Infinity 225 954556 - Welding machine Telwin - Free user manual and instructions

Features	Details
Machine type	Welding machine
Power supply	230 V
Welding current	From 20 to 225 A
Weight	About 20 kg
Dimensions	Length: 500 mm, Width: 300 mm, Height: 400 mm
Welding process	MIG\/MAG, MMA
Recommended use	For light to medium welding jobs, ideal for DIYers and professionals.
Included accessories	Welding torch, ground cable, protective mask (depending on model)
Maintenance	Regularly check connections, clean nozzles and filters.
Safety	Use personal protective equipment (PPE): gloves, mask, appropriate clothing.
Warranty	2 years (depending on the retailer)

Frequently Asked Questions - Infinity 225 954556 Telwin

What type of gas should I use with the Telwin Infinity 225?

For MIG\/MAG welding, use an inert gas such as argon or an argon-CO2 mixture depending on the material to be welded.

How do I adjust the welding current on the machine?

Use the current adjustment knob on the control panel to set the welding power according to the material thickness.

What should I do if the machine does not start?

Check that the machine is properly plugged in, the circuit breaker has not tripped, and all cables are securely connected.

How do I change the wire spool?

Open the spool compartment, remove the old spool, install the new one, ensuring the wire is properly wound and fed into the conduit.

What types of materials can I weld with the Telwin Infinity 225?

You can weld ferrous and non-ferrous metals, including steel, stainless steel, and aluminum.

How do I clean the welding torch?

Disconnect the torch, remove the nozzle, and clean it with a soft wire brush or cloth. Make sure there are no welding residues.

What should I do if the welding wire jams?

Check if the wire is feeding correctly. If the problem persists, clean the feed conduit and ensure there are no obstructions.

The machine is making unusual noises, what should I do?

Check connections and cables, and ensure no parts are loose. If the noise continues, contact a professional for inspection.

What is the warranty for the Telwin Infinity 225?

The standard warranty is usually 2 years, but this may vary depending on the retailer. Check specific terms at purchase.

How do I store the machine properly?

Store the machine in a dry place, protected from moisture and extreme temperatures. Unplug and clean it before storage.

