Vector Welding Newyork2500 User manual

OPERATING INSTRUCTIONSOPERATING INSTRUCTIONS
Newyork2500 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 VECTO R weldin g equipm ent c omb ines adv anced invert er techn olo gy,the hig hest
quality standards of a premium brand and low prices to a unique value for money. Inverter
technology is an essential component of process improvement and minimizes energy
consumption. In all our equipment, we therefore trust on the MOSFET technology from
Toshiba and Infineon IGBT technology from SIEMENS. Their innovative solutions 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 sectors such as Oil pipeline, chemical, automotive, shipbuilding, boiler,
electric power construction, nuclear power, aerospace, military, industrial installation,
brid g e c onstr u ction and othe r indu s tries , the high e st quali t y r e quire ments are met
successfully with VECTOR welding equipment.
V E C TOR i s o n e o f t h e l e ading s upplie r s o f w e l d i ng e q u i pment - d i s c o v e r o ur
possibilities - profit from our vision to offer modern, high-performance welding
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 these trendsetting strategy. In addition to the
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--------------------------------------------------------------------- 26-28
6. Maintenance
6.1 Maintenance------------------------------------------------------------------------- 29-29
2. Summary
2.2 Working principle-------------------------------------------------------------------- 06-06
2.1 Brief Introduction-------------------------------------------------------------------- 06-06
2.4 Specifications------------------------------------------------------------------------ 07-08
2.5 Duty cycle----------------------------------------------------------------------------- 08-08
2.6 Packaged Items---------------------------------------------------------------------- 08-08
2.3 --------------------------------------------------------07-07Volt- 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
AC/DC PLASMA SERIES EQUIPMENT
3. Operation
3.2 Control panel--------------------------------------------------------------------------- 14-17
3.1 Layout for the panel----------------------------------------------------------------- 09-14
3.3 Setup for stick (MMA) welding----------------------------------------------------- 17-17
3.4 Set-up for lift tig (GTAW) welding-------------------------------------------------- 18-18
3.6 Operation environment-------------------------------------------------------------- 20-20
3.5 Setup for cutting----------------------------------------------------------------------- 19-20
3.7 Operation notices--------------------------------------------------------------------- 21-21
4. Welding technique
4.1 TIG basic welding technique------------------------------------------------------- 21-21
4.2 Joint froms in tig-------------------------------------------------------------------- 22-22
4.3 The explanation of welding quality----------------------------------------------- 22-22
4.4 TIG parameters matching---------------------------------------------------------- 22-24
4.5 MMA basic welding technique---------------------------------------------------- 24-25

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 PLASMA SERIES EQUIPMENTAC/DC PLASMA 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 PLASMA SERIES EQUIPMENTAC/DC PLASMA SERIES EQUIPMENT

0706
2.1 Brief Introduction
SummarySummary
Newyork2500 welding machines 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 ork frequency
transformer with the cabinet medium frequency transformer. Thus, its characterized with
portable, small size, light weight, low consumption and etc.
Newyork2500 machines Characteristics::
◆MCU control system, responds immediately to any changes.
◆High frequency and high voltage for arc igniting to ensure 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.
◆D o u b l e p u r p o s es: A C i n v e r ter T I G a n d D C i n v e r t er T I G / M M A, E x c e l lent
performance on AL-alloy, carbon steel, stainless steel, titanium.
The parameters of on the front panel all can be adjusted continuously and steplessly,
such as start current, crater arc current, welding current, base current, duty ratio, upslope
igniting to ensure the success ratio of igniting arc.
◆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.
Intelligent protection: over-current, over-h eat, when the mentioned problems
time, downslope time, pre-gas, post-gas, pulse frequency, AC frequency, balance, hot start,
arc force and length etc. When welding, it takes high frequency and high voltage for arc
2.2 Working Principle
The working principle of Newyork2500 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.
230V,50Hz
2.3 Volt- Ampere Characteristic
N e w y o r k 2 5 0 0 w e l d i n g m a c h i n e
h a s a n e x c e l l e n t v o l t - a m p e r e
c h a r a c t e r i s t i c , w h o s e g r a p h i s
s h o w n a s t h e f o l l o w i n g f i g u r e .
T h e r e l a t i o n b e t w e e n t h e c o n -
v e n t i o n a l r a t e d l o a d i n g v o l t a g e
U a n d t h e c o n v e n t i o n a l w e l d i n g
2
c u r r e n t I i s a s f o l l o w s :
2
When I ≤600A, U =10+0.04I (V);
2 2 2
When I ≤600A, U =20+0.04I (V);
2 2 2
When I ≤600A, U =80+0.4I (V);
2 2 2
When I >600A,U =34(V).
2 2
When I >600A,U =44(V).
2 2
TIG
MMA
CUT
2.4 Specifications
170A @ 25%, 26.8V / 85A @ 100%, 23.4V
200A @ 40%, 18V / 126A @ 100%, 15V
50A @ 40%, 100V / 25A @ 100%, 90V
11.5 kg
10 - 170A
10 - 200A
20 - 50A
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)
Welding Current Range (CUT Mode)
Single Phase Generator Requirement
MMA Welding Output, 40ºC, 10 min.
TIG Welding Output, 40ºC, 10 min.
CUT Welding Output, 40ºC, 10 min.
Open circuit voltage (MMA/TIG)
Open circuit voltage（CUT)
Protection Class
Maximum Input Current
Effective Input Current
SIWM DIGITAL Newyork2500
Fan Cooled
EN 60974-1 / IEC 60974-1
1
230V +/- 15%
50/60Hz
60V DC
250V DC
IP23
Inverter Power Source
AC/DC PLASMA SERIES EQUIPMENTAC/DC PLASMA SERIES EQUIPMENT

