1. Introduction
This manual provides essential information for the safe and effective operation, setup, and maintenance of your TELWIN 816039 Superior 250 Inverter Welder. This machine is designed for MMA (Manual Metal Arc) and TIG-Lift DC (Direct Current) welding processes. Please read this manual thoroughly before operating the equipment.
2. Safety Information
Welding operations involve significant risks. Adherence to safety precautions is paramount to prevent injury or damage. Always follow local safety regulations and guidelines.
- Electric Shock: Welding current can be lethal. Ensure proper grounding. 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. Use fume extraction if necessary.
- Arc Rays: Arc rays can cause eye and skin burns. Always wear a welding helmet with appropriate shade filter and protective clothing.
- Fire and Explosion: Welding sparks and hot metal can cause fires. Keep flammable materials away from the welding area. Have a fire extinguisher readily available.
- Burns: Hot metal and slag can cause severe burns. Wear protective clothing, gloves, and footwear.
- Machine Placement: Place the welder on a stable, level surface. Ensure adequate ventilation around the machine to prevent overheating.
- Power Supply: Connect the welder to a power supply that matches the machine's requirements. Ensure the power cord is in good condition.
3. Product Features
The TELWIN 816039 Superior 250 Inverter Welder offers advanced features for efficient and reliable welding:
- Inverter Technology: Provides stable welding current and high efficiency.
- MMA and TIG-Lift DC Welding: Versatile for various welding applications.
- Microprocessor Control: Ensures precise control over welding parameters.
- Wide Electrode Compatibility: Suitable for cellulosic, aluminum, rutile, basic, stainless, and cast iron electrodes up to 6 mm diameter.
- Compact and Lightweight Design: Enhances portability and ease of use.
- High Stability of Welding Current: Maintains consistent performance even with variations in power supply voltage.
- Instant Drop Transfer Control: Optimizes weld quality.
- Adjustable Arc Force and Hot Start: Customizable settings based on electrode type.
- Anti-Stick Device: Prevents electrode sticking to the workpiece.
- VRD (Voltage Reduction Device): Enhances safety by reducing open-circuit voltage.
- Remote Control Predisposition: Allows for optional remote control integration.
- Protection Systems: Includes thermostatic, overvoltage, undervoltage, and overcurrent protections.
- Motogenerator Compatibility: Operates with motogenerators (+/-15%).
4. Setup
Before operating the welder, ensure proper setup:
- Unpacking: Carefully remove the welder and all accessories from the packaging. Inspect for any shipping damage.
- Placement: Position the welder on a stable, non-flammable surface. Ensure at least 30 cm (12 inches) of clear space around the machine for ventilation.
- Power Connection: Connect the power cable to a suitable electrical outlet that meets the specifications listed in Section 7. Ensure the power switch on the welder is in the "OFF" position before connecting.
- Ground Clamp Connection: Attach the ground clamp cable to the negative (-) terminal on the front panel of the welder. Securely attach the ground clamp to the workpiece or welding table, ensuring good electrical contact.
- Electrode Holder (MMA) / TIG Torch (TIG-Lift) Connection:
- For MMA welding, connect the electrode holder cable to the positive (+) terminal.
- For TIG-Lift welding, connect the TIG torch cable to the negative (-) terminal (for DC TIG). If using a TIG torch with a gas valve, connect the gas hose to a suitable inert gas cylinder (e.g., Argon) with a regulator.
5. Operating Instructions
5.1 Control Panel Overview
Refer to Figure 1 for the location of the following controls:
- Current Adjustment Knob: Located on the right side of the control panel, this knob adjusts the welding current from 10 A to 250 A. The scale indicates current values and recommended electrode diameters.
- MMA/TIG Selector Switch: A toggle switch to select between MMA (Stick) welding and TIG-Lift welding modes.
- Indicator Lights:
- Power Indicator: Illuminates when the machine is powered on.
- Thermal Protection Indicator: Illuminates if the machine overheats, indicating that welding should cease until the light extinguishes.
