Hanshen NBC-250D User manual

OPERATION
MANUAL
Inverter CO2/MAG Gas Shielded
Welding Machine
NBC-250D/350M
Attention:
For your safety, please only allow technicians to operate, maintain
and repair this machine.
You are advised to read this operation manual thoroughly before
operating the machine. Please keep this manual for future reference
and safety information.

-1-
CONTENT
1. Characteristics……………………………………………………..2
2. Safety information…………………………………………………3
3. Technical parameters………………………………………………4
4. Installation and connection………………………………………..5
5. Function introduction……………………………………………...8
6. Operation…………………………………………………………10
7. Daily maintenance and troubleshooting………………………….14
8. Circuit diagram…………………………………………………...17

-2-
1. CHARACTERISTICS
NBC-250D/350M inverter CO2/MAG welding machine is a high quality and semi-automated arc
welding machine. This product adopts DSP digital control technology,stable performance,with
function of wave control, can realize CO2 welding, CO2 spot welding and MMA welding.It is
mainly applied in welding low carbon steel, low metal alloys and other dark metals. Mixed gas or
flux cord wire can be used to weld stainless steel. NBC series has outstanding characteristics of
thyristor welding machine:
1.1 High quality of welding
Adopts Independent Intellectual Property Rights controlling circuit to ensure the
performance as well as the outstanding dynamic response, which gives an aesthetic weld.
1.2 Outstanding molten globule elimination function, coupled with special arc ignition circuit can
lead to almost 100% arc ignition success.
1.3 Stable welding process
Adopts high-speed feedback circuit, anti-interference system, and anti-internet fluctuation to
fulfill stable welding.
1.4 Electricity saving
Advanced PWM inverter technology and the compensation from the grid voltage greatly
reduce the input voltage hence saves electricity.
1.5 Preset function
Straightforward welding current display, easy operation and is suitable for first time learner.
1.6 Greatly reduces splashing
Adopts waveform control technology, which greatly reduces splashing and enables all
position welding.
1.7 Small size and light weight
Compared to thyristor controlled welding machine, NBC series is much lighter and smaller, the
weight is about 1/6 of the thyristor ones. Good adaptability under all kinds of conditions and
environments.
1.8 Multi-usage
With CO2 welding, MMA welding,CO2 spot welding functions.

-3-
2. SAFETY INFORMATION
2.1 To avoid fatal accidents, please observe the following:
a. Ensure that you operate the equipment with the power source of correct voltage as provided
by your country;
b. Ensure that you comply with the laws of your country on position for welder’s installation,
high-pressure gas, storage of materials and treatment of exhaust;
c. Ensure that you wear the safety equipment and dress for the protection of your eyes and skin;
d. Ensure that there is proper ventilation in place of welding to prevent injury or harm from
smoke and gas exhaustion;
e. Do not open the DOS shell of the welder or use it in open position.
2.2 Prevention from burning and fire
a. Always keep the welder at least 50cm away from the wall and inflammables;
b. Keep sparks away from tinder or the open holes;
c. Fasten the welder properly with fixed bolts if it is to be installed on high position for use;
d. Do not weld tubes, hermetic tubes or vessels through which combustion gas is traveling.
2.3 Connection and usage
a. Always disconnect the power when trying to connect gas to the welder.
b. Do not touch any electrical components in the welder or wear wet or torn gloves.
c. Make sure the correct cables are being used.
d. Do not put weight on the cable or place the workpiece in contact with the cable.
e. Always make sure the cable is correctly connected and wrap any naked wires with
insulation tape.
f. Please only allow authorized electrician to earth the welder and other accessories.
g. Disconnect all power when not in use.
2.4 Other noticeable points
a. If the welder is put on inclined surface, please make sure it does not fall.
b. Do not use the welding power for tube defrosting.

-4-
3. TECHNICAL SPECIFICATION
Table 1 Technical specifications
Model
Specifications
NBC-250D
NBC-350M
Rated input voltage (V)
3-380V,50Hz
Rated input current (A)
17
24
Output current adjustable
range（A）
60-250
60-350
Output voltage adjustable
range (V)
17-27
17-32
Open circuit voltage（V）
54
64
Rated duty cycle
60（Room temperature 40℃）
Welding wire diameter
0.6、0.8mm
0.8、1.0mm
Insulation grading
F
Shell protection degree
IP21S
Dimension
(W×D×H mm)
475*235*410(mm)
565*280*500(mm)
Weight（kg）
18
26.5
NB：According to CISPR 11, the electromagnetic compatibility of this welder is type A