0908
Summary
Note 3: Motor start fuses or thermal circuit breakers are recommended for this application.
Check local requirements for your situation in this regard.
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.
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
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 in sulation of the component parts. To exp lain the 10 minu te duty c yc le period the
following example is used. Suppose a Welding Power Source is designed to operate at
a 50% duty cycle, 200 am pe re s at 28 volts. This means that it has be en designed and
built to provide the rated amperage (200A) for 5 minutes, i.e. arc welding time, out of
every 10 minute period (50% of 10 minutes is 5 minutes). During the other 5 minutes of
the 10 minute period the Welding Power Source must idle and be allowed to cool. The
thermal cut out will operate if the duty cycle is exceeded.
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 300
CUT
MMA
TIG
Duty Cycle(PERCENTAGE)
Welding Current(AMPS)
Safe
Operating
Region
(CUT)
Safe Operating Region
(TIG&STICK)
◆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
◆Plasma Torch 4m PT-31
◆Air Regulator
◆3m Gas Hose
◆Operating Manual
2.6 Packaged Items
11
10
93
92
4
12
13
14
15
95
17
916
18 19
9
8
7
6
91
4
3.1 Layout For The Panel
Front
Operation
AC/DC PLASMA SERIES EQUIPMENTAC/DC PLASMA SERIES EQUIPMENT

10 11
Operation Operation
Behind
20
22
21
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 th e w e l d p o o l w i th
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 the electrode sticks in spite of the arcrorce device, the
machine a u t o m at ically s w i t c h e s o v e r to t h e m i n i m u m
curren t w ith in abo ut 1 seco nd to pre ven t t he ele ctr ode
f r o m o ve r h e ati n g . I n o r de r t o e a si l y s e par a t e the
e l e c tro d e a nd e lec t r o de h ol d e r t o p r ote c t t he w eld 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 PLASMA SERIES EQUIPMENTAC/DC PLASMA SERIES EQUIPMENT

12 13
Operation Operation
Minimum
Current
Press & hold
Trigger
Release
Trigger
Note: that when operating in GTAW (HF and LIFT TIG modes), the power source will
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 torch trigger must remain 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.
13. Process Selection Button
The process selection control is used to select the desired welding mode. Three
modes are available, MMA (Stick),GTAW (TIG) and CUT modes.
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
duty bayonet type terminals. It is essential, however, that the male plug is inserted
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
duty bayonet type terminals. It is essential, however, that the 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 PLASMA SERIES EQUIPMENTAC/DC PLASMA SERIES EQUIPMENT

14 15
Operation Operation
CAUTION
Loose welding terminal connections can cause overheating and result 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
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 TIG WELD current. This parameter also 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%
Thi s p ara mete r s ets t he perc entage on tim e o f t he PUL SE FREQ UENC Y for Hig h
weld current when the PULSE is ON.
11.Pulse Frequency
Setting ranges 1HZ -200HZ
This parameter sets the PULSE FREQUENCY when the PULSE is ON.
AC/DC PLASMA SERIES EQUIPMENTAC/DC PLASMA SERIES EQUIPMENT

