 1 4 SYNERGIC PULSED MIG WELDING To access this operating mode turn knob 10 to make the selection shown in the figure Select MIG MAG procedure Short arc ma Short arc si Arc puls m oprrons Arc puls s Mig mag 01 Mig mag 02 Once the selection has been made the display shows the page for selecting the welding wire material Select the type of wire OF TRONS MIG MAG 910 100 335GB REVOI 21 of 44 The parameters that do not appear on the screen can be accessed by turning knob 10 Once the type of wire has been selected by pressing knob 10 the page for setting the diameter of the welding wire opens Select wire diameter ORTTONS MIG MAG So Ao S SS Once the type of wire has been selected this screen is displayed Ready to weld 47 e 16 3 v gt Wire Speed Arc 10 MIG MAG z 2 4 s
19. the welding parameters to the different materials to be welded During welding with synergic regulation knob 9 shown in fig 1 allows adjusting the wire thickness i e the welding power The wire speed is automatically adjusted to the set power in relation to the type and diameter of the wire selected The percentage of the arc length can be changed via the arc length parameter The welding quality can be improved even further by regulating the Electronic Inductance parameter to regulate the electronic inductance follow the same procedure as that for setting the wire speed The 2 4 stroke parameter allows setting the operation in 2 stroke or 4 stroke mode 2t In the 2 stroke operating mode the torch button welds for the entire time it is pressed 4t In the 4 stroke operating mode the first pressing of the torch button starts the welding process and a second pressing stops the welding process The Crater Filler function is active in this mode when the torch button is pressed for the second time at the end of welding the current decreases from the set value until it reaches zero in a time set between zero and ten seconds by the current downslope t Menu 2 2 can be accessed by pressing knob 10 for 3 seconds and turning it pre gas 1 setting of the time in which upon the pressing of the torch button the gas flows without the arc being established post gas t setting of the time in which upon
20. welding torch Fig 4 This accessory will have a long duration if the periodic checks are conducted on the gas nozzle Fig 4A and the wire guide tip Fig 4B These parts must be kept clean and intact Replace the wire guide when the wire does not slide properly 5 2 CONNECTION FOR MIG WELDING WITH SPOOL OR PUSH PULL TORCH 1 Connect the ground cable to the appropriate connector 12 shown in figure 1 Insert by aligning the key with the groove and tighten by turning in a clockwise direction until it stops Do not over tighten 2 Connect the torch to the connector positioned on the front panel 15 shown in fig 1 by turning it in a clockwise direction until it stops Do not over tighten 3 Connect the signal connector of the torch to the appropriate female jack 19 4 Turn the tap 23 shown in figure 3 to the MIG GAS position counter clockwise direction If the Spool torch cannot be connected with connector 15 and therefore it is not possible to proceed with step 2 follow these instructions 1 Connect the ground cable to the appropriate connector 12 shown in figure 1 910 100 335GB REVOI 30 of 44 Insert by aligning the key with the groove and tighten by turning in a clockwise direction until it stops Do not over tighten 2 Connect the torch cable to the connector 11 shown in figure 1 Insert by aligning the key with the groove and tighten by turning in a clockwise direction until it stops Do not ov
21. 2 If instead there are difficulties in sustaining the arc decrease the inductance value To obtain the best results follow these tips 1 Keep the torch at a 45 angle from the workpiece Keep the gas nozzle Fig 4A at a distance of around 6 mm from the workpiece 2 Continuously move the torch 3 Weld with a small zigzag movement in order to adjust the size of the weld bead to the desired value 4 Do not weld in the presence of strong wind Strong wind could carry the gas away from the weld pool which could lead to porous welding 5 Keep the wire clean never use rusty wires 6 Do not bend or twist the torch cable 7 When changing the wire spool clean the wire guide tube with compressed air 8 Periodically remove any dust from the air inlets using low pressure compressed air Always direct the jet of air from the inside of the machine towards the outside in order to prevent dirt from being pushed inside the welding machine 8 3 MMA WELDING 80 140 120 170 180 250 Fig 8 Welding currents in relation to the electrode diameter To weld in MMA manual mode follow these steps 1 Select the manual MMA welding mode as described in section 3 3 2 Using knob 9 shown in figure 1 set the welding current in relation to the type of electrode and thickness of the workpiece the current value set appears on the display Figure 8 shows the indicative current values suitable for the various electrode diameters however always
22. ACION SOND DA RITEMERSI NON DEFINITIVE IN QUANTO SUSCETTIBILI DI POSSIBILI MODIFICHE SECONDO Gil OBELIGHI LEGATI AL DECRETO LEGISLATIVO 151 2005 CHE OTTEMPERA LA DIE TTIVA 200786 CE This product contains electrical or electronic materials The presence of these materials may if not disposed of property have potential adverse affects on the environment Presence of this label on the product means it must nat 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 IT your supplier offers a disposal facility please use it or alternatvely contact your local to find out how to properly dispose of this product Hur for EU L nder eren Sie Elektroger te nicht im den Hausm ll Gera Europ ischer 2002 96 EG ber Elekira und El ktromk Aligerat und Umset zuna in matianales Recht m ssen verbrauchte Eleklrewerkzeuge getrennt gesammelt und einer urmeeltgerechten VWiedervenrwertung zuaef hrt werden Ma tirar nuncalas aparatos el ctricos junte con los residuos en general De conformidad a la Directiva Europea ZODZ B5 EC relativa alos Residuos de Equipes Elec ticos o Electr nicos RAEE y al acuerdo de la legislaci n nacional los equipos el ctricas deber n ser recogidas y reciclades respetanda el medioambiente Come propietario del equipo deber informar de las sistemas y lugares apropiados para la reco gda d
23. CAEDE e ui t Ec REP 4 NOMINAL DI WE v Tc ERE 5 TECHNICAL SPE CUFIC A MONS 6 IMPORTANT EINSTRUCIIONS e sube E ine quc tM Reo dod ae Mae 7 1 GENERAL FEATURES AND NOTES ON CONSULTING THE MANUAL rmn 10 2 DESCRIPTION OF TITE MAGLHINE tou toe tosta a Sete Qe gae Mae dur 12 3 DESCRIPTION OF THE VARIOUS TYPES OF WELDINQGQ eene 15 ENIGMA G WEEDING EU t 15 3 1 1 MANUAL SHORT ARC MIG eed ee etat dene e veau Nee etu dene 16 3 12 5 YINERGIC SHORT MIG WELDING 18 321 MANUAL PULSED MIG WELDING nesim 20 S dS VNERGIC PULSED MIO WELDING sermien n n repete 21 SALI WELDING pene reer ND HUM 24 OSA TRADITIONAL WELDING quite ea qu tat iba eq bid emus 23 9 2 2 PUBSED TIC WELDING 26 dS E DILIGEN N ne 24 3 ELNDANUAXESNEMEA W ELDING PESE Ue Ne E ean Pe e peas tu qu Neue needed 28 23 5 2 SYNERGIC NINEA WBLDIINGE deii ERI EE ARI 20 A PONWEROSUPPEY CONNECTION ed euT DEAE depu cro M aa PRU 30 SUD TPETCONINISCITONS bandeau eros ceu 30 5 1 CONNECTION FOR MIG WELDING WITH TRADITIONAL TORCH 30 5 2 CONNECTION FOR MIG WELDING WITH SPOOL OR PUSH PULL TORCH
24. GROUND CABLE USED CABLE 3 1 MIG MAG WELDING To select this welding method go to the selection menu if necessary press button 2 start Select MIG MAG with knob 10 and press to confirm Ready to weld MMA MIG MAG TIG OPTTONS MIG MAG welding In MIG MAG Metal Inert Gas and Metal Active Gas welding a metal electrode consisting of a wire is melted in a weld pool The wire electrode is continuously fed by a welding torch at a constant and controlled speed As the wire is fed it touches the piece to weld and an electric arc is produced The arc melts the wire which is then deposited on the workpiece Welding with continuous feeding of the wire allows using a higher current density than that used in welding with coated electrodes This allows increasing weld penetration and reducing the number of passes required to fill the join This welding machine can use the following types of wire 1 Solid wire must always be used with protective gas connection of line 3 Fig 5 2 Flux cored wire for welding with gas its central part contains a mineral product for improving the welding characteristics must always be used with gas connection of line 3 of Fig 5 910 100 335GB REVOI 15 of 44 For an excellent welding performance it is recommended to use welding spray This will increase the sealing capacity and reduce weld spatter There are four main MIG MAG welding methods 1 Manual short arc 2 Synergic Short Arc
