Operating In Manual Mode; General Principles - Telwin ELECTROMIG 400 SYNERGIC Manuel D'instructions

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, you return to manual mode.
7.2 Synergic operating mode
Synergic mode setting (Fig I-3)
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 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 adjustment scale varies between - 5 % ÷ 0 ÷ + 5 %; in most cases, with the knob
in the intermediate position (0,
displayed on the LCD display on the left of the graphic symbol of the welding beam
and disappears after a preset 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.
0.6 - 0.8 - 0.9 - 1.0 - 1.2 - 1.6 mm
CO or Ar/CO
2
0.8 - 0.9 - 1.0 - 1.2 - 1.6 mm
Ar/O or Ar/CO mixtures (1 - 2 %)
2 2
0.8 - 1.0 - 1.2 mm
) there is an optimal base setting (the value is
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:
- : Duration of inrush current. If the parameter is set to zero (OFF), this function
is disabled. Settings from 0 (OFF) to 3 Sec. Factory value: OFF.
mixtures
Pressing knob C-5 again, the following appears:
2
- : Inrush current.
Pressing knob C-5 again, the following appears:
- : Welding current SLOPE DOWN. Used to gradually reduce the current on
Ar releasing the torch button. Settings from 0 (OFF) to 3 Sec. Factory value: OFF.
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, you return to synergic mode.
8. CONTROLLING THE TORCH PUSH-BUTTON
8.1 Setting the torch push-button control mode (Fig. l-5)
Press the knob (Fig. C-5) for at least 3 seconds to access the parameter setting menu.
When menu 2 appears, press again.
8.2 Torch push-button control mode
It is possible to set 4 different torch push-button control modes:
2T mode
: welding begins when the torch push-button is pressed and ends when the push-
button is released.
4T mode
: welding begins when the torch push-button is pressed and released, and ends
only when the torch push-button is pressed and released a second time. This mode is
useful for long welding operations.
4T Bi-Level mode
: welding begins when the torch push-button is pressed and released. Each time
it is pressed/released it switches from current
It only terminates when the torch push-button is pressed for a certain set time.
Spot welding mode
: Used for MIG/MAG spot welding with control of welding duration.
9. INFO MENU
Both in manual mode
press knob C-5 for at least 3 seconds. On appearance of menu 3 (Fig. I-6), press
again: turning the knob C-5 we can obtain information on the software installed.
Pressing knob C-5 again, you return to manual (or synergic) mode.
10. UNIT OF MEASUREMENT MENU
Both in manual mode
menu, press knob C-5 for at least 3 seconds. On appearance of menu 4 (Fig. I-7),
press again: now you can set the metric or imperial units of measurement. Pressing
knob C-5 again, you return to manual (or synergic) mode.
11. CALIBRATION MENU
Only in manual mode
least 3 seconds. On appearance of menu 5 (Fig. I-8), press again: now you can
calibrate the welding machine so it complies with directive EN50504-4. Pressing knob
C-5 again, you return to manual (or synergic) mode.
12. MMA WELDING: PROCESS DESCRIPTION
12.1 GENERAL PRINCIPLES
- It is essential to follow the recommendations provided by the manufacturer on the
electrode packaging which indicates the correct electrode polarity and relative rated
current.
- Welding current is regulated to suit the diameter of the electrode being used and the
type of soldering to be performed; an example of the currents used for the various
electrode diameters can be seen below:
- 8 -
to current
and synergic mode , to access the INFO menu,
and synergic mode , to access the
, to access the menu, press knob C-5 for at
and vice versa.