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INSTRUCTION MANUAL PRIMA MULTI 190 VERSION 01-13 1 of 16 PRIMA MULTI 190
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INSTRUCTION MANUAL PRIMA MULTI 190

VERSION 01-13 1 of 16

PRIMA MULTI 190

INSTRUCTION MANUAL PRIMA MULTI 190

VERSION 01-13 2 of 16

TABLE OF CONTENTS 1. IMPORTANT SAFETY RECOMMENDATIONS ...................................................................................... page 3 2. TECHNICAL FEATURES ........................................................................................................................ page 5 3. CONTROL OF CURRENT PEAKS ......................................................................................................... page 6 4. GAS CONNECTION ............................................................................................................................... page 6 5. LOADING OF WIRE COILS .................................................................................................................... page 6 6. REVERSE POLARITY………………………………………………………………………………………….page 6 7. OPERATION DESCRIPTION.................................................................................................................. page 7 8. ARC LENGTH ADJUSTMENT ................................................................................................................ page 7 9. INDUCTANCE ADJUSTMENT ................................................................................................................ page 7 10. ADJUSTMENT AND DISPLAY ................................................................................................................ page 8 11. PROGRAMS MULTIFUNCTION WELDING PRIMAMULTI 190 ............................................................. page 9 12. PACKING……………………………………………………………………………………………………….page 10 13. UNPACKING……………………………………………………………………………………………… ....... page 10 14. STORAGE………………………………………………………………………………………………… ....... page 10 15. LIFTING AND HANDLING………………………………………………………………………………… .... page 10 16. CONNECTION-INSTALLATION-WARNINGS-CHECKS……………………………………………… ..... page 11 17. START UP…………………………………………………………………………………… ......................... page 11 18. LIMIT OF USE………………………………………………………………………………. ......................... page 12 19. ENVIRONMENT…………………………………………………………………………….. ........................ page 12 20. STARTING THE MACHINE………………………………………………………………… ........................ page 12 21. MAINTENANCE……………………………………………………………………………… ....................... page 12 22. SCHEDULED MAINTENANCE…………………………………………………………….. ....................... page 12 23. EXTRAORDINARY MAINTENANCE……………………………………………………… ........................ page 13 24. FIRE…………………………………………………………………………………………… ....................... page 13 25. DISASSEMBLY – DISPOSAL………………………………………………………………. ....................... page 13 26. ALARMS AND SIGNALS……………………………………………………………………. ....................... page 14 27. ELECTRIC DIAGRAM………………………………………………………………………. ........................ page 15

INSTRUCTION MANUAL PRIMA MULTI 190

VERSION 01-13 3 of 16

IMPORTANT SAFETY RECOMMENDATIONS BEFORE USING THIS GENERATOR, CAREFULLY READ THE CONTENTS OF THIS MANUAL. THIS MANUAL MUST BE KEPT IN A SAFE PLACE, WHICH MUST BE KNOWN AND ACCESSIBLE TO ALL USERS FOR THE ENTIRE LIFE AND OPERATION OF THE MACHINE. THIS GENERATOR MUST ONLY BE USED FOR WELDING OPERATIONS.

1. DECLARATION OF CONFORMITY The machine described in this manual must be used professionally in an industrial environment. This machine is built in compliance with the EN 50199 standard (electromagnetic compatibility) and EN 60974-1 standard. In case of malfunction, contact a qualified technician.

1.1 WEEE DIRECTIVE The symbol on the packaging of the product indicates that it cannot be disposed of as normal domestic waste. The machine must be sent to special collection facilities and/or operators specialised in the disposal of electric/electronic waste. The correct disposal of the machine’s parts and components will help prevent potential negative consequences to the environment and human health. For more detailed information please contact your local waste disposal authorities.

2. SAFETY PRECAUTIONS The electric arc generated in welding or cutting may be harmful to you and others. Therefore, the operator must be well informed and instructed on the risks and dangers deriving from the welding operations and described in this manual.

ELECTRIC SHOCK – CAN KILL

Connect the machine to the mains power supply according to the applicable safety standards, making sure the mains installation itself complies with these standards and is fitted with an appropriate earth connection. Do not touch with bare hands the conductive elements or potentially conductive elements of the machine, its cables and electrodes, and do not use wet gloves and clothing. Insulate yourself from

the workpiece and the ground. Make sure to work in a safe environment and position.