USER MANUAL Infinity 225 954556 Telwin

(PT) MANUAL DE INSTRUÇÕES

..................................................................................................................................................................135-136- 5 - INVERTERWELDINGMACHINESFORTIGANDMMAWELDINGDESIGNEDFOR INDUSTRIALANDPROFESSIONALUSE. Note:Inthefollowingtexttheterm“weldingmachine”willbeused. 1.GENERALSAFETYCONSIDERATIONSFORARCWELDING The operator should be properly trained to use the welding machine safely andshouldbeinformedabouttherisksrelatedtoarcweldingprocedures,the associatedprotectionmeasuresandemergencyprocedures. (Pleaserefertotheapplicablestandard“EN60974-9:Arcweldingequipment. Part9:InstallationandUse). - Avoiddirectcontactwiththeweldingcircuit:theno-loadvoltagesuppliedby theweldingmachinecanbedangerousundercertaincircumstances. - When the welding cables are being connected or checks and repairs are carriedouttheweldingmachineshouldbeswitchedoffanddisconnected fromthepowersupplyoutlet. - Switch off the welding machine and disconnect it from the power supply outletbeforereplacingconsumabletorchparts. - Maketheelectricalconnectionsandinstallationaccordingtothesafetyrules andlegislationinforce. - Theweldingmachineshouldbeconnectedonlyandexclusivelytoapower sourcewiththeneutralleadconnectedtoearth. - Make sure that the power supply plug is correctly connected to the earth protectionoutlet. - Donotusetheweldingmachineindamporwetplacesanddonotweldinthe rain. - Donotusecableswithworninsulationorlooseconnections. - Donotweldoncontainersorpipingthatcontainsorhascontainedammable liquidorgaseousproducts. - Donotoperateonmaterialscleanedwithchlorinatedsolventsornearsuch substances. - Donotweldoncontainersunderpressure. - Removeallammablematerials(e.g.wood,paper,ragsetc.)fromtheworking area. - Provideadequateventilationorfacilitiesfortheremovalofweldingfumesnear thearc;asystematicapproachisneededinevaluatingtheexposurelimitsfor the welding fumes, which will depend on their composition, concentration andthelengthofexposureitself. - Keep the gas bottle (if used) away from heat sources, including direct sunlight. - Useelectricinsulationthatissuitableforthetorch,theworkpieceandany metalpartsthatmaybeplacedonthegroundandnearby(accessible). Thiscannormallybedonebywearinggloves,footwear,headprotectionand clothingthataresuitableforthepurposeandbyusinginsulatingboardsor mats. - Alwaysprotectyoureyeswiththerelativelters,whichmustcomplywithUNI EN169orUNIEN379,mountedonmasksorusehelmetsthatcomplywithUNI EN175. Use the relative re-resistant clothing (compliant with UNI EN 11611) and weldinggloves(compliantwithUNIEN12477)withoutexposingtheskinto the ultraviolet and infrared rays produced by the arc; the protection must extend to other people who are near the arc by way of screens or non- reectivesheets. - Noise:Ifthedailypersonalnoiseexposure(LEPd)isequaltoorhigherthan85 dB(A)becauseofparticularlyintensiveweldingoperations,suitablepersonal protectivemeansmustbeused(Tab.1). - The ow of the welding current generates electromagnetic elds (EMF) aroundtheweldingcircuit. Electromagneticeldscaninterferewithcertainmedicalequipment(e.g.Pace- makers,respiratoryequipment,metallicprosthesesetc.). Adequateprotectivemeasuresmustbeadoptedforpersonswiththesetypesof medicalapparatus.Forexample,theymustbeforbiddenaccesstotheareain whichweldingmachinesareinoperation. Thiswelding machineconforms totechnicalproductstandardsfor exclusive useinanindustrialenvironmentforprofessionalpurposes.Itdoesnotassure compliancewiththebasiclimitsrelativetohumanexposuretoelectromagnetic eldsinthedomesticenvironment. Theoperatormustadoptthefollowingproceduresinordertoreduceexposure toelectromagneticelds: - Fastenthetwoweldingcablesasclosetogetheraspossible. - Keepheadandtrunkasfarawayaspossiblefromtheweldingcircuit. - Neverwindweldingcablesaroundthebody. - Avoidweldingwiththebodywithintheweldingcircuit.Keepbothcableson thesamesideofthebody. - Connecttheweldingcurrentreturncabletothepiecebeingwelded,asclose aspossibletotheweldingjoint. - Donotweldwhilecloseto,sittingonorleaningagainsttheweldingmachine (keepatleast50cmawayfromit). - Do not leave objects in ferromagnetic material in proximityof the welding circuit. - Minimumdistanced:20cm(Fig.O). -ClassAequipment: Thiswelding machineconforms totechnicalproductstandardsfor exclusive use in an industrial environment and for professional purposes. It does not assure compliance with electromagnetic compatibility in domestic dwellings and in premises directly connected to a low-voltage power supply system feedingbuildingsfordomesticuse. EXTRA PRECAUTIONS - WELDINGOPERATIONS: - Inenvironmentswithincreasedriskofelectricshock. - Inconnedspaces. - Inthepresenceofammableorexplosivematerials. MUSTBEevaluatedinadvancebyan“Expertsupervisor”andmustalwaysbe carriedoutinthepresenceofotherpeopletrainedtointerveneinemergencies. Allprotectivetechnical measures MUST be taken asprovidedin7.10;A.8; A.10oftheapplicablestandardEN60974-9:Arcweldingequipment.Part9: InstallationandUse”. -The operatorMUST NOT BE ALLOWED to weldin raised positions unless safetyplatformsareused. -VOLTAGE BETWEEN ELECTRODE HOLDERS OR TORCHES: working with more than one welding machine on a single piece or on pieces that are connected electrically may generate a dangerous accumulation of no-load voltagebetweentwodifferentelectrodeholdersortorches,thevalueofwhich mayreachdoubletheallowedlimit. An expert coordinator must be designated to measuring the apparatus to determine if any risks subsist andsuitableprotectionmeasures can be adopted,asforeseenbysection7.9oftheapplicablestandard“EN60974-9: Arcweldingequipment.Part9:InstallationandUse”. RESIDUAL RISKS - OVERTURNING:positiontheweldingmachineonahorizontalsurfacethatis abletosupporttheweight:otherwise(e.g.inclinedorunevenoorsetc.)there isdangerofoverturning. -IMPROPER USE: it is hazardous to usethe weldingmachine forany work otherthanthatforwhichitwasdesigned(e.g.de-icingmainswaterpipes). - Donotusethehandletohangtheweldingmachine. 2.INTRODUCTIONANDGENERALDESCRIPTION 2.1INTRODUCTION This welding machine is a power source for arc welding, made specically for TIG (DC) (AC/DC) welding with HF or LIFT strike and MMA welding with coated electrodes ENGLISH INDEX 1.GENERALSAFETYCONSIDERATIONSFORARCWELDING..........................5 2.INTRODUCTIONANDGENERALDESCRIPTION...............................................5

