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summarised on the rating plate and have the following meaning:due to one of the following faults:1- Protection rating of the covering. - Thermal protection: inside the machine the temperature is excessive. The2- Symbol for power supply line: machine is ON but does not deliver current until a normal temperature is reached.1~: single phase alternating voltage; Once this happens the re-start is automatic.3~: three phase alternating voltage. - Mains over/undervoltage protection: the machine is blocked: the power supply3- Symbol S: indicates that welding operations may be carried out in environments with voltage is 15% above or below the rating plate value. WARNING: Exceeding theheightened risk of electric shock (e.g. very close to large metallic volumes).upper voltage limit, as above, will cause serious damage to the device.4- Symbol for welding procedure provided. - ANTI STICK protection: automatically shuts down the welding machine if the5- Symbol for internal structure of the welding machine. electrode sticks to the material being welded so that it can be removed manually6- EUROPEAN standard of reference, for safety and construction of arc welding without damaging the electrode holder clamp.machines.3- Potentiometer to regulate welding current with graduated scale in Amps, which7- Manufacturer's serial number for welding machine identification (indispensable for also allows regulation during welding.technical assistance, requesting spare parts, discovering product origin).8- Performance of the welding circuit:4- - - MMA electrode welding- U : maximum no-load voltage (open welding circuit).The choice between the two positions in MMA is made according to the type0- I /U : current and corresponding normalised voltage that the welding machine canof electrode used.2 2 A special device, the Arc Control System, ensures the optimum welding dynamic,supply during welding.an easy start (HOT START), and a fluid weld (ARC FORCE) for all types of- X : Duty cycle: indicates the time for which the welding machine can supply the electrode:corresponding current (same column). It is expressed as %, based on a 10 minutescycle (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,Basic, aluminium, cellulose electrodes (mod. CE), etc.the thermal safeguard will trigger (the welding machine will remain in standby untilits temperature returns within the allowed limits).- A/V-A/V: shows the range of adjustment for the welding current (minimumRutile, stainless steel electrodes, etc.maximum) at the corresponding arc voltage.9- Technical specifications for power supply line:TIG welding with SCRATCH strike- U : Alternating voltage and power supply frequency of welding machine (allowed (HOT START and ARC FORCE switched off).1limit ±10%).6 - Negative quick plug (-) to connect welding cable.- I 1 max: Maximum current absorbed by the line.- I : Effective current supplied.4.2.2.2 Back panel (FIG. D2)1eff1 - power supply cable 2p + (W).10- : Size of delayed action fuses to be used to protect the power line. 2 - General luminous switch O/OFF - I/ON.11- Symbols referring to safety regulations, whose meaning is given in chapter 1“General safety considerations for arc welding”.5. INSTALLATION_____________________________________________________________________________________________________________________Note: The data plate shown above is an example to give the meaning of the symbols andnumbers; the exact values of technical data for the welding machine in your possessionWARNING! CARRY OUT ALL INSTALLATION OPERATIONS ANDmust be checked directly on the data plate of the welding machine itself.ELECTRICAL CONNECTIONS WITH THE WELDING MACHINE COMPLETELYSWITCHED OFF AND DISCONNECTED FROM THE POWER SUPPLY OUTLET.3.2 OTHER TECHNICAL DATATHE ELECTRICAL CONNECTIONS MUST BE MADE ONLY AND EXCLUSIVELY BY- WELDING MACHINE WITH TWO-POSITION SELECTOR AND ELECTRODE- AUTHORISED OR QUALIFIED PERSONNEL._____________________________________________________________________________________________________________________HOLDER CLAMP: see table 1 (TAB.1A, 2A)- WELDING MACHINE WITH THREE-POSITION SELECTOR AND ELECTRODE- 5.1 PREPARATIONHOLDER CLAMP: see table 2 (TAB.1B, 2B)Unpack the welding machine, assemble the separate parts contained in the package.The weight of the welding machine is shown in table 1 (TAB.1)5.1.1 Assembling the return cable-clamp (FIG. E)4. DESCRIPTION OF THE WELDING MACHINE4.1 BLOCK DIAGRAM (FIG. B)5.1.2 Assembling the welding cable-electrode holder clamp (FIG. E)The welding machine consists basically of power modules made on PCB's, optimised to 5.2 HOW TO LIFT THE WELDING MACHINE (FIG. G)achieve outstanding reliability and reduced maintenance.All welding machines with 3-position selectors (FIG.D) should be lifted using the special1- Input: 1-phase power supply, rectifier unit and levelling capacitors. strap supplied for this purpose.2- Transistor switching bridge (IGBT) and drivers: commutes the rectified power Make sure the connection between the strap and the hook is as in the diagram.supply voltage to high frequency alternating voltage and adjusts the poweraccording to the required welding current/voltage.5.3 POSITION OF THE WELDING MACHINE3- High frequency transformer: the voltage converted by block 2 powers the primary Choose the