Ronix RH-4602 User manual

ARC WELDING INVERTER
RH-4602

USER MANUAL 1
TECHNICAL DATA
Model RH-4602
Rated Input voltage 220V
Rated Input Power 8.2 KVA
Rated Output Power 200A
Welding Current Range 10-200A
No Load voltage 65V
Rated duty Cycle 60%
Weight 8KG
SAFETY
Welding is dangerous, and may cause damage to you and others, so
take good protection when welding. For details, please refer to the
operator safety guidelines in conformity with the accident prevention
requirements of the manufacturer.
Prof essional training is needed before operating the machine
Use labor protection welding supplies authorized by national security
supervision department
The operator must be qualified personnel with a valid «metal welding
(OFC) operations» operation certificate
Cut off power before maintenance or repair.
Electric shock-may lead to serious injury or even death
Install earth device according to the application criteria
Never touch the machine parts with bare skin or in wet gloves when the
machine is still operating
Make sure that you are insulated from the ground and work piece
Make sure that your working position is safe
Smoke & Gas-may be harmful to health
Keep your head away from smoke and gas to avoid inhalation of exhaust
gas from welding.

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Keep the working environment properly ventilated with exhaust or
ventilation equipment when welding.
Arc radiation-may damage eyes or burn skin
Wear suitable welding masks and protective clothing to protect your
eyes and bod.
Use suitable masks or screens to protect spectators from harm.
Improper operation may cause fire or explosion
Welding sparks may result in a fire, so please make sure there are no
combustible materials nearby and pay attention to fire hazard.
Have a fire extinguisher nearby, and have a trained person to use it.
Airtight container welding is forbidden.
Do not use these machines for pipe thawing.
Hot work piece may cause severe scalding
Do not contact hot work piece with bare hands.
Cooling is needed during continuous use of the welding torch.
Magnetic fields affect cardiac pacemaker
Pacemaker users should be away from the welding spot before medical
consultation.
Moving parts may lead to personal injury
Keep yourself away from moving parts such as fan.
All doors, panels, covers and other protective devices should be closed
during operation.
Please seek professional help when encountering machine failure
Consult the relevant contents of this manual if you encounter any
difficulties in installation and operation.
Contact the service center of your supplier to seek professional help if
you still cannot fully understand after reading the manual or still cannot
solve the problem.

USER MANUAL 3
GENERAL DESCRIPTION
Advanced IGBT inverter technology
High inverter frequency greatly reduces the volume and weight of the
welder.
Great reduction in magnetic and resistance loss obviously enhances the
welding efficiency and energy saving effect.
Switching frequency is beyond audio range, which almost eliminates
noise pollution.
LEADING CONTROL MODE
Advanced control technology meets various welding applications and
greatly improves the welding performance.
It can be widely used in acid and basic electrode welding.
Easy arc starting, less spatter, stable current and good shaping.
FEATURES OF ARC SERIES
Efficiency, energy saving, portable, stable arc, high no-load voltage, and
with good compensation of arc force, are able to meet various welding
requirements in field work.
OPERATION CONTROL AND DESCRIPTION
.FRONT CONTROL PANEL (SEE FIGURE 1)
Output terminal: To connect the work clamp (-)
Output terminal: To connect the electrode holder (+)
Arc force current knob: To adjust the arc force current
Power LED: To indicate the power. Power LED on indicates that the
power switch of the machine is on.
Overheating LED: To indicate overheating. Overheating LED on
indicates that the temperature inside the machine is too high and the
machine is under overheating protection status.
Welding current knob: To adjust the output current.
Digital meter: To display the welding current.

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.BACK CONTROL PANEL (SEE FIGURE 2)
Fan
Power switch: Power ON/OFF switch.
Power input: Power input cable
I
0
Power
input cable
Fan
power
switch
Output terminal
(work clamp)
Output terminal
(electrode holder)
Arc force current knob
Power LED
Overheating LED
Welding current knob
Digital meter
INSTALLATION, DEBUGGING AND OPERATION
NOTE:
Please install the machine strictly according to the following steps.
Turn off the power supply switch before any electric connection operation.
5.1 INSTALLATION METHOD
1) A primary power supply cable is available for this welding machine.
Connect the power supply cable to the rated input power.
2) The primary cable should be tightly connected to the correct socket
to avoid oxidization
3) Check whether the voltage value varies in acceptable range with a
multi-meter
4) Insert the cable plug with electrode holder into the«+» socket on the
front panel of the welding machine, and tighten it clockwise

USER MANUAL 5
5) Insert the cable plug with work clamp into the socket on the front
panel of the welding machine, and tighten it clockwise
6) Ground connection is needed for safety purpose.
The connection as mentioned above in 6.1(4) and 6.1(5)is DCEP connection.
Operator can choose DCEN connection according to work piece and
electrode application requirement. Generally, DCEP connection
is recommended for basic electrode, while there is no special requirement
for acid electrode.
5.2 OPERATION METHOD
1) After being installed according to the above method, and the power
switch being switched on, the machine is started with the power LED on
and the fan working
2) Pay attention to the polarity when connecting. Phenomena such as
unstable arc, spatter, and electrode sticking could happen if improper
mode is selected. Exchange the polarity if necessary
3) Select cable with larger cross-section to reduce the voltage drop if the
secondary cables (welding cable and earth cable) are long
4) Preset the welding current according to the type and size of the
electrode, clip the electrode and then welding can be carried out by
short circuit arc starting. For welding parameters, please refer to 6.3
5.3 WELDING PARAMETERS TABLE (FOR REFERENCE ONLY)
Electrode dia. (mm) Recommended
welding current (A)
Recommended
welding voltage (V)
1.0 20~60 20.8~22.4
1.6 44~84 21.76~23.36
2.0 60~100 22.4~24.0
2.5 120~80 24.8~23.2
3.2 148~108 24.92~23.32
4.0 180~140 27.2~24.6

