SincoSald NOVAMIX 541 AC/DC DP Instruction Manual
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SincoSald NOVAMIX 541 AC/DC DP Instruction Manual

Wp3-4r feeder g.r.3
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MODEL
NOVAMIX 541 AC/DC DP
WP3-4R FEEDER
G.R.3
INSTRUCTION MANUAL
for installation,
use and maintenance
of welding
machines.
Original instructions in Italian.
Please keep for future use.
1.995.223 EN - Rev. 1.1

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  • Page 1 MODEL NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 INSTRUCTION MANUAL for installation, use and maintenance of welding machines. Original instructions in Italian. Please keep for future use. 1.995.223 EN - Rev. 1.1...

  • Page 2: Table Of Contents

    NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 Contents 1. PREFACE 1.1. PURPOSE OF THE INSTRUCTION MANUAL FOR USE AND MAINTENANCE 1.2. RECIPIENTS 1.3. STORAGE OF THE INSTRUCTION MANUAL 1.4. UPDATING THE INSTRUCTION MANUAL 1.5. HOW TO READ THE INSTRUCTION MANUAL 1.6.
  • Page 3 NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 6. MACHINE USE 6.1. MACHINE LAYOUT DESCRIPTION 6.1.1. Layout for the front and rear panel 6.1.2. Front and rear panel layout of wire feeder 6.1.3. Internal panel layout of wire feeder 6.2. FRONT PANEL FUNCTIONS AND DESCRIPTIONS 6.2.1.

  • Page 4: Preface

    NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 1. PREFACE THE OFFICIAL LANGUAGE CHOSEN BY THE MANU- FACTURER IS ITALIAN. The manufacturer cannot be held liable for translations in other languages that do 1.1. PURPOSE OF THE INSTRUCTION not conform to the original meaning (ORIGINAL IN- MANUAL FOR USE AND MAINTENANCE STRUCTIONS).

  • Page 5: Storage Of The Instruction Manual

    NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 1.5. HOW TO READ • capable of comprehending and interpreting the operator manual and the safety instructions; THE INSTRUCTION MANUAL • familiar with the emergency procedures and how The Manual is split into chapters, each one dedicated to implement them;...

  • Page 6: General Information

    NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 2. GENERAL INFORMATION Explanation of the NOVAMIX 541 AC/DC DP plate Pos. 1 Name and address of the manufacturer and trademark 2.1. MANUFACTURER Pos. 2 Identification of the welding machine model IDENTIFICATION DATA Pos.

  • Page 7: Declarations Of Conformity

    NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 WP3 - 4R FEEDER plate G.R.3 plate Explanation of the G.R.3 plate Pos. 1 Name and address of the manufacturer and trademark Pos. 2 Cooling unit model identification Pos. 3 Reference to the regulation followed for cooling unit construction: IEC 60974-2 Pos.

  • Page 8: Information On Technical Assistance

    NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 2.5. INFORMATION 3. SAFETY ON TECHNICAL ASSISTANCE 3.1. GENERAL SAFETY WARNINGS The machines are covered by a warranty, as provided for in the general conditions of sale. WARNING: your safety depends on you!!! If during the warranty period you experience a mal- - Follow all safety rules carefully.
  • Page 9 NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 • Operations at reduced safety levels must be car- A) Electric shock ried out in strict accordance with the instructions ELECTRIC SHOCK CAN BE FATAL!!! given in the relevant descriptions; - All electric shocks are potentially fatal.
  • Page 10 NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 - REMEMBER: The arc can blind or damage your - Never refill the cylinders, but have them refilled by eyes. The arc is dangerous up to a distance of 15 specialised companies. metres. Never look at the arc with the naked eye! - Do not modify or exchange the cylinder fittings.
  • Page 11 NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 Wear a mask with protective glass on the outside and H) Moving parts can cause damage adiactinic glass filter inside. This is MANDATORY for Moving parts, such as the fan, can cut fingers and welding/cutting operations, in order to protect the hands and catch clothes.
  • Page 12 NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 a) Power cables, control cables, transmission system chine must never be modified in any part except for and telephone cables that pass near the welding modifications planned and authorised by the manu- machine.

