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SincoSald NOVAMIG 403 E Instruction Manual For Installation, Use And Maintenance

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MODEL
NOVAMIG 403 E
NOVAMIG 503 E
WS3-4R FEEDER
G.R.3
INSTRUCTION MANUAL
for installation,
use and maintenance
of welding
machines.
Original instructions in Italian.
Please keep for future use.
1.995.233 EN - Rev. 1.1

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  • Page 1 MODEL NOVAMIG 403 E NOVAMIG 503 E WS3-4R FEEDER G.R.3 INSTRUCTION MANUAL for installation, use and maintenance of welding machines. Original instructions in Italian. Please keep for future use. 1.995.233 EN - Rev. 1.1...

  • Page 2: Table Of Contents

    NOVAMIG 403 E - NOVAMIG 503 E WS3-4R 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 WS3-4R FEEDER - G.R.3 6. MACHINE USE 6.1. MACHINE LAYOUT DESCRIPTION 6.1.1. Front and rear panel layout of welding machine (NOVAMIG 403 E - 503 E) 6.1.2. Front and rear panel layout of wire feeder 6.1.3. Internal panel layout of wire feeder 6.1.4.

  • Page 4: Preface

    NOVAMIG 403 E - NOVAMIG 503 E WS3-4R 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...

  • Page 5: Storage Of The Instruction Manual

    NOVAMIG 403 E - NOVAMIG 503 E WS3-4R 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

    NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - G.R.3 2. GENERAL INFORMATION Explanation of the NOVAMIG 403 E plate Pos. 1 Name and address of the manufacturer 2.1. MANUFACTURER and trademark IDENTIFICATION DATA Pos. 2 Identification of the welding machine model Pos.
  • Page 7 NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - G.R.3 NOVAMIG 503 E plate Pos. 11a Service factor: 60 % Pos. 11b Service factor: 100 % Pos. 12 Rated welding current (I2) Pos. 12a Value of the rated welding current at 60% NOVAMIG 503 E Pos.

  • Page 8: Declarations Of Conformity

    NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - G.R.3 2.4. SAFETY STANDARDS Pos. 9 Feeder service factor (X): this data indicates the feeder service factor as a percentage The machine was built in accordance with the follow- of a 10-minute work cycle. Example X =...

  • Page 9: Preparation By The Customer

    NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - G.R.3 2.6. PREPARATION BY 3. SAFETY THE CUSTOMER 3.1. GENERAL SAFETY WARNINGS Unless otherwise agreed in the contract, the follow- ing are normally the Customer's responsibility: WARNING: your safety depends on you!!! •...
  • Page 10 NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - 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 11 NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - G.R.3 to the cornea. - Do not lift the cylinders from the ground by hold- - Use masks with lenses, with a minimum DIN 10 or ing them by the valve or by the cap, or by using DIN 11 protection grade.
  • Page 12 NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - G.R.3 Wear protective clothing and welder gloves, head- hands and catch clothes. gear and high shoes with safety tip. Button the shirt Keep all doors, covers and guards closed and securely collars and pocket flaps and wear trousers without in place.
  • Page 13 NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - G.R.3 a) Power cables, control cables, transmission system the welding and cutting operations. The welding ma- and telephone cables that pass near the welding chine must never be modified in any part except for machine.

  • Page 14: Intended Use

    NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - G.R.3 3.2. INTENDED USE • checking all mechanical parts; • inspection of all the safety devices installed on the The system should only be used for the purpose for machine;...

  • Page 15: Safety Devices

    NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - G.R.3 3.5. SAFETY DEVICES 3.6. SIGNS Welding machines are equipped with safety devices The safety signs must always be clearly visible and it designed to prevent damage to the operator or to the is absolutely forbidden to remove or hide them.

  • Page 16: Residual Risks

    NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - G.R.3 Explosion hazard: Noise: This symbol indicates the presence of Hearing protection must be worn explosive substances or explosion hazard. near this symbol. 3.7. RESIDUAL RISKS Careful use of the machine minimises the probability of accidents;...

  • Page 17: Installation

    NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - G.R.3 4. INSTALLATION suspicious cases, open the packaging and to ver- ify the safety of the machine and any loose units. 4.1. SHIPPING 4.4. HANDLING AND LIFTING The shipment, also depending on the destination, can be carried out by different means.

  • Page 18: Unpacking

    NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - G.R.3 ATTENTION: The machine must remain packed during unloading from the means of transport and until it is transferred to its destination. IMPORTANT: The Manufacturer cannot be held liable for damage caused to persons or property due to utilising lifting systems other than those described above.

  • Page 19: Storage

    NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - G.R.3 Do not lift the machine by the FEEDER or genera- for safety in workplaces and electrical installations. tor handles. Appropriate safety devices must be provided for its The machine has a sturdy handle integrated in the operation in line with those required in the area of frame for handling.

  • Page 20: Connections

    NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - G.R.3 4.9. CONNECTIONS to the protection conductor (system earth). The yellow-green wire should NEVER be combined Electrical connections with another phase wire for a voltage withdrawal. The machine's internal connections are carried out Do not touch live parts.

  • Page 21: Machine Description

    NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - G.R.3 5. MACHINE DESCRIPTION 5.1. OPERATING PRINCIPLE NOVAMIG series welding systems have been designed for continuous wire welding under protection of gas, in short and spray arc, with the use of solid and animated steel, stainless steel and aluminium wires.

  • Page 22: Features And Main Components

    NOVAMIG 403 E - NOVAMIG 503 E WS3-4R 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 machine is installed and must, however, ensure good •...

