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Summary of Contents for TEAMWELDER MIG drive Synergic puls
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Page 1: Operating Instructions
Operating instructions Wire feed unit MIG-DRIVE SYNERGIC PULS 299-031000-TWD01 18.10.2016 Observe additional system documents! -
Page 2: General Instructions
+49 2623 9276400. A list of authorised sales partners can be found at www.teamwelder.com. Liability relating to the operation of this equipment is restricted solely to the function of the equipment. -
Page 3: Table Of Contents
Contents Notes on the use of these operating instructions Contents 1 Contents ..............................3 2 For your safety ............................6 Notes on the use of these operating instructions ................6 Explanation of icons ........................7 Part of the complete documentation ....................8 Safety instructions .......................... - Page 4 Contents Notes on the use of these operating instructions 5.3.6 Further welding parameters ..................41 5.3.7 MIG/MAG functional sequences / operating modes ............. 42 5.3.7.1 Explanation of signs and functions ..............42 5.3.8 Conventional MIG/MAG Welding (GMAW non synergic) ..........45 5.3.8.1 Setting the operating point (welding output)..........
- Page 5 Contents Notes on the use of these operating instructions 10 Replaceable parts ..........................73 10.1 Wire feed rollers ........................... 73 10.1.1 Wire feed rollers for steel wire ..................73 10.1.2 Wire feed rollers for aluminium wire ................73 10.1.3 Wire feed rollers for cored wire ..................73 10.1.4 Conversion kit .......................
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Page 6: For Your Safety
For your safety Notes on the use of these operating instructions For your safety Notes on the use of these operating instructions DANGER Working or operating procedures which must be closely observed to prevent imminent serious and even fatal injuries. •... -
Page 7: Explanation Of Icons
For your safety Explanation of icons Explanation of icons Symbol Description Symbol Description Indicates technical aspects which the Activate and release/tap/tip user must observe. Switch off machine Release Switch on machine Press and keep pressed Switch Wrong Turn Numerical value – adjustable Correct Menu entry Signal light lights up in green... -
Page 8: Part Of The Complete Documentation
For your safety Part of the complete documentation Part of the complete documentation These operating instructions are part of the complete documentation and valid only in combination with all other parts of these instructions! Read and observe the operating instructions for all system components, especially the safety instructions! The illustration shows a general example of a welding system. -
Page 9: Safety Instructions
For your safety Safety instructions Safety instructions WARNING Risk of accidents due to non-compliance with the safety instructions! Non-compliance with the safety instructions can be fatal! • Carefully read the safety instructions in this manual! • Observe the accident prevention regulations and any regional regulations! •... - Page 10 For your safety Safety instructions WARNING Risk of injury due to improper clothing! During arc welding, radiation, heat and voltage are sources of risk that cannot be avoided. The user has to be equipped with the complete personal protective equipment at all times.
- Page 11 For your safety Safety instructions CAUTION Smoke and gases! Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to the ultraviolet radiation of the arc! • Ensure that there is sufficient fresh air! •...
- Page 12 For your safety Safety instructions CAUTION Electromagnetic fields! The power source may cause electrical or electromagnetic fields to be produced which could affect the correct functioning of electronic equipment such as IT or CNC devices, telecommunication lines, power cables, signal lines and pacemakers. •...
