Tig Welding - Castolin Eutectic POWERmax2 Operating Manual And Spare Parts List

For welding jobs done under conditions of increased
electrical danger, the following open-circuit voltage ra-
tings apply:
for DC - peak value 113 V,
for AC - peak value 68 V, effective value 48 V.
An AC voltage occurring in the welding circuit may not
exceed 48V. This also applies to welding rectifiers being
used for welding purposes when the equipment is used
e.g. inside a boiler or tank etc. Welding rectifiers for use
inside boilers, tanks and the like must always be clearly
marked with the letter
Workpiece clamp
If the electric flex of the workpiece clamp is shorter than
the torch hose pack or the manual electrode cable -
meaning that the clamp cannot be fixed anywhere imme-
diately near the welding zone - then the welding current
will find its own way back. It may do this via machine parts
(e.g. during repair work) , ball-bearings, electric switches
etc. This may then cause certain parts to become red-
hot, make chains and steel cables snap, and even cause
the PE conductor to melt through.
All this can also happen if the workpiece clamp has
simply not been fastened properly, or only laid on the
surface of the workpiece, in which case the course taken
by the current will depend on the presence of "bridges"
or angle bars and the like (Fig. 1).
L (T)
3
N (MP)
PE
Fig. 1: Power source may never stand on electrically conductive
ground!
Connection to workpiece: NEVER like this! Use a firmly
connected clamp.
PE conductors will be destroyed if the welding current ever
has to find its own way back.
Personal protection
As a basic safeguard, insulating gloves should be
worn on both hands when welding. These protect
against electric shocks (from the open-circuit vol-
tage of the welding current circuit) , harmful rays
(heat and ultra-violet rays) , and against splashes of
red-hot metal or slag.
Solid, insulating footwear should be worn, which
should also insulate the wearer in wet conditions.
Ordinary shoes are not suitable as falling globules of
molten metal can cause burns.
Suitable clothing must be worn - NO synthetics!
Do not look at the arc with unprotected eyes. Use
only protective welding shields with the prescribed
type of safety glass. As well as heat and light rays,
which may cause dazzling or burns, the arc also
gives off ultra-violet rays. These are invisible, and if
the welder is insufficiently protected against them
they can cause conjunctivitis, which only makes it-
self felt several hours later and is extremely painful.
8
(safety) .
Quite apart from this, ultra-violet rays have the same
effect as sunburn on unprotected parts of the body.
Welder´s mates or persons in the immediate vicinity
of the arc must also be made aware of the danger
and provided with the necessary protective appa-
ratus; if necessary, protective screens must be
erected.
Care must always be taken to provide sufficient
fresh air, especially when welding in enclosed spa-
ces, since smoke and harmful gases are produced
during the welding process.
Containers which have been used to store gas, fuel,
mineral oils or other such substances must not be
welded, even if they have been standing empty for a
long time, since there is a high risk of explosion from
any residue.
Special regulations apply to enclosed spaces where
there is a danger of explosion.
Welds which are exposed to heavy stresses and
which have to fulfil strict safety requirements must
only be performed by particularly well-trained and
experienced welders. Examples include things such
as pressurised containers, track rails, trailer coup-
lings, and so on.
Welding with coated electrodes
Commissioning
Follow safety recommendations.
Connect mains plug.
Insert welding and ground cable in sockets accor-
ding to the polarity recommended for the type of
electrode and
Turn on main switch
The diode lights up.
Turn selector switch
ration .
Select welding current strength on read-out poten-
tiometer .
Start welding.
In the event of thermal overload the diode
and the equipment is automatically switched to stand-
by mode.
When the temperature level falls below the temperature
limit, the product is operational once more.
In practice
Possible causes for unexpected machine cut-off:
soiled or concealed ventilation slits,
defective fan,
ambient temperature exceeding 40°C,
duty cycle is exceeded (sequence duration, or cur-
rent amperage).
The POWERmax 2 compensates mains voltage fluctua-
tions of ± 10% avoiding secondary current fluctuations.

TIG welding

TIG welding can be carried out using a gas-cooled TIG
welding torch G 140 RA (140 A / 60% duty cycle DC) or
G 220 RA (220 A / 40% duty cycle DC) with a 4 or 8 m
long cable assembly and an additional adapter cable.
The welding current setting is carried out on the equip-
ment (read-out potentiometer
The ignition of the arc is carried out by means of contact
ignition.
and turn right to lock.
.
to manual electrode ope-
lights up
).