Manual Telwin FORCE 165 (page 6 of 104) (All languages)

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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

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.

OPTIONAL ACCESSORIES:

- MMA 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:

- U

: maximum no-load voltage.

- I

: 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:

- U

: Alternating voltage and power supply frequency of welding

machine (allowed limit ±10%):

- I

1 max

: Maximum current absorbed by the line.

- I

1eff

: effective 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THEWELDING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.

The ”DUAL VOLTAGE AUTOMATIC” model has a device that

automatically recognises the power supply voltage (115V AC- 230V

AC) and sets up the machine for correct operation.

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)).

- GREEN LED shows that the machine is connected to a 230V AC

power supply.

- ORANGE LED shows that the machine is connected to a 115V AC

power supply.

During operation at 115V AC it is possible that prolonged and

sizeable voltage surges will cause the machine to switch to

230V AC operation for safety.

In such circumstances, to resume welding, the machine must

be switched off and on again.

 WaituntiltheLED(Fig.C(3))hasgoneoutcompletelybefore

switching on again.

CONTROL, REGULATION AND CONNECTION DEVICES

WELDINGMACHINE

Front Panel

Fig. C

1- Positive quick plug (+) to connect welding cable.

2- YELLOWLED: normally off, when ON it means that the welding

current cannot ow due to one of the following faults:

- Thermal protection: inside the machine the temperature is

excessive. The machine is ON but does not deliver current

until a normal temperature is reached. Once this happens the

re-start is automatic.

- Mains over/undervoltage protection: the machine is

blocked: the power supply voltage is 15% above or below the

rating plate value. WARNING:Exceedingtheuppervoltage

limit, as above, will cause serious damage to the device.

- ANTI STICK protection: automatically shuts down the

welding machine if the electrode sticks to the material being

welded so that it can be removed manually without damaging

the electrode holder clamp.

3- GREEN LED: Connection to the mains, machine ready to work.

4- Potentiometer to regulate welding current with graduated scale

in Amps, which also allows regulation during welding.

(The “DUAL VOLTAGE AUTOMATIC” model has a double

graduated Ampere scale).

5- Negative quick plug (-) to connect 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.

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Telwin FORCE 165 Manual

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