25. ING To access this operating mode turn knob 10 to make the selection shown in the figure Select MMA procedure Manual synergic DIS Once selected the display shows the page for selecting the type of electrode Select MMA procecure Rutile Basic Inox OPTIONS Cellulosic MMA Aluminium DEDE Once the type of electrode has been selected by pressing knob 10 the page for setting the diameter of the electrode opens Select MMA procedure Ole th ONS MMA Synergic In this way the welding process has all the data necessary for setting the correct value of the welding current gt 56 A 26 0 v Arc Force MMA Hot Start Synergic Hot start ct Basic 2 0mm Knob 9 shown in figure 1 allows fine tuning the welding current 910 100 335GB REVO1 29 of 44 The other parameters shown in the figure can also be regulated via knob 10 Arc Force allows increasing the percentage of the current proportional to the set current that the welding machine can force in order to keep the arc well established Hot Start allows increasing the percentage of the welding current proportional to the set current that the welding machine can force once the arc has been established Hot start T allows setting the time in which the hot start current can be forced 4 POWER SUPPLY CONNECTION Before connecting the machine check the voltage number of phases and frequency of the power supply The power supply voltage
26. R WELDING e mail info fimer com DICHIARAZIONE DI CONFORMIT CE DECLARACI N DE CONFORMIDAD CE BEKREFTELSE OM OVERENSSTEMMELSE CE CE DECLARATION OF CONFORMITY DECLARA O DE CONFORMIDADE CE OVERENSSTEMMELSESERKUERING CE KONFORMITATSERKLARUNG CE F RSAKRAN OM OVERENSSTAMMELSE CE DECLARATION DE CONFORMIT CE VERKLARING VAN CONFORMITEITCE YHDENMUKAISUUSVAKUUTUS CE Si dichiara che l apparecchio tipo We hereby state that the machine type Wir erkl ren dass das Ger t Typ On d clare que la machine type declara que el aparato tipo TM236 Declara se que a maquina tipo MODEL Vi forsakrar att maskinen av typ Verklaard wordt dat het apparaat type Vi bekreftelser at maskinen type Vi erklrerer at maskinen type Todistamme etta laite mallia conforme alle direttive conforme alle norme is in compliance with the directives is in compliance with the rulls den Richtlinien entspricht den Normen entspricht est conforme aux directives est conforme aux normes es conforme a las directivas 2006 42 CE es conforme a las normas conforme as directivas seed conforme as normas dn i verensstammelse med direktiven 2002 95 CE s 2 verensstammelse med direktiven overeenkomstig de richtlijnen overeenkomstig de richtlijnen er i overensstemmelse med direktivene er i overensstemmelse med direktivene er i overensstemmelse med direktivene er i overensstemmelse med direktivene on yhdenmukainen direktiivissa on yhdenmukainen direkt
27. SOLUTION 1 2 1 e Restore the mains power Restore the mains power Let the machine cool down until the ror message disappears 1 Check the torch 2 Move the electrode away from the ground connection 1 Blow with air replace nozzle 2 Loosen 3 Check the wire guide sheath 1 Replace 2 Replace 3 Clean 4 Replace 1 Tighten the clamp and control 2 Clean or replace the contact nozzle and wire guide nozzle 1 Remove the encrustations 2 The distance between the torch and the piece must be 5 10 mm the angle must not be less than 60 in respect to the workpiece 3 Increase the quantity 4 Dry with a hot air pistol or other instruments 2 Shorten the arc 1 Pieces dirty Low penetration 2 Welding with very high thermal input 3 Poor quality welding wire 4 Base materials with elevated quantities of carbon sulphur and other impurities 1 Current too low 2 Irregular wire power supply 3 Major differences in the edges 4 1 2 2 Reduce the welding current 3 Change the welding wire 1 Increase the current 2 See previous points Bevel too small Low melting rate Brusque movements of the torch 1 Move the torch continuously Incorrect inductance value 2 Change the inductance value 3 Oxidized material 3 Clean 1 1 Unsuitable type of wire 70 Change metype owe Change the type of wire 2 Poor of the workpieces
28. T CURRENT MAXIMUM EFFECTIVE INPUT CURRENT APPLICABLE STANDARDS RANGE OF WELDING VOLTAGE CURRENT DUTY CYCLE RATED WELDING CURRENT CONVENTIONAL LOAD VOLTAGE YEAR OF CONSTRUCTION LEERLAUFNENNSPANNUNG NENNSPEISESPANNUNG HOCHSTER NENNSPEISESTROM H CHSTER EFFEKTIVER SPEISESTROM PRODUKTNORMEN SCHWEISSSPANNUNGSSTROMBEREICH AUSSETZBETRIEB SCHWEISSNENNSTROM KONVENTIONELLE LASTSPANNUNG BAUJAHR TENSION NOMINALE A VIDE TENSION NOMINALE D ALIMENTATION COURANT NOMINAL D ALIMENTATION MAXIMUM COURANT EFFECTIF D ALIMENTATION MAXIMUM NORMES DE PRODUIT PLAGE DE COURANT TENSION DE SOUDAGE CYCLE INTERMITTENT COURANT NOMINAL DE SOUDAGE TENSION CONVENTIONNELLE DE CHARGE ANN E DE PRODUCTION TENSI N NOMINAL EN VAC O TENSI N NOMINAL DE ALIMENTACI N IMA CORRIENTE NOMINAL DE ALIMENTACI N M XIMA CORRIENTE EFECTIVA DE ALIMENTACI N NORMAS DE PRODUCTO MBITO DE LA CORRIENTE DE TENSI N DE SOLDADURA CICLO DE INTERMITENCIA CORRIENTE NOMINAL DE SOLDADURA TENSI N CONVENCIONAL DE CARGA ANO DE FABRICACI N sivSNvad HOSLNad TONVdSSA 5 of 44 TECHNICAL SPECIFICATIONS CONSTRUCTION DATA WEIGHT Kg Dimensions Width mm Depth mm Height mm Degree of protection Height ASL m Operating temp C Storage temp C Test temp C Applicable regulations Group class Thermal protection
29. URA UTILIZZABILE IN AMBIENTE A MAGGIOR RISCHIO DI SCOSSA ELETTRICA ALIMENTAZIONE GRADO DI PROTEZIONE TIPO DI CORRENTE DI SALDATURA MANUFACTURER S NAME ADRESS AND COMPANY LOGO MODEL SERIAL NUMBER BLOCK DIAGRAM WELDING OUTPUT SUITABLE FOR USE IN HIGH VOLTAGE AREAS POWER SUPPLY DEGREE OF PROTECTION TYPE OF WELDING OUTPUT CURRENT NAME ADRESSE UND LOGO DES HERSTELLERS MODELL SERIENNUMMER BLOCKSCHALTBILD SCHWEISSAUSGANG IN UMGEBUNG MIT H HERER STROMSCHLAGGEFAHR VERWENDBAR SPEISUNG SCHUTZART SCHWEISSSTROMTYP NOM ADRESSE ET LOGO CONSTRUCTEUR MODELE NUMERO DE SERIE SCHEMA FONCTIONNEL SORTIE DE SOUDURE UTILISABLE EN MILIEU RISQUE D ELECTRIFICATION LEV E ALIMENTATION DEGRE DE PROTECTION TYPE DE COURANT DE SOUDAGE NOMBRE DIRECCI N Y LOGOTIPO DEL FABRICANTE MODELO N MERO DE SERIE ESQUEMA BLOQUES SALIDA DE SOLDADURA SE PUEDE UTILIZAR EN AMBIENTES CON MAYOR RIESGO DE DESCARGAS EL CTRICAS ALIMENTACI N GRADO DE PROTECCI N TIPO DE CORRIENTE DE SOLDADURA 910 100 335GB REVOI TENSIONE NOMINALE A VUOTO TENSIONE NOMINALE DI ALIMENTAZIONE MASSIMA CORRENTE NOMINALE DI ALIMENTAZIONE MASSIMA CORRENTE EFFETTIVA DI ALIMENTAZIONE NORME DI PRODOTTO RANGE CORRENTE TENSIONE DI SALDATURA CICLO DI INTERMITTENZA CORRENTE NOMINALE DI SALDATURA TENSIONE CONVENZIONALE DI CARICO ANNO DI FABBRICAZIONE INPUT VOLTAGE RATED INPUT VOLTAGE MAXIMUM RATED INPU
30. YOUR BRAND YOUR WELDING LECCI f eu i gt xdi Jae ta is TU m vie Xi 7 USER MANUAL TM 236 PULSE SYNERGIC GEN Fimer SpA Via Brigatti 59 20050 RONCO BRIANTINO MILAN Italy Tel 39 0396079326 Fax 39 0396079334 www fimer com info fimer com Istruzioni Originali Original instructions MOODY A MEMBER LT bersetzung der Originalbetriebsanleitung Notice originale Manual original USER AND MAINTENANCE MANUAL Firmer S p A would like to thank you for choosing this welding machine if used according to the instructions reported in this user and maintenance manual it will accompany you in your work for many years without any problem The manual is an integral part of the equipment and must always accompany the machine each time it is moved or resold The user is responsible for making sure the machine is complete and in good working order Fimer S p A has the right to make changes at any time and without notice The rights of translation reproduction and adaptation in whole or in part and with any means including scanned documents copies film and microfilm are reserved and prohibited without Fimer s written authorisation TABLE OF CONTENTS DECLARATION OR CONFORMITY eee eb M ete beca sete m oO Io
