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Elettronica Todescato L/160 Operating Instructions And Maintenance

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Summary of Contents for Elettronica Todescato L/160

  • Page 3: Table Of Contents

    INDEX SECTION 1: Description and main features of the welder 1.1 Presentation 1.2 Warranty 1.2.1 Exclusion from warranty 1.3 Machine identification 1.4 Equipment 1.5 Machine description and use limitation 1.5.1 Description 1.5.2 Use limitation 1.6 Noise 1.7 Technical features SECTION 2: Safety and prevention 2.1 Safety 2.1.1 General safety regulations 2.2 Safety signs (Symbols)

  • Page 4: Presentation

    This manual gives information regarded as necessary to know, use correctly and carry out normal maintenance operations on this welder « L/160 » (hereinafter referred to as machine) fabricated by «Elettronica Todescato S.r.l.» in Arcugnano (Vicenza) Italy (hereinafter referred to as Manufacturer).

  • Page 5: Exclusion From Warranty

    1.2.1 EXCLUSIONS FROM WARRANTY This warranty shall be null and void (apart from the causes given in the Purchase Contract): If the machine is used with incorrect voltage. If the damage is due to insufficient maintenance or lack of proper service. If, following repairs carried out by the owner without manufacturers consent due to installation of non-original spare parts, the machine has been changed and the damage was caused by this changes.

  • Page 6: Machine Identification

    1.3 MACHINE IDENTIFICATION Each machine is equipped of identification plate (fig.1 # 21), giving the following Information: Name and address of Manufacturer; «CE» Mark; A) Machine type; B) Year of fabrication; C) Serial number; D) Voltage; E) Ampere; F) Watt; G) Frequency;...

  • Page 7: Equipment

    UE Declaration of Conformity annexed to each machine. 1.5.1 DESCRIPTION The «ET Hydrogen Welder L/160» can be used in craftwork or industrial workshop with a minimum volume of 30 m³ and provided with natural ventilation by means of suitable openings to the outside in compliance with the regulations in force in the user’s country.

  • Page 8: Noise

    DANGER Any use whatsoever different from those quoted here within and not included or not directly inferred from this instructions’ manual, will be regarded as «NOT ALLOWED». It is not permitted to operate the machine when the flame is out. This would result in, accumulation of explosive mixture in the surrounding environment and pollution caused by the methyl alcohol.

  • Page 9: Fig.2 Machine Layout

    FIG. 2– MACHINE LAYOUT Gas production It/h Water consumption cc/h Alcohol consumption cc/h Booster tank capacity Maximum power Watt Electrolyte Weight...

  • Page 10: Section 2: Safety And Prevention 2.1 Safety

    SECTION 2 Safety and Prevention 2.1 SAFETY The owner of the machine must instruct personnel about the risk of industrial accident, the safety device installed for operator safety and on general industrial accident prevention regulations applied by law in the country where the machine is to be operated. Operator safety is a matter of considerable importance for machine design and fabrication.

  • Page 11: Safety Signs (Symbols)

    The personnel must not perform under their own initiative operations or interventions that lie outside their competence. The personnel are obliged to notify their superiors of any problem or dangerous situation that may arise. The machine has been commissioned and tested with all the parts included within the standard equipment.

  • Page 12: Safe Use And Maintenance

    2.3 SAFE USE AND MAINTENANCE ATTENTION It is prohibited for the machine to be used by: o Persons who have not read and understood the instructions given in this manual; o Inexperienced persons; o Persons not in good physical/mental health. Periodically check that the machine and its protection devices are in perfect working order.

  • Page 13: Un-Packaging

    3.3 UN-PACKAGING Make sure that: - The welder has not suffered damage during transportation and, if necessary, report to the manufacturer or authorized reseller. 3.4 POSITIONING Set the welder on a solid and stable surface, away from heat sources. Allow for at least 50 cm free space for the cooling louvres on the machine sides, for proper air circulation.

  • Page 14: Section 4: Use 4.1 Connection To The Electric Circuit

    SECTION 4 4.1 CONNECTION TO THE ELECTRIC CIRCUIT Check that the main voltage corresponds to the voltage indicated on the plate at the rear of the welder (Fig. 1 # 21). Test the electrical circuit grounding to make sure that is it efficient. Slide the switch (Fig.1 # 1) to the “O”...

  • Page 15: Tank Filling

    3. Remove the safety cap (Fig.1 # 2). 4. By means of a funnel, poor slowly the electrolyte previously prepared thought the filling neck (Fig.1 # 3) and into the tank (Fig.5 # 46). The “MAX” yellow light (Fig.1 # 5) will go out.

  • Page 16: Hazardous Operations

    3) Dose container, shake it up and wait until the product is fully dissolved, before using. 4.6 HAZARDOUS OPERATIONS DANGER When the flames are burning: Do not unscrew the handle knob screw (Fig.1 # 8). Do not unscrew the Safety Cap (Fig.1 # 2). Do not bring flames or sparkles near the filling neck and the safety cap (Fig.1 # 2, 3).

  • Page 17: Stopping The Machine

    DANGER You can adjust the flames by operating on the power control knob (Fig.1 # 4) which regulates the power and then consequently the flame. This should be set within the limit values presented, see Table 2 / Table 2A. Setting the power level below the minimum value allowed would cause a pressure drop that would melt the burner tip, resulting in back fire in the Booster Tank.

  • Page 18: Safety Device

    Insufficient amount of de-oxidizer. Lack of gas in the supply channel. Backfire causes a faint detonation in the Booster Tank and if there is not deoxidizer, the flame will reach the Tank (Fig.5 # 47). To restart the welder you must perform those operations: 1) Turn off the welder.

