Kedr MIG 160GDM User manual

MIG 160GDM/180GDM
WELDING MACHINE
USER MANUAL

Preface
This manual includes hardware descri tion and o eration introduction of the equi ments. For your
and other eo le’s safety, lease read the manual carefully.
Pay attention
Pay attention to the words after the signs below.
Sign Description
The words after this sign means there is great otential danger,
which may cause major accident, damage or even death, if it is
not followed.
The words after this sign means there is some otential danger,
which may cause hurt or ro erty lose, if it is not followed.
The words after this sign means there is otential risk, which may
cause equi ment fault or break, if it is not followed.
Version
Version YF-TAE-0059, A0, Released at 30th, 03, 2016.
The contents of this manual are u dated irregularity for u dating of roduct. The manual is only
used as o eration guide, exce t for other romises. No warranties of any kind, either ex ress or
im lied are made in relation to the descri tion, information or suggestion or any other contents of
the manual.
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Content
1 Safety warning............................................................................................................................... 3
2 Product.......................................................................................................................................... 7
2.1 General............................................................................................................................... 7
2.2 Technical data.................................................................................................................... 8
3 Installation................................................................................................................................... 10
4 O eration................................................................................................................................... 13
4.1 Front anel layout............................................................................................................. 13
4.2 O eration instruction......................................................................................................... 13
4.3 Welding environment and safety....................................................................................... 16
4.4 Welding roblems and resolution.................................................................................... 17
5 Daily maintenance and checking.............................................................................................. 18
6 Trouble shooting and fault finding.............................................................................................. 21
A endix Ⅰ Welding arameter list.................................................................................................. 22
A endix Ⅱ Circuit diagram............................................................................................................. 23
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1 Safety warning
The safety notes listed in this manual is to ensure correct use of the machine and to kee
you and other eo le from being hurt.
The design and manufacture of welding machine considers safety. Please refer to the safety
warning listed in the manual to avoid accidents.
Different damage would be caused by wrong o eration of the equi ment as follows. Please
read the user manual carefully to reduce such damage.
Sign Description
Any contact of electric parts may cause fatal electric shock or burnt.
Gas and fumes are harmful to health.
peration in narrow space may cause choke .
Spark and hot workpiece after welding may cause fire.
Bad connected cable may cause fire.
Uncompleted connection of workpiece side circuit may cause fire.
Never weld on the case of tinder stuff, or it may cause explode.
Never weld airtight containers such as slot, pipe etc., or it may
break.
Arc ray may cause eye inflammation or skin burnt.
Spark and residue will burn your eyes and skin.
Toppling over of the gas cylinder will cause body hurt.
Wrong use of the gas cylinder will lead to high-pressure gas
eruption and cause human hurt.
Never let fingers, hair, clothes or etc. near the moving parts such as
the fan.
The wire shoot out of the torch may stab eyes, face and other naked
parts.
Never stand in front of the swang equipment or under it, or it may fail
and cause injury.
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Please follow the rules below to avoid heavy accidents.
Never use the equi ment to do other things but welding.
Follow related regulations for the construction of the in ut-driven ower source, choice of
lace, usage of high- ressure gas, storage, configuration, safe-kee ing of work iece after
welding and dis osal of waste, etc.
Nonessentials do not enter the welding area.
Peo le using heart acemaker is not allowed to get close to the welding machine or area
without doctor’s ermission. The magnetism created by energizing the welding machine
can have a bad effect to the acemaker.
Install, o eration, check and maintain the equi ment by rofession ersonnel.
Understanding the contents of the user manual for safety.
Please follow the rules below to avoid electric shock。
Kee away from any electric arts.
Earth the machine and work iece by rofessional ersonnel.
Cut off the ower before installation or checking, and restart 5 minutes later. The
ca acitance is chargeable device. Please ensure it has no voltage before start again even
if the ower source is cut off.
Do not use wire with inadequate section surface or damage insulation sleeve or even
ex osed conductor.
Do ensure well isolation of wire connection.
Never use the device when the enclosure is removed.
Never use broken or wet insulation gloves.
Use firenet when work at high osition.
Check and maintain regularly, don’t use it until the broken arts are fixed well.
