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SincoSald NOVAMIG 503 DP WP3-4R FEEDER G.R.3 Instruction Manual

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MODEL
NOVAMIG 503 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.
1.995.215 EN - Rev. 1.1

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  • Page 1 MODEL NOVAMIG 503 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. 1.995.215 EN - Rev. 1.1...

  • Page 2: Table Of Contents

    NOVAMIG 503 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 NOVAMIG 503 DP WP3-4R FEEDER - G.R.3 6. MACHINE USE 6.1. MACHINE LAYOUT DESCRIPTION 6.1.1. Front and rear panel layout of welding machine 6.1.2. Front and rear panel layout of wire feeder 6.1.3. Internal panel layout of wire feeder 6.1.4. Front and rear panel layout of water cooling 6.2.

  • Page 4: Preface

    NOVAMIG 503 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

    NOVAMIG 503 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

    IDENTIFICATION DATA Pos. 2 Identification of the welding machine model Pos. 3 Welding machine serial number MANUFACTURER: SINCOSALD S.r.l Pos. 4 Welding machine type symbol: Transform- er - Rectifier for arc welding HEADQUARTERS - OFFICES Pos. 5 Reference to the legislation followed for...

  • Page 7: Declarations Of Conformity

    NOVAMIG 503 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

    NOVAMIG 503 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 NOVAMIG 503 DP WP3-4R FEEDER - G.R.3 It is, however, essential to diligently follow the follow- manual, which must always be available at the work- ing indications: place. • It is absolutely forbidden to operate the machine All safety features placed on moving parts to prevent automatically with the fixed and/or mobile guards accidents and safeguard safety can not be modified removed;...
  • Page 10 NOVAMIG 503 DP WP3-4R FEEDER - G.R.3 - DO NOT use CONTACT LENSES!!! The intense heat - Never delete or alter the name, number or other emanating from the electric arc could stick them markings on the cylinders. It is illegal and dangerous. to the cornea.
  • Page 11 NOVAMIG 503 DP WP3-4R FEEDER - G.R.3 radiation emitted by the electric arc, by sparks and H) Moving parts can cause damage slag from molten metal, using fireproof clothing, Moving parts, such as the fan, can cut fingers and which covers all exposed surfaces of the body. hands and catch clothes.
  • Page 12 NOVAMIG 503 DP WP3-4R FEEDER - G.R.3 Below is a list of services to consider: welding machine must be correctly closed during 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 13: Intended Use

    NOVAMIG 503 DP WP3-4R FEEDER - G.R.3 3.2. INTENDED USE damage, deformation, corrosion, wear or altera- tion to the original characteristics; The welding system should only be used for the pur- • checking all mechanical parts; pose for which it was constructed, thus, to generate •...

  • Page 14: Safety Devices

    NOVAMIG 503 DP WP3-4R 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. welding machine itself.

  • Page 15: Residual Risks

    NOVAMIG 503 DP WP3-4R 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 16: Installation

    NOVAMIG 503 DP WP3-4R 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 17: Unpacking

    NOVAMIG 503 DP WP3-4R 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 18: Storage

    NOVAMIG 503 DP WP3-4R FEEDER - G.R.3 Do not lift the machine by the FEEDER or genera- in force for safety in workplaces and electrical instal- tor handles. lations. The welder has a sturdy handle integrated in the Appropriate safety devices must be provided for its frame for handling.

  • Page 19: Connections

    NOVAMIG 503 DP WP3-4R 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. by qualified personnel sent by the manufacturer.

  • Page 20: Machine Description

    NOVAMIG 503 DP WP3-4R 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. The NOVAMIG.series welding system composition is shown below.

  • Page 21: Features And Main Components

    NOVAMIG 503 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 machine is installed and must, however, ensure good •...

  • Page 22: Technical Specifications

    NOVAMIG 503 DP WP3-4R FEEDER - G.R.3 5.7. TECHNICAL SPECIFICATIONS The following table shows the main technical specifications relating to the machine: Parameters NOVAMIG 503 DP Power supply, three phases 400 V – 50/60 Hz Fuse 50 A MAX current 46 A Noise emissions <...

  • Page 23: Machine Use

    NOVAMIG 503 DP WP3-4R FEEDER - G.R.3 6. MACHINE USE 12. No water LED 13. Alarm Led 14. Power Led 6.1. MACHINE LAYOUT DESCRIPTION 15. The digital meter 16. 2T/4T Selector Switch 6.1.1. Front and rear panel layout of welding 17.

  • Page 24: Internal Panel Layout Of Wire Feeder

    NOVAMIG 503 DP WP3-4R FEEDER - G.R.3 6.2. FRONT PANEL FUNCTIONS 6.1.3. Internal panel layout of wire feeder AND DESCRIPTIONS 6.2.1. Front Panel Functions of wire feeder 1. Spool holder assembly 2. Wire feed assembly 6.1.4. Front and rear panel layout of water cooling 1.

