Telwin FORCE 168 Mode D'emploi page 6

- the welding machine does not fall within the requisites of IEC/EN
61000-3-12 standard.
Should it be connected to a public mains system, it is the installer's
responsibility to verify that the welding machine itself is suitable for
connecting to it (if necessary, consult the distribution network
company).
- Unless otherwise specified (MPGE), the welding machines are
compatible with power generating sets for voltage oscillations up to
± 15%.
For correct use, the power generating set must be brought to
steady conditions before being able to connect the inverter.
- PLUG AND OUTLET:
- The 230V model is fitted at the factory with a power supply cable
and normalised plug, (2P + T) 16A/250V .
It can therefore be connected to 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.
- For welding machines without a plug (115/230V models),
connect a normalised plug (2P + T) - 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.
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WARNING! Failure to observe the above rules will make the
(Class 1) safety system installed by the manufacturer ineffective
with consequent serious risks to persons (e.g. electric shock)
and objects (e.g. fire).
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CONNECTION OF THE WELDING CABLES
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WARNING! BEFORE
CONNECTIONS MAKE SURE THE WELDING MACHINE IS
SWITCHED OFF AND DISCONNECTED FROM THE POWER
SUPPLY OUTLET.
Table (TAB. 1) gives the recommended values for the welding cables
2
(in mm ) depending on the maximum current supplied by the welding
machine.
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MMA WELDING
Almost all coated electrodes are connected to the positive pole (+) of
the power source; as an exception to the negative pole (-) for acid
coated electrodes.
WELDING OPERATIONS WITH DIRECT CURRENT
Connecting the electrode-holder clamp welding cable
On the end take a special terminal that is used to close the uncovered
part of the electrode.
This cable is connected to the terminal with the symbol (+)
Connecting the welding current return cable
This is connected to the piece being welded or to the metal bench
supporting it, as close as possible to the join being made.
This cable is connected to the terminal with the symbol (-)
Warnings:
- Turn the welding cable connectors right down into the quick
connections (if present), to ensure a perfect electrical contact;
otherwise the connectors themselves will overheat, resulting in
their rapid deterioration and loss of efficiency.
- The welding cables should be as short as possible.
- Do not use metal structures which are not part of the workpiece to
substitute the return cable of the welding current: this could
jeopardise safety and result in poor welding.
6. WELDING: DESCRIPTION OF THE PROCEDURE
- It is most important that the user refers to the maker's instructions
indicated on the stick electrode packaging. This will indicate the
correct polarity of the stick
suitable current.
- The welding current must be regulated according to the diameter of
the electrode in use and the type of the joint to be carried out: see
below the currents corresponding to various electrode diameters:
ø Electrode (mm)
1,6
2
2,5
3,2
4
- The user must consider that, according to the electrode diameter,
MAKING THE FOLLOWING
electrode and the most
Welding current (A)
min. max.
25 - 50
40 - 80
60 - 110
80 - 160
120 - 200
higher current values must be used for flat welding, whereas for
vertical or overhead welds lower current values are necessary.
- As well as being determined by the chosen current intensity, the
mechanical characteristics of the welded join are also determined
by the other welding parameters i.e. arc length, working rate and
position, electrode diameter and quality (to store the electrodes
correctly, keep them in a dry place protected by their packaging or
containers).
Procedure
- Holding the mask IN FRONT OF THE FACE, strike the electrode tip
on the workpiece as if you were striking a match. This is the correct
strike-up method.
WARNING: do not hit the electrode on the workpiece, this could
damage the electrode and make strike-up difficult.
- As soon as arc is ignited, try to maintain a distance from the
workpiece equal to the diameter of the electrode in use. Keep this
distance as much constant as possible for the duration of the weld.
Remember that the angle of the electrode as it advances should be
of 20-30 grades (Fig. G).
- At the end of the weld bead, bring the end of the electrode
backward, in order to fill the weld crater, quickly lift the electrode
from the weld pool to extinguish the arc.
CHARACTERISTICS OF THE WELD BEAD
7. MAINTENANCE
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WARNING! BEFORE CARRYING OUT MAINTENANCE
OPERATIONS MAKE SURE THE WELDING MACHINE IS
SWITCHED OFF AND DISCONNECTED FROM THE MAIN POWER
SUPPLY.
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EXTRAORDINARY MAINTENANCE
EXTRAORDINARY MAINTENANCE OPERATIONS SHOULD BE
CARRIED OUT ONLY AND EXCLUSIVELY BY SKILLED OR
AUTHORISED ELECTRICAL-MECHANICAL TECHNICIANS.
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WARNING! BEFORE REMOVING THE WELDING MACHINE
PANELS AND WORKING INSIDE THE MACHINE MAKE SURE THE
WELDING MACHINE IS SWITCHED OFF AND DISCONNECTED
FROM THE MAIN POWER SUPPLY OUTLET.
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If checks are made inside the welding machine while it is live, this
may cause serious electric shock due to direct contact with live
parts and/or injury due to direct contact with moving parts.
- Inspect the welding machine regularly, with a frequency
depending on use and the dustiness of the environment, and
remove the dust deposited on the transformer, reactance and
rectifier using a jet of dry compressed air (max. 10bar).
- Do not direct the jet of compressed air on the electronic boards;
these can be cleaned with a very soft brush or suitable solvents.
- At the same time make sure the electrical connections are tight
and check the wiring for damage to the insulation.
- At the end of these operations re-assemble the panels of the
welding machine and screw the fastening screws right down.
- Never, ever carry out welding operations while the welding
machine is open.
8. TROUBLESHOOTING
IN CASE OF UNSATISFACTORY FUNCTIONING, BEFORE
SERVICING MACHINE OR REQUESTING ASSISTANCE, CARRY
OUT THE FOLLOWING CHECK:
- Check that the welding current, which is regulated by the
potentiometer with a graduated amp scale, is correct for the
diamter and electrode type in use.
- Check that when general switch is ON the relative lamp is ON. If
this is not the case then the problem is located on the mains
(cables, plugs, outlets, fuses, etc.)
- Check that the yellow led (ie. thermal protection interruption-
either over or undervoltage or short circuit) is not lit.
- Check that the nominal intermittance ratio is correct. In case there
is a thermal protection interruption, wait for the machine to cool
down, check that the fan is working properly.
- Check the mains voltage: if the value is too high or too low the
welding machine will be stopped.
- Check that there is no short-circuit at the output of the machine: if
this is the case eliminate the incovenience.
- Check that all connections of the welding circuit are correct,
particularly that the work clamp is well attached to the workpiece,
with no interferring material or surface-coverings (ie. Paint).
- Protective gas must be of appropriate type (Argon 99,5%) and
quantity.
- 6 -
Fig. H