16 17
Operation Operation
3.3 Setup For STICK (MMA) Welding
WARNING
Bef ore c onne ctin g t he wor k c lamp to the work and
inserting the electrode in the electrode holder make
sure the mains power supply is switched off.
CAUTION
CAUTION
Remove any packaging material prior to use. Do not
block the air vents at the front or rear of the Welding
Power Source.
Loo se weld ing ter mina l c onne ctio ns can cau se
overheating and result in the male plug 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
connect the work lead to the positve welding terminal.If in doubt consult the electrode
12.Wave Balance
Setting arranges 10%-30%
T h i s p ar a m ete r o pe r a tes i n A C T I G mo d e a nd i s u se d t o se t t h e p en e t ra t i o n t o
cl eaning action ratio for the AC weld current. Gen erally WAVE BALANCE i s set t o
3 0 % f o r A C S T IC K w e l d i n g . T h e WAV E BA L AN C E c o n tr o l c h a n g e s th e r a t i o o f
penetration to cleaning action of the AC TIG welding arc. Maximum weld penetration
is a chieved when the WAVE BALANCE control is set to 1 0%. Maximum cleaning of
h e a v i l y o x i d i s ed a l u m i ni u m o r m a g n e s i um a l l o y s i s a c h i e v e d w h e n t he WAV 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 Balance control for adequate arc cleaning action at the sides and in
front o f the wel d puddle. AC B ala nce should b e fine t une d accord ing to h ow hea vy o r
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.
Not e : D ecrea sing the AC Freq u ency soft e ns the arc and broad ens the wel d pudd le
for a w ider w e ld 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.
Wider bead and cleaning action Narrower bead, with no visible cleaning
power supply
Earth Clamp Electrode Holder
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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
3.5 Setup For Cutting
In order for the unit to function correctly, it must be installed properly. Follow the procedure
given below for correct installation:
1. Read the safety rules given in this manual carefully.
2. Check on receiving the unit that there are no defective parts or parts damaged during
transportation.
CAUTION
Do not point the torch jet at foreign bodies.
3. Set your unit up in an area which is adequately ventilated and make sure that the air
vents are not obstructed.
4. Connect the power supply cable to a socket located as near as possible to the work area,
so that the unit can be switched off quickly in case of emergency.
5. Your machine has a 16 amp plug fitted, before use check that the green/yellow earth is
connected to the earth pin socket of fitted plug.
6. Make sure that the mains supply switch and any fuses have a value which ± 15% the
maximum current absorbed by the unit. All fuses should be the slow-blow type.
7. Any extensions of power supply cable should have the same cross-section as the power
supply cable. The extension leads, however, should only be used when absolutely
necessary. It is important to note that any extension of mains cables or torch cables will
possibly affect the cutting performance of this cutting equipment, due to the fact that the
resistance of the cable will reduce voltage input, which is determined by the length of the
cable. The supplied length of main cables and torch cables is recommended.
8. Fasten the earth clamp to the piece to be cut, If the surface of the piece to be cut is
painted, rusty or covered with insulating material, clean the surface so that
satisfactory contact between the piece and the earth clamp can be obtained.
9. Make sure that the torch has been assembled with the correct components and that the
cutting tip is suitable for the cutting current.
10. Connect air to regulator and adjust regulator to deliver 5-6 bar 90ltr/min
11. Switch the unit on using the main switch located on the back side.
13. Once cutting is over, release the torch button to put out the arc. A period of post-flow
time 45 to 75 seconds (required for torch cooling) will follow. Do not disconnect air
until this cooling period has been completed. Failure to do this will result in torch head
damage.
12. Contact the copper tip of the torch to the work piece, press the button of the forch until
the cutting operation.
the arc-starting and raise the cutting torch about 1mm above the work piece, and perform
AC/DC PLASMA SERIES EQUIPMENTAC/DC PLASMA SERIES EQUIPMENT

21
20
Operation Welding technique
CAUTION
Avoi d u nnec essa ry ligh ting of the p ilot arc t o p r eve n t e xces sive
con sump tion of the elec trod e a nd nozz le.
CAUTION
During cutting the speed of the torch movement should be in accordance with the
thickness of the piece to be cut. Excessive speed causes a return of incandescent
towards the torch which shortens the life of the parts of the torch most subject to
wear and tear. The metal fouling on the nozzle should be removed as soon as possible.
power supply
Air compressor
Earth Clamp Plasma torch
◆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.
3.6 Operation Environment
3.7 Operation Notices
◆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.
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
AC/DC PLASMA SERIES EQUIPMENTAC/DC PLASMA 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.
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
Welding techniqueWelding technique
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
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.
AC/DC PLASMA SERIES EQUIPMENTAC/DC PLASMA SERIES EQUIPMENT

