Telwin ELECTROMIG 550 SYNERGIC Manuel D'instructions page 8

5.3.3.2 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. Connect this
cable to the clamp with the symbol (+) (Fig. B-3).
5.3.3.3 Torch
- Insert the current cable in the specific fast clamp (-) (Fig. B-4). Connect the gas hose
of the torch to the cylinder.
5.3.4 WELDING CIRCUIT CONNECTIONS IN MMA MODE
Almost all the coated electrodes should be connected to the positive pole (+) of the
generator; an exception is the negative pole (-) for electrodes with acid coating.
5.3.4.1 Connection of the electrode-holder clamp welding cable
Bring a special clamp on the clamp used to tighten the exposed part of the electrode.
Connect this cable to the clamp with the symbol (+) (Fig. B-3).
5.3.4.2 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. Connect this
cable to the clamp with the symbol (-) (Fig. B-4).
5.4 LOADING THE WIRE SPOOL (Fig. G1, G2)
ATTENTION! BEFORE LOADING THE WIRE, MAKE SURE THE
WELDING MACHINE IS OFF AND DISCONNECTED FROM THE MAINS.
MAKE SURE THE WIRE FEEDERS, THE WIRE GUIDE HOSE AND THE TORCH
CONTACT PIPE CORRESPOND WITH THE DIAMETER AND NATURE OF THE
WIRE TO BE USED AND THAT THEY ARE CORRECTLY MOUNTED. DO NOT
WEAR PROTECTIVE GLOVES WHEN THREADING THE WIRE.
- Open the reel area door.
- Unscrew the spool lock nut.
- Position the wire spool on the reel; make sure the reel pulling pin is correctly housed
in its hole (1a).
- Tighten the spool lock nut, using spacers as and where necessary (1a).
- Free the pressure counter-roller/s and distance it/them from the lower roller/s (2a);
- Make sure the pulling feeder/s is/are suitable for the wire being used (2b).
- Free the wire end, cut off the misshaped end by cutting it cleanly and without leaving
a burr; rotate the spool counter-clockwise and position the wire end into the wire feed
input, pushing it by 50-100 mm into the torch connecting wire feed (2c).
- Reposition the counter-roller/s, adjusting the pressure at an intermediate value,
make sure the wire is positioned correctly in the hollow of the lower feeder/s (3).
- Remove the nozzle and contact tube (4a).
- Insert the welding machine plug into the mains socket, switch on the welding
machine, press the torch push-button or the wire forward push-button (Fig. C-2) and
wait for the end of the wire which is running along the whole wire feed casing, to exit
by 10-15 cm from the front of the torch, then release the push-button.
ATTENTION! During these operations the wire is being powered and is
subject to mechanical force; if suitable precautions are not taken there
is a danger of electric shock and wounds, and electric arcs striking:
- Do not direct the torch mouth against parts of the body.
- Do not approach the torch gas cylinder.
- Remount the contact tube and the nozzle onto the torch (4b).
- Make sure the wire exits regularly; set the roller pressure and reel braking (1b) to the
lowest values possible, making sure the wire does not slide in the hollow and that
when the drive stops the wire turns do not become loose because of too much spool
inertia.
- Cut the end of the wire that exits from the nozzle by 10-15 mm.
- Close the reel area door.
5.5 REPLACING THE TORCH WIRE GUIDE SHEATH (FIG. H)
Before replacing the sheath, straighten out the torch cable to make sure there are no
loops.
5.5.1 Spiral sheath for steel wire
1- Remove the nozzle and contact tube from the torch head.
2- Unscrew the sheath lock nut on the central connector and slide out the existing
sheath.
3- Slide the new sheath into the torch cable and gently push it until it comes out of the
torch head.
4- Hand tighten the sheath lock nut back in place.
5- Cut the wire flush with the sheath and gently squeeze them together; remove it
from the torch cable.
6- Bevel the sheath cutting zone and reposition it in the torch-cable duct.
7- Use a key to tighten the lock nut back in place.
8- Remount the contact tube and the nozzle.
5.5.2 Synthetic sheath for aluminium wire
Perform operations 1, 2 and 3 foreseen for steel sheaths (do not consider operations
4, 5, 6, 7 and 8).
9- Screw the aluminium contact tube back in place checking that it comes into contact
with the sheath.
10- Insert the brass nipple, the OR ring onto the opposite end of the sheath (torch
coupling side), maintain a light pressure on the sheath and tighten the sheath lock
nut. The excess section of the sheath shall be removed later on (see (13)). Slide
out the capillary tube for steel sheaths from the wire feeder torch coupling.
11- NO CAPILLARY TUBE IS FORESEEN for aluminium sheaths with diameters of
1.6-2.4 mm (yellow colour); the sheath will be inserted in the torch coupling without
it.
Cut the capillary tube for aluminium sheaths measuring 1-1.2 mm (red colour) to
a length of 2 mm less than the one used for the steel tube and insert it on the free
end of the sheath.
12- Insert and block the torch in the wire feeder coupling, mark the sheath at 1-2 mm
from the rollers, now extract the torch again.
13- Cut the sheath to the foreseen measurement without deforming the inlet hole.
Remount the torch in the wire feeder coupling and mount the gas nozzle.
