Telwin HILO TECHNOMIG 240 WAVE 230V Manuel D'instructions page 10

- : This is the initial "HOT START" overcurrent, the display shows the
percentage increase as to the value of the selected welding current. This adjustment
improves starting.
- : This is the dynamic "ARC-FORCE" overcurrent, the display shows the
percentage increase as to the value of the pre-selected welding current. This
adjustment improves welding fluidity, prevents the electrode from adhering to the
workpiece and makes it possible to use different types of electrodes.
- : ON/OFF: this enables or disables the device that reduces the loadless
output voltage (ON or OFF setting). With the VRD enabled, operator safety increases
when the welding machine is on but not in the welding mode.
The actual welding settings (welding current, voltage and the diameter of the
suggested electrode) are shown in the left section of the display.
11. TIG DC WELDING: PROCESS DESCRIPTION
11.1 GENERAL PRINCIPLES
TIG DC welding is suitable for all types of low-alloy and high carbon steel, and heavy
metals such as copper, nickel, titanium and their alloys (FIG. N). An electrode with 2%
Cerium (grey band) is normally used for TIG DC welding with electrode at the (-) pole.
The tungsten electrode must be axially sharpened using a grinding wheel, see FIG. O;
make sure the tip is perfectly concentric to prevent arc deviation. The electrode must
be ground along its length. This operation must be repeated periodically according
to the use and wear state of the electrode, or when the electrode itself has been
accidentally contaminated, oxidised or used incorrectly. For the welding to be good,
the exact diameter of the electrode must be used with the exact current, see table
(TAB. 6). The electrode normally projects from the ceramic nozzle by 2-3 mm, but can
reach 8 mm for welding edges.
The weld is created by the edges that melt. Filler metal is not needed when welding
suitably prepared thin material (up to about 1 mm) (FIG. P).
A greater thickness requires rods made from the same material as the basic material
and with a suitable diameter, with edges that have been suitably prepared (FIG. Q).
For welding to be successful, the pieces must be carefully cleaned and free from
oxide, grease, oil, solvent, etc.
11.2 PROCEDURE (LIFT STRIKE)
- Use the knob B-5 to adjust the welding current to the required rate; adjust this value
during welding processes to adapt to the actual heat transfer required.
- Make sure the gas is flowing correctly.
The arc ignites through contact, distancing the tungsten electrode from the
workpiece. Igniting in this manner causes less electric-irradiated disturbances and
reduces tungsten inclusions and electrode wear to a minimum.
- Place the tip of the electrode on the workpiece, pressing gently.
- Immediately lift the electrode by 2-3 mm to obtain the ark strike.
The welding machine initially supplies reduced current. After a few seconds, the set
welding current is issued.
- Quickly lift the electrode from the workpiece to interrupt welding.
11.3 TFT DISPLAY IN TIG MODE (Fig. L-12)
The actual welding settings (welding current and voltage) are shown in the left section
of the display.
12. ALARM SIGNALS (TAB. 7)
Reset is automatic when the reason for alarm activation stops.
Alarm messages that can appear on the display:
DESCRIPTION
Thermal protection alarm
Overvoltage/undervoltage alarm
Auxiliary voltage alarm
Welding overcurrent alarm
Torch short-circuit alarm
Alarm for wirefeeder failure
Off-line alarm
Line-error alarm
Cooling unit alarm
When the welding machine is switched off, the Over/under voltage alarm signal may
appear for a few seconds.
13. SETTINGS MENU (Fig. L-13)
13.1 MODE MENU (Fig. L-14)
Use to select settings on the screens in MIG-MAG mode:
- : all settings are displayed as described above.
- : Fig. L-17. The piece to be welded and the welding seam shape are
indicated in this mode. Press button C-6 to access all the other settings.
When operating in "EASY" mode, it is impossible to weld in MIG MANUAL and PoP
mode.
13.2 SET UP MENU (Fig. L-15)
Used to set the following:
- : language.
- : time and date.
- : metric or UK unit of measure.
13.2.1 FUNCTIONS BLOCK
After selecting the setup icon
push buttons simultaneously and then confirm by pressing the multifunction knob (C-
5). The screen displays the icon
when pressed:
- : no protection; it is possible to browse, set and modify all welding
parameters.
- : intermediate protection; it is only possible to modify the basic welding
parameters.
, press the wire feed (C-2) and gas bleed (C-3)
used to set 3 different function block levels
- : maximum protection; it is impossible to modify any parameters.
13.3 SERVICE MENU (Fig. L-16)
This provides information on the welding machine status.
13.3.1 INFO MENU
- : welding machine operations in days (DDDD), hours (HH), minutes
(mm).
- : welding machine working days (DDDD), hours (HH), minutes (mm).
- : alarms list.
13.3.2 FIRMWARE MENU
- : use to update the welding machine software via USB pen drive.
- : use to reset the welding machine to its default settings.
- : software release installed.
13.3.3 REPORT MENU
Use to generate a report and save it to a USB pen drive. The report contains various
information on the welding machine status (software installed, life/working hours,
alarms, selected welding process etc.).
13.3.4 CALIBRATION
After selecting the service icon
push buttons simultaneously and then confirm by pressing the multifunction knob (C-
5). The screen displays the icon
meet EN 50504 standard requirements when pressed.
13.4 AQUA MENU
It allows to activate / deactivate
13.5 Menu setting for torch T1,T2.T2 (3 torch version only)
After selecting the icon, on the screen there will appear the icons of the three
torches (Tab. 3):
- : Torch T1
- : Torch T2
- : Torch T3
13.6 JOBS MENU (Fig. L-18)
Used to:
- : save a job in the welding machine internal memory.
- : retrieve and load a previously saved job.
- : cancel a previously saved job.
- : import jobs from a USB device.
- : export jobs to a USB device.
- : allow saving of welding parameters to the USB device.
14. MAINTENANCE
WARNING! BEFORE CARRYING OUT MAINTENANCE OPERATIONS
MAKE SURE THE WELDING MACHINE IS SWITCHED OFF AND DISCONNECTED
FROM THE MAIN POWER SUPPLY.
14.1 ROUTINE MAINTENANCE:
ROUTINE MAINTENANCE OPERATIONS CAN BE CARRIED OUT BY THE
OPERATOR.
14.1.1 Torch
- Do not put the torch or its cable on hot pieces; this would cause the insulating
materials to melt, making the torch unusable after a very short time.
- Make regular checks on the gas pipe and connector seals.
- Accurately match collet and collet body with the selected electrode diameter in order
to avoid overheating, bad gas diffusion and poor performance.
- At least once a day check the terminal parts of the torch for wear and make sure they
are assembled correctly: nozzle, electrode, electrode-holder clamp, gas diffuser.
- Before using the welding machine, always check the terminal parts of the torch for
wear and make sure they are assembled correctly: nozzle, electrode, electrode-
holder clamp, gas diffuser.
14.1.2 Wire feeder
- Make frequent checks on the state of wear of the wire feeder rollers, regularly
remove the metal dust deposited in the feeder area (rollers and wire-guide infeed
and outfeed).
14.2 EXTRAORDINARY MAINTENANCE
EXTRAORDINARY MAINTENANCE MUST ONLY BE CARRIED OUT BY
TECHNICIANS WHO ARE EXPERT OR QUALIFIED IN THE ELECTRIC-
MECHANICAL FIELD, AND IN FULL RESPECT OF THE IEC/EN 60974-4
TECHNICAL DIRECTIVE.
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
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, press the wire feed (C-2) and gas bleed (C-3)
used to calibrate the welding machine to
the G.R.A. function.