Description Of The Welding Machine; Recommendations For Use - DECAWELD D-MIG 230 AC Manuel D'instruction

„ Switch off the welding machine and pull the plug out of the power socket before carrying
out any manual operations on the moving parts of the wire feeder.
EMF Electromagnetic Fields
Welding current creates electromagnetic fields (EMF) near the welding circuits and
the welder. Electromagnetic fields may interfere with medical prostheses such as
pacemakers.
Suitable and sufficient measures should be implemented to protect those operators
having such aids. For instance, they should not be allowed to enter that area where
welding equipment is used. Any operator having such aids should consult their doctor
before coming close to an area where welding equipment is used.
This device meets the specific requirements of the product technical standard and is
intended for professional use in an industrial environment only. Compliance to expected
limits for human exposure to electromagnetic fields at home is not ensured.
Follow these strategies to minimise exposure to electromagnetic fields (EMF):
„ Do not place your body between the welding cables. Both welding cables should be on
the same side of your body.
„ Twist both welding cables together and secure them with tape when possible.
„ Do not wrap the welding cables around your body.
„ Connect the earth cable to the workpiece as close as possible to the area to be
welded.
„ Keep your head and trunk as far as possible from the welding circuit. Do not work
close to the welder, or seated or leaning on it. Minimum distance: Fig 7 Da = cm 50;
Db = cm.20
Class A equipment
This equipment has been designed to be used in professional and industrial
environments.
If this equipment is used in domestic environments and those directly connected to a
low voltage power supply network which supplies buildings used for domestic purposes,
it may be difficult to ensure compliance to electromagnetic compatibility as the result of
conducted or radiated disturbances.
Welding in conditions of risk
„ If welding needs to be done in conditions of risk (electric discharges, suffocation, the
presence of inflammable or explosive materials), make sure that an authorised expert
evaluates the conditions beforehand. Make sure that trained people are present who
can intervene in the event of an emergency. Use the protective equipment described in
5.10; A.7; A.9 of the IEC or CLC/TS 62081 technical specification.
„ If you are required to work in a position raised above ground level, always use a safety
platform.
„ If more than one welding machine has to be used on the same piece, or in any case on
pieces connected electrically, the sum of the no-load voltages on the electrode holders or
on the torches may exceed the safety levels. Make sure that an authorised expert evaluates
the conditions beforehand to see if such risk exists and adopt the protective measures
described in 5.9 of the IEC or CLC/TS 62081 technical specification if required.
Additional warnings
„ Do not use the welding machine for purposes other than those described, for example
to thaw frozen water pipes.
„ Place the welding machine on a flat stable surface, and make sure that it cannot move.
It must be positioned in such a way as to allow it to be controlled during use but without
the risk of being covered with welding sparks.
„ The continuous wire is electrified when the welding machine is on. Take care not to
cause short circuits.
„ Do not work with the welding machine hung from the body, using straps or any other device.
„ Do not lift the welding machine. No lifting devices are fitted on the machine.
„ Do not use cables with damaged insulation or loose connections.