5.1.2 Assembling the welding cable-electrode holder clamp (FIG. E) ..............7

8.TROUBLESHOOTING...........................................................................................8 page page- 6 - (rutile, acid, basic). The particular features of this welding machine (INVERTER), such as high-speed and precise adjustment, result in excellent quality welds. The inverter system of regulation at the power supply input (primary) also leads to a drastic decrease in the volume of both the transformer and the levelling reactance so that it is possible to build a considerably smaller, lighter welding machine, highlighting its advantages of easy handling and transport. 2.2ACCESSORIESONREQUEST(ifnotplanned) - Argon bottle adapter. - Welding current return cable complete with earth clamp. - Manual remote control with 1 potentiometer. - Manual remote control with 2 potentiometers. - Pedal remote control. - MMA welding kit. - TIG welding kit. - Self-darkening mask: with xed or adjustable lter. - Gas connector and pipe for hook-up with Argon bottle. - Pressure reducing valve with gauge. - Torch for TIG welding. - TIG torch with potentiometer. - AMERICA trolley. 3.TECHNICALDATA 3.1DATAPLATE(FIG.A) The most important data regarding use and performance of the welding machine are summarised on the rating plate and have the following meaning:

1- Protection rating of the covering.

2- Symbol for power supply line:

1~: single phase alternating voltage; 3~: three phase alternating voltage.

3- Symbol S : indicates that welding operations may be carried out in environments

with heightened risk of electric shock (e.g. very close to large metallic volumes).

4- Symbol for welding procedure provided.

5- Symbol for internal structure of the welding machine.

6- EUROPEAN standard of reference, for safety and construction of arc welding

7- Manufacturer’s serial number for welding machine identication (indispensable for

technical assistance, requesting spare parts, discovering product origin).

8- Performance of the welding circuit:

: current and corresponding normalised voltage that the welding machine can supply during welding. - X: Duty cycle: indicates the time for which the welding machine can supply the corresponding current (same column). It is expressed as %, based on a 10 minutes cycle (e.g. 60% = 6 minutes working, 4 minutes pause, and so on). If the usage factors (on the plate, referring to a 40°C environment) are exceeded, the thermal safeguard will trigger (the welding machine will remain in standby until its temperature returns within the allowed limits). - A/V-A/V : shows the range of adjustment for the welding current (minimum maximum) at the corresponding arc voltage.

9- Technical specications for power supply line:

: Alternating voltage and power supply frequency of welding machine (allowed limit ±10%). - I 1max : Maximum current absorbed by the line. - I 1eff : Effective current supplied.

: Size of delayed action fuses to be used to protect the power line.

11- Symbols referring to safety regulations, whose meaning is given in chapter 1

“General safety considerations for arc welding”. Note: The data plate shown above is an example to give the meaning of the symbols and numbers; the exact values of technical data for the welding machine in your possession must be checked directly on the data plate of the welding machine itself. 3.2OTHERTECHNICALDATA -WELDINGMACHINE:seetable1(TAB.1). -TORCH: seetable2(TAB.2). Theweldingmachineweightisshownintable1(TAB.1). 4.DESCRIPTIONOFTHEWELDINGMACHINE 4.1BLOCKDIAGRAM The welding machine consists basically of power and control modules made on PCB’s and optimised to achieve perfect reliability and reduced maintenance. This welding machine is controlled by a microprocessor that allows a large number of parameter settings so as to achieve perfect welding in any condition and with any material. However, to make the best use of its properties it is necessary to be fully aware of its possibilities. Description(FIG.B)

1- Three-phase power supply input, rectier unit and levelling capacitors.