31. access this operating method turn knob 10 to make the selection shown in the figure Select TIG procedure Lift arc Lift arc pul OPTIONS Once selected this screen is displayed Ready to weld gt 150 A 16 0 v 2 A Strokes TIG pre gas LER Are DOSE Gas T Menu 2 2 be accessed by pressing knob 10 for 3 seconds and turning tt initial I downslope t Water pump P2 2 During welding knob 9 shown in figure 1 allows regulating the welding current whose value is continually displayed on the display the display also shows the relative arc voltage The other parameters shown in the figure can also be regulated via knob 10 2 4 strokes setting of the 2 stroke or 4 stroke operating mode 2t In the 2 stroke operating mode the torch button welds for the entire time it is pressed 4t In the 4 stroke operating mode the first pressing of the torch button starts the welding process and a second pressing of this button stops the welding process pre gas t setting of the time in which upon the pressing of the torch button the gas flows without the arc being established post gas t setting of the time in which upon release of the torch button the gas continues to flow after the arc has been turned off Menu 2 2 can be accessed by pressing knob 10 for 3 seconds and turning it Initial I setting of the initial value of the current when the torch button only active in 4
32. check to see if different values are reported on the electrode packet 3 Connect the ground terminal to the piece to weld 4 Position the electrode in the electrode holder 5 Start to weld keeping a distance of 3 4 mm between the electrode and the workpiece Weld with a small zigzag movement in order to adjust the size of the weld bead to the desired value 6 To end the welding process interrupt the arc by moving the electrode away from the workpiece 910 100 335GB REVOI 37 of 44 To weld in Synergic MMA mode follow these steps 1 Select the Synergic MMA welding mode as described in section 3 3 2 Set the type of electrode using knob 9 shown in figure 1 section 3 3 2 3 Connect the ground terminal to the piece to weld 4 Position the electrode in the electrode holder 5 Start to weld keeping a distance of 3 4 mm between the electrode and the workpiece Weld with a small zigzag movement in order to adjust the size of the weld bead to the desired value 6 To end the welding process interrupt the arc by moving the electrode away from the workpiece Attention If using Basic electrodes before resuming an interrupted welding process remove any excess from the protection cover by tapping the electrode on a metallic surface otherwise it will not be possible to re establish the welding arc 8 4 TIG WELDING To weld in TIG mode follow these steps 1 Select the TIG program via knob 9 shown in figure 1 2 Using this
33. ded Larger pieces require a higher welding current and a faster wire speed The wire speed must be adjusted during welding to obtain the best result The quality of the welding can be improved even further by regulating the Inductance parameter according to the instructions reported in section 8 1 the electronic inductance can be regulated by following the same procedure as that for setting the wire speed The 2 4 stroke parameter allows setting the operation in 2 stroke or 4 stroke mode 2t In the 2 stroke operating mode the torch button welds for the entire time it is pressed 4t In the 4 stroke operating mode the welding process starts with the first pressing of the torch button and stops when this button is pressed for a second time The Crater Filler function is active in this mode When the torch button is pressed for the second time at the end of welding the current decreases from the set value until it reaches zero in a time set between zero and ten seconds by the current downslope Menu 2 2 can be accessed by pressing knob 10 for 3 seconds and turning tt pre gas t setting of the time in which upon the pressing of the torch button the gas flows without the arc being established post gas t setting of the time in which upon release of the torch button the gas continues to flow after the arc has been turned off current downslope t setting of the time in which upon release of the torch butt
34. e Regulation of electronic inductance Ferrous materials SG2 SG3 min lt gt med Stainless steel Ni Cr Aluminium Al Silicone Copper Silicone Cu Si3 Copper Aluminium CU AI8 Figure 7 Reference values for the current wire diameter wire speed and electronic inductance 910 100 335GB REVOI 35 of 44 To weld in MIG manual mode follow these steps 1 Set the welding current in relation to the thickness of the workpiece and the diameter of the wire using knob 9 shown in figure 1 Step 1 of Fig 7 Display 16 of Fig 1 shows the current value 2 Depending on the current select the diameter of the wire Step 2 of Fig 7 3 Depending on the diameter of the wire set the advancement speed using knob 10 of Fig 1 4 According to the material used adjust the electronic inductance 5 Connect the ground terminal to the workpiece 6 Start welding keeping the length of the electric arc between 5 and 10 mm 7 f necessary adjust the wire speed knob 10 of Fig 1 To obtain the best welding result adjust potentiometer 10 until you hear a strong and regular buzzing noise similar to the sound of oil being fried It is recommended to carry out some test welds on a metallic sheet that has been removed of any coating rust or paint To obtain the best results follow these tips 1 Keep the torch at a 45 angle from the workpiece Keep the gas nozzle Fig 4A at a distance of circa 6 mm from the workpiece 2 Co
35. e buttons back sp cancels the last letter entered gt moves the cursor to the right lt moves the cursor to the left OK confirms the name of the working point 910 100 335GB REVOI 42 of 44 910 100 335GB REVOI Per RAEE s tendono i nfuti di A pparecchiature Elettriche ed Eletirnichie WEE incluse di tui icemponenti 1 scHoinsiermi pd i materiali di consume che sone parte integran e del prodotto nel momento in cui si assume la dersane di disfarsene La Legislazione prevede la suddiisone in 2 categone principali chiamate RAEE PROFESSIONALI o RAEE DOMESTICI Per PROFESSIONAL intendono tutti i iut di apparecchiabure elettriche ed eletiraniche destnate ad uso pret mene rcustnaic Per RAEE DOMESTICO s inbendono tuti i generation ad alimentaziane manatase can comente d usc MAX lt 200 pon rero accessor Per bo smaltmento di un RAEE DOMESTICS si avranno 2 possibilita aie raso si decidesse di comprare una nuova apparecchiatura equivalence f utkzzatnre potra consegnaria al dst tu fore ii quale devra mirato geatudamente deposta nela Comunale ned conkenitare a appesta Kkenbfieata come FUGDSRLPPRMENTC Par lo smaltmenta di un RACE PROFESSIONALE alla data c radazicng ciel Manuale di singani non essendo ancora pie l apaiicanona dela Nomatwa si prega ci contattare d Hiei Eton avo par informazioni i merito alto ALLA DATA DELL A REDAZIONE DEL PRESENTE D ISTRLEZICINI QUESTE INFORM
36. e los mismas Aplicar esta Directiva Europea proteger amp el medioambiente y su salud Me pas Jeter les appareils lectriques avec les d chets ordinaires Conform ment la Directive Europ enne 2002 96 EC relative aux D chets d quipements lectriques ou lectroniques DEEE et sa transposition dans la l gislation nationale les appareils lectriques doivent tre collect s part et soumis un recyclage respectuex de l envirannement En tant que propri taire de l quipement vous devriez vous informer sur les syst mes de collecte approuv s aupr s nos repr sentants locaux Apphquer cette Directive Eurbp enne ameliarera l envirennement et la sant voyyenue aeTpoHede vranmician pid MOE TO KIRET c CTXOJTONAM E