-5-
4. INSTALLATIONS AND CONNECTION
4.1 Places for use
Always place the welder on a dry, clean and solid ground for use.
Do not use the welder at the following locations:
a. direct sunshine or rain
b. dusty with inflammable gas
c. harmful and caustic gas
d. highly humid steam
e. high vibration
f. small space with less than 50cm distance to surroundings
g. temperature higher than +40℃or lower than-10℃
4.2 Earthing
Connect the welder’s earthing connector to the earthing line to avoid damage from electric shocks.
4.3 Ventilation
To ensure welding quality, please minimize the effect the wind has on arc. In enclosed space,
please make sure there is enough oxygen from ventilation.
4.4 Power and cable
Table 2 Power and cable
Power
3Phase AC（380V）50Hz
Model
NBC-250D
NBC-350M
Capacity
Suitable power
11KVA above
16KVA above
Engine power
generator
11KVA*2 above
16KVA*2 above
Input protective
equipment
Fuse
26A
36A
Cable cross
sectional area
Power input
4mm2 above
6mm2 above
Power output
25mm2 above
35mm2 above
Earthing line
10mm2 above
10mm2 above
Please install electricity leakage safeguard protector when the ground is damp or operate on
iron plate and rack.
Please only use the appointed wire feeder.

-6-
4.5 Connection
a．All connections must be made with compilation to table 2.
b．All cables should have good conductivity and all naked wires must be wrapped with
insulation tape.
c. After finishing the cable connections, please make sure the power supply cover is securely
closed and the screws are fastened. Please do not operate the machine when the cover is
open.
d. Please do not exert force onto the cables.

-7-
Figure 1 Connection Illustration

-8-
5. FUNCTIONS INTRODUCTION
5.1 Front control panel
Figure 2. NBC-350M front and back control panel
Table 3 Power source function introduction
Serial
number
Names
Functions
1
Current display
Output ammeter, displays the relative magnitude of wire
feeding speed when on standby; displays the actual welding
current magnitude during actual welding process.
2
Voltage display
Output voltmeter, displays the set value of voltage when on
standby; displays the actual welding voltage during actual
welding process.
3
MAG/MMA
MAG/MMA option buttons
4
Crater arc on/
crater arc off/
spot welding
Crater arc on/crater arc off/spot welding option buttons

-9-
5
Gas test
when the switch is in ‘Gas test’, the solenoid valve is on, CO2
gas flow can be checked if it is of suitable amount
6
Wire feeder
Connect the wire feeder control cable.
7
-
Welding machine output negative
8
+
Welding machine output anode
9
Inductance
regulation
when in MAG or spot welding condition, will change welding
stability,penetration and splash
10
Crater arc voltage
MAG: adjust the crater arc voltage when in “crater arc on”
MMA: adjust the pushing current,Can change the arc stiffness,
reducing welding spatter
Spot welding: adjust spot welding time
11
Crater arc current
MAG: adjust the crater arc current when in “crater arc on”
MMA: adjust the welding current
Spot welding: adjust spot welding interval time
12
Wire feeding(8A)
When the control circuit of wire feeder is in a short circuit, the
fuse will break to protect the transformer.
13
Power supply box
Used to connect the welder into 380V power.
14
Air break switch
Aim to protect the welder from overloading or defect. Under
normal condition, the switch is lifted up and stays on
15
Power（2A）
When the control circuit of welding machine is in a short
circuit, the fuse will break to protect the transformer.
16
Heating fuse(8A)
When there is a short circuit in the heating pressure reducing
flow meter, the fuse will break to protect the transformer.
17
Heating power
output plug
To provide 36V heating power for heating pressure reducing
flow meter
18
Cooling fan
To cool the internal parts.
19
Grounding bolt
Ground this bolt securely for safety.
5.2 Wire feeder panel
Figure 3. Control panel illustration of wire feeder

