Permaweld MIG 4OO User manual

Pei-mawe!d
MIG 4OO
WELDING MACHINE
USER MANUAL
EL NUEVO ELECTRODO PUNTO CAFE
iPRUEBELO LE VA A GUSTAR!

Preface
This manual includes hardware description and operation introduction of MULTI 400S
equipment. For your and other people's safety, please read the manual carefully.
Pay attention
Pay attention to the words after the signs below.
Version
The contents of this manual are updated irregularity for updating of product. The manual is only used
as operation guide, except for other promises. No warranties of any kind, either express or implied
are made in relation to the description, information or suggestion or any other contents of the
manual.
The image shown here is indicative only. lf there is inconsistency between the image and the actual
product, the actual product shall govern.
l:
&uu*n** The words after this sign means there is great potential danger,
which may cause major accident, damage or even death, if it is not
followed.
A*ooNrNG The words after this sign means there is some potential danger,
which may cause hurt or property lose, if it is not followed.
&otr*N.oN The words after this sign means there is potential risk, which may
cause equipment fault or break, if it is not followed.
Sign Description

Gontent
1 Safety warning ........................1
2 Product ................6
2.1 General ........6
2.2 Technical data ......... ........7
3 lnstallation............... ................8
4 Operation................ ..............11
4.1 Front panel layout .........11
4.2 Operation instruction ........................12
4.3 Welding environment and safety ......12
4.4 Welding problems and resolution.............. ..........13
5 Daily maintenance and checking............. ...................15
6 Trouble shooting and fault finding ............18
Appendix I Welding parameter |ist.............. ...................22

1 Safety warning
The safety notes listed in this manual is to ensure correct use of the machine and to keep you
and other people 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 operation of the equipment as follows. Please
read the user manual carefully to reduce such damage.
o+ Any contact of electric parts may cause fatal electric shock or burnt.
+
+Gas and fumes are harmful to health. Operation in narrow space may cause choke .
+
+
+
+
Spark and hot workpiece after welding may cause fire.
Bad connected cable may cause fire.
lncompletion 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.
,4r Arc ray may cause eye inflammation or skin burnt.
Spark and residue wil! burn your eyes and skin.
+
+
+ Toppling over of the gas cylinder will cause body hurt.
+ Wrong use of the gas cylinder will Iead 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 inlul
Sign Description
&
tl

I DANSER Please follow the rules below to avoid heavy accidents.
O Never use the equipment to do other things but welding.
O Follow related regulations for the construction of the input-driven power source, choice of
place, usage of high-pressure gas, storage, configuration, safe-keeping of workpiece after
welding and disposal of waste, etc.
O Nonessentials do not enter the welding area.
O People using heart pacemaker is not allowed to get close to the welding machine or area
without doctor's permission. The magnetism created by energizing the welding machine
can have a bad effect to the pacemaker.
O lnstall, operation, check and maintain the equipment by profession personnel.
O Understanding the contents of the user manual for safety.
A
'/t\ OnNgen please foilow the rutes below to avoid electric shock.
a Keep away from any electric parts.
a Earth the machine and workpiece by professional personnel.
a Cut off the power before installation or checking, and restart 5 minutes later. The
capacitance is chargeable device. Please ensure it has no voltage before start again even if
the power source is cut off.
O Do not use wire with inadequate section surface or damage insulation sleeve or even
exposed conductor.
a Do ensure well isolation of wire connection.
a Never use the device when the enclosure is removed.
a Never use broken or wet insulation gloves.
O Use firenet when work at high position.
O Check and maintain regularly, don't use it until the broken parts are fixed well.
O Turn off the power when not in used.
O Follow the national or local related standard and regulations when using the AC welding
machine at narrow or high position,
t\
/t\ Onrue f n Please follow the below notes to avoid fire and explode, etc.
a No combustible in welding area.
a Keep off combustible when welding.
a Keep hot workpiece after welding away from flammable gas.
O Do move away the combustible around when weld the dooryard, ground and wall,.
a The wire connection of base metal should be as close to the welding place as possible.
O Never weld those facilities with gas pipe or airtight slot.
O Put flre extinguisher around the welding area to prevent fire.