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Page 13: Transport And Installation
For your safety Transport and installation Transport and installation WARNING Risk of injury due to improper handling of shielding gas cylinders! Improper handling and insufficient securing of shielding gas cylinders can cause serious injuries! • Observe the instructions from the gas manufacturer and any relevant regulations concerning the use of compressed air! •... -
Page 14: Intended Use
Intended use Applications Intended use WARNING Hazards due to improper usage! The machine has been constructed to the state of the art and any regulations and standards applicable for use in industry and trade. It may only be used for the welding procedures indicated at the rating plate. -
Page 15: Documents Which Also Apply
In case of unauthorised changes, improper repairs, non-compliance with specified deadlines for "Arc Welding Equipment – Inspection and Testing during Operation", and/or prohibited modifications which have not been explicitly authorised by TEAMWELDER, this declaration shall be voided. An original document of the specific declaration of conformity is included with every product. -
Page 16: Machine Description - Quick Overview
Machine description – quick overview Front view Machine description – quick overview Front view Figure 4-1 Item Symbol Description Carrying handle Wire spool casing Protective cap Cover for the wire feed mechanism and other operating elements. Depending on the machine series, additional stickers with information on the replacement parts and JOB lists will be located on the inside. -
Page 17: Rear View
Machine description – quick overview Rear view Rear view Figure 4-2 Item Symbol Description 7-pole connection socket (digital) • Control lead for wire feed unit Connecting nipple G¼, shielding gas connection Quick connect coupling (red) coolant return Connector plug, welding current "+" Welding current connection on wire feed unit Quick connect coupling (blue) coolant supply... -
Page 18: Inside View
Machine description – quick overview Inside view Inside view Figure 4-3 Item Symbol Description Wire spool casing Wire spool holder Turning mandrel support The wire feeder is placed onto the power source turning mandrel using this support to enable horizontal pivoting of the machine. Wire feed unit Push-button gas test / rinse hose package >... -
Page 19: Machine Control - Operating Elements
Machine description – quick overview Machine control – Operating elements Machine control – Operating elements The setting ranges for the parameter values are summarised in the Parameter overview section > see 12.1 chapter. Figure 4-4 Item Symbol Description Welding data display (3-digit) Displays the welding parameters and the corresponding values >... - Page 20 Machine description – quick overview Machine control – Operating elements Item Symbol Description Welding parameter display mode/power-saving mode push-button ------ Welding current ----- Welding voltage -------- Material thickness -------- Wire feed speed Press for 2 s to put the machine into power-saving mode. To reactivate, activate one of the operating elements >...
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Page 21: Design And Function
Design and function Transport and installation Design and function WARNING Risk of injury from electric shock! Contact with live parts, e.g. welding current sockets, is potentially fatal! • Follow safety instructions on the opening pages of the operating instructions. • Commissioning may only be carried out by persons who have the relevant expertise of working with arc welding machines! •... -
Page 22: Notes On The Installation Of Welding Current Leads
Design and function Transport and installation 5.1.2 Notes on the installation of welding current leads Incorrectly installed welding current leads can cause faults in the arc (flickering). Lay the workpiece lead and hose package of power sources without HF igniter (MIG/MAG) for as long and as close as possible in parallel. -
Page 23: Stray Welding Currents
Design and function Transport and installation Fully unroll welding current leads, torch hose packages and intermediate hose packages. Avoid loops! Always keep leads as short as possible! Lay any excess cable lengths in meanders. Figure 5-3 5.1.2.1 Stray welding currents WARNING Risk of injury due to stray welding currents! Stray welding currents can destroy protective earth conductors, damage machines and... -
Page 24: Intermediate Hose Package Connection
Design and function Transport and installation 5.1.3 Intermediate hose package connection CAUTION Risk of injury due to electrical current! The earth cable on the intermediate tube package must not be connected to the welding machine or wire feed unit! • Remove the earth cable or push it back into the tube package. -
Page 25: Intermediate Hose Package Strain Relief
Design and function Transport and installation 5.1.4 Intermediate hose package strain relief Missing or incorrectly fitted strain relief! Connection sockets or connection plugs on the machine, or the intermediate tube package, may be damaged if the strain relief is missing or incorrectly fitted. The strain relief takes the strain from cables, plugs and sockets. -
Page 26: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)
Design and function Transport and installation 5.1.5 Shielding gas supply (shielding gas cylinder for welding machine) WARNING Risk of injury due to improper handling of shielding gas cylinders! Improper handling and insufficient securing of shielding gas cylinders can cause serious injuries! •... -
Page 27: Shielding Gas Volume Settings
Design and function Transport and installation 5.1.5.2 Shielding gas volume settings CAUTION Electric shocks! When setting the shielding gas quantity, high voltage ignition pulses or open circuit voltage are applied at the welding torch; these can lead to electric shocks and burning on contact. -
Page 28: Welding Torch Cooling System
Design and function Transport and installation 5.1.6 Welding torch cooling system Insufficient frost protection in the welding torch coolant! Depending on the ambient conditions, different liquids are used for cooling the welding torch > see 5.1.6.1 chapter. Coolants with frost protection (KF 37E or KF 23E) must be checked regularly to ensure that the frost protection is adequate to prevent damage to the machine or the accessory components. -
Page 29: Welding Data Display
Design and function Welding data display Welding data display Figure 5-9 The push-button for the welding parameter display mode is next to the display. Each time the push-button is pressed the display changes to the next parameter. After the last parameter is reached the display continues with the first parameter. -
Page 30: Mig/Mag Welding
Design and function MIG/MAG welding MIG/MAG welding 5.3.1 Welding torch connection Equipment damage due to improperly connected coolant pipes! If the coolant pipes are not properly connected or a gas-cooled welding torch is used, the coolant circuit is interrupted and equipment damage can occur. •... - Page 31 Design and function MIG/MAG welding Figure 5-10 Item Symbol Description Welding torch Welding torch hose package Welding torch connection (Euro or Dinse torch connector) Welding current, shielding gas and torch trigger integrated 19-pole connection socket (analogue) For connecting analogue accessory components (remote control, welding torch control lead, etc.) Quick connect coupling (blue) coolant supply...