Description of the welding machine

The welding machine is a current generator for continuous wire welding, suited to welding
carbon or light alloy steels using a special FLUX cored wire, without protective gas.
The electrical characteristic of the transformer is flat.
Main parts Fig. 1
A) Spool compartment access door
B) Spool holder reel
C) Wire feeder
D) Power cable
E) ON/OFF switch
F) Torch connector (Some welding machines have directly connected cables)
G) Earth cable/inductor connector (Some welding machines have directly connected
cables)
Technical data
A data plate is affixed to the welding machine. Fig. 2 shows an example of this plate.
A) Constructor name and address
B) European reference standard for the construction and safety of welding equipment
C) Symbol of the welding machine internal structure
D) Symbol of the foreseen welding process
E) Symbol of the continuous current delivered
F) Input power required:
1˜ alternate single phase voltage, frequency
G) Level of protection from solids and liquids
H) Symbol indicating the possibility to use the welding machine in environments
potentially subject to electric discharges
I) Welding circuit performance
U0V Minimum and maximum open circuit voltage (open welding circuit).
I2, U2 Current and corresponding normalised voltage delivered by the welding
machine.
X Duty cycle. Indicate how long the welding machine can work for and how
950493-06 22/08/16
long it must rest for in order to cool down. The time is expressed in % on the
basis of a 10 minute cycle (e.g. 60% means 6 min. work and 4 min. rest).
A / V Current adjustment field and corresponding arc voltage.
J) Power supply data
U1
Input voltage (permitted tolerance: +/- 10%)
I1 eff Effective absorbed current
I1 max Maximum absorbed current
K) Serial number
L) Weight
M) Safety symbols: Refer to Safety Warnings
Technical data for torch and wire feeder Fig.4
„ Connections to the mains must be made by expert or qualified personnel.
„ Make sure that the welding machine is switched off and the plug is not in the power
socket before carrying out this procedure.
„ Make sure that the power socket that the welding machine is plugged into is protected
by safety devices (fuses or automatic switch) and grounded.
„ The device must be connected only to a supply system, with an earthed 'neutral' lead.
Assembly and electrical connections
¾ Assembly the detached parts found in the packaging. Fig.6.
¾ Check that the electrical supply delivers the voltage and frequency corresponding to
the welding machine and that it is fitted with an automatic switch suited to the maximum
delivered rated current (I2max) Fig. 3,1.
¾ Plug. If the welding machine is not fitted with a plug, fit a normalised plug (2P + T for
1Ph) of suitable capacity to the power cable Fig.3,2.
Preparing the welding circuit
¾ Connect the ground lead to the welding machine and to the piece to be welded, as close
as possible to the point to be welded.
L
The recommended sections (mm2) of the welding cable, based on the maximum
delivered rated current (I2 max), are shown in Fig. 3,3.
Installing the continuous wire
For installation, follow the instructions in Fig. 5.
The material and diameter of the wire must correspond to the wire feeder roller Fig.5,3,a,
the contact tip Fig. 5,7,b and the torch liner. If the measurements do not match, there may
be problems with the smooth running of the wire.
L
The pressure of the wire pressing knob Fig. 5,3,c is important for correct operation. If
the wire slips, there will be problems with the welding; if on the other hand it is too tight,
it may be deformed and will not run smoothly through the torch. It can be adjusted as
follows: screw the wire pressing knob until it starts to draw the wire, then, if the wire
is soft (aluminium, cored wire) turn the screw once more; if the wire is hard (steel,
stainless steel, etc.) turn the screw three more times.
L
To remove the continuous wire easily from the welding machine, cut the wire between
the spool and the wire feeder, keeping it taut, and then tie it to the spool. The open
the wire guider arm and, using a pair of pliers, pull the piece of wire out of the torch.
Welding process: description of controls and signals
Once you have put the welding machine into operation, switch it on, open the protective
gas valve and carry out the adjustments following the order shown in the description of
the controls, Fig. 1.
1) Adjusting the welding current
Select the welding current according to the work to be carried out. Start with a low current
if the metal is thin. Then increase the current until the best position is found.
L
Do not adjust the welding current while welding, as the current could damage the
switches.
2) Adjusting the wire speed
To start welding, press the trigger on the torch and adjust the continuous wire speed
Fig.3,4 The speed is correct when the noise of the welding arc is regular and constant. If
the speed is too fast, the wire presses against the piece, and if it is too slow the welding
arc stretches and the wire melts in drops. If you cannot find the correct speed, adjust the
welding current instead.
3) Thermal cutout signal
The warning light switched on means that the thermal protection is running.
If the duty cycle "X" shown on the data plate is exceeded, a thermal cutout stops the
machine before any damage is caused. Wait for operation to be resumed and, if possible,
wait a few minutes more.
If the thermal cutout continues to cut in, the welding machine is being pushed beyond its
normal performance levels. Do not continuously exceed the welding conditions, as this
could damage the welding machine.

Recommendations for use

„ Only use an extension lead when absolutely necessary and providing it has an equal or
larger section to the power cable and is fitted with a grounding conductor.
„ Do not block the welder air intakes. Do not store the welder in containers or on shelving
that does not guarantee suitable ventilation.
„ Do not use the welder in any environment in the presence of gas, vapours, conductive
powders (e.g. iron shavings), brackish air, caustic fumes or other agents that could
damage the metal parts and electrical insulation.
L
The electric parts of the welder have been treated with protective resins. When used for
the first time, smoke may be noticed; this is caused by the resin drying out completely.
The smoke should only last for a few minutes.
6
Starting up