TW821075 - Welding machine Telwin - Free user manual and instructions

USER MANUAL TW821075 Telwin

BEFORE USING THE WELDING MACHINE READ THE INSTRUCTION MANUAL CAREFULLY. CONTINUOUS WIRE WELDING MACHINE FOR MIG/MAG AND FLUXARCWELDINGDESIGNEDFORINDUSTRIALAND PROFESSIONAL USE. Note:Inthefollowingtexttheterm“weldingmachine”willbe used. 1.GENERALSAFETYCONSIDERATIONSFORARCWELDING The operator should be properly trained to use the welding machine safely and should be informed about the risks related to arc welding procedures, the associated protection measures and emergency procedures. (Please refer to the applicable standard ”EN 60974-9: Arc weldingequipment.Part9:InstallationandUse). - Avoid direct contact with the welding circuit: the no-load voltagesuppliedby the weldingmachinecan bedangerous under certain circumstances. - When the welding cables are being connected or checks and repairs are carried out the welding machine should be switched off and disconnected from the power supply outlet. - Switch off the welding machine and disconnect it from the power supply outlet before replacing consumable torch parts. - Make the electrical connections and installation according to the safety rules and legislation in force. - The welding machine should be connected only and exclusivelytoapowersourcewiththeneutralleadconnected to earth. - Make sure that the power supply plug is correctly connected to the earth protection outlet. - Do not use the welding machine in damp or wet places and do not weld in the rain. - Do not use cables with worn insulation or loose connections. - Do not weld on containers or piping that contains or has containedammableliquidorgaseousproducts. - Donotoperateonmaterialscleanedwithchlorinatedsolvents or near such substances. - Do not weld on containers under pressure. - Removeallammablematerials(e.g.wood,paper,ragsetc.) from the working area. - Provide adequate ventilation or facilities for the removal of welding fumes near the arc; a systematic approach is needed inevaluatingtheexposurelimitsfortheweldingfumes,which will depend on their composition, concentration and the length of exposure itself. - Keep the gas bottle (if used) away from heat sources, including direct sunlight. - Make sure there is adequate electrical insulation with respect to the torch, the workpiece and any (accessible) earthed metal partsinthevicinity. This is normally achieved by wearing gloves, shoes, head coverings and clothing designed for this purpose and by using insulating platforms or mats. - Alwaysprotectyoureyeswiththerelativelters,whichmust comply with UNI EN 169 or UNI EN 379, mounted on masks or use helmets that comply with UNI EN 175. Use the relative re-resistant clothing (compliant with UNI EN11611)andweldinggloves(compliantwithUNIEN12477) without exposing the skin to 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: If the daily personal noise exposure (LEPd) is equal toor higher than85 dB(A) becauseof particularly intensive weldingoperations,suitablepersonalprotectivemeansmust be used (Tab. 1). - The ow of the welding current generates electromagnetic elds(EMF)aroundtheweldingcircuit. Electromagnetic elds can interfere with certain medical equipment (e.g. Pace-makers, respiratory equipment, metallic prostheses etc.). Adequate protective measures must be adopted for persons with these types of medical apparatus. For example, they must be forbidden access to the area in which welding machines are in operation. This welding machine conforms to technical product standards forexclusiveuseinanindustrialenvironmentforprofessional purposes. It does not assure compliance with the basic limits relative to human exposure to electromagnetic elds in the domesticenvironment. The operator must adopt the following procedures in order to reduceexposuretoelectromagneticelds: - Fasten the two welding cables as close together as possible. - Keep head and trunk as far away as possible from the welding circuit. - Neverwindweldingcablesaroundthebody. - Avoidweldingwiththebodywithintheweldingcircuit.Keep both cables on the same side of the body. - Connect the welding current return cable to the piece being welded, as close as possible to the welding joint. - Do not weld while close to, sitting on or leaning against the welding machine (keep at least 50 cm away from it). - Donotleaveobjectsinferromagneticmaterialinproximityof the welding circuit. - Minimum distance d= 20 cm (Fig. M). - ClassAequipment: This welding machine conforms to technical product standards for 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 feeding buildings for domestic use. EXTRA PRECAUTIONS - WELDINGOPERATIONS: - Inenvironmentswithincreasedriskofelectricshock; - Inconnedspaces; - Inthepresenceofammableorexplosivematerials; MUSTBEevaluatedinadvancebyan“Expertsupervisor” and must always be carried out in the presence of other peopletrainedtointerveneinemergencies. All protective technical measures MUST be taken as provided in 7.10; A.8;A.10 of the applicable standard EN 60974-9: Arc welding equipment. Part 9: Installation and Use”. - WeldingMUSTNOTbeallowediftheweldingmachineorwire feeder is supported by the operator (e.g. using belts). - The operator MUST NOT BE ALLOWED to weld in raised positions unless safety platforms are used. - VOLTAGEBETWEENELECTRODEHOLDERSORTORCHES: 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 voltage between two differentelectrodeholdersortorches,thevalueofwhichmay reach double the allowed limit. An expert coordinator must be designated to measuring the apparatus to determine if any risks subsist and suitable protection measures can be adopted, as foreseen by section