2- Transistor (IGBT) switching bridge and drivers; commutes the rectied power

supply voltage to high frequency alternating voltage and adjusts the power according to the required welding current/voltage.

3- High frequency transformer; the voltage converted by block 2 powers the primary

winding; its function is to adjust the voltage and current to the values needed for the arc welding procedure and at the same time to form galvanic separation of the welding circuit from the power supply line.

4- Secondary rectier bridge with levelling inductance; commutes the alternating

voltage / current supplied by the secondary winding into very low ripple direct current / voltage.

5- Transistor (IGBT) switching bridge and drivers; transforms the secondary output

current from DC to AC for TIG AC welding (if present).

6- Control and adjustment electronics; controls the welding current value

instantaneously and compares it with the operator’s setting; modulates the control impulses from the IGBT drivers that make the adjustment.

7- Welding machine operation control logic; sets the welding cycles, controls the

actuators, supervises the safety systems.

11- Welding machine cooling fan.

2- Power cable (2 P + T (Single-phase)), (3 P + T (Three-phase)).

3- Coupler for connecting the gas hose (bottle - welding machine pressure reducer)

5- Connector for water cooling unit (if present).

6- Connector for remote control:

Three different types of remote control can be connected to the welding machine using the relative 14-pole connector at the back. Each device is recognised automatically and can be used to adjust these parameters: - Remotecontrolwithonepotentiometer: rotating the potentiometer knob varies the main current from minimum to maximum. The main current can only be adjusted with the remote control. - Pedalremotecommand: the value of the current is determined by the position of the pedal. Furthermore, in TIG 2T mode, pressing the pedal acts as a start command for the machine placed on the torch push-button (if installed). - Remotecontrolwithtwopotentiometers: the rst potentiometer adjusts the main current. the second potentiometer adjusts another parameter that depends on the welding mode being used. Rotating this potentiometer displays the parameter being varied (which can no longer be controlled using the panel knob). The meaning of the second potentiometer is: ARC FORCE if in the MMA mode and END SLOPE if in the TIG mode. - TIGtorchwithpotentiometer. Itisobligatorytousea5-poletorchadapterforanyTIGTORCHwith anon-boardadjustmentpotentiometerinordertoprotecttheweldingmachine frominternalbreakage.

4.2.2FrontpanelFIG.D

1- Positive (+) fast coupling for connecting the welding cable.

2- Negative (-) fast coupling for connecting the welding cable.

3- Connector for connecting the torch push-button.

4- Coupler for connecting the TIG torch gas hose.

5a.Weldingtypesettingpush-button(PROCESS). Allows selection of the desired process:

welding with coated electrode (MMA).

TIG welding with high frequency ark strike (TIG HF).

TIG welding with arc strike starting with contact (TIG HF).

in TIG mode, it indicates direct current welding (DC).

in TIG mode, it indicates alternating current welding (AC), if installed. 5b.Cyclesettingpush-buttonforTIGwelding(MODE). Enables selection of the operating mode. Shortpress:

welding begins when the torch push-button is pressed and ends when the torch push-button is released.

welding begins when the torch push-button is pressed and released, and ends only when the torch push-button is pressed and released a second time.

welding begins when the torch push-button is pressed and released. On each short press/release the current passes from the value set to the value and vice versa. Welding ends when the push-button is pressed and then released for a set long time.

enables spot welding with duration time control of the welding on the display (ashing icon).

enables short spot welding (10-100msec) with duration time control of the welding on a display (ashing icon). Prolongedpressing(PULSE):

enables pulsation of the current (level change) with setting as you wish of the characteristic parameters , , and .

enables pulsation of the current with automatic settings to the predened values of the characteristic parameters , and based on the current set (these values can however be modied). 5c.Multi-functionknob. Based on the pre-settings with the buttons, it enables selection and adjustment of the parameters by displaying the value set on the display. Inparticular,inMMA,theparametersthatcanbechangedare: - enabling/disabling the “Voltage Reduction Device” for a safe start at low voltage.

