Telwin DIGITAL MIG 180, Instruction Manual

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INDEX
ENGLISH
1. GENERAL SAFETY CONSIDERATIONS FOR ARC WELDING . . . . . . . . 4 5.4.3 Voltage change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.5CONNECTION OF THE WELDING CABLES . . . . . . . . . . . . . . . . . . . . 5
5.5.1 Connection to the gas bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2. INTRODUCTION AND GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . 4
5.5.2 Connecting the welding current return cable. . . . . . . . . . . . . . . . . 5
2.1 MAIN FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5.5.3 Connecting the torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2STANDARD ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5.5.4 Connecting the spool gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.3OPTIONAL ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.6LOADING THE WIRE REEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.7LOADING THE WIRE REEL ONTO THE SPOOL GUN . . . . . . . . . . . . . 6
3. TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1DATA PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6. WELDING: DESCRIPTION OF THE
3.2OTHER TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6.1WELDING WITH THE MIG TORCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4. DESCRIPTION OF THE WELDING MACHINE . . . . . . . . . . . . . . . . . . . . . 5
6.2WELDING WITH THE SPOOL GUN . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1Control, adjustment and connection devices . . . . . . . . . . . . . . . . . . . . . 5
6.3SPOT WELDING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6.4OVERLOAD PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6.5PROGRAMMING THE WELDING PARAMETERS. . . . . . . . . . . . . . . . . 6
5. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6.6RESETTING ALL PARAMETERS TO THE DEFAULT VALUES . . . . . . . 6
5.1PREPARATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.1.1 Assembling the return cable-clamp . . . . . . . . . . . . . . . . . . . . . . . 5
7. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.2HOW TO LIFT THE WELDING MACHINE . . . . . . . . . . . . . . . . . . . . . . . 5
7.1ROUTINE MAINTENANCE: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.3SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7.1.1 Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.4CONNECTION TO THE MAIN POWER SUPPLY . . . . . . . . . . . . . . . . . 5
7.1.2 Wire feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.4.1 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7.2EXTRAORDINARY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 5.4.2 Plug and outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CONTINUOUS WIRE WELDING MACHINE FOR MIG/MAG ARC WELDING
DESIGNED FOR INDUSTRIAL AND PROFESSIONAL USE.
Note: In the following text the term “welding machine" will be used.
EXTRA PRECAUTIONS
1. GENERAL SAFETY CONSIDERATIONS FOR ARC
WELDING OPERATIONS:
- In environments with increased risk of electric shock; WELDING
- In confined spaces;
The operator should be properly trained to use the welding machine safely and
- In the presence of flammable or explosive materials;
should be informed about the risks related to arc welding procedures, the
MUST BE evaluated in advance by an “Expert supervisor” and must always
associated protection measures and emergency procedures.
be carried out in the presence of other people trained to intervene in
(Refer also to the “IEC TECHNICAL SPECIFICATION or CLC/TS 62081”:
emergencies.
INSTALLATION AND USE OF EQUIPMENT FOR ARC WELDING).
Technical protection measures MUST BE taken as described in 5.10; A.7;
A.9. of the “IEC TECHNICAL SPECIFICATION or CLC/TS 62081”.
- Welding MUST NOT be allowed if the welding machine or wire feeder is
supported by the operator (e.g. using belts).
- The operator MUST NOT BE ALLOWED to weld in raised positions unless
- Avoid direct contact with the welding circuit: the no-load voltage supplied by
safety platforms are used.
the welding machine can be dangerous under certain circumstances.
- VOLTAGE BETWEEN ELECTRODE HOLDERS OR TORCHES: working with
- When the welding cables are being connected or checks and repairs are
more than one welding machine on a single piece or on pieces that are
carried out the welding machine should be switched off and disconnected
connected electrically may generate a dangerous accumulation of no-load
from the power supply outlet.
voltage between two different electrode holders or torches, the value of which
- Switch off the welding machine and disconnect it from the power supply
may reach double the allowed limit.
outlet before replacing consumable torch parts.
