Power Fist 8560229 User manual

Smart TIG Inverter
Welding Machine

SPECIFICATIONS
INTRODUCTION
Smart TIG Inverter
Welding Machine

SAFETY

8560229 Smart TIG Inverter Welding Machine V4.0
3. Keep all others away during welding and keep anyone not wearing the appropriate safety equipment away
from the work area.
4. Store tools properly in a safe and dry location. Keep tools out of the reach of children.
5. Remove fire hazards from the welding area. Remember, welding sparks and hot materials from welding
can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines.
6. Have a fire extinguisher readily available.
7. Where compressed gases are to be used at the job site, special precautions should be taken to prevent
hazardous situations.
8. When not welding, make certain that no part of the electrode circuit is touching the workpiece or the
ground . Accidental contact can cause overheating and create a fire hazard .
WARNING! Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to
insure that such procedures will not cause flammable or toxic vapours from substances inside the tanks,
drum, or containers. They can cause an explosion even though they have been "cleaned".
8. Vent hollow castings or containers before heating, cutting or welding. They may explode.
9. Sparks and spatter are thrown from the welding arc. Wear oil free protective clothing such as leather
gloves, heavy shirt, cuff-less pants, high shoes and a cap over your hair. Wear ear plugs when welding out
of position or in confined spaces. Always wear safety glasses with side shields when in a welding area.
10. Connect the work cable to the work as close to the welding area as practical. Work cables connect to the
building framework or other locations away from the welding area increase the possibility of the welding
current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards
or overheat lifting chains or cables until the fail.
WARNING! Rotating parts may be dangerous.
11. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly
operating regulators designed for the gas and pressure used. All hoses, fittings , etc . should be suitable for
the application and maintained in good condition.
12. Cylinders should be located:
a. Away from areas where they may be struck or subjected to physical damage.
b. A safe distance from arc welding or cutting operations and any other source of heat, sparks or flame.
13. Never allow the electrode, electrode holder or any other electrically "hot" parts to touch a cylinder.
14. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
15. Valve protection caps should always be in place and hand tight except when the cylinder is in use or
connected for use.
NOTE: Minimize distractions in the work environment. Distractions can cause you to lose control of the tool.
PERSONAL SAFETY
WARNING! Wear personal protective equipment approved by the Canadian Standards Association (CSA) or
American National Standards Institute (ANSI).
1. Keep all equipment safety guards, covers, and devices in place and in good repair. Keep hands, hair,
clothing, and tools away from V-belts, gears , fans, and all other moving parts when starting, operating or
repairing equipment.
2. Do not put your hands near the engine fan.
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V4.0 Smart TIG Inverter Welding Machine 8560229
3. Dress properly, wear protective equipment. Use breathing, ear, eye, face, foot, hand , and head protection.
Always wear ANSI approved impact safety goggles, which must provide both frontal and side protection.
Protect your hands with suitable gloves. Wear a full face shield if your work creates metal filings or wood
chips . Protect your head from falling objects by wearing a hard hat. Wear an ANSI approved dust mask or
respirator when working around metal, wood and chemical dusts and mists. Wear ANSI approved
earplugs. Protective, electrically non-conductive clothes and non-skid footwear are recommended when
working. Wear steel-toed boots to prevent injury from falling objects.
4. Control the tool, personal movement and the work environment to avoid personal injury or damage to the
tool. Stay alert, watch what you are doing and use your common sense.
5. Keep articles of clothing, hair, etc ., away from moving parts to avoid entanglement with tool.
CAUTION! Do not wear jewelry or metal objects when welding.
6. Do not operate any machine I tool when tired or under the influence of drugs , alcohol or medications.
7. Do not overreach when operating a tool. Proper footing and balance enables better control of a tool in
unexpected situations.
8. Use clamps or other practical ways to support or secure the work piece to a stable platform. Holding the
work piece by hand or against your body is not stable and may lead to loss of control and injury.
9. Do not touch live electrical parts.
PERSONAL PROTECTIVE EQUIPMENT
1. Arc rays can injure eyes. Always wear welding goggles or a welding mask that provide front and side
protection for the eyes.
a. Eye protection equipment should comply with ANSI Z87.1 standards.
b. Wear protective goggles when cleaning welding spatter.