37. e outside This lifts the upper wire feeder rollers 28 of Fig 3 Remove any wire remaining in the previous welding spool 5 Insert the wire in the inlet tube 30 of Fig 3 of the wire feeder motor and let it slide under the wire feeder rollers 6 Lower the upper rollers 28 of Fig 3 and close the plastic knobs 26 of Fig 3 of the wire pressure regulator Tighten gently if too tight the wire may block and cause damage to the motor however if too loose the rollers will not be able to pull the wire 7 Connect the power supply cord turn on the switch 17 of Fig 2 and press the wire advancement button 6 of Fig 1 At this point the welding wire will slide into the torch cable When it exits from the torch release the button Turn off the machine and replace the wire guide tip Fig 4B and gas nozzle Fig 4A on the torch Attention Keep the torch away from your face to prevent injuring yourself with the wire Attention When in movement the wire feed rollers may crush your fingers N B Periodically check the state of the wire feed rollers and replace them when they are worn out failure to replace the rollers may compromise the correct feeding of the wire N B When changing the wire diameter make sure the value corresponding to the diameter of the wire used is facing towards the outside of the machine Remember that the rollers with a V shaped cavity are suitable for pulling iron or steel wires While rollers wit
38. ed on a flat stable surfa ce that extends further than the units own dimensions in all directions A A A CLEAN LOCATIONS The installation area must be kept clean and dry to be sure the Welder fans do not draw in small objects or liquids Not only could the equip ment malfunction but a serious risk of fire outbreak could be created REPAIRS Never attempt to repair the Welder yourself Always refer to the manufacturer or an authonzed repairer All warranty provisions will immediately become null and void if any repair or attempt to repair not specifically authorized in writing or handled by Fimer S p A is camed out Furthermore Fimer S p A will accept no responsibility for any malfunction or damage resulting as a consequen ce of such unauthorized action i TECHNICAL ASSISTANCE The Welder must be taken to an authorized Technical Assi stance Centre if the equipment has been damaged in any way or if any one of the following events occurs liquid infiltration dama ge caused by falling objects exposure to rain or humidity exceeding the specified limits malfunction performance failure or if the equip ment has been dropped 910 100 335GB REVOI SPARE PARTS Use only manufacturer recommended spare parts AAA Other spare parts could cause equipment mal function The use of non original spare parts will also result in the war ranty provisions becoming null and void releasing the manufacturer from any responsibili
39. elding parameters can be set with this Knob turn the knob to select the parameter and press to confirm turn the knob again to change the set value and press again to confirm the new value 11 front inlet MMA Mode Electrode holder TIG Mode Ground clamp MIG Mode with gas Not used MIG Mode without gas Ground clamp 12 front inlet MMA Mode Ground clamp TIG Mode TIG torch MIG Mode with gas Ground clamp MIG Mode without gas Not used 13 Remote connector This connector allows using the following types of torches MIG torch GAN Spool MIG torch Push Pull TIG torch 14 GAS outlet MMA Mode inactive internal tap positioned on NO GAS MIG Mode with gas inactive internal tap positioned on MIG GAS MIG Mode without gas inactive internal tap positioned on NO GAS TIG Mode Gas connection to the welding torch Internal tap positioned on TIG GAS 15 Euroconnector quick connector for welding torch This connector is used to supply welding gas to the torch the electrical contacts of the torch button and the welding current 16 Air grills FIGURE 2 16 Air grills 17 ON OFF switch turns the machine on and off 18 Input cable connection cable to the mains power equipped with plug 20 Connector for supplying power to the liquid cooling system Optional Warning the connector contains dangerous voltages NEVER use it for purposes other than those for which it was specifically designed 21 Welding gas i
40. er tighten 3 Connect the gas hose of the torch to the appropriate inlet 14 shown in figure 1 Connect the signal connector of the torch button to the appropriate female jack 13 4 5 Turn the tap 23 shown in figure to the TIG GAS position clockwise direction 5 3 CONNECTION FOR TIG WELDING 1 Connect the ground cable to the appropriate connector positioned on the front panel 11 of Fig 1 Align the key with the groove and insert tighten the connector by turning it in a clockwise direction until it stops Do not over tighten 2 Connect the torch to the connector positioned on the front panel 12 of Fig 1 3 Insert by aligning the key with the groove and tighten by turning in a clockwise direction until it stops Do not over tighten 4 Connect the gas hose of the torch to the appropriate inlet 14 shown in figure 1 5 Connect the signal connector of the torch button to the appropriate female jack 13 6 Turn the tap 23 shown in figure 3 to the TIG GAS position clockwise direction 5 4 CONNECTION FOR MMA WELDING 1 Connect the cable of the electrode holder to the connector located on the front panel 11 of Fig 1 Insert by aligning the key with the groove and tighten by turning in a clockwise direction until it stops Do not over tighten 2 Connect the ground cable to the appropriate connector positioned on the front panel 12 of Fig 1 Align the key with the groove and
41. eroom etc where toxic inflamma ble or explosive materials are or have been located or stored Cistems in particular may still contain toxic flammable or explosi ve gases and vapours years after they have been emptied A NEVER weld a cistern that contains or has stored toxic inflammable or explosive materials They could still contain toxic flammable or explosive gases and vapours years after they have been emptied If you are obliged to weld a cistern ALWAYS passivate it by filling it with sand simi lar inert substance before starting any work SERIOUS DANGER 2 SERIOUS DANGER 3 NEVER use the Welder to melt frozen water pipes VENTILATION Together with the previous instructions the following pre cautions should be strictly observed WELDING ENVIRONMENT VENTILATION Ventilate the welding environment carefully Maintain N sufficient air flow to avoid toxic or explosive gas accumulation Welding processes on certain kinds or combinations of metals can generate toxic fumes In the event of this happening use air sup ply respirators BEFORE welding read and understand the wel ding alloy safety provisions PROTECTIVE WELDING GASES Together with the previous instructions the following precaulions should be striclly observed when welding with protective gases SA GAS TYPES These welders use only inert non flammable gases for welding arc protection It is important that the appropriate t
42. g of the torch button starts the welding process and a second pressing of this button stops the welding process 910 100 335GB REVOI 26 of 44 pre gas t setting of the time in which upon the pressing of the torch button the gas flows without the arc being established post gas t setting of the time in which upon release of the torch button the gas continues to flow after the arc has been turned off Menu 2 2 can be accessed by pressing knob 10 for 3 seconds and turning it back ground I setting of the base current i e the current that is maintained continually for the entire duration of the welding process and that is increased during the pulse peak Initial 1 setting of the initial value of the current when the torch button only active in 4 stroke mode final 1 setting of the final value of the current after the current downslope t of the torch button only active in 4 stroke mode current downslope t setting of the time in which upon release of the torch button the current decreases by the set value until reaching the final value only in 4 stroke mode current upslope t setting of the time in which upon pressing of the torch button the current increases by the initial 1 value until it reaches the set value only in 4 stroke mode total period t setting of the pulse period pulse period t setting of the duration of the pulse Water pump if ON the water pump is enabled if OFF the cooling water
