Sweiss SKYARC One FX User manual

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2012 12
．
OPERATORS’ MANUAL
Inverter DC MMA Arc Welding Machine
SKYARC One FX / 2050
IMPORTANT: Read this Owner’s Manual Completely before attempting to
use this equipment. Save this manual and keep it handy for quick reference. Pay
particular attention to the safety instructions we have provided for your protection.
Contact your distributor if you do not fully understand this manual.
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INTRODUCTION
CONTENT
§1 SAFETY............................................................................................................................................ 1
§1.1 SIGNAL EXPLANATION .................................................................................................................1
§1.2 ARC WELDING DAMAGE..............................................................................................................1
§1.3 THE KNOWLEDGE OF ELECTRIC AND MAGNETIC FIELDS ...........................................................4
§2 SUMMARY....................................................................................................................................... 6
§2.1 BRIEF INTRODUCTION .................................................................................................................6
§2.2 WORKING PRINCIPLE ..................................................................................................................7
§2.3 VOLT-AMPERE CHARACTERISTIC ...............................................................................................7
§3 INSTALLATION & ADJUSTMENT .............................................................................................. 7
§3.1 PARAMETERS...............................................................................................................................7
§3.2 DUTY CYCLE & OVER HEAT.........................................................................................................8
§3.3 WELDING POLARITY CONNECTION WAY.......................................................................................8
§3.3.1 MMA (take DM-1600P for an example) .........................................................................8
§3.3.2 TIG (take DM-1600P for an example) ............................................................................9
§4 OPERATION CONTROL AND CONNECTORS...................................................................... 10
§4.1 LAYOUT FOR FRONT & REAR PANEL (EXAMPLE FOR DM-1600P) ...........................................10
§4.2 WORK PROCESS.......................................................................................................................11
§4.3 WELDING CURRENT ADJUSTMENT.............................................................................................11
§4. 4 WELDING OPERATION...............................................................................................................12
§4.4.1 Striking arc way ...............................................................................................................
12
§4.4.2 Manipulation of electrode ...............................................................................................
12
§4.5 WELDING PARAMETERS.............................................................................................................12
§4.5.1 Joint form in MMA ...........................................................................................................
12
§4.5.2 Electrode selection..........................................................................................................
13
§4.6 ARC WELDING DEFECT AND PREVENT METHOD .....................................................................14
§4.7 OPERATION ENVIRONMENT.......................................................................................................15
§4.8 OPERATION NOTICES................................................................................................................15
§5 MAINTENANCE & TROUBLESHOOTING............................................................................... 16
§5.1 MAINTENANCE...........................................................................................................................16
§5.2 TROUBLESHOOTING...................................................................................................................17
§5.3 ELECTRICAL PRINCIPLE DRAWING .............................................................................................20
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SAFETY
§1 SAFETY
§1.1 Signal Explanation
The above signals mean warning! Notice! Running parts and getting an electric shock or
thermal parts will take damage for your body or others. The corresponding notices are as
follows. It is quite a safe operation after taking several necessary protection measures.
§1.2 Arc Welding Damage
The following signals and word explanations are to some damages for your body or
others happening on the welding operation. While seeing these, please remind of
yourself or others to be dangerous.
Only ones who are trained professionally can install, debug, operate, maintain and
repair the equipment.
During the operation, non-concerned people should be lift, especially for children.
After shut off the machine power, please maintain and examine the equipment
according to §5 because of the DC voltage existing in the electrolytic capacitors.
ELECTRIC SHOCK CAN KILL.
Never touch electrical parts.
Wear dry, hole-free gloves and clothes to insulate yourself.
Insulate yourself from work and ground using dry insulation. Make certain the insulation is
large enough to cover your full area of physical contact with work and ground.
Take carefully when using the equipment in small place, falling-off and wet
circumstance. Never close the machine power before installation and adjustment.
Ensure to install the equipment correctly and ground the work or metal to be welded
to a good electrical (earth) ground according to the operation manual.
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
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SAFETY
insulate hands.
In semiautomatic or automatic wire welding, the electrode, electrode reel, welding
head, nozzle or semiautomatic welding gun are also electrically “hot”.
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.