6. MIG-MAG WELDING: PROCESS DESCRIPTION
6.1 SHORT ARC
Wire welding and detachment of the drop takes place via subsequent short-circuits of
the wire tip and weld pool (up to 200 times per second). The stick-out length of the wire
is normally between 5 and 12mm.
Carbon, low-alloy steel
- Usable wire diameter:
- Usable gas:
Stainless steel
- Usable wire diameter:
- Usable gas:
Aluminium and CuSi/CuAl
- Usable wire diameter:
- Usable gas:
PROTECTION GAS
The protective gas flow rate must be 8-14 l/min.
7. MIG-MAG OPERATION MODEE
7.1 Operating in manual mode
Manual mode setting (Fig I-1)
In manual mode, the wire feeding speed and the welding voltage
are adjusted separately. The knob C-5 adjusts the wire speed, the knob (Fig. C-6)
adjusts the welding voltage (which determines the welding power and influences the
seam shape). The welding current is shown on the display only during welding.
Advanced parameter setting: MENU 1 (Fig I-2)
Press the knob C-5 for at least 3 seconds to access the advanced parameter setting
menu. When menu 1 appears, again press:
- : electronic reactance. A higher value determines a hotter welding bath.
Settings from 0 (low reactance machines) to 100% (high reactance machines).
Factory value: 50 %
Pressing knob C-5 again, the following appears:
: Soft-start. Use to adjust wire feed rate as welding starts, in order to optimise
-
arc strike. Settings from 20 to 100% (start in % of full capacity speed). Factory value:
50 %
Pressing knob C-5 again, the following appears:
- : Burn-back. Use to adjust the wire burn-back time when welding is stopped.
Settings from 0 to 1 Sec. Factory value: 0.08 Sec.
Pressing knob C-5 again, the following appears:
: Post-gas. Use to adapt the protective gas outflow starting from when welding
-
is stopped. Settings from 0 to 10 Sec. Factory value: 1Sec.
Pressing knob C-5 again, the following appears:
- + : It increases or decreases the wire feed speed according to the
display. Adjustment from -5 to +5m/min. Factory value: 0 m/min.
Pressing knob C-5 again, you return to manual mode.
7.2 Synergic operating mode
Synergic mode setting
Pressing button C-4, you can access the preset programs on the machine (TAB.
6). Turning the knob C-5 you can slide all the programs (PRG 01 ÷ 40). Select the
program chosen by pressing and releasing the same knob. To know the program
loaded, simply press button C-4.
The welding machine sets itself automatically in the best operation conditions
established by the different synergy curves that are saved. The user only has to select
the material thickness (or the speed of wire feed or welding current) using knob C-5
to begin welding.
The welding voltage and current is shown on the display only during welding.
Adjustment of the welding seam shape
Adjustment of the shape of the seam takes place using the knob (Fig. C-6) that
regulates the arc length thereby establishing the greater or lesser welding temperature
input.
The settings scale varies from 10 ÷ 0 ÷ 10 (note: turning the knob also indicates the
preset voltage value); in most cases, the knob in the intermediate position (0,
has an optimal base setting (the value is shown on the LCD display on the left of the
graphic symbol of the welding seam and disappears after a set time).
Using the knob (Fig. C-6), the graphic indication on the display of the shape of the
welding changes showing a more convex, flat or concave result.
Convex shape . It means there is a low thermal load, therefore welding is "cold",
with little penetration; therefore, turning the knob clockwise you obtain more thermal
load with the effect of welding with greater melting.
Concave shape . It means there is a high thermal load, therefore welding is too
"hot", with excessive penetration; then, turn the knob anti-clockwise to obtain greater
melting.
7.2.1 ATC Mode (Advanced Thermal Control)
This is enabled automatically when the thickness selected is less or equal to
1.5mm.
Description: the particular instantaneous control of the welding arc and
the ultra rapid correcting of parameters minimize current spikes, something that is
characteristic of Short Arc transfer procedures, to the advantage of a low thermal load
on the piece to be welded. The result, on the one hand, is reduced deformation of
materials and, on the other, a fluid and accurate transfer of the weld material and the
creation of a welding seam that is easy to model.
Advantages:
- easy welding of thin materials;
- decreased deformation of material;
- stable arc even when working with low currents;
- rapid and accurate spot welding;
- easier coupling of spaced sheets.
7.2.2 Advanced parameter setting: MENU 1 (Fig I-4)
Press the knob C-5 for at least 3 seconds to access the advanced parameter setting
menu. When menu 1 appears, again press:
- : electronic reactance correction. A higher value determines a hotter welding
bath. Settings from - 50 % (low reactance machines) to + 50 % (high reactance
machines). Factory value: 0 %
Pressing knob C-5 again, the following appears:
- : Burn-back correction. Use to adjust the wire burn-back time when welding is
stopped. Settings from - 10 % to + 10 %. Factory value: 0 %
Pressing knob C-5 again, the following appears:
- 8 -
0.6 - 0.8 - 0.9 - 1.0 - 1.2 - 1.6 mm
CO
2
0.8 - 0.9 - 1.0 - 1.2 - 1.6 mm
Ar/O or Ar/CO
2
(Fig I-3)
or Ar/CO mixtures
2
mixtures (1 - 2 %)
2
0.8 - 1.0 - 1.2 mm
Ar
)