A
/l\WnRUlt'tC rhe gas and fumes are harmful to heatth, please wear protective
device according to regulations.
O Wear exhaust equipment and breathe preventive facilities to prevent gas poisoning or
choke.
O Use suggested part exhaust equipment and breathe preventive facilities to prevent hurt or
poisoning by gas and other powder, please.
a To prevent oxygen-deficiency, air out the gas-filled room which is full of COz and argon on
the bottom, When operating on trunks, boilers, cabins, etc.
O Please accept the supervisor's inspection when operating in narrow space. Air the room
and wear breathe preventive facilities.
O Never operate in degrease, washing or spray space.
O Using breathe preventive facilities when weld shielded steel for it will cause poisonous dust
and gas.
A
/!\ WnnrutmC rhe arc, spark, residue and noise are harmfulto health, please wear
protective appliance.
O Eye protection against arc is recommended when welding or supervise welding.
O Please wear preventive spectacles.
O Welder's gloves, welder's goggles, long sleeve clothes, leather apron, and other standard
protection equipments must be worn for welding operation.
O A screen to protect other people against the arc must be set in the welding place.
'WARNING Please follow the notes betow to avoid gas cylinder toppling over or
broken.
O Use the gas cylinder correctly.
O . Use the equipped or recommended gaseous regulator.
a Read the manual of gaseous regulator carefully before using it, and pay attention to the
safety notes.
O Fix the gas cylinder with appropriative holder and other relative parts.
O Never put the cylinder under high temperature or sunshine environment. ,
a Keep your face away from the gas cylinder exit when opening it.
O Put on the gas shield when it is not used.
O Never put the torch on the gas cylinder. The electrode can not meet the gas cylinder.
&*O*NING Any touch of the switch part will cause injury, please note the
following.
3

O Never use the machine when the enclosure is off.
O lnstall, operate, check and maintain the machine by professional person.
O Keep your fingers, hair, clothes etc. away from the switch parts such as the fan.
A*O**'*" The wire end may deal damage, please note the following.
a 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.
O Keep your eyes, face or other naked parts away from the end of torch when feeding the
wire manually or pressing the switch.
A
/!\ nfff NTlON For better work efficiency and power source maintenance, prease
note the following.
O Precautions against toppling over.
O Never use the welding equipment for pipe thawing.
a Lift the power source from side when use the up-down forklift truck to avoid toppling over.
O When using the crane for lift, tie the rope to the ears with an angle no more than 915 to the
vertical direction.
a When lifting the welding machine which equipped with gas cylinder and wire feeder,
download them from the power source and ensure the horizontal of the machine. Do fix the
gas cylinder with belt or chain when moving it to avoid body hurt.
a Ensure fastness and insulation when lifting the wire feeder through the swing ring for
welding.

A*r*NTlsN Electromagnetic interference needing attention.
O lt may need extra preventive measures when the equipment is used in particular location.
O Before the installation, please estimate the potential electromagnetism problems of the
environment as follows.
a) Upper and lower parts of the welding equipments and other nearby power cable, control
cable, signal cable and phone cable.
b)Wireless electric as well as TV radiation and reception equipment.
c) Computer and other control equipments.
d) Safety-recognition equipment etc. Such as supervise of industrial equipments.
e) Health of people around. Such as personnel using the heart pacemaker or audiphone.
f) Equipments for adjustment and measurement.
g) Anti-disturb capability of other used equipments .Users should ensure these equipments
and the environment are compatible, which may need extra preventive measures.
h) Practical state of the welding and other activities.
O Users should observe the following dos and don'ts to decrease radiation interference.
a) Connect the welding equipments to the power supply lines.
b) Maintain the welding equipments 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 parts and other parts nearby.
e)The workpiece should be well earth.
f) Shield or protect the other cable and equipments to decrease the effects of disturbances.
The welding equipments can be complete shielded in some special conditions.
O Users are responsible for interference due to welding.

