Worldwel Longrun 500LMP User manual

INVERTER PULSE MIG WELDER
500LMP
OPERATION MANUAL
● Full digital control and user friendly interface
● Digital memory function
● Welding diameter selction
● Saving power consumption by high-tech IGBT
● Ideal to weld stainless steel and aluminum
Model Unit 500LMP
Input voltage V 380V, 3PH, 50-60Hz
Output current A 25~500
Input capacity KVA 25
Input current A 46A
Open circuit voltage V 80
Output Voltage V 14~50
Duty cycle % 60
Wire diameter mm Ф0.8、Ф1.0、Ф1.2、Ф1.6
Gas flow L/min 15~20
Weight Kg 54
Dimension (W×D×H) mm 710×355×575
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General Safe Practices
■
Wear approved safety glasses with side shields under your welding helmet or face shield and at all
times in the work area.
■
When working above floor level, use a safety belt to protect yourself from a fall should you get a
shock.
■ Do not install or place machine on or over combustible surfaces.
■Be sure that all installation, operation, maintenance and repair procedures are performed only by
qualified persons.
Electric shock can kill.
■Wear Dry, hole-free insulating gloves and body protection. Do not touch electrode with bare hand. Do
not wear wet or damaged gloves.
■ Do not touch live electrical parts.
■ Never dip the electrode in water for cooling.
■ Properly install and ground all equipment.
■Protect yourself from electric shock by insulating yourself from work and ground. Use non-flammable,
dry insulating material if possible, or use dry rubber mats, dry wood or plywood, or other dry insulating
material big enough to cover your full area of contact with the work or ground, and watch for fire.
■ Turn off input power using the disconnect switch at the fuse box before working on the equipment.
■Frequently inspect input power cable for damage or bare wiring and repair or replace cable
immediately if damaged.
Fumes and gases can be dangerous.
■Cutting may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.
When cutting, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to
keep fumes and gases away from the breathing zone.
■Use enough forced ventilation or local exhaust (forced suction) at the arc to remove the fumes from
your breathing area.
■Wear complete body protection. Wear oil-free protective clothing such as leather gloves, heavy shirt,
cuffless pants and high boots.
Arc rays can burn eyes and skin.
■Use welding helmet with correct shade of filter to protect your eyes from sparks and the rays of the
arc.
■Wear welders cap and safety glasses with side shields. Use ear protection when welding out of position
or in confined spaces. Button shirt collar.
■ Use a ventilating fan to remove the fumes from the breathing zone and welding area.
Welding sparks can cause fire or explosion.
■Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding
sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go
through small cracks and opening to adjacent areas. Avoid welding near hydraulic lines.
■When not use, make certain no part of the electrode circuit is touching the work or ground. Accidental
contact can cause overheating and create a fire hazard.
■Do not cut on drums, tanks, or any closed containers unless a qualified person has tested it and
declared it or prepared it to be safe.
■
Connect the work cable to the work as close to the cutting area as practical. Work cables connected to
the building framework or other locations away from the cutting area increase the possibility of the
cutting current passing through lifting chains, crane cables or other alternate circuits. This can create
fire hazards or overheat lifting chains or cables until they fail.

■ INSTALLATION
● The welding machine shall be installed at a place ;
 free from the inflammables
 less humidity, dirt and dust
 protecting from influence of direct sunlight, wind and rain
 not generated oil vapor and corrosive gas
 operating temperature range is from -10℃ to 40℃
 least 30㎝ away from wall and other welding machine
● Input Connection (Rear of the machine)
Be sure the voltage, phase and frequency of the input power is as specified on the name plate
located on the rear panel of the machine.
 To connect the power cables, turn the power switch OFF
 Verify the voltage to be supplied from main power.
 Open the cover of terminal plate and connect the power cable to the power input terminal on the rear
of the machine and close the cover of terminal plate.
 For grounding the machine, connect a ground wire to the ground terminal marked with the symbol is
located on the rear panel of the machine.
 Connect a power cord of gas regulator to the 110V outlet on rear of the machine.
● Output Connection (Front of the machine)
 Connect the work cable to the "METAL" terminal.
 To connect the Wire feeder, connect a electrode cable from wire feeder to the "TORCH" terminal and a
Remote control cable from the wire feeder to the "REMOTE CONTROL" receptacle.
 Install a gas regulator on a gas tank and connect a gas hose of extension cable from wire feeder to the gas
regulator on gas tank.
CO2 Torch connection to wire feeder
 Connect a wire feeding cable of torch to the wire feeding cable receptacle of wire feeder.
 Connect a torch switch connector of torch to the torch switch receptacle of wire feeder.
 Connect a gas hose of torch to the gas hose receptacle of wire feeder.

