Sohal IR Series User manual

INVERTER WELDING (IR)
&
INVERTER Tig + MMA (IRT)
MANUAL
2016
www.sohal.org

INDEX
Theory
A model block diagram of machine
Quick know-how
Installation Guide
Using machines / Starting work
Setting Gas Pre-Flow Time
Fault Finding
Connection Diagram of IR welding machine
Connection Diagram of IRT welding machine
3
3
4
5
6
6
7-8
9
10
Page no.

THEORY
A MODEL BLOCK DIAGRAM OF MACHINE
Filter / Snubber
Inductive Filter
3-Ph Bridge Rectifier
MCB for ON/OFF
& Protection
Power ON
Soft Starter
DC CAp.
IGBT Bridge.
Main Transformer
Output Rectifier
DCL
OUTPUT TERMINALS
Current Sensor
Control Transformer
IGBT DRIVER
IR series welding machines are based on inverter technology by which the
50/60 Hz input supply is first converted to DC by diodes, then filtered by
electrolytic capacitors for ripple free pure DC volts, then this DC volts are
inverted to medium frequency (20KHz) AC, then step down by small
efficient transformer, then re-converted to Low volt DC suitable for
welding.
Control PCB
3

Quick kow-how :
MODEL: IR
MODEL: IRT
Current adjustment
Knove
Negative output terminal
Connect it to work
Positive output terminal
Connect it to holder
Display
Main supply cable
(Backside)
Current adjustment
Knove
Main supply cable
(Backside)
Display
Positive output terminal
Connect work lead
Or
Holder for arc welding
Negative output terminal
Connect tig torch here
Or
Work lead for arc welding
Torch gas connection
Torch plug
Argon gas post flow time
Adjustment
Argon gas inlet
(Backside)
4
*
*This switch has two functions.
1. Select Electrode or Tig mode.
2. For Argon pre-flow set, rotate post-flow knob in MMA position. Screen show pre flow saving,
when message disappear. Set switch to Tig mode and set post-flow.
Output ON LED
Output ON LED
Shielding Gas Check Push Button

Installation Guide:
ÜPlace machine 6 to 12 inches above from ground, This will escape it from sudden water
flow, dust and scrap.
ÜLeave at least 6 inches space all-around the machine for proper cooling.
ÜConnect power supply through MCB or MCCB, never connect through old(used) knife
type power on switch
ÜBe sure machine body is properly grounded, before switching it on.
ÜSwitch off machine during connecting or removal of output leads.
ÜThroughly tighten the fasteners of output terminals.
Supply Cable:
4-core 2.5 mm sq. for IR300 & IRT 300
4-core 4 mm sq. for IR400 & IRT 400
4-core 6 mm sq. for IR500 & IRT500
Welding or Work cable:
35 mm sq. for IR300 & IRT 300
50 mm sq. for IR400 & IRT 400
75 or 50 mm sq. for IR500 & IRT500
Tig Torch:
Air Cooled for IRT 300
Air Cooled or Water Cooled(preffered) IRT 400
Water Cooled IRT500
5

Using IRxxx :
ÜConnect Work lead to working table or job. Keep welding holder away from work
connections.
ÜSwitch on mains from socket and from backside MCB.
ÜSelect and clamp desired welding electrode in holder and set welding current according
to rod size as mentioned on it’s cartoon.
ÜMake a trial weld, then modify current setting if needed.
ÜMachine is ready for production work.
Using IRTxxx :
ÜFor arc welding, move toggle switch towards MMA on front panel of machine and do
the same procedure as written above for IRxxx.
Ü
For Tig Welding do following steps.
ÜConnect Work lead from +ve terminal to working table or job.
ÜConnect Tig torch at -ve terminal and connect gas pipe at gas nipple and connect torch
plug.
ÜPlace a sharp grinded tungsten electrode in torch head and tight 2-4 mm outside of
ceramic nozzle.
ÜConnect shielding gas(argon) at gas inlet nipple, backside of machine.
ÜSwitch on mains from socket and from backside MCB.
ÜPush Gas Check Button from front panel and adjust the gas flow from gas regulator
and flow-meter according to working conditions. Preferably between 2 to 6 liter per
minute
ÜProgram Gas Pre-flow time:
1. Set TIG/MMA switch back to MMA.
2. Rotate post-flow knob in MMA position. Screen show Pre-flow sec., Set the
desired value, if not sure set it to minimum (0.1 sec.). After a second screen
shows pre flow saving. when saving message changed to Welding Current. Set
TIG/MMA seitch to TIG mode.
3. Every time when Pre-flow will done. Don’t forget to set Post Flow Time.
ÜSet Post-Flow time between 2 to 5 sec. If want to use machine at full current set it to 5
second.
ÜSet welding current according to job.
ÜMake a trial weld, then modify current setting if needed.
ÜMachine is ready for production work.
6