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Table 4 Wire feeder panel function introduction
Serial
number
Names
Functions
1
Current adjustment
knob
Used to adjust welding current, when preset the current, it
will display the relative graduated value from 2-100.
2
Manual wire
feeding button
Used to feed the wire into torch before welding.
3
Voltage adjustment
knob
Used to adjust voltage.
6. OPERATION
6.1 Preparation
a. Switch the power on, the power indicator light of the welder will be on, the fan starts to
work. N.B. When pressing the torch switch, there will be an out voltage, the shell of the
heating pressure reducing flow meter will heat up.
b. Choose the appropriate wires based on different workpiece, then choose the right wire-
feeding wheel, nozzle based on the wires chosen.
c. Press ‘Manual wire-feeding’ button, wire is then fed into the torch.
d. Switch to ‘Gas test’ on the torch panel, adjust the flow meter valve, choose the appropriate
flow, and then switch to ‘welding’ status.
6.2.1 Spot weld and short seam weld
a. Switch the end arc ON/OFF to ‘OFF’ position.
b. Adjust the ‘welding current’, ‘welding voltage’ knobs according to welding preference.
c. Press the torch switch, the welder will start working; release the welding torch switch,
welding process will be stopped. When using the welding trolley, press ‘start’, welder will
start working; press ‘start’ again, welding process will be stopped.

-11-
6.2.2 Long weld seam and large current welding
a. Switch the end arc ON/OFF to ‘ON’ position.
b. Adjust the ‘welding current’, ‘welding voltage’ knobs according to welding preference.
c. Press the torch switch, arc will be ignited, then the welder will enter normal working state,
the torch switch can be now release, the welder will continue to weld; press the torch switch
again, the welder will enter an ending arc (filling arc crater) state, and output a smaller norm,
now release the torch switch, the welder will stop welding.
6.3 process specification
Table 5 welding technology specification 1
Plate
thickness
(mm)
Wire
diameter
Φ
(mm)
Root
gap
(mm)
Welding
Current
(A)
Welding
Voltage
(V)
Weldi
ng
speed
(cm/
min)
Distance
between
nozzle
and base
metal
(mm)
Gas
Flow
(L/min)
I-shaped
butt welding
Low speed condition
0.8
0.8,
0.9
0
6070
1616.5
5060
10
10
1.0
0.8,
0.9
0
7585
1717.5
506
0
10
1015
1.2
0.8,
0.9
0
8090
1718
506
0
10
1015
1.6
0.8,
0.9
0
95
105
1819
45
50
10
1015
2.0
1.0,
1.2
00.5
110
120
19
19.5
45
50
10
1015
2.3
1.0,
1.2
0.5
1.0
120
130
19.520
45
50
10
1015
3.2
1.0,
1.2
1.0
1.2
140
150
2021
45
50
1015
1015
4.5
1.0,
1.2
1.0
1.5
170
185
2223
40
50
15
15
6.
0
1.2
1.2
1.5
230
260
2426
40
50
15
1520
1.2
1.2
1.5
230
260
2426
40
50
15
1520
9.
0
1.2
1.2
1.5
320
340
3234
40
50
15
1520
1.2
1.2
1.5
320
340
3234
40
50
152
1520
High speed condition
0.8
0.8,0.9
0
89
16.5
120
10
15
1.0
0.8,0.9
0
100
17
120
10
15
1.2
0.8,0.9
0
110
18
120
10
15
1.6
1.0,1.2
0
160
19
120
10
15
2.0
1.0,1.2
0
180
20
80
15
15
2.3
1.0,1.2
0
200
22
100
15
20
3.2
1.2
0
240
25
100
15
20

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Table 6 welding technology specification 2
Plate
thick
ness
(mm
)
Weldi
ng
length
(mm)
Wire
diameter

(mm)
Welding
Current
(A)
Weldin
g
Voltage
(V)
Weldin
g speed
(cm/mi
n)
Distanc
e
betwee
n
nozzle
and
base
matal
(mm)
Targe
t
positi
on
A/B
Gas
flow
(L/min
)
T-shaped flat
fillet welding
Low speed condition
1.0
2.53
0.8，0.9
7080
1718
5060
10
A
1015
1.2
3
3.5
0.9，1.0
8590
1819
5060
10
A
1015
1.6
3
3.5
1.0，1.2
100
110
18
19.5
5060
10
A
1015
2.0
3
3.5
1.0，1.2
115
125
19.520
5060
10
A
1015
2.3
3
3.5
1.0，1.2
130
140
19.521
5060
10
A
1015
3.2
3.54
1.0，1.2
150
170
2122
4550
15
A
1520
4.5
4.55
1.0，1.2
180
200
2324
4045
15
A
1520
6
5
5.5
1.2
230
260
2527
4045
20
A
1520
8，9
67
1.2，1.6
270
380
2935
4045
25
B
2025
High speed condition
12
78
1.2，1.6
300
380
3235
3540
25
B
2025
1.0
2
2.5
0.8，0.9
140
1920
150
10
A
15
1.2
3
0.8，0.9
140
1920
110
10
A
15
1.6
3
1.0，1.2
180
2223
110
10
A
1520
2.0
3.5
1.2
210
24
110
15
A
20
2.3
3.5
1.2
230
25
100
20
A
25
3.2
3.5
1.2
260
27
100
20
A
25
4.5
4.5
1.2
280
30
80
20
B
25
6
5.5
1.2
300
33
70
25
B
25

