Installation - Telwin TIG DC Series Bedienungsanleitung

3. TECHNICAL DATA
3.1 DATA 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
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
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:
- TORCH:
The welding machine weight is shown in table 1 (TAB. 1).
4. WELDING MACHINE DESCRIPTION
4.1 BLOCK DIAGRAM
The welding machine basically consists of a combination of power and control
modules realised on circuit boards optimised to achieve maximum reliability and
reduced maintenance.
4.1.1 LIFT strike welding machine (FIG. B)
1- Single-phase power line input, rectifier group, power factor correction circuit (PFC
if foreseen) and levelling capacitors.
2- Transistor switching bridge (GBT) and drivers: switches the rectified power
supply voltage to high frequency AC voltage and regulates the output according to
the welding current/voltage required.
3- High frequency transformer: the primary winding is powered by the voltage
converted by block 2; this adapts the voltage and current to the frequency required
by the arc welding procedure while providing galvanised insulation of the welding
circuit from the power supply line.
4- Secondary rectifier bridge with levelling inductance: switches the voltage / AC
supplied by the secondary winding into extremely low wave DC voltage.
5- Control and adjustment electronics: instantly checks the welding current value
and compares it to the value set by the operator; it also modulates the command
pulses of the IGBT drivers that adjust the system.
6- Welding machine operating control logic: sets the welding cycles and monitors
the safety systems.
7- Control panel to set and view operating modes and parameters.
8- Welding machine cooling fan.
4.2 CONTROL, ADJUSTMENT AND CONNECTION DEVICES
4.2.1 COMPACT welding machine with LIFT strike
4.2.1.1 Front panel (FIG. C)
1- Buttons to set operating modes and parameters.
- Primary function: MMA or TIG selection
- Secondary function (press and hold in MMA mode): Hot Start, Arc Force and,
where applicable, VRD device enabling / disabling settings.
Rapid press-and-release of the button allows users to select the parameter to be
controlled by the encoder (5) with relative value indicated on the display (3).
Press and hold the button to exit this settings procedure.
Hot Start ("hot XX" on the display):
Initial overcurrent regulator setting ((from 0-100%) with the percentage increase
compared to the preset welding current value indicated on the display. This
setting facilitates the striking of the electric arc.
Arc Force ("arc XX" on the display):
Dynamic overcurrent regulator setting ((from 0-100%) with percentage increase
compared to the preset welding current value indicated on the display. This
setting improves welding fluidity and prevents the electrode from sticking to the
piece.
VRD ("vrd XX" on the display):
No-load voltage reduction device (ON-OFF switch) with device enabled "vrd
ON" and device disabled "vrd OFF" indications on the display (3). This device
increases safety levels for operators when the welding machine is ON but not in
the welding position.
Note: For models where programmed, 2 different settings of the maximum
available welding current can be selected.
CL.1: Setting with reduction of the maximum welding current (less power
available).
CL.2: Setting without reduction of the maximum welding current (more power
available).
This specific function can be accessed by holding down the selection pushbutton
when switching on the welding machine (with closure of the main switch).
CL.1 is set initially, and it is also possible to carry out a general reset of the
parameters (res ON/OFF).
The procedure can be exited as described previously.
2- Operating mode and parameter settings LEDs:
see table 1 (TAB. 1).
see table 2 (TAB. 2).
2a
Fixed LED: MMA mode enabled
Blinking LED: Arc Force, Hot Start, VRD adjustment (where applicable).
2b
Fixed LED: TIG mode enabled
3- Alphanumeric display
4- Yellow LED: OFF by default, when ON this indicates that the welding machine is
blocked, (the machine is ON without generating current) after one of the following
protection devices has been triggered:
- Thermal relay: the temperature inside the welding machine is too high. The
machine resets its standard default settings automatically. "AL.2" alarm on the
display.
- Line overvoltage and undervoltage safeguard: the voltage is +/- 15% higher
or lower than the rated value. "AL.1" alarm on the display.
WARNING: Exceeding the above indicated overcurrent threshold can cause
serious damage to the device.
- ANTI STICK protection: The electrode is stuck to the material to be welded; it
can be removed manually.
The machine resets its standard default settings automatically.
5- Encoder to adjust welding settings; adjustments can be carried out while welding
operations are in progress.
6- Negative quick connector (-) to connect the welding cable.
7- Positive quick connector (+) to connect the welding cable.
4.2.1.2 Rear panel (FIG. D)
1 - Power cable 2p + ( ).
2 - Main power switch O/OFF – I/ON (luminous).

