Introduction And General Description; Technical Data - Telwin 953000 Bedienungsanleitung

2. INTRODUCTION AND GENERAL DESCRIPTION

2.1 INTRODUCTION
This welding machine is a power source for arc welding, made specifically for MMA
direct current (DC) welding with all coated electrodes and TIG-DC welding with LIFT
strike.
2.2 OPTIONAL ACCESSORIES
- MMA welding Kit.
- TIG welding torch.
- Argon gas bottle adapter.
- Pressure reducing valve with gauge.
- Self-darkening mask: with fixed and adjustable glass.
- Welding current return cable complete with earth terminal.

3. TECHNICAL DATA

3.1 DAT A PLATE (FIG. A)
The most important data regarding use and performance of the welding machine are
summarised on the rating plate and have the following meaning:
1- Protection rating of the covering.
2- Symbol for power supply line:
1~: single phase alternating voltage;
3~: three phase alternating voltage.
3- 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).
4- Symbol for welding procedure provided.
5- Symbol for internal structure of the welding machine.
6- EUROPEAN standard of reference, for safety and construction of arc welding
machines.
7- Manufacturer's serial number for welding machine identification (indispensable for
technical assistance, requesting spare parts, discovering product origin).
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 can
2 2
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 minutes
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- 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
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:
- ELECTRODE HOLDER CLAMP: see table (TAB.2)
4. DESCRIPTION OF THE WELDING MACHINE
This model is a constant current rectifier for arc welding, controlled by a transistor bridge
(IGBT).
The particular properties of this regulation system (INVERTER), such as high-speed,
precise adjustment, mean that the welding machine gives excellent quality when
welding with all coated electrodes (MMA) and in TIG-DC welding.
The inverter system of regulation at the power supply input (primary) also leads to a
great decrease in the volume of both the transformer and the levelling reactance so that
it is possible to build a considerably smaller, lighter welding machine, highlighting its
ease of handling and transport.
The welding machine consists basically of power modules made on PCB's, optimised to
achieve outstanding reliability and reduced maintenance.
Description (FIG. B)
1- Input: 3-phase power supply, rectifier unit and levelling capacitors.
2- Transistor switching bridge (IGBT) and drivers: commutes the rectified power
supply voltage to high frequency alternating voltage and adjusts the power
according to the required welding current/voltage.
3- High frequency transformer: the voltage converted by block 2 powers the primary
winding; its function is to adjust the voltage and current to the values needed for the
arc welding procedure and at the same time to form galvanic separation of the
welding circuit from the power supply line.
4- Secondary rectifier bridge with levelling inductance: commutes the alternating
voltage/current supplied by the secondary winding into very low ripple direct
current/voltage.
5- Control and adjustment electronics: they control the welding current value
instantaneously and compare it with the operator's setting; they modulate the control
impulses from the IGBT drivers that make the adjustment.
They determine the dynamic response of the current during electrode melting/fusion
(instantaneous short circuits) and supervise the safety systems.
4.1 CONTROL, ADJUSTMENT AND CONNECTION DEVICES
4.1.1 BACK PANEL (FIG. C)
1-Remote control connector:
- Manual remote control with one potentiometer.
- Manual remote control with two potentiometers.
- Pedal remote control.
2- Main switch O/OFF - I/ON.
3- Power supply cable 3P + (P.E).
4.1.2 FRONT PANEL (FIG. D)
1- Potentiometer for regulating arc-force and hot start: can be adjusted from 0%
minimum to 100% maximum. At the minimum values an optimal welding dynamic
(hot start) is obtained for "soft" electrodes (e.g. rutile, stainless steel), at high values
an optimal welding dynamic is obtained for "hard" electrodes (e.g. acid, basic,
cellulose).
2- Green LED: if the LED is on this shows the welding machine is powered. If it is off this
see table (TAB.1)
shows that the welding machine is not powered or that there is a fault in the
electronics.
3- Potentiometer for regulating welding current, with graduated scale in amps: can
also be used for adjustment during welding.
4 - Y ellow LED: normally off, when on it means that the welding machine has shut
down because one of the following safeguards has triggered:
- Thermal relay: the temperature inside the welding machine is too high. The
welding machine will remain switched on but will not supply current until a normal
temperature is reached. Reset is automatic.
- Main supply over- or under-voltage safeguard : shuts down the welding machine if
