Vector Welding London2400 User manual

OPERATING INSTRUCTIONSOPERATING INSTRUCTIONS
London2400 Welding Machine
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VECTOR DIGITAL – We optimize the quality and prices
Looking to the future, sustainability, environment friendly and high on the customer-oriented
competence - the key words to which we are responsible.
For this reason, we develop our own powerful brand VECTOR .
In VE CTOR w eld ing eq uip men t comb ine s adva nc ed inve rt er tech no log y, the hi ghe st
quality standards of a premium brand and low prices to a unique value for money. Inverter
tec hnology is an essential component of proces s i mprov ement and mini mizes energy
consumption. In all our equipment, we therefore trust on the MOSFET technology from
Toshi ba and Inf ineon IGBT tech nology from SIEME NS. Their innov ative solut ions are
setting new standards in welding technology.
VECTOR welding equipment can be used on nearly all weld able metals. It is particularly
suitable when quality welds are extremely important. Private gardening - motorcycles,
cars, trucks, classic cars, model making, stair and balcony railings or in the professional
and industrial secto rs such as Oil pi peline, chemic al, auto motive, shipbu ilding, boiler,
electric power construction, nuclear power, aerospace, military, industrial installation,
br i d g e co n stru c t ion a n d ot h e r in d u str i e s, th e hig h e st qu a lit y r equ i r emen t s are m et
successfully with VECTOR welding equipment.
V E C TOR i s o n e o f t h e l e a d i ng su p p l i e r s o f w e ldi n g e q u i p m e n t - dis c o v e r o u r
possi bilitie s - profit from our vis ion to o ffer modern, high-per fo rmanc e weldin g
equipment at unbeatable prices.
On the basis of 4 strategic objectives, our company work day by
day to optimize this vision:
◆Number 1 in Technology
◆Number 1 in the prices
◆Number 1 in Service
◆Number 1 in the environmental compatibility
More than 30,000 enthusiastic customers trust our equipment in the welding and plasma
technology. They confirm the success of t hes e trendsetting strategy. In addition to t he
stringent quality test and the test in the production, we subject the equipment a thorough
inspection before delivery. We guarantee delivery of spare parts and repair of all equipment.
The customer is served during and after the warranty period from us. In case of problems,
call us , we are always available. You are also welcome to visit us. Highly qualified employees
are dedicated to carrying out their various tasks with expertise and passion. Our motivated
team will always find a positive solution for you. Everyone is welcome to test our equipment
in detail under the guidance of our experts.
Private gardening, industry or professional, in every area you win if you rely on technology
of welding equipment from VECTOR.
For questions or suggestions, please contact us.www.smart-iwm.com
WARNINGS
Read and understand this entire Manual and your employer’s safety
practices before installing, operating ,or servicing the equipment.
While The operating instructions provide an introduction to the safe
use of the products.
• Read the operating instructions for all system components!
• Observe accident prevention regulations!
• Observe all local regulations!
• Confirm with a signature where appropriate.
Record the following information for Warranty purposes:
Where Purchased:
Purchase Date:
Serial NO.:
Published by:
VECTOR WELDING TECHNOLOGY GMBH
Hansestrasse 101.
51149, Koln, Germany
www.smart-iwm.com

1.1 Arc welding damage--------------------------------------------------------------01-04
1.2 Effects of low frequency electric and magnetic fields----------------------- 04-04
1.3 Symbol chart------------------------------------------------------------------------ 05-05
1. Safety instructions
5. Troubleshooting
5.1 Troubleshooting----------------------------------------------------------------------25-27
6. Maintenance
6.1 Maintenance------------------------------------------------------------------------- 28-28
2. Summary
2.2 Working principle-------------------------------------------------------------------- 07-07
2.1 Brief Introduction-------------------------------------------------------------------- 06-07
2.4 Specifications------------------------------------------------------------------------ 08-09
2.5 Duty cycle----------------------------------------------------------------------------- 09-09
2.6 Packaged Items---------------------------------------------------------------------- 09-09
2.3 --------------------------------------------------------08-08Volt- ampere characteristic
WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING
YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRU-
CTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage
to other equipment or property, if the operator does not strictly observe all safety rules
and take precautionary actions.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or severe burns. The electrode and
work circuit is electrically live whenever the output is on. The input power circuit and
machine internal circuits are also live when power is on. In semi-automatic or automatic
wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding
wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating mats or covers.
4. Disconnect input power or stop engine before installing or servicing this equipment.
Lock input power disconnect switch open, or remove line fuses so power cannot be
turned on accidentally.
5. Properly install and ground this equipment according to its Owner ’s Manual.
WARNING
1.1 Arc Welding Damage
Safe practices have developed from past experience in the use of welding and cutting.
These practices must be learned through study and training before using this equipment.
Some of these practices apply to equipment connected to power lines; other practices
apply to engine driven equipment. Anyone not having extensive training in welding and
cutting practices should not attempt to weld.
Safe practices are outlined in the European Standard EN60974-1 entitled: Safety in
welding and allied processes Part 2: Electrical HAVE ALL INSTALLATION, OPERATION,
MAINTENANCE, ANDREPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.
Safety instructions
01
3. Operation
3.2 Control panel--------------------------------------------------------------------------- 15-18
3.1 Layout for the panel----------------------------------------------------------------- 10-15
3.3 Setup for stick (MMA) welding----------------------------------------------------- 18-18
3.4 Set-up for lift tig (GTAW) welding-------------------------------------------------- 19-19
3.5 Operation environment-------------------------------------------------------------- 20-20
3.6 Operation notices--------------------------------------------------------------------- 20-20
4. Welding technique
4.1 TIG basic welding technique------------------------------------------------------- 20-20
4.2 Joint froms in tig-------------------------------------------------------------------- 21-21
4.3 The explanation of welding quality----------------------------------------------- 21-21
4.4 TIG parameters matching---------------------------------------------------------- 21-23
4.5 MMA basic welding technique---------------------------------------------------- 23-24
AC/DC WIG SERIES EQUIPMENT

