SincoSald NOVATIG 303 AC/DC LCD G.R.3 Instruction Manual
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SincoSald NOVATIG 303 AC/DC LCD G.R.3 Instruction Manual

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MODEL
NOVATIG 303 AC/DC LCD
G.R.3
INSTRUCTION MANUAL
for installation,
use and maintenance
of welding
machines.
Original instructions in Italian.
Please keep for future use.
1.995.243 EN - Rev. 1.2

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Summary of Contents for SincoSald NOVATIG 303 AC/DC LCD G.R.3

  • Page 1 MODEL NOVATIG 303 AC/DC LCD G.R.3 INSTRUCTION MANUAL for installation, use and maintenance of welding machines. Original instructions in Italian. Please keep for future use. 1.995.243 EN - Rev. 1.2...

  • Page 2: Table Of Contents

    NOVATIG 303 AC/DC LCD 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 303 AC/DC LCD G.R.3 6. MACHINE USE 6.1. MACHINE LAYOUT DESCRIPTION 6.1.1. Layout for the front and rear panel 6.2. WELDING OPERATION 6.2.1. Operation of DC TIG HF/LIFT welding method 6.2.2. Operation of AC TIG HF/LIFT welding method 6.2.3. Operation of the MMA welding method 6.2.4.

  • Page 4: Preface

    NOVATIG 303 AC/DC LCD 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 303 AC/DC LCD G.R.3 1.5. HOW TO READ THE INSTRUCTION • capable of comprehending and interpreting the operator manual and the safety instructions; MANUAL • familiar with the emergency procedures and how The Manual is split into chapters, each one dedicated to implement them;...

  • Page 6: General Information

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

  • Page 7: Declarations Of Conformity

    NOVATIG 303 AC/DC LCD G.R.3 2.3. DECLARATIONS OF CONFORMITY Pos. 11b Service factor: 60 % Pos. 11c Service factor: 100 % The machine is constructed in compliance with the Pos. 12 Rated welding current (I2) relevant EU Directives, applicable at the time of its Pos.

  • Page 8: Preparation By The Customer

    NOVATIG 303 AC/DC LCD G.R.3 2.6. PREPARATION BY THE CUSTOMER 3. SAFETY Unless otherwise agreed in the contract, the follow- 3.1. GENERAL SAFETY WARNINGS ing are normally the Customer's responsibility: • Room preparations, including any building work WARNING: your safety depends on you!!! and/or ducting systems required;...
  • Page 9 NOVATIG 303 AC/DC LCD G.R.3 anisms installed on the machine; direct superior of any defects or anomalies presented • Operations at reduced safety levels must be car- on the mobile parts. ried out in strict accordance with the instructions A) Electric shock given in the relevant descriptions;...
  • Page 10 NOVATIG 303 AC/DC LCD G.R.3 DIN 11 protection grade. chains, slings or magnets. - Protect people near the welding area. - Do not attempt to mix any gas inside the cylinders. - REMEMBER: The arc can blind or damage your - Never refill the cylinders, but have them refilled by eyes.
  • Page 11 NOVATIG 303 AC/DC LCD G.R.3 gear and high shoes with safety tip. Button the shirt H) Moving parts can cause damage collars and pocket flaps and wear trousers without Moving parts, such as the fan, can cut fingers and cuff to avoid the entry of sparks and slag. hands and catch clothes.
  • Page 12 NOVATIG 303 AC/DC LCD 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. facturer and carried out by persons authorised by the b) Radio or television transmitters and receivers.

  • Page 13: Intended Use

    NOVATIG 303 AC/DC LCD 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

    NOVATIG 303 AC/DC LCD 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 situations, prohibitions or instructions during use or operations connected to it, as in the following exam- ples:...

  • Page 15: Residual Risks

    NOVATIG 303 AC/DC LCD 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

    NOVATIG 303 AC/DC LCD G.R.3 4.4. HANDLING AND LIFTING ATTENTION: The machine must remain packed during unloading from the means of transport ATTENTION: handling and lifting must be carried and until it is transferred to its destination. out by trained and qualified operators, using IMPORTANT: The Manufacturer cannot be held appropriate means and methods, to avoid risks liable for damage caused to persons or property...

  • Page 17: Storage

    NOVATIG 303 AC/DC LCD G.R.3 Do not lift the machine by the FEEDER or genera- tor handles. The welder has a sturdy handle integrated in the frame for handling. N.B. These lifting and handling devices com- ply with the provisions prescribed by European standards.

  • Page 18: Assembly/Positioning

    NOVATIG 303 AC/DC LCD G.R.3 4.9. CONNECTIONS lowing the wiring diagram and arrangements set out in Laws and/or Technical Standards currently in force for Electrical connections safety in workplaces and electrical installations. The machine's internal connections are carried out Appropriate safety devices must be provided for its by qualified personnel sent by the manufacturer.