initial overcurrent (0-100% adjustment) to optimise welding arc strike.

main welding current (output current in Amperes).

dynamic overcurrent (0-100% adjustment) to optimise uidity of the welding and avoid electrode sticking.- 7 - Inparticular,inTIG,theparametersthatcanbechangedare: - pre-gas time of safety gas ow before starting welding (0-10 seconds adjustment).

initial current maintained for a set time in 2T (50msec) and for the time the push-button is pressed, in 4T (0-100% adjustment).

initial ramp time of the current from value I

can also be modied with the pedal remote command. Adjustment, however, must be made before activating the commanditself.

main welding current, in PULSED and Bi-Level mode is the current at higher level (output current in Amperes).

basic current, in PULSED and Bi-Level mode is the value which can be alternated with the main one during welding (adjustment in Amperes).

pulsation frequency and for AC/DC models in TIG AC it represents the frequency of the welding current (adjustment in Hertz).

balance percentage, in PULSED mode is the ratio between the time in which the current is at the highest level and the total pulsation period, for AC/DC models in TIG AC it represents the ratio between the time with positive current and the time with negative current.

nal ramp time of the current from value I

to I end (0.1-10 seconds adjustment). In OFF ramp not present.

nal current, in 2T it is the current maintained after the nal ramp if the ramp time is over zero, in 4T it is the current maintained after the nal ramp for the entire time in which the torch push-button remains pressed.

post-gas time of safety gas ow starting from welding stoppage (0-10 seconds adjustment).

pre-heating energy, if installed, only for AC/DC models in TIG AC adjusts pre-heating of the electrode to facilitate start-up (2.6-53 A*Sec adjustment). In OFF pre-heating not present. Otherexplanatoryiconsonthedisplay:

warning/alarm, in general combined with the code indicated on the display, drawing attention to possible anomalies/automatic protection activated on the welding machine.

thermal protection, combined with and the code on the display, warning the condition of internal heating limits has been reached.

active output, indicates voltage is present (power enabled) in the output sockets of the welding machine.

remote command, indicates connection and control is active on the remote command.

position pointer, in 4T with under a preset value, it indicates setting of a minimum initial current that makes the welding arc visible with push-button pressed. This allows precise selection of the starting point of the welding (if the initial current is set beyond a certain limit the function automatically disables).

factory parameters, indicates setting of all the parameters at a preset value useful for wide-ranging operativity. The user can set the main current as wished to alter the other automatic settings. It is possible to re-activate this condition at any time by switching off and back on the welding machine with the push-button on the multi-function knob (FIG. D - 5c) pressed. Explanatoryalarmmessagesonthealphanumericaldisplay(FIG.D-5d): - AL.1 : the primary circuit protection thermal switch has been triggered (if installed). - AL.2 : the secondary circuit protection thermal switch has been triggered. - AL.3 : power line overvoltage protection has been triggered. - AL.4 : power line undervoltage protection has been triggered. - AL.8 : auxiliary voltage out of range. Resetting is automatic when the reason for alarm activation stops. 5.INSTALLATION WARNING! CARRY OUT ALL INSTALLATION OPERATIONS AND ELECTRICAL CONNECTIONS WITH THE WELDING MACHINE COMPLETELY SWITCHEDOFFANDDISCONNECTEDFROMTHEPOWERSUPPLYOUTLET. THEELECTRICALCONNECTIONSMUSTBEMADEONLYANDEXCLUSIVELY BYAUTHORISEDORQUALIFIEDPERSONNEL. 5.1PREPARATION(FIG.P) Unpack the welding machine, assemble the separate parts contained in the package.

