Telwin DIGITAL SUPERMIG 610 SYNERGIC [8/132] Welding description of the procedure
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Telwin DIGITAL SUPERMIG 610 SYNERGIC [8/132] Welding description of the procedure

Telwin DIGITAL SUPERMIG 490 SYNERGIC [8/132] Welding description of the procedure
- Do not direct the mouthpiece of the torch towards parts of the body.
Aluminium and alloys
- Keep the torch away from the gas bottle.
- Suitable wire diameter: 0.8-1.6mm
- Re-fit the contact tip and the nozzle onto the torch (4b).
- Welding current range: 120-360A
- Check that wire feed is regular; set the roller and spindle braking pressure to the
- welding voltage range : 24-30V
minimum possible values making sure that the wire does not slide in the groove and
- suitable gases : Ar 99.9%
when feed is halted the loops of wire are not loosened by excessive reel inertia.
- Cut the end of the wire so that 10-15 mm protrude from the nozzle.
The contact tip should generally be 5-10mm inside the nozzle, the higher the arc
- Close the wire feeder door.
voltage the further inside; the length of free wire (stick-out) should normally be between
10 and 12mm. Use the minimum reactance outlet.
5.7 RECALLING THE WIRE REEL ONTO THE SPOOL GUN (Fig. L)
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Application: Horizontal welding with thicknesses of at least 3-4mm (very fluid pool);
execution rate and deposit rate are very high (high heat transfer).
WARNING! BEFORE STARTING THE OPERATIONS TO RECALL THE WIRE
6.2 ADJUSTING THE WELDING PARAMETERS
MAKE SURE THE WELDING MACHINE IS SWITCHED OFF AND DISCONNECTED
6.2.1 Shielding gas
FROM THE MAIN POWER SUPPLY OR THAT THE SPOOL GUN IS DISCONNECTED
shielding gas flow rate should be:
FROM THE WELDING MACHINE.
short arc: 8-14 l/min
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spray arc: 12-20 l/min
depending on welding current intensity and nozzle diameter.
MAKE SURE THE WIRE PULLER ROLLERS, THE WIRE GUIDE HOSE AND THE
SPOOL GUN CONTACT TUBE HAVE SUITABLE DIAMETERS CORRESPONDING
6.2.2 Welding current (FIG. N)
TO THAT OF THE WIRE TO BE USED AND MAKE SURE THEY ARE ASSEMBLED
Is determined for a given wire diameter by its own advancement speed. Remember that
CORRECTLY. DO NOT WEAR PROTECTIVE GLOVES WHEN THREADING IN THE
for a given current the wire advancement speed is inversely proportional to the diameter
WIRE.
used.
- Remove the cover by undoing the appropriate screw (1).
Approximate values for the current in manual welding mode for the most commonly
- Position the wire reel on the reel holder.
used wires are given in the table (TAB. 4).
- Free the pressure counter-roller and move it away from the lower roller (2).
- Free the end of the wire, cut off the distorted end with a clean cut leaving no burrs;
6.2.3 Arc voltage
turn the reel anti-clockwise and thread the end of the wire into the wire-guide infeed,
Can be adjusted at short intervals (steps) by switches on the power source. Voltage
pushing it 50-100mm inside the lance (2).
must comply with the chosen speed of wire advancement (current), and with the wire
- Reposition the counter-roller, adjusting the pressure to an intermediate value and
diameter and shielding gas used. This may be set out in the following equation giving the
make sure the wire is correctly positioned in the lower roller recess (3).
medium value:
- Brake the reel holder slightly by adjusting the appropriate screw.
U = (14 + 0,05 x l )
- Switch on the welding machine, putting the switch to ( I ), press the spool gun button
2 2
and wait until the end of the wire runs through the complete wire guide hose and 10-
where :U = arc voltage in volts;
2
15 cm comes out of the front of the torch then release the torch button.
l = welding current in amperes.
