Telwin 954009 - General Safety Considerations for Arc Welding

- 5 -
CONTINUOUSWIREWELDINGMACHINESFORMIG-MAGANDFLUXTIG,MMA
ARCWELDINGDESIGNEDFORPROFESSIONALANDINDUSTRIALUSE.
Note:Inthefollowingtexttheterm“weldingmachine”willbeused.
1.GENERALSAFETYCONSIDERATIONSFORARCWELDING
The operator should be properly trained to use the welding machine safely
and should be informed about the risks related to arc welding procedures, the
associated protection measures and emergency procedures.
(Pleaserefertotheapplicablestandard“EN60974-9:Arcweldingequipment.
Part9:InstallationandUse).
- Avoiddirectcontactwiththeweldingcircuit:theno-loadvoltagesuppliedby
the welding machine can be dangerous under certain circumstances.
- When the welding cables are being connected or checks and repairs are
carried out the welding machine should be switched off and disconnected
from the power supply outlet.
- Switch off the welding machine and disconnect it from the power supply
outlet before replacing consumable torch parts.
- Make the electrical connections and installation according to the safety rules
and legislation in force.
- The welding machine should be connected only and exclusively to a power
source with the neutral lead connected to earth.
- Make sure that the power supply plug is correctly connected to the earth
protection outlet.
- Do not use the welding machine in damp or wet places and do not weld in the
rain.
- Do not use cables with worn insulation or loose connections.
- Iftheweldingmachinehasaliquidcoolingunitthellingoperationsshould
be carried out with the welding machine switched off and disconnected from
the power supply outlet.
- Donotweldoncontainersorpipingthatcontainsorhascontainedammable
liquid or gaseous products.
- Do not operate on materials cleaned with chlorinated solvents or near such
substances.
- Do not weld on containers under pressure.
- Removeallammablematerials(e.g.wood,paper,ragsetc.)fromtheworking
area.
- Provide adequate ventilation or facilities for the removal of welding fumes near
the arc; a systematic approach is needed in evaluating the exposure limits for
the welding fumes, which will depend on their composition, concentration
and the length of exposure itself.
- Keep the gas bottle (if used) away from heat sources, including direct sunlight.
- Use electric insulation that is suitable for the torch, the workpiece and any
metal parts that may be placed on the ground and nearby (accessible).
This can normally be done by wearing gloves, footwear, head protection and
clothing that are suitable for the purpose and by using insulating boards or
mats.
- Alwaysprotectyoureyeswiththerelativelters,whichmustcomplywithUNI
EN169orUNIEN379,mountedonmasksorusehelmetsthatcomplywithUNI
EN 175.
 Use the relative re-resistant clothing (compliant with UNI EN 11611) and
weldinggloves(compliantwithUNIEN12477)withoutexposingtheskintothe
ultraviolet and infrared rays produced by the arc; the protection must extend
to other people who are near the arc by way of screens or non-reective
sheets.
- Noise:Ifthedailypersonalnoiseexposure(LEPd)isequaltoorhigherthan85
dB(A) because of particularly intensive welding operations, suitable personal
protective means must be used (Tab. 1).
- The ow of the welding current generates electromagnetic elds (EMF)
around the welding circuit.
Electromagneticeldscaninterferewithcertainmedicalequipment(e.g.Pace-
makers, respiratory equipment, metallic prostheses etc.).
Adequate protective measures must be adopted for persons with these types of
medical apparatus. For example, they must be forbidden access to the area in
which welding machines are in operation.
This welding machine conforms to technical product standards for exclusive
use in an industrial environment for professional purposes. It does not assure
compliance with the basic limits relative to human exposure to electromagnetic
eldsinthedomesticenvironment.
The operator must adopt the following procedures in order to reduce exposure
toelectromagneticelds:
- Fasten the two welding cables as close together as possible.
- Keep head and trunk as far away as possible from the welding circuit.
- Never wind welding cables around the body.
- Avoid welding with the body within the welding circuit. Keep both cables on
the same side of the body.
- Connect the welding current return cable to the piece being welded, as close
aspossibletotheweldingjoint.
- Do not weld while close to, sitting on or leaning against the welding machine
(keepatleast50cmawayfromit).
- Do not leave objects in ferromagneticmaterialinproximityof the welding
circuit.
- Minimumdistanced:20cm(Fig.N).
- ClassAequipment:
This welding machine conforms to technical product standards for exclusive
use in an industrial environment and for professional purposes. It does not
assure compliance with electromagnetic compatibility in domestic dwellings
and in premises directly connected to a low-voltage power supply system
feeding buildings for domestic use.
