Telwin Force 168 MPGE [5/84] ______________________________________________
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Telwin Force 168 MPGE [5/84] ______________________________________________

Telwin Force 125 [5/84] ______________________________________________
3- Symbol S: indicates that welding operations may be carried out in
environments with heightened risk of electric shock (e.g. very
CONTROL, REGULATION AND CONNECTION DEVICES
close to large metallic volumes).
WELDING MACHINE
4- Symbol for welding procedure provided.
Front Panel
5- Symbol for internal structure of the welding machine.
Fig. C
6- EUROPEAN standard of reference, for safety and construction of
1 - Positive quick plug (+) to connect welding cable.
arc welding machines.
2 - YELLOW LED: normally off, when ON it means that the welding
7- Manufacturer's serial number for welding machine identification
current cannot flow due to one of the following faults:
(indispensable for technical assistance, requesting spare parts,
- Thermal protection: inside the machine the temperature is
discovering product origin).
excessive. The machine is ON but does not deliver current until
8- Performance of the welding circuit:
a normal temperature is reached. Once this happens the re-
- U : maximum no-load voltage.
start is automatic.
0
- Mains over/undervoltage protection: the machine is blocked:
- I /U : current and corresponding normalised voltage that the
2 2
the power supply voltage is 15% above or below the rating plate
welding machine can supply during welding
value. WARNING: Exceeding the upper voltage limit, as
- X : Duty cycle: indicates the time for which the welding machine
above, will cause serious damage to the device.
can supply the corresponding current (same column). It is
- ANTI STICK protection: automatically shuts down the welding
expressed as %, based on a 10 minutes cycle (e.g. 60% = 6
machine if the electrode sticks to the material being welded so
minutes working, 4 minutes pause, and so on).
that it can be removed manually without damaging the
If the usage factors (on the plate, referring to a 40°C
electrode holder clamp.
environment) are exceeded, the thermal safeguard will trigger
3- GREEN LED : Connection to the mains, machine ready to work.
(the welding machine will remain in stand-by until its
4 - Potentiometer to regulate welding current with graduated scale in
temperature returns within the allowed limits).
Amps, which also allows regulation during welding.
- A/V-A/V: shows the range of adjustment for the welding current
(The “DUAL VOLTAGE AUTOMATIC” model has a double
(minimum-maximum) at the corresponding arc voltage.
graduated Ampere scale).
9- Technical specifications for power supply line:
5 - Negative quick plug (-) to connect welding cable.
- U : Alternating voltage and power supply frequency of welding
1
machine (allowed limit ±10%):
Back panel
- I : Maximum current absorbed by the line.
1 max
Fig. D
- I : effective current supplied.
1eff
1 - Mains cable with E.E.C. 2p plug + (W).
10- : Size of delayed action fuses to be used to protect the
(For the “DUAL VOLTAGE AUTOMATIC” model the cable has no
power line.
plug).
11- Symbols referring to safety regulations, whose meaning is given in
2 - General luminous switch O/OFF - I/ON.
chapter 1 “General safety considerations for arc welding”.
Note: The data plate shown above is an example to give the meaning
5. INSTALLATION
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.
WARNING! CARRY OUT ALL INSTALLATION OPERATIONS
AND ELECTRICAL CONNECTIONS WITH THE WELDING
OTHER TECHNICAL DATA
MACHINE COMPLETELY SWITCHED OFF AND DISCONNECTED
- WELDING MACHINE:
- see table 1 (TAB.1)
FROM THE POWER SUPPLY OUTLET.
- %USE AT 20°C (if present on the top cover of the welding
THE ELECTRICAL CONNECTIONS MUST BE MADE ONLY AND
machine)
EXCLUSIVELY BY AUTHORISED OR QUALIFIED PERSONNEL.
________________________________________________________________________________
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
PREPARATION
each electrode change; this datum is given also in percentage
Unpack the welding machine, assemble the separate parts contained
(%USE) which is the value in comparison with the maximum
in the package.
number of weldable electrodes.
Assembling the return cable-clamp
- ELECTRODE HOLDER CLAMP: see table 2 (TAB.2)
Fig. E
The weight of the welding machine is given in the table 1 (TAB.1)
Assembling the welding cable-electrode holder clamp
4. DESCRIPTION OF THE WELDING MACHINE
Fig. F
The unit is comprised of power modules which have been developed
on a specially printed circuit designed to maximise reliability and
HOW TO LIFT THE WELDING MACHINE
reduce maintainance.
All the welding machines described in this handbook should be lifted
Fig. B
using the handle or strap supplied if provided for the particular model
1 - Mains input (single phase), rectifier unit and condenser.
(fitted as described in FIG. L).
2 - Transistors and drivers switching bridge (IGBT).
It turns the mains rectified voltage into high frequency alternate
POSITION OF THE WELDING MACHINE
voltage and permits power regulation according to the
Choose the place to install the welding machine so that the cooling air
current/voltage of the weld to be done.
inlets and outlets are not obstructed (forced circulation by fan, if
present); at the same time make sure that conductive dusts, corrosive
3 - High frequency transformer: the primary windings are fed by the
vapours, humidity etc. will not be sucked into the machine.
voltage converted by Block 2, it has the function of adapting
Leave at least 250mm free space around the welding machine.
voltage and current to the values required by the arc welding
procedure and, simultaneously, isolates the welding circuit from
______________________________________________
the mains.
4 - Secondary rectifier bridge with inductance: this changes the
WARNING! Position the welding machine on a flat surface
alternate voltage/current supplied by the secondary windings into
with sufficient carrying capacity for its weight, to prevent it from
continuous current/voltage at a low wave-length.
tipping or moving hazardously.
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.
CONNECTION TO THE MAIN POWER SUPPLY
Determines the dynamic response of the current while the
- Before making any electrical connection, make sure the rating data
electrode melts (instantaneous short circuits), and supervises
of the welding machine correspond to the mains voltage and
the safety systems.
frequency available at the place of installation.
- The welding machine should only be connected to a power supply
The "DUAL VOLTAGE AUTOMATIC" model has a device that
system with the neutral conductor connected to earth.
automatically recognises the power supply voltage (115V AC- 230V
- To ensure protection against indirect contact use residual current
AC) and sets up the machine for correct operation.
devices of the following types:
The user will be able to understand whether the machine power
supply is 115V AC or 230V AC from the colour of the LED (Fig C (3)).
- Type A ( ) for single phase machines;
- GREEN LED shows that the machine is connected to a 230V AC
power supply.
- Type B ( ) for 3-phase machines.
- ORANGE LED shows that the machine is connected to a 115V AC
- To comply with the requirements of the EN 61000-3-11 (Flicker)
power supply.
standard we recommend connecting the welding machine to
During operation at 115V AC it is possible that prolonged and
interface points of the power supply that have an impedance of less
sizeable voltage surges will cause the machine to switch to
than Zmax =0.24 ohm.
230V AC operation for safety.
- the welding machine does not fall within the requisites of IEC/EN
In such circumstances, to resume welding, the machine must
61000-3-12 standard.
be switched off and on again.
Should it be connected to a public mains system, it is the installer's
Wait until the LED (Fig.C(3)) has gone out completely before
responsibility to verify that the welding machine itself is suitable for
switching on again.
- 5 -

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