WARNING FLYING SPARKS and HOT METAL
can cause injury.
Chipping and grinding cause flying metal. As welds cool, they can throw off slag.
1. Wear approved face shield or safety goggles. Side shields recommended.
2. Wear proper body protection to protect skin.
WARNING ARC RAYS can burn eyes and skin,
NOISE can damage hearing.
Arc rays from the welding process produce intense heat and strong ultraviolet rays that
can burn eyes and skin. Noise from some processes can damage hearing.
1. Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes
when welding or watching;
2. Wear approved safety glasses. Side shields recommended;
3. Use protective screens or barriers to protect others from flash and glare;
warn others not to watch the arc;
4. Wear protective clothing made from durable, flame-resistant material(wool and leather)
and foot protection;
5. Use approved ear plugs or ear muffs if noise level is high;
6. Never wear contact lenses while welding.
WARNING FUMES AND GASES can be hazardous
to your health.
Welding produces fumes and gases. Breathing these fumes and gases can be hazardous
to your health.
1. Keep your head out of the fumes. Do not breathe the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes
and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Work in a confined space only if it is well ventilated, or while wearing an air-supplied
respirator. Shielding gases used for welding can displace air causing injury or death.
Be sure the breathing air is safe.
5. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat
and rays of the arc can react with vapours to form highly toxic and irritating gases.
6. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless
the coating is removed from the weld area, the area is well ventilated, and if necessary,
while wearing an air- supplied respirator. The coatings and any metals containing these
elements can give off toxic fumes if welded.
WARNING WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding arc. The fly sparks and hot metal, weld spatter,
hot workpiece, and hot equipment can cause fires and burns. Accidental contact of
electrode or welding wire to metal objects can cause sparks, overheating, or fire.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables far away from the welding arc. If this is not possible, tightly
cover them with approved covers.
4. Be alert that welding sparks and hot materials from welding can easily go through small
cracks and openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
WARNING CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can
explode. Since gas cylinders are normally part of the welding process, be sure to treat
them carefully.
1. Protect compressed gas cylinders from excessive heat, mechanical shocks, and arcs.
2. Install and secure cylinders in an upright position by chaining them to a stationary support
or equipment cylinder rack to prevent falling or tipping.
3. Keep cylinders away from any welding or other electrical circuits.
4. Never allow a welding electrode to touch any cylinder.
5. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the
specific application; maintain them and associated parts in good condition.
6. Turn face away from valve outlet when opening cylinder valve.
7. Keep protective cap in place over valve except when cylinder is in use or connected
for use.
8. Read and follow instructions on compressed gas cylinders, associated equipment.
WARNING ENGINE FUEL can cause fire or explosion.
Engine fuel is highly flammable.
1. Stop engine before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near any sparks or open flames.
3. Allow engine to cool before fuelling. If possible,check and add fuel to cold engine before
beginning job.
4. Do not overfill tank — allow room for fuel to expand.
5. Do not spill fuel. If fuelling is spilled, clean up before starting engine.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the
hidden side.
7. Do not weld on closed containers such as tanks or drums.
8. Connect work cable to the work as close to the welding area as practical to prevent
welding current from travelling long, possibly unknown paths and causing electric
shock and fire hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire at contact tip when not
in use.
0302
Safety instructions Safety instructions AC/DC WIG SERIES EQUIPMENTAC/DC WIG SERIES EQUIPMENT

WARNING
SPARKS can cause battery gases to explode;
BATTERY ACID can burn eyes and skin.
Batteries contain acid and generate explosive gases.
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting battery cables.
3. Do not allow tools to cause sparks when working on a battery.
4. Do not use welder to charge batteries or jump start vehicles.
5. Observe correct polarity (+ and –) on batteries.
WARNING STEAM AND PRESSURIZED HOT COOLANT
can burn face, eyes, and skin.
The coolant in the radiator can be very hot and under pressure.
1. Do not remove radiator cap when engine is hot. Allow engine to cool.
2. Wear gloves and put a rag over cap area when removing cap.
3. Allow pressure to escape before completely removing cap.
NOTE
To reduce magnetic fields in the workplace, use the following procedures.
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cable around the body.
4. Keep welding Power Source and cables as far away from body as practical.
5. The people with heart-pacemaker should be away from the welding area.
1.2 Effects Of Low Frequency Electric and Magnetic Fields
1.3 Symbol Chart
Note that only some of these symbols will appear on your model.
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 conslusion, we should minimize exposure
to EMF as few as possible.
WARNING MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut fingers and hands and catch loose
clothing.
1. Keep all doors, panels, covers, and guards closed and securely in place.
2. Stop engine before installing or connecting unit.
3. Have only qualified people remove guards or covers for maintenance and troubleshooting
as necessary.
4. To prevent accidental starting during servicing, disconnect negative (-) battery cable
from battery.
5. Keep hands, hair, loose clothing, and tools away from moving parts.
6. Reinstall panels or guards and close doors when servicing is finished and before
starting engine.
0504
Safety instructions Safety instructions AC/DC WIG SERIES EQUIPMENTAC/DC WIG SERIES EQUIPMENT

