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Summary of Contents for TEAM WELDER MIG 302 S SYNERGIC
- Page 1 Operating instructions Welding machine MIG 302 S Synergic 299-030500-TWD01 25.09.2015...
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Page 2: General Information
General information CAUTION Read the operating instructions! The operating instructions provide an introduction to the safe use of the products. • Read the operating instructions for all system components. • Observe the applicable accident prevention regulations. • Observe all country-specific statutory provisions. •... -
Page 3: Table Of Contents
Contents Notes on the use of these operating instructions Contents 1 Contents ..............................3 2 Safety instructions ..........................5 Notes on the use of these operating instructions ................5 Explanation of icons ........................6 General ............................7 Transport and installation ......................11 2.4.1 Lifting by crane ...................... - Page 4 Contents Notes on the use of these operating instructions 6 Maintenance, care and disposal ......................42 General ............................42 Maintenance work, intervals......................43 6.2.1 Daily maintenance tasks ....................43 6.2.1.1 Visual inspection ................... 43 6.2.1.2 Functional test ....................43 6.2.2 Monthly maintenance tasks ..................
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Page 5: Safety Instructions
Safety instructions Notes on the use of these operating instructions Safety instructions Notes on the use of these operating instructions DANGER Working or operating procedures which must be closely observed to prevent imminent serious and even fatal injuries. • Safety notes include the "DANGER" keyword in the heading with a general warning symbol. •... -
Page 6: Explanation Of Icons
Safety instructions Explanation of icons Explanation of icons Symbol Description Special technical points which users must observe. Correct Wrong Press Do not press Press and keep pressed Turn Switch Switch off machine Switch on machine enter the menu ENTER Navigating in the menu NAVIGATION Exit the menu EXIT... -
Page 7: General
Safety instructions General General DANGER Electric shock! Welding machines use high voltages which can result in potentially fatal electric shocks and burns on contact. Even low voltages can cause you to get a shock and lead to accidents. • Do not touch any live parts in or on the machine! •... - Page 8 Safety instructions General WARNING Explosion risk! Apparently harmless substances in closed containers may generate excessive pressure when heated. • Move containers with inflammable or explosive liquids away from the working area! • Never heat explosive liquids, dusts or gases by welding or cutting! Smoke and gases! Smoke and gases can lead to breathing difficulties and poisoning.
- Page 9 Safety instructions General CAUTION Obligations of the operator! The respective national directives and laws must be observed for operation of the machine! • National implementation of the framework directive (89/391/EWG), as well as the associated individual directives. • In particular, directive (89/655/EWG), on the minimum regulations for safety and health protection when staff members use equipment during work.
- Page 10 Safety instructions General CAUTION EMC Machine Classification In accordance with IEC 60974-10, welding machines are grouped in two electromagnetic compatibility classes - See 8 Technical data chapter: Class A machines are not intended for use in residential areas where the power supply comes from the low-voltage public mains network.
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Page 11: Transport And Installation
Safety instructions Transport and installation Transport and installation WARNING Incorrect handling of shielding gas cylinders! Incorrect handling of shielding gas cylinders can result in serious and even fatal injury. • Observe the instructions from the gas manufacturer and in any relevant regulations concerning the use of compressed air! •... -
Page 12: Lifting By Crane
Safety instructions Transport and installation 2.4.1 Lifting by crane WARNING Risk of injury during lifting by crane When lifting the machine by crane, persons may be severely injured by falling machines or mount-on components. • Simultaneous lifting of system components such as power source wire feeder or cooling unit without suitable crane components is not allowed. -
Page 13: Ambient Conditions
Safety instructions Ambient conditions Ambient conditions CAUTION Installation site! The machine must not be operated in the open air and must only be set up and operated on a suitable, stable and level base! • The operator must ensure that the ground is non-slip and level, and provide sufficient lighting for the place of work. -
