Data Plate; Other Technical Data - Telwin ELECTROMIG 400 SYNERGIC Manuel D'instructions

- The operator MUST NOT BE ALLOWED to weld in raised positions unless
safety platforms are used.
- VOLTAGE BETWEEN ELECTRODE HOLDERS OR TORCHES: working with
more than one welding machine on a single piece or on pieces that are
connected electrically may generate a dangerous accumulation of no-load
voltage between two different electrode holders or torches, the value of which
may reach double the allowed limit.
An expert coordinator must be designated to measuring the apparatus to
determine if any risks subsist and suitable protection measures can be
adopted, as foreseen by section 7.9 of the applicable standard "EN 60974-9:
Arc welding equipment. Part 9: Installation and Use".
- The use of the machine must be limited to the operator only.
- The operator must disconnect the cable and the electrode holder from the
machine once the MMA welding is over.
- The area around the welding machine must be forbidden to third parties. It
also should not be left unattended.
- The torches not in use should be stored in their housing.
RESIDUAL RISKS
- OVERTURNING: position the welding machine on a horizontal surface that is
able to support the weight: otherwise (e.g. inclined or uneven floors etc.) there
is danger of overturning.
- IMPROPER USE: it is hazardous to use the welding machine for any work
other than that for which it was designed (e.g. de-icing mains water pipes).
- IMPROPER USE: the use the welding machine by more than one operator at
the same time may be dangerous.
- MOVING THE WELDING MACHINE: Always secure the gas bottle, taking
suitable precautions so that it cannot fall accidentally (if used).
- Do not use the handle to hang the welding machine.
The safety guards and moving parts of the covering of the welding machine
and of the wire feeder should be in their proper positions before connecting the
welding machine to the power supply.
WARNING! Any manual operation carried out on the moving parts of the wire
feeder, for example:
- Replacing rollers and/or the wire guide;
- Inserting wire in the rollers;
- Loading the wire reel;
- Cleaning the rollers, the gears and the area underneath them;
- Lubricating the gears.
SHOULD BE CARRIED OUT WITH THE WELDING MACHINE SWITCHED OFF
AND DISCONNECTED FROM THE POWER SUPPLY OUTLET.
2. INTRODUCTION AND GENERAL DESCRIPTION
This welding machine is a source of current for arc welding, made specifically for MAG
welding carbon steel or weak alloys with CO
using tubular full or core electrode wires.
It is also ideal for MIG welding stainless steel with Argon gas containing + 1-2%
oxygen and aluminium and CuSi3, CuAl8 (brazing) with Argon gas, using electrode
wires that are suitable for the workpiece to be welded..
It is particularly suitable for light metalwork fabrication and in body shops, for welding
galvanized plates, high stress stainless steel and aluminium. SYNERGIC operation
ensures fast and easy welding parameter setting, always guaranteeing high arc
control and welding quality.
The welding machine can be used for TIG welding in direct current (DC), with arc
striking upon contact (LIFT ARC mode). It welds all types of steel (carbon, low- and
high-alloy) and heavy metals (copper, nickel, titanium and their alloys) with a gas
shield of pure (99.9%) Ar or, for special uses, with an Argon/Helium mix. It can also be
used for MMA electrode welding in direct current (DC) using coated electrodes (rutile,
acid, basic).
2.1 MAIN CHARACTERISTICS
MIG-MAG
- Operating modes:
- manual;
- synergic;
- Wire speed, welding current and voltage shown on the display.
- 2T, 4T, 4T Bi-level, Spot operation selection.
TIG
- Start LIFT.
- Wire speed and welding current shown on an LCD screen.
MMA
- Arc force, hot start adjusting.
- VRD device.
- Anti-stick protection.
- Wire speed and welding current shown on an LCD screen.
OTHER
- Setting the metric or UK system.
- Possibility to set the machine parameters (voltage, current, wire speed).
- Possibility to save and retrieve customised software.
PROTECTION
- Thermostatic safeguard.
- Protection against accidental short-circuits caused by contact between torch and
earth.