0706
2.1 Brief Introduction
SummarySummary
TIG London2400 AC/DC welding machine adopts the latest pulse width modulation
(PWM) technology and insulated gate bipolar transistor (IGBT) power module, which can
change work frequency to medium frequency so as to replace the traditional hulking work
frequency transformer with the cabinet medium frequency transformer. Thus, its charac-
terized with portable, small size, light weight, low consumption and etc.
The parameters of TIG London2400 AC/DC on the front panel all can be adjusted con-
tinuously and steplessly, such as start current, crater arc current, welding current, base cur-
rent, duty ratio, upslope time, downslope time, pre-gas, post-gas, pulse frequency, AC fre-
quency, balance, hot start, arc force etc. When welding, it takes high frequency and high
voltage for arc igniting to ensure the success ratio of igniting arc.
TIG London2400 AC/DC Characteristics:
◆MCU control system, responds immediately to any changes.
◆Hig h f reque ncy and h igh volt age fo r a rc igniti ng to e nsure the success ratio of
igniting arc, the reverse polarity ignition ensures good ignition behavior in TIG-AC
welding.
◆Avoid AC arc-break with special means, even if arc-break occurs the HF will keep
the arc stable.
◆Pedal control the welding current.
◆In DC TIG without HFopertation, If the tungsten electrode touches the workpiece
when welding, the current will drop to short-circuit current to protect tungsten.
◆
occoured, the alarm lamp on the front panel will be on and the output current will
be cut off. It can self-protect and prolong the using life.
◆Dou b l e pur p o s e s: A C in v e r t er TI G / MMA a nd DC i n vert e r T IG/ M M A , Exc e l l ent
performance on AL-alloy, carbon steel, stainless steel, titanium.
According to choosing the front panel functions, the following five welding ways
can be realized.
DC MMA
DC TIG
DC Pulse TIG
AC TIG
AC Pulse TIG
Intelligent pr ot ec ti on: o ve r- cu rr ent, over-he at , whe n t he mentioned p roblems
1. For DC MMA, polarity connection can be chosen according to different electrodes;
2. For D C TIG, D CEP is used normally (wor kpi ece conne cte d to po sitive po lar ity, while
t orc h conn ec ted to negat ive po lar it y). This co nnect ion ha s many ch ara ct ers , such
as s t a b l e w e l d i ng arc, l o w t u n g s t e n pole lo s s , m o r e w elding cu r r e n t , n a r r o w and
deep weld;
3. For AC TIG (rectangle wave), arc is more stable than Sine AC TIG. At the same time,
you can not only obtain the max penetration and the min tungsten pole loss, but also
obtain better clearance effect;
4. DC Pulsed TIG has the following characters:
1) Pulse heating. Metal in Molten pool has short time on high temperature status
and freezes quickly, which can reduce the possibility to produce hot crack of the
materials with thermal sensitivity .
2) The workpiece gets little heat. Arc energy is focused. Be suitable for thin sheet
and super thin sheet welding.
3) Exactly control heat input and the size of the molten pool. The depth of penetration
is even. Be suitable for welding by one side and forming by two sides and all position
welding for pipe.
4) High frequency arc can make metal for microlite fabric, eliminate blowhole and
improve the mechanical performance of the joint.
5) High frequency arc is suitable for high welding speed to improve the productivity.
TIG London2400 AC/DC –series welding machines is suitable for all positions welding
for various plates made of stainless steel, carbon steel, alloyed steel, titanium, magnesium,
cuprum, etc, Which is also applied to pipe installment, mould mend, petrochemical, archi-
tecture, decoration, car repair, bicycle, handicraft and common manufacture.
MMA-------Manual Metal Arc Welding
PWM-------Pulse-Width Modulation
IGBT--------Insulation Gate Bipolar Transistor
TIG----------Tungsten Insert Gas Welding
2.2 Working Principle
The working principle of London2400 welding machines is shown as the following figure.
Single-phase 230V work frequency AC is rectified into DC (about 312 V), then is converted
to medium frequency AC (about 20-40KHz) by inverter device (IGBT module), after reducing
voltage by medium transformer (the main transformer) and rectifying by medium frequency
rectifier (fast recovery diodes), then is outputted DC or AC by selecting IGBT module. 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.
AC/DC WIG SERIES EQUIPMENTAC/DC WIG SERIES EQUIPMENT

0908
Summary
2.3 Volt- Ampere Characteristic
When I ≤600A, U =10+0.04I (V);
2 2 2
When I >600A,U =34(V).
2 2
TIG London2400 AC/ DC welding
machine has an excellent volt-ampere
characteristic, whose graph is shown
as the following figure. The relation
between the conventional rated loa-
ding voltage U and the conventional
2
welding current I is as follows:
2
2.4 Specifications
170A @ 25%, 26.8V / 85A @ 100%, 23.4V
200A @ 40%, 18V / 126A @ 100%, 15V
9.88 kg
10 - 170A
10 - 200A
15.4A
30.9A
10KVA
H360mmxW160mmxD380mm
Description
Weight
Power Source Dimensions
Cooling
Welder Type
European Standards
Number of Phases
Nominal Supply Voltage
Nominal Supply Frequency
Welding Current Range (MMA Mode)
Welding Current Range (TIG Mode)
Single Phase Generator Requirement
MMA Welding Output, 40ºC, 10 min.
TIG Welding Output, 40ºC, 10 min.
Open circuit voltage (MMA/TIG)
Protection Class
Maximum Input Current
Effective Input Current
SIWM DIGITAL London2400
Fan Cooled
EN 60974-1 / IEC 60974-1
1
230V +/- 15%
50/60Hz
60V DC
IP23
Inverter Power Source
Note 3: Motor start fuses or thermal circuit breakers are recommended for this application.
Check local requirements for your situation in this regard.
Note 1: The Effective Input Current should be used for the determination of cable size &
supply requirements.
Note 2: Generator Requirements at the Maximum Output Duty Cycle.
NOTE
Due to variations that can occur in manufactured products, claimed performance, voltages,
ratings, all capacities, measurements, dimensions and weights quoted are approximate
only. Achievable capacities and ratings in use and operation will depend upon correct
installation, use, applications, maintenance and service.
2.5 Duty Cycle
The rated duty cycle of a Welding Power Source, is a statement of the time it may be
operated at its rated welding current output without exceeding the temperature limits of
the i ns ul ation of the co mp on ent parts. To exp la in the 10 minute duty cycle p er io d the
following example is used. Suppose a Welding Power Source is designed to operate at
a 5 0% duty cycle, 200 am pe re s at 2 8 vol ts . This means that it has been designed and
built to provid e the rat ed amperag e (200A) for 5 minu te s, i.e. arc weldi ng time, out of
every 10 minute period (50% of 10 minutes is 5 minutes). During the other 5 minutes of
the 10 minute per iod th e We lding Pow er Source must i dle and b e a llowe d to cool . Th e
thermal cut out will operate if the duty cycle is exceeded.
Duty Cycle(PERCENTAGE)
Welding Current(AMPS)
◆2.5m Power cable
◆200 Amp Electrode Holder With 2.5m cable
◆200 Amp Earth Clamp With 2.5m cable
◆4m TIG Torch WP-17
◆4m TIG Torch WP-17
◆3m Gas Hose
◆Operating Manual
2.6 Packaged Items
2525 5050 7575 100100 125125 150150 175175
00
1 01 0
2 02 0
3 03 0
4 04 0
5 05 0
6 06 0
7 07 0
8 08 0
9 09 0
1 0 01 0 0
200225 250 27527500
Safe Operating Region
(TIG&STICK)
300
MMA
TIG
Summary
AC/DC WIG SERIES EQUIPMENTAC/DC WIG SERIES EQUIPMENT

10 11
Operation Operation
Behind
3.1 Layout For The Panel
Front
11
10
93
92
4
12
13
14
15
95
17
916
18 19
9
8
7
6
91
4
20
22
21
AC/DC WIG SERIES EQUIPMENTAC/DC WIG SERIES EQUIPMENT