Maintain the electrode holder, work clamp, welding cable and welding machine in
good, safe operating condition. Replace damaged insulation.
Never dip the electrode in water for cooling.
Never simultaneously touch electrically “hot” parts of electrode holders connected to
two welders because voltage between the two can be the total of the open circuit
voltage of both welders.
When working above floor level, use a safety belt to protect yourself from a fall should
you get a shock.
FUMES AND GASES CAN BE DANGEROUS.
Welding may produce fumes and gases hazardous to health. Avoid breathing 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 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.
Do not weld in locations near chlorinated hydrocarbon vapors coming from
degreasing, cleaning or spraying operations. The heat and rays of the arc can react with
solvent vapors to form phosgene, a highly toxic gas, and other irritating products.
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.
Read and understand the manufacturer’s instructions for this equipment and the
consumables to be used, including the material safety data sheet and follow your
employer’s safety practices.
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SAFETY
ARC RAYS CAN BURN.
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.
Use suitable clothing made from durable flame-resistant material to protect your skin
and that of your helpers from the arc rays.
Protect other nearby personnel with suitable, non-flammable screening and /or warn them
not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.
SELF-PROTECTION
Keep all equipment safety guards, covers and devices in position 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.
Do not put your hands near the engine fan. Do not attempt to override the governor or
idler by pushing on the throttle control rods while the engine is running.
DO NOT adds the fuel near an open flame welding arc or when the
engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel
from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling
tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.
WELDING SPARKS can cause fire or explosion.
Remove fire hazards from the welding area. If this is not possible, cover them to
prevent the welding sparks from starting a fire. Remember that welding sparks and hot
materials from welding can easily go through small cracks and openings to adjacent
areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.
Where compressed gases are to be used at the job site, special precautions should
be used to prevent hazardous situation.
When not welding, make certain no part of the electrode circuit is touching the work or
ground. Accidental contact can cause overheating and create a fire hazard.
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 vapors from substances
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SAFETY
inside. They can cause an explosion even though they have been “cleaned”.
Vent hollow castings or containers before heating, cutting or welding. They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil free protective garments
such as leather gloves, heavy shirt, cuff less trousers, high shoes and a cap over your
hair. Wear ear plugs when welding out of position or in confined places. Always wear
safety glasses with side shields when in a welding area.
Connect the work cable to the work as close to the welding area as practical. Work cables
connected 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 they fail.
Rotating parts may be dangerous.
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.
Always keep cylinders in an upright position securely chained to an undercarriage or fixed
support.
Cylinders should be located:
-Away from areas where they may be struck or subjected to physical damage.
-A safe distance from arc welding or cutting operations and any other source of
heat, sparks, or flame.
Never allow the electrode, electrode holder or any other electrically “hot” parts to
touch a cylinder.
Keep your head and face away from the cylinder valve outlet when opening the
cylinder valve.
Valve protection caps should always be in place and hand tight except when the
cylinder is in use or connected for use.
§1.3 The knowledge of Electric and Magnetic Fields
Electric current flowing through any conductor causes localized Electric and Magnetic
Fields (EMF). The discuss on the effect of EMF is ongoing all the world. Up to now, no material
evidences show that EMF may have effects on health. However, the research on damage of
EMF is still ongoing. Before any conclusion, we should minimize exposure to EMF as few as
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SAFETY
possible.
In order to minimize EMF, we should use the following procedures:
Route the electrode and work cables together – Secure them with tape when
possible. All cables should be put away and far from the operator.
Never coil the power cable around your body.
Make sure welding machine and power cable to be far away from the operator as far
as possible according to the actual circumstance.
Connect the work cable to the workpiece as close as possible to the area being
welded. The people with heart-pacemaker should be away from the welding arc.
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SUMMARY
§2 Summary
§2.1 Brief Introduction
SKYARC One FX /2050 welders are general MMA arc welder which adopts the
latest pulse width modulation (PWM) technology and the insulated gate bipolar
transistor (IGBT) power module. It uses digital control system. It can change work
frequency to medium frequency so as to replace the traditional hulking work frequency
transformer with the cabinet medium frequency transformer. Thus, it is characterized
with portable, small size, low consumption and etc.