the main supply voltage is too high (greater than 460V ac) or too low (less than
330Vac).
- Short circuit safeguard : there has been a short circuit lasting longer than 1.5 sec
(electrode stuck to piece) and the welding machine is shut down. Reset is
automatic.
- Phase failure safeguard: there is a phase failure in the welding machine power
supply.
5- Function selector: used to select the desired welding procedure:
- MMA position for welding with electrode, consequently with adjustment of
cold start and arc force using control panel potentiometer (from 0 to 100%).
- TIG-LIFT position for TIG welding with LIFT start at 20A (without arc force
and cold start) and hence the ARC-FORCE potentiometer is disabled at the
control panel.
6- Negative quick connector (-) for connecting welding cable.
7- Positive quick connector (+) for connecting welding cable.
5. INSTALLATION
_____________________________________________________________________________________________________________________
WARNING! CARRY OUT ALL INSTALLATION OPERATIONS AND
ELECTRICAL CONNECTIONS WITH THE WELDING MACHINE COMPLETEL Y
SWITCHED OFF AND DISCONNECTED FROM THE POWER SUPPLY OUTLET .
THE ELECTRICAL CONNECTIONS MUST BE MADE ONLY AND EXCLUSIVEL Y BY
AUTHORISED OR QUALIFIED PERSONNEL
_____________________________________________________________________________________________________________________
5.1 PREPARATION (FIG. E)
Unpack the welding machine, assemble the separate parts contained in the
package.
5.1.1 Assembling the return cable-clamp
5.1.2 Assembling the welding cable-electrode holder clamp
5.2 HOW TO LIFT THE WELDING MACHINE
All the welding machines described in this manual should be lifted using the special belt
supplied with the machine (assembled as described in FIG.E).
5.3 POSITION OF THE WELDING MACHINE
Choose the place to install the welding machine so that the cooling air inlets and outlets
are not obstructed (forced circulation by fan, if present); at the same time make sure that
conductive dusts, corrosive vapours, humidity etc. will not be sucked into the machine.
Leave at least 250mm free space around the welding machine.
WARNING! Position the welding machine on a flat surface with sufficient
carrying capacity for its weight, to prevent it from tipping or moving hazardously.
5.4 CONNECTION TO THE MAIN POWER SUPPLY
- Before making any electrical connection, make sure the rating data of the welding
machine correspond to the mains voltage and frequency available at the place of
installation.
- The welding machine should only be connected to a power supply system with the
neutral conductor connected to earth.
5.4.1 Plug and outlet
Connect a normalised plug (3P + T) 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 1 (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! Failure to observe the above rules will make the (Class 1) safety
system installed by the manufacturer ineffective with consequent serious risks
to persons (e.g. electric shock) and objects (e.g. fire).
_____________________________________________________________________________________________________________________
5.5. CONNECTION OF THE WELDING CABLES
_____________________________________________________________________________________________________________________
WARNING! BEFORE MAKING THE FOLLOWING CONNECTIONS MAKE
SURE THE WELDING MACHINE IS SWITCHED OFF AND DISCONNECTED FROM
THE POWER SUPPLY OUTLET.
Table (TAB. 1) gives the recommended values for the welding cables (in mm )
depending on the maximum current supplied by the welding machine.
_____________________________________________________________________________________________________________________
5.5.1 MMA welding
Practically all coated electrodes are connected to the positive terminal (+) of the power
source, with the exception of acid-coated electrodes which are connected to the
negative terminal (-).
Connecting the electrode-holder clamp welding cable
- The terminal has a special clamp which is used to close the uncovered part of the
electrode.
Connecting the welding current return cable
- This is connected to the piece to be welded or to the metal bench on which it rests, as
close as possible to the joint being made.
5.5.2 TIG welding with LIFT start
- TIG Torch: the current-carrying cable should be connected to the negative terminal
(-).
- Earth return cable: this should be connected to the positive terminal (+); the earth
clamp at the other end should be connected to the piece to be welded or to a metal
bench, as close as possible to the joint being made.
- Connection to the protective gas bottle for TIG welding. Screw the pressure
reduction valve on to the bottle valve. Please note that the protective gas flow rate
(litres/minute) can only be regulated using the pressure control valve on the bottle.
Prepare the flexible pipe for feeding the protective gas to the torch. Open the manual
valve on the torch before welding and close it at the end of welding.
- 10 -
(FIG. F)
(FIG. G)
2