FUMES AND GASES – CAN BE HAZARDOUS TO YOUR HEALTH

Keep your face away from welding fumes and try not to breathe the emissions. Work in a well ventilated environment and, if necessary, wear approved masks and/or personal protection devices and aspirators.

ULTRAVIOLET AND INFRARED RAYS – CAN BURN EYES AND SKIN

Protect your face and eyes with an approved welding helmet fitted with proper filtering lenses, and protect your hands and body with approved safety clothing. Use protective screens or barriers to protect others from flash, glare and sparks.

WELDING – CAN CAUSE FIRE AND BURNS Welding spatter can cause fire and skin burns. Make sure the working environment does not have any flammable substances or materials and always wear protective clothing.

INSTRUCTION MANUAL PRIMA MULTI 190

VERSION 01-13 4 of 16

NOISE This machine does not produce noise levels exceeding 80 dB. However, it is recommended to wear approved ear protection if noise level is high.

PACEMAKERS The magnetic field generated during the arc welding process could affect the functioning of pacemakers. Wearers of life support devices (e.g. pacemakers) should consult their doctor before performing any type of welding operation.

EXPLOSIONS Do not weld near pressurised containers, explosive or potentially explosive powder, fumes or gas. Gas cylinders and pressure reducers must be in perfect working order and must be handled with care.

GENERAL INFORMATION THIS MACHINE IS A DIRECT CURRENT GENERATOR BUILT AND DESIGNED TO WELD CONDUCTIVE MATERIALS (METALS AND ALLOYS) BY MEANS OF AN ELECTRIC ARC PROCESS. THIS IS THE ONLY USE PERMITTED. For the definition of the terms used in this manual, refer to the standard UNI EN 292. This machine has been manufactured in compliance with the following regulations:

Machine Safety Directive 2004/108 CE

2006/42/CE Directive, electromagnetic compatibility.

2006/95/CE Directive, low voltage electric material.

EN 50063 Standard, building and installation of resistance welders.

UNI EN 292/1 and 292/2 Standard, machinery safety.

INSTRUCTION MANUAL PRIMA MULTI 190

VERSION 01-13 5 of 16

TECHNICAL FEATURES

MIG/MAG TIG MMA

1~ 230 V 50/60 Hz

16-25 A

4,8 KVA 4,8 KVA 4,8 KVA

8 ÷ 190 A 5 ÷ 190 A 10 ÷ 190 A

190 A 40% 160 A 60%

140 A 100%

190 A 40% 160 A 60%

140 A 100%

180 A 40% 160 A 60%

130 A 100%

0,6-0,8-1,0 SG2

0,8-1,0 SST 0,9 FLUX 0,8-1,0 Al

0,8-1,0 CuSi

--- ---

ø 100 - 1 Kg ø 200 - 5 Kg

--- ---

--- --- ø 1.5 ÷ 4

Electronic

IP 21 S

10 Kg

118 x 360 x 300

INSTRUCTION MANUAL PRIMA MULTI 190

VERSION 01-13 6 of 16

MOTOR GENERATOR – CONTROL OF CURRENT PEAKS The standard machine is also set up to operate with motor generators and/or long power supply cords, within the voltage limits of +/- 10% of the V 230. When the voltage exceeds these limits, the machine stops functioning and the front display will indicate the current peak, as shown in the figure.

GAS CONNECTION The generator is fitted with one gas connection tubes, connect the pressure reducer on the cylinder, then connect the gas tubes, open the cylinders and adjust the gas output at around 12 litres/minutes for each outlet.

ATTENTION: Make sure the cylinders are well secured to the cylinder support before proceeding with the welding process.