SKYARC One FX / 2050 have excellent performances: real time display and current
preset makes it convenient to use; fan demand makes the machine save the energy;
constant current output makes welding arc more stable; fast dynamic response speed
reduces the impact from the arc length fluctuation to the current; accurate stepless
current adjustment and pre-setting function. There are also some automatic protection
functions for under voltage, over current, over heat, etc. inside the welders, when the
problems listed before occurred, the alarm on the front panel is light and at the same
time the output current will be cut off. It can self-protect and prolong the using life and
greatly improved the reliability and practicability of the welders.
SKYARC One FX / 2050 welders can also realize TIG operation. While MMA
operation, if the electrode touches workpiece over two seconds, the welding current will
drop to the minimum current automatically to protect the electrode. While TIG operation,
the minimum current will be outputted firstly until the arc is ignited by lifting method, the
output current will rise to the preset value, which can protect the electrode. At the same
time, the arc force and hot start will be provided with MMA operation.
MMA——Manual Metal Arc welding;
PWM——Pulse-Width Modulation;
IGBT——Insulation Gate Bipolar Transistor;
TIG——Tungsten Inert Gas welding.
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SUMMARY
§2.2 Working Principle
The working principle of SKYARC One FX / 2050 ULTRA POWER welder is shown as the
following figure. Single phase 110V 220V±10%work frequency (50/60 Hz) AC is rectified into DC,
then by ULTRA POWER circuit,－DC(about 370V)is converted to medium
frequency AC (about 20KHz) by inverter device (IGBT module), after reducing voltage by
medium transformer (the main transformer) and rectified by medium frequency rectifier (fast
recovery diodes), and is outputted by inductance filtering. The circuit adopts current feedback
control technology to insure current output stably. Meanwhile, the welding current parameter
can be adjusted continuously and steplessly to meet with the requirements of welding craft.
§2.3 Volt-Ampere Characteristic
SKYARC One FX / 2050 welders have excellent volt-ampere characteristic, seeing
the following graph. In MMA welding, the relation between the rated loading voltage U2
and welding current I2is as follows:
When I2≤600A，U2＝20＋0.04 I2（V）；When I2＞600A，U2＝44（V）.
U
2
V
（44
Volt-ampere characteristic
64
）
Working
The relation of the rated loading
voltage&welding current
point
20
0
600
I
2
A
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INSTALLATION AND ADJUSTMENT
§3 Installation & Adjustment
§3.1 Parameters
7
Models
SKYARC One FX
Parameters
Input power
Single phase,98V-165V,50/60Hz
Single phase,177V-265V, 50/60Hz
TIG
MMA
TIG
MMA
Rated input current
A
23
33
15
23.5
Rated input power
KW
2.62
3.75
3.3
5.02
Power factor
0.99
0.99
Welding current range
A
5
125
5
170
Max no-load voltage(V)
71
71
Efficiency
≥80
≥80
Duty
cycle
40 ℃
10
50%
125A
30%
125A
40%
160A
40%
160A
（）
minutes
see §3.2
）
100%
100A
100%
60A
100%
80A
100%
80A
（
Protection class
（）
～
IP23S
～
Insulation class
F
Dimensions of Machine
％
400×140×230
％
L×W×H
mm
Weight
Kg
7.8
（，
Note: The above parameters are subject to change with the improvement of machines.
），
）
Models
SKYARC 2050 FX
Parameters
Input power
Single phase 98V-165V
50/60Hz
Single phase 177V-265V
50/60Hz
（
）（
）
TIG
MMA
TIG
MMA
Rated input current
A
23
33
23
32
（
）
Rated input power
KW
2.62
3.75
5.24
6.72
Power factor
0.99
0.99
Welding current range
A
5
110
，
5
200
，
Max no-load voltage(V)
52
52
Efficiency
（）
≥80
≥80
Duty
cycle
40 ℃
10
50%
125A
30%
125A
50%
200A
50%
200A
minutes
see §3.2
）
100%
100A
100%
60A
100%
80A
100%
80A
（
Protection class
（）
～
IP23S
～
Insulation class
F
Dimensions of Machine
％
400×140×230
％
L×W×H
mm
Weight
Kg
8
（
，