  • Page 19: Preliminary Checks

    NOVATIG 303 AC/DC LCD G.R.3 5. MACHINE DESCRIPTION ATTENTION: the yellow-green wire of the welding machine power cable must always be connected to the protection conductor (system earth). The 5.1. OPERATING PRINCIPLE yellow-green wire should NEVER be combined with another phase wire for a voltage withdrawal. The NOVATIG series welding systems were designed Do not touch live parts.

  • Page 20: Environmental Conditions

    NOVATIG 303 AC/DC LCD G.R.3 5.3. ENVIRONMENTAL CONDITIONS 5.4. LIGHTING The machine does not require particular environ- The lighting of the area of installation must comply mental conditions. The machine must be installed in- with the laws in force in the country where the ma- doors in a well-lit, ventilated industrial building with chine is installed and must, however, ensure good solid and level flooring.

  • Page 21: Noise

    NOVATIG 303 AC/DC LCD G.R.3 5.6. NOISE 5.7. TECHNICAL SPECIFICATIONS The equivalent continuous A-weighted sound pres- The following table shows the main technical specifi- sure level, emitted by the machine at the workplace cations relating to the machine: in full operating conditions, is less than 70 dB (A). These emissions comply with the limits of the regula- tions in force and are not such as to generate danger for operators.

  • Page 22: Machine Use

    NOVATIG 303 AC/DC LCD G.R.3 6. MACHINE USE 6.1. MACHINE LAYOUT DESCRIPTION 6.1.1. Layout for the front and rear panel 1. “--” Output terminal. 2. TIG torch remote connection socket.* 3. TIG torch gas connector. 4. “+” Output terminal. 5. Inlet gas connector. 6.
  • Page 23 NOVATIG 303 AC/DC LCD G.R.3 B. Welding parameter setting interface: a welding D. Function selection interface button: Press this parameter and its orresponding value may be key to switch (A), (B), (C). selected and set by rotating Knob (F) and Knob (G) in the interface.

  • Page 24: Operation Of Dc Tig Hf/Lift Welding Method

    NOVATIG 303 AC/DC LCD G.R.3 6.2.1. Operation of DC TIG HF/LIFT welding method 1. Selection of the welding method (DC MODEL): 1. In the main interface, press the key to enter the function selection interface; 2. In the function selection interface, rotate L-Knob to select the TIG HF welding method and press it for confirmation.Rotate R-Knob to select the wave.(DC/AC).
  • Page 25 NOVATIG 303 AC/DC LCD G.R.3 Q-Start 3. Welding and parameter setting interface The Q-Start (quick START) feature helps to interconnect the workpieces during the initial 1. In the main interface, press key to enter the phase of the welding process. When this function is welding interface.
  • Page 26 NOVATIG 303 AC/DC LCD G.R.3 Parameter description and scope (PULSE ON): Parameters (DC TIG) Values Pre Gas 0-2.0S Start Current 10-290A Up Slope 0-10.0S Peak Current 10-290A Base Current 10-290A Down Slope 0-10.0S End Current 10-290A Post Gas 0-10.0S Duty Ratio 5-95% Pulse Frequency 0.5-999Hz...

  • Page 27: Operation Of Ac Tig Hf/Lift Welding Method

    NOVATIG 303 AC/DC LCD G.R.3 6.2.2. Operation of AC TIG HF/LIFT welding 2. Selection and setting of welding method: method 1. In the main interface, press the key to enter the welding parameter setting interface; 1. Selection of the welding method (AC MODEL): 2.
  • Page 28 NOVATIG 303 AC/DC LCD G.R.3 • Rapid generation of welding pool (suitable for surface treatment of tools, molds and large size castings) • Weld plates of various thickness (1mm to 10mm). It is better not to exceed 50% of the DC waveform, otherwise it will affect the pickling of the parts and the appearance of the weld bead.
  • Page 29 NOVATIG 303 AC/DC LCD G.R.3 Parameter description and scope (PULSE ON): Parameter description and scope (PULSE OFF and Repeat mode): Parameters (AC TIG) Values Parameters (AC TIG) Values Pre Gas 0-2.0S Pre Gas 0-2.0S Start Current 10-290A Start Current 10-290A Up Slope 0-10.0S Up Slope...
  • Page 30 NOVATIG 303 AC/DC LCD G.R.3 Down slope etration and less heated affected area for the same When the trigger is released, the welding current current setting. Slower frequency will result in a wid- will reduce gradually over the time selected down er, softer arc shape.

