SincoSald NOVATIG 503 AC/DC Instruction Manual
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SincoSald NOVATIG 503 AC/DC Instruction Manual

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MODEL
NOVATIG 503 AC/DC
G.R.3
INSTRUCTION MANUAL
for installation,
use and maintenance
of welding
machines.
Original instructions in Italian.
Please keep for future use.
1.995.217 EN - Rev. 1.1

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Summary of Contents for SincoSald NOVATIG 503 AC/DC

  • Page 1 MODEL NOVATIG 503 AC/DC G.R.3 INSTRUCTION MANUAL for installation, use and maintenance of welding machines. Original instructions in Italian. Please keep for future use. 1.995.217 EN - Rev. 1.1...

  • Page 2: Table Of Contents

    NOVATIG 503 AC/DC 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. TERMS, SYMBOLS AND PICTOGRAMS 2.
  • Page 3 NOVATIG 503 AC/DC G.R.3 6. MACHINE USE 6.1. MACHINE LAYOUT DESCRIPTION 6.1.1. Layout for the front and rear panel 6.1.2. Further Controls Explained 6.2. POWER SUPPLY INPUT CONNECTION 6.3. INSTALLATION & OPERATION FOR MMA WELDING 6.3.1. Set up installation for MMA Welding 6.3.2.

  • Page 4: Preface

    NOVATIG 503 AC/DC 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

    NOVATIG 503 AC/DC 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

    NOVATIG 503 AC/DC G.R.3 2. GENERAL INFORMATION NOVATIG 503 AC/DC plate explanation Pos. 1 Name and address of the manufacturer 2.1. MANUFACTURER and trademark IDENTIFICATION DATA Pos. 2 Identification of the welding machine model MANUFACTURER: SINCOSALD S.r.l Pos. 3 Welding machine serial number Pos.

  • Page 7: Declarations Of Conformity

    NOVATIG 503 AC/DC G.R.3 2.3. DECLARATIONS OF CONFORMITY Pos. 11b Service factor: 100 % Pos. 12 Rated welding current (I2) The machine is constructed in compliance with the Pos. 12a Value of the rated welding current at 60 % relevant EU Directives, applicable at the time of its Pos.

  • Page 8: Preparation By The Customer

    NOVATIG 503 AC/DC G.R.3 2.6. PREPARATION BY THE CUSTOMER 3. SAFETY Unless otherwise agreed in the contract, the follow- 3.1. GENERAL ing are normally the Customer's responsibility: • Room preparations, including any building work SAFETY WARNINGS and/or ducting systems required;...
  • Page 9 NOVATIG 503 AC/DC G.R.3 It is, however, essential to diligently follow the follow- All safety features placed on moving parts to prevent ing indications: accidents and safeguard safety can not be modified • It is absolutely forbidden to operate the machine or removed, but must be adequately safeguarded.
  • Page 10 NOVATIG 503 AC/DC G.R.3 B) Radiation - Do not expose cylinders to excessive heat, sparks, Ultraviolet radiation, emitted from the electric arc, molten slag or flames. can damage the eyes and burn the skin. - Do not tamper with the cylinder valves.
  • Page 11 NOVATIG 503 AC/DC G.R.3 - Do not keep combustible materials such as light- DO NOT WELD or cut where solvent vapours can ers or matches in your pocket. be drawn into the welding atmosphere or if radiant energy can penetrate into atmospheres containing...
  • Page 12 NOVATIG 503 AC/DC G.R.3 Work area control to prevent E.M. interference which may have been deposited on the transformer Before installing the welding machine it is necessary or on the diodes of the rectifier unit; to do this use a to check the work area to detect the existence of ser- jet of dry, clean air.

  • Page 13: Intended Use

    NOVATIG 503 AC/DC G.R.3 They include: ATTENTION: It cannot therefore be used as a de- • inspection of all supporting structures, which vice tor thaw pipes; any improper use automati- cally voids the warranty and excludes the man- must not show any signs of cracking, breakage,...

  • Page 14: Signs

    NOVATIG 503 AC/DC 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

    NOVATIG 503 AC/DC G.R.3 3.7. RESIDUAL RISKS Careful use of the machine minimises the probability of accidents; however, during the use of the machine it is necessary to strictly observe the safety rules de- scribed in this manual. Blinding: Protection goggles or mask must be worn near this symbol.

