Aluminium Welding; Maintenance; Possible Problems And Remedies - CEA Compact 270 Manuel D'instructions

• Remove the gas-guide and wire-guide nozzles, allowing the
wire to flow freely during loading. Remember that the con-
tact tip must correspond to the wire diameter.
• Set the wire speed potentiometer on position 3 (pos. 3, fig.
D).
• Push the torch push button or the motor check push button
until the wire end comes out from the torch.
• Tighten the contact tip on the torch.
• Attach the correct gas-guide nozzle.
• Protect the gas-guide nozzle and the wire-guide nozzle of
the torch from sprays of solder.
• Connect the clamp of the ground lead to the piece to be wel-
ded (see fig. G).
• The welding machine is ready for welding.
• To begin welding, approach the point to be welded and
press the button on the torch.
• When you have finished welding, remove the waste, turn off
the machine and close the gas cylinder.
CONTINUOUS WELDING
Select the most suitable wire tension adjustment and speed,
using the respective controls, in function of the type of work to
be carried out. Press the torch button to start the welding cur-
rent and advancement of the wire and perform welding. After
completely the weld, release the torch button to stop the wire
advancement motor immediately. The generator is powered for
a few seconds, long enough to burn the excess wire emerging
from the torch. The gas solenoid remains open to provide for
maintaining an inert atmosphere around the welding zone. This
function is called "burn-back" and is adjustable. The control
circuit is powered, ready for the next welding cycle.
SPOT WELDING
This type of welding is recommended for repairs in automobile
body shops.
• Replace the gas-guide nozzle with
the special type for spot welding
(see fig. H)
• Set the spot welding time with the
potentiometer (pos. 5, fig. D)
• Select the most suitable tension
and speed adjustment, using the respective controls, in fun-
ction of the type of work to do.
• Press the gas-guide nozzle perpendicular to the part to be
welded.
• Press the torch button to start the welding current and
advancement of the wire.
• At the end of the set spot welding time, the wire stops
advancing automatically.
• Pressing the torch button again begins a new welding cycle.
• Release the torch button.

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 1-1,5 bar.

Maintenance

IMPORTANT: Any eventual maintenance must be carried
out by expert, qualified personnel. The guarantee is invali-
dated if the final user attempts to repair any damage done
to the machine by himself.
ATTENTION: Before carrying out any inspection of the inside
of the generator, disconnect the system from the supply.
GENERATOR
The maintenance of this equipment is limited to the cleaning of
the inside of the frame and periodic inspection of worn cables
or loose connections. At regular intervals disconnect the wel-
der from the mains, take off the cover and use dry compressed
air to remove possible accumulations of dirt and dust. During
this operation do not direct the jet of air onto electronic com-
ponents. Check, that the gas circuit is completely free from
impurities and that the connections are tight and that there are
no leaks. Carefully check that the electric valve does not leak.
Check the wire feeder rolls periodically and replace them when
wear impairs the regular flow of the wire (slipping etc).
TORCH
The torch is subjected to high temperatures and is also stres-
sed by traction and torsion. We recommend not to twist the
wire and not to use the torch to pull the welder. As a result
oftheabovethetorchwill requirefrequent maintenance such as:
• cleaning welding splashes from the gas diffuser so that the
• substitution of the contact point when the hole is deformed;
• cleaning of the wire guide liner using trichloroethylene or
• check of the insulation and connections of the power cable;
REPLACEMENT OF THE ELECTRONIC CARD
ATTENTION: Static can damage the circuit boards! It is
advisable to wear an "antistatic bracelet when working
with the circuit boards or their components.
Proceed as follows:
• Open the moving part of the cover on the right-hand side
• Remove the black fibre board cover by unscrewing the 3
Fig. H
• Remove the circuit board connectors.
• Take the plugs off the handles located on the front rack
• The circuit board can now be removed and replaced;
• Reverse the procedure to fit the new card.
The detection of eventual problems and their solution. The
power supply line is the major source of problems. In the
event of a fault proceed as follows:
1) Check the voltage of the supply;
2) Check the state of the line connection at the plug and the
3) Check that the main fuses are not burnt out or loose;
4) Check the following for defects:
12
gas flows freely;
specific solvents;
the connections must be in good electrical and mechanical
condition.
using the relative bolts.
screws with a suitable screwdriver (fig. I).
panel and then remove them with a suitable box wrench.

Possible problems and remedies

main switch;
• The switch and wall outlet that power the machine
• The plug and mains cable
• The welder switch
2000H919 Fig. I