Telwin ADVANCE 227 MV/PFC TIG DC-LIFT VRD User manual

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(EN)
INSTRUCTION MANUAL
WARNING!BEFORE USING THE WELDING MACHINE READ THE
INSTRUCTION MANUAL CAREFULLY.
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 o
and disconnected from the power supply outlet.
- Switch o 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.
- 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 adequate electrical insulation with regard to the electrode, the
work piece and any (accessible) earthed metal parts in the vicinity.
This is normally achieved by wearing gloves, shoes, head coverings
and clothing designed for this purpose and by using insulating
platforms 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. I).
- 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 risk of electric shock
- In conned spaces
- In the presence of ammable or explosive materials
MUST BE evaluated in advance by an“Expert supervisor”and must
always be carried out in the presence of other people trained to
intervene in emergencies.
All protective technical measures MUST be taken as provided in
7.10;A.8;A.10 of the applicable standard EN 60974-9:Arc welding
equipment. Part 9:Installation and Use”.
- The operator MUST NOT BE ALLOWED to weld in raised positions
unless safety platforms are used.
- VOLTAGE BETWEEN ELECTRODE HOLDERS OR TORCHES:working
with more than one welding machine on a single piece or on
pieces that are connected electrically may generate a dangerous
accumulation of no-load voltage between two dierent electrode
holders or torches, the value of which may reach double the
allowed limit.
An expert coordinator must be designated to measuring the
apparatus to determine if any risks subsist and suitable protection
measures can be adopted, as foreseen by section 7.9 of the
applicable standard “EN 60974-9:Arc welding equipment. Part 9:
Installation and Use”.
RESIDUAL RISKS
- IMPROPER USE:it is hazardous to use the welding machine for any
work other than that for which it was designed (e.g. de-icing mains
water pipes).
- Do not use the handle to hang the welding machine.
2. INTRODUCTION AND GENERAL DESCRIPTION
This welding machine is a power source for arc welding, made specically
for direct current (DC) .
The specic characteristics of this regulation system (INVERTER), i.e. high
speed and precise regulation, mean the welding machine gives excellent
results when welding both with coated electrodes (rutile, acid, basic).
Regulation with the “inverter” system at the input of the power supply

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line (primary) means there is a drastic reduction in the volume of both the
transformer and the levelling reactance. This allows the construction of a
welding machine with extremely reduced weight and volume, enhancing
its advantages of easy handling and transportation.
ACCESSORIES SUPPLIED ON REQUEST:
- MMA welding kit.
- TIG welding kit.
3. TECHNICAL DATA
DATA PLATE
The most important data regarding use and performance of the welding
machine are summarised on the rating plate and have the following
meaning:
Fig. A
1- Protection rating of the covering.
2- Symbol for power supply line:
1~: single 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 identication
(indispensable for technical assistance, requesting spare parts,
discovering product origin).
8- Performance of the welding circuit:
- U0:maximum no-load voltage.
- I2/U2:current and corresponding normalised voltage that the
welding machine 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 stand-by 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 specications for power supply line:
- U1:Alternating voltage and power supply frequency of welding
machine (allowed limit ±10%):
- I1 max:Maximum current absorbed by the line.
- I1e:eective current supplied.
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.
OTHER TECHNICAL DATA
- WELDING MACHINE:
- see table 1 (TAB.1)
- %USE AT 20°C (if present on the top cover of the welding machine)
USE AT 20°C, it gives, for each diameter (Ø ELECTRODE), the number
of weldable electrodes within an interval of 10 minutes (ELECTRODES
10 MIN) at 20°C with a pause of 20 seconds for each electrode change;
this datum is given also in percentage (%USE) which is the value in
comparison with the maximum number of weldable electrodes.
- ELECTRODE HOLDER CLAMP:see table 2 (TAB.2)
The weight of the welding machine is given in the table 1 (TAB.1)
4. DESCRIPTION OF THEWELDING MACHINE
The unit is comprised of power modules which have been developed on
a specially printed circuit designed to maximise reliability and reduce
maintainance.
Fig. B
1- Power supply input (1~), rectier group and balancing capacitors.
2- Transistors and drivers switching bridge (IGBT).
It turns the mains rectied voltage into high frequency alternate
voltage and permits power regulation according to the current/
voltage of the weld to be done.