■ WIRE TYPE SELECT
Process
Wire type Diameter（mm） Alloy type Sheild gas
MIG/MAG
Pulse welding
Aluminum
Magnesium Alloy
(8 AlMg 5)
Φ1.0, Φ1.2, Φ1.6
LF2~LF16, 5005, 5052,
5183, 5356
100% Ar
Aluminum
(9 Al)
L1~L5,
1060, 1035, 1100, 1200,
1370
Aluminum
Silicon Alloy
(7 AlSi 5)
LT1, 4A11, 4043, 4047
Stainless steel
(3CrNi 188)
(4CrNi 199) Φ0.8, Φ1.0, Φ1.2,
Φ1.6
304, 308, 309, 316 97.5% Ar+2.5%CO2
Mild steel
(2 Steel) E70 82% Ar+18% CO2
Silicon copper
Alloy
(6 CuSi)
Φ1.2, Φ1.6 HS211 100% Ar
Aluminum
Copper Alloy
(5 CuAl)
Φ1.0, Φ1.2, Φ1.6 HS214 100% Ar
MIG/MAG
Welding
Mild steel
(1 Steel)
Φ0.8, Φ1.0, Φ1.2,
Φ1.6 E70
100% CO2
82% Ar
+18%CO2
■ Input cable
Model Pulse MIG-500
Input power 380V, 3PH
Ideal Input
capacity
Normal 38KVA
Generator 50KVA
Input protect
Fuse 50A
Circuit
breaker 63A
Cable
Input power ≥6mm2
Output
power 70mm2
Ground cable ≥6mm2

■ FRONT PANEL

1
Volume
Adjust various data setting
2
Data Select Button F2
Adjustable Date : Arc Length, Welding voltage, Working condition
3
Data Select Button F1
Adjustable Date : Motor speed, Welding current, Arc power, Arc concentration
4
Program button
Use saved data
5Save button Use to enter setup menu or save data.
6Wire diameter select Use to select wire diameter
7Wire material select Use to select Wire material and shield gas
8Function select
Use to select function
1. Crater off
2. Hold
3. Crater(Start current / Crater current control)
4. Arc spot
9Welding method select
Use to select welding method
1. Double Pulse MIG
2. MIG
3. STICK
4. TIG
5. Gouging
10 F2 Button LED
11 JOB LED It shows that load data from saved job
12 Welding speed LED It shows the welding speed (cm/min)
13 Welding voltage LED It shows welding voltage
14 Arc length difference LED
It shows Arc length differences
- short arc length
0 standard
+ long arc length
15 Machine internal temperature
LED
16 Arc Power / Arc
Concentration
It shows that arc power adjustment during MIG / MAG pulse welding
- arc power decrease
0 standard
+ arc power increase
In MIG / MAG welding, arc concentration is set during short-circuit control
- strong arc and stable
0 standard
+ smooth arc and low spatter
17 Motor speed LED It shows the motor speed (M/min)
18 Welding current LED It shows the welding current
19 Base metal thickness LED It shows the Base metal thickness
20 Welding angle LED It shows the Welding angle (“a”)
21 F1 Selection LED It shows the F1 is selected
22 Program LED It shows the program is selected
23 Hidden data Menu LED Lights when hidden data is modified
■ Adjust hidden data
 Simultaneously press and release the Save button (5) and the wire selection button (6).
 The, the Hidden Data menu LED (23) lights up and you can modify the hidden data.
 When the user presses the save button 5 after the modification is finished, the data is stored and
the hidden data menu LED 23 is also turned off while exiting from the hidden data adjustment
menu.
 After selecting the value to be corrected with the wire selection button (6), you can modify the