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NOTE:
This table is suitable for mild steel welding. For other materials, consult
related materials and welding process for reference.
WORKING ENVIRONMENT
CAUTION:
1) Welding should be carried out in dry environment with humidity of
90% or less.
2) The temperature of the working environment should be between -10c
and 40c.
3) Avoid welding in the open air unless sheltered from sunlight and rain.
Keep it dry at all times and do not place it on wet ground or in puddles.
4) Avoid welding in dusty area or environment with corrosive chemical
gas.
5) Gas shielded arc welding should be operated in environment without
strong airflow.
SAFETY TIPS
Over-current/over-voltage/over-heating protection circuit is installed
in this machine. When the network voltage, output current or inner
temperature exceeds the set standard, the machine will stop
automatically. However, excessive use (e.g. too high voltage) of machine
will lead to welder damage. Therefore, please note:
2.1 Ventilation
This welder can create powerful cutting current that has strict cooling
requirements that cannot be met with natural ventilation. Therefore the
internal fan is very important in enabling the machine to work steadily
with effective cooling. The operator should make sure that the louvers be
uncovered and unblocked. The minimum distance between the machine
and nearby objects should be 30cm. Good ventilation is of critical
importance to the normal performance and lifespan of the machine
2.2 Welding operation is forbidden while the machine is overload.

USER MANUAL 7
Remember to observe the max load current at any moment (refer to the
corresponding duty cycle). Make sure that the welding current should
not exceed the max load current. Overload could obviously shorten the
machines lifespan, or even damage the machine
2.3 Over-voltage is forbidden
Regarding the power supply voltage range of the machine, please
refer to «Main Parameters» table. This machine is of automatic voltage
compensation, which enables the maintaining of the voltage range within
the given range. In case that the input voltage exceeds the stipulated
value, it would possibly damage the components of the machine
2.4 An earth terminal is available for the machine. Connect it with an
earth cable (section>=5mm2) to avoid the static and electric shock
2.5 A sudden halt may occur with the red LED on the front panel on
while the machine is of over-load status. Under this circumstance, it
is unnecessary to restart the machine. Keep the built-in fan working to
lower the temperature inside the machine. Cutting can be continued
after the inner temperature falls into the standard range and the red LED
is off.
MAINTENANCE
The following operation requires sufficient professional knowledge on
electric aspect and comprehensive safety knowledge. Operators should
be holders of valid qualification certificates which can prove their skills
and knowledge. Make sure the input cable of the machine is cut off from
the electricity utility before uncovering the welding machine
1. Check periodically whether inner circuit connection is in good condition
(esp. Plugs). Tighten the loose connection. If there is oxidization, remove
it with sandpaper and then reconnect
2. Keep hands, hair and tools away from the moving parts such as the
fan to avoid personal injury or machine damage
3. Clean the dust periodically with dry and clean compressed air. If
welding environment with heavy smoke and pollution, the machine
should be cleaned daily. The pressure of compressed air should be at

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a proper level in order to avoid the small parts inside the machine being
damaged.
4. Avoid rain, water and vapor infiltrating the machine. If there is, dry it
and check the insulation of the equipment (including that between the
connections and that between the connection and the enclosure). Only
when there are no abnormal phenomena anymore, can the machine be
used.
5. Check periodically whether the insulation cover of all cables is in good
condition. If there is any dilapidation, rewrap it or replace it.
6. Put the machine into the original packing in dry location if it is not to
be used for a long time.
TROUBLE SHOOTING
The following operation requires professional knowledge on electric
aspect and comprehensive safety knowledge. Operators should be
holders of valid qualification certificates which can prove their skills and
knowledge. Make sure the input cable of the machine is cut off from the
electricity utility before uncovering the welding machine.

USER MANUAL 9
.COMMON MALFUNCTION ANALYSIS AND SOLUTION:
Malfunction Phenomena Cause and Solution
Turn on the machine, the power
LED is off, the fan doesn›t work,
and no welding output
Check if the power is closed No input
power
Turn on the machine the fan
works, but the output current is
unstable and can›t be controlled
by potentiometer when welding.
The current potentiometer fails. Re-
place it.
Check if any loose contact exists inside
the machine. If any reconnect
Turn on the machine, the power
LED is on, the fan work, but no
welding output.
Check if any loose contact exists inside
the machine.
Open circuit or loose contact occurs at
the joint of output terminal.
The overheating LED is on.
The machine is under over-heating
protection status. It can recover auto-
matically after the welding machine is
cooled.
Check if the thermal switch is ok.
Replace it if damaged.
Turn electrode holder becomes
very hot.
The rated current of the electrode
holder is smaller than its actual working
current. Replace it with a bigger rated
current.
Excessive spatter in MMA
welding
The output polarity connection incor-
rect. Exchange the polarity.