place to install the welding machine so that the cooling air inlets and outletswinding; its function is to adjust the voltage and current to the values needed for the are not obstructed (forced circulation by fan, if present); at the same time make sure thatarc welding procedure and at the same time to form galvanic separation of the conductive dusts, corrosive vapours, humidity etc. will not be sucked into the machine.welding circuit from the power supply line.Leave at least 250mm free space around the welding machine.4- Secondary rectifier bridge with levelling inductance: commutes the alternating _____________________________________________________________________________________________________________________voltage/current supplied by the secondary winding into very low ripple directcurrent/voltage.WARNING! Position the welding machine on a flat surface with sufficient5- Control and adjustment electronics: they control the welding current value carrying capacity for its weight, to prevent it from tipping or moving hazardously.instantaneously and compare it with the operator's setting; they modulate the control_____________________________________________________________________________________________________________________impulses from the IGBT drivers that make the adjustment.They determine the dynamic response of the current during electrode melting/fusion(instantaneous short circuits) and supervise the safety systems.5.4 CONNECTION TO THE MAIN POWER SUPPLY- Before making any electrical connection, make sure the rating data of the weldingmachine correspond to the mains voltage and frequency available at the place ofinstallation.- The welding machine should only be connected to a power supply system with theneutral conductor connected to earth.- To ensure protection against indirect contact use residual current devices of thefollowing types:4.2 CONTROL DEVICES, ADJUSTMENT AND CONNECTION4.2.1 WELDING MACHINE WITH TWO-POSITION SELECTOR4.2.1.1 Front panel (FIG. C1)1 - Positive quick plug (+) to connect welding cable.2 - YELLOW LED: normally off, when ON it means that the welding current cannot flowdue to one of the following faults: - Type A ( ) for single phase machines;- Thermal protection: inside the machine the temperature is excessive. Themachine is ON but does not deliver current until a normal temperature is reached.Once this happens the re-start is automatic.- Mains over/undervoltage protection: the machine is blocked: the power supplyvoltage is 15% above or below the rating plate value. WARNING: Exceeding theupper voltage limit, as above, will cause serious damage to the device.- ANTI STICK protection: automatically shuts down the welding machine if theelectrode sticks to the material being welded so that it can be removed manuallywithout damaging the electrode holder clamp.3- GREEN LED : Connection to the mains, machine ready to work.4- Potentiometer to regulate welding current with graduated scale in Amps, whichalso allows regulation during welding.5- Function selector: used to select the desired welding procedure:MMA electrode weldingThe HOT START and ARC FORCE devices ensure an easy start and a fluidweld for all types of electrodes.TIG welding with SCRATCH strike(HOT START and ARC FORCE switched off).6 - Negative quick plug (-) to connect welding cable.4.2.1.2 Back panel (FIG. C2)1 - power supply cable 2p + (W).2 - General luminous switch O/OFF - I/ON.- Type B ( ) for 3-phase machines.- To comply with the requirements of the EN 61000-3-11 (Flicker) standard werecommend connecting the welding machine to interface points of the power supplythat have an impedance of less than Zmax =0.21 ohm.- The welding machine does not fall within the requisites of IEC/EN 61000-3-12standard.Should it be connected to a public mains system, it is the installer's responsibility toverify that the welding machine itself is suitable for connecting to it (if necessary,consult the distribution network company).- Unless otherwise specified (MPGE), the welding machines are compatible withpower generating sets for voltage oscillations up to ± 15%.For correct use, the power generating set must be brought to steady conditionsbefore being able to connect the inverter.5.4.1 Plug and outletFor models fitted with a cable and plug, it is recommended to use a welding machinewith a welding current of less than 140A; if you wish to use the welding machine at fullcapacity, the plug should be replaced with one with a suitable capacity for the fuse, asindicated on the side of the technical specifications plate. For models without a fittedplug, connect a standard (2P + T) plug of appropriate capacity to the power supply cableand prepare a power supply outlet fitted with fuses or an automatic circuit-breaker; thecorresponding earth terminal should be connected to the (yellow-green) earthconductor of the power supply. Table 1 (TAB. 1) shows the recommended delayed fusesizes, in amps, for the main supply, which have been chosen according to the weldingmachine's maximum rated current output, and the nominal power supply voltage._____________________________________________________________________________________________________________________4.2.2 WELDING MACHINE WITH THREE-POSITION SELECTOR WARNING! Failure to observe the above rules will make the (Class 1) safety4.2.2.1 Front panel (FIG. D1)1 - Positive quick plug (+) to connect welding cable.system installed by the manufacturer ineffective with consequent serious risks2 - YELLOW LED: normally off, when ON it means that the welding current cannot flowto persons (e.g. electric shock) and objects (e.g. fire)._____________________________________________________________________________________________________________________- 6 -