2 Product
2.1 General
The welding machine applies the most advanced inversion technology in the world.
The principle of inversion is to transform the power frequency of 50Hzi60Hz into direct current
and invert it into high frequency through high-power device IGBT, then perform voltage-drop
and commutation with the output high-power D.C power supply via Pulse Width Modulation
(PWM). Since the switch power inversion technology is adopted, the weight and volume
decrease greatly while the conversion efficiency increase by more than 30%. lts characteristics
are: stable wire feed rate, little splatter, portable, energy-saving, low electromagnetic noise.
Our COz gas shielded welding machine is equipped with unique electronic reactor circuit, which
can precisely control the short-circuiting transfer and mixed transfer resulted in better
performance than other machines. Compared with silicon controlled welding machine and
tapped welding, our products have the following advantages: stable wire feed rate, portable,
energy-saving, electromagnetic noise free. Besides, our products spatter less, easier arc
starting, deep welding pool, high duty cycle etc. With high efficiency and energy-saving features,
this equipment is applicable in large-scale plants such as shipyards, steel structure plants etc..
Thank you for choosing our products. Please feel free to propose your valuable suggestions;
we will make efforts to perfect our products and service.
&*u*NrNG
The machine is mainly used in industrial fields. lt will cause radion interference if used
indoors. Please take through precaution measures.

2.2 Technical data
Type
Description MIG 400
Power voltage (V) 3 phase480v!10%
Frequency (Hz) 50/60
65
Rated input current (A) MIG: 20.7
MMA: 21.9
Output current adjustment
(A)
MIG:50-400
MMA:25-400
Output voltage (V) MIG:16.5-34
MMA:21-36
Duty cycle (%) MIG:60%
MMA:60%
Power factor 0.93
Efficiency (%) 85
Type of wire feeder lnternal
Wire feed speed (m/min) 2-18
Post flow time (S) 1.0r0.5
Welding-wire diameter
(mm) 0.811.011.2
lnsulation grade F
Housing protection grade tP21
Welding thickness (mm) More than 0.8
Weight (kg) 155
Overall dimension
L.W*H (mm) 1 1 80.560.1 080
7

3 lnstallation
The welding equipment is equipped with power voltage compensation device. lt keeps the
machine work normally when power voltage fluctuating t15% of rated voltage.
When using long cable, in order to reduce voltage drop, big section cable is suggested. lf the
cable is too long, it will affect the performance 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.
a 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 power interface has been reliably and independently grounded. Both ways
can be used together for better security.
Installation Procedures:
. Connect the gas cylinder with COz decompression flow mete tightly to COz mouth behind
the machine via air tube.
lnsert the swift plug of earth cable into socket at the front panel.
Set the wire wheel with wire on the wheel axis, the wheel hole should be matched with the
wheelfixer.
Choose wire slot according to wire diameter..
Loosen the screw of wire-pressing wheel, pit the wire into slot via wire-lead tube, adjust the
wire-pressing wheel to keep wire fix from gliding, but strength should be suitable in case
the wire distorts and affects wire sending.
Wire roll should turn clockwise rotation to let out wire, to prevent wire from gliding; wire is
usually set to the fixed hole on the wheel side. To prevent the bent wire from getting stuck,
please cut off this part of the wire.
Put and tighten the torch on the output socket and put the wire into the torch by hand.
This procedure must be operated by electrician!
Connect proper power cable to the distribution box with corresponding capacity according to the
input voltage and current (See technical parameter table). Do not connect to the inappropriate
voltage and make sure that the difference of power supply is within permitted range.
a
o
o
a
r-
8

Installation diagram (MMA / MIG)
MIG MODE:
Power supply
ffi naon*uro
o ooB
:!=r
ffi[

MMA MODE:
Notes: Turn the welding machine to MMA mode for heating the gas cylinder to prevent
COz meter icing when it is not working under MIG mode.
Power supply
a
o oO!
n'3 o
::EE
e o o oo
ooo
a
10

