DECA WELD JOB 522P LAB

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Overview

Important Technical Specifications
Usage Features
Assembly and Electrical Connections
Preparing the Welding Circuit MIG
Installing the Continuous Wire
Wire Load Function
Gas Test Function
Preparing the Welding Circuit MMA
Preparing the Welding Circuit TIG
SD Card Connector
Maintenance Features
Ordinary Maintenance (to be carried out periodically by the operator depending on use)
Every time the wire spool is replaced
Extraordinary Maintenance (to be carried out by expert staff or qualified electrical mechanics periodically depending on use)

This document describes a range of welding machines that differ in some of their characteristics. The specific model can be identified in Fig. 1.

The welding machine is a current generator for continuous wire welding, commonly known as MIG/MAG, suitable for welding carbon or light alloy steels, stainless steel, and aluminum using protective gas. The electrical characteristic of the transformer is flat (constant voltage). The welding machine is a current transformer for manual arc welding using MMA coated electrodes and TIG with a torch that strikes the arc on contact. The delivered current is direct. The electrical characteristic of the transformer is of the falling type. The welding machine is built using electronic INVERTER technology.

Important Technical Specifications

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: D1: MIG; D2: TIG; D3 MMA.
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:
- UOV Minimum and maximum open circuit voltage (open welding circuit).
- I2, U2 Current and corresponding normalized voltage delivered by the welding machine.
- X Duty cycle. Indicates how long the welding machine can work for and how 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.8

Usage Features

Assembly and Electrical Connections

Assemble the detached parts found in the packaging Fig.10.
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. 9,1.
This equipment does not apply to the requirements set out in the IEC/EN61000-3-12 standard. If this equipment is connected to a low voltage power supply network, either the installer or the user is responsible for checking that this can be done (consult the distribution system operator if required).
In order to comply with the requirements set out in the EN61000-3-11 (Flicker) standard, it is advisable to connect the welder to the supply network interface points having an impedance lower than the reference Zmax = Fig.9,4.
Power plug. The effective absorbed current "I1 eff" is indicated on the technical plate of the welding machine when it is used at maximum power. Connect the welding machine to a normalized plug (2P+T per 1Ph) of capacity sufficient to deliver maximum power. Fig 9,2. If a 16A plug is connected to the welding machine, follow the instructions in Fig.9.

Preparing the Welding Circuit MIG

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.
Connect the torch** to the welding machine socket. Select the polarity of the torch**. For selection follow the instructions in Fig.5.
The torches with speed controls on the handle and Spool guns have a pin that must be connected in the socket G Fig. 1.

Installing the Continuous Wire

For installation, follow the instructions in Fig. 3.
The material and diameter of the wire must correspond to the wire feeder roller, the contact tip and the torch liner. If the measurements do not match, there may be problems with the smooth running of the wire.
The pressure of the wire pressing knob 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.

Wire Load Function

Press the button "Q" inside the coil compartment and then the button on the torch. The wire is loaded even after releasing the button "Q" until the button on the torch is pressed.

Installing the Protective Gas Cylinder and Pressure Reducer**

Place the protective gas cylinder in an upright position, far away from the welding area. Use the welding machine support or some other fixed part so that there is no risk of it falling or being damaged.
For installation, follow the instructions in Fig. 4.

Gas Test Function

Press the button "P" inside the coil compartment. The solenoid valve remains open until the button is pressed again, or it will close automatically after 30 seconds.

Preparing the Welding Circuit MMA

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.
Connect the cable with the electrode holder gripper** to the welding machine and mount the electrode on the gripper. Refer to the electrode manufacturer's instructions concerning connection and welding current.

Preparing the Welding Circuit TIG

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.
Connect the TIG torch** power connector to the negative attachment on the welding machine and mount the electrode. The torch must be fitted with a gas flow adjustment valve.
Connect the TIG torch gas pipe to the output of the pressure reducer mounted on an ARGON protection gas cylinder.
The recommended sections (mm2) of the welding cable, based on the maximum delivered rated current (I2 max), are shown in Fig. 9,3.

SD Card Connector

The connector is useful for updating the software of the machine and uploading new synergistic programs.
Insert the sd card when the machine is off.
Switch on the machine.
The software is loaded. At the end of the update the control panel gets back to the normal status.
Remove the sd card.

Maintenance Features

Switch off the welder and remove the plug from the power socket before carrying out any maintenance operations.

Ordinary Maintenance (to be carried out periodically by the operator depending on use):

Check the gas hose, torch cable and ground cable connections.
Clean the contact tip and the gas diffuser with an iron brush. Replace if worn.
Clean the outside of the welder with a damp cloth.

Every time the wire spool is replaced:

Check the alignment, cleanliness and state of wear of the wire roll Fig.7.
Remove any metal powder deposited on the wire feeder mechanism.
Clean the wire guide liner with anhydrous solvent and grease remover and dry with compressed air.
Check the condition of the warning labels. Replace any worn parts.

Extraordinary Maintenance (to be carried out by expert staff or qualified electrical mechanics periodically depending on use):

Inspect the inside of the welder and remove any dust deposited on the electrical parts (using compressed air) and the electronic cards (using a very soft brush and appropriate cleaning products).
Check that the electrical connections are tight and that the insulation on the wiring is not damaged.