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Page 32: Wire Feed
Design and function MIG/MAG welding 5.3.2 Wire feed CAUTION Risk of injury due to moving parts! The wire feeders are equipped with moving parts, which can trap hands, hair, clothing or tools and thus injure persons! • Do not reach into rotating or moving parts or drive components! •... -
Page 33: Inserting The Wire Spool
Design and function MIG/MAG welding 5.3.2.2 Inserting the wire spool CAUTION Risk of injury due to incorrectly secured wire spool. If the wire spool is not secured properly, it may come loose from the wire spool support and fall to the ground, causing damage to the machine and injuries. •... -
Page 34: Changing The Wire Feed Rollers
Design and function MIG/MAG welding 5.3.2.3 Changing the wire feed rollers Unsatisfactory welding results due to faulty wire feeding! Wire feed rollers must be suitable for the diameter of the wire and the material. • Check the roller label to verify that the rollers are suitable for the wire diameter. Turn or change if necessary! •... - Page 35 Design and function MIG/MAG welding Figure 5-13 Item Symbol Description Adjusting nut Feed roll tensioner Fixing the clamping unit and setting the pressure. Clamping unit Knurled screw Pressure roller Wire feed nipple Guide tube Drive roller Axle • Extend and lay out the torch hose package. •...
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Page 36: Spool Brake Setting
Design and function MIG/MAG welding 5.3.2.5 Spool brake setting Figure 5-14 Item Symbol Description Allen screw Securing the wire spool retainer and adjustment of the spool brake • Tighten the Allen screw (8 mm) in the clockwise direction to increase the braking effect. Tighten the spool brake until the wire spool no longer turns when the wire feed motor stops but without it jamming during operation! 299-031000-TWD01... -
Page 37: Definition Of Mig/Mag Welding Tasks
Design and function MIG/MAG welding 5.3.3 Definition of MIG/MAG welding tasks This machine range features simple operation with a very wide range of functions. • JOBs (welding tasks consisting of welding process, type of material, wire diameter and type of shielding gas) are pre-defined for all common welding tasks. -
Page 38: Welding Task Selection
Design and function MIG/MAG welding 5.3.4 Welding task selection MIG/MAG pulse arc welding can be selected with JOBs 6, 8, 9, 10, 11, 13, 14,15, 34, 35, 36, 37, 74, 75, 76, 77, 237, 238 and 239. If an attempt is made to set another JOB to pulse, "noP" = "no Pulse" appears briefly on the display and the machine is reset to default. -
Page 39: Choke Effect / Dynamics
Design and function MIG/MAG welding 5.3.4.1 Choke effect / dynamics Figure 5-16 Item Symbol Description Push-button, throttling effect (arc dynamics) ----- Arc is harder and more narrow ----- Arc is softer and wider Welding parameter setting dial For setting the welding performance, for selecting the JOB (welding task) and for setting other welding parameters. -
Page 40: Mig/Mag Operating Point
Design and function MIG/MAG welding 5.3.5 MIG/MAG operating point 5.3.5.1 Selecting the welding parameter display mode The operating point (welding power) can be displayed or set as the welding current, material thickness or wire speed. Figure 5-17 5.3.5.2 Operating point setting using material thickness The process of setting the operating point by means of the panel thickness parameter is described as an example below. -
Page 41: Further Welding Parameters
Design and function MIG/MAG welding 5.3.6 Further welding parameters Validity of the settings. Spot time, pause time and wire feed speed settings apply to all JOBs. Throttling effect/dynamics, gas post-flow time, gas pre-flow time and wire burn-back correction are stored for each JOB individually. -