EXTRA PRECAUTIONS
-WELDINGOPERATIONS:
- In environments with increased riskof electric shock
 -Inconnedspaces
 -Inthepresenceofammableorexplosivematerials
ENGLISH
INDEX
1.GENERALSAFETYCONSIDERATIONSFORARCWELDING ....................................................................5
2.INTRODUCTIONANDGENERALDESCRIPTION .........................................................................................6
2.1 INTRODUCTION........................................................................................................................................6
2.2 METAL WELDABILITY ............................................................................................................................... 6
2.3 STANDARD ACCESSORIES ..................................................................................................................... 6
2.4 OPTIONAL ACCESSORIES ......................................................................................................................6
3. TECHNICAL DATA...........................................................................................................................................6
3.1 DATA PLATE (FIG. A).................................................................................................................................6
3.2 OTHER TECHNICAL DATA .......................................................................................................................6
4.DESCRIPTIONOFTHEWELDINGMACHINE .............................................................................................. 6
4.1 CONTROL DEVICES, ADJUSTMENT AND CONNECTION (FIG. B)........................................................6
4.1.1 Welding machine with integrated wire feed ......................................................................................6
4.2 WELDING MACHINE CONTROL PANEL (FIG. C) .................................................................................... 6
4.3 RECALLING AND STORING PROGRAMS ...............................................................................................8
4.3.1 RECALLING MANUFACTURER’S PRE-STORED PROGRAMS ....................................................8
4.3.1.1 MIG-MAG SYNERGIC programs .........................................................................................8
4.3.1.2 OPERATION IN MANUAL MODE (“PRG 0”) ........................................................................8
4.3.2 STORING AND RECALLING CUSTOMISED MIG-MAG PROGRAMS ...........................................8
4.3.2.1 Introduction ...........................................................................................................................8
4.3.2.2 Storage capacity for customised MIG-MAG programs .........................................................8
4.3.2.3 Storage procedure (SAVE) ................................................................................................... 8
4.3.2.4 Procedure for recalling a customised program (RECALL) ...................................................8
5. INSTALLATION ................................................................................................................................................8
5.1 PREPARATION .......................................................................................................................................... 8
5.2 HOW TO LIFT THE WELDING MACHINE (FIG. E) ................................................................................... 8
5.3 POSITION OF THE WELDING MACHINE ................................................................................................8
5.4 CONNECTION TO THE MAIN POWER SUPPLY .....................................................................................8
5.4.1 Note .................................................................................................................................................. 8
5.4.2 Plug and outlet ..................................................................................................................................8
5.5 CONNECTION OF THE WELDING CABLES ........................................................................................... 8
5.5.1 MIG-MAG WIRE WELDING (FIG.F) .................................................................................................8
5.5.1.1 Connecting the gas bottle .....................................................................................................8
5.5.1.2 Connecting the torch ............................................................................................................8
5.5.1.3 Connecting the welding current return cable ........................................................................8
5.5.2 TIG WELDING (FIG. G) ....................................................................................................................8
5.5.2.1 Connection to the gas bottle .................................................................................................8
5.5.2.2 Connecting the welding current return cable ........................................................................8
5.5.2.3 Connecting the torch ............................................................................................................8
5.5.3 MMA WELDING WITH COATED ELECTRODE (FIG. H) .................................................................8
5.5.3.1 Connecting the electrode-holder clamp ................................................................................8
5.5.3.2 Connecting the welding current return cable ........................................................................9
5.5.4 WARNINGS ...................................................................................................................................... 9
5.6 LOADING THE WIRE REEL (FIG. I) ..........................................................................................................9
5.7 REPLACING THE LINER IN THE TORCH (FIG. N) ..................................................................................9
5.7.1 Coiled hose for steel wires ...............................................................................................................9
5.7.2 Synthetic hose for aluminium wires .................................................................................................. 9
6.WELDING:DESCRIPTIONOFTHEPROCEDURE ........................................................................................9
6.1 MIG-MAG WELDING .................................................................................................................................9
6.1.1 SHORT ARC TRANSFER MODE .....................................................................................................9
6.1.1.1 ROOT MIG TRANSFER MODE ...........................................................................................9
6.1.2 SPRAY ARC TRANSFER MODE .....................................................................................................9
6.1.3 PULSE ARC TRANSFER MODE .....................................................................................................9
6.1.4 ADJUSTING THE WELDING PARAMETERS IN MIG-MAG ............................................................9
6.1.4.1 Protective gas ......................................................................................................................9
6.1.4.2 Welding current ..................................................................................................................10
6.1.4.3 Arc voltage and arc pinch-off .............................................................................................. 10
6.1.5 BI-LEVEL AND PULSE ON PULSE OPERATION .......................................................................... 10
6.2 TIG (DC) WELDING ................................................................................................................................. 10
6.2.1 LIFT strike .......................................................................................................................................10
6.3 MMA WELDING WITH COATED ELECTRODES ....................................................................................10
6.4 WELD QUALITY ......................................................................................................................................10
7. MAINTENANCE ............................................................................................................................................ 10
7.1 ROUTINE MAINTENANCE ......................................................................................................................10
7.1.1 Torch ............................................................................................................................................... 10
7.1.2 Wire feeder ..................................................................................................................................... 10
7.2 EXTRAORDINARY MAINTENANCE .......................................................................................................10
8.TROUBLESHOOTING(TAB.8) .....................................................................................................................10
page page