4 Operation
4.1 Front panel layout
The image shown here is indicative only. The actual product may differ.
1Positive output terminal 8. GASMATER switch button
2. Negative output terminal LAbnormal indicator
3. Current adjustment button 10. Voltage meter
4. Voltage adjustment button 11 Current meter
5. Arc trait adjustment button 12. Torch joint
6. MMA/MlG switch button
7. 2Tl4T switch button
5. MMA/MIG switch button
11
12. Torch joint

t;
4.2 Operation i nstruction
o Front panel instruction
a) MMA/MIG button. Press it to change the welding mode of MIG or MMA. The indicator
would light on.
b) 2Tl4T button. The description as follows.
2T mode applies to spot welding. The welding machine starts working by press the torch
switch, and stops when release it.
4T mode is suitable for long time welding. The arc current starts when pressing the torch
switch first time. Then the machine welds by release the switch. The crater current occurs
when press the switch again, and the machine stops welding when release it.
c) Voltage adjustment knob. Adjust the range of output voltage.
d) Current adjustment knob. Adjust the range of output current.
e) Electric arc characteristic knob. Adjust the sofUhard range of the electric arc to achieve
perfect welding performance.
o Polarity conversion ioint
This machine has the polarity conversion; There are positive output terminal and negative
output terminal between wire feeder and wire spool; When use solid wire with gas
protection, torch socket should be connected to the positive output terminal, ground cable
should be connected to the negative output terminal; When use flux-cored wire, the two
connected cable should be exchanged.
4.3 Welding environment and safety
. Working surrounding
a) Welding should be carried out in dry surroundings. The air humidity level should not be
higher than 90%.
b) The temperature should be between -10"C to 40'C.
c) Don't use the welding machines in sunshine or rain. Keep it off water.
d) Don't use the machines in the places of dust or corrosive air.
e) MIG welding should not be carried out in places with quick air flow
. Safety norms
Protection circuit of over-voltage, over-current and over-heat circuits are designed in the
welding machines. lt will stop working automatically when the input voltage, output current
or internal temperature exceed the rated value. But if the machines are excessively used,
12

4.2 Operation i nstruction
a Front pane! instruction
a) MMA/MIG button. Press it to change the welding mode of MIG or MMA, The indicator
would light on.
b) 2Tl4T button. The description as follows.
2T mode applies to spot welding. The welding machine starts working by press the torch
switch, and stops when release it.
4T mode is suitable for long time welding. The arc current starts when pressing the torch
switch first time. Then the machine welds by release the switch. The crater current occurs
when press the switch again, and the machine stops welding when release it.
c) Voltage adjustment knob. Adjust the range of output voltage.
d) Current adjustment knob. Adjust the range of output current.
e) Electric arc characteristic knob. Adjust the sofUhard range of the electric arc to achieve
perfect welding performance.
o Polarity conversion joint
This machine has the polarity conversion; There are positive output terminal and negative
output terminal between wire feeder and wire spool; When use solid wire with gas
protection, torch socket should be connected to the positive output terminal, ground cable
should be connected to the negative output terminal; When use flux-cored wire, the two
connected cable should be exchanged,
4.3 Welding environment and safety
. Working surrounding
a) Welding should be carried out in dry surroundings. The air humidity level should not be
higher than 90%.
b) The temperature should be between -10'C to 40'C.
c) Don't use the welding machines in sunshine or rain. Keep it off water.
d) Don't use the machines in the places of dust or corrosive air.
e) MIG welding should not be carried out in places with quick air flow.
. Safety norms
Protection circuit of over-voltage, over-current and over-heat circuits are designed in the
welding machines. lt will stop working automatically when the input voltage, output current
or internal temperature exceed the rated value. But if the machines are excessively used,
12