5. INSTALLATION

WARNING! THE WELDING MACHINE MUST BE TURNED OFF
AND DISCONNECTED FROM THE MAINS BEFORE COMMENCING ANY
INSTALLATION AND POWER CONNECTION OPERATIONS.
ALL ELECTRICAL CONNECTIONS MUST BE EXCLUSIVELY PERFORMED BY
EXPERT OR QUALIFIED OPERATORS.
5.1 ASSEMBLY
5.1.1 Assembling the return cable-clamp (FIG. E)
5.1.2 Assembling the welding cable-electrode holder clamp (FIG. F)
5.2 WELDING MACHINE LIFTING PROCEDURES
All welding machines described in this manual must be lifted using the built-in handle.
5.3 WELDING MACHINE INSTALLATION POSITION
Before installing the welding machine, check there are no obstacles blocking the
cooling air input and output zones (fan powered forced ventilation); also check that
no conductive dust, corrosive fumes, humidity etc. can be sucked into the machine.
Make sure there is at least 250mm clearance space surrounding the welding machine.
WARNING ! Position the welding machine on a flat surface with a
suitable load capacity to prevent overturning or hazardous movements.
5.4 CONNECTING THE MACHINE TO THE MAINS
- Before making any electrical connections, check that the data on the welding
machine rating plate corresponds to the power supply current and frequency
available in the installation zone.
- The welding machine must only be connected to a power supply system with a
grounded neutral conductor.
- Use differential switches to ensure protection against indirect contact as follows:
- Type A ( ) for single-phase machines;
- In order to meet all EN 61000-3-11 (Flicker) Standard requirements, it is
recommended to connect the welding machine to the power supply interface
sockets that guarantee impedance of less than Zmax = 0.25 ohm (single phase).
- The welding machine does not meet IEC/EN 61000-3-12 Standard requirements
(models without PFC).
If it is connected to a public power grid, the installer or user is responsible for
checking that the welding machine can be safely connected (if in doubt, contact the
relative electricity board).
5.4.1 Plug and socket
- The single phase welding machines with absorbed current lower or equal to 16A are
supplied with a power cable fitted with a normalised plug (2P+T) 16A \ 250V .
- The single phase welding machines with absorbed current higher than 16A are
supplied with a power cable to be connected to a suitable normalised plug (2P+T).
Use a mains socket fitted with a fuse or circuit breaker; the relative earth lug must
be connected to the power supply protective ground wire (yellow-green).
- Table 1 (TAB.1) shows the recommended delayed fuse sizes, in amps, for the main
supply, which have been chosen according to the maximum rated current output
from the welding machine, and to the nominal power supply voltage
5.5 WELDING CIRCUIT CONNECTIONS
WARNING! THE WELDING MACHINE MUST BE TURNED OFF AND
DISCONNECTED FROM THE MAINS BEFORE COMMENCING ANY CONNECTION
OPERATIONS.
Table 1 (TAB.1) lists the recommended welding cable values (in mm
max rated current output of the welding machine.
5.5.1 TIG welding
Torch connection
- Insert the current power cable into the quick connect terminal (-). Connect the torch
gas pipe to the cylinder.
Connecting the welding current return cable
- To be connected to the piece being welded or to the metal workbench on which it is
positioned, as close as possible to the joint that is being made
This cable is to be connected to the terminal with the (+) symbol.
Connection to the gas bottle
- Screw the pressure reducing valve to the gas bottle valve divided, where necessary,
by a specific reducer supplied as an accessory.
- Connect the gas delivery pipe to the reducer valve and tighten the supplied clamp.
- Loosen the pressure reducer valve adjuster ring nut before opening the gas bottle
valve.
- Open the bottle and regulate the gas flow (l/min) according to the standard ratings
seen in the table (TAB. 3); this pressure reducer ring nut can also be used to tweak
the gas flow during welding operations. Check seal tightness on all pipes and
- 6 -
) according to the
2