Fault finding :
Replace with new one
(potentiometer 5K)
Clean terminals by
emery paper, replace
damaged thimble.
Replace cable
Connect work lead
properly to job or
working table.
Wait for 5 minutes to
lower the inside
temperature, if fan faulty
replace it.
Check water valve, pipe
bent and no water from
source
Send machine to
Service Center
Send machine to
Service Center
Replace faulty item.
Knob faulty
Loose or damaged
connection on output
terminals.
Welding cable
damaged.
Work lead has not
properly connected to
job.
Machine is overheated
due to working
continuously at full
or
Cooling fan faulty
Water is not flowing
through torch.
DCL, Transformer or
PCB 271C faulty
Main Transformer faulty
or 12-V fan faulty or
PCB276 faulty.
12-Volt Fan OR
PCB276
The current adjustment
knove does not work in
proper way and current
display does not follow
correctly it’s movement.
Welding stops
automatically with-out
no message on display
Welding stops
automatically, display
blink and following
message on display
1. Thermostat Cut
2. T. coolant Fail
(if Optional pressure
switch connected in
machine)
3. Sensor Overload
4. CT overload
5. +12V Fail OR (-)12V
Fail
PROBLEM CAUSE SOLUTION
7

Increase post flow time
from knob
Connect torch to
negative terminal
Change gas cylinder
Change the direction of
table fan or switch of
ceiling fan, if working in
open area: shield the
job from flowing air
Replace torch or torch
head
Less post flow time
Wrong polarity of Tig
torch
Argon gas problems.
Like:
Gas is not pure
Blowing wind flows
away the gas
Fault in torch head
Tig Problems
Tungsten Electrode
being black
White ash on job and
tungsten electrode
burn fast
Weld burns
8

PCB276
CN1
CN2
CN3
CN4
-12 V
12 V
5 V
0 V
Output’s
POWER SUPPLY
PCB
12 V
0 V
0
220 V ~
Chasis
Input
Grey
Grey
Green
Red
Black
Black
Pink
Orange
Blue
PCB271B
CN1
CN5
CN7
CN2
CN10
CN8
CN6
CN4
CN9
Orange
L. Gray
L. Gray
D. Gray
Blue
WELDING CURR.
300
PCB255
Capacitive Filter
4K7 Lin.
T1
(Main Transformer)
Output Terminal (-Ve) Output Terminal (+Ve)
DCL1
415-V, 3-Ph, INPUT
Ferrite
Beads
CONNECTION DIAGRAM OF IR300/400/500
AC 220-V
Bridge
CT
o
90 C
1uf /250 X2 0.1uf /250 X2
220 Volt /14 (431/14)
(July, 2014)
LINK LINK
IGBT & DRIVER
SET
(CHOKE)
Ferrite
Beads
4K7 2W
2 X (431/14)
2 X (100R 2W)
.1 / 275 X2
2 X (100R 2W)
.1 / 275 X2
2200/16
NC
4x 100K2W
300A
400A
500A
Machine PCB
275A
275B
275B
PCB216
Note: #
DCL
Capacitor

PCB276
CN1
CN2
CN3
CN4
-12 V
12 V
5 V
0 V
Output’s
POWER SUPPLY
PCB
12 V
0 V
0
220 V ~
Chasis
Input
Grey
Grey
Green
Red
Black
Black
Pink
Orange
Blue
PCB271B
CN1
CN5
CN7
CN2
CN10
CN8
CN6
CN4
CN9
Orange
L. Gray
L. Gray
D. Gray
Blue
WELDING CURR.
300
PCB255
Capacitive Filter
4K7 Lin.
T1
Output Terminal (-Ve) Output Terminal (+Ve)
DCL1
415-V, 3-Ph, INPUT
Ferrite
Beads
AC 220-V
DC 12-V
Bridge
CT
o
90 C
1uf /250 X2
0.1uf /250 X2
220/14
Machine W. Cable
300A
400A
500A
35 mm sq.
50 mm sq.
70 mm sq.
CONNECTION DIAGRAM OF IRT300/400/500
(Main Transformer)
PCB278
CN1 CN4
CN5
Torch Plug
TIG / MMA
H.F.
F
I
L
T
E
R
VALVE
Ar
LINK LINK
IGBT & DRIVER
SET
4x 100K2W
PCB216
Note: #
2 X (431/14)
2 X (100R 2W)
.1 / 275 X2
2 X (100R 2W)
.1 / 275 X2
Fill with Turns
300A
400A
500A
Machine PCB
275A
275B
275B
(July, 2014)
2200/16
24-V
T47 IP
DCL
Capacitor

www.sohal.org
Mfrs:
SOHAL ELECTRIC WORKS
13243, Link Road, Chowk Dholewal, Ludhiana-141003.
[phone], 2531116, [email protected]www.sohal.org,
11