Telwin WAVE ELECTROMIG 230 Manuel D'instructions page 7

10- Power cable;
11- Hose connector for torch protective gas;
4.1.2 WELDING MACHINE CONTROL PANEL (Fig. C)
1- TFT Display.
2- Manual wire jog button. This jogs the wire forward in the torch sheath without
having to touch the torch button; this is a momentary action and the speed is set
and fixed.
3- Manual gas solenoid valve start button. This enables the flow of gas (pipe bleeds,
flow rate adjustment) without the need to use the torch button; once pressed, the
solenoid valve remains enabled for 10 seconds or until it is pressed again.
4- Multi-function button:
- : access to the main menu;
- : enabling/disabling of the parameter to be displayed on the welding
screen;
5- Multi-function knob:
- rotate the knob to scroll through the various menu items;
- press to access the selected item, rotate to change the setting, press again to
confirm the value;
- press and hold for at least 3 seconds to set the variables in synergic mode
(material type, wire diameter, gas type, 2T, 4T, 4T bi-level, SPOT).
6- Multi-function button:
- : access to the parameter to be displayed on the welding screen;
- : back to the main menu.
7- USB port.
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 = 0.28 ohm.
- The welding machine falls within the requisites of IEC/EN 61000-3-12 standard.
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.
CARRYING OUT THE FOLLOWING
2
- 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. 30 kg.
- When using Argon gas or an Argon/CO
onto 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
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-3) 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.
5.3.2.4 Spool gun (Fig. B)
Insert the spool gun (B-6) into the dedicated connector (B-2), fully tightening the
locking ring nut manually. Also insert the control cable connector into the relative
socket (B-5). The welding machine automatically acknowledges the spool gun.
5.3.3 WELDING CIRCUIT CONNECTION IN TIG MODE
5.3.3.1 Connecting the gas bottle
- Screw the pressure reducer onto the gas bottle valve, placing the relative reduction
supplied as an accessory between them;
- Connect the gas input hose to the pressure reducing valve and tighten the supplied
strip.
- Loosen the adjustment ring nut of the pressure reducing valve before opening the
gas bottle valve.
- Open the gas bottle and adjust the quantity of gas (l/min.) according to the
recommended usage data, see table (TAB. 5); the gas flow can be adjusted while
welding, always using the ring nut of the pressure reducer. Check the seal of the
hoses and connections.
ATTENTION! Always close the gas bottle valve when you have finished
working.
5.3.3.2 Connecting the welding current return cable
- Connect it 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-7).
5.3.3.3 Torch
- Insert the current cable into the relative quick coupling (-) (Fig. B-8). Connect the gas
hose of the torch to the gas bottle
5.3.4 WELDING CIRCUIT CONNECTION IN MMA MODE
Almost all the coated electrodes are connected to the positive pole (+) of the generator,
with an exception for acid coated electrodes, which must be connected to the negative
pole (-).
5.3.4.1 Welding wire clamp electrode-holder connection
Takes a special clamp for tightening the uncovered part of the electrode to the terminal.
Connect this cable to the clamp with the symbol (+) (Fig. B-7).
5.3.4.2 Connecting the welding current return cable
- Connect it 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-8).
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.
) according
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).
- 7 -
mixture 2 , screw the pressure reducer(*)
2