CEA CONVEX 4000 vision Operator's Manual page 14

are part of the interconnection cable and should be con-
nected as follows:
• Interconnection cable on generator side: connect up
tubes to their rapid couplings (blue and red coloured) at
the back of the coolant system.
• Wire feeder side connecting cable: connect the red and
blue pipes to their respective bulkhead grommets on the
rear panel of the feeder.
2) Connect up the earthing system cable to the rapid cou-
pling marked by a - (negative) symbol and then the rel-
evant ground clamps to the piece being welded or to its
support in an area free from rust, paint and grease. Using
particularly long earthing cables reduces the voltage and
causes some problems from increased resistance and in-
ductance of the cables that could cause faulty welding. Fol-
low instructions to avoid these problems:
• Use earthing and extension cables with appropriate sec-
tion.
• Lay out the cables as a flat as possible to prevent them
from coiling up.
2B - Connecting the cables - Welding with a
NEGATIVE POLE TORCH (Fig. B2)
1) Connect the generator - feeder connection cable using the
extension cable in addition to invert the polarity (optional).
WARNING: Do not disconnect the wire-feeder until the ma-
chine has been switched off.
Connect up the interconnection cables (power cable, an-
cillary wiring and gas tube) to the special attachments and
couplings shown in Fig. B2.
The delivery (blue coloured) and return (red coloured) wa-
ter tubes, used for cooling the torch of the welding machine,
are part of the interconnection cable and should be con-
nected as follows:
• Interconnection cable on generator side: connect up
tubes to their rapid couplings (blue and red coloured) at
the back of the coolant system.
• Wire feeder side connecting cable: connect the red and
blue pipes to their respective bulkhead grommets on the
rear panel of the feeder.
2) Connect up the earthing system cable to the rapid cou-
pling marked by a + (positive) symbol and then the relevant
ground clamps to the piece being welded or to its support in
an area free from rust, paint and grease. Using particularly
long earthing cables reduces the voltage and causes some
problems from increased resistance and inductance of the
cables that could cause faulty welding. Follow instructions
to avoid these problems:
• Use earthing and extension cables with appropriate sec-
tion.
• Lay out the cables as a flat as possible to prevent them
from coiling up.
3 - Welding
1) Start the welding machine by selecting position 1 on the
line switch (Pos. 4, Fig. A).
2) Make the adjustments and do the parameter settings on
the VS control panel (read the enclosed manual carefully).
3) Load the wire (see the relevant paragraph in the feeder
manual) using the motor test button, after having removed
the wire guide nozzle from the torch to allow the wire to
come out freely during loading (remember that the wire
guide nozzle must correspond to the diameter of the wire
used).
4) Open the tap on the cylinder slowly and adjust the reduc-
er knob to obtain a pressure of about 1,3 to 1,7 bar, and
then activate the gas test button and regulate the flow to
a value between 14 and 20 lit/min to suit the current used
for welding.
5) The welding machine is ready to weld. Make the adjust-
ments and select the parameters for the feeder or, if se-
lected, on the VS control panel (read the enclosed manual
carefully). Start welding by moving close to the welding
point and press the torch button.
6) Once welding has been completed remove any slag, switch
off the machine (which is only to be done when the fan is
not running), and close the gas cylinder.
Spot welding
The substantial difference with MIG-MAG welding is essential-
ly related to the torch and the adjustments that must be made
on the VS control panel.
• The gas guide nozzle specifically for spot welding must be
fitted on the torch (see Fig. C).
• On the VS control panel, select the spot welding mode and
set the time.
To begin spot welding:
• Press the torch button to start the welding current and wire
feed.
• When the spot welding time expires, the wire feed stops au-
tomatically.
• When the torch button is pushed again a new welding cy-
cle starts.
• Release the torch button.
FIG. C
Interval welding
The basic difference from spot welding is the addition of an ad-
ditional time known as the "stitch pause".
On the VS control panel, select the interval welding mode and
then set the following times for it:
• Stitch time.
• Stitch pause.
To begin interval welding:
• Press the torch button to start the welding current and wire
feed.
• At this point the welding machine automatically carries out a
succession of welded portions followed by a pause, accord-
ing to the times entered previously. This procedure stops au-
tomatically only when the torch button is released.
• When the torch button is pushed again the torch begins a
new interval welding cycle.
Aluminium welding
To weld with aluminum wire proceed as follows:
• Replace the drive rolls with special ones for aluminium wire.
• Use a torch with a 3M cable and a carbon Teflon sheath.
• Set the pressure between the drive rollers at the minimum,
by turning the screw provided.
• Use argon gas at a pressure of 1,3 - 1,7 bar and regulate
the flow to a value between 14 and 20 lit/min to suit the cur-
rent used for welding.
MMA electrode welding
On the CONVEX 4000-5000 vision machine, electrode weld-
ing is used to weld most metals (different types of steel, etc.)
using coated rutilic and basic electrodes with diameters rang-
ing from Ø 1.6 mm to Ø 6 mm, and devices that the user can
adjust for "Arc Force", "Hot Start", and Anti-sticking functions
to avoid the electrodes sticking.
1) Connecting the welding cables (Fig. D):
Disconnect the machine from the mains power supply and
connect the welding cables to the output terminals (Posi-
tive and Negative) of the welding machine, attaching them
to the clamp and ground with the polarity specified for the
type of electrode being used (Fig.D). Always follow the
electrode manufacturer's instructions. The welding cables
must be as short as possible, they must be near to one
another, positioned at or near floor level. Do not touch the
electrode clamp and the ground clamp simultaneously.
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