2
Remember that in comparison with the no-load voltage supplied for each step, the arc
- With the Spool gun connected, switch on the machine, press the spool gun button
voltage will be less 2-4V for every 100A delivered. The argon/CO mixtures require arc
2
and wait for the end of the wire to pass completely through the wire guide hose and
voltage of 1-2V less than that required with CO .
2
for 10-15 cm to come out of the front of the torch, release the torch button.
6.2.4 Weld quality
5.8 REPLACING THE LINER IN THE TORCH (FIG. M)
The quality of the weld seam is higher when less spatter is produced. this is determined
Before proceeding to replace the hose, lay out the torch cable straight without any
principally by a correct balance of the welding parameters: current (wire speed), wire
bends.
diameter, arc voltage etc., as well as a correct choice of choke intakes.
In the same way the torch position must comply with the data in figure (FIG. O) in order
5.8.1 Coiled hose for steel wires
to avoid excessive spatter and faults on the weld seam. The weld speed (i.e. the
1- Unscrew the nozzle and contact tip on the torch head.
advancement speed along the joint) is also a determining factor for the correct
2- Unscrew the hose locking nut on the central connector and remove the old hose.
execution of the seam. This is particularly important for good penetration and correct
3- Insert the new hose into the cable-torch duct and push it gently until it comes out of
shape of the seam.
the torch head.
The most common welding flaws are summarized in TAB.5.
4- Tighten up the hose locking nut by hand.
5- Trim off all the excess protruding hose pressing it slightly; remove it from the torch
7. MAINTENANCE
cable again.
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6- Smooth the part where the hose was cut and reinsert it into the cable-torch duct.
7- Tighten up the nut again using a spanner.
WARNING! BEFORE CARRYING OUT MAINTENANCE OPERATIONS MAKE
8- Reassemble the contact tip and nozzle.
SURE THE WELDING MACHINE IS SWITCHED OFF AND DISCONNECTED FROM
THE MAIN POWER SUPPLY.
5.8.2 Synthetic hose for aluminium wires
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Carry out operations 1, 2, 3 as given for the steel hose (ignore operations 4, 5, 6, 7, 8).
7.1 ROUTINE MAINTENANCE
9- Re-tighten the contact tip for aluminium, making sure it comes into contact with the
ROUTINE MAINTENANCE OPERATIONS CAN BE CARRIED OUT BY THE
hose.
OPERATOR.
10-At the other end of the hose (torch connector end) insert the brass nipple and the OR
ring and, keeping slight pressure on the hose, tighten the hose locking nut.
7.1.1.Torch
Extract the capillary pipe for steel hoses from the wire feeder torch connector.
- Do not put the torch or its cable on hot pieces; this would cause the insulating
11-THE CAPILLARY PIPE IS NOT REQUIRED for aluminium hoses of diameter 1.6-
materials to melt, making the torch unusable after a very short time.
2.4mm (coloured yellow); the hose is therefore inserted into the torch connector
- Make regular checks on the gas pipe and connector seals.
without it.
- Every time the wire reel is changed, blow out the wire-guide hose using dry
Cut the capillary pipe for aluminium hoses of diameter 1.2-1.6mm (coloured red) to
compressed air (max. 5bar) to make sure it is not damaged.
approx. 2mm shorter than the steel pipe, and insert it into the free end of the hose.
- To control, before every I use, check the wear and correct assembly of the parts at
12-Insert and lock the torch into the wire feeder connector, mark the hose at 1-2mm
the end of the torch: nozzle, contact tip, gas diffuser.
from the rollers, take the torch out again.
13-Cut the hose to the required size, without distorting the inlet hole.
7.1.2 Wire feeder
Reassemble the torch in the wire feeder connector and assemble the gas nozzle.
- Make frequent checks on the state of wear of the wire feeder rollers, regularly
remove the metal dust deposited in the feeder area (rollers and wire-guide infeed
6. WELDING: DESCRIPTION OF THE PROCEDURE
and outfeed).