  • Page 13: Intended Use

    NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 3.3. CONTRAINDICATIONS FOR USE • inspection of all the safety devices installed on the machine; The machine must not be used: • ll connections with pins and screws; • For uses other than those specified by the man- •...

  • Page 14: Signs

    NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 3.6. SIGNS The safety signs must always be clearly visible and it is absolutely forbidden to remove or hide them. Generally there are signals or signs on the machine or in the work environment that indicate dangerous...

  • Page 15: Residual Risks

    NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 4. INSTALLATION 4.1. SHIPPING The shipment, also depending on the destination, can be carried out by different means. The packed machine must be properly anchored to the means of transport in order to avoid uncontrolled movements.

  • Page 16: Handling And Lifting

    NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 suspicious cases, open the packaging and to ver- ATTENTION: The machine must remain packed ify the safety of the machine and any loose units. during unloading from the means of transport and until it is transferred to its destination.

  • Page 17: Storage

    NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 • Complete the unloading operations by carefully Remove the protective caps from the threaded lowering the machine from the pallet. holes and tighten up the lifting eye-bolts. Do not lift the machine by the FEEDER or genera- tor handles.

  • Page 18: Assembly/Positioning

    NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 to carry out the activity, sufficiently ventilated and il- ATTENTION: The machine must be positioned so luminated, with a stable and levelled support surface. as not to obstruct the entry and exit of the air from the cooling slots.

  • Page 19: Preliminary Checks

    NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 THREE-PHASE connections Before putting the machine into operation, a number of checks and controls must be carried out in order to prevent errors or accidents during the Start-up phase: Wire colour Connection • Check that the machine has not been damaged Black "R"...

  • Page 20: Machine Description

    NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 5. MACHINE DESCRIPTION 5.1. OPERATING PRINCIPLE The NOVAMIX series welding systems were designed for MIG/MAG - TIG - MMA welding. The NOVAMIX.series welding system composition is shown below. Wire feeder Gas cylinder Trolley...

  • Page 21: Features And Main Components

    NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 5.2. FEATURES 5.4. LIGHTING AND MAIN COMPONENTS The lighting of the area of installation must comply with the laws in force in the country where the • 4.3 inches LCD screen machine is installed and must, however, ensure good •...

  • Page 22: Technical Specifications

    NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 5.7. TECHNICAL SPECIFICATIONS The following table shows the main technical specifications relating to the machine: Parameters NOVAMIX 541 AC/DC DP Power supply, three phases 400 V – 50/60 Hz Fuse 50 A MAX current...

  • Page 23: Machine Use

    NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 6. MACHINE USE 14. Repeat trigger mode indicator. 15. Air cooling mode indicator 16. Water cooling mode indicator 6.1. MACHINE LAYOUT DESCRIPTION 17. 2T trigger mode indicator. 18. 4T trigger mode indicator. 6.1.1. Layout for the front and rear panel 19.

  • Page 24: Front And Rear Panel Layout Of Wire Feeder

    NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 6.2. FRONT PANEL FUNCTIONS 6.1.2. Front and rear panel layout of wire feeder AND DESCRIPTIONS 6.2.1. Front Panel Functions of wire feeder 1. Adjustment Knob 2. Adjustment Knob 3. MIG-MAG Pulse SYN/ MIG-MAG dual pulse SYN/ 1.

  • Page 25: Operating Process Of Wire Feeder

    NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 6.2.2. Operating process of wire feeder 1. Welding method selection (press the selector switch (1) to select, the corresponding indicator light) MIG-MAG Pulse SYN MIG-MAG dual pulse SYN MIG-MAG Manual MIG-MAG SYN 2. Welding mode selection (press the selector switch (2) to select, the corresponding indicator light).
  • Page 26 NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 2T mode Pre Gas Time Slow Feed Time Post Gas Time Gun Switch Burn back Time Gas Supply Wire Feed Output Voltage Output Current Welding conditions 4T mode Self Locking Function Gun Switch...
  • Page 27 NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 S4T mode Transition Time Gun Switch Burn back Time Gas Supply Wire Feed Output Voltage Output Current Initial conditions Welding conditions End Current conditions Spot weld Gun Switch Gas Supply Wire Feed Output Voltage...

