Standard Accessories; Optional Accessories; Technical Specifications - Telwin SUPERMIG 500i XD PACK Bedienungsanleitung

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.
- It is forbidden to lift the trolley together with the welding machine, the wire feeder
and the cooling unit (when present).
- 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).
- RISK OF BURNS
Some parts of the welding machine (torch, electrode-holder clamp) and the adjacent
areas can reach temperatures over 65°C: adequate protective clothing must be
worn.
Allow the just welded piece to cool before touching it!
- 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.
ENVIRONMENTAL CONDITIONS (EN 60974-1)
- Use the welding machine with the following environmental conditions only:
• ambient temperature between -10°C and 40°C;
• relative humidity of the air not exceeding 50% at 40°C;
• relative humidity of the air not exceeding 90% at 20°C;
• The surrounding air must be free of dust, acid, gas or corrosive substances, etc.
STORAGE
- Position the machine and its accessories (with or without packaging) in closed
premises.
- The ambient temperature must be between -20°C and 55°C.
If the machine is planned with liquid cooling and an ambient temperature under 0°C:
use the anti-freeze liquid suggested by the manufacturer or completely empty the
hydraulic circuit and the tank of liquid.
Always use adequate measures to protect the machine from humidity, dirt and
corrosion.
DISPOSAL
Do not dispose of this welding machine as normal household waste at the end of its
life cycle.
The user is responsible for disposing of this electrical equipment in collection
points designated for disposal and recycling of electrical equipment or contact the
shop where you purchased the product. This provision only refers to disposal of the
equipment within the European Union (WEEE).
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
or core electrode wires (tubular).
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
protective gas or Argon/CO mixes, using full
2 2
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.
- Operation selection 2T, 4T, Spot.
TIG
- Start LIFT.
- Welding voltage and current shown on an LCD screen.
MMA
- Operating modes:
- Direct current MMA;
- Pulse current MMA;
- Arc force settings, hot start.
- VRD device.
- Anti-stick protection.
- Welding voltage and current shown on an LCD screen.
GOUGING
- Gouging voltage and current shown on an LCD screen.
OTHER
- Setting the metric or UK system.
- Possibility of connecting a semi-automatic type wire feeder unit (
- Automatic recognition of the G.R.A. liquid cooling unit (AQUA version only).
PROTECTION
- Thermostatic protection.
- Protection against accidental short-circuits caused by contact between torch and earth.
- Protection against irregular voltage (power supply voltage too high or too low).
- Protection for insufficient pressure on the liquid cooling circuit of the torch (AQUA version
only).

2.2 STANDARD ACCESSORIES

- MIG torch.
- MIG torch (liquid cooled in AQUA version).
- Return cable complete with earth clamp.
- Torch holder stand.
- G.R.A liquid cooling unit. (AQUA version only).

2.3 OPTIONAL ACCESSORIES

- Argon bottle adapter.
- Self darkening mask.
- MIG/MAG welding kit.
- MMA welding kit.
- TIG welding kit.
- Trolley.
- Gouging Kit.

3. TECHNICAL SPECIFICATIONS

3.1 DATA PLATE
WELDING MACHINE
The main data on use and performance of the welding machine are summarised on the
rating plate with the following meaning:
1- EUROPEAN reference standard for safety and construction of arc welding machines.
2- Manufacturer's name and address.
3- Name of model.
4- Symbol of welding machine internal structure.
5- Symbol of planned welding procedure.
6- Symbol S : indicates cleaning operations can be carried out in an environment with
increased risk of electric shock (e.g. in close proximity of large metal masses).
7- Symbol of the power supply:
1~: single-phase alternating voltage;
3~: three-phase alternating voltage.
- Protection rating of the casing.
9- Characteristic data of the power supply:
- U : Alternating voltage and power supply frequency to the welding machine (allowed
1
limits ±10%).
- I : Absorbed maximum current from line.
1 max
- I : Effective power supply current.
1 eff
10- Welding circuit performance:
- U
: maximum no load voltage (welding circuit open).
0
- I /U
: Normalized corresponding current and voltage which can occur supplied by
2 2
the welding machine during welding.
- X : Duty cycle ratio: indicates the time during which the welding machine can supply
the corresponding current (same column). It is expressed as a %, based on a 10min
cycle (e.g. 60% = 6 working minutes, 4 rest minutes; and so on).
If the use factors (of plate, referring to 40°C ambient temperature) are surpassed, the
thermal switch activates (the welding machine stays in stand-by until its temperature
goes back within the permitted limits).
- A/V-A/V : It indicates the settings range of the welding current (minimum- maximum)
at the corresponding arc voltage.
11- Serial number to identify the welding machine (essential for technical assistance, spare
part requests, tracing of product origin).
12- : Value of delayed activation fuses to implement for line protection.
13- Symbols referring to safety standards whose meaning is outlined in chapter 1 "General
safety for arc welding".
WIRE FEEDER UNIT
The main information on use and performance of the wire feeder unit is summarised
on the data plate and has the following meaning:
1- EUROPEAN reference standard for safety and construction of the wire feeder unit.
2- Symbol of the power supply:
: direct voltage;
3- Protection rating of the casing.
4- U
: Wire feeder unit power supply voltage.
1
5- I : Absorbed current with maximum load.
1
- 6 -
CV
).
Fig. A1
Fig. A2