2. Wear welding gloves that provide protection based on the work materials.
3. Non-skid footwear is recommended to maintain footing and balance in the work environment.
4. Wear protective clothing designed for the work environment and tool.
5. Wear a NIOSH approved respirator when working on materials that produce dust or particulate matter.
6. Wear hearing protection gear.
7. Wear appropriate protective clothing, gloves , and shoes.
8. Use a nonflammable partition/door curtain to protect other from arc rays and sparking.
PERSONAL PRECAUTIONS
Control the tool, personal movement and the work environment to avoid personal injury or damage to tool.
1. Do not operate any tool when tired or under the influence of drugs, alcohol or medications.
2. Avoid wearing clothes or jewelry that can become entangled with the moving parts of a tool. Keep long
hair covered or bound.
3. Do not overreach when operating a tool. Proper footing and balance enables better control in
unexpected situations.
4. Support the workpiece or clamp it to a stable platform. Holding the workpiece by hand or against your
body may lead to personal injury.
5. Securely hold this tool using both hands. Using a tool with only one hand can result in loss of control.
SPECIFIC SAFETY PRECAUTIONS
ARC WELDING PRECAUTIONS
WARNING! Electric shock can kill.
1. Never touch electrical parts.
2. Wear dry, hole-free gloves and clothes to insulate yourself.
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8560229
Smart TIG Inverter Welding Machine V4.0
3. Insulate yourself from the work and the ground using dry insulation. Make certain that the insulation is
large enough to cover your full area of physical contact with the work and the ground.
4. Take care when using the equipment in confined places, areas where falling may occur, and wet areas.
5. Never install or adjust the machine while it is connected to the power source.
6. Make sure to install the equipment correctly and ground the work or metal to be welded to a good
electrical grounding.
7. The electrode and work (or ground) circuits are electrically "hot" when the welder is ON. Do not touch
these "hot" parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.
8. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or
semiautomatic welding guns are also electrically "hot".
9. Always be sure the work cable makes a good electrical connection with the metal being welded. The
connection should be as close as possible to the area being welded.
10. Maintain the electrode holder, work clamp, welding cable, and welding machine in good, safe operating
condition. Replace damaged insulation.
11. Never dip the electrode in water for cooling.
12. Never simultaneously touch electrically "hot" parts of electrode holders connected to two welders because
the voltage between the two can be the total of the open circuit voltage of both welders.
13. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.
FUMES AND GASES PRECAUTIONS
Welding may produce fumes and gases hazardous to health. Avoid breathing in these fumes and gases. When
welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and
gases away from the breathing zone. When welding with electrodes which require special ventilation such as
stainless or hard facing or on lead or cadmium plated steel and other metals or coatings which produce highly
toxic fumes, keep exposure as low as possible and below the Threshold Limit Values using local exhaust or
mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required.
Additional precautions are also required when welding on galvanized steel.
1. Do not weld in locations near chlorinated hydrocarbon vapours coming from degreasing , cleaning or
spraying ope rations. The heat and rays of the arc can react with solvent vapou rs to form phosgene, a
highly toxic gas, and other irritating products.
2. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough
ventilation, especially in confined areas, to insure breathing air is safe.
3. Read and understand the manufacturer's instructions for this equipment and the consumables to be used,
including the material safety data sheet (MSDS) and follow safe practices.
ARC RAYS CAN BURN
1. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc
when welding or observing open arc welding.
2. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your
helpers from the arc rays.
3. Protect other nearby personnel with suitable, non-flammable screening and I or warn them not to watch
the arc nor expose themselves to the arc rays or to hot spatter or metal.
4. Keep all flammable materials (wood, cloth, fuel, gases, etc.) away from the welding area.
5. Keep the welding area isolated to prevent the spread of fire.
6. Ensure that pieces to be welded are clean and the work area is cleared.
7. Do not weld on or near sealed tanks, there is a risk of explosion.
8. Keep a fire extinguisher near the welding area at all time s.
9. Do not use the welder if it is overloading.
10. Watch for the risk of fire after welding.
6
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USE AND CARE OF THE TOOL