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 techniques used for arc welding 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 electr odes dealt with i n thi s pub lication can be use d in most posit ions, i.e. they
are suitable for welding in flat, horizontal, vertical and overhead positions. Numerous
applications call for welds to be made in positions intermediate between these. 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
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 the job becomes much easier. You can add much to your peace of mind by wearing
a leather apron and gauntlets. You won't be worrying then about being burnt 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
arm freel y along as the elect rode b urns do wn. If th e lead is slu ng ove r your shoulder,
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 faulty, otherwise you are risking an
electric shock.
Welding techniqueWelding technique
25
24
AC/DC PLASMA SERIES EQUIPMENTAC/DC PLASMA SERIES EQUIPMENT

Troubleshooting Troubleshooting
27
26
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
Troubles Solution
Fan is broken
The power board 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
Reasons
Change fan
Clean it
Change capacitor
The power light damaged or
connection is not good
Change it
Change it
Change the power light
3
Turn on the power
source, power
indicator is lit, fan
is working, there
is no welding
output.
Control board is broken
st
1 inverter circuit damaged
nd
2 feedback circuit is fault
Change it
Replace it
Change it
Display panel is broken
4
The power cable is broken
Turn on the power
source, fan is not
working, power
indicator is not lit
The power cable connected not
good
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
Repair or change it
Connect correctly
Power on switch is damaged
The power board is broken
Nr. Troubles Solution
Reasons
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
7
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
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
Arc can not be
ignited (TIG) ,
there is spark
on the HF
igniting board
8
The HF igniting board does not work
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
Repair or change it
Adjust the distance (about 0.8mm)
Check the welding torch switch,
control cable and aero socket.
Check and reconnect
Arc can not be
ignited (TIG) ,
there is no spark
on the HF
igniting board
9
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
No argon gas flow or the air tube
connect not good Check and reconnect
Turn on the
power source,
everything is
normal , but no
HF igniting
10 Remove it
Change it
Gas always flows Something is in the valve
Electromagnetic valve is damaged
5The number of the
display is not
intact
The display panel is damaged Change the display panel
Digital tube is broken Change it
13
Repair or change it
Change it
Change it
No AC output
while selecting
"AC" for O251
The power board is broken
The AC drive board damaged
The AC IGBT/IGBT module damaged
11
Gas cylinder is close or gas
pressure is low
Something is in the valve
Open or change the gas cylinder
Remove it
Change it
Change it
Pressure too high or air regulator is
broken Check gas
No gas flow (TIG) Electromagnetic valve is damaged
Air tube is brocken
12
Checking if the electorde stick to
the work piece that the anti-stick
function is on
Repair or change it
The welding
current cannot
be adjusted Control board is broken
Shut off the power when changing the torch
Separate the electrode and
work piece
Repair or change it Control board is broken
AC/DC PLASMA SERIES EQUIPMENTAC/DC PLASMA SERIES EQUIPMENT

Troubleshooting
O bserve tha t whether panel k nob and switch in the front and at the
back of arc weld ing machine are fle xible ane put corre ctly in p lace.If
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 place immed iately; Please get in touch wit h maintenan ce servi ce
department if there are no accessories
Af ter tur n-on pow er, w atch /lis ten t o t hat whe ther the arc w eldi ng
machine has shaking, whistle calling or peculiar smell. If there is one
of the above p roble m s, f i nd o ut t he r eason t o g e t r i d of, if you c an’t
find out the reason, Please contact local this area agent or the branch
company
Observe that whether the display value of LED is intact. 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 normal welding
craft, please adjust it
Check up that Whether fan is damaged and is normal to rotate or control
. If the fan is damaged,please change immediately.If the fan does 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 connector is loose 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 elding machine more, enable customers to carry on simp le examinatio n and
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.
29
28
Nr. Troubles Solution
Reasons
14
The welding
current displayed
isn't accordant
with the actual
value
Air flow is not correctly connected
Machine is broken
The min value displayed isn't
accordant with the actual value
Adjust potentiometer Imin on
the control board
Adjust potentiometer Imax on
the control board
The max value displayed isn't
accordant with the actual value
17
18
19
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 the welding circuit is correct,
for example the earth clamp is
connected to work piece
Connect the tig torch to negative
terminal
Adjust the position of earth clamp
Connect the circuit correctly
Check the air flows
Consult the dealer or the
manufacturer
Select the correct size of tungsten
electrode
Tig electrode melts
when welding
Arc flutters during
Tig welding
When Cut function
is selected ,there is
HF but cannot cutting
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
Change to suitable setting AC Width adjustment is not correct
16
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
Check and repair main circuit
and drive board
Thermal overload
indicator light is on
Check the power supply
Change the fan
Input voltage is too low
Fan is broken
Maintenance
AC/DC PLASMA SERIES EQUIPMENTAC/DC PLASMA SERIES EQUIPMENT