Deca D-MIG 635 TD [9/64] Starting up
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Deca D-MIG 635 TD [9/64] Starting up

Deca D-MIG 635 TD [9/64] Starting up
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950595-05 18/07/16
falling or being damaged.
For installation, follow the instructions in Fig. 7.
Gas Application
Argon All non-ferrous metals (aluminium)
Argon + 1-3%O
2 Stainless steel
Argon + 20%CO2 Low carbon steel
CO2 Low carbon steel
L Argon/CO2 is preferable to CO2 as it guarantees better results.
L Close the gas valve on the cylinder and zero-set the pressure reducer once you have
nished work.
** (This component may not be included with some models).
Welding process: description of controls and signals
Once you have put the welding machine into opera-tion, switch it on, open the protective
gas valve and carry out the adjustments following the order shown in the description of
the controls, Fig. 1.
Synergic MIG control
The Synergic MIG control facilitates the welding machine operator’s work as it manages
wire speed, soft start and burn back in a synergic way with the rest of the machine settings.
The welding machine operator must simply activate one of the pre-set programs.
The Synergic MIG control is active with all the torches provided for the welding machine.
1) Adjusting the welding current
Select the welding current according to the work to be carried out. Start with a low current
if the metal is thin. Then increase the current until the best position is found.
L Do not adjust the welding current while welding, as the current could damage the
switches.
2) Synergic / Manual welding mode selection
Upon starting the machine, the Synergic MIG control is set in synergic mode, in the last
program used.
The message “Synergic” and the program set are displayed on the display.
Synergic program setting
¾ Select in the following order: wire type: “WIRE”, its diameter: “WIRE DIAM”, gas type:
“GAS”. The values ash when there are more options available for wire type. Press
the corresponding switches to conrm or modify the selection. Once the selection is
completed, all the indicators will be xed on. If you attempt to weld, without completing
the selections, the welder would not start and the message “SET” is shown on the display.
¾ Place the potentiometer on the neutral value “0” of the “SYN” scale. Then, adjust the
value proposed by the Synergic MIG control up to +/- 20%.
Manual welding mode
¾ Press the “Man /Syn” switch. The message “Manual” is displayed on the screen. The
welding machine operates in regular mode.
¾ Adjust the wire speed with the potentiometer: Fig. 3,4.
3) 2 stroke 4 stroke selector
In the 4 stroke position the torch button changes function. When the button is pressed,
the gas is delivered, and when released welding starts. By pressing the button once more
the welding stops, and once more again also the gas delivery stops.
The selection is shown on the display.
4) Selector for Continuous welding: “Cont”; Spot welding:
“Spot”; “Stitch” (sequence of welding cycles and pause)
¾ Press the switch several times to select the welding mode.
The selection is shown on the display.
¾ Adjust the welding time in the “Spot” and “Stitch” modes with the “+ , -“ switches .
¾ The selection is shown on the display.
L In the “Stitch” mode you can also adjust the pause time present in the secondary
parameters.
5) Secondary parameters selector
¾ Press the “Menu” switch several times to select the parameter and change its value
with the “+ , -” switches. Modications become active 5 seconds after the last switch
release, when the control automatically exits the secondary parameters list.
The selection is shown on the display.
Burn back: Modies the length of the wire that remains outside the contact tip at
the end of the welding operation. The setting carried out at the factory should be
correct.
Soft start: Modies the approach speed of the wire to the piece to be welded at the
start of welding. The setting carried out at the factory should be correct.
Pause time: Pause time in “Stitch” mode
Back light: Display brightness
Contrast: Screen and message contrast
L Welding not allowed while “Menu” is open.
L Adjustments are not allowed when torch switch is pressed. Only the potentiometer on
the control or on the torch is active.
6) Ammeter Voltmeter
The welding voltage and current values are shown on the display during welding and for
10 seconds after welding ends.
7) Thermal cut-out signal
The message “Thermal protection” on the display signals that the thermal cut-out
protection is on.
If the duty cycle “X” shown on the data plate is exceeded, a thermal cutout stops the
machine before any damage is caused. Wait for operation to be resumed and, if possible,
Technical data
A data plate is afxed to the welding machine. Fig. 2 shows an example of this plate.