7.9 of the applicable standard ”EN 60974-9: Arc welding

equipment.Part9:InstallationandUse”.- 6 - RESIDUAL RISKS - OVERTURNING:positiontheweldingmachineonahorizontal surface that is able to support the weight: otherwise (e.g. inclinedorunevenoorsetc.)thereisdangerofoverturning. - IMPROPERUSE:itishazardoustousetheweldingmachine for any work other than that for which it was designed (e.g. de-icing mains water pipes). - MOVING THE WELDING MACHINE: Always secure the gas bottle, taking suitable precautions so that it cannot fall accidentally (if used). The safety guards and moving parts of the covering of the welding machine and of the wire feeder should be in their proper positions before connecting the welding machine to the power supply. WARNING! Any manual operation carried out on the moving partsofthewirefeeder,forexample: - Replacingrollersand/orthewireguide; - Inserting wire in the rollers; - Loading the wire reel; - Cleaning the rollers, the gears and the area underneath them; - Lubricating the gears. SHOULD BE CARRIED OUT WITH THE WELDING MACHINE SWITCHED OFF AND DISCONNECTED FROM THE POWER SUPPLY OUTLET. - Do not use the handle to hang the welding machine. -Neverlifttheweldingmachine.

2. INTRODUCTION AND GENERAL DESCRIPTION

This welding machine is a power source used for arc welding and has been designed specically for MAG welding of carbon steel and low- alloy steel with either CO

mixture shielding gas using solid or cored (tubular) electrode wires. They are also suitable for MIG welding of stainless steel using Argon gas + 1-2% oxygen and of aluminium with Argon gas using electrode wires with a composition suited to the piece to be welded (only models in Fig. B1). It is also possible to use cored wires in applications without protective gas by adapting the polarity of the torch to the wire manufacturer’s recommendations (ModelinFig.B2usesonlyuxcorewire). STANDARDACCESSORIES: - torch; - return cable complete with earth clamp; - wheels kit (in models on wheels).

DATA PLATE The most important data regarding use and performance of the welding machine are summarised on the rating plate and have the following meaning: Fig. A

1- EUROPEAN standard of reference, for safety and construction

of arc welding machines.

2- Symbol for internal structure of the welding machine.

3- Symbol for welding procedure provided.

4- 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).

5- Symbol for power supply line:

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

6- Protection rating of the covering.

7- Technical specications for power supply line:

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

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 min. 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- Manufacturer’s serial number for welding machine identication

(indispensable for technical assistance, requesting spare parts, discovering product origin).

: 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.

CONTROL, ADJUSTMENT AND CONNECTION DEVICES

ELECTRICAL CONNECTIONS WITH THE WELDING MACHINE

COMPLETELY SWITCHED OFF AND DISCONNECTED FROM

THEPOWERSUPPLYOUTLET. THE ELECTRICAL CONNECTIONS MUST BE MADE ONLY AND EXCLUSIVELY BY AUTHORISED OR QUALIFIED PERSONNEL. PREPARATION Fig. C Unpack the welding machine, assemble the separate parts contained in the package. Assemblingtheprotectivemask Fig. D Assembling the return cable-clamp Fig. E HOWTOLIFTTHEWELDINGMACHINE None of the welding machines described in this manual is equipped with a lifting device. SITE Locate the welding machine in an area where openings for cooling air are not obstructed (forced circulation with fan), leave at least 250mm free space around the welding machine; check that conductive dusts, corrosive vapours, humidity etc., will not enter welding machine. WARNING! Position the welding machine on a at surface with sufcient carrying capacity for its weight, to preventitfromtippingormovinghazardously. CONNECTION OF PLUG AND SOCKET (only applicable to modelssuppliedwithoutplug): connect a normalised plug (2P + T for 1ph, 3P + T for 3ph) 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- 7 - the earth conductor (yellow-green) of the power supply line. Table 1 (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. - To carry out voltage change operations(only the 3-phase version), take off the panel to gain access to the inside of the machine, and prepare the voltage change terminal board so that the connection indicated on the special indicator plate corresponds to the available power supply voltage. Fig. F Reassemble the panel carefully using the appropriate screws. Warning! Inthefactorythemachineissetatthehighestvoltageofthe availablerange,e.g.