5.1.1Assemblingthereturncable-clamp(FIG.E)

5.1.2Assemblingtheweldingcable-electrodeholderclamp(FIG.E)

5.2POSITIONOFTHEWELDINGMACHINE Choose the place to install the welding machine so that the cooling air inlets and outlets are not obstructed (forced circulation by fan, if present); at the same time make sure that conductive dusts, corrosive vapours, humidity etc. will not be sucked into the machine. Leave at least 250mm free space around the welding machine. WARNING! Position the welding machine on a at surface with sufcientcarryingcapacityforitsweight,topreventitfromtippingormoving hazardously. 5.3CONNECTIONTOTHEMAINPOWERSUPPLY - Before making any electrical connection, make sure the rating data of the welding machine correspond to the mains voltage and frequency available at the place of installation. - The welding machine should only be connected to a power supply system with the neutral conductor connected to earth. - To ensure protection against indirect contact use residual current devices of the following types: - Type A ( ) for single phase machines; - Type B ( ) for 3-phase machines. - In order to satisfy the requirements of the EN 61000-3-11 (Flicker) standard we recommend connecting the welding machine to the interface points of the main power supply that have an impedance of less than: Zmax = 0.234 Ohm (1/N/PE 230V) 200A DC - The IEC/EN 61000-3-12 Standard does not apply to the welding machine. If the welding machine is connected to an electrical grid, the installer or user must make sure that the machine can indeed be connected (if necessary, consult the company that manages the electrical grid).

Connect a normalised plug (2P + P.E) (1~); (3P + P.E) (3~) - having sufcient capacity- to the power cable and prepare a mains outlet tted with fuses or an automatic circuit- breaker; the special earth terminal should be connected to the earth conductor (yellow- green) of the power supply line. Table (TAB.1) shows the recommended delayed fuse sizes in amps, chosen according to the max. nominal current supplied by the welding machine, and the nominal voltage of the main power supply. WARNING!Failuretoobservetheaboveruleswillmakethe(Class1) safetysysteminstalledbythemanufacturerineffectivewithconsequentserious riskstopersons(e.g.electricshock)andobjects(e.g.re). 5.4CONNECTIONOFTHEWELDINGCABLES WARNING!BEFOREMAKINGTHEFOLLOWINGCONNECTIONSMAKE SURETHEWELDINGMACHINEISSWITCHEDOFFANDDISCONNECTEDFROM THEPOWERSUPPLYOUTLET. Table (TAB. 1) gives the recommended values for the welding cables (in mm

depending on the maximum current supplied by the welding machine.

Connectingthetorch - Insert the torch current cable into the appropriate quick terminal (-). Connect the three-pin connector (torch button) to the appropriate socket. Connect the torch gas pipe to the appropriate connector. Connectingtheweldingcurrentreturncable - This is connected to the piece to be welded or to the metal bench on which it rests, as close as possible to the joint being made. This cable is connected to the terminal with the (+) symbol. Connectingthegasbottle - Screw the pressure reducing valve to the gas bottle valve, rst inserting the special reduction accessory supplied when argon gas is used. - Connect the gas inow hose to the pressure reducing valve and tighten the hose clamp supplied. - Loosen the ringnut for adjusting the pressure reducing valve before opening the valve on the bottle. - Open the valve on the bottle and adjust the quantity of gas (l/min) according to the suggestions for use given in the table (TAB.4); if it is necessary to adjust the gas ow during welding this should always be done by adjusting the ring nut on the pressure reduction valve. Make sure there are no leaks in the piping and connectors. WARNING!Alwaysclosethegasbottlevalveattheendofthejob.

Almost all coated electrodes are connected to the positive pole (+) of the power source; as an exception to the negative pole (-) for acid coated electrodes. Connectingtheelectrode-holderclampweldingcable On the end take a special terminal that is used to close the uncovered part of the electrode. This cable is connected to the terminal with the symbol (+) Connectingtheweldingcurrentreturncable This is connected to the piece being welded or to the metal bench supporting it, as close as possible to the join being made. This cable is connected to the terminal with the symbol (-) Warnings: - Turn the welding cable connectors right down into the quick connections (if present), to ensure a perfect electrical contact; otherwise the connectors themselves will overheat, resulting in their rapid deterioration and loss of efciency. - The welding cables should be as short as possible. - Do not use metal structures which are not part of the workpiece to substitute the return cable of the welding current: this could jeopardise safety and result in poor welding. 6.WELDING:DESCRIPTIONOFTHEPROCEDURE 6.1TIGWELDING TIG welding is a welding procedure that exploits the heat produced by the electric arc that is struck, and maintained, between a non-consumable electrode (tungsten) and the piece to be welded. The tungsten electrode is supported by a torch suitable for transmitting the welding current to it and protecting the electrode itself and the weld pool from atmospheric oxidation, by the ow of an inert gas (usually argon: Ar 99.5) which ows out of the ceramic nozzle (FIG.G). To achieve a good weld it is absolutely necessary to use the exact electrode diameter with the exact current, see the table (TAB.3). The electrode usually protrudes from the ceramic nozzle by 2-3mm, but this may reach 8mm for corner welding.- 8 - Welding is achieved by fusion of the edges of the joint. For properly prepared thin pieces (up to about 1mm) weld material is not needed (FIG.H). For thicker pieces it is necessary to use ller rods of the same composition as the base material and with an appropriate diameter, preparing the edges correctly (FIG.I). To achieve a good weld the pieces should be carefully cleaned and free of oxidation, oil, grease, solvents etc.