12 13
Operation Operation
Minimum
Current
Press & hold
Trigger
Release
Trigger
Not e: tha t when oper ating in GTAW (HF and LIFT TIG mod es), the power source wil l
remain activated until the selected down slope time has elapsed
4T Latch mode this mode of welding is mainly used for long welding runs to reduce
operator fatigue. In this mode the operator can press and release the torch trigger and
the output will remain active. To deactivate the power source, the trigger switch must
again be pressed and released, thus eliminating the need for the operator to hold the
torch trigger.
12. Trigger Mode Control Button (HF TIG and LIFT TIG Mode only)
The trigger mode control is used to switch the functionality of the torch trigger between
2T and 4T.
output to be active.
Press and hold the torch trigger to activate the power source (weld). Release the torch
trigger switch to cease welding.
2T Normal Mode In this mode, the tor ch trigger must r emain pressed for thewelding
9. Frequency Indicator (Hz)
Frequency indicator, when the setting programm in pulse frequency ,this indicator will
be on.
11. Thermal Overload Indicator Light
This welding power source is protected by a self resetting thermostat. The indicator will
illuminate if the duty cycle of the power source has been exceeded. Should the thermal
overload indicator illuminate the output of the power source will be disabled. Once the
power source cools down this light will go OFF and the over temperature condition will
automatically reset. Note that the mains power switch should remain in the on position
such that the fan continues to operate thus allowing the unit to cool sufficiently. Do not
switch the unit off should a thermal overload condition be present.
10. Power ON Indicator
The POWER ON indicator illuminates when the ON/OFF switch is in the ON position and
the correct mains voltage is present.
1. Digital Ammeter / Parameter meter
The digital Ammeter is used to display the actual output current of the power source. It is
also used to display Parameters in Programming Mode.
Depending on the Programming Parameter selected, the status indictor adjacent to the
Ammeter will illuminate to show the units of the programming parameter.
When welding, the Ammeter will display actual welding current.
2. Hot Start
Arcforce Correction
Hot Start Function reliably ignites the electrode
and melts perfectly to ensure the best quality
even at the start of the seam. this solution makes
lack of fusion and cold welds a thing of the past
and significantly reduces weld reinforcement.
Adjust the hot start current here and the time here.
During the welding process, arcforce prevents
t h e e l e c t r o d e s t i c k i n g i n t h e w e l d p o o l w i t h
increases in current. this makes it easier to weld
large-drop melting electrode types at low current
strengths with a short arc in particular.
I
t
Anti-stick prevents the electrode from annealing.
If t he electrode sticks in spite of t he arcrorce device, the
machine automatically switches over to t h e m i n i m u m
cu rre n t wi thi n ab out 1 se con d to pre ven t th e el ect r ode
f r o m o v e r h e a ti n g . I n or d e r t o ea s i l y s e p a r a te t h e
e l e c t ro d e a n d e l e c t r o d e h o l d e r t o p r o t e c t t h e w e l d e r.
Antistick
Antistick
U
I
3. JOB and SAVE
You can press JOB to select the memory records that you have saved before from 1-9.
For the new setting of present current Amps ,just press SAVE.
4. Mode Button
Press the MODE button to toggle AC and DC output in LIFT TIG, HF TIG.
5. Current adjusting button/functions choosing
Clockwise rotate to enlarge the current, and anti-clockwise rotate to reduce the current.
If you need to choose different programming parameters (the eighth mark), press the
button and release it to choose different functions.
7. Current Indicator
When setting programm in the peak current, base current, ending current and rem , this
current indicator will be on.
6. Time Indicator (s)
Time indicator , when setting programm in gas pre-flow, up slope, down slope and gas
post-flow, this indicator will be on.
8. Percentage Indicator(%)
Percentage indicator, when setting programm in pulse duty cycle , this indicator will be
on .
AC/DC WIG SERIES EQUIPMENTAC/DC WIG SERIES EQUIPMENT

14 15
Operation Operation
CAUTION
Loose welding terminal connections can cause overheating and r esult in the male plug
being fused in the terminal.
22. Power switch
before using the machine. Pull the switch to the closure state of “AN” to operate the
machine, and pull the switch to “AUS” after use. Turn off the power input, and the machine
will stop operating.
21. Gas input port
The gas port is connected with the gas valve output port. After connection, check whether
there is gas leakage.
20. Program downloading port
Change the program downloading connection port, and use the plastic cover to prevent
the dust from polluting and oxidizing the port after use.
19. 5 Pin Control Socket
The 5 pin receptacle is used to connect a trigger switch or remote control to the welding
Power Source circuitry:
To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.
1
2
3
4
5
9
11 6
7
8
13 12
10
3.2 Control Panel
.Gas Pre-Flow 1
Absolute setting range 0.1s to 5s (0.1S increments)
This parameter operates in TIG modes only and is used to provide gas to the weld zone
prior to striking the arc, once the torch trigger switch has been pressed. This control is
used to dramatically reduce weld porosity at the start of a weld.
2.Initial Current
The main current Setting range 10AMP to 200AMP
This parameter operates in (4T) TIG modes only and is used to set the start current for TIG.
The Start Current remains on until the torch trigger switch is released after it has been
depressed.
Note: The maximum initial current available will be limited to the set value of the base
14. Pulse Button
Press the PULSE button to toggle Pulse On and OFF.
Typically from 1 to 10 PPS. Provides a heating
and cooling effect on the weld puddle and can
reduce distortion by lowering the average
amperage. This heating and cooling effect also
produces a distinct ripple pattern in the weld
bead. The relationship between pulse frequency
and travel speed determines the distance
between the ripples. Slow pulsing can also be
coordinated with filler metal addition and
increase overall control of the weld puddle
In excess of 40 PPS, Pulsed TIG becomes more
audible than visible-causing increased puddle
agitation for a better as-welded microstructure.
Pulsing the weld current at high speeds-between
a high Peak and a low Background amperage-
can also constrict and focus the arc.This results
in maximum arc stability, increased penetration
and increased travel speeds(Common Range:
100-500 PPS).
The Arc-Sharpening effects of high speed
pulsing are expanded to new dimensions. The
ability to pulse at 5,000PPS further enhances
arc stability and concentration potential-which
is extre mely beneficial to automation where
maximum travel tspeeds are required.
15. Programming Parameter Indicators
These indicator lights will illuminate when programming.
16. Positive Welding Terminal
Positive Welding Terminal. Welding current flows from the Power Source via heavy
du ty bayonet type terminals. It is essential, however, that the male plug is inserte d
and turned securely to achieve a sound electrical connection.
and turned securely to achieve a sound electrical connection.
17. Negative Welding Terminal
Negative Welding Terminal. Welding current flows from the Power Source via heavy
du ty bayonet type te rmi nal s. It is essential, however, that t he male plug is inserted
18. Shielding Gas Outlet
The Shielding Gas Outlet located on the front panel is a fast connection of a suitable
TIG Torch.
AC/DC WIG SERIES EQUIPMENTAC/DC WIG SERIES EQUIPMENT
13. Process Selection Button
The process selection control is used to select the desired welding mode. Two modes
are available, GTAW (TIG), and MMA (Stick) modes.