5.5 CONNECTION OF THE WELDING CABLES 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 usedincorrectly.WARNING! BEFORE MAKING THE FOLLOWING CONNECTIONS MAKEThe following table indicates approximate diameters for the electrodes, bearing in mindSURE THE WELDING MACHINE IS SWITCHED OFF AND DISCONNECTED FROM that for DC welding (with the electrode on the (-) pole) an electrode with 2% CeriumTHE POWER SUPPLY OUTLET.(grey band) is usually used.2Table (TAB. 1) gives the recommended values for the welding cables (in mm )To achieve a good weld it is absolutely necessary to use the exact electrode diameterdepending on the maximum current supplied by the welding machine. with the exact current. The electrode usually protrudes from the ceramic nozzle by 2-_____________________________________________________________________________________________________________________3mm, but protrusion may reach 8mm for corner welding (see TAB. 3).5.5.1 MMA WELDINGAlmost all coated electrodes are connected to the positive pole (+) of the power source;as an exception to the negative pole (-) for acid coated electrodes.Connecting the electrode-holder clamp welding cableOn the end take a special terminal that is used to close the uncovered part of theelectrode.This cable is connected to the terminal with the symbol (+)6.2.1 Procedure (TIG)- Holding the mask IN FRONT OF THE FACE, strike the electrode tip on the workpieceas if you were striking a match. This is the correct strike-up method.- To interrupt welding, lift the electrode quickly away from the piece.7. MAINTENANCE_____________________________________________________________________________________________________________________WARNING! BEFORE CARRYING OUT MAINTENANCE OPERATIONS MAKEConnecting the welding current return cableThis is connected to the piece being welded or to the metal bench supporting it, as close SURE THE WELDING MACHINE IS SWITCHED OFF AND DISCONNECTED FROMas possible to the join being made.THE MAIN POWER SUPPLY._____________________________________________________________________________________________________________________This cable is connected to the terminal with the symbol (-)7.1 ROUTINE MAINTENANCE5.5.2 TIG welding with scratch strike ROUTINE MAINTENANCE OPERATIONS CAN BE CARRIED OUT BY THE- TIG Torch: the current-carrying cable should be connected to the negative terminal OPERATOR.(-).- Earth return cable: this should be connected to the positive terminal (+); the earth 7.1.1 Torchclamp at the other end should be connected to the piece to be welded or to a metal - Do not put the torch or its cable on hot pieces; this would cause the insulatingbench, as close as possible to the joint being made.materials to melt, making the torch unusable after a very short time.- Connection to the protective gas bottle for TIG welding. Screw the pressure - Make regular checks on the gas pipe and connector seals.reduction valve on to the bottle valve. Please note that the protective gas flow rate - Accurately match collet and collet body with the selected electrode diameter in order(litres/minute) can only be regulated using the pressure control valve on the bottle. to avoid overheating, bad gas diffusion and poor performance.Prepare the flexible pipe for feeding the protective gas to the torch. Open the manual - At least once a day check the terminal parts of the torch for wear and make sure theyvalve on the torch before welding and close it at the end of welding.are assembled correctly: nozzle, electrode, electrode-holder clamp, gas diffuser.WARNING! Always close the gas bottle valve at the end of the job.- Before using the welding machine, always check the terminal parts of the torch forWarnings:- Turn the welding cable connectors right down into the quick connections (if present),to ensure a perfect electrical contact; otherwise the connectors themselves willoverheat, resulting in their rapid deterioration and loss of efficiency.wear and make sure they are assembled correctly: nozzle, electrode, electrodeholderclamp, gas diffuser.7.2 EXTRAORDINARY MAINTENANCE- The welding cables should be as short as possible. EXTRAORDINARY MAINTENANCE OPERATIONS SHOULD BE CARRIED OUT- Do not use metal structures which are not part of the workpiece to substitute the ONLY AND EXCLUSIVELY BY SKILLED OR AUTHORISED ELECTRICALreturncable of the welding current: this could jeopardise safety and result in poor MECHANICAL TECHNICIANS.welding._____________________________________________________________________________________________________________________WARNING! BEFORE REMOVING THE WELDING MACHINE PANELS AND6. WELDING: DESCRIPTION OF THE PROCEDUREWORKING INSIDE THE MACHINE MAKE SURE THE WELDING MACHINE ISSWITCHED OFF AND DISCONNECTED FROM THE MAIN POWER SUPPLY6.1 MMA WELDINGOUTLET.