  • Page 28: User Parameter Adjustment (Fx)

    NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 6.2.3. User parameter adjustment (Fx) 2. User parameter function introduction Adjustable Display Function Mode range pre gas 0-5s post gas 0-10s slow feed time 0-10s burn back 0-10 spot weld time 0-10s delta pulse...

  • Page 29: Job Mode

    NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 DUAL PULSE FREQUENCY Call the JOB programs Set low frequency pulse frequency, as shown in Fig- • Press the JOB key (2),the JOB LED is on. ure regulating the value of time T, namely, fish scale •...
  • Page 30 NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 produce constant output current (DC). This means TIG settings with different types of electrode and arc length; A) TIG 2T/4T Trigger Control the welding voltage varies to keep the current constant. This can cause instability in some welding...
  • Page 31 NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 2. 0~t1: Pre-gas time (0.1~2.0s) 8. t4~t5: The output current slopes down to the 3. t1~t2: Arc is ignited and the output current rises crater current. The downslope time can be to the setting welding current (Iw or Ib) from the adjusted;...
  • Page 32 NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 • Up slope setting indicator (c) • Pulse mode ‘off’ indicator (33.) When the trigger is activated, the welding current • Pulse mode ‘On’ indicator (25.) • Clean Width Area/ AC Balance Adjustment (m) will increase gradually over the time selected up to the set main welding current (d).
  • Page 33 NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 AC/DC Output Modes press press press press AC MMA DC MMA AC TIG DC TIG B) AC Triangle Wave Welding Output (27.) Lift TIG Ignition is a compromise that minimises Reduced heat input for same current setting.

  • Page 34: Connecting The Welding Machine To The Power Supply

    NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 6.3. CONNECTING THE WELDING MA- play show number (The number is adjustable from 1 to 9), and the ‘Job’ indicator will be lit. CHINE TO THE POWER SUPPLY • Turn the knob to select the number for save the The welding machine is designed to operate on a parameters.(For example, let's choose JOB 1).
  • Page 35 NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 MIG-MAG Dual Pulse SYN Function 8. Gas Test 9. Material thickness /Current/ Wire Speed Display 10. Voltage/ Inductance Display MIG-MAG SYN Function 1. Voltage/ Arc length/ Inductance Set 2. Material thickness /Current/ Wire Speed Set 3.

  • Page 36: Installation & Operation For Mma Welding

    NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 6.4. INSTALLATION & OPERATION FOR MMA WELDING 1. Connection of Output Cables Connection of Output Cables Two sockets are available on this welding machine. For MMA welding the electrode holder is shown be connected to the positive socket, while the earth lead (work piece) is con- nected to the negative socket, this is known as DCEP.

  • Page 37: Installation & Operation For Tig Welding

    NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 6.5. INSTALLATION & OPERATION FOR TIG WELDING 1. Insert the earth cable plug into the positive socket on the front of the machine and tighten it. 2. Plug the welding torch into the negative socket on the front panel, and tighten it.
  • Page 38 NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 NOTE: Air cooling mode without cooling device, 12. Set torch operation 2T / 4T. and the water pipe is not needed for the air cool- ing mode. • When 2T operation is selected press trigger Gas starts, touch and lift arc start, release trigger Gas 10.
  • Page 39 NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 LIFT ARC DC TIG Operation Lift Arc ignition allows the arc to be started easily in DC TIG by simply touching the tungsten to the work piece and lifting it up to start the arc. This pre- vents the tungsten tip sticking to the work piece and breaking the tip from the tungsten electrode.

  • Page 40: Gun Switch Control Current

    NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 6.5.1. Gun switch control current UP/DOWN GUN Adjust current button, when it’s pushed up, the current increase, when it’s pushed down, the current Gun switch decrease. Socket Pin Function Not connected Not connected...
  • Page 41 NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 REMOTE GUN Adjust current roller wheel, when it’s roll upwards, the current increase, when it’s roll downwards, the cur- rent decrease. Gun switch Socket Pin Function Not connected Not connected Remote Amps 10k ohm (maximum) connection...

  • Page 42: Spool Gun Control

    NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 6.5.2. Spool Gun Control 226 Spool Gun Remote Control Socket Socket Pin Function Spool gun motor Not connected Not connected Spool gun motor 10k ohm (maximum) connection to 10k ohm remote control potentiometer.