3- High frequency transformer: the primary windings are fed by the
voltage converted by Block 2, it has the function of adapting voltage
and current to the values required by the arc welding procedure and,
simultaneously, isolates the welding circuit from the mains.
4- Secondary rectier bridge with inductance: this changes the
alternate voltage/current supplied by the secondary windings into
continuous current/voltage at a low wave-length.
5- Electronic and regulation board: this instantly checks the value of the
welding current against that selected by the user, it modulates the
commands of the IGBT drivers, which control Regulation. Determines
the dynamic response of the current while the electrode melts
(instantaneous short circuits), and supervises the safety systems.
CONTROL, ADJUSTMENT AND CONNECTION DEVICES
WELDING MACHINE
at the front:
Fig. C
1- Encoder (1) selection and adjustment of the welding parameters; it
enables adjustment even during welding.
Operating modes and parameters:
- First function on short press of encoder (1):
In MMA selection and setting of ARC “Arc Force” HOT “Hot
Start”and I2“output current”.
- Second function on prolonged press of encoder (1):
After prolonged pressing, selection takes place via encoder (1)
among MMA, MMA VRD and TIG LIFT cyclically with ashing
indication on the display (2) of the mode.
To exit this adjustment procedure, encoder pressing is necessary.
Hot Start (on display““):
Adjustment parameter of the initial overcurrent (adjustment
0-100%); the display shows the percentage increase as to the value
of the pre-selected welding current. This adjustment facilitates the
electric arc strike.
Arc Force (on display“”):
Adjustment parameter of the dynamic overcurrent (adjustment
0-100%); the display shows the percentage increase as to the value
of the pre-selected welding current. This setting improves welding
uidity and prevents the electrode from sticking to the metal piece.
VRD (on display“”):
Reduction device of the loadless output voltage (on-o selection)
with indication on the display (2). The VRD device is enabled if the
“VRD” icon appears on the display, the device is not active without
the icon.
This device increases operator safety when the welding machine is
on but not in the welding mode.
RESET PARAMETERS:
For this specic function, you can access it keeping the encoder (1)
pressed during start-up of the welding machine (with main switch
closure).
Switching on and keeping the encoder selection (1) pressed, the
Reset mode activates and RES OFF is displayed, rotating the encoder
(1) you alternatively select ON / OFF.
You can exit this selection/setting by prolonged pressing the
encoder selection (1), conrming selection of Reset and therefore
with start-up of the board.
Instead, with a single, short press of the encoder selection (1), you
enter the setting menu of the current ranges where you can set the
current reduction class (CL1 high current, CL2 low current), rotating
the encoder (1) you alternatively select CL1/CL2.
To conrm and start the board, prolonged press the encoder
selection (1).
2- Display:
:
It indicates output voltage on quick couplings (3) and (4).
Alarm icon “ ”: normally o, when on it indicates the welding
machine is blocked (the machine remains on without supplying
power) due to intervention of one of the following guards:
- Protection against line overvoltage:the voltage is outside the
range +/- 15% compared to the plate value. Alarm on display
“AL.3”.
- Protection against line undervoltage:the voltage is outside
the range +/- 15% compared to the plate value. Alarm on display
“AL.4”.
ATTENTION:Exceeding the upper limit, stated above, will
seriously damage the device.
- ANTI STICK protection:the electrode is stuck to the material to

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weld, you can remove it manually.
Resetting to normal is automatic.
- Alarm icon ” ” +thermal protection icon ” ”: an excess
temperature has been reached inside the welding machine.
Resetting to normal operation is automatic. Alarm on display
“AL.2”.
3- Negative (-) quick coupling for connecting the welding cable.
4- Positive (+) quick coupling for connecting the welding cable.
Back panel
Fig. D
1- Mains cable with E.E.C. 2p plug + ( ).
(For the“DUAL VOLTAGE AUTOMATIC” model the cable has no plug).
2- General luminous switch O/OFF - I/ON.
5. INSTALLATION
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.
PREPARATION
Unpack the welding machine, assemble the separate parts contained in
the package.
Assembling the return cable-clamp
Fig. E
Assembling the welding cable-electrode holder clamp
Fig. F
HOW TO LIFT THE WELDING MACHINE
All the welding machines described in this manual must be lifted using
the handle.
POSITION OF THEWELDING 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 at surface
with sucient carrying capacity for its weight, to prevent it from
tipping or moving hazardously.
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.
- To ensure protection against indirect contact use residual current
devices of the following types:
- Type A ( ) for single phase machines;
- Type B ( ) for 3-phase machines.