6.1 METHODS OF METAL TRANSFER
6.1.1 Short arc
7.2 EXTRAORDINARY MAINTENANCE
The melting of the electrode wire and the detachment of the drop is produced by
EXTRAORDINARY MAINTENANCE OPERATIONS SHOULD BE CARRIED OUT
repeated short circuits (up to 200 times per second) from the tip of the wire to the molten
ONLY AND EXCLUSIVELY BY SKILLED OR AUTHORISED ELECTRICAL-
pool.
MECHANICAL TECHNICIANS.
Carbon and mild steels
_____________________________________________________________________________________________________________________
- Suitable wire diameter: 0.6-1.2mm
- Welding current range: 40-210A
WARNING! BEFORE REMOVING THE WELDING MACHINE PANELS AND
- Arc voltage range: 13-23V
WORKING INSIDE THE MACHINE MAKE SURE THE WELDING MACHINE IS
- Suitable gases: CO , mix Ar/CO , Ar/CO /O
2 2 2 2
SWITCHED OFF AND DISCONNECTED FROM THE MAIN POWER SUPPLY
Stainless steels
OUTLET.
- Suitable wire diameter: 0.8-1mm
_____________________________________________________________________________________________________________________
- Welding current range: 40-160A
- Arc voltage range: 14-20V
If checks are made inside the welding machine while it is live, this may cause
- Suitable gases: mix Ar/O , Ar/CO (1-2%)
serious electric shock due to direct contact with live parts and/or injury due to
2 2
Aluminium and alloys
direct contact with moving parts.
- Suitable wire diameter: 0.8-1.6mm
- Inspect the welding machine regularly, with a frequency depending on use and the
- Welding current range: 75-160A
dustiness of the environment, and remove the dust deposited on the transformer,
- Arc voltage range: 16-22V
reactance and rectifier using a jet of dry compressed air (max. 10bar).
- Suitable gases: Ar 99.9%
- Do not direct the jet of compressed air on the electronic boards; these can be
- Wire stick out: 5-12mm
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.
Generally, the contact tip should be flush with the nozzle or protrude slightly when
- At the end of these operations re-assemble the panels of the welding machine and
using the thinnest wires and lowest arc voltages; the length of free wire (stick-out) will
screw the fastening screws right down.
normally be between 5 and 12mm. Select the minimum reactance outlet for carbon or
- Never, ever carry out welding operations while the welding machine is open.
mild steels with C0 gas (wire diameters 0.8-1.2mm) and average for the same material
2
with Ar/CO gas, high for stainless steel and aluminium.
2
8. TROUBLESHOOTING (TAB.6)
_____________________________________________________________________________________________________________________
Application: Welding in all positions, on thin material or for the first passage in bevelled
edges, with the advantage of limited heat transfer and highly controllable pool.
WARNING! CARRYING OUT CERTAIN CHECKS IMPLIES THE RISK OF
CONTACT WITH LIVE AND/OR MOVING PARTS.
Note: SHORT ARC transfer for welding aluminium and alloys should be used with great
_____________________________________________________________________________________________________________________
care (especially with wires of diameter >1mm) because the risk of melting defects may
arise.
Before carrying out any operation on the wire feeder or inside the welding machine it is
absolutely necessary to refer to section 7 “ MAINTENANCE”.
6.1.2 Spray arc
Higher voltages and currents than for "short arc" are used here to achieve the melting of
the wire. The wire tip does not come into contact with the molten pool; an arc forms from
the tip and through it flows a stream of metallic droplets. These are produeced by the
continuous melting of the electrode wire without short-circuits involved.
Carbon and mild steels
- Suitable wire diameter: 0.8-1.6mm
- Welding current range: 180-450A
- Arc voltage range : 24-40V
- Suitable gases : mix Ar/CO , Ar/CO /O
2 2 2
Stainless steels
- Suitable wire diameter: 1-1.6mm
- Welding current range: 140-390A
- Welding voltage range : 22-32V
- Suitable gases : mix Ar/O , Ar/CO (1-2%)
2 2
- 8 -

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