400V <= Voltage setting at the factory. CONNECTIONTOTHEMAINPOWERSUPPLY - 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. - To comply with the requirements of the EN 61000-3-11 (Flicker) standard we recommend connecting the welding machine to interface points of the power supply that have an impedance of less than Zmax =0.1 ohm. - the welding machine falls within the requisites of IEC/EN 61000-3- 12 standard. WARNING! Failure to observe the above rules will make the (Class 1) safety system installed by the manufacturer ineffective with consequent serious risks to persons (e.g. electric shock) and objects(e.g.re). CONNECTIONOFTHEWELDINGCABLES

) depending on the maximum current supplied by the welding machine. Connection to the gas bottle (if used) - Gas bottle can be loaded on welding machine bottle support platform: max 20 kg. - Screw the pressure reducing valve(*) onto the gas bottle valve, inserting the appropriate adapter supplied as an accessory, for when the gas used is Argon or an Argon /CO

mixture. - Connect the gas inlet pipe to the pressure-reducing valve and tighten the band supplied. - Loosen the adjustment ring nut on the pressure-reducing valve before opening the bottle valve. (*) Accessory to be purchased separately if not supplied with the product. Connecting the welding current return cable This is connected to the piece being welded or to the metal bench supporting it, as close as possible to the join being made. Connectingthetorch(onlyforversionswithEUROconnector) Engage the torch with its dedicated connector by tightening the locking ring manually as far down as it will go. Prepare the wire for loading the rst time by dismantling the nozzle and the contact tube to ease its exit. Changing the polarity (onlyforGAS-NOGASversions) Fig. G - Open the reel compartment door. - MIG/MAG welding (gas): - Connect the torch cable from the wire feeder to the red terminal

- Connect the clamp return cable to the black terminal (-). - FLUX welding (no gas): - Connect the torch cable from the wire feeder to the black terminal

- Connect the clamp return cable to the red terminal (+). - Close the reel compartment door. LOADINGTHEWIREREEL(Fig.H)

WARNING! BEFORE STARTING THE OPERATIONS

TO LOAD THE WIRE MAKE SURE THE WELDING MACHINE IS SWITCHED OFF AND DISCONNECTED FROM THE MAIN POWERSUPPLYOUTLET. MAKE SURE THAT THE WIRE FEEDER ROLLERS, THE WIRE GUIDE HOSE AND THE CONTACT TIP OF THE TORCH MATCH THE DIAMETER AND TYPE OF WIRE TO BE USED AND MAKE SURE THAT THESE ARE FITTED CORRECTLY. WHEN INSERTING AND THREADING THE WIRE DO NOT WEAR PROTECTIVE GLOVES. - Open the reel compartment door. - Position the wire reel on the spindle, holding the end of the wire upwards; make sure the tab for pulling the spindle is correctly seated in its hole (1a). - Release the pressure counter-roller(s) and move them away from the lower roller(s) (2a-b); - Make sure that the towing roller(s) is suited to the wire used (2c). - Free the end of the wire and remove the distorted end with a clean cut and no burr; turn the reel anti-clockwise and thread the end of the wire into the wire-guide infeed, pushing it 50-100mm into the wire guide of the torch tting (2d). - Re-position the counter-roller(s), adjusting the pressure to an intermediate value, and make sure that the wire is correctly positioned in the groove of the lower roller(s) (3) - Use the adjustment screw located at the centre of the spindle to apply a slight braking pressure on the spindle itself (1b). - Remove the nozzle and contact tip (4a). - Insert the welding machine plug in the power supply outlet, switch on the welding machine, press the torch button and wait for the end of the wire to pass through the whole of the wire guide hose and protrude by 10-15 cm from the front part of the torch, release the button. WARNING!Duringtheseoperationsthewireisliveand subject to mechanical stress; therefore if adequate precautions are not taken the wirecould causehazardous electricshock, injuryandstrikingofelectricarcs: - Do not direct the mouthpiece of the torch towards parts of the body. - Keep the torch away from the gas bottle. - Re-t the contact tip and the nozzle onto the torch (4b). - Check that wire feed is regular; set the roller and spindle braking pressure to the minimum possible values making sure that the wire does not slide in the groove and when feed is halted the loops of wire are not loosened by excessive reel inertia. - Cut the end of the wire so that 10-15 mm protrude from the nozzle. - Close the reel compartment door. 6.WELDING:DESCRIPTIONOFTHEPROCEDURE - Connect the return cable to the piece to be welded. - Check the polarity (only for FLUX versions). - If solid wire is used, open and adjust the ow of shielding gas by means of the pressure reducer. NOTE: remember to shut the shielding gas off when you nish work. - Switch the welder on and set the welding current by means of the switches or rotary switch (if any). Fig. I- 8 - - To start welding press the torch button. - To adjust the welding parameters adjust the wire feed rate (where provided) using the appropriate knob until even welding is obtained (Fig. B-3). SPOTWELDINGFUNCTION(where provided) Fig. L - To change the welding time operate the adjustment knob (Fig. B-5).