Turn off the ower when not in used.
Follow the national or local related standard and regulations when using the AC welding
machine at narrow or high osition.
Please follow the below notes to avoid fire and explode, etc.
No combustible in welding area.
Kee off combustible when welding.
Kee hot work iece after welding away from flammable gas.
Do move away the combustible around when weld the dooryard, ground and wall,.
The wire connection of base metal should be as close to the welding lace as ossible.
Never weld those facilities with gas i e or airtight slot.
Put fire extinguisher around the welding area to revent fire.
The gas and fumes are harmful to health, please wear protective
device according to regulations.
Wear exhaust equi ment and breathe reventive facilities to revent gas oisoning or
choke.
Use suggested art exhaust equi ment and breathe reventive facilities to revent hurt or
oisoning by gas and other owder, lease.
To revent oxygen-deficiency, air out the gas-filled room which is full of CO2 and argon on
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the bottom, When o erating on trunks, boilers, cabins, etc.
Please acce t the su ervisor’s ins ection when o erating in narrow s ace. Air the room
and wear breathe reventive facilities.
Never o erate in degrease, washing or s ray s ace.
Using breathe reventive facilities when weld shielded steel for it will cause oisonous dust
and gas.
The arc, spark, residue and noise are harmful to health, please wear
protective appliance.
Eye rotection against arc is recommended when welding or su ervise welding.
Please wear reventive s ectacles.
Welder’s gloves, welder’s goggles, long sleeve clothes, leather a ron, and other standard
rotection equi ments must be worn for welding o eration.
A screen to rotect other eo le against the arc must be set in the welding lace.
Please follow the notes below to avoid gas cylinder toppling over or
broken.
Use the gas cylinder correctly.
Use the equi ed or recommended gaseous regulator.
Read the manual of gaseous regulator carefully before using it, and ay attention to the
safety notes.
Fix the gas cylinder with a ro riative holder and other relative arts.
Never ut the cylinder under high tem erature or sunshine environment.
Kee your face away from the gas cylinder exit when o ening it.
Put on the gas shield when it is not used.
Never ut the torch on the gas cylinder. The electrode can not meet the gas cylinder.
Any touch of the switch part will cause injury, please note the
following.
Never use the machine when the enclosure is off.
Install, o erate, check and maintain the machine by rofessional erson.
Kee your fingers, hair, clothes etc. away from the switch arts such as the fan.
The wire end may deal damage, please note the following.
Never look into the electric conduction hole when checking the wire feeding is normal or
not, , or the shooting wire may stab your eyes and face.
Kee your eyes, face or other naked arts away from the end of torch when feeding the
wire manually or ressing the switch.
For better work efficiency and power source maintenance, please
note the following.
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Precautions against to ling over.
Never use the welding equi ment for i e thawing.
Lift the ower source from side when use the u -down forklift truck to avoid to ling over.
When using the crane for lift, tie the ro e to the ears with an angle no more than φ15 to the
vertical direction.
When lifting the welding machine which equi ed with gas cylinder and wire feeder,
download them from the ower source and ensure the horizontal of the machine. Do fix the
gas cylinder with belt or chain when moving it to avoid body hurt.
Ensure fastness and insulation when lifting the wire feeder through the swing ring for
welding.
Electromagnetic interference needing attention.
It may need extra reventive measures when the equi ment is used in articular location.
Before the installation, lease estimate the otential electromagnetism roblems of the
environment as follows.
a) U er and lower arts of the welding equi ments and other nearby ower cable, control
cable, signal cable and hone cable.
b) Wireless electric as well as TV radiation and rece tion equi ment.
c) Com uter and other control equi ments.
d) Safety-recognition equi ment etc. Such as su ervise of industrial equi ments.
e) Health of eo le around. Such as ersonnel using heart acemaker or audi hone.
f) Equi ments for adjustment and measurement.
g) Anti-disturb ca ability of other used equi ments .Users should ensure these equi ments
and the environment are com atible, which may need extra reventive measures.
h) Practical state of the welding and other activities.
