Telwin DIGITAL SUPERMIG 490 SYNERGIC [6/132] Introduction and general description
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Telwin DIGITAL SUPERMIG 490 SYNERGIC [6/132] Introduction and general description

Telwin DIGITAL SUPERMIG 610 SYNERGIC [6/132] Introduction and general description
feeder, for example: 4.1.1 Welding machine (FIG.B)
- Replacing rollers and/or the wire guide on the front side:
- Inserting wire in the rollers 1- Main switch with indicator light.
- Loading the wire reel 2- Jogged adjustment of arc voltage.
- Cleaning the rollers, the gears and the area underneath them 3- Fuse.
- Lubricating the gears 4- Negative polarity quick connections, corresponding to different reactance levels, for
SHOULD BE CARRIED OUT WITH THE WELDING MACHINE SWITCHED OFF AND
connecting the earth cable.
DISCONNECTED FROM THE POWER SUPPLY OUTLET.
on the back side:
5- Welding current cable exit.
6- Control cable exit.
• Never lift the welding machine.
7- Water cooling unit fuse.
8- Power supply cable IN with cable lock.
2. INTRODUCTION AND GENERAL DESCRIPTION
9- 5-pin connector for water cooling unit.
2.1 INTRODUCTION
This welding machine consists of a power source and a separate wire feeder,
4.1.2 Wire feeder (FIG. C)
connected to it by a cable bundle. The power source is a constant voltage 3-phase
on the front side:
powered rectifier with jogged adjustment and multiple reactance outlets. The wire
1- Control panel (see description).
feeder is supplied with a 4-roller microprocessor-controlled wire feeder unit with the
2- 14-pin connector for spool gun connection.
possibility of automatic wire feed rate settings depending on the properties of the
3- Rapid connections for the MIG torch water pipes (just for the W.C. models).
material being welded, of the protective gas and of wire diameter.
4- Rapid connectors for the torch cable, EURO series.
This welding machine is designed for use with the SPOOL GUN torch, used for welding
on the back side:
aluminium and steel when the power source and piece to be welded are far apart.
5- Low voltage fuse.
In the R.A. (water-cooled) version the wire feeder is provided with pipes and couplings
6- Gas pipe connection.
for connecting the water-cooled torch to the cooling unit.
7- Positive polarity quick latch.
8- 14-pin connector for control cable.
2.2 MAIN FEATURES
- Power supply voltage monitor.
4.2 WIRE FEEDER CONTROL PANEL (FIG. D)
- Spot, 2/4-stroke operation.
1- GREEN LED: indicates that the welding machine is connected to the main supply
- Automatic torch recognition.
and is ready for operation.
- Regulation of wire slope up, post-gas time, wire burn-back time.
WARNING: Under faulty power supply conditions, the followingconditions will
- Storing/loading customised programmes
occur:
- Ready for use with SPOOL GUN torch.
- intermittent buzzer;
- Thermostatic safeguards.
- the display will show ALL UPP or ALL LOW.
- Safeguard for insufficient water pressure (only for the R.A. version).
We recommend switching the welder off to prevent it being damaged.
2- A : LED on: the display shows the welding current.
2.3 WELDABILITY OF MATERIALS
Intermittent LED: Wire feed rate up slope programming mode
The welding machine is suitable for MAG welding of carbon or mild steels using CO
2
shielding gas and Ar/CO or Ar/CO /O mixtures (Ar-Argon generally >80%) with both
2 2 2
3- m/min LED on: the display shows wire feed rate.
flux core and tubular wire.
Intermittent LED: Wire burn back time programming mode
It is possible to use tubular wire without shielding gas (self-shielding gas) by adjusting
torch polarity according to the wire manufacturer's instructions.
4- sec: LED on: the display shows spot welding time
For MAG welding of stainless steel, similar methods are use to those for carbon steel,
Intermittent LED: Post-gas time programming mode
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%).
