Connection To The Main Power Supply - Telwin ELECTROMIG 400 SYNERGIC Manuel D'instructions

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. D)
Unpack the welding machine and assemble the separate parts included in the
package.
Assembling the clamp-return cable Fig. E
Assembling the welding cable electrode-holder clamp FIG. F
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 = 0.13 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
mode
mode
).
CARRYING OUT THE
mixture, screw the pressure reducer(*) onto
2
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.
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. 5); 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.
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. G)
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.
FOLLOWING
- 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
) according when the drive stops the wire turns do not become loose because of too much spool
2
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.
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