An expert coordinator must use measuring instruments to determine the
- Make the electrical connections and installation according to the safety rules
existence of a risk and should take suitable protection measures as detailed
and legislation in force.
in 5.9 of the “IEC TECHNICAL SPECIFICATION or CLC/TS 62081”.
- The welding machine should be connected only and exclusively to a power
source with the neutral lead connected to earth.
- Make sure that the power supply plug is correctly connected to the earth
RESIDUAL RISKS
protection outlet.
- Do not use the welding machine in damp or wet places and do not weld in the
- OVERTURNING: position the welding machine on a horizontal surface that
rain.
is able to support the weight: otherwise (e.g. inclined or uneven floors etc.)
- Do not use cables with worn insulation or loose connections.
there is danger of overturning.
- IMPROPER USE: it is hazardous to use the welding machine for any work
other than that for which it was designed (e.g. de-icing mains water pipes).
- Do not weld on containers or piping that contains or has contained flammable
- MOVING THE WELDING MACHINE: always secure the gas bottle, taking
liquid or gaseous products.
suitable precautions so that it cannot fall accidentally.
- Do not operate on materials cleaned with chlorinated solvents or near such
substances.
- Do not weld on containers under pressure.
- Remove all flammable materials (e.g. wood, paper, rags etc.) from the working
area.
The safety guards and moving parts of the covering of the welding machine and
- Provide adequate ventilation or facilities for the removal of welding fumes
of the wire feeder should be in their proper positions before connecting the
near the arc; a systematic approach is needed in evaluating the exposure
welding machine to the power supply.
limits for the welding fumes, which will depend on their composition,
concentration and the length of exposure itself.
- Keep the gas bottle away from heat sources, including direct sunlight.
WARNING! Any manual operation carried out on the moving parts of the wire
feeder, for example:
- Replacing rollers and/or the wire guide;
,
*
- Use adequate electrical insulation with regard to the electrode, the work piece
- Inserting wire in the rollers;
and any (accessible) earthed metal parts in the vicinity. - Loading the wire reel;
This is normally achieved by wearing gloves, shoes, head coverings and - Cleaning the rollers, the gears and the area underneath them
clothing designed for this purpose and by using insulating platforms or mats.
- Lubricating the gears
- Always protect your eyes using masks or helmets with special actinic glass. SHOULD BE CARRIED OUT WITH THE WELDING MACHINE SWITCHED OFF
Use special fire-resistant protective clothing and do not allow the skin to be AND DISCONNECTED FROM THE POWER SUPPLY OUTLET.
exposed to the ultraviolet and infrared rays produced by the arc; other people
in the vicinity of the arc should be protected by shields of non-reflecting - Never lift the welding machine
curtains.
2. INTRODUCTION AND GENERAL DESCRIPTION
Microprocessor controlled, fan-cool ed, three-phase welding machine on wheels for
MIG-MAG welding and brazing. Especially suitable for use in light carpentry and body
shop, for welding galvanised sheet, high stress (high yields) materials, stainless steel
- The electromagnetic fields generated by the welding process may interfere
and aluminium. It allows automatic setting of wire speed according to the features of
with the operation of electrical and electronic equipment.
the material being welded, the shielding gas and the wire diameter.
Users of vital electrical or electronic devices (e.g. pace-makers, respirators
This welding machine is designed for use with the SPOOL GUN torch, used for welding
etc.) should consult a doctor before stopping in the vicinity of areas where
aluminium and steel when the power source and piece to be welded are far apart.
this welding machine is used.
Users of vital electrical or electronic devices should not use the welding
2.1 MAIN FEATURES:
machine.
- Power supply voltage monitor.
- Spot, 2/4-stroke operation.
- Automatic torch recognition.
- Regulation of wire slope up, post-gas time, wire burn-back time.
- Ready for use with SPOOL GUN torch.
- This welding machine complies with the requirements of the technical
- Thermostatic protection.
standard for the product for use only and exclusively in industrial
environments and for professional purposes. It is not guaranteed to meet
2.2 STANDARD ACCESSORIES:
electromagnetic compatibility requirements in the home.
- torch.
- return cable complete with earth clamp.
- gas regulator.
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