2 2
5- PRG: LED on: the display is showing the user’s customised work programme.
MIG welding of aluminium and its alloys should be carried out using wires with a
6- 3-digit alphanumeric display. Shows:
composition that is compatible with the material to be welded using pure Ar (99.9%) as
a)
shielding gas.
- the welding current in amps. The value shown is the setting with the welding
MIG brazing, typically, can be carried out on galvanised plate with copper alloy wires
machine in no-load status, while it is the real value during operation.
(e.g. copper-silicon or copper-aluminium) with pure Ar (99.9%) shielding gas.
- wire feed rate in m/min.
- spot-welding time
2.4 STANDARD ACCESSORIES
- the user’s customised work programme number.
- ARGON cylinder adapter.
b) in programming mode:
- Cable and earth clamp.
- burn-back time
- Gas regulator 2 manometers.
- post-gas time
- G.R.A. water cooling unit
- wire feed rate slope up
(just for the R.A. version).
c) in the presence of alarms:
- MIG torch
- “ALL UP” : overvoltage safeguard on power line triggered.
(water-cooled in the R.A. version).
- “ALL LOU” : undervoltage safeguard on power line triggered.
- Wire feeder.
- “ALL thr” : Thermal relay triggered due to overheating in welding machine.
- “ALL GRA” : safeguard triggered due to insufficient pressure in water-cooled
2.5 OPTIONAL ACCESSORIES
torch cooling circuit;
- G.R.A. water cooling unit
- “ALL SPL” : the voltage setting made by the switches is too high to use the
(standard accessory on the R.A. models).
SPOOL GUN.
- Torch holder mobile arm kit.
7- Dual function button: if pressed and released it will show the welding current, wire
- Connection cables kit for the R.A. models 4m, 10m and 30m.
feed rate and spot welding time (only if spot welding operation is selected!)
- Connection cables kit 4m and 10m.
If the button is pressed for at least 3 seconds, this gives access to welding
- Reel cover kit.
parameter programming mode.
- Voltmeter board
To exit programming mode press the button again for at least 3 seconds.
- Wire feeder wheel kit.
8- SYNERGIC DEFAULT: LED on: indicates that wire feed is at recommended rate (pre-
- Aluminium welding kit.
set default value)
- Cored wire welding kit .
9- Knob for adjusting wire feed rate and for setting accessory welding parameters (in
- 5m MIG torch 350A, 500A.
programming mode).
- 3m MIG torch 500A R.A.
10- Button for selecting 2/4-stroke, spot welding.
(standard accessory on the R.A. models).
11- Button for selecting type of material being welded (steel, stainless steel, aluminium,
- 5m MIG torch 500A R.A.
silicon-copper or aluminium-copper alloys for MIG brazing, FREE for flux core wire)
- Spool gun.
12- Button for selecting welding gas.
13- Wire diameter selector button.
3. TECHNICAL DATA
14- LED indicating triggering of safeguard due to insufficient pressure in water-cooled
3.1 DATA PLATE (FIG. A)
torch cooling circuit.
The most important data regarding use and performance of the welding machine are
15- LED indicating triggering of thermal relay due to overheating in welding machine.
summarised on the rating plate and have the following meaning:
16- LED indicating detection of spool gun.
1- Protection rating of the covering.
17- 2-digit alphanumeric display. Indicates the position of the welding machine
2- Symbol for power supply line:
switches.
1~: single phase alternating voltage;
18- Key for saving (SAVE) customised welding programs (see section 4.8.2).
3~: three phase alternating voltage.
19- Key for recalling (RECALL) customised welding programs (see section 4.8.3).
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).
4.3 WELDING WITH THE MIG TORCH (Fig. B, C, D)
4- Symbol for welding procedure provided.
- Switch on the welding machine,
5- Symbol for internal structure of the welding machine.