  • Page 25: Operating Process Of Wire Feeder

    NOVAMIG 503 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) 1.995.215 EN - Rev.
  • Page 26 NOVAMIG 503 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 Gas Supply Wire Feed Output Voltage...
  • Page 27 NOVAMIG 503 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 Output Current Sport Weld Time 3.

  • Page 28: User Parameter Adjustment (Fx)

    NOVAMIG 503 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 dual pulse 0.5-3.0hz frequency dual pulse duty...

  • Page 29: Job Mode

    NOVAMIG 503 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. • Select the required JOB number by the adjust- ure regulating the value of time T, namely, fish scale pattern of density regulation.

  • Page 30: Mma Function - Front Panel Description

    NOVAMIG 503 DP WP3-4R FEEDER - G.R.3 6.2.6. MMA Function - Front Panel Description 6.2.8. MIG Function - Front Panel Description MIG-MAG Pulse SYN Function 1. Voltage/ Arc length/ Inductance Set 2. Material thickness /Current/ Wire Speed Set 3. MIG-MAG Pulse SYN Function Select 1.
  • Page 31 NOVAMIG 503 DP WP3-4R FEEDER - G.R.3 MIG-MAG Dual Pulse SYN Function 6. Water/Air Cooling Mode Select 7. Function Select, refer to par. 6.6. 8. Gas Test 9. Material thickness /Current/ Wire Speed Display 10. Voltage/ Inductance Display MIG-MAG SYN Function 1.

  • Page 32: Installation & Operation For Mma Welding

    NOVAMIG 503 DP WP3-4R 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 33: Installation & Operation For Tig Welding

    NOVAMIG 503 DP WP3-4R 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. 3.
  • Page 34 NOVAMIG 503 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 35 NOVAMIG 503 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 36: Gun Switch Control Current

    NOVAMIG 503 DP WP3-4R FEEDER - G.R.3 6.4.1. 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 Not connected Not connected Trigger...
  • Page 37 NOVAMIG 503 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 to 10k ohm remote control potentiometer Trigger...

  • Page 38: Spool Gun Control

    NOVAMIG 503 DP WP3-4R 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. Zero ohm (minimum) connection to 10k ohm remote control potentiometer.

  • Page 39: Pedal Switch Control

    NOVAMIG 503 DP WP3-4R FEEDER - G.R.3 6.4.3. 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 40: Installation & Operation For Mig Welding

    NOVAMIG 503 DP WP3-4R 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 41 NOVAMIG 503 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 42 NOVAMIG 503 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 43: Welding Functions

    NOVAMIG 503 DP WP3-4R FEEDER - G.R.3 6.6. WELDING FUNCTIONS Display Function PRE GAS POST GAS SLOW FEED TIME BURN BACK SPOT WELD TIME DELTA PULSE CURRENT DUAL PULSE FREQUENCY DUAL PULSE DUTY DUAL PULSE BASE CURRENT ARC LENGTH START CURRENT PERCENT START CURRENT ARC LENGTH END CURRENT PERCENT END CURRENT ARC LENGTH...

  • Page 44: Maintenance

    NOVAMIG 503 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 45: Welding Machine Repairs

    NOVAMIG 503 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 46: Diagnostics And Troubleshooting

    NOVAMIG 503 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 (1st thermal relay) Over-heating Yellow lamp (thermal protection) always on...

  • Page 47: Accessories And Spare Parts

    NOVAMIG 503 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 The Manufacturer is always at your disposal for any disposal of the waste produced by the machine dur- type of information regarding the use, maintenance,...
  • Page 48 NOVAMIG 503 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 49: Annexes

    NOVAMIG 503 DP WP3-4R FEEDER - G.R.3 10. ANNEXES 10.1. WIRING DIAGRAMS 1.995.215 EN - Rev. 1.1...

  • Page 50: Spare Parts

    NOVAMIG 503 DP WP3-4R FEEDER - G.R.3 10.2. SPARE PARTS Pos. Code Description Pos. Code Description Pos. Code Description Heat sink mounting 8.295.099 Handle 8.211.016 PCB mounting sheet 1 8.211.022 sheet 8.211.028 Machine cover 8.215.170 Fuse base 8.292.012 Rectifier bridge 8.293.005 Capacitor PCB 8.215.171 Fuse 8.211.076 Heat sink...
  • Page 51 NOVAMIG 503 DP WP3-4R FEEDER - G.R.3 FEEDER WP3-4R Pos. Code Description Pos. Code Description Pos. Code Description 8.251.014 Right panel 8.295.085 Knob 8.251.016 PCB mounting sheet 1 8.291.010 Left panel 8.295.096 Tube 8.255.015 Wheel Wheel mounting 8.291.011 Seal 8.251.022 Connection bar 8.251.019 sheet 8.255.001 Handle sleeve...
  • 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...

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