  • Page 16: Installation

    THE PACKAGING CONTAINS: For transport to the final installation site, it is prefera- No. 1 NOVATIG 503 AC/DC welding machine ble to use a forklift or pallet truck, taking care that the No. 1 G.R.3. cooling unit lifting forks support the entire crate.

  • Page 17: Unpacking

    NOVATIG 503 AC/DC G.R.3 generally weighing less than 25 kg, the packaging consists of a cardboard box without lifting pallets. It can be easily lifted by two operators and taken to the place of use. ATTENTION: The machine must remain packed during unloading from the means of transport and until it is transferred to its destination.

  • Page 18: Storage

    NOVATIG 503 AC/DC G.R.3 4.6. STORAGE To achieve an adequate level of safety, the electri- cal system to which the machine is connected must In the case of inactivity, the machine must be stored provide, at the user's full charge, an earthing system...

  • Page 19: Preliminary Checks

    NOVATIG 503 AC/DC G.R.3 IMPORTANT: The personnel qualified to carry out Gas hose connection the electrical connection must make sure of the perfect efficiency of the earthing of the electrical ATTENTION: Cylinders can explode if damaged!!! system and must check that the line voltage and...

  • Page 20: Overview

    NOVATIG 503 AC/DC G.R.3 5. OVERVIEW • 2T/4T trigger control. • AC waveforms include square wave, sine wave, triangular wave. 5.1. OPERATING PRINCIPLE • AC balance control monitors the oxide and helps better cleaning during aluminum welding The NOVATIG series welding systems were designed •...

  • Page 21: Vibrations

    NOVATIG 503 AC/DC G.R.3 5.5. VIBRATIONS These emissions comply with the limits of the regula- tions in force and are not such as to generate danger Under operating conditions that comply with the in- for operators. dications for proper use, the vibrations are not such Arc welding processes can, however, produce noise as to cause hazardous situations.

  • Page 22: Machine Use

    NOVATIG 503 AC/DC G.R.3 6. MACHINE USE 12. Water cooling system error indicator. 13. Alarm indicator. 14. Repeat trigger mode indicator. 6.1. MACHINE LAYOUT DESCRIPTION 15. Air cooling mode indicator 16. Water cooling mode indicator 6.1.1. Layout for the front and rear panel 17.

  • Page 23: Further Controls Explained

    NOVATIG 503 AC/DC G.R.3 6.1.2. Further Controls Explained cooler power and the water cooling protection sys- tem. If using air cooled torch, select ‘Air’ option (15.) LH Digital Multifunction Display (9.) by pressing the button Before welding this displays the setting selected or Note the welding machine comes standard with a being adjusted using the control knob (24.).
  • Page 24 NOVATIG 503 AC/DC G.R.3 the value shown on the LH display (9.). Adjust the pa- to the setting welding current (Iw or Ib) from the rameter by turning the knob. If left inactive for sever- min welding current. al seconds, display will revert back to main welding 4.
  • Page 25 NOVATIG 503 AC/DC G.R.3 2T Mode Loosen the welding Welding current is gun switch The setting base current Ib Arc is Arc is Press and hold ignited turned off the welding gun switch 4T Mode Repress down the switch Welding current...
  • Page 26 NOVATIG 503 AC/DC G.R.3 • Start current setting indicator (b) lower pulse duty will have the opposite effect. Unit(%) Available in 4T trigger mode, sets a welding current and setting range (5-95%). 10-100% of the main welding current activated when •...
  • Page 27 NOVATIG 503 AC/DC G.R.3 AC/DC Output Modes press press press press AC MMA DC MMA AC TIG DC TIG HF Ignition (High Frequency) sends a pulse of h i g h the base metal and prevents welding current flowing, it also contaminates the weld pool. Reverse current...

  • Page 28: Power Supply Input Connection

    NOVATIG 503 AC/DC G.R.3 accessed, it will automatically load. water may be used as a coolant liquid, though it is • To return to normal parameter settings, press the not recommended for the long term reliability of control knob again or wait for 3 seconds (which...