- 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 = 0.17 ohm (200A).
- the welding machine does not fall within the requisites of IEC/EN
61000-3-12 standard.
Should it be connected to a public mains system, it is the installer’s
responsibility to verify that the welding machine itself is suitable
for connecting to it (if necessary, consult the distribution network
company).
- Unless otherwise specied (MPGE), the welding machines are
compatible with power generating sets for voltage oscillations up to ±
15%.
For correct use, the power generating set must be brought to steady
conditions before being able to connect the inverter.
- PLUG AND OUTLET:
- The 230V model is tted at the factory with a power supply cable
and normalised plug, (2P + T) 16A/250V .
It can therefore be connected to a mains outlet tted 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.
- Forweldingmachines withouta plug(115/230V models), connect
a normalised plug (2P + T) - having sucient capacity- to the power
cable and prepare a mains outlet tted 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!Failure to observe the above rules will make the
(Class 1) safety system installed by the manufacturer ineective with
consequent serious risks to persons (e.g. electric shock) and objects
(e.g. re).
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 mm2) depending on the maximum current supplied by the welding
machine.
MMA WELDING
Almost all coated electrodes are connected to the positive pole (+) of
the power source; as an exception to the negative pole (-) for acid coated
electrodes.
WELDING OPERATIONS WITH DIRECT CURRENT
Connecting the electrode-holder clamp welding cable
On the end take a special terminal that is used to close the uncovered
part of the electrode.
This cable is connected to the terminal with the symbol (+).
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 (-).
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 eciency.
- 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.
6. MMA WELDING:PROCESS DESCRIPTION
- It is indispensable to refer to the electrode manufacturer's instructions
regarding the correct polarity and the optimal welding current
(generally, these instructions are outlined on the packaging of the
electrodes).
- Welding current is regulated to suit the diameter of the electrode being
used and the type of soldering to be performed; an example of the
currents used for the various electrode diameters can be seen below:

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Ø Electrode (mm) Welding current (A)
min. max.
1.6 25 50
2 40 80
2.5 60 110
3.2 80 160
4 120 200
- Remember that for the same diameter electrode, high levels of current
will be used for at welding, whilst lower current levels will be used for
vertical or overhead welding.
- The mechanical characteristics of the welded joint are determined by
the intensity of the selected current and also other welding parameters
such as the length of the arc, the operating speed and position, the
diameter and quality of the electrodes (to ensure correct conservation,
use special packaging or containers to store and protect the electrodes
against humidity).
Procedure:
- Keeping the mask IN FRONT OF YOUR FACE, rub the tip of the electrode
on the piece to be welded, moving as if striking a match; this is the most
correct method for igniting the arc.
ATTENTION:DO NOT TAP the electrode against the workpiece, which
could damage the coating and make arc striking dicult.
- As soon as the arc has struck, try to keep the electrode at a distance
from the workpiece that is equivalent to the diameter of the electrode
being used, and keep this distance as constant as possible while
welding; remember that the electrode angle while moving forward
must be approx. 20-30 degrees (Fig. G).
- At the end of the welding seam, take the electrode end slightly back as
to the forward direction, above the crater to ll it, then quickly lift the
electrode from the weld pool to switch o the arc.
ASPECTS OF THEWELDING SEAM
Fig. H
TIG WELDING:PROCESS DESCRIPTION
TIG welding is a welding procedure that takes advantage of the heat
produced by the electric arc which is struck, and maintained, between
an infusible electrode (Tungsten) and the piece to weld. The Tungsten
electrode is supported by a torch suitable for transmission of the welding
current and protecting the electrode itself and the welding bath from
atmospheric oxidation through an inert gas ow (normally Argon: Ar
99.5%) which exits the ceramic nozzle (FIG. L).
TIG DC welding is suitable for all types of low-alloy and high carbon steel,
and heavy metals such as copper, nickel, titanium and their alloys.
An electrode with 2% Cerium (grey band) is normally used for TIG DC
welding with electrode at the (-) pole.
The tungsten electrode must be axially sharpened using a grinding
wheel, see FIG. M; make sure the tip is perfectly concentric to prevent
arc deviation. The electrode must be ground along its length. This
operation must be repeated periodically according to the use and wear
state of the electrode, or when the electrode itself has been accidentally
contaminated, oxidised or used incorrectly.