  • Page 19: Section 5: Maintenance 5.1 Generalities

    SECTION 5 MAINTENANCE 5.1 GENERALITIES ATTENTION Any maintenance operation inside the welder must be performed solely by recognized technicians who have been officially trained. DANGER INSIDE THE MACHINE THERE ARE LIVE COMPONENTS (230 OR 115 VOLT AC), CONTACT WITH THESE PARTS CAN CAUSE ELECTRIC SHOCK. 5.2 EVERY SIX MONTHS Disconnect the plug from the intake.

  • Page 20: Every Four Years

    5.4 EVERY FOUR YEARS Every four years the machine must undergo a complete technical and operational review. Such work must be performed by the manufacturing firm or at the dealers location with skilled technical personnel. ATTENTION The manufacturing firm is not liable for any damage caused by the machine due to lack of review.

  • Page 21: Trouble Shooting

    5. 9 TROUBLE SHOOTING We list hereunder the more frequent, operational complications, failures , relevant causes, and provide a brief description on how to repair or adjust the equipment, so as to bring the equipment to acceptable working usage within the intended manufacturers parameters. Ensuring proper safety standards are abided by, maintaining functional performance , while keeping the integrity of the warranty guarantee established by the manufacture.
  • Page 22 -Faulty potentiometer - One of the two rectifier diodes Substitute the potentiometer (Fig. 5 # 27) is not conducting. How to spot the faulty diode: Remove the cover ( Fig. 5 # 32) from the frame. Start the welder and let it work for 5-6 minutes with the flame off and the power control set at the maximum value.
  • Page 23 -The power transformer (Fig. 5 # 40) Empty the tank ( Fig. 5 # is short-circuited . 50 ) and dry accordingly, verify that the anode in ( Fig. 5 # 46 ) and that it is -The fan motor (Fig. 5 # 35) is isolated from the cathode short-circuited.
  • Page 24 Replace the check valve Clean the apparatus - Check valve blocked 6) No gas comes out of the See sec. 5.10.3 and 5.2 burner tip -Torch /burner tip obstructed -Booster tank obstructed In case of gas leakage, repeat steps REMEDY 3 above. -Gas leakage in pneumatic channels a) before opening flame , wait...
  • Page 25 TROUBLE SHOOTING FOR OVER-PRESSURE Possible reasons for Over-pressure Indicators 1) The power control knob is too high for the selected needles (SEE TABLE 2/Table 2A) 2) A backfire has blocked the flame arrester or the check valve is blocked. 3) An obstruction of boric acid crystals has blocked the booster tank, the torches or the needles.
  • Page 26 5.10 INTERVENTIONS 5.10.1 WHAT TO DO IN ORDER TO SEE IF THE TANK IS SHORT- CIRCUITED 1) Disconnect the plug from the correct outlet. 2) Remove the screws and remove the two copper conductors (Fig.5 # 59) from the tank cover (Fig.

  • Page 27: Checking Valve Tightness

    5.10.3 CHECKING VALVE TIGHTNESS When the welder is on, the working pressure must be approximately, (1.0- 1.2 Bar). Then, after turning off the welder, check that the pressure reading on the pressure gauge drops to the approx. 0.5 Bar, over 5-6 minutes. If the pressure drop is greater than 0.5 Bar, replace the valve (see. 5.10.4). ATTENTION If is very important that the valve is tight, since this enables the machine to maintain a minimum pressure of approx.

  • Page 28: Replacing The Electrolyte

    5.10.5 REPLACING THE ELECTROLYTE 1) Empty the spent electrolyte. 2) Pour 1 liter demineralized water into the tank, shake well and empty. 3) Repeat this operation until the water that comes out is clean. 4) Pour the new electrolyte into the tank (sec. 4.2). SECTION 6 SPARE PARTS 6.1 SPARE PARTS Orders for spare parts should be sent to the Manufacturer or Authorized Distributor specifying the...
  • Page 30 Rif. Cod. Description 1976 Three position switch 1200 Safety cap 1050 Power control knob Minimum level indicator light yellow (See Fig. 1 page 6) Maximum level indicator light red (See Fig. 1 page 6) Booster Tank Handle knob Booster holder with 1/8" fitting Torch (see table 1 page 6) 1-5-10-15 Burner tip diameter 0,6-0,7-0,8-0,9 mm (see table 1 page 6)
  • Page 33 TABLE 2 WELDER MOD. L/160 Standard Torch Torches Burner tip external diameter Lt/h Ø 0.5 mm (orange) Ø 0.6 (violet) Ø 0.7 mm (black) Ø 0.7 mm (black) Ø 0.7 mm=N°70 (black) Ø 0.7 mm (black) Ø 0.8 mm (green) Ø...
  • Page 34 TABLE 2* A for welder mod. L/160 SPECIAL TORCH ( with one nozzle ) HOW TO ADJUST THE POWER ACCORDING TO NEEDLE TIP SIZE : and simultaneously Adjust the check the gas sup- Power Con- ply indicator, ac- trol Knob cording to Min and Max L/h.
  • Page 35 Replacement of the flame arrester: Turn off the welder, unscrew the safety cap, close the shut off valve, unscrew the exagon and replace the flame arrester (51) and O. Ring 52-54 (See Table 6 below). Tab. 6 - Special torch welder mod L/160...
  • Page 36 User Information • The symbol aforementioned above, indicates that the equipment machinery is subject to separated collection, from the moment the user determines to get rid of the object, (including its various components, sub- components, subsystems and consumable items that are an integral part of the product.) •...
  • Page 37 ELETTRONICA TODESCATO S.r.l. 36057 Arcugnano (Vicenza) Italia – Via A. Volta, 9/A-C Tel. +39 0444 289227 Fax +39 0444 299229 www.elettronicatodescato.com info @elettronicatodescato.com...

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