Page 14: Intended Use
Intended use Applications Intended use WARNING Hazards due to improper usage! Hazards may arise for persons, animals and material objects if the equipment is not used correctly. No liability is accepted for any damages arising from improper usage! • The equipment must only be used in line with proper usage and by trained or expert staff! •... -
Page 15: Machine Description
Machine description Front view Machine description Front view Figure 4-1 Item Symbol Description Lifting lug Welding voltage step switch To set the welding voltage Main switch, machine on/off Connection socket, workpiece lead "Hard" choke tapping Connection socket, workpiece lead "Medium" choke tapping Wheels, fixed castors Wheels, guide castors Cooling air inlet... -
Page 16: Rear View
Machine description Rear view Rear view Figure 4-2 Item Symbol Description Slide latch, lock for the protective cap Protective cap Cover for the wire feed mechanism and other operating elements. Depending on the machine series, additional stickers with information on the replacement parts and JOB lists will be located on the inside. -
Page 17: Inside View
Machine description Inside view Inside view Figure 4-3 Item Symbol Description Wire spool holder Wire feed unit 299-030500-TWD01 25.09.2015... -
Page 18: Machine Control - Operating Elements
Machine description Machine control – Operating elements Machine control – Operating elements Figure 4-4 Item Symbol Description Button, Welding task / operating point The parameters are set on the rotary transducer Wire speed display (m/min) Welding current display (A) Sheet metal thickness display (mm) Display and select the jobs (welding tasks, selection via job list).Change the JOBs by holding down the button (approx. - Page 19 Machine description Machine control – Operating elements Item Symbol Description "Runtime parameters" button The parameters are set on the rotary transducer Gas post-flow time (0.0 s to 10.0 s) Wire burn-back (-50% to +50%) Spot time / pulse time (0.1 s to 5.0 s) Pulse pause (0.1 s to 2.0 s) Button, Test welding parameters Press the button and set the required welding voltage on the step switch at the same...
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Page 20: Design And Function
Design and function General Design and function General WARNING Risk of injury from electric shock! Contact with live parts, e.g. welding current sockets, is potentially fatal! • Follow safety instructions on the opening pages of the operating instructions. • Commissioning may only be carried out by persons who have the relevant expertise of working with arc welding machines! •... -
Page 21: Transport And Installation
Design and function Transport and installation CAUTION Damage due to incorrect connection! Accessory components and the power source itself can be damaged by incorrect connection! • Only insert and lock accessory components into the relevant connection socket when the machine is switched off. •... -
Page 22: Mains Connection
Design and function Mains connection Mains connection DANGER Hazard caused by improper mains connection! An improper mains connection can cause injuries or damage property! • Only use machine with a plug socket that has a correctly fitted protective conductor. • If a mains plug must be fitted, this may only be carried out by an electrician in accordance with the relevant national provisions or regulations! •... -
Page 23: Welding Torch And Workpiece Line Connection
Design and function Welding torch and workpiece line connection Welding torch and workpiece line connection Figure 5-2 Item Symbol Description Connection socket, workpiece lead "Hard" choke tapping Connection socket, workpiece lead "Medium" choke tapping Welding torch connection (Euro or Dinse torch connector) Welding current, shielding gas and torch trigger integrated •... -
Page 24: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)
Design and function Shielding gas supply (shielding gas cylinder for welding machine) Shielding gas supply (shielding gas cylinder for welding machine) 5.7.1 Connecting the shielding gas supply WARNING Risk of injury due to improper handling of shielding gas cylinders! Improper handling and insufficient securing of shielding gas cylinders can cause serious injuries! •... - Page 25 Design and function Shielding gas supply (shielding gas cylinder for welding machine) Before connecting the pressure regulator to the gas cylinder, open the cylinder valve briefly to expel any dirt. Figure 5-3 Item Symbol Description G¼” connecting nipple Shielding gas connection on the pressure regulator. Bracket for shielding gas cylinder Securing elements for shielding gas cylinder (strap/chain) Shielding gas cylinder...