value data by turning the volume (1). When modifying P05 and P06, move to the percentage
value with the F2 button and you can change the data by the volume (1)
■ Hidden data adjustments / modifiable data items
No Item Setting range Minimum Reset Factory set
P01 Burn back time 0.01-2.00s 0.01s 0.08s 0.03s
P02 Motor speed on open circuit
voltage 1.0-21.0M/min 0.1M/min 3.0M/min 3.0M/min
P03 Pre-flow time 0.1-10.0s 0.1s 0.20s 0.20s
P04 Post-flow time 0.1-10.0s 0.1s 1.0s 2.0s
P05 Start current 1-200％ 1％ 135％ 100％
P06 Crater current 1-200％ 1％ 50％ 30％
P07 Up-down slope time 0.1-10.0s 0.1s 2.0s 2.0s
P08 Spot time 0.5-5.0s 0.1s 2.0s 2.0s
P09 Remote control on/off OFF/ON OFF OFF
P10 Water cooling on/off OFF/ON ON OFF
P11 Double pulse frequency 0.5-5.0Hz 0.1Hz OFF 3.3
P12 Double pulse arc length -50-+50 1 0.0 1.0
P13 Double pulse speed 0-2m 0.1m 2.0m 2.0m
P14 Double pulse width 10-90% 1% 50% 50%
P15 Single pulse frequency OFF/UI/UU/II OFF UU
P16 Fan delay time 5-15min 1min 15min 15min
P17 Up-slope time 0-10S 1S OFF 0.1
P18 Down slope time 0-10S 1S OFF OFF
P19 Synergic / Individual mode
on/off OFF/ON ON ON
Note: If you press the volume (1) for about 3 seconds, the welder will be set to the initial state.
If an error occurs during operation, the welder is automatically protected and the error code is
displayed on the digital window with the code number.

■ Symptom and solution
Code no.
Symptoms Cause Solution
E40
Communication error
between Main PCB
and Display PCB
1. Cable failure
2. Main PCB failure
1. Check and replace the cable
2. Replace the Main PCB
E41 Wire feeder
communication error
1. Cable failure
2. Wire feeder PCB failure
1. Check and replace the cable
2. Replace the Wire feeder PCB
E42
Communication error
between the welder
and wire feeder
1. Connect failure between the welder and
wire feeder
2. Internal cable failure
3. Wire feeder PCB failure
4. Main PCB failure
1. Check the cable in Wire feeder and
the welder
2. Check and replace the internal cable
3. Replace Wire feeder PCB
4. Replace Main PCB
E33 Welding wire stick to
base metal
At the end of welding, welding wire sticks
to base material
Turn off the main power and detach
welding wire from base metal.
E34 Input error of Wire
feeder
1. Cable failure
2. Welding voltage and current volume
failure in Wire feeder.
1. Check and replace the cable
2. Replace the volume of wire feeder.
E30 Wire feeder overload 1. Welding wire is finished.
2. Motor overload, Motor Failure.
1. Replace with new welding wire
2. Replace motor
E15 Power supply error
1. Torch switch pressed at power-on
2. Open circuit voltage error
3. Current detected
4. Welding wire is fed
5. Gas detected
1. Release torch switch
2. Check that Output cable is short
circuit.
E17 Over current
1. Over current
2. Hole sensor failure
3. Signal cable disconnected
4. Main PCB failure
1. Check main circuit
2. Supply input power
3. Check signal cables
4. Replace Main board
E18 Output voltage error 1. Voltage feedback cable got damaged
2. Main pcb failure
1. Check Voltage feedback cable and
replace it
2. Replace Main board
E19 Temperature protect
1. Overheat in side of welding machine
2. Temperature sensor fault
3. Signal cable failure
4. Main pcb failure
1. Check the ventilation and follow
duty cycle of machine
2. Replace temp. sensor
3. Check Signal cables
4. Replace Main pcb
E10 Torch switch error No weld even pressing torch switch for a
long time
Torch switch off
E88 Motor don’t work Motor board failure Check and replace Wire feeder board

Thank you very much for choosing our machine
Please record your machine identification information below for future reference. This
information can be found on the nameplate of your machine.
Product Name INVERTER PULSE MIG ARC WELDER
Model Number 500LMP
Date Manufactured
Serial Number
Date Purchased
Where Purchased
Where you use
Whenever you request replacement parts or information on this machine, always supply
the information you have recorded above. The date number is especially important when
identifying the correct replacement parts.
Complete this form, please fax it to our selling agency in your country or us for warranty
statement.
Worldwel Co., Ltd.
11-101, Songlim-dong, Dong-gu, Incheon-city, Korea
TEL : [phone] FAX : [phone]
www.worldwel.com