Telwin Supermig 480 Serie Manual De Instrucciones página 7

4.2 THERMAL SAFEGUARD (Fig. B-5, C-2)
The thermostatic safeguard pilot lamp switches on under overheating conditions,
interrupting the power supply; resetting takes place automatically after a few minutes
cooling off.
4.3 PROTECTION FOR INSUFFICIENT PRESSURE OF THE WATER COOLING
CIRCUIT (FIG. B-6)
The pilot lamp switches on under conditions of insufficient pressure of the water
cooling circuit. Under this condition, the welding machine does not provide power.
5. INSTALLATION
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WARNING! CARRY OUT ALL INSTALLATION OPERATIONS AND
ELECTRICAL CONNECTIONS WITH THE WELDING MACHINE COMPLETELY
SWITCHED OFF AND DISCONNECTED FROM THE POWER SUPPLY OUTLET.
THE ELECTRICAL CONNECTIONS MUST BE MADE ONLY AND EXCLUSIVELY BY
AUTHORISED OR QUALIFIED PERSONNEL.
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5.1 PREPARATION (FIG. D)
Unpack the welding machine, assemble the separate parts contained in the package.
5.2 HOW TO LIFT THE WELDING MACHINE
None of the welding machines described in this manual are equipped with a lifting
device.
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.
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WARNING! Position the welding machine on a flat surface with sufficient
carrying capacity for its weight, to prevent it from tipping or moving hazardously.
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5.4 CONNECTION TO THE MAIN POWER SUPPLY
5.4.1 Note
- 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.
- To comply with the requirements of the EN 61000-3-11 (Flicker) standard we
recommend connecting the welding machine to interface points of the power supply
that have an impedance of less than Zmax = 0.02ohm.
- The welding machine falls within the requisites of IEC/EN 61000-3-12 standard.
5.4.2 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. The 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.
5.4.3 Voltage change (FIG. E)
To carry out voltage change operations(only the three phase version), take off the panel
to gain access to the inside of the machine, and prepare the voltage change terminal
board so that the connection indicated on the special indicator plate corresponds to the
available power supply voltage.
Reassemble the panel carefully using the appropriate screws.
Warning! In the factory the machine is set at the highest voltage of the available
range, e.g.
U 400V Ü Voltage setting at the factory.
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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).
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5.5 CONNECTION OF THE WELDING CABLES (FIG. F)
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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.
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5.5.1 Connection to the gas bottle
Gas bottle can be loaded on welding machine bottle support platform: max 60 kg.
- Screw the pressure reducing valve onto the gas bottle valve, inserting the appropriate
adapter supplied as an accessory, for when the gas used is Argon or an
Argon /CO mixture.
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- Connect the gas inlet pipe to the pressure-reducing valve and tighten the band
supplied.
- Loosen the adjustment ring nut on the pressure-reducing valve before opening the
bottle valve.
5.5.2 Connection to the wire feeder
- Carry out the connections to the wire feeder (rear panel):
- welding current cable to quick connection (+);
- control cable to appropriate connector.
- Make sure the connectors are firmly tightened in order to prevent overheating and
loss of efficiency.
- Connect the gas pipe from the pressure-reducing valve on the bottle and lock it with
the clip supplied.
5.5.3 Connecting the welding current return cable
- This is connected to the piece being welded or to the metal bench supporting it, as
close as possible to the join being made.
- This cable is connected to the terminal with the symbol (-).
5.5.4 Connecting the torch
- Engage the torch with its dedicated connector by tightening the locking ring
manually as far down as it will go.
- Prepare the wire for loading the first time by dismantling the nozzle and the contact
tip to ease its exit.
5.5.5 Warnings
- Turn the welding cable connectors right down into the quick connections (if present),
to ensure a perfect electrical contact; otherwise the connectors themselves will
overheat, resulting in their rapid deterioration and loss of efficiency.
- The welding cables should be as short as possible.