43. h a U shaped cavity are suitable for aluminium wires 910 100 335GB REVOI 32 of 44 7 CONNECTION OF THE GAS CYLINDER AND REGULATOR Only for MIG and TIG welding In case of MMA welding skip this whole section Fig 6 Cylinder and pressure reducer Before connecting the gas cylinder first choose the most suitable type of gas for the welding to be executed This section contains some recommendations MIG WELDING OF CARBON STEEL For welding this type of material use a welding gas mixture consisting of ARGON 80 CO2 20 This gas mixture allows obtaining well joined and aesthetically pleasing weld beads Pure CO2 can be used which will result in tight beads and more penetrating welds but with a significant amount of spatter MIG WELDING OF STAINLESS STEEL AND WELD BRAZING WITH CU S13 WIRES For welding these types of materials use a welding gas mixture consisting of ARGON 98 CO2 2 or ARGON 98 min O2 2 MIG WELDING OF ALUMINIUM For welding this type of material use pure ARGON as a protection gas TIG WELDING Before connecting the gas cylinder check that it contains pure Argon gas Do not use other gases Refer to Figure 6 and carefully follow the procedure below 1 Connect the pressure gauge 2 to the cylinder 3 Tighten the nut 6 connecting the gauge 2 to the cylinder 3 Be careful to not over tighten too much force could damage the valve 1 of the cylinder 2 Connect the gas hose 4 t
44. here ow isthe torch button P is the potentiometer for controlling the current M is the external wire feeder motor 11 1 MIG WELDING WITH STANDARD TORCH The connector is not used because all the necessary contacts are made using Euroconnector 13 shown in figure 1 11 2 MIG WELDING WITH SPOOL OR PUSH PULL TORCH lf using a Spool torch supplied by Fimer the connection to the remote connector is direct If not connect the two wires of the torch button to terminals A and E of the connector the negative of the torch s wire feeder motor to terminal F and the positive to terminal G as shown in figure 10 Some types of torches also allow regulating the welding power at a distance Turn the potentiometer on the torch to set the welding power in a range between zero and the set value This requires connecting the potentiometer P to the torch as shown in figure 10 The value of the potentiometer is not critical components between 2 2kOhm and 10kOhm 1 2W can be used 11 3 TIG WELDING Connector 13 in Figure 1 connects the torch s welding button to the machine by means of terminals A and E shown in figure 10 The connection is made automatically by connecting the TIG welding torch 11 4 MMA WELDING Remote connector 13 shown in figure 1 allows bringing the current regulation close to the welding point This requires connecting the potentiometer P to the torch as shown in figure 10 The value of the potentiometer is not critical c
45. iivissa MILANO Ogni intervento o modifica non autorizzati dalla FIMER faranno decadere la validit di questa dichiarazione Any tampering or change unauthorized by FIMER shall immediately invalidate this statement Eingriffe und nderungen ohne die Genehmigung von FIMER machen die vorliegende Erkl rung ung ltig Toute op ration ou modification non autoris es par FIMER feront d choir la validit de cette d claration Cualquier intervenci n o modificaci n no autorizadas por FIMER anular n la validez de esta declaraci n Qualquer interven o ou modifica o que nao seja autorizada pela FIMER anulara a validade desta declara o Denna f rsakran upph r att galla vid eventuella ingrepp eller andringar som ej ar godkanda av FIMER ledere niet door FIMER geautoriseerde ingreep of wijziging doet de geldigheid van deze verklaring vervallen Denne bekreftelse bortfaller ved evt inndgep eller endringer som ikke er godkjent al FIMER Denne erklaering bortfalder ved evt indgeb eller aerendringer der ikke er godkendt afae FIMER Jokainen valiintulo tai muutos ei valtuutettu FIMER rappldittaa k fseisen lausunnon pitavyyden 910 100 335GB REVOI 4 of 44 NOMINAL DATA LEISTUNGSCHILDER PLAQUE DONEES PLACA DE CARACTERISTICAS 9 1 2 3 4 5 6 7 8 9 CWANMOAMP YN 1 BASWN CONSAPOVp mphpm NOME INDIRIZZO E LOGO COSTRUTTORE MODELLO NUMERO DI SERIE SCHEMA BLOCCHI USCITA DI SALDAT
46. ing the risk of being burned by hot slag READ THE INSTRUCTION MANUAL CAUTION SAFETY WARNINGS EYE PROTECTION Indicating that eye protection is required to avoid flying debns This equipment is designed solely for industrial or professional use As such only experienced or ful ly trained people should use the equipment The user and or owner is responsible for ensuring inexperienced person nel does not have access to the equipment Fimer SpA declines all responsibility for injury or dama ge caused by inexperienced improper or neglectful use of its equipment A workman must look after his tools carefully Remember that any tool or equipment can become a hazard if it is not looked A after properly Equipment in a state of disrepair or neglect can be dangerous If it does not operate properly or overheats the electricity supply should be removed immediately and the unit should be returned to the sup plier for repair Read this manual carefully before using your Welder A You can then do a better and safer job By reading this manual you will learn more about the possibilities limitations and potential dangers of welding Retain this manual for the entire lifa of the equipment It should be kept within the operator s reach at all times ensure you are not subjected to unnecessary risks However The safety information contained this manual is guide to the operator must be competent and careful at
47. insert tighten the connector by turning it in a clockwise direction until it stops Do not over tighten 3 Turn the tap 23 shown in figure to the NO GAS position central position Attention Some types of electrodes require the negative polarity on the electrode holder and the positive polarity on the ground cable if so invert the connection Make sure to follow the instructions on the electrode packet for the correct polarity 910 100 335GB REVOI 31 of 44 6 INSTALLATION OF THE WELDING WIRE Only for MIG welding in case of MMA or TIG welding skip this whole section Attention Before installing the wire always remove the gas nozzle Fig 4A and the wire guide tip Fig 4b from the welding torch Fig 4 1 Disconnect the power supply cord 18 of Fig 2 2 Unscrew the knob positioned at the centre of the spool holder 22 of Fig 3 if necessary remove the used spool 3 Remove the plastic protection of the new spool and position the spool on the holding reel 22 of Fig 3 Replace the knob Remember that the Allen screw positioned at the centre of the reel is the braking system of the wire Screw it to obtain the best braking condition if tightened too much it can cause too much braking which tends to block the motor of the wire feeder However if not tightened enough the wire may not stop immediately at the end of the welding process 4 Unscrew the knobs of the wire feeder 26 of Fig 3 and turn them towards th
48. interfere with other apparatus take the fol lowing precautionary measures T Check the Welder s side panels are securely fastened 2 Shorten the power supply cables Place EMC filters between the Welder and the power source Con tact Fimer Technical Dept in this respect EMC compatibility CISPR 11 Group 2 Class 9 of 44 1 GENERAL FEATURES AND NOTES ON CONSULTING THE MANUAL The TM236 welding machines use INVERTER technology They are extremely compact and versatile machines that can be used in all situations where high performances must be achieved in a limited amount of space These welders are for Synergic MIG MAG Short Arc and Pulsed conventional MIG MAG Short Arc and Pulsed TIG and MMA Synergic and conventional welding The innovative interface system allows a simple and intuitive use of the machine with the possibility to personalise nearly every welding parameter All the main parameters of the machine are stored on a special memory card SD Card in this way your machine will always be up to date with the most recent developments in the welding field e g synergic curves for new materials etc The removal of the memory card prevents the machine from operating which therefore makes it an effective antitheft system and protection device against improper use The wire spool of 300 mm necessary for MIG welding is lodged internally The advanced control techniques adopted allow reaching quality res