- 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 stickelectrode and the most suitable current.If checks are made inside the welding machine while it is live, this may cause- The welding current must be regulated according to the diameter of the electrode in serious electric shock due to direct contact with live parts and/or injury due touse and the type of the joint to be carried out: see below the currents corresponding direct contact with moving parts.to various electrode diameters:- Inspect the welding machine regularly, with a frequency depending on use and theø Electrode (mm)Welding current (A)dustiness of the environment, and remove the dust deposited on the transformer,min.max.reactance and rectifier using a jet of dry compressed air (max. 10bar).1,6 25 - 50- Do not direct the jet of compressed air on the electronic boards; these can be cleaned2 40 - 80with a very soft brush or suitable solvents.2,5 60 - 110- At the same time make sure the electrical connections are tight and check the wiring3,2 80 - 160for damage to the insulation.4 120 - 200- At the end of these operations re-assemble the panels of the welding machine and- The user must consider that, according to the electrode diameter, higher current screw the fastening screws right down.values must be used for flat welding, whereas for vertical or overhead welds lower - Never, ever carry out welding operations while the welding machine is open.current values are necessary.- As well as being determined by the chosen current intensity, the mechanical 8. TROUBLESHOOTINGcharacteristics of the welded join are also determined by the other welding IN CASE OF UNSATISFACTORY FUNCTIONING, BEFORE SERVICING MACHINEparameters i.e. arc length, working rate and position, electrode diameter and quality OR REQUESTING ASSISTANCE, CARRY OUT THE FOLLOWING CHECK:(to store the electrodes correctly, keep them in a dry place protected by their - Check that the welding current, which is regulated by the potentiometer with apackaging or containers).graduated amp scale, is correct for the diamter and electrode type in use.- The properties of the weld also depend on the ARC-FORCE value (dynamic - Check that when general switch is ON the relative lamp is ON. If this is not the casebehaviour) of the machine. The selector switch on the panel can be used to select this then the problem is located on the mains (cables, plugs, outlets, fuses, etc.)parameter. If the selector is switched to the "TIG with scratch strike" position, the - Check that the yellow led (ie. thermal protection interruption- either over orARC-FORCE and HOT START functions are completely eliminated.undervoltage or short circuit) is not lit.It should be noted that high ARC-FORCE values achieve better penetration and allow - Check that the nominal intermittance ratio is correct. In case there is a thermalwelding in any position typically with basic and cellulose electrodes.protection interruption, wait for the machine to cool down, check that the fan is- It is possible that welding with particular rutile electrodes creates excessive spray: in working properly.this case we recommend turning the selector on the front of the welding machine to - Check the mains voltage: if the value is too high or too low the welding machine willthe TIG position.be stopped.6.1 1 Procedure- Check that there is no short-circuit at the output of the machine: if this is the caseeliminate the incovenience.- Holding the mask IN FRONT OF THE FACE, strike the electrode tip on the workpiece - Check that all connections of the welding circuit are correct, particularly that theas if you were striking a match. This is the correct strike-up method.work clamp is well attached to the workpiece, with no interferring material orWARNING: do not hit the electrode on the workpiece, this could damage the surface-coverings (ie. Paint).electrode and make strike-up difficult. - Protective gas must be of appropriate type (Argon 99,5%) and quantity.- As soon as arc is ignited, try to maintain a distance from the workpiece equal to thediameter of the electrode in use. Keep this distance as much constant as possible forthe duration of the weld. Remember that the angle of the electrode as it advancesshould be of 20-30 grades (FIG. H).- At the end of the weld bead, bring the end of the electrode backward, in order to fill theweld crater, quickly lift the electrode from the weld pool to extinguish the arc.CHARACTERISTICS OF THE WELD BEAD (FIG. HI)6.2 TIG WELDING WITH SCRATCH STRIKETIG welding is a welding procedure that exploits the heat produced by the electric arcthat is struck, and maintained, between a non-consumable electrode (tungsten) and thepiece to be welded. The tungsten electrode is supported by a torch suitable fortransmitting the welding current to it and protecting the electrode itself and the weld poolfrom atmospheric oxidation, by the flow of an inert gas (usually argon: Ar 99%) whichflows out of the ceramic nozzle.To achieve a good weld the pieces should be carefully cleaned and free of oxidation, oil,grease, solvents etc.It is necessary to sharpen the tungsten electrode axially on a grinding wheel, as shownin FIG. L making sure that the tip is perfectly centred to prevent arc deviation. It isimportant to carry out the grinding along the length of the electrode. This operation- 7 -
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Ð¡ÐºÐ°ÑÐ°ÑÑ ÑÑÐºÐ¾Ð²Ð¾Ð´ÑÑÐ²Ð¾ Ð¿Ð¾Ð»ÑÐ·Ð¾Ð²Ð°ÑÐµÐ»Ñ Ð´Ð»Ñ Telwin Technology 228