  • Page 29: Operation For Mma Welding

    NOVATIG 503 AC/DC G.R.3 1. Connect the earth lead to “-”, tighten clockwise; 6.3.2. Operation for MMA Welding 2. Connect the earth clamp to the work piece. 1. According to the above method to install is Contact with the work piece must be firm contact...

  • Page 30: Installation & Operation For Tig Welding

    NOVATIG 503 AC/DC G.R.3 6.4. INSTALLATION & OPERATION FOR 6. If using a water cooled torch, connect the water cooler interface cable from the rear of the power TIG WELDING source to the rear of the water cooler. 6.4.1. Set up installation for TIG Welding 7.

  • Page 31: Operation For Tig Welding

    NOVATIG 503 AC/DC G.R.3 Note: POTENTIOMETER • Secure the gas cylinder in an upright position by chaining them to a stationary support to prevent Adjust current roller falling or tipping. wheel, when it’s roll upwards, the current increase, when it’s roll 6.4.2.

  • Page 32: Remote Control Configuration

    NOVATIG 503 AC/DC G.R.3 Pin Remote Plug Connection Remote Amps Trigger Trigger Down Switch Switch Short Circuit Potentiometer UP/DOWN Function Socket Pin Potentiometer Up/down Not connected Not connected Not connected Not connected 10k ohm (maximum) connection to 10k ohm Not connected...

  • Page 33: Wire Foot Pedal Configuration

    NOVATIG 503 AC/DC G.R.3 complete. (Synchronization has to accomplish in How to remove the control function of Remote 10s after the display is blank). control box on welding machine 4. Switch the machine off and back on again to start 1.

  • Page 34: Start-Up

    NOVATIG 503 AC/DC G.R.3 6.6. START-UP 6.8. DECOMMISSIONING After turning on machine or line power, conduct a During long periods of inactivity it is necessary to: careful visual inspection of the entire machine and - Disconnect the power supply from the gener-...

  • Page 35: Maintenance

    NOVATIG 503 AC/DC G.R.3 7. MAINTENANCE 7.4. ROUTINE MAINTENANCE General requirements 7.1. MACHINE ISOLATION The machine is designed to minimise routine main- tenance, thus it is up to the operator to assess its Before carrying out any type of Maintenance or Re- condition and suitability for use.

  • Page 36: Welding Machine Repairs

    NOVATIG 503 AC/DC G.R.3 ATTENTION: These operations, although simple, - If repairs are not carried out by the manufacturer, must be performed by a Qualified or Qualified repaired welding machines, in which some com- and Authorised Technician. ponents have been replaced or modified, must be...

  • Page 37: Diagnostics And Troubleshooting

    NOVATIG 503 AC/DC 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 38: Accessories And Spare Parts

    NOVATIG 503 AC/DC G.R.3 8. ACCESSORIES AND SPARE PARTS 9. ADDITIONAL INSTRUCTIONS 8.1. CUSTOMER SERVICE 9.1. WASTE DISPOSAL The Manufacturer is always at your disposal for any It is the responsibility of the user, in accordance with type of information regarding the use, maintenance, the laws in force in their country, to ensure correct and installation of the equipment.
  • Page 39 NOVATIG 503 AC/DC 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 ecoR Consortium "it" the user can deliver it to the distributor, who will have to collect it for free.

  • Page 40: Annexes

    NOVATIG 503 AC/DC G.R.3 10. ANNEXES 10.1. WIRING DIAGRAMS 1.995.217 EN - Rev. 1.1...

  • Page 41: Spare Parts

    NOVATIG 503 AC/DC G.R.3 10.2. SPARE PARTS Pos. Code Description Pos. Code Description Pos. Code Description 8.295.099 Handle 8.222.013 Transformer 8.295.109 Fuse base 8.221.027 Machine cover 8.292.010 Hull sensor 8.295.108 Fuse 8.291.009 Left panel 8.292.005 Inductance 8.291.012 Right panel 8.295.075 AC contactor 8.223.078 HF absorb PCB...
  • Page 42 NOVATIG 503 AC/DC G.R.3 1.995.217 EN - Rev. 1.1...
  • Page 43 NOVATIG 503 AC/DC G.R.3 1.995.217 EN - Rev. 1.1...
  • Page 44 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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