- Protection against irregular voltage (power supply voltage too high or too low).
- Anti-stick (MMA).
protective gas or Argon/CO mixes,
2 2
2.2 STANDARD ACCESSORIES
- Torch.
- Return cable complete with earth clamp.
- Torch holder stand.
2.3 OPTIONAL ACCESSORIES
- Argon bottle adapter.
- Self darkening mask.
- MIG/MAG welding kit.
- MMA welding kit.
- TIG welding kit.
3. TECHNICAL DATA
3.1 DATA PLATE
The most important data regarding use and performance of the welding machine are
summarised on the rating plate and have the following meaning:
1- EUROPEAN standard of reference, for safety and construction of arc welding
machines.
2- Symbol for internal structure of the welding machine.
3- Symbol for welding procedure provided.
4- Symbol S: indicates that welding operations may be carried out in environments
with heightened risk of electric shock (e.g. very close to large metallic volumes).
5- Symbol for power supply line:
1~ : single phase alternating voltage;
3~ : 3-phase alternating voltage.
6- Protection rating of the covering.
7- Technical specifications for power supply line:
- U : Alternating voltage and power supply frequency of welding machine (allowed
1
limit ±10%).
- I : Maximum current absorbed by the line.
1 max
- I : effective current supplied.
1eff
8- Performance of the welding circuit:
- U : maximum no-load voltage (open welding circuit).
0
- I /U : current and corresponding normalised voltage that the welding machine
2 2
can supply during welding.
- X : Duty cycle: indicates the time for which the welding machine can supply the
corresponding current (same column). It is expressed as %, based on a 10 min.
cycle (e.g. 60% = 6 minutes working, 4 minutes pause, and so on).
If the usage factors (on the plate, referring to a 40°C environment) are exceeded,
the thermal safeguard will trigger (the welding machine will remain in standby
until its temperature returns within the allowed limits).
- A/V-A/V : shows the range of adjustment for the welding current (minimum
maximum) at the corresponding arc voltage.
9- Manufacturer's serial number for welding machine identification (indispensable for
technical assistance, requesting spare parts, discovering product origin).
10- : Size of delayed action fuses to be used to protect the power line.
11- Symbols referring to safety regulations, whose meaning is given in chapter 1
"General safety considerations for arc welding".
Note: The data plate shown above is an example to give the meaning of the symbols
and numbers; the exact values of technical data for the welding machine in your
possession must be checked directly on the data plate of the welding machine itself.
3.2 OTHER TECHNICAL DATA:
- WELDING MACHINE: see table 1 (TAB. 1)
- MIG TORCH: see table 2 (TAB. 2)
- TIG TORCH: see table 3 (TAB. 3)
- ELECTRODE-HOLDER CLAMP: see table 4 (TAB. 4)
The weight is of the welding machine is outlined on table 1 (TAB. 1).
4. DESCRIPTION OF THE WELDING MACHINE
4.1 CONTROL, ADJUSTMENT AND CONNECTION DEVICES.
4.1.1 WELDING MACHINE (Fig. B)
At the front:
1- Control panel (see description);
2- Torch coupling;
3- Positive (+) quick coupling for connecting the welding cable;
4- Negative (-) quick coupling for connecting the welding cable;
5- Earth return cable and clamp;
6- Welding cable and torch;
At the back:
7- Main ON/OFF switch;
8- Power cable;
9- Hose connector for torch protective gas;
4.1.2 WELDING MACHINE CONTROL PANEL (Fig. C)
1- LCD 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.
- If pressed, it allows access to preset machine programs.
- If pressed, for at least 3 seconds it allows you to:
- save a job on the machine internal memory.
- load a previously saved job.
5- Multi-function knob.
Rotation enables:
- wire speed feed adjustment in
- welding power adjustment in
- welding current adjustment in TIG mode (
- welding current adjustment in MMA mode (
- if pressed for at least 3 seconds, it enables access to various setting menus of
the machine.
- 6 -
Fig. A
mode
mode
)
)