Telwin ELECTROMIG 550 SYNERGIC Manuel D'instructions page 7

3.2 OTHER TECHNICAL DATA:
- WELDING MACHINE: see table 1 (TAB. 1)
- WIRE FEEDER UNIT: see table 2 (TAB.2)
- MIG TORCH: see table 3 (TAB. 3)
- TIG TORCH: see table 4 (TAB. 4)
- ELECTRODE-HOLDER CLAMP: see table 5 (TAB. 5)
The weight of the welding machine and wire feeder unit is outlined on table 1,
2 (TAB. 1, 2).
4. DESCRIPTION OF THE WELDING MACHINE
4.1 CONTROL, ADJUSTMENT AND CONNECTION DEVICES.
4.1.1 WELDING MACHINE (Fig. B1, B2, B3)
At the front:
1- Control panel (see description);
2- Torch coupling;
3- Positive (+) quick coupling for connecting the welding cable;
4- Negative (-) quick coupling for connecting the welding cable;
5- Earth return cable and clamp;
6- Welding cable and torch;
At the back:
7- Main ON/OFF switch;
8- Power cable;
9- Hose connector for torch protective gas;
10- Positive quick coupling (+) for connection welding current cable with wire feeder
unit.
11- Connector 14p for connection command cable with wire feeder unit.
12- G.R.A. safety fuse;
20- Welding machine safety fuse.
4.1.2 WIRE FEEDER UNIT (Fig. B3)
at the front:
13- Connector 14p for connection of the remote command (on request);
14- Quick couplings for the MIG torch water pipes (for AQUA version only).
At the back:
15- Connector 14p for connection command cable with welding machine (AQUA
version only);
16- Positive quick coupling (+) for connection welding current cable with the welding
machine (R.A version only);
17- Quick coupling for cooling water delivery and return pipe connection (AQUA
version only);
18- Wire feeder safety fuse;
19- Connection cables fastening belt (AQUA version only).
4.1.3 WELDING MACHINE CONTROL PANEL (Fig. C)
1- LCD display.
2- Manual wire jog button. This jogs the wire forward in the torch sheath without
having to touch the torch button; this is a momentary action and the speed is set
and fixed.
Pressing the button also causes the light to switch on in the feeder compartment
(version with separate wire feeder unit only).
3- Manual gas solenoid valve start button. This enables the flow of gas (pipe bleeds,
flow rate adjustment) without the need to use the torch button; once pressed, the
solenoid valve remains enabled for 10 seconds or until it is pressed again.
4- Multi-function button.
- If pressed, it allows access to preset machine programs.
- If pressed, for at least 3 seconds it allows you to:
- save a job on the machine internal memory.
- load a previously saved job.
5- Multi-function knob.
Rotation enables:
- wire speed feed adjustment in
- welding power adjustment in
- welding current adjustment in TIG mode (
- welding current adjustment in MMA mode (
- if pressed for at least 3 seconds, it enables access to various setting menus of
the machine.
6- Multi-function knob.
Rotation enables:
- adjustment of the welding seam (welding voltage) in
- adjustment of the welding seam (arc length) in
- not enabled in TIG and MMA mode.
- if pressed for at least 3 seconds, it allows selection of the welding process (
, , ,
N.B.: RE-SETTING OF ALL FACTORY PARAMETERS (RESET)
Press all buttons (C-5, C-6) together at start-up to reset the welding parameters to
default settings.
5. INSTALLATION
WARNING! ALL INSTALLATION OPERATIONS AND ELECTRICAL
CONNECTIONS MUST ALWAYS BE CARRIED OUT WITH THE WELDING
MACHINE SWITCHED OFF AND DISCONNECTED FROM THE POWER
SUPPLY.
THE ELECTRIC CONNECTIONS MUST ONLY BE CARRIED OUT BY EXPERT OR
QUALIFIED TECHNICIANS.
ASSEMBLY (Fig. D1, D2)
Unpack the welding machine and assemble the separate parts included in the
package.
Assembling the clamp-return cable Fig. E
mode
mode
)
)
mode
mode
).