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Table 7 welding technology specification 3
Plate
thickne
ss
(mm)
Wire
diamete
r

(mm)
Welding
current
(A)
Welding
voltage
(V)
Weldi
ng
speed
(cm/m
in)
Distan
ce
betwe
en
nozzle
and
base
metal
(mm)
Target
position
A/B/C
Flat welding lab
joints(thin plate)
Low speed condition
0.8
0.8 ，
0.9
6070
1617
4045
10
A
1015
1.2
0.8 ，
0.9
8090
1819
4550
10
B
1015
1.6
0.8 ，
0.9
90100
1920
4550
10
B
1015
2.3
0.8 ，
0.9
100130
2021
4550
10
C
1015
1.0 ，
1.2
120150
2021
4550
10
C
1015
3.2
1.0 ，
1.2
150180
2022
3545
1015
C
1015
4.5
1.2
200250
2426
4050
1015
C
1015
High speed condition
2.3
3.2
1.2
220
24
150
15
B或C
25
300
26
250
15
B或C
25
Table 8 welding technology specification4
Plate
thickn
ess
(mm)
Wire
diamet
er

(mm)
Welding
current
(A)
Welding
voltage
(V)
Welding
speed
(cm/min)
Distanc
e
between
nozzle
and
base
metal
(mm)
Gas
flow
(L/min)
Conner joint
(thin plate)
Low speed
condition
1.6
0.8，0.9
6575
1617
4045
10
1015
2.3
0.8，0.9
80100
1920
4045
10
1015
3.2
1.0，1.2
130150
2022
3540
1015
1015
4.5
1.0，1.2
150180
2123
3035
1015
1015

-14-
7. DAILY MAINTENANCE AND TROUBLE SHOOTING
WARNING:
Only maintain or check the machine when the power is cut off.
7.1 Attention：
a. Make sure the welding cables are securely connected otherwise the connectors will be
burnt, which causes instability during welding.
b. Avoid the contact between naked cable or connector and the metal on the ground to
prevent short circuit.
c. Avoid wearing down and breaking of the welding and control cable.
d. Avoid machine distortion from impact; do not put loads on welder.
e. Keep ventilation on.
f. For long-term best performance, please conduct regular checks i.e. regular checks of
internal parts and cleaning of some parts.
g. Under normal condition, there will be enough accumulation of sparks and oil dusts inside
the welder during 6 months. If the environment is not as clean, there will even more sparks
and oil dusts. It is advised to check and clean the machine every 3 months.
h. Conduct regular checks on cable, knobs and other parts on the panel.
I. Change the wire feeding wheel and nozzle on a regular basis and clean the wire feeding
tube.

-15-
7.2 Trouble shooting
Table 9 Trouble shooting
Serial
number
Troubles
Possible causes
Solutions
1
Indicator light is not on after
switching on power.
1. Damage to air switch on
back panel
2. Fuse broke
1. Change air switch
2. Change fuse
2
When the power is switched
on, the air switch shuts off.
1. Air switch is broken
2. IGBT is broken
3. 3-phase commutate bridge
broke
4. Controlling panel is broken
1. Change air switch
2. Change IGBT
3. Change 3-phase
commutate bridge
4. Change controlling
panel
3
When welding,ampere meter
display E01
1.For a long time overload
running
1.According to the welding
machine duty cycle to use
4
Cannot adjust welding
current
1. Wire feeder control cable
breaks or control PCB is
damaged.
2. The connection wire of
current divider is broken.
3. Controlling panel of the
welder broke.
1. Change wire feeder
control cable or PCB.
2. Reconnect the lines
3. Change control panel of
the welder.
5
Unstable arc, big splash
1. Wrong procedure
2. Badly worn nozzle
1. Correct procedure
2. Change nozzle
6
Heating pressure reducing
flow meter won’t heat up
1. Heating pressure reducing
flow meter is broken
2. Short circuit
3. Broken fuse
4. No output from welder
1. Change heating pressure
reducing flow meter
2. Fix the heating cable
3. Change 8A fuse
4. Check if there is output
from welder.