16 17
Operation Operation
12.Wave Balance
Setting arranges 10%-30%
T h i s p a r a m e t e r o p e r a t e s i n A C T I G mo d e a n d i s u s e d t o s e t t h e p e n e t r a t i o n t o
cl ea ning a ction ra ti o for t he AC wel d curren t. Gener al ly WAV E BALA NC E is set t o
3 0 % f o r AC S T I C K w e l d i n g . T h e W AV E B A L A N C E c o n t r o l c h a n g e s t h e r a t i o o f
penetration to cleaning action of the AC TIG welding arc. Maximum weld penetration
i s ach ie ve d whe n the WAVE BA LA NC E con tr ol is se t t o 10% . Max im um clean in g of
h e a v i l y o x i d i s e d a l u m i n i u m o r m a g n e s i u m a l l o y s i s a c h i e v e d w h e n t h e W AV E
B A L A N C E c o n t r o l i s s e t t o 3 0 %
Wider bead, good penetration
ideal for buildup work
Narrower bead for fillet welds and
automated applications
Wider bead and cleaning acting Narrower bead and cleaning acting
AC Balance Control
Controls arc cleaning action. Adjusting the % EN of the AC wave controls the width of the
etching zone surrounding the weld.
Note : Set the AC Balanc e control for adequate arc cleani ng action at the sides and in
fr ont of the wel d pudd le. A C Bala nce sh o ul d be fin e tune d ac cor din g to ho w he av y or
thick the oxides are.
Wider bead, good penetration
ideal for buildup work
Narrower Bead, Good Penetration
Ideal For Buildup Work
AC Frequency control
Controls the width of the arc cone. Increasing the AC frequency provides a more focused
arc with increased directional control.
No t e : De c rea s i ng th e AC F r e que n c y so f ten s the a rc an d br o a den s the w eld p u d dle
fo r a wi der w eld b ead.
11. AC Frequency
Setting ranges 50HZ-200HZ
This parameter operates in AC TIG mode only and is used to set the frequency for the
AC weld current.
3.Up Slope
Setting ranges :0.1S-10S (0.1S increments)
This parameter operates in (2T and 4T) TIG modes only and is used to set the time for the
weld current to ramp up, after the torch trigger switch has been pressed then released,
from Initial Current to High or base current.
4.Peak Current
Setting ranges
10AMP to 200AMP (DC TIG mode), 10 to 200A (AC HF TIG mode)
This parameter sets the TI G WE LD current. This parameter al so sets the STICK weld
current.
5.Base Current
Setting ranges
10AMP to 200AMP (DC TIG mode), 10AMP to 200AMP (AC HF TIG mode)
Secondary current (TIG)/pulse pause current.
6.Down Slope
Setting ranges 0.1-10s
This parameter operates in TIG modes only and is used to set the time for the weld current
to ramp down, after the torch trigger switch has been pressed to end current. This control
is used to eliminate the crater that can form at the completion of a weld.
7.End current
Setting ranges 10A-200A
This parameter operates in (4T) TIG modes only and is used to set the finish current for TIG.
The end Current remains ON until the torch trigger switch is released after it has been
depressed.
Note: The maximum crater current available will be limited to the set value of the base
current.
8.Post Flow
9. Remote Control
Setting ranges 1-10S
The system independently identifies the remote control, and when the indicator light is
on, the welding current can be adjusted by remote (foot or welding gun).
This parameter operates in TIG modes only and is used to adjust the post gas flow
time once the arc has extinguished. This control is used to dramatically reduce
oxidation of the tungsten electrode.
10.Pulse Width
Setting ranges 10%-90%
Th i s pa ram e ter set s th e pe r cen t age on time o f th e PU LSE FRE Q UEN C Y f or Hi gh
weld current when the PULSE i s ON.
11.Pulse Frequency
Setting ranges 1HZ -200HZ
This parameter sets the PULSE FREQUENCY when the PULSE is ON.
AC/DC WIG SERIES EQUIPMENTAC/DC WIG SERIES EQUIPMENT

18 19
Operation Operation
3.4 Set-up For LIFT TIG (GTAW) Welding
WARNING
Before any welding is to begin, be sure to wear all
appropriate and recommended safety equipment.
4. Slowly open the Argon Cylinder Valve to the fully open position.
5. Connect the work lead clamp to your work piece.
6. The tungsten must be ground to a blunt point (similar to a pencil) in order to achieve
optimum welding results. See illustration. It is critical to grind the tungsten electrode
in the direction the grinding wheel is turning. Grind at a 30 degree angle and never
to a sharp point.
7. Install the tungsten with approximately 1.6mm to 3.2mm sticking out from the
gas cup, ensuring you have correct sized collet.
8. Tighten the back cap.
9. Turn the switch to the “ON” position. The power L.E.D. light should illuminate.
10. Set the welding process to LIFT TIG.
11. Set the Weld Current Control Knob to the desired amperage.
12. You are now ready to begin LIFT TIG Welding.
The following set up is known as Straight Polarity or DC electrode positive. This is
commonly used for DC LIFT TIG welding on most materials such as steel and stainless
steel.
1. Switch the ON/OFF Switch (located on the rear panel) to OFF.
2. Connect the work lead cable to the positive output terminal, and the LIFT TIG Torch
cable to the negative output terminal.
3. Connect the gas line/hose to the proper shielding gas source.
NOTE
Ar./GAS(TIG/WIG) power supply
Earth Clamp TIG Torch
3.3 Setup For STICK (MMA) Welding
WARNING
Be f ore con n ect i ng t h e wo rk cl amp to t h e wo r k an d
inserting the ele ctro de in the electro de holder make
sure the mains power supply is switched off.
CAUTION
CAUTION
Remove any pa ckaging material prior to use. Do not
block the air vents at the front or rear of the Welding
Power Source.
Lo o se we ldi n g te rmi n al co nne c tio n s ca n ca u se
ove rheatin g and result in the mal e p lug being fused
in the bayonet terminal.
For Alkaline Electrode,connect the electrode holder to the positive welding termimal
Electrode,please connect the electrode holder to the negative welding termimal and
manufacturer. Welding current flows from the Power Source via heavy duty bayonet type
terminals. It is essential, however, that the male plug is inserted and turned securely to
achieve a sound electrical connection. Select STICK mode with the process selection
control.
a n d c o n n e c t t h e w o r k l e a d t o t h e n e g a t i v e w e l d i n g t e r m i n a l , w h i l e f o r t h e A c i d
con nect the wor k l ead to the positv e w eldin g t erminal .If in doub t c onsul t t he ele ctrode
Wider bead and cleaning action Narrower bead, with no visible cleaning
power supply
Earth Clamp Electrode Holder
AC/DC WIG SERIES EQUIPMENTAC/DC WIG SERIES EQUIPMENT