- VRD Indicator: Illuminates when the Voltage Reduction Device is active, indicating reduced open-circuit voltage for enhanced safety.
5.2 MMA (Stick) Welding
- Select MMA Mode: Set the MMA/TIG selector switch to "MMA".
- Insert Electrode: Securely insert the appropriate electrode into the electrode holder.
- Adjust Current: Turn the current adjustment knob to set the desired welding amperage based on the electrode type and diameter, and the material thickness.
- Power On: Switch the main power switch to "ON". The power indicator light should illuminate.
- Strike Arc: Gently scratch the electrode against the workpiece to initiate the arc. Maintain a consistent arc length.
- Weld: Move the electrode steadily along the joint, maintaining the arc and travel speed.
5.3 TIG-Lift DC Welding
- Select TIG Mode: Set the MMA/TIG selector switch to "TIG".
- Prepare TIG Torch: Ensure a sharpened tungsten electrode is correctly installed in the TIG torch. Connect the gas hose to an inert gas supply (e.g., Argon) and set the gas flow rate.
- Adjust Current: Turn the current adjustment knob to set the desired welding amperage.
- Power On: Switch the main power switch to "ON".
- Initiate Arc (Lift-Arc): Gently touch the tungsten electrode to the workpiece. Lift the torch slightly (1-2 mm) to initiate the arc. The machine will automatically sense the contact and initiate the arc at a low current, then ramp up to the set current.
- Weld: Maintain a consistent arc length and travel speed, feeding filler rod if necessary.
6. Maintenance
Regular maintenance ensures the longevity and optimal performance of your welder.
- Cleaning: Periodically clean the exterior of the machine with a dry, soft cloth. Use compressed air to blow out dust from the ventilation grilles, ensuring the machine is unplugged before cleaning.
- Cable Inspection: Regularly inspect welding cables, electrode holder, ground clamp, and power cord for cuts, cracks, or damaged insulation. Replace damaged components immediately.
- Terminal Connections: Ensure all cable connections to the welder terminals are tight and free from corrosion.
- Storage: Store the welder in a clean, dry environment, protected from dust and moisture, when not in use.
7. Troubleshooting
This section addresses common issues you might encounter:
| Problem | Possible Cause | Solution |
|---|---|---|
| Welder does not power on. | No power supply; faulty power cord; internal fuse blown. | Check power outlet and circuit breaker. Inspect power cord. Contact service if fuse is suspected. |
| No welding arc. | Poor ground connection; incorrect current setting; wet electrode; faulty cables. | Ensure ground clamp has good contact. Adjust current. Use dry electrodes. Inspect cables. |
| Thermal protection light is on. | Overheating due to prolonged use or insufficient ventilation. | Allow the machine to cool down. Ensure clear ventilation. Reduce duty cycle. |
| Electrode sticks frequently (MMA). | Low current setting; improper arc striking technique; damp electrode. | Increase current. Improve arc striking. Use dry electrodes. |
For issues not listed here or if troubleshooting steps do not resolve the problem, contact qualified service personnel.
8. Specifications
- Model: TELWIN 816039 Superior 250 Inverter
- Welding Processes: MMA, TIG-Lift DC
- Regulation Range: 10 - 250 A
- Dimensions (L x W x H): 41 x 17 x 34 cm
- Net Weight: 8.4 kg
- Electrode Diameter (MMA): Up to 6 mm (for various types including cellulosic, aluminum, rutile, basic, stainless, cast iron)
- Protection Features: Thermostatic, Overvoltage, Undervoltage, Overcurrent, Anti-Stick, Hot Start, Arc Force, VRD
- Motogenerator Compatibility: Yes (+/-15%)
9. Warranty and Support
For warranty information, please refer to the warranty card included with your product or contact your authorized TELWIN dealer. For technical support or service, please contact TELWIN customer service or an authorized service center. Keep your purchase receipt as proof of purchase for warranty claims.