49. knob select Lift Arc or Pulsed Lift Arc program 3 Set the welding current via knob 10 shown in figure 1 4 Connect the ground terminal to the workpiece 5 Press the torch button in order to start the gas flow and regulate the flow via the tap positioned on the cylinder indicatively 6 litres minute 6 Rest the ceramic of the torch on the workpiece and turn in order to bring the tungsten electrode in contact with the workpiece 7 Slowly lift the tip of the tungsten electrode from the workpiece using the ceramic end of the TIG torch as a lever 8 Once the arc has been established the current gradually rises until it reaches the set value 9 Start to weld keeping the same distance from the weld pool that is being created 910 100 335GB REVOI 38 of 44 9 REPLACEMENT OF SHEATH INSIDE THE TORCH CABLE Follow these instructions to replace the sheath of the wire guide Torch side remove gas inr da Unscrew the wire guide tip B Connector side C unscrew the end Ex D E and take hold of the end of the sheath with some pliers and start to extract it Complete the extraction of the sheath Z Insert the new sheath and push it all the way down H Re screw the wire guide tip B onto the torch Complete by re screwing the gas nozzle A Figure 9 Replacement of wire guide sheath 910 100 335GB REVOI 39 of 44 10 REMOTE CONNECTION Figure 10 shows the connections of the remote connector 13 shown in figure W
50. l cables are appropriately gauged for the input power required by your specific Welder This precaution applies also to extension cables if used All extension cables must be straight Coiled cables can overheat becoming dange rous Twisted or coiled cables can also cause Welder malfunction WEIGHT LOADS CABLE GAUGES 7 of 44 OVERLOAD PROTECTION Check that the power source supplying the Welder cames the correct voltage and is safety protected The power switch must open all the power supply circuits If a single phase connection is used both the live and the neutral poles must be open If a three wire connection is used all three poles must be open Four wire circuits require all poles and neutral open Time delayed fuses or K standard circuit breakers should be used EARTHING A If the Welder was not already supplied with a plug connect the earth wire first When removing the plug disconnect the earth wire last PLUG AND POWER SUPPLY If the Welder already has a plug attached check that itis appro pnate for the wall socket you intend using Never tamper with the power cable CABLE COLOURS A A The green yellow wire is for earthing Don t use it for anything else RELOCATION 1 A Some Welders are extremely heavy therefore care should be taken when relocating the unit Check the floor or platform wei ght load limitations before relocating the unit if the Welder is to be used even only temporarily in a non
51. nlet MMA Mode Not used TIG Mode GAS connection to the cylinder MIG Mode with gas GAS connection to the cylinder MIG Mode without gas Not used FIGURE 3 19 Nominal data 22 Wire spool 23 Gas tap The gas tap has three positions MIG GAS Position sends welding gas coming from connection 21 of the cylinder to the Euroconnector use this position for MIG welding with gas NO GAS Position interrupts the gas flow use this position for MMA welding and MIG welding without gas TIG GAS Position sends welding gas coming from connection 21 of the cylinder to inlet 14 location on the front use this position for TIG welding 25 Wire Feeder 26 Wire pressure regulators allow regulating the tension of the welding wire 27 Wire feeder motor 28 Upper wire feed rollers 29 Lower wire feed rollers 30 Wire inlet of the wire feeder motor 910 100 335GB REVOI 14 of 44 3 DESCRIPTION OF THE VARIOUS TYPES OF WELDING This chapter briefly describes the various welding methods and the main settings that need to be set in order to execute them The reading of this chapter is not sufficient for knowing how to use the machine correctly Therefore it is also important to read the following sections especially the chapters regarding the methods for connecting the torches and ground cables WES Lors dmi MEER 15 of fig 1 11 t fig 1 12 of fig 1 NOT USED ELECTRODE GROUND HOLDER TIG NOT USED GROUND TORCH CABLE CABLE TORCH NOT
52. ntinuously move the torch 3 Weld with a small zigzag movement in order to adjust the size of the weld bead to the desired value 4 Do not weld in the presence of strong wind Strong wind could carry the gas away from the weld pool which could lead to porous welding 5 Keep the wire clean never use rusty wires 6 Do not bend or twist the torch cable 7 When changing the wire spool clean the wire guide tube with compressed air 8 Periodically remove any dust from the air inlets using low pressure compressed air Always direct the jet of air from the inside of the machine towards the outside in order to prevent dirt from being pushed inside the welding machine Pulsed Mode This operating mode is only for expert users it is mainly used as an alternative to MIG Synergic Pulsed welding in rare cases when due to special type of materials a satisfying result cannot be found using the pre set programs In this operating mode knob 9 of figure 1 sets the welding current Knob 10 of figure 1 sets all the other parameters as described in section 3 1 3 8 2 Synergic MIG welding synergic MIG welding allows automatically adjusting the machine settings to the different materials and different thicknesses to be welded Compared to manual welding it has a pre set program menu capable of satisfying practically any type of welding requirement However as described in more detail below a certain liberty is available for changing the parameter
53. o the gauge 2 and secure with a pipe clamp 5 3 Connect the other end of the gas hose 4 to the appropriate inlet positioned on the back of the machine 21 of Fig 2 and secure with a pipe clamp 4 Open the valve 1 of the cylinder 3 Press the torch button and check that the gas flows correctly Attention The cylinders contain highly pressurised gas Handle with care Improper handling 910 100 335GB REVOI 33 of 44 could lead to serious accidents Do not place the cylinders on top of each other and do not expose to excessive heat flames or sparks Do not allow the cylinders to strike against each other Contact your gas supplier for more information on how to use and handle the cylinders Attention Do not use the cylinder if you find oil leaks grease or damaged parts Immediately contact your gas supplier if these conditions exist 910 100 335GB REVOI 34 of 44 8 WELDING PROCESSES 8 1 Manual MIG welding N B These instructions are for reference only and are applicable for welding thicknesses up to around 4 mm The regulation depends on the materials wire thickness connection position and welding gas Step 1 Selection of the current be welding in Ampere A according to this proportion 0 025 1A Cz e g 3mm 125A Convert the thickness of the material to Step 2 Selection of the wire diameter Step 3 Selection of wire speed 30x120 3 5m min Step 4 Selection of electronic inductanc