- Do not use metal structures which are not part of the workpiece to substitute the
return cable of the welding current: this could jeopardise safety and result in poor
welding.
5.5.6 Connecting the water cooling unit (G.R.A). (only for the R.A. version) (FIG.
G1)
- Remove the top cover from the welding machine (1).
- Insert the G.R.A. (2).
- Attach the G.R.A. to the back using the screws supplied.
- Close the top cover on the welding machine (3).
- Connect the G.R.A. to the welding machine using the cable supplied.
- Connect the water pipes to the quick-release couplings.
- Switch on the G.R.A. following the procedure described in the handbook supplied
with the cooling unit.
WARNING: when the power supply outlet for the cooling unit is not used it is
necessary to insert the corresponding plug supplied with the welding machine
(excluding the version with I max=350A) (FIG. G2).
5.6 LOADING THE WIRE REEL (FIG. H1, H2)
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WARNING! BEFORE STARTING THE OPERATIONS TO LOAD THE WIRE
MAKE SURE THE WELDING MACHINE IS SWITCHED OFF AND DISCONNECTED
FROM THE MAIN POWER SUPPLY OUTLET.
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MAKE SURE THAT THE WIRE FEEDER ROLLERS, THE WIRE GUIDE HOSE AND
THE CONTACT TIP OF THE TORCH MATCH THE DIAMETER AND TYPE OF WIRE
TO BE USED AND MAKE SURE THAT THESE ARE FITTED CORRECTLY. WHEN
INSERTING AND THREADING THE WIRE DO NOT WEAR PROTECTIVE GLOVES.
- Position the wire reel on the spindle, holding the end of the wire upwards; make sure
the tab for pulling the spindle is correctly seated in its hole (1a).
- Release the pressure counter-rollers and move them away from the lower rollers
(2a);
- Make sure that the towing rollers is suited to the wire used (2b).
- Free the end of the wire and remove the distorted end with a clean cut and no burr;
turn the reel anti-clockwise and thread the end of the wire into the wire-guide infeed,
pushing it 50-100mm into the wire guide of the torch fitting (2c).
- Re-position the counter-rollers, adjusting the pressure to an intermediate value, and
make sure that the wire is correctly positioned in the groove of the lower rollers (3)
- Use the adjustment screw located at the centre of the spindle to apply a slight braking
pressure on the spindle itself (1b).
- Remove the nozzle and contact tip (4a).
- Insert the welding machine plug in the power supply outlet, switch on the welding
machine, press the torch button and wait for the end of the wire to pass through the
whole of the wire guide hose and protrude by 10-15 cm from the front part of the
torch, release the button.
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WARNING! During these operations the wire is live and subject to mechanical
stress; therefore if adequate precautions are not taken the wire could cause
hazardous electric shock, injury and striking of electric arcs:
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- Do not direct the mouthpiece of the torch towards parts of the body.
- Keep the torch away from the gas bottle.
- Re-fit the contact tip and the nozzle onto the torch (4b).
- Check that wire feed is regular; set the roller and spindle braking pressure to the
minimum possible values making sure that the wire does not slide in the groove and
when feed is halted the loops of wire are not loosened by excessive reel inertia.
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- Cut the end of the wire so that 10-15 mm protrude from the nozzle.
- Close the wire feeder door.
5.7 REPLACING THE LINER IN THE TORCH (FIG. I)
Before proceeding to replace the hose, lay out the torch cable straight without any
bends.
5.7.1 Coiled hose for steel wires
1- Unscrew the nozzle and contact tip on the torch head.
2- Unscrew the hose locking nut on the central connector and remove the old hose.
3- Insert the new hose into the cable-torch duct and push it gently until it comes out of
the torch head.
4- Tighten up the hose locking nut by hand.
5- Trim off all the excess protruding hose pressing it slightly; remove it from the torch
cable again.
6- Smooth the part where the hose was cut and reinsert it into the cable-torch duct.
7- Tighten up the nut again using a spanner.
8- Reassemble the contact tip and nozzle.
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