Users should observe the following dos and don’ts to decrease radiation interference.
a) Connect the welding equi ments to the ower su ly lines.
b) Maintain the welding equi ments regularly.
c) The cable should be short enough to be close to each other and the ground.
d) Ensure the safety of all the welding metal arts and other arts nearby.
e) The work iece should be well earth.
f) Shield or rotect the other cable and equi ments to decrease the effects of disturbances.
The welding equi ments can be com lete shielded in some s ecial conditions.
Users are res onsible for interference due to welding.
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2 Product
2.1 General
The welding machine a lies the most advanced inversion technology in the world.
The rinci le of inversion is to transform the ower frequency of 50Hz/60Hz into direct current
and invert it into high frequency through high- ower device IGBT, then erform voltage-dro
and commutation with the out ut high- ower D.C ower su ly via Pulse Width Modulation
(PWM). Since the switch ower inversion technology is ado ted, the weight and volume
decrease greatly while the conversion efficiency increasing of more than 30%.
Additional to MIG, the machine has the functions of STICK and TIG, and the MIG function
includes 100% CO2 and mixed gas. The machine ado ts full digital anel dis lay, which can
realize synergic adjustment of feeding s eed and welding voltage as well to regulate the
welding arameters easily.
Our CO2 gas shielded welding machine is equi ed with unique electronic reactor circuit, which
can recisely control the short-circuiting transfer and mixed transfer resulted in better
erformance than other machines. Com ared with silicon controlled welding machine and
ta ed welding, our roducts have the following advantages: stable wire feed rate, ortable,
energy-saving, electromagnetic noise free. Besides, our roducts s atter less, easier arc
starting, dee welding ool, high duty cycle etc.
This equi ment is ortable with full function of STICK, TIG and lasma cutting having merits of
high-efficiency; ower-saving etc .It is es ecially suitable for family usage and need of different
metal or techniques demand.
Thank you for choosing our roducts. Please feel free to ro ose your valuable suggestions;
we will make efforts to erfect our roducts and service.
The machine is mainly used in industrial fields. It will cause radion interference if used
indoors. Please take through precaution measures.
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2.2 Technical data
Type
Item
MIG 160GDM
Power voltage (V) 1 hase ~ 230V±15%
Frequency (Hz) 50/60
Rated in ut current (A) 28
Out ut current adjustment (A)
10-160 (MMA)
50-160 (MIG)
10-160 (TIG)
Out ut voltage (V)
20.4-26.4 (MMA)
16.5-22 (MIG)
10.4-16.4 (TIG)
No-load voltage(V) 64
Duty cycle (%)/ 40°C 25 (MMA)
30 (MIG)
35 (TIG)
Power factor 0.73
Efficiency (%) 80
Ty e of wire feeder Internal
Wire feeding s eed (m/min) 3-12
Post flow time (S) 1
Wire diameter (mm) 0.8
Insulation grade F
Housing rotection grade IP21
Welding thickness (mm) 2-10
Weight (kg) 8
Overall dimension L*W*H (mm) 386*170*300
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Type
Item
MIG 180GDM
Power voltage (V) 1 hase ~ 230V15%
Frequency (Hz) 50/60
Rated in ut current (A)
28 (MMA)
27.4 (MIG)
20.5 (TIG)
Out ut current adjustment (A)
10-160 (MMA)
50-180 (MIG)
10-180 (TIG)
Out ut voltage (V)
20.4-26.4 (MMA)
16.5-23 (MIG)
10.4-17.2 (TIG)
No-load voltage (V) 64
Duty cycle (%)/ 40°C 25
Power factor 0.73
Efficiency (%) 80
Ty e of wire feeder Internal
Wire feeding s eed (m/min) 3-12
Post flow time (S) 1
Wire diameter (mm) 0.8
Insulation grade F
Housing rotection grade IP21
Welding thickness (mm) 2-10
Weight (kg) 8
Overall dimension L*W*H (mm) 386*170*300
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3 Installation
The welding equi ment is equi ed with ower voltage com ensation device. It kee s the
machine work normally when ower voltage fluctuating ±15% of rated voltage.
When using long cable, in order to reduce voltage dro , big section cable is suggested. If the
cable is too long, it will affect the erformance of arcing and other system function, it is
suggested to use the recommend length.
Make sure the intake of the machine is not covered or blocked to avoid the malfunction of
the cooling system.