LOADING OF WIRE COILS The machine is set up to use wire coils with a diameter of 100 mm (with the kit of the assembly also wire coils with a diameter of 200 mm). The welding machine can weld any type of material. a) Make sure the wire feed rollers are positioned according to the diameter of the wire used; b) Position the coil, insert the wire between the rollers and in the Euro connection, and then secure the rollers

properly; c) Connect the MIG/MAG torch;

d) Press the torch button, the wire will exit slowly, press the button (+) on check panel together the button on the torch, in this phase the wire will exit quickly and there is not exit of the gas to avoid unnecessary waste

REVERSE POLARITY : ATTENTION: In the processes of welding TIG and FLUX (flux cored wire without gas) is necessary to reverse the polarity welding by changing the position of the lugs into the terminal.

Significa corretta alimentazione

169V picco di corrente rilevata al momento del blocco.

INSTRUCTION MANUAL PRIMA MULTI 190

VERSION 01-13 7 of 16

OPERATION DESCRIPTION

ATTENTION: The thickness of the base materials is calculated according to a normal horizontal welding procedure. In case of joints or different positions, increase or reduce the current/thickness values.

ADJUSTMENT OF THE ARC LENGTH The arc length has thermal effects on the welding to be executed, and therefore, depends on the thickness of the piece to be welded. Effects of the arc length on the welding process.

LONG ARC (+):

The welding becomes flatter and the bead becomes wider, consequently the welding temperature increases.

SHORT ARC (-):

The welding becomes more concentrated and the bead becomes smaller, consequently the welding temperature decreases.

ADJUSTMENT OF THE INDUCTANCE Effect of the adjustment of the inductance on the weld bead.

HIGH INDUCTANCE (+)

With a high inductance, the welding gets wider and the penetration decreases.

LOW INDUCTANCE (-) With a low inductance, the welding gets smaller and the penetration increases.

INSTRUCTION MANUAL PRIMA MULTI 190

VERSION 01-13 8 of 16

ADJUSTMENT AND DISPLAY

Leedd::

1) Blinking during the turning the knob.

2) Short flashes with the welding machine is standby. saldatrice è in standby.

LLeedd::

Blinking with welding points active

Connector earth cable

Key Set: 1) Press for 3 seconds to start

to welding programs Menù with the keys (+) and (-) select the wished welding program.

2) Press more times to visualize the current in Amper, voltage in Volts, the speed of the wire m/min.

Display:

Visualize programs, values and alarms. P= synergic and manual programs. T= thickness material (mm). A= welding current (A) V= welding voltage (V) M= wire speed (m/min) Arc= arc length (from -15 to +15)

Connector Euro for:: 1. Mig/Mag/Flux Torch

2. Tig Torch

3. Mma Gun(electrode)

Knob:

1) With synergic programs P1÷P11, turn the knob to select the

thickness t in mm of the sheet to

weld. 2) With manual programs

P12 Man, P13 Mma and P14 Tig, turn the knob to select the welding current

Key Timer:

1) Press to activate or not activate the welding points..

2) Press for 3 seconds for select with the keys (+) and (-) the time in seconds about the welding point.

Led:

1) Led on, indicate the welding synergic funcion activated with the programs P1÷P11.

2) Led off, indicate the welding function P12 Man, P13 Mma and P14 Tig.

Key ̶ : 1) Press to shorten the doing

operation in standby and in welding.

2) Press to the search of programs (P..) with activated menù.

3) Press to shorten the welding time with activated timer.

Key + ( ):

1) Press to lengthen the arc, doing operation in standby and in welding.

2) Press to the search of programs (P..) with activated menù

3) Press to increase the time of the welding point with active timer.

4) Press the key and together the button on the torch to activate the fast forward function of the wire without gas leakage

Switch on-off

INSTRUCTION MANUAL PRIMA MULTI 190

VERSION 01-13 9 of 16

PROGRAMS MULTIFUNCTION WELDING PRIMAMULTI 190

PROG N°

MATERIALE BAS

MATERIAL WIRE

WIRE Ø mm GAS NOTES

P1 Syn

Steel or Iron SG2 0.6 Mix Program SYNERGIC with gas Ar-CO2 (Mix).For thicknesses greater than 3 mm using wire with a larger diameter.

P2 Syn

Steel or Iron SG2 0.8 Mix Program SYNERGICO with gas Ar-CO2 (Mix).

P3 Syn

Steel or Iron SG2 1.0 Mix Program SYNERGIC with gas Ar-CO2 (Mix).

