Telwin MIG-MAG Instruction Manual Download Page 5

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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

safety platforms are used.

- 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

- Trolley

voltage between two different electrode holders or torches, the value of which
may reach double the allowed limit.

An expert coordinator must use measuring instruments to determine the

(only TIG and MMA)

existence of a risk and should take suitable protection measures as detailed in
5.9 of the “IEC TECHNICAL SPECIFICATION or CLC/TS 62081”.

(only TIG and MMA)

RESIDUAL RISKS

- OVERTURNING: position the welding machine on a horizontal surface that is

able to support the weight: otherwise (e.g. inclined or uneven floors etc.) there
is danger of overturning.

- Never lift the trolley assembled with the welding machine, wire feeder and

cooling system (when present).

- 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).

- MOVING THE WELDING MACHINE AND ITS TROLLEY: always secure the gas

bottle with appropriate equipment, to prevent it falling accidentally.

3. TECHNICAL DATA

3.1 DATA PLATE (FIG. A)

The safety guards and moving parts covers of the welding machine and of the

The most important data regarding use and performance of the welding machine are

wire feeder should be in their proper positions before connecting the welding

summarised on the rating plate and have the following meaning:

machine to the power supply.

Protection rating of the covering.

Symbol for power supply line:

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

Symbol

: indicates that welding operations may be carried out in environments with

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

WARNING! Any manual operation carried out on the moving parts of the wire

Symbol for welding procedure provided.

feeder, for example:

Symbol for internal structure of the welding machine.

- Replacing rollers and/or the wire guide

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

- Inserting wire in the rollers

machines.

- Loading the wire reel

Manufacturer's serial number for welding machine identification (indispensable for

- Cleaning the rollers, the gears and the area underneath them

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

- Lubricating the gears

Performance of the welding circuit:

SHOULD BE CARRIED OUT WITH THE WELDING MACHINE SWITCHED OFF AND

- U :

maximum no-load voltage (open welding circuit).

DISCONNECTED FROM THE POWER SUPPLY OUTLET.

- I /U :

current and corresponding normalised voltage that the welding machine can

supply during welding.

2. INTRODUCTION AND GENERAL DESCRIPTION

- X :

Duty cycle: indicates the time for which the welding machine can supply the

2.1 INTRODUCTION

corresponding current (same column). It is expressed as %, based on a 10

This welding machine consists of a power source and a separate wire feeder connected

minutes cycle (e.g. 60% = 6 minutes working, 4 minutes pause, and so on).

to it by a cable bundle.

If the usage factors (on the plate, referring to a 40°C environment) are exceeded,

The power source is a multi-procedure (continuous and pulsed MIG/MAG SYNERGIC,

the thermal safeguard will trigger (the welding machine will remain in standby until

TIG and MMA) 3-phase powered rectifier with microprocessor controlled electronic

its temperature returns within the allowed limits).

regulation (switch-mode), with primary side whole bridge.

- A/V-A/V:

shows the range of adjustment for the welding current (minimum

maximum) at the corresponding arc voltage.

Technical specifications for power supply line:

- U :

Alternating voltage and power supply frequency of welding machine (allowed

limit

0%).

- I

: Maximum current absorbed by the line.

1 max

- I

: Effective current supplied.

1eff

10-

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.

3.2 OTHER TECHNICAL DATA
- WELDING MACHINE: see table 1 (TAB.1)
- TORCH:

see table 2 (TAB.2)

Main ON/OFF switch.

14-pin connector for remote control connection (optional).

5-pin connector for water-cooled system.

2.3 STANDARD ACCESSORIES

2.4 OPTIONAL ACCESSORIES

- The only permitted lifting method is that described in the “INSTALLATION”

section of this manual.