21
20
Operation Welding technique
TIG Welding Application Shot
4.1 TIG Basic Welding Technique
Gas Tungsten Arc Welding (GTAW) or TIG (Tungsten Inert Gas) as it is commonly referred
to, is a welding process in which fusion is produced by an electric arc that is established
between a single tungsten (non- consumable) electrode and the work piece. Shielding is
obtained from a welding grade shielding gas or welding grade shielding gas mixture which
is generally Argon based. A filler metal may also be added manually in some circumstances
depending on the welding application.
Gas Cup
Either Ceramic,
High-lmpact or
Water Cooled
Metal
Work Piece
can Be Any Commercial
Metal
Welds Made With or
Without Addition
of Filler Metal Inert Gas
Shields Electrode
and Weld Puddle
Tungsten Electrode
Non-Consumable
3.6 Operation Notices
◆Height above sea level is below 1000m.
◆Operation temperature range:-10˚C~+40˚C.
◆Relative humidity is below 90%(20˚C).
◆Preferably site the machine some angles above the floor level,the maximum
angle does not exceed 15˚.
◆The content of dust,acid,corrosive gas in the surrounding air or substance
can not exceed normal standard.
◆Take care that there is sufficient ventilation during welding.There is at least
30cm free disstance between the machine and wall.
3.5 Operation Environment
◆Read safty instruction and Chapter 1 carefully before attempting to use this
equipment.
◆Connect the ground wire the machine directly
◆In case closing the power switch, no-load voltage may be exported.Do not touch
the output electrode with any part of your body.
◆Before operation,no concerned people should be left,Do not watch the arc in
unprotected eyes.
◆Ensure good ventilation of the machine to improve duty ratio.
◆Turn off the engine when the operation finished to economize energy source.
◆When power switch shuts off protectively because of failure.Don’t restart it until
until problem is resolved.
Otherwise,the range of problem will be extended.
4.4 TIG Parameters Matching
The corresponding relationship between gas nozzle
diameter and electrode diameter
Gas nozzle diameter/mm
6.4
8
9.5
11.1
Electrode diameter/mm
0.5
1.0
1.6 or 2.4
3.2
Notice: the above parameters originate from <<Welding Dictionary>> P142,Volume 1 of Edition 2.
04
Gas nozzle and the shield gas flow rate
Welding
current range/A
DC positive connection AC
Gas nozzle
diameter/mm
Gas flow
1
rate/L•min-
Gas nozzle
diameter/mm
Gas flow
1
rate/L•min-
10~100
101~150
151~200
201~300
4~9.5
4~9.5
6~13
8~13
4~5
4~7
6~8
8~9
8~9.5
9.5~11
11~13
13~16
6~8
7~10
7~10
8~15
Notice: the above parameters originate from <<Welding Dictionary>> P149,Volume 1 of Edition 2.
Protect effect best better good bad worst
Welding area color bright argent orange-yellow blue-purple caesious white powder
of titanium oxid
The relation of welding area color & protect effect of Ti-alloy
4.3 The explanation of welding quality
The relation of welding area color & protect effect of stainless steel
Protect effect best better good bad worst
Welding area color argent,golden blue red-grey grey black
a butt joint b lap joint c coner joint d T joint
4.2 Joint froms in TIG
AC/DC WIG SERIES EQUIPMENTAC/DC WIG SERIES EQUIPMENT

23
22
TIG of stainless steel(single run welding)
Workpiece
thickness
/mm
Joint form
tungsten
electrode
diameter
/mm
welding
wire
diameter
/mm
Argon gas
flow rate/
1
L•min-
welding
current
(DCEP)
Welding
speed/
cm•min-1
0.8
1.0
1.5
1.5
2.4
2.4
3.2
3.2
4.8
4.8
6.0
Butt joint
Butt joint
Butt joint
Corner joint
Butt joint
Corner joint
Butt joint
Corner joint
Butt joint
Corner joint
Butt joint
1.0
1.6
1.6
1.6
1.6
1.6
1.6
1.6
2.4
3.2
4.0
1.6
1.6
1.6
1.6
2.4
2.4
2.4
2.4
3.2
3.2
4.0
5
5
7
7
7
7
7
7
8
9
10-12
20~50
50~80
65~105
75~125
85~125
95~135
100~135
115~145
150~225
175~250
220~300
66
56
30
25
30
25
30
25
25
20
25
Notice: the above parameters originate from <<Welding Dictionary>> P150,Volume 1 of Edition 2.
Welding techniqueWelding technique
Tungsten
Electrode
Diameter/mm
Sharpened of
the Electrode
Diameter/mm
Angle of Cone(º) Background
Current/a
1.0
1.0
1.6
1.6
2.4
2.4
3.2
4.0
0.125
0.25
0.5
0.8
0.8
1.1
1.1
1.5
12
20
25
30
35
45
60
90
2~15
5~30
8~50
10~70
12~90
15~150
20~200
20~300
Tungsten Electrode
Parameters of piping back sealing welding for mild steel(DCEP)
Piping
diameter
Φ/mm
Tungsten
electrode
diameter/mm
Gas nozzle
diameter/mm
Welding
wire diameter/mm
Welding current/A
Welding
current/A
Arc
voltage/V
Argon flow
1
rate/L•min-
Welding
1
rate/cm•min-
38
42
60
76
108
133
159
219
273
325
2.0
2.0
2.0
2.5
2.5
2.5
2.5
2.5
2.5
2.5
8
8
8
8~10
8~10
8~10
8~10
8~10
8~10
8~10
2
2
2
2.5
2.5
2.5
2.5.
2.5
2.5
2.5
75~90
75~95
75~100
80~105
90~110
90~115
95~120
100~ 120
110~ 125
120~ 140
11~13
11~13
11~13
14~16
14~16
14~16
14~16
14~16
14~16
14~16
6~8
6~8
7~9
8~10
9~11
10~12
11~13
12~14
12~14
12~14
4~5
4~5
4~5
4~5
5~6
5~6
5~6
5~6
5~6
5~6
Notice: the above parameters originate from <<Welding Dictionary>> P167, Volume 1 of Edition 2.
Notice: the above parameters originate from《Welding Dictionary》P538, Volume 2 of Edition 2.
Parameters of AC TIG(MMA) for Aluinum and its alloy
Steet
thickness
/mm
Welding
wire
diameter
/mm
Tungsten
eletrode
diameter
/mm
Pre-heat
Temper
-ature/ºC
Welding
current/A
Argon flow
1
rate/L•min-
Gas nozzle
diameter
/mm Remark
1.6
1.6~2.0
2~2.5
2~3
3
3~4
4
4~5
4~5
2
2
2~3
3
4
4
5
5
5
100
100~150
45~60
50~80
90~120
150~180
180~200
180~240
240~280
260~320
280~340
1
1.5
2
3
4
5
6
8
10
7~9
7~9
8~12
8~12
10~15
10~15
16~20
16~20
16~20
8
8
8~12
8~12
8~12
10~12
14~16
14~16
14~16
Flange welding
Flange or butt
welding by
one side
Butt welding
V-groove
butt welding
12
14
16
18
20
16~20
22~25
4~5
5~6
5~6
5~6
5~6
5~6
5~6
5~6
5~6
6
6
6
6
6~7
150~200
180~200
200~220
200~240
200~260
200~260
200~260
300~360
340~380
340~380
360~400
360~400
300~380
360~400
18~22
20~24
20~24
25~30
25~30
25~30
30~35
16~20
16~20
16~20
16~20
20~22
16~20
20~22
X-groove
butt welding
4.5 MMA Basic Welding Technique
Arc Welding Practice
The tec hniqu es used for a rc weldin g are almost identical regardless of what types of
metals are being joined. Naturally enough, different types of electrodes would be used
for different metals as described in the preceding section.
Welding Position
Th e elec tro de s de al t wi th in t his pu bli catio n ca n be used in mos t posi ti ons , i.e. th ey
are suitable for welding in flat, horizontal, vertical and overhead positions. Numerous
applica tions c all for welds to be made in po sitions intermedi ate betw een thes e. Some
of the common types of welds are shown
Flat Position,
Down Hand Butt Weld
Flat Position,
Gravity Fillet Weld
Horizontal Position,
Butt Weld
Horizontal-Vertical
(HV) Position
AC/DC WIG SERIES EQUIPMENTAC/DC WIG SERIES EQUIPMENT