- Select the type of material, the type of gas and the wire diameter by pressing buttons
6- EUROPEAN standard of reference, for safety and construction of arc welding
(11,12, 13) respectively.
machines.
- Set the welding current by means of the switch and rotary switch (if present) (Fig. N).
7- Manufacturer's serial number for welding machine identification (indispensable for
- The display will show the welding current corresponding to the setting that has just
technical assistance, requesting spare parts, discovering product origin).
been made. Pressing button (7) will show the corresponding factory setting for the
8- Performance of the welding circuit:
wire feed rate (LED (8) SYNERGIC DEFAULT on).
- U : maximum no-load voltage (open welding circuit).
NOTE: ensure good welding results can be ensured by varying the wire feed rate
0
within a preset interval. This interval is indicated by LED (8) SYNERGIC DEFAULT
- I /U : current and corresponding normalised voltage that the welding machine can
2 2
lighting up; outside the SYNERGIC DEFAULT interval the LED will go off.
supply during welding.
- Select the welding mode by pressing button (10).
- X : Duty cycle: indicates the time for which the welding machine can supply the
- Press the torch button to start welding.
corresponding current (same column). It is expressed as %, based on a 10 minutes
NOTE: during welding the display will show the actual value of the current.
cycle (e.g. 60% = 6 minutes working, 4 minutes pause, and so on).
- Wire feed rate can be modified by turning knob (7), and the display will instantly show
If the usage factors (on the plate, referring to a 40°C environment) are exceeded,
the corresponding value; the current reading will re-appear as soon as the adjustment
the thermal safeguard will trigger (the welding machine will remain in standby until
has been completed.
its temperature returns within the allowed limits).
Important: the welding machine will store all the parameters for the last welding job to
- A/V-A/V: shows the range of adjustment for the welding current (minimum
be carried out (material, gas, wire diameter, wire feed rate).
maximum) at the corresponding arc voltage.
9- Technical specifications for power supply line:
4.4 WELDING WITH THE SPOOL GUN (Fig. B,C, D)
- U : Alternating voltage and power supply frequency of welding machine (allowed
1
- Switch on the welding machine,
limit 10%).
- Select the type of material, the type of gas and the wire diameter by pressing buttons
- I : Maximum current absorbed by the line.
1 max
(11, 12, 13) respectively.
- I : Effective current supplied.
- Set the welding current by means of the switch and rotary switch (if present) (Fig. N).
1eff
10- : Size of delayed action fuses to be used to protect the power line.
- The display will show the welding current corresponding to the setting that has just
11- Symbols referring to safety regulations, whose meaning is given in chapter 1
been made. Pressing button (7) will show the corresponding factory setting for the
“General safety considerations for arc welding”.
wire feed rate (LED (8) SYNERGIC DEFAULT on).
Note: The data plate shown above is an example to give the meaning of the symbols and
NOTE: ensure good welding results can be ensured by varying the wire feed rate
numbers; the exact values of technical data for the welding machine in your possession
within a preset interval. This interval is indicated by LED (8) SYNERGIC DEFAULT
must be checked directly on the data plate of the welding machine itself.
lighting up; outside the SYNERGIC DEFAULT interval the LED will go off.
- Select the welding mode by pressing button (10).
3.2 OTHER TECHNICAL DATA
- Press the torch button to start welding.
- WELDING MACHINE: see table 1 (TAB.1)
NOTE: during welding the display will show the actual value of the current.
- TORCH: see table 2 (TAB.2)
- It is possible to modify the wire feed rate by adjusting the spool gun potentiometer,
- WIRE FEEDER: see table 3 (TAB.3)
and the display will instantly show the corresponding value; the current reading will re-
appear as soon as the adjustment has been completed.
- Under critical welding conditions, the wire diameter LED will flash.
4. DESCRIPTION OF THE WELDING MACHINE
Important: spool operation is disabled when the current setting made by the switches is
4.1 CONTROL, ADJUSTMENT AND CONNECTION DEVICES
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