6.1.1HFandLIFTstrike

HFstrike: The electric arc is struck without contact between the tungsten electrode and the piece being welded, by means of a spark generated by a high frequency device. This strike mode does not entail either tungsten inclusions in the weld pool or electrode wear and gives an easy start in all welding positions. Procedure: Press the torch button, bringing the tip of the electrode close to the piece (2 -3mm), wait for the arc strike transferred by the HF pulses and, when the arch has struck, form the weld pool on the piece and proceed along the joint. If there are difculties in striking the arc even though the presence of gas is conrmed and the HF discharges are visible, do not insist for long in subjecting the electrode to HF action, but check the integrity of the surface and the shape of the tip, dressing it on the grinding wheel if necessary. At the end of the cycle the current will fall at the slope down setting. LIFTstrike: The electric arc is struck by moving the tungsten electrode away from the piece to be welded. This strike mode causes less electrical-radiation disturbance and reduces tungsten inclusions and electrode wear to a minimum. Procedure: Place the tip of the electrode on the piece, using gentle pressure. Press the torch button right down and lift the electrode 2-3mm with a few moments’ delay, thus striking the arc. Initially the welding machine supplies a current I LIFT , after a few moments the welding current setting will be supplied. At the end of the cycle the current will fall to zero at the slope down setting.

TIG DC welding is suitable for all low- and high-carbon steels and the heavy metals, copper, nickel, titanium and their alloys. For TIG DC welding with the electrode to the (-) terminal the electrode with 2% thorium (red band) is usually used or else the electrode with 2% cerium (grey band). It is necessary to sharpen the tungsten electrode axially on the grinding wheel, as shown inFIG. L, making sure that the tip is perfectly concentric to prevent arc deviation. It is important to carry out the grinding along the length of the electrode. This operation should be repeated periodically, depending on the amount of use and wear of the electrode, or when the electrode has been accidentally contaminated, oxidised or used incorrectly.

6.1.3TIGACwelding(ifinstalled)

This type of welding can be used to weld metals such as aluminium and magnesium, which form a protective, insulating oxide on their surface. By reversing the welding current polarity it is possible to “break” the surface layer of oxide by means of a mechanism called “ionic sandblasting”. The voltage on the tungsten electrode alternates between positive (EP) and negative (EN). During the EP period the oxide is removed from the surface (“cleaning”or “pickling”) allowing formation of the pool. During the EN period there is maximum heat transfer to the piece, allowing welding. The possibility of varying the balance parameter in AC means that it is possible to reduce the EP current period to a minimum, allowing quicker welding. Higher balance values give quicker welding, greater penetration, a more concentrated arc, a narrower weld pool and limited heating of the electrode. Lower values give a cleaner piece. If the balance value is too low this will widen the arc and the de-oxidised part, overheat the electrode with consequent formation of a sphere on the tip making it more difcult to strike the arc and control its direction. If the balance value is too high this will create a “dirty” weld pool with dark inclusions. The table (TAB. 4) summarises the effects of parameter changes in AC welding. The instructions for this welding procedure are also valid. The table (TAB. 3) shows suggested values for welding on aluminium; the most suitable electrode is a pure tungsten electrode (green band).