  • Page 43: Pedal Switch Control

    NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 6.5.3. Pedal switch control • When plug the twelve-lead aero-socket of pedal switch in it. Welder will identify the pedal switch, the weld- ing current knob on the front panel will can’t use, and only 2T can be selected.

  • Page 44: Installation & Operation For Mig Welding

    NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 6.6. INSTALLATION & OPERATION 4. Connect the gas line to gas connector on the rear panel of wire feeder. Check for Leaks! FOR MIG WELDING 5. Connect the control cable of wire feeder with the 1.
  • Page 45 NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 NOTE: Air cooling mode without cooling device 14. Remove the gas nozzle and contact tip from the and the water pipe is not needed for the air cool- torch neck. ing mode. 11. Place the Wire Spool onto the Spool Holder. Snip the wire from the spool being sure to hold the wire to prevent rapid uncoiling.
  • Page 46 NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 18. Carefully open the gas cylinder valve and set the required gas flow rate. 19. Select 2T/4T/S4T/Spot Weld trigger function. 21. Set the required welding parameters to suit the material thickness being welded, it will show on the digital meter.

  • Page 47: Acronyms Display

    NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 6.7. ACRONYMS DISPLAY Display Function SPOT WELD TIME PRE GAS POST GAS SOFT START BURN BACK DUAL PULSE FREQUENCY DUAL PULSE DUTY DUAL PULSE BASE CURRENT ARC LENGTH START CURRENT PERCENT START CURRENT ARC LENGTH...

  • Page 48: Maintenance

    NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 7. MAINTENANCE 7.4. ROUTINE MAINTENANCE General requirements 7.1. MACHINE ISOLATION The machine is designed to minimise routine mainte- nance, thus it is up to the operator to assess its condi- Before carrying out any type of Maintenance or tion and suitability for use.

  • Page 49: Welding Machine Repairs

    NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 Remove dust or foreign materials every 6 months, B) Repair measures which may have been deposited on the transformer - After having carried out a repair, be careful to or on the diodes of the rectifier unit; to do this use a re-order the wiring, so that there is a secure insula- jet of dry, clean air.

  • Page 50: Diagnostics And Troubleshooting

    NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 7.6. DIAGNOSTICS AND TROUBLESHOOTING For defects or malfunctions of the machine not described in this manual, please contact the manufacturer. List of error code Error Type Error code Description Lamp status Over-heating Yellow lamp (thermal protection) always on...

  • Page 51: Accessories And Spare Parts

    NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 ACCESSORIES AND SPARE 9. ADDITIONAL INSTRUCTIONS PARTS 9.1. WASTE DISPOSAL 8.1. CUSTOMER SERVICE It is the responsibility of the user, in accordance with the laws in force in their country, to ensure correct...
  • Page 52 NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 There are 2 ways to discard DOMESTIC WEEE: For the management of "WEEE", SINCOSALD relies a) If you decide to buy a new equivalent equipment, on Erion Consortium. the user can deliver it to the distributor, who will have to collect it for free.

  • Page 53: Annexes

    NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 10. ANNEXES 10.1. WIRING DIAGRAMS 1.995.223 EN - Rev. 1.1...

  • Page 54: Spare Parts

    NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 10.2. SPARE PARTS Pos. Code Description Pos. Code Description Pos. Code Description 8.211.027 Machine cover 8.295.094 Fan 8.293.004 Emc PCB 8.291.012 Right panel 8.211.021 Fixing plate for fan 8.293.003 Wireless circuit PCB 8.215.164 Fan 8.293.010 Power PCB...
  • Page 55 NOVAMIX 541 AC/DC DP WP3-4R FEEDER G.R.3 FEEDER WP3-4R Pos. Code Description Pos. Code Description Pos. Code Description 8.251.014 Right panel 8.251.016 PCB mounting sheet 1 8.295.085 Knob 8.291.010 Left panel 8.255.015 Wheel 8.295.096 Tube Wheel mounting 8.291.011 Seal 8.251.022 Connection bar 8.251.019...
  • Page 56 SINCOSALD S.r.l Headquarters - Offices via della Fisica, 26/28 20864 Agrate Brianza (MB) Italy Tel: +39 039 641171 Fax: +39 039 6057122 export@sincosald.it www.sincosald.it...

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