Vertical Position,
Butt Weld
Vertical Position,
Fillet Weld Vertical Position,
Fillet Weld Overhead Position,
Fillet Weld
Joint Preparations
In many cases, it will be possible to weld steel sections without any special preparation.
For heavier sections and for repair work on castings, etc., it will be necessary to cut or grind
an angle between the pieces being joined to ensure proper penetration of the weld metal
and to produce sound joints.
In general, surfaces being welded should be clean and free of rust, scale, dirt, grease, etc.
Slag should be removed from oxy-cut surfaces.
Arc Welding Technique - A Word to Beginners
For those who have not yet done any welding, the simplest way to commence is to run beads
on a piece of scrap plate. Use mild steel plate about 6.4mm (1/4") thick and a 3.2mm (1/8")
electrode. Clean any paint, loose scale or grease off the plate and set it firmly on the work
bench so that welding can be carried out in the downhand position. Make sure that the work
clamp is making good electrical contact with the work, either directly or through the work
table. For light gauge material, always clamp the work lead directly to the job, otherwise
a poor circuit will probably result.
The Welder
Place yourself in a comfortable position before beginning to weld. Get a seat of suitable
height and do as much work as possible sitting down. Don't hold your body tense. A taut
attitude of mind and a tensed body will soon make you feel tired. Relax and you will find
that th e job becomes much easier. You can add much to your peace of mi nd by weari ng
a leathe r apron and gau ntlets. You won't be worryi ng then about bei ng bur nt or sparks
setting alight to your clothes.
Place the work so that the direction of welding is across, rather than to or from your body.
The electrode holder lead should be clear of any obstruction so that you can move your
a rm f re ely alon g as the e le ctrod e bur ns d ow n. I f the lead i s slung o ver your sh oulde r,
it allows greater freedom of movement and takes a lot of weight off your hand. Be sure the
insulation on your cable and electrode holder is not fault y, otherwise you are risking an
electric shock.
Welding technique
25
24
5.1 Troubleshooting
◆Before arc welding machines are dispatched from the factory, they have already been
debugged accurately. So forbid anyone who is not authorized by us to do any change to
the equipment!
◆Maintenance course must be operated carefully. If any wire becomes flexible or is
misplaced, it maybe potential danger to user!
◆Only professional maintenance personal who is authorized by us could overhaul the
machine!
◆Guarantee to shut off the arc welding machine’s power before turn on the outline of
the equipment!
◆If there is any problem and has no the authorized professional maintenance personal,
please contact local agent or the branch company!
If there are some simple troubles of welding machine, you can consult the following
overhauling chart:
Nr.
1
2
3
4
5
Troubles Solution
Fan is broken
The power board is broken
The power cable is broken
There is something in the fan
The start capacitor of fan damaged
Turn on the power
source, power
indicator is lit, fan
is not working.
Turn on the
power source,
fan is working,
power indicator
is not lit
Turn on the power
source, fan is not
working ,power
indicator is not lit
Turn on the power
source, power
indicator is lit, fan
is working, there
is no welding
output.
The number of the
display is not
intact
Reasons
Change fan
Clean it
Change capacitor
The power light damaged or
connection is not good
The power cable connected not
good
Control board is broken
st
1 inverter circuit damaged
nd
2 feedback circuit is fault
Digital tube is broken
The display panel is damaged Change the display panel
Display panel is broken
The light of the power indicator is
broken and the problems
mentioned in Nr. 2
Change the light of the power
indicator or refer to the solution
in Nr. 2
Change it
Change it
Change it
Change it
Repair or change it
Change the power light
Connect correctly
Power on switch is damaged
The power board is broken
Change it
Replace it
Change it
Change it
6
No no-load
voltage output
(MMA)
If the overheat indicator is on
The main circuit is broken
The machine is broken
Wait a few minutes, the machine
can be operated normal
Check and repair
Consult the dealer or the
manufacturer
Troubleshooting
AC/DC WIG SERIES EQUIPMENTAC/DC WIG SERIES EQUIPMENT

