1. Introduction
This manual provides essential information for the safe and efficient operation, maintenance, and troubleshooting of your TOTAL TW22005 Digital Welding Machine Inverter. Please read this manual thoroughly before using the machine to ensure proper handling and to prevent injury or damage.
The TOTAL TW22005 is a 200 Amp Digital Welding Machine Inverter designed for various welding applications. It features IGBT Inverter Technology for stable arc performance and efficient power usage.
2. Safety Instructions
Always prioritize safety when operating welding equipment. Failure to follow these instructions can result in serious injury or death.
- Personal Protective Equipment (PPE): Always wear a welding helmet with appropriate shade, flame-resistant clothing, welding gloves, and safety shoes.
- Ventilation: Ensure adequate ventilation to remove welding fumes, which can be hazardous to health.
- Electrical Safety:
- Ensure the power supply matches the machine's requirements (1~220-240V).
- Never operate the machine with damaged cables or connectors.
- Ensure proper grounding of the workpiece and the machine.
- Avoid welding in wet conditions.
- Fire Prevention: Keep flammable materials away from the welding area. Have a fire extinguisher readily available.
- Arc Rays: Welding arc rays can cause eye and skin burns. Protect yourself and bystanders.
- Electromagnetic Fields (EMF): Persons with pacemakers or other medical implants should consult their doctor before operating welding equipment.
3. Setup and Connections
Before starting any welding operation, ensure the machine is correctly set up and all connections are secure.
- Unpacking: Carefully remove the welding machine and all accessories from its packaging. Inspect for any shipping damage.
- Placement: Place the welding machine on a stable, level surface, ensuring adequate clearance for ventilation around the unit.
- Power Connection: Connect the power cord to a suitable 1~220-240V power outlet. Ensure the power switch on the machine is in the OFF position before connecting.
- Earth Clamp Connection: Connect the earth clamp cable to the negative (-) terminal on the front panel of the welding machine. Securely attach the earth clamp to the workpiece or welding table, ensuring good electrical contact.
- Electrode Holder Connection: Connect the electrode holder cable to the positive (+) terminal on the front panel of the welding machine. Insert the welding electrode into the electrode holder.
Image Description: The image displays the teal and white TOTAL TW22005 Digital Welding Machine Inverter from a three-quarter front view. The machine has a handle on top, ventilation grilles on the sides, and a control panel on the front with a digital display, an amperage adjustment knob, and power/overheat indicator lights. Below the control panel are the positive (red) and negative (black) terminals for welding cable connections. To the left of the main machine, a smaller diagram illustrates the basic setup: the welding machine connected to a 1~220-240V power source, with an electrode holder connected to the workpiece and an earth clamp also connected to the workpiece (base metal), completing the circuit.
4. Operating Instructions
Follow these steps for safe and effective operation of your welding machine.
- Power On: Once all connections are secure, switch the power button to the ON position. The digital display should illuminate, and the 'POWER' indicator light will turn on.
- Set Amperage: Use the amperage adjustment knob on the front panel to set the desired welding current. The digital display will show the selected amperage. Refer to electrode manufacturer guidelines for recommended settings.
- Prepare Workpiece: Ensure the workpiece is clean, dry, and free of rust, paint, or grease to ensure good electrical conductivity and a quality weld.
- Start Welding: Strike an arc by gently touching the electrode to the workpiece and quickly lifting it slightly to maintain the arc. Maintain a consistent arc length and travel speed.
- Monitor Overheat Indicator: If the 'OVER-HEAT' indicator light illuminates, the machine has exceeded its thermal limit. Stop welding immediately and allow the machine to cool down. The light will turn off when it's safe to resume.
- Power Off: After completing your welding tasks, switch the power button to the OFF position and disconnect the machine from the power supply.
5. Maintenance
Regular maintenance ensures the longevity and optimal performance of your welding machine.
- Cleaning:
- Periodically clean the exterior of the machine with a dry, soft cloth.
- Use compressed air to blow out dust and debris from the ventilation grilles. Ensure the machine is unplugged before cleaning.
- Cable Inspection: Regularly inspect welding cables, electrode holder, and earth clamp for cuts, cracks, or loose connections. Replace damaged components immediately.
- Storage: Store the welding machine in a clean, dry, and well-ventilated area, away from direct sunlight and extreme temperatures.
- Professional Service: For internal repairs or complex issues, contact qualified service personnel. Do not attempt to open the machine casing yourself, as it may void the warranty and expose you to electrical hazards.
6. Troubleshooting
This section addresses common issues you might encounter with your welding machine.
| Problem | Possible Cause | Solution |
|---|---|---|
| Machine does not power on. | No power supply; Power switch off; Blown fuse/tripped breaker. | Check power outlet and cord; Ensure power switch is ON; Check building's electrical panel. |
| No welding arc. | Poor earth clamp connection; Loose welding cable connections; Incorrect amperage setting; Wet electrode. | Ensure good contact for earth clamp; Tighten all cable connections; Adjust amperage; Use dry electrodes. |
| 'OVER-HEAT' indicator is on. | Machine has overheated due to prolonged use or insufficient ventilation. | Stop welding and allow the machine to cool down. Ensure ventilation grilles are clear. |
| Unstable arc. | Incorrect amperage; Poor electrode quality; Contaminated workpiece; Long arc length. | Adjust amperage; Use quality electrodes; Clean workpiece; Maintain proper arc length. |
7. Specifications
Key technical specifications for the TOTAL TW22005 Digital Welding Machine Inverter:
- Model: TW22005
- Brand: TOTAL
- Type: Digital Welding Machine Inverter
- Amperage: 200 Amp
- Power Source Type: AC
- Input Voltage: 1~220-240V
- Technology: IGBT Inverter Technology
- Material: Stainless Steel
- Color: Multi (Teal White)
- Item Weight: 1 Kilograms
- Package Dimensions: 24.5 x 9.6 x 1.9 cm
- Included Components: TW22005 (main unit)
8. Warranty and Support
For warranty information, service, or technical support, please refer to the documentation provided with your purchase or contact TOTAL customer service. Keep your purchase receipt as proof of purchase for warranty claims.
Note: Unauthorized repairs or modifications may void your warranty.