For the welding to be good, the exact diameter of the electrode must be
used with the exact current, see table (TAB. 3).
The electrode normally projects from the ceramic nozzle by 2-3 mm, but
can reach 8 mm for welding edges.
The weld is created by the edges that melt. Filler metal is not needed
when welding suitably prepared thin material (up to about 1 mm) (FIG.
N).
A greater thickness requires rods made from the same material as the
basic material and with a suitable diameter, with edges that have been
suitably prepared (FIG. O). For welding to be successful, the pieces must
be carefully cleaned and free from oxide, grease, oil, solvent, etc.
Procedure (LIFT strike)
- Use the knob to adjust the welding current to the required rate; adjust
this value during welding to adapt to the actual heat transfer required.
- Make sure the gas is owing correctly.
The arc ignites through contact, distancing the tungsten electrode
from the workpiece. This strike mode causes less electric-irradiated
disturbances and reduces tungsten inclusions and electrode wear to a
minimum, rest the tip of the electrode on the piece, with light pressure
and lift the electrode by 2-3mm with a few seconds delay, thereby
obtaining arc strike. Initially, the welding machine supplies current IBASE
and after a few seconds, the welding current set will be supplied.
- Quickly lift the electrode from the workpiece to interrupt welding.
7. MAINTENANCE
WARNING!BEFORE CARRYING OUT MAINTENANCE
OPERATIONS MAKE SURE THE WELDING MACHINE IS SWITCHED OFF
AND DISCONNECTED FROM THE MAIN POWER SUPPLY.
EXTRAORDINARY MAINTENANCE
EXTRAORDINARY MAINTENANCE MUST ONLY BE CARRIED OUT BY
TECHNICIANS WHO ARE EXPERT OR QUALIFIED IN THE ELECTRIC-
MECHANICAL FIELD, AND IN FULL RESPECT OF THE IEC/EN 60974-4
TECHNICAL DIRECTIVE.
WARNING!BEFORE REMOVING THE WELDING MACHINE
PANELS AND WORKING INSIDE THE MACHINE MAKE SURE THE
WELDING MACHINE IS SWITCHED OFF AND DISCONNECTED FROM
THE MAIN POWER SUPPLY OUTLET.
If checks are made inside the welding machine while it is live, this
may cause serious electric shock due to direct contact with live parts
and/or injury due to direct contact with moving parts.
- Inspect the welding machine regularly, with a frequency depending
on use and the dustiness of the environment, and remove the dust
deposited on the transformer, reactance and rectier using a jet of dry
compressed air (max. 10bar).
- Do not direct the jet of compressed air on the electronic boards; these
can be cleaned with a very soft brush or suitable solvents.
- At the same time make sure the electrical connections are tight and
check the wiring for damage to the insulation.
- At the end of these operations re-assemble the panels of the welding
machine and screw the fastening screws right down.
- Never, ever carry out welding operations while the welding machine is
open.
- After having carried out maintenance or repairs, restore the connections
and wiring as they were before, making sure they do not come into
contact with moving parts or parts that can reach high temperatures.
Tie all the wires as they were before, being careful to keep the high
voltage connections of the primary transformer separate from the low
voltage ones of the secondary transformer.
Use all the original washers and screws when closing the casing.
8. TROUBLESHOOTING
IN CASE OF UNSATISFACTORY FUNCTIONING, BEFORE SERVICING
MACHINE OR REQUESTING ASSISTANCE, CARRY OUT THE
FOLLOWING CHECK:
- Check that the welding current, which is regulated by the
potentiometer with a graduated amp scale, is correct for the diamter
and electrode type in use.
- Check that when general switch is ON the relative lamp is ON. If this is
not the case then the problem is located on the mains (cables, plugs,
outlets, fuses, etc.)
- Check that the yellow led (ie. thermal protection interruption- either
over or undervoltage or short circuit) is not lit.
- Check that the nominal intermittance ratio is correct. In case there is
a thermal protection interruption, wait for the machine to cool down,
check that the fan is working properly.
- Check the mains voltage: if the value is too high or too low the welding
machine will be stopped.
- Check that there is no short-circuit at the output of the machine: if this
is the case eliminate the incovenience.
- Check that all connections of the welding circuit are correct,
particularly that the work clamp is well attached to the workpiece, with
no interferring material or surface-coverings (ie. Paint).
- Protective gas must be of appropriate type (Argon 99.5%) and quantity.