-16-
7
Press torch switch, wire
feeding is normal but no gas
flow.
1. Control motherboard of the
welder is broken
2. Electromagnetic valve is
broken
1. Change the control
motherboard.
2）Change the
electromagnetic valve.
8
Press the torch switch, wire-
feeder does not work, and no
open-circuit voltage.
1. Torch switch is broken.
2. Control cable of the wire-
feeder is broken.
1. Change torch.
2. Fix the control cable of
wire-feeder.
7.3 Solutions after diagnose
7.3.1 Broken fuse
After diagnosing the causes (e.g. overloading, short circuit and etc.), change the fuse. If the fuse is
broken again after closing the circuit, please shut off the power and contact us.
7.3.2 Problems with the PCB.
Please contact us.
7.3.3 Other faults
Please check corresponding parts and change them.
7.3.4 Others
Please check if there is any wrong or loose connection
7.4 After-sale service
a. Please refer to this manual for any common faults.
b. Please contact the seller or manufacturer for repair.
c. Please provide the following information when requesting a repair:
Your name, address and contact number.
Model number and machine type.
Details of any problems or faults.

-17-
8. CIRCUIT DIAGRAM
送丝机电路
M
-
+
SSJ
24V
QF
45
6 12 3
W
V U
~
~ ~
BR1 MDS50-16
RY4
MYG20D-911K
VT1
GU50HCU120B3S
D1-4
MM80FU040BC
D5-8
MM80FU040BC
R2,3 2W/10Ω
C2-3
103P/1KV
R1
25W/250Ω
C1
CT81-103P/3KV
C2
CT81-103P/3KV
C1
MKP-DL-100UF/800V
S1 DZ47-63/D32
8 7 5 6
4 3 1 2
L4
+
-
FL 400A/75m V
RP3 47K
FUSE1 2A
C13 CBB610-1UF/630VAC
D2
IN4007
D1
IN4007 A
15A502
V
B502
R1
1W/10K
TS
IPB
RJ:JUC-17F-80℃
RP2 收弧电压
RP1
收弧电流
T1:FH4.702.092
CT2
弧特性
~9V ~19V ~19V
FUSE2 8A
~27V
380V 220V 0V
FS
12T
DC24V
200FZY2-D/220V
4K7
4K7
R6
1W/510K
R1
1W/10K
R2
1W/10K
R4
1W/10K
R3
1W/10K
97 96
1 3
2
3
97
2 1
CN3
CN4
CN5
8
7
6 5
1
3
CN1
2 1
1
3
CN2
~19V ~19V
1
98 2
2
2
D1 SR1A0 D2 SR1A0
D3 SR1 A0 D4 SR1 A0
R2
2W/22Ω
A B
R2,3
2W/10Ω
C2-3
103P/1KV
TR1
C-6,7,8
2.2UF/630V
993
105
97
415V
FH7.820.467B(2014/09/12)
HC-S-AP2
FH7.820.294C HC-Ⅱ -AP3
FH7.820.295B
R2 1W/220Ω
R1
15W/47Ω C1 102P/2KV
R3
15W/47Ω C3 102P/2KV
R2
15W/47Ω C2 102P/2KV
R4
15W/47Ω C4 102P/2KV
3 4
7 8
4
5
4
5
6
5
4
3
2
1
FH7.820.491B
FH7.820.482B
FH7.820.482B
主控板 PCB1
CN7
1 6 2 3 2 2
FUSE3 8A
1
1
2
2
3
3
1
3
CN8
2
4
5
1 2 3
1
2
4
3
5
CN5
CN1
6
1
2
3
CN10
1
2
4
3
5
CN2
6
1
2
4
3
5
6
1 2 4 3 5 6 1 2 3
1
2
4
3
5
CN3
6
7
8
1
2
3
4
1 2 3
4
R2 R1
R3
C1,C2,C3:2.2UF/6 30V R1,R2,R3:1W/510K FH7.820.492A
RY4
MYG20D-911K
FH7.820.474 FH7.820.474
CN3 CN2
CN1
CN4
38
38
47
115
115
61
115
67
49
115
48
98
97
96
115
40
56
208
200
201
97
105
1
2
3
75
76
33 15 70
71
TVS1 P6KE18CA TVS2 P6KE18CA
TVS3 P6KE18CA TVS4 P6KE18CA
12T
R1
2W/27Ω
NBC-M-AP1
81
82
83
84
85
86
81
82
83
84
85
86
28
29
34
35
22 23 87 87 89 89 88 88
FH7.820.541A