Introduction And General Description; Technical Data - Telwin Supermig 480 Serie Manual De Instrucciones

- Welding MUST NOT be allowed if the welding machine or wire feeder is
supported by the operator (e.g. using belts).
- 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 different electrode holders or torches, the value of which
may reach double the allowed limit.
An expert coordinator must use measuring instruments to determine the
existence of a risk and should take suitable protection measures as detailed in
5.9 of the "IEC TECHNICAL SPECIFICATION or CLC/TS 62081".
RESIDUAL RISKS
- OVERTURNING: position the welding machine on a horizontal surface that is
able to support the weight: otherwise (e.g. inclined or uneven floors etc.) there
is danger of overturning.
- 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).
- MOVING THE WELDING MACHINE: Always secure the gas bottle, taking
suitable precautions so that it cannot fall accidentally.
The safety guards and moving parts covers of the welding machine and of the
wire feeder should be in their proper positions before connecting the welding
machine to the power supply.
WARNING! Any manual operation carried out on the moving parts of the wire
feeder, for example:
- Replacing rollers and/or the wire guide
- Inserting wire in the rollers
- Loading the wire reel
- Cleaning the rollers, the gears and the area underneath them
- Lubricating the gears
SHOULD BE CARRIED OUT WITH THE WELDING MACHINE SWITCHED OFF AND
DISCONNECTED FROM THE POWER SUPPLY OUTLET.
• Never lift the welding machine.

2. INTRODUCTION AND GENERAL DESCRIPTION

2.1 INTRODUCTION
This welding machine is made up by a current power supply and by a separate wire
feeder that is connected to it by a cable bundle. The power source consists of three-
phase, constant voltage power supply rectifier with step adjustment and with reactance
multi-sockets. The wire feeder is equipped with a 4-roller feeding unit.
In the R.A. version, the wire feeder is equipped with piping and fittings for connecting
the water-cooled torch to the cooling unit.
2.2 MAIN CHARACTERISTICS
- Spot-welding timing adjustment.
- 2T/4T operation, Spot (version with I max = 420A, 550A).
- Wire up-slope adjustment, final wire burn-back (version with I max = 420A, 550A).
- Thermostatic safeguard.
- Protection for insufficient water pressure (only for R.A. version).
2.3 WELDABILITY OF MATERIALS
The welding machine is suitable for MAG welding of carbon or mild steels using CO
shielding gas and Ar/CO or Ar/CO /O mixtures (Ar-Argon generally >80%) with both
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flux core and tubular wire.
It is possible to use tubular wire without shielding gas (self-shielding gas) by adjusting
torch polarity according to the wire manufacturer's instructions.
For MAG welding of stainless steel, similar methods are use to those for carbon steel,
while it is necessary to use flux core or tubular wire identical to or compatible with the
base material and mixtures of Ar/O or Ar/CO shielding gas (Ar generally > 98%).
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MIG welding of aluminium and its alloys should be carried out using wires with a
composition that is compatible with the material to be welded using pure Ar (99.9%) as
shielding gas.
MIG brazing, typically, can be carried out on galvanised plate with copper alloy wires
(e.g. copper-silicon or copper-aluminium) with pure Ar (99.9%) shielding gas.
2.4 STANDARD ACCESSORIES
- ARGON cylinder adapter.
- Cable and earth clamp.
- Gas regulator 2 manometers.
- G.R.A. water cooling unit
(just for the R.A. version).
- MIG torch
(water-cooled in the R.A. version).
- Wire feeder.
2.5 OPTIONAL ACCESSORIES
- G.R.A. water cooling unit
(standard accessory on the R.A. models).
- Torch holder mobile arm kit.
- Connection cables kit for the R.A. models 4m, 10m and 30m.
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2
2
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- Connection cables kit 4m and 10m.
- Reel cover kit.
- Double timing electronic board (version with I max = 350A).
- Voltmeter ammeter board (optional for version with I max = 420A, 550A).
- Wire feeder wheel kit.
- Aluminium welding kit.
- 5m MIG torch 350A, 500A.
- 3m MIG torch 500A R.A.
(standard accessory on the R.A. models).
- 5m MIG torch 500A R.A.

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 can
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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
: : Effective current supplied.
- I
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: see table 1 (TAB.1)
- TORCH: see table 2 (TAB.2)
- WIRE FEEDER: see table 3 (TAB.3)
The welding machine's weight is specified in table 1 (TAB.1)
4. WELDING MACHINE DESCRIPTION
4.1 CONTROL, ADJUSTMENT AND CONNECTION DEVICES
4.1.1 Welding machine (FIG. B)
front side:
1- Main switch with pilot lamp.
2- Arc voltage step adjustment.
3- Fuse.
4- Negative polarity quick-latches, corresponding to different reactance levels, for
connecting the earth cable.
5- Thermostat-tripping pilot lamp.
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6- Pilot lamp for the tripping of the torch cooling circuit's insufficient pressure
protection.
rear side:
7- Welding current cable exit.
8- Control cable exit.
9- Water cooling unit fuse.
10- Entry of power supply cable with cable clamp.
11- 5p connector for water cooling unit.
4.1.2 Wire feeder (FIG. C)
front side:
1- Wire feeding speed.
2- Thermostat tripping pilot lamp.
3- Welding time.
4- Torch function selector pushbutton (2T-4T).
5- Solenoid valve active pilot light.
6- Torch quick latch connector.
7- Quick latch fittings for torch water piping (only R.A. version).
rear side:
8- Low voltage fuse.
9- Gas pipe fitting.
10- Positive polarity quick latch.
11- 14-pole connector for control cable
inner side: (only versions with I max = 420A, 550A)
12- Wire speed up slope adjustment.
13- Final wire burn back adjustment.
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