1. Introduction
This manual provides essential information for the safe and efficient operation, setup, and maintenance of your Telwin BIMAX 162 TURBO 230V continuous wire welding machine. This machine is designed for FLUX (no gas) and MIG-MAG (gas) welding, and is also equipped for spot welding. Please read this manual thoroughly before using the equipment.
2. Safety Instructions
WARNING: Welding operations can be dangerous. Always follow safety precautions to prevent injury or damage.
- Electric Shock: Always ensure the machine is properly grounded. Do not touch live electrical parts. Wear dry welding gloves.
- Fumes and Gases: Welding produces fumes and gases that can be hazardous to health. Work in a well-ventilated area or use a fume extractor.
- Arc Rays: Arc rays can burn eyes and skin. Always wear a welding helmet with appropriate filter lenses and protective clothing.
- Fire and Explosion: Welding sparks and hot metal can cause fires. Keep flammable materials away from the welding area.
- Burns: Hot metal and equipment can cause severe burns. Wear protective gloves and clothing.
- Moving Parts: Keep hands and body clear of moving parts like wire feed rollers.
Always disconnect the power supply before performing any maintenance or adjustments.
3. Product Overview
The Telwin BIMAX 162 TURBO is a versatile continuous wire welding machine designed for various welding tasks. Key features include:
- Multi-process Capability: Supports FLUX (no gas) and MIG-MAG (with gas) welding.
- Spot Welding Function: Equipped for spot welding with electronic time regulation.
- Integrated Fan: Ensures efficient cooling during operation.
- Thermostatic Protection: Automatically shuts down the machine to prevent overheating.
- Portability: Mounted on wheels for easy movement within the workspace.
- Accessories: Supplied with FLUX welding accessories.
Image 1: Telwin BIMAX 162 TURBO 230V Welding Machine. This image shows the overall design of the welding machine, highlighting its compact structure and integrated wheels for mobility.
4. Setup
- Unpacking and Inspection: Carefully remove the welding machine from its packaging. Inspect for any signs of damage during transit. Report any damage to your supplier immediately.
- Placement: Position the machine on a stable, level surface, ensuring adequate ventilation around the unit. The machine is equipped with wheels for easy relocation.
- Power Connection: Connect the machine to a 230 V, 50/60 Hz single-phase power supply. Ensure the power outlet is properly grounded and capable of handling the machine's maximum power draw (up to 3.7 kW).
- Wire Spool Installation: Open the wire compartment and install the appropriate welding wire spool (0.1 to 1.2 mm diameter). Thread the wire through the feed mechanism according to the instructions provided on the machine or in a separate wire installation guide.
- Connecting Welding Accessories:
- Ground Clamp: Connect the ground clamp cable to the appropriate terminal on the machine and securely attach the clamp to the workpiece, ensuring good electrical contact.
- Welding Torch: Connect the welding torch cable to the designated connector on the machine. Ensure all connections are tight.
- Gas Cylinder (for MIG-MAG): If performing MIG-MAG welding, connect the gas regulator to the appropriate shielding gas cylinder and then connect the gas hose from the regulator to the machine's gas inlet.
5. Operating Instructions
Before operating, ensure all safety precautions are understood and followed.
5.1. Powering On and Initial Settings
- Turn on the main power switch on the machine.
- Select the desired welding process (FLUX or MIG-MAG) using the control panel.
- Adjust the welding current (amperage) and wire feed speed according to the material thickness and wire type. The regulation range is 30 to 145 Amperes.
5.2. FLUX Welding (No Gas)
- Ensure the machine is set to FLUX mode.
- No external shielding gas is required as the flux-cored wire produces its own shielding.
- Proceed with welding, maintaining proper arc length and travel speed.
5.3. MIG-MAG Welding (With Gas)
- Ensure the machine is set to MIG-MAG mode.
- Open the valve on the shielding gas cylinder and set the flow rate on the regulator to the recommended level for your application.
- Proceed with welding, ensuring consistent gas flow for proper shielding.
5.4. Spot Welding
- Select the spot welding function on the control panel.
- Adjust the electronic regulation for the spot welding time as required for the material thickness.
- Position the torch and activate the trigger for a controlled spot weld.
6. Maintenance
Regular maintenance ensures the longevity and optimal performance of your welding machine. Always disconnect the power supply before performing any maintenance.
- Daily: Check the welding torch nozzle and contact tip for wear. Clean any spatter. Ensure the ground clamp connection is clean and secure.
- Weekly/Monthly: Clean the wire feed rollers and guide tubes. Inspect all cables for damage. Check the cooling fan for obstructions.
- Storage: When not in use, store the machine in a clean, dry environment, protected from dust and moisture.
7. Troubleshooting
Refer to this section for common issues and their potential solutions.
| Problem | Possible Cause | Solution |
|---|---|---|
| Machine does not power on. | No power supply; tripped circuit breaker; faulty power cable. | Check power connection and circuit breaker. Inspect power cable for damage. |
| No arc or weak arc. | Poor ground connection; incorrect settings; worn contact tip; wire feed issue. | Ensure good ground contact. Adjust amperage/wire speed. Replace contact tip. Check wire feed mechanism. |
| Machine overheats and shuts down. | Exceeded duty cycle; blocked ventilation; fan malfunction. | Allow machine to cool down. Ensure clear ventilation. Check fan operation. |
| Poor weld quality (porosity, spatter). | Incorrect gas flow (MIG-MAG); contaminated workpiece; incorrect settings; worn consumables. | Check gas flow and connections. Clean workpiece. Adjust settings. Replace nozzle/tip. |
If problems persist, contact Telwin customer support or a qualified service technician.
8. Specifications
| Feature | Value |
|---|---|
| Model | BIMAX 162 TURBO 230V |
| Part Number | 821012 |
| Product Code (from image) | 07170110 |
| Network Voltage | 230 V - 50/60 Hz (Single-phase) |
| Maximum Power | 1.4 / 3.7 Kw |
| No-load Voltage | 31 Volts |
| Regulation Range | 30 / 145 Amperes |
| Electrode/Wire Diameter | 0.1 to 1.2 mm |
| Product Dimensions (L x W x H) | 650 x 330 x 490 mm (from OCR image) |
| Item Weight | 26 KG (from OCR image) / 25 Kilograms (from Amazon data) |
| Thermostatic Protection | Yes |
| Welding Types | FLUX (no gas), MIG-MAG (gas), Spot Welding |
| Display Type | Digital |
Note: Specifications are subject to change without notice. Refer to the product label for the most accurate information.
9. Warranty and Support
For warranty information, technical support, or service, please contact your authorized Telwin dealer or visit the official Telwin website. Keep your purchase receipt as proof of purchase for warranty claims.
Telwin Official Website: www.telwin.com