- Use the knob to adjust the welding current to the desired value; if necessary adjust during welding to the actual required heat transfer. - Press the torch button and make sure the gas ow from the torch is correct; if necessary, adjust pre-gas and postgas times; these times should be adjusted according to operating conditions, the postgas delay in particular should be long enough to allow the electrode and weld pool to cool at the end of welding without coming into contact with the atmosphere (oxidation and contamination). TIGmodewith2Tsequence: - Press the torch button (P.T.) right down to strike the arc with a current of I

. The current will increase according to the START SLOPE UP setting to the welding current value. - To interrupt welding, release the torch button so that either the current gradually decreases (if the FINAL SLOPE DOWN parameter has been enabled) or the arc is extinguished immediately, followed by postgas. TIGmodewith4Tsequence: - The rst time the button is pressed it will strike the arc with a current equal to I

When the button is released the current will increase according to the START SLOPE UP setting to the welding current value; this value is maintained even with the button is released. When the button is pressed again the current will decrease according to the FINAL SLOPE DOWN setting, until it reaches I end . The I end current will be maintained until the button is released to terminate the welding cycle and start the postgas phase. If, on the other hand, the button is released while the FINAL SLOPE DOWN function is proceeding, the welding cycle will terminate immediately and the postgas phase will start. TIGmodewith4TandBI-LEVELsequence: - The rst time the button is pressed it will strike the arc with a current equal to I

When the button is released the current will increase according to the START SLOPE UP setting to the welding current value; this value is maintained even when the button is released. Now, every time the button is pressed (the time between pressure and release should be short) the current will change between the setting for the BI-LEVEL I

- When the button is kept pressed down for a longer space of time the current will decrease according to the FINAL SLOPE DOWN setting, until it reaches I end . The

end current will be maintained until the button is released to terminate the welding cycle and start the postgas phase. If, on the other hand, the button is released while the FINAL SLOPE DOWN function is proceeding, the welding cycle will terminate immediately and the postgas phase will start (FIG.M). TIGSPOTandTIGTHINSPOTmode: - Welding is carried out by keeping the torch push-button pressed until the pre-set time has been reached (spot time). 6.2MMAWELDING - It is most important that the user refers to the maker’s instructions indicated on the stick electrode packaging. This will indicate the correct polarity of the stick electrode and the most suitable current. - The welding current must be regulated according to the diameter of the electrode in use and the type of the joint to be carried out: see below the currents corresponding to various electrode diameters: Ø Electrode (mm) Weldingcurrent(A) Min. Max.

- The user must consider that, according to the electrode diameter, higher current values must be used for at welding, whereas for vertical or overhead welds lower current values are necessary. - As well as being determined by the chosen current intensity, the mechanical characteristics of the welded join are also determined by the other welding parameters i.e. arc length, working rate and position, electrode diameter and quality (to store the electrodes correctly, keep them in a dry place protected by their packaging or containers). - The properties of the weld also depend on the ARC-FORCE value (dynamic behaviour) of the welding machine. The setting for this parameter can be made either on the panel or using the remote control with 2 potentiometers. - It should be noted that high ARC-FORCE values achieve better penetration and allow welding in any position typically with basic electrodes, low ARC-FORCE values give a softer, spray-free arc typically with rutile electrodes. The welding machine is also equipped with HOT START and ANTI STICK devices to guarantee easy starts and to prevent the electrode from sticking to the piece.

- Holding the mask IN FRONT OF THE FACE, strike the electrode tip on the workpiece as if you were striking a match. This is the correct strike-up method.

WARNING: do not hit the electrode on the workpiece, this could damage the

electrode and make strike-up difcult. - As soon as arc is ignited, try to maintain a distance from the workpiece equal to the diameter of the electrode in use. Keep this distance as much constant as possible for the duration of the weld. Remember that the angle of the electrode as it advances should be of 20-30 grades. - At the end of the weld bead, bring the end of the electrode backward, in order to ll the weld crater, quickly lift the electrode from the weld pool to extinguish the arc (CHARACTERISTICSOFTHEWELDBEAD-FIG.N). 7.MAINTENANCE

INNEHÅLLSFÖRTECKNING

:TIG THIN SPOT TIG SPOT