Assembling the welding cable electrode-holder clamp FIG. F
G.R.A installation (AQUA version only): refer to the instruction manual in the
cooling unit.
5.1 POSITIONING THE WELDING MACHINE
Choose the place where the welding machine is to be installed so that there are no
obstructions to the cooling air inlets and outlets; at the same time make sure that
conductive dust, corrosive vapours, humidity etc. cannot be drawn into the machine.
Leave at least 250 mm of free space all around the welding machine.
WARNING! Position the welding machine on a level surface with
sufficient load-bearing capacity, so that it cannot be tipped over or
shift dangerously.
5.2 CONNECTION TO THE MAIN POWER SUPPLY
- Before making any electrical connection, check the rating plate data on the welding
machine to make sure they correspond to the voltage and frequency of the available
power supply where the machine is to be installed.
- The welding machine must be connected only and exclusively to a power supply with
the neutral conductor connected to earth.
- To guarantee protection against indirect contact use the following types of residual
current devices:
- 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 = 0.10 ohm.
- 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).
5.2.1 Plug and outlet
Connect a normalised plug (3P + P.E) - having sufficient capacity- to the power cable
and prepare a mains outlet fitted 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! Non-compliance with the above regulations renders
the manufacturer's safety system (class I) inefficient, with resulting
serious risks to people (e.g. electric shock) and things (e.g. fire).
5.3 WELDING CIRCUIT CONNECTION
5.3.1 Recommendations
ATTENTION! BEFORE
CONNECTIONS, MAKE SURE THE WELDING MACHINE IS OFF AND
DISCONNECTED FROM THE MAINS.
Table 1 (TAB. 1) gives the recommended values for welding cables (in mm
to the maximum energy supplied by the welding machine.
In addition:
- Fully rotate the welding cable connectors in the quick couplings (if present), to
guarantee perfect electric contact; if this is not the case the connectors will overheat
with consequent fast deterioration and loss of efficiency.
- Use the shortest welding cables possible.
- Do not use metal structures that are not part of the workpiece to replace the welding
current return cable; this can endanger safety and give unsatisfactory welding
results.
5.3.2 WELDING CIRCUIT CONNECTION IN MIG-MAG MODE
5.3.2.1 Connecting the gas bottle (if used)
- Gas bottle that can be loaded onto the supporting surface of the trolley: max. 60 kg.
- When using Argon gas or an Argon/CO
the gas bottle valve, placing the relative pressure reducing valve supplied as an
accessory.
- Connect the gas input hose to the pressure reducing valve and tighten the strip.
- Loosen the adjustment ring nut of the pressure reducing valve before opening the
gas bottle valve.
(*) Accessory to be purchased separately if not supplied with the product.
5.3.2.2 Connecting the welding current return cable
Connect the cable to the piece to be welded or the metal bench on which the workpiece
is placed, as close as possible to the joint being worked.
5.3.2.3 Torch (Fig. B)
Insert the torch (B-6) into the dedicated connector (B-2), fully tightening the locking
ring nut manually. Prepare the torch to receive the wire for the first time, removing the
nozzle and the contact pipe, to make exiting easier.
AQUA version only:
Connect the external cooling pipes to the relative couplings paying attention to the
instructions below:
: COOLANT DELIVERY (Cold - blue coupling element);
: COOLANT RETURN (Hot - red coupling element).
5.3.3 WELDING CIRCUIT CONNECTIONS IN TIG MODE
5.3.3.1 Gas cylinder connection
- Screw the pressure reducer onto the cylinder gas valve, if necessary, inserting the
specific reduction supplied as an accessory.
- Connect the input hose of the gas reducer and tighten with the supplied strip.
- Loosen the adjustment ring nut of the pressure reducer before opening the cylinder
valve.
- Open the cylinder and adjust the quantity of gas (l/min) according to the illustrative
use data, see table (TAB. 6); any adjustments in gas flow can be carried out during
welding always using the pressure reducer ring nut. Check the tubing and fittings.
WARNING! Always close the gas cylinder valve at the end of work.
- 7 -
CARRYING OUT THE FOLLOWING
2
mixture, screw the pressure reducer(*) onto
2
) according