  • Page 31: Operation Of The Mma Welding Method

    NOVATIG 303 AC/DC LCD G.R.3 6.2.3. Operation of the MMA welding method 2. Selection and setting of welding parameters: 1. In the main interface, press key to enter the 1. Selection of the welding method: welding parameter setting interface; 2. In the welding parameter setting interface, rotate 1.
  • Page 32 NOVATIG 303 AC/DC LCD G.R.3 Parameter description and scope (PULSE ON): When pulse off 2. In the welding parameter setting interface, rotate L-Knob to select the parameter as required and Parameters (MMA) Values rotate R-Knob to set a value for the parameter. Hot Start 0-100% Hot Start Time...

  • Page 33: Job Memory

    NOVATIG 303 AC/DC LCD G.R.3 Arc force An MMA welding power source is designed to produce constant output current (CC).This means with different types of electrode and arc length; the welding voltage varies to keep the current constant. This can cause instability in some welding conditions as MMA welding electrodes will have a minimum voltage they can operate with and still have a stable arc.

  • Page 34: Installation & Operation For Mma Welding

    NOVATIG 303 AC/DC LCD G.R.3 6.3. INSTALLATION & OPERATION FOR 6.3.2. Operation for MMA Welding MMA WELDING 1. According to the above method to install is cor- rect, turn the power switch, so that the power 6.3.1. Set up installation for MMA Welding switch is “ON”...

  • Page 35: Installation & Operation For Tig Welding

    NOVATIG 303 AC/DC LCD G.R.3 6.4. INSTALLATION & OPERATION FOR 10. With the corresponding input power supply terminal or socket good contact and prevent TIG WELDING oxidation; 6.4.1. Set up installation for TIG Welding 11. With a multi meter measure the input voltage is within the fluctuation range;...
  • Page 36 NOVATIG 303 AC/DC LCD G.R.3 POTENTIOMETER UP/DOWN Adjust current roller Adjust current wheel, when it’s roll button, when it’s upwards, the current pushed up, the cur- decrease, when it’s rent increase, when roll downwards, the it’s pushed down, current increase. switch Gun switch the current decrease.

  • Page 37: Remote Control Configuration

    NOVATIG 303 AC/DC LCD 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 remote control potentiometer Wiper arm connection to 10k ohm remote...

  • Page 38: Wire Foot Pedal Configuration

    NOVATIG 303 AC/DC LCD G.R.3 7. When the remote control panel or foot pedal is 2. Press the encoder on the front control panel of the idles for 10 seconds, it will automatically go into power supply, meanwhile turn on the machine. “sleep”...

  • Page 39: Wireless Foot Pedal Configuration

    NOVATIG 303 AC/DC LCD G.R.3 6.5.3. Wireless foot pedal Configuration Wireless foot pedal is a kind of device which can control current in real time through wireless module. How to use Step 1: turn on the foot pedal Step 2: press the left button in 10s and power on the machine at the same time, you can see the load screen, then loosen the left button;...

  • Page 40: Maintenance

    NOVATIG 303 AC/DC LCD 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 Re- tion and suitability for use.

  • Page 41: Welding Machine Repairs

    NOVATIG 303 AC/DC LCD 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 marked so that the person who carried out the re- Remove dust or foreign materials every 6 months, pair can be identified.

  • Page 42: Diagnostics And Troubleshooting

    NOVATIG 303 AC/DC LCD 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 43: Accessories And Spare Parts

    NOVATIG 303 AC/DC LCD G.R.3 8. 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, ing production.
  • Page 44 NOVATIG 303 AC/DC LCD 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 45: Annexes

    NOVATIG 303 AC/DC LCD G.R.3 10. ANNEXES 10.1. WIRING DIAGRAMS 1.995.243 EN - Rev. 1.2...

  • Page 46: Spare Parts

    NOVATIG 303 AC/DC LCD G.R.3 10.2. SPARE PARTS Pos. Code Description Pos. Code Description Pos. Code Description 8.295.099 HANDLE STICK 250 NEAR 8.215.162 IGBT 8.291.015 PANEL 8.221.046 COVER 8.295.103 INSULATION BLOCK 24 TEN THOUSAND 8.293.004 EMC PCB 3 MOSAIC 1 8.225.090 HEAT SINK 8.225.084 TURN SWITCH...
  • Page 47 NOVATIG 303 AC/DC LCD G.R.3 Pos. Code Description Pos. Code Description 8.261.000 MAIN ENGINE JUNCTION PLATE 8.261.006 BOTTOM PLATE 8.261.001 COVER 8.265.002 T-JUNCTION 8.291015 STICK 250 REAR PANEL 8.265.001 PRESSURE SWITCH 8.261.002 FRONT PANEL SEALING PLATE 8.265.003 INLET CONNECTOR 8.255.014 WATER QUICK SOCKET (BLUE) 8.263.000 WATER PUMP 8.255.013 WATER QUICK SOCKET (RED) 8.261.007 PUMP MOUNTING PLATE...
  • Page 48 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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