Page 42: Mig/Mag Functional Sequences / Operating Modes
Design and function MIG/MAG welding 5.3.7 MIG/MAG functional sequences / operating modes 5.3.7.1 Explanation of signs and functions Symbol Meaning Press torch trigger Release torch trigger Shielding gas flowing Welding output Wire electrode is being conveyed Wire creep Wire burn-back Gas pre-flows Gas post-flows Non-latched... - Page 43 Design and function MIG/MAG welding Non-latched mode Figure 5-21 Step 1 • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). • Wire feed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece; welding current flows. •...
- Page 44 Design and function MIG/MAG welding Latched mode Figure 5-22 1. cycle • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at “creep speed” • Arc ignites when the wire electrode makes contact with the workpiece Welding current flows •...
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Page 45: Conventional Mig/Mag Welding (Gmaw Non Synergic)
Design and function MIG/MAG welding 5.3.8 Conventional MIG/MAG Welding (GMAW non synergic) You can only change the JOB number when no welding current is flowing. Figure 5-23 Item Symbol Description JOB- Welding task push-button (JOB) LIST Select the welding task from the welding task list (JOB-LIST). The list can be found inside the protective cap on the wire feeder and in the appendix to these operating instructions. -
Page 46: Setting The Operating Point (Welding Output)
Design and function MIG/MAG welding 5.3.8.1 Setting the operating point (welding output) Figure 5-24 5.3.9 MIG/MAG automatic cut-out The welding machine ends the ignition process or the welding process with an • ignition fault (no welding current flows within 5 s after the start signal) •... -
Page 47: Tig Welding
Design and function TIG welding TIG welding 5.4.1 Welding torch connection TIG welding torches to be connected to a Euro torch connector are available in two versions: • TIG combi welding torches are connected to the Euro torch connector of the wire feeder and to the (-) welding current plug of the power source. -
Page 48: Welding Task Selection
Design and function TIG welding 5.4.2 Welding task selection • Select TIG JOB 127 > see 11.1 chapter. You can only change the JOB number when no welding current is flowing. Figure 5-26 Item Symbol Description JOB- Welding task push-button (JOB) LIST Select the welding task from the welding task list (JOB-LIST). -
Page 49: Further Welding Parameters
Design and function TIG welding 5.4.3 Further welding parameters • Preselection: Select TIG JOB 127 > see 5.4.2 chapter. NAVIGATION ENTER EXIT Figure 5-28 Display Setting/selection Gas pre-flow time Ignition current Up-slope time Down-slope time End current Gas post-flow time 299-031000-TWD01 18.10.2016... -
Page 50: Tig Arc Ignition
Design and function TIG welding 5.4.4 TIG arc ignition 5.4.4.1 Liftarc Figure 5-29 The arc is ignited on contact with the workpiece: a) Carefully place the torch gas nozzle and tungsten electrode tip onto the workpiece and press the torch trigger (liftarc current flowing, regardless of the main current set). -
Page 51: Function Sequences/Operating Modes
Design and function TIG welding 5.4.5 Function sequences/operating modes 5.4.5.1 Legend Symbol Meaning Press torch trigger Release torch trigger Welding current Gas pre-flows Gas post-flows Non-latched Latched Time Upslope time Downslope time Down Ignition current start End-crater current 299-031000-TWD01 18.10.2016... - Page 52 Design and function TIG welding Non-latched mode Figure 5-30 1st cycle • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). The arc is ignited using liftarc. • The welding current flows with the value set for the starting current I start •...