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Page 26: Setting The Shielding Gas Quantity
Design and function Shielding gas supply (shielding gas cylinder for welding machine) 5.7.2 Setting the shielding gas quantity Welding process Recommended shielding gas quantity MAG welding Wire diameter x 11.5 = l/min MIG brazing Wire diameter x 11.5 = l/min MIG welding (aluminium) Wire diameter x 13.5 = l/min (100 % argon) Gas nozzle diameter in mm corresponds to l/min gas throughput... -
Page 27: Inserting The Wire Electrode
Design and function Inserting the wire electrode Inserting the wire electrode 5.8.1 Inserting the wire spool CAUTION Risk of injury due to incorrectly secured wire spool. If the wire spool is not secured properly, it may come loose from the wire spool holder and fall to the ground, causing damage to the machine and injuries. -
Page 28: Changing The Wire Feed Rollers
Design and function Inserting the wire electrode 5.8.2 Changing the wire feed rollers Unsatisfactory welding results due to faulty wire feeding! Wire feed rollers must be suitable for the diameter of the wire and the material. • Check the roller label to verify that the rollers are suitable for the wire diameter. Turn or change if necessary! •... -
Page 29: Inching The Wire Electrode
Design and function Inserting the wire electrode 5.8.3 Inching the wire electrode CAUTION Risk of injury due to moving parts! The wire feeders are equipped with moving parts, which can trap hands, hair, clothing or tools and thus injure persons! •... - Page 30 Design and function Inserting the wire electrode Figure 5-6 Item Symbol Description Feed roll tensioner Fixing the clamping unit and setting the pressure. Clamping unit Knurled nut Pressure roller Wire feed nipple Guide tube Drive rollers "Undetachable" knurled screws Wire feed nipple with wire stabiliser •...
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Page 31: Spool Brake Setting
Design and function Inserting the wire electrode 5.8.4 Spool brake setting Figure 5-7 Item Symbol Description Allen screw Securing the wire spool retainer and adjustment of the spool brake • Tighten the Allen screw (8 mm) in the clockwise direction to increase the braking effect. Tighten the spool brake until the wire spool no longer turns when the wire feed motor stops but without it jamming during operation! 299-030500-TWD01... -
Page 32: Welding Machine Control
Design and function Welding machine control Welding machine control 5.9.1 Select JOB number (welding task) This microprocessor-controlled control works according to the one-dial operation principle. Only the gas type, material type and wire electrode diameter should be set as the JOB number on the control, as well as welding output via the step switch. -
Page 33: Setting The Operating Point (Welding Output)
Design and function Welding machine control 5.9.2 Setting the operating point (welding output) For setting the operating point in JOB “0” (manual) . The following settings therefore apply to JOBs 1–24 only. Operating Action Result element Select the parameter via which the welding output is to be set: using the panel thickness using the wire speed using the welding current... -
Page 34: Setting The Operating Mode And Runtime Parameters
Design and function Welding machine control 5.9.4 Setting the operating mode and runtime parameters The parameter values set are preset in the JOB and can be modified if necessary. Operating Action Result element Select operating mode: Non-latched Latched Spots Interval Select welding parameter: Set gas post-flow time "GnS"... -
Page 35: Setting The Expert Parameters
Design and function Welding machine control 5.9.5 Setting the expert parameters The parameter values set are preset in the JOB and can be modified if necessary. Operating Action Result element Select expert parameters. The combination of button must be pressed within 3 seconds. Select expert parameters: Gas pre-flow time "GvS"... -
Page 36: Welding Parameter Ignition Time "Tzn" Diagram
Design and function Welding machine control 5.9.6 Welding parameter ignition time "tZn" diagram In the ignition time, the wire feed continues to run at creep speed after the arc is ignited; the ignition behaviour is improved with the optimum setting. The factory setting is that the ignition time is already optimally preset for various materials. -
Page 37: Mig/Mag Functional Sequences / Operating Modes
Design and function MIG/MAG functional sequences / operating modes 5.10 MIG/MAG functional sequences / operating modes There are optimum pre-sets for welding parameters such as gas pre-flow and burn back, etc. for numerous applications (although these can also be changed if required). 5.10.1 Explanation of signs and functions Symbol Meaning... -
Page 38: Non-Latched Mode