A) Constructor name and address
B) European reference standard for the construction and safety of welding equipment
C) Symbol of the welding machine internal structure
D) Symbol of the foreseen welding process
E) Symbol of the continuous current delivered
F) Input power required:
1˜ alternate single phase voltage, frequency
3˜ alternate three-phase voltage, frequency
G) Level of protection from solids and liquids
H) Symbol indicating the possibility to use the welding machine in environments
potentially subject to electric discharges
I) Welding circuit performance
U0V Minimum and maximum open circuit voltage (open welding circuit).
I2, U2 Current and corresponding normalised voltage delivered by the welding
machine.
X Duty cycle. Indicate how long the welding machine can work for and how
long it must rest for in order to cool down. The time is expressed in % on the
basis of a 10 minute cycle (e.g. 60% means 6 min. work and 4 min. rest).
A / V Current adjustment eld and corresponding arc voltage.
J) Power supply data
U1 Input voltage (permitted tolerance: +/- 10%)
I1 eff Effective absorbed current
I1 max Maximum absorbed current
K) Serial number
L) Weight
M) Safety symbols: Refer to Safety Warnings
Technical data for torch and wire feeder Fig.4
Starting up
Connections to the mains must be made by expert or qualied personnel.
Make sure that the welding machine is switched off and the plug is not in the power
socket before carrying out this procedure.
Make sure that the power socket that the welding machine is plugged into is protected
by safety devices (automatic switch) and grounded.
The device must be connected only to a supply system, with an earthed ‘neutral’ lead.
Assembly and electrical connections
¾ Assembly the detached parts found in the packaging Fig.8.
¾ Check that the electrical supply delivers the voltage and frequency corresponding to
the welding machine and that it is tted with an automatic switch suited to the maximum
delivered rated current (I2max) Fig. 3,1.
L The requirements set out in the IEC/EN61000-3-12 standard do not apply to this
equipment. If this equipment is connected to low voltage power supply network, either
the installer or the user is responsible for checking that this can be done (consult the
distribution system operator if required).
¾ Plug. If the welding machine is not tted with a plug, t a normalised plug (2P+T for 1Ph
and 3P+T for 3Ph) of suitable capacity to the power cable Fig.3,2.
¾ If the welding machine is designed to operate at two different voltages, select the required
voltage on the terminal board, which is accessed by removing the cover. Fig. 5.
L The welding machines are set to the highest voltage at the factory.
Preparing the welding circuit
¾ In welding machines with external wire feeders, connect the power and control cables
to the sockets on the generator and trolley.
The external wire feeder is designed for use only and exclusively togheter with the
specic welding machine; indipendent use is prohibited.
¾ Connect the ground lead to the welding machine and to the piece to be welded, as
close as possible to the point to be welded. In welding machines with several sockets,
it is possible to select different levels of welding penetration. Generally speaking, low
outlets should be used for thin metals.
¾ Connect the torch** to the welding machine socket.
L The recommended sections (mm2) of the welding cable, based on the maximum
delivered rated current (I2 max), are shown in Fig. 3,3.
Installing the continuous wire
For installation, follow the instructions in Fig. 6.
The material and diameter of the wire must correspond to the wire feeder roller Fig.
6,4,a, the contact tip Fig. 6,8,b and the torch liner. If the measurements do not match,
there may be problems with the smooth running of the wire.
L Cored wire requires a special roller with a knurled groove to ensure drawing.
L The pressure of the wire pressing knob Fig. 6,4,c is important for correct operation. If
the wire slips, there will be problems with the welding; if on the other hand it is too tight,
it may be deformed and will not run smoothly through the torch. It can be adjusted as
follows: screw the wire pressing knob until it starts to draw the wire, then, if the wire
is soft (aluminium, cored wire) turn the screw once more; if the wire is hard (steel,
stainless steel, etc.) turn the screw three more times.
L To remove the continuous wire easily from the welding machine, cut the wire between
the spool and the wire feeder, keeping it taut, and then tie it to the spool. The open the
wire guider arm and, using a pair of pliers, pull the piece of wire out of the torch.
Installing the protective gas cylinder** and pressure reducer**
Place the protective gas cylinder in an upright position, far away from the welding area.
Use the welding machine support or some other xed part so that there is no risk of it

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