P4 Syn

Steel or Iron SG2 0.6 CO2 Program SYNERGIC with gas CO2.

P5 Syn

Steel or Iron SG2 0.8 CO2 Program SYNERGIC with gas CO2.

P6 Syn

Steel or Iron SG2 1.0 CO2 Program SYNERGIC with gas CO2.

P7* Syn

Steel or Iron Cored wire

Flux 0.9

No Gas

Program SYNERGIC with cored wire, without gas. Use roll with 0,8 mm throat.

P8 Syn

Inox steel Inox 0.8 Mix Program SYNERGIC with gas mixture Ar-CO2 (Mix).

P9 Syn

Steel or Iron Cu-Si3 0.8 Ar Program SYNERGIC with gas Argon.

P10 Syn

Steel or Iron Cu-Si3 0.8 Mix Program SYNERGIC special with gas mixture Ar-CO2

(Mix).

P11 Syn

Aluminum Al-Mg5 1.0 Ar Program SYNERGIC with gas Argon.

P12 Syn

Aluminum Al-Si12 1.0 Ar Program SYNERGIC with gas Argon.

P13* Tig

Steel or Iron Tungstene 2.4 Ar Program SYNERGIC for welding TIG DC Lift with gas Argon.

P14* Tig

Steel or Iron Tungstene 2.4 Mix Program SYNERGIC special for welding TIG DC Lift with gas mixture Ar-CO2 (Mix).

P15 Mma

Steel or Iron Electrodes 1.5÷4.0 --- Program MANUAL for electrode welding (MMA).

P16 --- --- --- --- No Prog

P17 --- --- --- --- No Prog

P18 Man

All All 0.6÷1.2 All The manual program requires adjustment of all parameters..

* ATTENTION: Reverse the polarity with the programs P7 Flux, P13 Tig and P14 Tig. The size of the throat of the roll feeder must be appropriate to the diameter of the wire being used. Tighten the wire feeder to approximately 2/3 for programs P1÷P10 and P18, for programs P11 and P12 to about 1/3. For best results use welding wires and gases listed.

INSTRUCTION MANUAL PRIMA MULTI 190

VERSION 01-13 10 of 16

EXAMPLE: Welding of steel sheet thickness of 1 mm with a synergic program P2.

Install a coil of wire type SG2 wire 0,8 mm

Install a gas cylinder Mix (Ar-CO2).

Check that the roll feeder is positioned on the side for wire 0.8.

Insert the wire and tighten the wire feeder to 2/3, to move the wire by pressing the torch button, to move the wire quickly without leakage of the gas, hold the button on the torch and key .

Check that the wire remains well placed in the throat of a roll. Check that the torch is mounted on the tip of the wire guide 0.8 mm. To select the welding program, press the for 3 seconds.

Press the keys or to look for and to visualize the wished program P2.

Press the key for 3 seconds to exit from menù, or waiting for some seconds for the automatic exit.

Turning the knob to select the values, t 1.0 indicates the thickness of the sheet metal to be welded, with this

setting you have the optimal parameters for the welding of steel sheet with thickness of 1 mm. Note: turning the knob, you can also change the values during the welding.

UTILITY:

With keys or to increase or decrease the length of the arc, the adjustment can also be done during

welding.

During the welding the display shows the following values: for Ampere, for Volt, for speed of the wire (m/min), to select the wished value press the

key .

PACKING The welding machine comes packed in a box on the pallet, fastened with steel strips and wrapped in a plastic film.

UNPACKING Remove the panels of the wooden case (if provided).

Remove the steel strips

Remove the protective plastic material and the cartboard.

Lift the spot welder with suitable means and remove the pallet.

CAUTION: The packing materials – wood, nails, plastics etc. – must not be left within the reach of children, as they could be a source of danger. The packing materials must be subdivided and disposed of in compliance with the applicable Codes.

STORAGE The spot welder must be stored at a temperature between 0 and 40 °C in a dry place, protected from weather and far from heat sources.

LIFTING AND HANDLING The welding machine must be lifted and handled with care, avoiding bumps and falls which could compromise its integrity.