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Page 53: Tig Automatic Cut-Out
Design and function TIG welding Latched mode Figure 5-31 1st cycle • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). The arc is ignited using liftarc. • The welding current flows with the value set for the starting current I start 2nd cycle •... -
Page 54: Mma Welding
Design and function MMA welding MMA welding CAUTION Risk of being crushed or burnt. When replacing spent or new stick electrodes • Switch off machine at the main switch • Wear appropriate safety gloves • Use insulated tongs to remove spent stick electrodes or to move welded workpieces and •... -
Page 55: Welding Current Setting
Design and function MMA welding 5.5.1.1 Welding current setting Figure 5-33 5.5.2 Arcforce During the welding process, arcforce prevents the electrode sticking in the weld pool with increases in current. This makes it easier to weld large-drop melting electrode types at low current strengths with a short arc in particular. -
Page 56: Hotstart Settings
Design and function MMA welding 5.5.3.1 Hotstart settings • Select MMA JOB 128 > see 5.5.1 chapter. EXIT ENTER NAVIGATION Figure 5-36 Display Setting/selection Hotstart current Hotstart time 5.5.4 Antistick Anti-stick prevents the electrode from annealing. If the electrode sticks in spite of the Arcforce device, the machine automatically switches over to the minimum current within about 1 second to prevent the electrode from overheating. -
Page 57: Remote Control
Design and function Remote control Remote control The manufacturer's warranty becomes void if non-genuine parts are used! • Only use system components and options (power sources, welding torches, electrode holders, remote controls, spare parts and replacement parts, etc.) from our range of products! •... -
Page 58: Special Parameters (Advanced Settings)
Design and function Special parameters (advanced settings) Special parameters (advanced settings) Special parameters (P1 to Pn) are applied for customer-specific configuration of machine functions. This allows the user maximum flexibility in optimising their requirements. These settings are not configured directly on the machine control since a regular setting of the parameters is generally not required. -
Page 59: Selecting, Changing And Saving Parameters
Design and function Special parameters (advanced settings) 5.7.1 Selecting, changing and saving parameters ENTER (Enter the menu) • Switch off machine at the main switch. • Press and hold the "left parameter selection" button and switch the machine on again at the same time. -
Page 60: Reset To Factory Settings
Design and function Special parameters (advanced settings) 5.7.1.1 Reset to factory settings All special parameters saved by the user will be overwritten by the factory settings! RESET Hard Soft Figure 5-39 Display Setting/selection Initialising Keep the push-button pressed until "InI" is shown on the display. Initialisation complete All customised welding parameters haven been overwritten by the factory settings. -
Page 61: Special Parameters In Detail
Design and function Special parameters (advanced settings) 5.7.1.2 Special parameters in detail Ramp time for wire inching (P1) The wire inching starts with a speed 1.0 m/min for 2 secs. It is subsequently increased to a ramp function to 6.0 m/min. The ramp time can be set between two ranges. During wire inching, the speed can be changed by means of the welding parameter setting rotary dial. -
Page 62: Machine Configuration Menu
Design and function Machine configuration menu Machine configuration menu 5.8.1 Selecting, changing and saving parameters ENTER (Enter the menu) • Switch off machine at the main switch. • Hold down the "welding parameter display mode" button and simultaneously switch the machine on again. -
Page 63: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal General DANGER Incorrect maintenance and testing! The machine may be cleaned, repaired and tested by skilled and qualified personnel only. A qualified person is one who, due to their training, knowledge and experience, can detect any hazards and possible consequential damage when checking the machine, and can take the necessary safety measures. -
Page 64: Maintenance Work, Intervals
Maintenance, care and disposal Maintenance work, intervals Maintenance work, intervals Repair and maintenance work may only be performed by qualified authorised personnel; otherwise the right to claim under warranty is void. In all service matters, always consult the dealer who supplied the machine. -
Page 65: Annual Test (Inspection And Testing During Operation)
07416/08-ECZ, and EKO-KOM with the Reg. No. F00034148. Meeting the requirements of RoHS We, TEAMWELDER Germany GmbH, hereby confirm that all products which we supply to you that are subject to the RoHS Directive comply with the requirements of the RoHS (Directive 2011/65/EU). -
Page 66: Rectifying Faults
Rectifying faults Checklist for rectifying faults Rectifying faults All products are subject to rigorous production checks and final checks. If, despite this, something fails to work at any time, please check the product using the following flowchart. If none of the fault rectification procedures described leads to the correct functioning of the product, please inform your authorised dealer. -
Page 67: Error Messages
Rectifying faults Error messages Error messages A welding machine error is indicated by an error code being displayed (see table) on the display on the machine control. In the event of a machine error, the power unit is shut down. The display of possible error numbers depends on the machine version (interfaces/functions). - Page 68 Rectifying faults Error messages Legend for categories (error reset) a) The error message will disappear once the error has been rectified. b) The error message can be reset by pressing a key button: Welding machine control Key button MIG 300 D3 Synergic not possible c) The error message can only be reset by switching the machine off and on again.