- In some models the wireguide tip is normally live; take care to prevent unwanted strikes. - The indicator light comes on when there is overheating and cuts off the power supply; it will reset automatically within a few minutes, after cooling down.

OPERATIONS MAKE SURE THE WELDING MACHINE IS SWITCHED OFF AND DISCONNECTED FROM THE MAIN POWERSUPPLY. ROUTINEMAINTENANCE: ROUTINE MAINTENANCE OPERATIONS CAN BE CARRIED OUT BY THE OPERATOR. Torch - Do not put the torch or its cable on hot pieces; this would cause the insulating materials to melt, making the torch unusable after a very short time; - Make regular checks on the gas pipe and connector seals; - Every time the wire reel is changed, blow out the wire-guide hose using dry compressed air (max. 5 bar) to make sure it is not damaged; - Before every use, check the wear and correct assembly of the parts at the end of the torch: nozzle, contact tip, gas diffuser. Wirefeeder - Make frequent checks on the state of wear of the wire feeder rollers, regularly remove the metal dust deposited in the feeder area (rollers and wire-guide infeed and outfeed). EXTRAORDINARY MAINTENANCE

MACHINE PANELS AND WORKING INSIDE THE MACHINE MAKESURETHEWELDINGMACHINEISSWITCHEDOFFAND DISCONNECTEDFROMTHEMAINPOWERSUPPLYOUTLET. Ifchecksaremadeinsidetheweldingmachinewhileitislive, this may cause serious electric shock due to direct contact with livepartsand/orinjuryduetodirectcontactwithmovingparts. - Inspect the welding machine regularly, with a frequency depending on use and the dustiness of the environment, and remove the dust deposited on the transformer, reactance and rectier using a jet of dry compressed air (max. 10 bar). - Do not direct the jet of compressed air on the electronic boards; these can be cleaned with a very soft brush or suitable solvents. - At the same time make sure the electrical connections are tight and check the wiring for damage to the insulation. - At the end of these operations re-assemble the panels of the welding machine and screw the fastening screws right down. - Never, ever carry out welding operations while the welding machine is open. - After having carried out maintenance or repairs, restore the connections and wiring as they were before, making sure they do not come into contact with moving parts or parts that can reach high temperatures. Tie all the wires as they were before, being careful to keep the high voltage connections of the primary transformer separate from the low voltage ones of the secondary transformer. Use all the original washers and screws when closing the casing. (IT) MANUALE ISTRUZIONE ATTENZIONE:

LASMACHINE MET CONTINUE DRAADVOEDING MET BOOG

of mengsels Argon/CO

EKSTRAORDINÆRT VEDLIKEHOLD

KEEVITUSAPARAAT Pilt. B1, B2

KEEVITUSAPARAADI TÕSTMINE

VU0 U1 V I1 effI1 max AA 50/60Hz

2- Arc voltage adjustment

5- Welding time (models with I

1- Interruptor general (ES)

5- Doba zvárania (modely s I