Installation - Telwin MMA Bedienungsanleitung

4. WELDING MACHINE DESCRIPTION
4.1 CONTROL, ADJUSTMENT AND CONNECTING DEVICES.
4.1.1 WELDING MACHINE (Fig. B)
At the front:
1- Control panel (see description);
2- Torch connection and SPOOL GUN (single torch version only);
3- PUSH PULL and SPOOL GUN torch control cable connector (single torch version
only);
4- Positive (+) quick coupling for connecting the welding cable;
5- Negative (-) quick coupling for connecting the welding cable;
6- Earth return cable and clamp;
7- SPOOL GUN (optional);
8- Welding cable and torch;
9- Return connector (red) for cooling liquid (for the AQUA version only);
10- Input connector (blue) for cooling liquid (for the AQUA version only);
11- Liquid tank cap (for the AQUA version only).
At the back:
12- Main ON/OFF switch;
13- Power cable;
14- Hose connector for torch protective gas;
15- G.R.A. protection fuse (R.A. version only);
16- Pipe connector for torch shielding gas T1;
17- Pipe connector for torch shielding gas T2;
18- Pipe connector for torch shielding gas T3;
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.
- : confirmation of the chosen values.
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, D1, D2a-b)
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
G.R.A. installation (AQUA version only): see instruction manual inside the water
cooling system.
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 = 0.24 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.
- 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
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-8) 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.
Connect the outside cooling pipes to the relative plugs and pay attention to the
following:
: LIQUID INPUT (Cold - blue connector)
: RETURN LIQUID (Hot - red connector)
5.3.2.4 Spool gun (single torch version only) (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. 6); 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).
- 7 -
CARRYING OUT THE FOLLOWING
2
mixture, screw the pressure reducer(*) onto
2
) according