Use ground cable whose section no less than 6mm2 to connect the housing and earth. The
method is to connect the grounded interface in the back to the earth device, or make sure
the earth end of ower interface has been reliably and inde endently grounded. Both ways
can be used together for better security.
Installation Procedures
Correct Installation of MIG
a) Connect the gas cylinder with CO2 decom ression flow mete tightly to CO2 mouth behind
the machine via air tube.
b) Insert the swift lug of earth cable into socket at the front anel.
c) Set the wire wheel with wire on the wheel axis, the wheel hole should be matched with the
wheel fixer.
d) Choose wire slot according to wire size.
e) Loosen the screw of wire- ressing wheel, it the wire into slot via wire-lead tube, adjust the
wire- ressing wheel to kee wire fix from gliding, but strength should be suitable in case
the wire distorts and affects wire sending.
f) Wire roll should turn clockwise rotation to let out wire, to revent wire from gliding; wire is
usually set to the fixed hole on the wheel side. To revent the bent wire from getting stuck,
lease cut off this art of the wire.
g) Put and tighten the torch on the out ut socket and ut the wire into the torch by hand.
Correct Installation of TIG
a) Connect the shielded-gas source correctly. The gas su lying route shall include gas
cylinder, argon decom ression flow meter and gas i e. The connecting arts of the gas
i e should be fastened by hose clam or other objects, in order to revent leakage and
air-in.
b) Connect the lug of TIG torch to “-“of the front anel, and fasten it clockwise.
c) Connect the lug of TIG torch to the relative interfaces of anel and fasten the screw.
d) Connect one end of the earth clam cable to “+” of the front anel, and fasten it clockwise,
the other end clam the work iece.
Correct Installation of STICK
a) Make sure cable with electrode holder and quick lug connected well. Connect the quick
lug to the socket “-” of the machine, and fasten it clockwise tightly.
b) Connect the quick lug at one end of the cable into the socket “+” of the machine, and
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fasten it clockwise, the other end clam s the work iece.
c) Please ay attention to the connecting terminal, DC welding machine has two connecting
ways: ositive connection and negative connection. Positive connection: holder connects
with “-” terminal, while work iece with the “+” terminal. Negative connection: work iece
with the“-” terminal, holder with the “+” terminal. Choose suitable way according to the
working situation. If unsuitable choice is made, it will cause unstable arc, more s atters
and conglutination. If such roblems occur, lease change the olarity of the fastened
lug. It should ado t negative connection when welding with alkaline electrode, while
ositive connection when welding with acid electrode.
This procedure shall be operated by electrician!
Connect ro er ower cable to the distribution box with corres onding ca acity according to
the in ut voltage and current (See technical arameter table). Do not connect to the
ina ro riate voltage and make sure that the difference of ower su ly is within ermitted
range.
Installation diagram (MIG)
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Installation diagram (TIG)
Installation diagram (STICK)
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4 peration
4.1 Front panel layout
MIG 180GDM
Front panel instruction.
1 - Data selection button
2 - Multifunctional data adjusting knob
Coarse adjustment by ressing and turning the knob.
Fine adjustment by turning the knob directly.
3 - Welding mode switch key.
Select the welding mode as MMA, TIG, MIG (CO2) and MIG (MIX).
4 - Multifunctional data dis lay
4.2 peration instruction
The starting up display
Switch on the welding ower source, the front anel dis lays as Fig. 1. After the【Welding
current dis lay】(or ress any key or knob on front anel) flashes for 5 seconds, the machine
enters into the welding mode that saved in the last shutdown.
Fig. 1: the starting-up display interface
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1
2
3
4

peration instruction under STICK mode.
a) When welding sto s, Press the【Welding mode switch key】，the STICK indicator lights
u ，and it turns into STICK mode.
b) When under STICK mode, ressing the 【VRD/2T/4T switch key】 for 5 second to selection
the VRD function, the function is enabled when the indicator lights u , and dis lays in
【multifunctional data dis lay】. Or, the VRD function is disabled when the indicator is off as
shown in Fig. 2.