Troubleshooting Troubleshooting
27
26
Nr.
7
8
9
10
11
Troubles Solution
The welding cable is not connected
with the two output if the welder
Connect the welding cable to
the welder's output
The welding cable is damaged
The earth cable connected unstably
The welding cable is too long
Input voltage not stable
There is oil or dust on the workpiece
Gas cylinder is close or gas
pressure is low
The HF igniting board does not work
Something is in the valve
Check if the function selected MMA Change the function to TIG
Check the HF funtion is selected Select the HF funtion
HF board is broken
Earth clamp connect not stable
Repair or change it
Check the earth clamp
Open or change the gas cylinder
Remove it
Remove it
Change it
Change it
Change it
The distance between discharger is
too short or too long
The malfunction of the welding gun
switch
No argon gas flow or the air tube
connect not good
No argon gas flow or the air tube
connect not good
Pressure too high or air regulator is
broken
There is no Argon flow or the
connection is poor
The distance between tungsten
electrode and workpiece is too long
Repair or change it
Check the earth cable
Use an appropriate welding cable
Check the power supply
Check and remove it
Reduce the distance
(about 3mm ,less than 5mm)
Check and reconnect
Repair or change it
Adjust the distance (about 0.8mm)
Check the welding torch switch,
control cable and aero socket.
Check and reconnect
Check and reconnect
Check gas
Arc can not be
ignited (TIG) ,
there is spark
on the HF
igniting board
Arc can not be
ignited (TIG) ,
there is no spark
on the HF
igniting board
Turn on the
power source,
everything is
normal , but no
HF igniting
No gas flow (TIG)
Gas always flows
Reasons
Electromagnetic valve is damaged
Air tube is brocken
Something is in the valve
Electromagnetic valve is damaged
Nr.
16
17
18
Troubles Solution
Over-heat protection ,too much
welding current Reduce the welding current
Reduce the welding time
Over-heat protection ,working too
much time
Over-current protection, current in
the main circuit is out of control
Tig torch is connected to the
positive terminal
Tungsten electrode is too big for
the welding current
Check the earth clamp position on
the work piece
Check and repair main circuit
and drive board
Connect the tig torch to negative
terminal
Adjust the position of earth clamp
Select the correct size of tungsten
electrode
Thermal overload
indicator light is on
Tig electrode melts
when welding
Arc flutters during
Tig welding
Reasons
15
The penetration
of molten pool is
not enough
Adjust the distance from torch
to work piece
Use the suitable length from
manufacturer
Increase the welding current
The welding current is adjusted
too low
The arc is too long in the welding
process
The power cable or the welding
cable is too long
12
Checking if the electorde stick to
the work piece that the anti-stick
function is on
Repair or change it
Repair or change it
Change to suitable setting
The welding
current cannot
be adjusted Control board is broken
Control board is broken
AC Width adjustment is not correct
Shut off the power when changing the torch
Separate the electrode and
work piece
13
14
Repair or change it
Check the power supply
Change the fan
Change it
Change it
No AC output
while selecting
"AC"
The welding
current displayed
isn't accordant
with the actual
value
The power board is broken
Input voltage is too low
Fan is broken
The AC drive board damaged
The AC IGBT/IGBT module damaged
The min value displayed isn't
accordant with the actual value
Adjust potentiometer Imin on
the control board
Adjust potentiometer Imin on
the control board
The max value displayed isn't
accordant with the actual value
AC/DC WIG SERIES EQUIPMENTAC/DC WIG SERIES EQUIPMENT

Maintenance
Obse rv e tha t whe th er pa ne l knob and s wi tc h in the fr on t and at th e
back of arc w el di ng ma ch ine are fle xi bl e ane pu t c orrectly i n pla ce .I f
the knob has not been put correctly in place, please correct, If you can’t
correct or fix the knob, please replace immediately
If the switch is not flexible or it can’t be put correctly in place, please
re pl ac e immediat el y; Pl ease g et in to uch with main te nance serv ic e
department if there are no accessories
Af ter tur n -on p owe r, wa tch /li s ten t o th at whet h er th e ar c we ldi n g
machine has s haking, whis tle cal lin g or peculiar sm ell. If there is one
of t h e abov e p robl e m s, fi n d out t h e re a s on to g et ri d of, i f you c a n’t
find out the reason, Please contact local this area agent or the branch
company
Observe that whet her the display value of LED is intac t. If the
display number is not intact, please replace the damaged LED. If it still
doesn’t work, please maintain or replace the display PCB
Observe that whether the min/max value on LED accords with the set
value.If there is any difference and it has affected the no rmal welding
craft, please adjust it
Check up that Whether fan is damaged and is normal to rotate or control
. If the fan is dama ged ,pl ease change immediately.If the fan d oes not
rotate after the arc welding machine is overheated, observe that whether
there is something blocked in the blade,if it is blocked,please get rid of;
If the fan does not rotate after getting rid of the above problems, you can
poke the blade by the rotation direction of fan.If the fan rotates normally,
the start capacity should be replaced; If not, change the fan
Observe that whether the fast co nnector i s loos e or overheated . If
the arc welding machine has the above problems,it should be fastened
or changed
Observe that Whether the current output cable is damaged. If it is
damaged, it should be wrapped up, insulated or changed
Using the dry compressed air to clear the inside of arc welding machine.
Especially forclearing up the dusts on radiator, main voltage transformer,
inductance, IGBT module, the fast recover diode and PCB, etc
Check up the bolt in arc welding machine,if it is loose,please screw
down it.If it is skid, please replace.If it is rusty,please erase rust on bolt
to ensure it works well
Whether the actual current accords with the displaying value.If they
does not accord, they should be regulated.The actual current value can
be measured by the adjusted plier-type ampere meter
Measure the insulating impedance among the main circuit,PCB and
case, if it below 1MΩ,insulation is thought to be damaged and need to
change, and need to change or strengthen insulation
Date
Daily
examination
Monthly
examination
Quarter-
yearly
examination
Yearly
examination
Maintenance item
◆Warning:For safety while maintaining the machine, please shut off the
supply power and wait for 5minutes,until capacity voltage already drop
to safe voltage 36V!
6.1 Maintenance
In order to guarantee that arc welding machine works high-efficiently and in safety,it must
be maintained regularly.Let customers understand the maintenance methods and means
of arc w el di ng mach in e m or e, enable c us to me rs to ca rr y on s im pl e exa mi na ti on an d
safeguarding by oneself,try one’s best to reduce the fault rate and repair times of arc
welding machine, so as to lengthen service life of arc welding machine.Maintenance
items in detail are in the following table.
28
AC/DC WIG SERIES EQUIPMENT