Telwin ELECTROMIG 400 SYNERGIC Manuel D'instructions page 9

Ø Electrode (mm)
1.6
2.0
2.5
3.2
4.0
5.0
6.0
8.0
- One can see that for the same diameter electrode, high levels of current will be
used for flat welding, whilst lower current levels will be used for vertical or overhead
welding.
- The mechanical characteristics of the welded joint are determined by the intensity
of the selected current and also other welding parameters such as the length of the
arc, the operating speed and position, the diameter and quality of the electrodes
(to ensure correct conservation, use special packaging or containers to store and
protect the electrodes against humidity).
WARNING:
Instability of the arc due to the composition of the electrode can occur,
depending on the brand, type and thickness of the electrode coatings.
12.2 PROCEDURE
- Keeping the mask IN FRONT OF YOUR FACE, rub the tip of the electrode on the
piece to be welded, moving as if striking a match; this is the most correct method for
igniting the arc.
WARNING: DO NOT TAP the electrode against the workpiece, which could
damage the coating and make arc striking difficult.
- As soon as the arc has struck, try to keep the electrode at a distance from the
workpiece that is equivalent to the diameter of the electrode being used, and keep
this distance as constant as possible while welding; remember that the electrode
angle while moving forward must be approx. 20-30 degrees.
- At the end of the welding seam, take the electrode end slightly back as to the forward
direction, above the crater to fill it, then quickly lift the electrode from the weld pool
to switch off the arc (Aspects of the welding seam - FIG. L).
12.3 MMA mode setting
MMA mode setting ( ) (Fig I-9)
Knob C-5 adjusts the welding current and diameter of the electrode recommended.
The welding voltage and current is shown on the display only during welding.
Advanced parameter setting: (Fig I-10)
Press the knob C-5 for at least 3 seconds to access the advanced parameter setting
menu:
- : ON/OFF; this enables or disables the device that reduces the loadless output
voltage (ON or OFF setting). Factory value: OFF. With the VRD enabled, operator
safety increases when the welding machine is on but not in the welding mode.
Pressing knob C-5 again, the following appears:
- : this is the initial "HOT START" overcurrent, the display shows the percentage
increase as to the value of the selected welding current. Settings from 0 to 100%.
Factory value: 50 %
Pressing knob C-5 again, the following appears:
- : 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.
Settings from 0 to 100%. Factory value: 50 %
Pressing knob C-5 again, you return to MMA mode.
13. TIG DC WELDING: PROCESS DESCRIPTION
13.1 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. M). 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. N;
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. The welding to be good, the
exact diameter of the electrode must be used with the exact current, see table (TAB.
5). The electrode normally projects from the ceramic nozzle by 2 - 3mm, 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. O).
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. P).
For welding to be successful, the pieces must be carefully cleaned and free from
oxide, grease, oil, solvent, etc.
13.2 PROCEDURE (LIFT STRIKE)
- Use the knob C-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 - 3mm 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.
13.3 LCD DISPLAY IN TIG MODE (Fig. L-11)
The actual welding settings (welding current and voltage) are shown in the top section
of the display.
14. ALARM SIGNALS (TAB. 7)
Reset is automatic when the reason for alarm activation stops.
Alarm messages that can appear on the display:
Welding current (A)
Min. Max.
30 50
40 80
60 110
90 140
120 180
170 250
230 350
320 400
CODE
02 Thermal protection alarm
03 / 04 Overvoltage/undervoltage alarm
18 Auxiliary voltage alarm
10 Welding overcurrent alarm
11 Torch short-circuit alarm
19 Feeder anomaly alarm
13 Off-line alarm
13 Line-error alarm
09 Cooling unit alarm
When the welding machine is switched off, the Over/under voltage alarm signal may
appear for a few seconds.
15. JOBS MENU
15.1 Save procedure (SAVE).
Following optimal adjustment of the welding machine for a certain type of weld,
proceed as follows:
- Press button C-4 for at least 3 seconds until the screw in Fig. I-12 appears.
- Turn the knob C-5 to choose the number with which you want to save the program
(J1 ÷ 10).
- Press button C-4 for at least 3 seconds until the SAVE icon (
15.2 Retrieval procedure of a customised program
- Press button C-4 for at least 3 seconds until the screw in Fig. I-12 appears.
- Turn the knob C-5 to choose the number used to save the program which you now
intend to use (J1 ÷ 10).
- Press button C-4 to load the chosen program
NOTES:
- A RETRIEVED PROGRAM CAN BE MODIFIED AS THE OPERATOR WISHES,
BUT THE MODIFIED VALUES ARE NOT AUTOMATICALLY SAVED. IF YOU
WANT TO SAVE THE NEW VALUES ON THE SAME PROGRAM YOU NEED TO
EXECUTE THE SAVING PROCEDURE.
- REGISTRATION OF CUSTOMISED PROGRAMS AND THE RELEVANT
SCHEDULING OF ASSOCIATED
RESPONSABILITY.
- CUSTOMISED PROGRAMS CANNOT BE SAVED IN MMA OR TIG ELECTRODE
MODE.
16. MAINTENANCE
WARNING! BEFORE CARRYING OUT MAINTENANCE OPERATIONS
MAKE SURE THE WELDING MACHINE IS SWITCHED OFF AND DISCONNECTED
FROM THE MAIN POWER SUPPLY.
16.1 ROUTINE MAINTENANCE:
ROUTINE MAINTENANCE OPERATIONS CAN BE CARRIED OUT BY THE
OPERATOR.
16.1.1 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.
16.1.2 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).
16.2 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
OUTLET.
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. 10 bar).
- 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.
- After having carried out maintenance or repairs, restore the connections and wiring
as they were before, making sure they do not come into contact with moving parts or
parts that can reach high temperatures. Tie all the wires as they were before, being
careful to keep the high voltage connections of the primary transformer separate
from the low voltage ones of the secondary transformer.
Use all the original washers and screws when closing the casing.
- 9 -
DESCRIPTION
) stops flashing.
PARAMETERS IS THE USER'S