PARTS IDENTIFICATION

WORKING PRINCIPLE

INSTALLATION & ADJUSTMENT

V4.0 Smart TIG Inverter Welding Machine 8560229
DUTY CYCLE & OVER HEAT
The letter "X" stands for duty cycle, which is defined
as the proportion of the time that a machine can
work continuously within a certain time (1 0
minutes). The rated duty cycle means the proportion
of the time that a machine can work continuously
within 10 minutes when it outputs the rated welding
current.
The relation between the duty cycle "X" and the
output welding current "I" is shown as the right
figure.
If the welder is overheating, the IGBT overheat
protection unit inside it will output an instruction to
cut the output current, and the overheat pilot light
X
Fig.3
The relation between duty cycle and
I00% !----------, ~
w7
--------- --- -------- r ----------
. '
25 o/o -----------------------1--------------t----------------------
' '
' '
' '
' '
' '
' '
' '
' '
! :
0 100 200 I ( A )
will illuminate on the front panel. At this time, the machine should be removed from service and cool down for
15 minutes to cool the fan. When operating the machine again, the welding output current or the duty cycle
should be reduced.
WELDING POLARITY CONNECTIONS
MMA
Fig.4
DC Positive Connection
DC Negative Connection
Choosing the connection of DCEN or DCEP is based on the arc stable burning condition. The different
electrodes need to be connected differently. Please refer to the electrode manual.
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WELDING OPERATION

In MMA welding, there are three motions to be used
with the end of the electrode: The electrode moves
to the molten pool along the axes; the electrode
swings right and left; the electrode moves along
the weld.
The operator can choose the manipulation of the
electrode based on the welding joint shape, welding
position, electrode spec, welding current, and
operational skill, etc.
WELDING PARAMETERS

8560229 Smart TIG Inverter Welding Machine V4.0
ELECTRODE SELECTION
The electrode diameter selection is based on the workpiece thickness, welding position, joint form , welding
layer, etc. Please refer to the following table:
The Welding current reference for different electrode diameter
Electrode 1.6 2.0 2.5 3.2 4.0
diameter I
mm
Welding
25 ~ 40 40 ~ 60 50~ 80 100 ~ 130 160 ~ 210
Current/ A
The relation between the welding current (I) factor (K) and electrode diameter (d) (I=Kxd :Carbon electrode)
Electrode 1.6
2 ~ 2.5 3.2 4.0
~ 6.0
diameter I mm
Factor I K
20 ~ 25
25-30 30-40 40-50
1. The electrode should be dry according to the electrode user manual before using. For reducing the
hydrogen of the molten pool and welding seam , and avoiding the blowhole and cold crack.
2. In the welding process , the arc must not be too long; otherwise , it will cause unstable arc burning , large
spatter, light penetration, undercut, blowhole , etc. If the arc is too short, it will cause the electrode to stick.
3. In MMA welding the arc length is usually equal to 0.5 to 1.0 time of the electrode diameter. The basic
electrode's arc length is not beyond the electrode diameter, it's better to choose the short arc welding; the
acid electrode's arc length is equal to the electrode diameter.
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V4.0 Smart TIG Inverter Welding Machine 8560229
ARC WELDING DEFECT AND PREVENTATIVE TIPS
Defect Reasons Preventative Methods
Welding seam doesn't meet The groove angle is not proper. Choose the proper groove angle
the requirement.
The root face and assembly gap is
and assembly gap, improve the
not equal.
assembly quality.
Welding technics parameters
Choose the proper
are awkward.
welding parameters.
More experience is required.
Undercut Over current. Choosing the proper welding
Arc length is too long.
current and speed.
The electrode angle is wrong.
The arc can 't be drawn too long .
Manipulation of the electrode is
The electrode angle should
not appropriate.
be appropriate.
Manipulation of the electrode
should be appropriate.
Incomplete penetration . The groove angle or gap is too Select and process the groove size
small, the root face is too big. correctly.
Welding parameters are not suitable, Assemble and ensure the clearance
or the assembly is not good.
is correct.
More experience is required. Select the suitable welding current
and speed.
More practice is required.
Incomplete fusion . The welding thermal input is too low. Chose the welding
The arc direction is lean.
parameters correctly.
There is rust and dust on the side of
Clean the workpiece.
the groove. Clear the layers better.
The slag between the layers is not
cleared well.
Overlap The temperature of the molten pool Chose parameters based on the
is too high. welding different position.
The liquid metal solidifies slowly. Carefully control the molten
hole size.
Crate The crater time lasts too short. In the crater, the electrode should
Too much current in the welding of a
be stayed for a short time or round
thin plate.
to manipulate the electrode after
the molten pool is filled in by metal,
move to the side of the crater.
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8560229
Smart TIG Inverter Welding Machine V4.0
Defect Reason Preventative Methods
Blowhole There are some impurities such as Clear out the impurities around the
dust, oil, rust, or water on the groove for about 20 to 30 mm.
workpiece surface and groove.
Take care to dry the electrode
The coating of the electrode is according to the electrode manual.
damped and is not drying.
Choose the parameters and
Current is too low or speed is too operate correctly.
great in the welding.
Use the short arc method.
The arc is too long or lean burning,
Welding operation in the filed
the molten pool protection is
should have wind protection.
not good.
The current is too high, the coating
Do not use improper electrodes.
of the electrode has fallen off and
has loose protection.
The electrode is not the proper type.
Inclusion and slag inclusion. The slag does not clear properly in Select the electrode with good
the middle layer in the slag detachability.
welding process .
Make sure to clear the slag in
Current is too lo w or welding speed the layers.
is too slo w.
Select the correct
The welding operation is not proper. welding parameters .
The welding material cannot match Adjust the electrode angle and the
the
workpiece. manipulation method.
The groove design and processing
are not proper.
Hot crack. In the process of solidification, inter Strictly control the percentage of
crystal segregation is caused. At the impurities in the welding material.
same time , with the effect of welding
Adjust the structure of
stress, a hot crack is formed.
welding material.
Use a basic electrode.
Cold crack.
Three reasons will cause a Adopt a low hydrogen type of
cold crack: basic electrode.
The structure forms martensite, Bake under instruction before use .
which is brittle , micro-cracks.
Remove the fouled or impure
The residual stress is caused by big
matter before use , reduce the
restraint intensity.
percentage of hydrogen.
There is residual hydrogen in the Use appropriate parameters and
w elding gap . heat input.
After weldin g, pe rform
dehydrog e nation at on ce .
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MAINTENANCE