54. omponents between 2 2kOhm and 10kOhm 1 2W can be used Turn the potentiometer on the torch to set the welding current in a range between zero and the set value 910 100 335GB REVOI 40 of 44 11 TROUBLESHOOTING The most common problems you may encounter and the relative solutions are listed below DEFECT Machine turns off Display OFF Display network error The machine suddenly stops operating after prolonged use Display temperature rise or overheating of inverter The machine does not work display inverter under power The wire does not advance when the wire feed roller turns Wire works in jerks or sporadically Porous weld bead CAUSE 1 No power on the mains power source 2 Check the mains voltage 1 The machine has overheated due to excessive use and the thermal protection has kicked in 1 MIG Short circuit on the welding torch 2 MMA electrode in contact with the ground connection 1 Dirt on the wire guide tip 2 Too much friction on the spool 3 Faulty torch 1 Faulty gas nozzle 2 Burning in the gas nozzle 3 Dirt on the throat of the wire feed roller 4 Throat of the wire feed roller worn 1 Bad contact between the ground clamp and the workpiece 2 Short circuit between the contact nozzle and the gas guide tube 1 No gas shield due to encrustations in the gas nozzle 2 Incorrect angle distance of the torch 3 Not enough gas 4 Wet pieces 5 Welding arc too long
55. on 5 Output connections 5 Output connections 5 1 Connection for MIG welding with traditional torch and 5 3 Connection for TIG welding gas 7 Connection of the gas cylinder and regulator 5 2 Connection for MIG welding with Spool or Push pull 8 Welding process torch and gas 8 4 TIG Welding 6 Installation of the welding wire 7 Connection of the gas cylinder and regulator 8 Welding process 8 1 Manual MIG welding MIG Welding pulsed manual Pulsed TIG welding General features General features Description of the machine Description of the machine Description of the various types of welding Description of the various types of welding MIG MAG welding TIG Welding Manual pulsed MIG welding Pulsed TIG welding Power supply connection Power supply connection Output connections Output connections Connection for MIG welding with traditional torch and Connection for TIG welding gas Connection of the gas cylinder and regulator Connection for MIG welding with Spool or Push pull Welding process torch and gas Pulsed TIG welding Installation of the welding wire Connection of the gas cylinder and regulator Welding process Manual MIG welding G Welding short arc synergic Manual MMA welding General features General features Description of the machine Description of the machine Description of the various types of welding Description of the various types of welding MIG MAG welding MMA Welding Synergic short arc MIG welding 3
56. on the current decreases by the set value until reaching zero only in 4 stroke mode burn back t setting of the burn back time Timer timer setting the timer sets the maximum time for continuous welding i e limits the time spent welding with the torch button pressed Water pump if ON the water pump is enabled if OFF the cooling water pump is disabled 910 100 335GB REVOI 17 of 44 3 1 2 SYNERGIC SHORT ARC MIG WELDING To access this operating mode turn knob 10 to make the selection shown in the figure Select MIG MAG procedure Short arc ma Short arc si ACE PUL MT Arc puls s tc mac Mig mag 01 Mig mag 02 Once the selection has been made the display shows the page for selecting the welding wire material Select the type of wire MIG MAG DM S The parameters that do not appear on the screen can be accessed by turning knob 10 Once the type of wire has been selected by pressing knob 10 the page for setting the diameter of the welding wire opens Select wire diameter Ole PONS MIG MAG Soo S9 Once selected this screen is displayed 16 3 v Arc length MIG MAG 2 4 strokes SoMa Wire speed Fe Inductance 0 6mm 1 2 910 100 335GB REVO1 18 of 44 Menu 2 2 can be accessed by pressing knob 10 for 3 seconds and turning tt Dre gae T DOSE GAS T downslope t ourn Dack Tt Timer Water pump P2 2 Synergic MIG welding allows easily adapting
57. pump is disabled Timer timer setting the timer sets the maximum time for continuous welding i e limits the time spent welding with the torch button pressed 3 3 MMA WELDING To select this welding method go to the selection menu if necessary press button 2 start Select MMA with knob 10 and press to confirm Ready to weld MMA MIG MAG TIG Arc welding with MMA Metal Manual Arc coated electrode or SMAW Shielded Metal Arc Welding is a manual welding procedure that makes use of the heat generated by an electric arc that strikes against a coated fusible electrode and the piece to be welded This procedure is commonly used in welding because of its versatility In fact it allows making joints in any position in the machine shop outdoors in confined areas or hard to access areas A vast range of electrodes is also available on the market for meeting the most varied requirements The striking of the arc occurs by bringing the electrode close to the workpiece During welding the following functions are active Arc Force allows increasing the welding current to prevent the arc from extinguishing itself Hot Start allows temporarily increasing the percentage of the welding current that the machine can force once the arc has been established This helps igniting the arc quickly and reliably Antisticking allows decreasing the output current if the operator makes an error and sticks the electrode to the workpiece
58. release of the torch button the gas continues to flow after the arc has been turned off current downslope t setting of the time in which upon release of the torch button the current decreases by the set value until reaching zero only in 4 stroke mode burn back t setting of the burn back time Timer timer setting the timer sets the maximum time for continuous welding i e limits the time spent welding with the torch button pressed Water pump if ON the water pump is enabled if OFF the cooling water pump is disabled 910 100 335GB REVOI 19 of 44 3 1 3 MANUAL PULSED MIG WELDING To access this operating mode turn knob 10 to make the selection shown in the figure Select BS TOC me Short arc ma Short arc si options Arc puls s tc mac Mig mag 01 Mig mag 02 Once selected this screen is displayed gt O A TO Iy Wire speed MIG MAG back groune 1 Aso oM burn back I burn back tL 2 4 strokes pa Menu 2 2 can be accessed by pressing knob 10 for 3 seconds and turning it Pre gas DOSE GAS amp downslope t bourn oack Tt Timer Water pump Arc length 2 2 During welding with manual regulation potentiometer 11 shown in fig 1 regulates the arc voltage whose value appears on the display the display also shows the relative welding current To regulate the wire speed turn knob 10 to select the wire speed parameter press the knob to confirm the value selected turn the knob
59. sed for the purposes described in this manual and must be used to thaw pipes 910 100 335GB REVOI 11 of 44 2 DESCRIPTION OF THE MACHINE Fig 1 12 13 1411 No Gas TIG MIG Gas 19 25 Fig 4A Fig 4B 910 100 335GB REVOI 12 of 44 FIGURE 1 1 Graphic display The display shows different screens depending on whether the machine is in welding mode or setting mode In welding mode the display is divided into five main parts Part 1 Pronto a saldare INIZIO GD 150 INDIETRO D gt Buttons Adjustable c value edu A i Hot start Manuale Part 3 T hot start Part 2 Highlighted Part 5 Part 4 value Part 1 State of the machine Part 2 Meaning of the active buttons buttons 2 3 4 5 of fig 1 Part 3 Value of the measurements set Part 4 Type of welding Part 5 Indicates the values set for the various welding parameters to change the set value highlight the value with knob 10 and press to confirm the value is highlighted as a negative Change the value by turning the knob and confirm the new value by pressing knob 10 again Adjustable value Indicates the welding parameter that can be changed with knob 9 Highlighted value Indicates the welding parameter that is being changed with knob 10 During the setting mode the display shows different screens according to the value being set at that moment see the following sections relating to the various welding methods The