The wire feeder is equipped with a 4-roller motorised wire puller unit with independent
adjustment of pulling pressure; the digital control panel is integrated with the
microprocessor adjustment board and it contains fundamentally three condensed
functions:

±1

a) PARAMETER SETTINGS AND ADJUSTMENTS

With this user interface it is possible to set and adjust the operating parameters,
select previously stored programs, view parameter status and values on the
display.

b) RECALLING PRE-STORED SYNERGIC PROGRAMS FOR MIG-MAG WELDING

These programs are pre-defined and stored by the manufacturer (so cannot be
modified); when the user recalls one of these programs, he can select a specific job
point (corresponding to a set of various independent welding parameters), adjusting
a single magnitude. This is the

SINERGY

concept, which makes it extremely easy to

achieve perfect adjustment of the welding machine depending on each specific
operating condition.

c) STORING/RECALLING CUSTOMISED PROGRAMS

This function is available when working within a synergic program and also when in
manual mode (in this case the setting for all the welding parameters is at the
discretion of the operator). This mode of operation allows the user to store and later

- WIRE FEEDER:

see table 3 (TAB.3)

recall a specific welding procedure.

4. DESCRIPTION OF THE WELDING MACHINE

2.2 METAL WELDABILITY

The welding machine is suitable for MIG welding of aluminium and its

alloys, MIG brazing is typically carried out on galvanised plate and MAG welding on
carbon, low alloy and stainless steels. It is also possible to weld with tubular wire,
without protective gas (self-shielding) by adjusting the torch polarity according to the
instructions given by the wire manufacturer.
MIG welding of aluminium and its alloys should be carried out using flux core wire with a
composition that is compatible with the material being welded and pure Ar (99.9%)
protective gas.
MIG brazing can be carried out, typically, on galvanised plate using flux core wire in
copper alloy (e.g. copper silicon or copper aluminium) with pure Ar (99.9%) protective
gas.
MAG welding of carbon and low alloy steel should be carried out using flux core or
tubular wire with a composition that is compatible with the material being welded and
CO and Ar/CO or Ar/CO /O mixtures as the protective gas (Ar-Argon normally > 80%).

For welding stainless steel Ar/O or Ar/CO gas mixtures are normally used (Ar

normally> 98%).

The welding machine is suitable for TIG welding in direct current (DC)

with contact arc strike, and is suitable for use with all steels (carbon, low and high alloys)
and heavy metals (copper, nickel, titanium and their alloys) with pure Ar (99.9%)
protective gas or, for particular operations, using Argon/Helium mixtures.

The welding machine is suitable for MMA electrode welding in direct

current (DC) with all types of coated electrodes.

- Adapter for ARGON IT bottle.
- Cable and earth clamp.
- Pressure reducing valve 2 pressure gauges.
- Connecting cables kit 1.5m.
- Water-cooled cooling unit G.R.A. (only for R.A. version).
- MIG torch (R.A. version).
- Wire feeder.

- Manual remote control 1 pot

- Manual remote control 2 pot.
- Remote control pedal

- Water-cooled cooling unit G.R.A.

(standard accessory on R.A. version)

-  Mobile arm torch-holder kit.
-  R.A. connecting cables kit 4 or 10, 30m.
-  Connecting cables kit 4 or 10m.
-  Reel cover kit.
-  Wirefeeder wheels kit.
-  Aluminium welding kit.
-  Tubular wire welding kit.
-  Welding kit MMA 600A.
- MIG torch 5m 500A.
- MIG torch 3m 500A R.A.
   (standard accessory on R.A. version.).
- MIG torch 5m 500A, R.A.
- TIG torch 4 or 8m, 220A.
- TIG torch 4m 350A, R.A.

4.1 CONTROL, ADJUSTMENT AND CONNECTION DEVICES
4.1.1 Welding machine (FIG.B)

on the front side:

Control panel (see description).

Fast negative socket (-) for welding power cable (Earth cable for MIG and MMA,

torch cable for TIG).

Gas link for TIG torch.

3p connector for TIG TORCH control cable.

Fast positive socket (+) for earth cable for TIG welding.

on the back side:

Gas tube connection (bottle)

for TIG welding

Fast positive socket (+) for welding power cable towards wire feeder.