8560229 Smart TIG Inverter Welding Machine V4.0
MAINTENANCE SCHEDULE
Remember that this schedule is based on the assumption that your machine will be used for its designed
purpose. Sustained high-load or high-temperature operation , or use in unusually wet or dusty conditions , will
require more frequent service.
Frequency
Maintenance
Daily examination
Check to make sure that the panel knob and the switch on the front and back of
the arc welding machine are flexible and put correctly in place. If the knob has not
been put correctly in place , please correct; if you cannot correct or fix the knob ,
please replace immediately.
If the switch is not flexible or it cannot be put correctly in place, please
replace immediately.
After turning the machine on , watch/listen to whether the arc welding machine is
shaking , making any strange sounds or smells. If there is one of the above
problems , have a qualified technician repair the welding machine.
Make sure that LED display is intact. If the display number is not intact , have the
LED display replaced.
Make sure that the Min./Max . value on the LED display matches with the set value .
If there is any difference and it has affected the normal welding operation ,
please adjust.
Check whether the fan is damaged and that it rotates properly. If the fan is
damaged , please have the machine repaired by a qualified service technician . If
the fan does not rotate after the arc welding machine is overheated, observe
whether there is something blocking the fan from rotating. Remove any
obstruction. If the fan does not rotate after removing the obstruction, have the
machine serviced by a qualified service technician.
Check to see if the fast connector is loose or overheated. If the fast connector is
loose ,it should be tightened or replaced.
Check to see if the current output cable is damaged. If it is damaged , have the
output cable replaced by a qualified service technician.
Monthly examination Use dry , compressed air to clear the inside of the arc welding machine. Make sure
to blow out dust from the radiator , main voltage transformer , inductance , IGBT
module , the fast recover diode and PCB , etc.
Make sure that all hardware is securely tightened on the arc
welding machine.
Quarterly examination Check to make sure that the actual current matches with the displaying value. If
they do not match, they should be regulated. The actual current value can be
measured by the adjusted plier-type ampere meter.
Yearly examina t ion Measure the insulating impedance among the main circuit , PCB and case ,if it is
below 1 MO , the insulation may be damaged and must be replaced .
WARNING! Only qualified service personnel should repair the machine. An improperly repaired machine
may present a hazard to the user and/or others.
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TROUBLE SHOOTING