INSTRUCTION MANUAL PRIMA MULTI 190

VERSION 01-13 11 of 16

CONNECTION – INSTALLATION – WARNINGS – CHECKS The connection must be made by qualified personnel in compliance with the applicable regulations connecting to an electrical panel to an efficient grounding system with a differential circuit breaker of adequate capacity to power the welder.(tab. 1 page 5, technical features).

CAUTION: The welding machine is monophase and is equipped with a power cable with two conductors, plus a third conductor used exclusively for connection to the grounding and thus must be connected to single-phase distribution lines, make the sizing of the power line, section of the conductors and the capacity of the fuses.

CAUTION: During all installation and connection operations, the machine must be absolutely isolated from the power supply line.

CAUTION: Installation must be made by qualified personnel in compliance with the applicable regulations and in accordance with the instructions of the manufacturer.

CAUTION: Before connecting the machine to the mains supply, make sure that the data on the nameplate of the spot welder correspond to the voltage and frequency of the mains supply available on site. Check that the installed power on the electric supply meter as well as the cables of the electrical plant are adequate for the rated power of the welding machine.

Electrical safety of the spot welder is obtained only when connected to an efficient grounding system made in compliance with the applicable Regulations. Have qualified personnel check the system for functional efficiency.

CAUTION: The Manufacturer cannot be held liable for possible damage caused by absence or inefficiency of the grounding system.

CAUTION: In case the user makes modifications, alterations or changes of the spot welder or integrates it in a plant, any liability of the Manufacturer decays and the user is obliged to remove the CE label.

The non-observance of the above instructions will render the safety system provided by the Manufacturer ineffective, causing serious risks of personal injuries and material damage.

START UP

CAUTION: Remember some safety precautions to be taken in order to avoid hazardous situations.

The operator must have adequate knowledge and training in resistance welding procedures with this type of spot welder.

Do not allow unauthorized persons to access the working area.

Avoid that more then one person works simultaneously on the same spot welder.

The spot welder is equipped with moving elements, therefore all precautions must be taken to prevent these elements from striking against persons or things

CAUTION: Do not wear magnetic metal objects as rings, bracelets, watches etc. during welding operations, because these objects can be violently attracted by the magnetic field generated by the spot welder or considerably overheated due to the Joule effect and cause burns. The operator must wear safety glasses, gloves and an apron to protect himself against ultraviolet rays made by the arc and against sparkling incandescent particles, burns and cuts in the hands.

Notes: The individual protective systems must be in compliance with the applicable Regulations.

INSTRUCTION MANUAL PRIMA MULTI 190

VERSION 01-13 12 of 16

LIMIT OF USE

This welding machine has been designed, dimensioned and manufactured for resistance welding on thin steel sheet. Any use with different welding procedures, non-iron metals, different sheet thickness as indicated may affect proper operation and cause damage to the welding machine.

Therefore the machine must be destined only for the use foreseen and described in this manual, any other use is to be considered improper and may cause hazards to the operator's safety and material damage.

The manufacturer cannot be held liable for possible personal injuries or material damage arising from improper or unreasonable use.

ENVIRONMENT

Working ambient temperature: 5°C to 35°C. Working air humidity: lower than 90%.

STARTING THE MACHINE

WARNING: The first start-up of the spot welder must be made by qualified personnel. Before performing any welding operation, a series of checks and adjustments must be made.

Make sure the electrical connection has been made properly and in compliance with the applicable Regulations.

Check that the gas is suitable for welding to be performed, open the gas cylinder and adjust the flow.

Check that the wire feed roller and the liner of the torch match the diameter of the wire used.

Set on the control of welding parameters depending on the type and quality of the sheet to be welded.

Operate the switch, turning on the display confirms the proper feeding of the welding machine.

Place the ground clamp close to the welding area.

Move to the welding area, press the button and run the welding torch.

CAUTION: The welding machine must be used by trained personnel.

MAINTENANCE CAUTION: Never remove the panels of the welding machine and access the interior without having previously removed the power cord from the power supply box. CAUTION: Possible checks inside the spot welding machine, performed when energized, can cause heavy electrical shocks generated by direct contact with current carrying parts. CAUTION: Maintenance must be performed by qualified personnel.