  • Page 23: Technical Specifications

    NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - G.R.3 5.7. TECHNICAL SPECIFICATIONS 6. MACHINE USE The following table shows the main technical specifi- 6.1. MACHINE LAYOUT DESCRIPTION cations relating to the machine: 6.1.1. Front and rear panel layout of welding...

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

    NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - G.R.3 12. No water LED 6.1.3. Internal panel layout of wire feeder 13. Alarm Led 14. Power Led 15. The digital meter 16. 2T/4T Selector Switch 17. Gas/Air cooling mode Selector Switch 18.

  • Page 25: Front Panel Functions And Descriptions

    NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - G.R.3 6.2. FRONT PANEL FUNCTIONS 6.2.2. Operating process of wire feeder AND DESCRIPTIONS 6.2.1. Front Panel Functions of wire feeder V / P / W ire V / P / W ire 1.
  • Page 26 NOVAMIG 403 E - NOVAMIG 503 E WS3-4R 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...

  • Page 27: User Parameter Adjustment (Fx)

    NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - G.R.3 3. Select the air/H O cooling method (press the but- 6.2.3. User parameter adjustment (Fx) ton (3), the corresponding light turns on) 4. Use the knob (4) to adjust voltage and induct- ance.

  • Page 28: Job Mode

    NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - G.R.3 6.2.4. JOB mode 6.2.5. Synergic Function V / P / W ire V / P / Wire In the JOB mode, 100 different JOB records can be This makes the setup of MIG welding more simple,...

  • Page 29: Mma Function - Front Panel Description

    NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - G.R.3 6.2.6. MMA Function - Front Panel Description 6.2.8. MIG Function - Front Panel Description MIG-MAG SYN Function V / P / W ire 1. Voltage/ Arc length/ Inductance Set 2.
  • Page 30 NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - G.R.3 MIG-MAG Manual Function MIG-MAG SYN Function V / P V / P / Wire / W ire 1. Voltage/ Inductance Set 1. Voltage/ Inductance Set 2. Material thickness /Current/ Wire Speed Set 2.

  • Page 31: Installation & Operation For Mma Welding

    NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - G.R.3 6.3. 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 32: Installation & Operation For Tig Welding

    NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - G.R.3 6.4. 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 33 NOVAMIG 403 E - NOVAMIG 503 E WS3-4R 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 34 NOVAMIG 403 E - NOVAMIG 503 E WS3-4R 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 35: Gun Switch Control Current

    NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - G.R.3 6.4.1. Gun switch control current Adjust current roller wheel, when it’s roll upwards, the current increase, when it’s roll downwards, the current decrease. Gun switch Remote control socket Socket Pin Function...

  • Page 36: Spool Gun Control

    NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - G.R.3 6.4.2. 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 37: Installation & Operation For Mig Welding

    NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - G.R.3 6.5. 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 38 NOVAMIG 403 E - NOVAMIG 503 E WS3-4R 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.
  • Page 39 NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - G.R.3 18. Carefully open the gas cylinder valve and set the 20. Select the required MIG-MAG function (MAN/ required gas flow rate. SYN). With the specific keys: 1 - select the wire diameter...

  • Page 40: Standard Welding Programs

    NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - G.R.3 6.6. STANDARD WELDING PROGRAMS 6.8. NORMAL STOP Display Function Turn the switch on the welder panel to OFF. To completely disconnect the power supply from the PRE GAS power line, turn the switch on the main panel to O.

  • Page 41: Maintenance

    NOVAMIG 403 E - NOVAMIG 503 E WS3-4R 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 42: Welding Machine Repairs

    NOVAMIG 403 E - NOVAMIG 503 E WS3-4R 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;...

  • Page 43: Diagnostics And Troubleshooting

    NOVAMIG 403 E - NOVAMIG 503 E WS3-4R 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...

  • Page 44: Accessories And Spare Parts

    NOVAMIG 403 E - NOVAMIG 503 E WS3-4R 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 45 NOVAMIG 403 E - NOVAMIG 503 E WS3-4R 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 46: Annexes

    NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - G.R.3 10. ANNEXES 10.1. WIRING DIAGRAMS 1.995.233 EN - Rev. 1.1...

  • Page 47: Spare Parts

    NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - G.R.3 10.2. SPARE PARTS NOVAMIG 403 E Pos. Code Description Pos. Code Description Pos. Code Description 8.295.099 Handle 8.295.084 IGBT 8.215.198 fuse base 8.221.026 Machine cover 8.292.012 Rectifier bridge 8.215.171 Fuse 8.221.009 Left panel...
  • Page 48 NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - G.R.3 NOVAMIG 503 E Pos. Code Description Pos. Code Description Pos. Code Description 8.295.099 Handle 8.211.014 Base panel 8.211.016 PCB mounting board 8.211.028 Machine cover 8.211.022 Heat sink mounting board 8.215.198 Fuse base...
  • Page 49 NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - G.R.3 FEEDER WS3-4R Pos. Code Description Pos. Code Description Pos. Code Description 8.251.014 Right panel 8.295.096 tube 8.295.071 Euro socket 35-70SQ 8.291.010 Left panel 8.251.022 Connection bar 8.215.194 9 pin aero socket 8.291.011 Seal...
  • Page 50 NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - G.R.3 1.995.233 EN - Rev. 1.1...
  • Page 51 NOVAMIG 403 E - NOVAMIG 503 E WS3-4R FEEDER - G.R.3 1.995.233 EN - Rev. 1.1...
  • Page 52 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...

This manual is also suitable for:

Novamig 503 eWs3-4r feederG.r.3

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