such as with input voltage higher than the rated, the machine might be damage. Please
pay close attention to the following matters.
a) Keep good ventilation!!
The welding machines work with high welding current. Nature air flow can't reach the
requirement of heat dissipation. So the fans are installed as cooling system to ensure
stable performance.
Make sure the ventilation windows are not covered or blocked. The distance between the
machines and things around should not be less than 0.3m. Good ventilation is good for
welding performance and operational life.
b) Never over Ioad!
Check the maximum rated current (according to the Duty Cycle chosen). Make sure the
welding current is never higher than the rated value. Over current running will obviously
shorten the operation life, even damage the machine.
c) Never over voltage!
The lnput Voltage could be found in Technical data diagram. The auto-compensation
function will keep the welding current in the rated range. lf the input voltage exceed the
permissible value, the machine would be damaged. Users should take protective
measures in advance to avoid it.
d) Make sure earth connected before operation.
On the rear panel of welding machine, a screw for earth connecting would be found. It must
be ground connected with cable whose section is bigger than 6mm2 before operation, to
avoid accidents caused by static or electricity leak.
4.4Welding problems and resolution
The phenomenon listed below may happen due to relevant accessories used, welding material,
surroundings and power supply. Pleas improve surroundings and avoid these problems..
o Arc starting difficulty. Arc interruption happens easily:
a) Examine whether grounding wire clamp contacts with the work pieces well.
b) Examine whether each joint has improper contact.
o The output current fails to reach rated value:
13

The deviation of power voltage from rated value may cause that the output current does no
accord with adjusted value. When the power voltage is lower than rated value, the
maximum output current may be lower than rated value.
o The current can not keep stable during operation:
This situation may relate to the following factors:
a) The voltage of electric power network changes;
b) Serious interference from electric power network or other electric facilities.
a Gas vent in welds:
a) Examine whether the gas supply circuit has leakage.
b) Examine whether there is sundries such as oil, dirt, rust, paint etc. on the surface.
14

5 Daily maintenance and checking
o Daily maintenance
a) Remove dust regularly with dry compressed air. lf the welding machine is used in
surroundings with heavy smoke and polluted air, it is necessary to remove dust at least one
time one month.
b) The pressure of compressed air shall fall to required level to prevent damage to small
components in the machine.
c) Examine inside electric joints and ensure perfect contact (Especially plugs and sockets).
Fasten the loosing joints. ln case of oxidation, remove oxide film with sand paper and
connect again.
d) Prevent water from entering into the machine and prevent the machine from getting moist.
lf any, blow and dry. Measure the insulation with megohmmeter to make sure it is qualified
to use.
e) lf the welding machine is not used for a long time, pack the machine in original package
and store in dry surroundings.
0 Every time the wire feeder operates for 300 hours, grind the electrical carbon brush and
clear up the armature commutator. Rinse speed reducer, apply 2# Molybdenum Disulfide
lubricant to the turbine, whirlpool rod and bearing.
A*o**,,*n
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.
15

. Daily checking
iNriliiirit|nilrr'l :'1'"'
.,...,.,.r,.,,,, i iliisiilrl'
Position Checking keys Remarks
Control panel Switch condition of operation, transfer and
installation. Test the power indicator.
Cooling fan Check if there is wind and the sound normal or
not. lf abnormal noise and no
wind, to check the inner.
Power part
When electrified, abnormal smellor not.
When electrified, abnormal vibration and buzz
or not. Color changing and heating or not in
appearance.
Periphery Gas pipe broken, loosen or not.
Housing and other fixed parts loosen or not.
i::tilN..
, .,f\i\ilii'ii
Position Checking keys Remarks
Loophole
lf installment fixed, the front
distorted Reason for air hole.
Attach splash or not. Reason for burning the torch.
(can use splash-proof material )
Electric hole lf installment fixed Reason of torch screw thread damage
Damage of its head and hole
blocked nor not Reason of unstable arc and broken arc
Wire sending
tube
Check the extended size of the
pipe
Have to be changed when less than
6mm, when the extended part too small,
the arc will be unstable.
Wire diameter and the tube
inner diameter match or not Reason of unstable arc, please use the
suitable tube.
Partial winding and extended Reason of poor wires sending and
unstable arc, please change.
Block caused by dirt in the tube,
and the remains of the wire
plating lay.
Reason of poor wire sending and
unstable arc, (use kerosene to wipe or
change new one.)
Wire sending tube broken O
circle wear out Pyrocondensation tube broken, change
new tube. Change new O circle
Gas bypass Forget to insert or the hole
blocked, or different factory
component.
May lead to vice (splash) because of
poor gas shield, torch body get burned
(arc in the torch), please handle.
16
WELDING POWER SUPPLY
WELDING TORCH