SCHEDULED MAINTENANCE Maintenance of components and wear materials must be performed on a regular basis once a week or more often according to the use and the environmental conditions as listed below.

Check and replace the wire guide and nozzle, eliminate the waste caused by the welding arc.

Check the integrity of the torch, cable and earth clip.

Check the status of the power cable.

Check the tightness of the gas tubes.

Inspect the welding machine and remove dust and particles that were deposited on the various components.

INSTRUCTION MANUAL PRIMA MULTI 190

VERSION 01-13 13 of 16

EXTRAORDINARY MAINTENANCE

Repair and replacement of components of the welding machine, if required, must be performed by qualified personnel using only original spare parts.

CAUTION: Replacement of components with not original spare parts and/or alterations of the machine causes the decay of any liability of the manufacturer for personal injuries or material damage that may arise.

FIRE In case of fire, use only powder extinguishers complying with the applicable Regulations.

CAUTION: NEVER USE LIQUID FIRE EXTINGUISHERS, BECAUSE THE MACHINE COULD BE ENERGIZED.

CAUTION: WHEN BURNING, SOME PARTS OF THE MACHINE MAY PRODUCE TOXIC COMBUSTION GASES OR SMOKE.

DISASSEMBLY - DISPOSAL CAUTION:

If the machine is to be put out of service, provide for disassembly and disposal according to the applicable Regulations.

Subdivide the different materials:

Metal

Electric material

Electronic material

Plastic and rubber material

ATTENTION: Waste materials must be subdivided and disposed of in compliance with the applicable Laws.

INSTRUCTION MANUAL PRIMA MULTI 190

VERSION 01-13 14 of 16

ALARMS AND SIGNALS

MESSAGE ON DISPLAY

DESCRIPTION OF THE MESSAGE SOLUTION OF THE PROBLEMS

= °C

followed by the value in degrees of

temperature.

The temperature of the machine has exceeded this limit, thermal protection with indication of

temperature.

Leave the machine turned on with the fan running, wait for it to continue to work.

= t°C

The temperature of the control board of the machine has exceeded this limit, thermal protection with indication of temperature.

Leave the machine turned on with the fan running, wait for it to continue to work.

= POL. You have selected a program that requires welding polarity reversal.

Reverse the negative and positive poles, acting on the terminals.

= vr.P. High friction in the sliding of the wire, limitation, wire pressure exceeded.

Replace the sheath, hold the torch at most stretched.

= vir Progress of the blocked wire.

Check the coil, torch, wire feeder and every possible obstacle to the advancement of the wire ..

= E01 Torch button pressed when the power of the welder.

Check the button on the torch.

= E02 Torch button pressed. The signal will terminate upon release of the torch button.

= tr.c. Torch in contact with the workpiece or ground.

Make sure that the torch has not been in contact with the workpiece or ground.

Display flashes during welding.

Values of welding different than the synergic program selected.

Make sure the wire is flowing properly, check the settings of welding.

Point flashes at the right of the display.

Welding values unreliable. The signal will expire on the next welding.

Point flashes at the right of the display.

The synergic welding is not stable. The signal will expire on the next welding.

= Mot Problem with the engine of the wire feeder. Check the motor connections.

= V.in Electrical power problem. Check that the mains voltage is within the normal range.

= r

Stability of the electricity grid, when you turn off the welding machine.

Check the connection to the electricity grid, switch, sockets, voltage and frequency.

= vc Electrical power problem. Check the voltage drop across the net.

= noP Welding program not exist

Central led flashing Automatic standby function, after seven minutes

of inactivity. Any intervention, the torch button, knob or button to revert to its normal operating state.

INSTRUCTION MANUAL PRIMA MULTI 190

VERSION 01-13 15 of 16

ELECTRIC DIAGRAM

INSTRUCTION MANUAL PRIMA MULTI 190

VERSION 01-13 16 of 16

PRIMA

PRIMA SRL I - 35020 ALBIGNASEGO / PD Via Garibaldi, 28 Tel. +39 049 8625963 r.a. - Fax. +39 049 8625968 P. IVA 00069400281 Reg. Impr. PD 43705 – R.E.A. PD 247779 Capitale Sociale Int. Vers. € 100.000,00 http: www.primasald.com


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