Fig. 2 Preset current display with VRD enabled under STICK mode
c) 【Multifunctional data dis lay】shows the reset current“080A”, its unit is am ere(A).
d) Adjusting the 【Multifunctional data adjusting knob】can change the welding current during
welding rocess, and dis layed in 【Multifunctional data dis lay】.
e) 3 seconds later after setting the welding arameters, the 【Multifunctional data dis lay】
would flashes for one time, which means the data has been saved. Moreover, the anel
would dis lay these data when restart the machine next time if the arameters kee
unchanged.
f) When erform welding, the dis lay shows the real time welding voltage and current. 5
seconds later, it returns to the reset current state.
peration instruction under TIG mode.
a) When welding sto s, ress the 【Welding mode switch key 】 ， the TIG indicator lights
u ，and it turns into TIG mode.
b) Under TIG mode, the multifunctional data dis lay is as shown in Fig.3.
Fig.3: The preset current under T TIG mode
c) 【multifunctional data dis lay】shows the reset current“080A”, its unit is am ere(A).
d) Adjusting the 【Multifunctional data adjusting knob】can change the welding current during
welding rocess, and dis lay in 【multifunctional data dis lay】.
e) 3 seconds later after setting the welding arameters, the 【multifunctional data dis lay】
would flashes for one time, which means the data has been saved.
f) When erform welding, the dis lay shows the real time welding voltage and current. 5
seconds later, it returns to the reset current state.
peration instruction under MIG mode (both 100% C 2 and mixed gas).
a) When welding sto s, ress【Welding mode button】，the welding machine turn into MIG
mode and MIG indicator lights on.
b) Under this mode, the 【Main dis lay】shows the reset voltage and reset wire s eed as
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Fig. 4.
Fig. 4: Preset voltage display under MIG mode
c) Press the 【Menu button】 for the 1st time, the 【Main dis lay】shows the fine adjusting range
of reset welding voltage. Turn the 【Data adjusting knob】 to set the range from -20% to
+20% as Fig.5.
Fig. 5 Fine adjustment of preset range of voltage under MIG mode
d) Press the 【Menu button】 for the 2nd time, the 【Main dis lay】shows the fine adjusting
range of inductance. Turn the 【Data adjusting knob】 to set the range from -10% to +10%
as Fig.6.
Fig.6 Fine adjustment of inductance range under MIG mode
e) Press the switch of MIG gun. It starts wire inching. And the 【Main dis lay】shows as Fig. 7.
When connected w.ith MIG gun, ress the torch switch for 5s without welding, the internal
wire s ool in the machine starts to rotate and wire feeding at a high s eed 11m/min for
20s.. Then it sto s automatically. When release the button in 20s, wire feeding sto s
automatically.
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Fig. 7: Wire inching display under MIG mode
f) The machine has the function of 2T/4T under MIG mode.
2T mode – ress the 【Menu button】 for 5s, the function is on and the 【Main dis lay】
shows “2T”. Press the torch switch, the machine starts welding, while release the switch,
welding sto s.
4T mode – Press the 【Menu button】 for 5s again, it turns into 4T mode and the 【Main
dis lay】 shows “4T”. Press the torch switch for 1st time, it goes into arc initiation current.
Release the switch for 1st time, the machine starts welding. Press the switch for 2nd time,
it goes into crater current. Release the switch for 2nd time, welding sto s.
g) Adjust 【Data adjusting knob 】during welding can realize the synergic mani ulation of
welding voltage and feeding s eed, which dis lays in【Main dis lay】. The adjustable range
is 16.9V 3.3m/min to 23.3V 11m/min 17.5V under 100% CO2 mode, 15.5V 3.3m/min to
19.5V 11m/min under mixed gas mode.
h) When erform welding, the dis lay shows the real time welding voltage and current. 5
seconds later, it returns to the reset welding voltage and wire s eed.
i) Release the torch switch, it sto s welding. The Main dis lay shows “HOLD” for 3 seconds.
The 【Main dis lay】 redis lays welding voltage and wire s eed.
Malfunction display of overheating protection
The Multifunctional data dis lay shows “-P- -EH-” and flashes continuously, the machine is not
working normally now. Only when the tem erature of the welding machine falls below 55 , the℃
overheating malfunction would disa ear, and the machine works normally, no need restart u .