60. set automatically To weld in Synergic MIG mode follow these steps 1 Depending on the material to be welded select one of the following programs using Knob 10 shown in figure 1 section 3 1 2 FE this program is for welding with solid iron wire e SS this program is for welding with stainless steel wire Ni Cr Al Mg this program is for welding with aluminium magnesium wire Al Si this program is for welding with aluminium silicone wire Al this program is for welding with aluminium wire 910 100 335GB REVOI 36 of 44 Cu Al this program is for welding with copper aluminium wire e Cu Si3 this is for welding with Cu Si3 This material is suitable for weld brazing especially galvanised sheet iron for automobiles e Inox A this program is for welding with flux cored steel wire e Fe A this program is for welding with flux cored iron wire 2 Set the diameter of the welding wire section 3 1 2 3 Set the thickness of the workpiece using knob 9 shown in figure 1 section 3 1 2 4 Connect the ground terminal to the workpiece 5 Start to weld keeping the electric arc at a length between 5 and 10 mm This usually achieves a very good welding result however the result may require further fine tuning if so proceed as follows 6 If too much incandescent material is generated increase the inductance value by setting the appropriate parameter via knob 10 shown in figure 1 section 3 1
61. trokes Wire speed 1 2 back groune 1 Dre gas post gas t downslope t bourn Wire speed ic PMET Water pump P2 2 Synergic Pulsed MIG welding allows obtaining a very clean welding i e without any spattering of the melted materials Pulsed welding is particularly suitable for welding materials such as stainless steel Ni Cr aluminium Al and copper silicone Cu Si3 but is not suitable for ferrous materials SG2 SG3 During welding with synergic regulation knob 9 shown in fig 1 allows adjusting the wire thickness i e the welding power The wire speed is automatically adjusted to the set power depending on the type and diameter of the wire selected The wire speed can be changed slightly via the wire speed parameter The other parameters shown in the figure can also be regulated via knob 10 Arc length setting this parameter variable from 10 up to 9 allows shortening negative values or lengthening positive values the welding arc 2 4 strokes setting of the 2 stroke or 4 stroke operating mode 2t In the 2 stroke operating mode the torch button welds for the entire time it is pressed 910 100 335GB REVOI 22 of 44 4t In the 4 stroke operating mode the first pressing of the torch button starts the welding process and a second pressing stops the welding process The Crater Filler function is active in this mode when the torch button is pressed for the second time
62. tside the area where welding will take place and attach the grounding clamp to the part to be welded 4 HUMIDITY Never weld in wet or humid environments 1 DAMAGED CABLES Never use damaged cables This applies to both the power and the welding cables DAMAGED CABLES Never remove the unit side panels If the side panels can be opened always checked they are closed tightly before starting any work FIRE PREVENTION Together with the previous instructions the following pre cautions should be strictly observed Welding operations require high temperatures therefore the risk of fire is great A A A WORKAREAFLOORNG o li SRR rm A The work area floonng MUST be fireproof WORK AREA SURFACES A Work benches or tables used during welding MUST have fireproof surfaces 8 of 44 A A WALL AND FLOOR PROTECTION The walls and flooring surrounding the welding environment must be shielded using non flammable materials This not only reduces the risk of fire but also avoids damage to the wal Is and floors during welding processes EXTINGUISHER Place an approved and appropriately sized fire extinguisher in the work environment Check its working order regularly carry out scheduled inspections and ensure that all parties involved know how to use one the work environment SERIOUS DANGER 1 NEVER weld in confined spaces e g in a con tainer vehicle a cistern or a stor
63. ty for malfunction or damage resulting as a con sequence of such action WELDING OPERATION SAFETY INSTRUCTIONS A A A CAUTION Welding processes can be dangerous for the operator and bystanders if the safety wamings and instructions are not heeded PERSONNEL PROTECTION Together with the previous instructions the following precautions should be strictly observed PROTECTION MASK Wear a protective non flammable welding mask AQ to protect your neck your face and the sides of your head Keep the front lens clean and replace it if it is broken or cracked Place a transparent protection glass between the mask and the welding area CLOTHING Wear close fitting closed non flammable pocke tless clothing 1 EYE PROTECTION NEVER look at the arc without appropriate eye protection A VENTILATION Weld in a well ventilated environment that does not have direct access to other work areas FUMES AND GASES 1 Clean away paint rust or any other dirt from the item to be welded to avoid the creation of dangerous fumes FUMES AND GASES 2 NEVER weld on metals containing zinc mercury chro mium graphite heavy metals cadmium or beryllium unless the operator and the bystanders use appropriate air supplied respirators HIGH VOLTAGE PROTECTION Together with the previous instructions the following pre cautions should be strictly observed CONFINED SPACES When welding in small environments leave the power source ou
64. ults that until today were only reserved to much larger and more expensive machines while maintaining a very high level of reliability and ease of use This machine allows executing the following types of welding MIG Welding short arc manual MIG Welding pulsed manual MIG Welding short arc synergic MIG Welding pulsed synergic TIG Welding Lift Arc TIG Welding Lift arc pulsed MMA Welding Manual MMA Welding Synergic A traditional and push pull or spool torch can also be used for MIG welding This user manual contains in depth information on the adjustments and operating modes of the machine its complete reading will allow you to appreciate its extreme flexibility and practicality of use Please note that the figures most frequently referred to figures 1 to 4 are grouped together on page 12 910 100 335GB REVOI 10 of 44 If you do not consider it necessary to read the manual completely depending on the type of welding to be executed we recommend reading at least the following sections as well as the warnings on page 6 of this manual MIG Welding short arc manual us Welding 1 General features General features 2 Description of the machine Description of the machine 3 Description of the various types of welding 3 Description of the various types of welding 3 1 MIG MAG welding 3 2 TIG Welding 3 1 1 Manual short arc MIG welding 3 2 1 Traditional TIG welding 4 Power supply connection 4 Power supply connecti
65. ype of gas is chosen for the type of welding being performed AA AA N UNIDENTIFIED GAS CYLINDERS NEVER use unidentified gas cylinders PRESSURE REGULATOR 1 NEVER connect the cylinder directly to the Welder Always use a pressure regulator PRESSURE REGULATOR 2 Check the regulator is performing its function properly Read the regulator instructions carefully PRESSURE REGULATOR 3 Never lubricate any part of the regulator PRESSURE REGULATOR 4 All regulators are designed for a specific type of gas AA Check the regulator is appropriate for the protective gas to be used 910 100 335GB REVOI CLEAN ENVIRONMENT Remove all flammable materials away from DAMAGED GAS CYLINDERS NEVER use damaged or faulty cylinders CYLINDER RELOCATION NEVER lift a gas cylinder by holding the regulator GAS CYLINDERS Do not expose ges cylinders to excessive heat sour ces sparks hot slag or flames Ri GAS HOSE 1 Check the gas hose is not damaged GAS HOSE 2 Always keep the gas hose well away from the work area ELECTRIC SHOCK Together with the previous instructions the following pre cautions should be strictly observed to reduce the risk of electric shock ELECTRIC SHOCK INJURY A DO NOT touch a person suffering from electric shock if he she is still in contact with the cables Switch the mains power source off immediately THEN provide assistance CABLE CONTACT A Do not tamper with

USER MANUAL TM 236 PULSE SYNERGIC/GEN

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