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Page 69: Resetting Jobs (Welding Tasks) To The Factory Settings
Rectifying faults Resetting JOBs (welding tasks) to the factory settings Resetting JOBs (welding tasks) to the factory settings 7.3.1 Resetting a single JOB ENTER RESET EXIT Figure 7-1 Display Setting/selection RESET to factory settings The RESET will be done after pressing the button. The menu will be ended when no changes are done after 3 sec. -
Page 70: Vent Coolant Circuit
Rectifying faults Vent coolant circuit Vent coolant circuit Coolant tank and quick connect coupling of coolant supply and return are only fitted in machines with water cooling. To vent the cooling system always use the blue coolant connection, which is located as deep as possible inside the system (close to the coolant tank)! Figure 7-3 299-031000-TWD01... -
Page 71: Technical Data
Technical data MIG-DRIVE SYNERGIC PULS Technical data MIG-DRIVE SYNERGIC PULS Performance specifications and guarantee only in connection with original spare and replacement parts! Supply voltage 42 VAC Maximum welding current at 60% DC 550 A Maximum welding current at 100% DC 420 A EMC class Safety identification... -
Page 72: Accessories
Accessories Internet Accessories Internet For the accessories available for your product go to www.teamwelder.com. Figure 9-1 299-031000-TWD01 18.10.2016... -
Page 73: Replaceable Parts
Replaceable parts Wire feed rollers Replaceable parts The manufacturer's warranty becomes void if non-genuine parts are used! • Only use system components and options (power sources, welding torches, electrode holders, remote controls, spare parts and replacement parts, etc.) from our range of products! •... -
Page 74: 10.1.4 Conversion Kit
Replaceable parts Wire feed rollers 10.1.4 Conversion kit Type Designation Item no. URUE VERZ>UNVERZ FE/AL Conversion kit, 37mm, 4-roller drive on non-toothed 092-000845-00000 rollers (steel/aluminium) URUE AL 4ZR4R 0,8+1,0 Conversion kit, 37mm, 4-roller drive for aluminium 092-000867-00000 URUE AL 4ZR4R 1,0+1,2 Conversion kit, 37mm, 4-roller drive for aluminium 092-000846-00000 URUE AL 4ZR4R 1,2+1,6... -
Page 75: Job-List
Appendix A JOB-List Appendix A 11.1 JOB-List Figure 11-1 For machine versions with pulsed arc welding procedures only. MIG/MAG pulse arc welding can be selected with JOBs 6, 8, 9, 10, 11, 13, 14,15, 34, 35, 36, 37, 74, 75, 76, 77, 237, 238 and 239. If an attempt is made to set another JOB to pulse, "noP" = "no Pulse" appears briefly on the display and the machine is reset to default. -
Page 76: Parameter Overview - Setting Information
Appendix B Parameter overview – setting information Appendix B Parameter overview – setting information 12.1 Parameters/function Setting range MIG/MAG Gas pre-flow time 20,0 Dynamic correction Gas post-flow time 20,0 Wire burn-back Gas pre-flow time Ignition current Up-slope time 20,0 Down-slope time 20,0 End current Gas post-flow time...
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