Design and function MIG/MAG functional sequences / operating modes 5.10.2 Non-latched mode Figure 5-10 Step 1 • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). • Wire feed motor runs at "creep speed". • Arc ignites after the wire electrode makes contact with the workpiece; welding current flows. •... -
Page 39: Latched Mode
Design and function MIG/MAG functional sequences / operating modes 5.10.3 Latched mode Figure 5-11 Step 1 • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). • Wire feed motor runs at "creep speed". • Arc ignites when the wire electrode makes contact with the workpiece; welding current flows. •... -
Page 40: Spot Welding
Design and function MIG/MAG functional sequences / operating modes 5.10.4 Spot welding Figure 5-12 1. Start • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). • Wire feed motor runs at "creep speed". • Arc ignites after the wire electrode makes contact with the workpiece; welding current flows. •... -
Page 41: Interval
Design and function MIG/MAG functional sequences / operating modes 5.10.5 Interval Figure 5-13 1. Start • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). • Wire-feed motor runs at "creep-start speed". • Arc ignites after the wire electrode makes contact with the workpiece; welding current flows. •... -
Page 42: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal DANGER Do not carry out any unauthorised repairs or modifications! To avoid injury and equipment damage, the unit must only be repaired or modified by specialist, skilled persons! The warranty becomes null and void in the event of unauthorised interference. •... -
Page 43: Maintenance Work, Intervals
Maintenance, care and disposal Maintenance work, intervals Maintenance work, intervals 6.2.1 Daily maintenance tasks • Check that all connections and wearing parts are hand-tight and tighten if necessary. • Check that all screw and plug connections and replaceable parts are secured correctly, tighten if necessary. -
Page 44: Disposing Of Equipment
Maintenance, care and disposal Disposing of equipment Disposing of equipment Proper disposal! The machine contains valuable raw materials, which should be recycled, and electronic components, which must be disposed of. • Do not dispose of in household waste! • Observe the local regulations regarding disposal! 6.3.1 Manufacturer's declaration to the end user •... -
Page 45: Rectifying Faults
Rectifying faults Checklist for rectifying faults Rectifying faults All products are subject to rigorous production checks and final checks. If, despite this, something fails to work at any time, please check the product using the following flowchart. If none of the fault rectification procedures described leads to the correct functioning of the product, please inform your authorised dealer. -
Page 46: Check The Machine Type Setting
Rectifying faults Check the machine type setting Check the machine type setting After switching on, the machine type that has been set is displayed for a short time, denoted as "tyP". If the machine type displayed does not match the machine, you have to correct this setting. •... -
Page 47: Resetting The Control (Reset All)
Rectifying faults Resetting the control (Reset all) Resetting the control (Reset all) All user settings will be overwritten with factory settings and must therefore be checked afterwards, or set up again! After resetting the machine control to the factory settings, it is essential that the machine type used is checked and reset if necessary. -
Page 48: Technical Data
Technical data Resetting the control (Reset all) Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Switching steps Setting range for welding 30 A to 300 A current Setting range for welding 15,5 V bis 29,0 V voltage Max. -
Page 49: Accessories
Accessories Internet Accessories Internet For the accessories available for your product go to www.teamwelder.com. Figure 9-1 299-030500-TWD01 25.09.2015... -
Page 50: Replaceable Parts
Replaceable parts Wire feed rollers Replaceable parts CAUTION Damage due to the use of non-genuine parts! The manufacturer's warranty becomes void if non-genuine parts are used! • Only use system components and options (power sources, welding torches, electrode holders, remote controls, spare parts and replacement parts, etc.) from our range of products! •... -
Page 51: Conversion Sets
Replaceable parts Wire feed rollers 10.1.4 Conversion sets Type Designation Item no. URUE VERZ>UNVERZ FE/AL Conversion kit, 37mm, 4-roller drive on non-toothed 092-000845-00000 rollers (steel/aluminium) URUE AL 4ZR4R 0,8+1,0 Conversion kit, 37mm, 4-roller drive for aluminium 092-000867-00000 URUE AL 4ZR4R 1,0+1,2 Conversion kit, 37mm, 4-roller drive for aluminium 092-000846-00000 URUE AL 4ZR4R 1,2+1,6... -
Page 52: Job-List
Appendix A JOB-List Appendix A 11.1 JOB-List Figure 11-1 299-030500-TWD01 25.09.2015... -
Page 53: Setting Instructions
Appendix B Setting instructions Appendix B 12.1 Setting instructions Figure 12-1 299-030500-TWD01 25.09.2015...
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