4.3 Welding environment and safety
Working surrounding
a) The machine works in environment where air conditions are dry with a dam ness level of
max 90%.
b) Ambient tem erature should be between -10 to 40 degrees centigrade.
c) Avoid welding in sunshine or raining. Avoid water entering the machine
d) Avoid welding in dust area or the environment with corrosive gas.
e) Avoid gas welding in the environment with strong airflow.
Safety norms
Our welding machine has a rotection circuit of over voltage, over current and over heat.
When voltage, out ut current and tem erature of machine are exceeding the rated
standard, welding machine will sto working automatically. Excessive o eration under over
voltage, over current or over heat may damage the machine; o erator must ay attention
to followings.
a) The working area is adequately ventilated！
The welding machine is medium and small model. But the running of the machine will also
generate high currents, which natural wind circulation cannot satisfy its cooling demands.
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Therefore, each machine has an internal fan to ensure its stable erformance. Make sure
the intake is not blocked or covered, there should be 0.3 meter distance from welding
machine to objects of environment. User should make sure the working area is adequately
ventilated. It is im ortant for the erformance and the longevity of the machine.
b) Do not over load！
The o erator should kee an eye on max duty current (Com ared to the selected duty
cycle) to make sure that the machine working current does not exceed max duty cycle
current. Over-load current will damage and even burn the machine.
If machine exceeds standard duty cycle, it may sto working and switch to rotection
status. The tem erature control switch is activated by over heat released under this
circumstance. Meanwhile, the over heat indicator lights u . Under this situation, you do not
need to ull out the ower lug since the internal fan can work to cool down the machine.
When the over heat indicator sto s, the tem erature has been lowed down to standard
range, o erator is able to starting working again.
c) No over voltage！
Power voltage can be found in diagram of arameters. Automatic com ensation circuit of
voltage will assure that welding current kee s is in allowable range. If ower voltage is
exceeding allowable range limits, it can damage the com onents of machine. The o erator
should understand this situation and take reventive measures.
d) There is a grounding cable behind welding machine with a mark. Before o eration, welding
crust must be grounded reliably with cable, in order to revent static electricity, and
accidents for electricity leaking.
4.4 Welding problems and resolution
The henomenon listed below may ha en due to relevant accessories used, welding material,
surroundings and ower su ly. Pleas im rove surroundings and avoid these roblems.
Arc starting difficulty. Arc interruption happens easily.
a) Examine whether grounding wire clam contacts with the work ieces well.
b) Examine whether each joint has im ro er contact.
The output current fails to reach rated value.
The deviation of ower voltage from rated value may cause that the out ut current does no
accord with adjusted value. When the ower voltage is lower than rated value, the
maximum out ut current may be lower than rated value.
The current can not keep stable during operation.
This situation may relate to the following factors:
a) The voltage of electric ower network changes;
b) Serious interference from electric ower network or other electric facilities.
Gas vent in welds.
a) Examine whether the gas su ly circuit has leakage.
b) Examine whether there is sundries such as oil, dirt, rust, aint etc. on the surface.
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5 Daily maintenance and checking
Daily maintenance
a) Remove dust regularly with dry com ressed air. If the welding machine is used in
surroundings with heavy smoke and olluted air, it is necessary to remove dust at least
one time one month.
b) The ressure of com ressed air shall fall to required level to revent damage to small
com onents in the machine.
c) Examine inside electric joints and ensure erfect contact (Es ecially lugs and sockets).
Fasten the loosing joints. In case of oxidation, remove oxide film with sand a er and
connect again.
d) Prevent water from entering into the machine and revent the machine from getting moist.
If any, blow and dry. Measure the insulation with megohmmeter to make sure it is qualified
to use.
e) If the welding machine is not used for a long time, ack the machine in original ackage
and store in dry surroundings.
f) Every time the wire feeder o erates for 300hours, grind the electrical carbon brush and
clear u the armature commutator. Rinse s eed reducer, a ly 2# Molybdenum Disulfide
lubricant to the turbine, whirl ool rod and bearing.
All the maintenance and testing must be carried out when the power supply is totally cut off.
Please make sure the power is off before opening the closure.
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