Worldwel Longrun LD Series User manual

LD SERIES Processes
INVERTER DC STICK WELDING MACHINE
LD SERIES
OPERATION MANUAL
DO NOT INSTALL, OPERATE OR MAINTAIN THIS MACHINE WITHOUT RE
ADING THIS MANUAL AND PLEASE ALWAYS THINK BEFORE YOU ACT.
www.worldwel.com

■ TECHNICAL SPECIFICATIONS
ITEM UNIT 200LD 200LD2/3 230LD 250LD3 300LD3 400LD3 500LD3
Input voltage V ingle phase, 220, 50/60Hz
Single
phase,
220,
50/60Hz(Standard)
or Single phase(220/440V –
Optional)
or Three phase(380V - Optional)
Single/Three Phase,
220/380/440V, 50/60Hz
Input capacity KVA 6.5 7.5 8 9 11.5 17.5 23.5
Open
circuit
voltage V 74.5 73 79 74.5 81.5
92V
@380V Input
Output current A 20~185 20~200 20~215 20~250 20~300 40~400 40~500
Output voltage V 24 26 23 27 29 35 38
Duty cycle % 60
Weight kg 8.6 9.4 10 15 16.5 40 53
Dimension
(W×D×H) mm 180 x 400 x 280 210x460x300 210x460x300 345x730x530 400x770x630

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 cord for damage or bare wiring and repair or replace cord immediately
if damaged.
Fumes and gases can be dangerous.
■ Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.
When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to
keep fumes and gases away from the breathing zone.
■ Use enough forced ventilation or local exhaust (forced suction) at the arc to remove the fumes from
your breathing area.
■ Use a ventilating fan to remove the fumes from the breathing zone and welding area.
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.
■ Wear complete body protection. Wear oil-free protective clothing such as leather gloves, heavy shirt,
cuffless pants and high boots.
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 welding, make certain no part of the electrode circuit is touching the work or ground.
Accidental contact can cause overheating and create a fire hazard.

■ Do not weld 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 welding area as practical. Work cables connected
to the building framework or other locations away from the welding area increase the possibility of
the welding current passing through lifting chains, crane cables or other alternate circuits. This can
create fire hazards or overheat lifting chains or cables until they fail.
■ 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.
․ Recommended cable specification
Item Unit 200LD 200LD2/3 230LD 250LD3 300LD3 400LD3 500LD3
Input cable
㎟
5.5 8
Holder cable
25 38 50
Earth cable

● OUTPUT CONNECTION

● FRONT PANEL
[ 200LD2/3 ]
[ 200LD, 230LD ]

[ 250LD3, 300LD3 ]
[ 400LD3, 500LD3 ]

1Ammeter Indicates the welding current.
2Power Lamp It indicates that the machine is on and input voltage is within acceptable
range.
3Current Lamp It indicates the machine is ready to adjust welding current.
4Warning Lamp
It indicates the thermal over load or output disabled by any electrical
problems or the failure of program. When it is on, the machine will not
supply power at the output.
5Power Switch When it is turn on, the cooling fan and all of electrical circuit inside the
machine will be operated.
6Control Fuse (5A) It will be broken by any electrical problems
7Current Volume Adjust the welding current
8Electric shock prevention device ESPD (electric shock prevention function) is to prevent user's electric
shock by cutting off short-circuit voltage is after welding is finished.
9ESPD Lamp It indicates ESPD function is on
10 Arc Force Lamp It indicates Arc force function is on
11 Hot start Lamp It indicates Hot start function is on
12 Arc force / Hot start Volume You can change Arc force / Hot start function by pressing knob.
And also, you can adjust arc force range / Hot start current by knob.
13 Arc force volume Adjust the Arc force
14 Pulse current Adjust the Pulse current
15 Pulse frequency Adjust the Pulse frequency
16 Pulse select button You can choose Pulse/Non Pulse mode

200LD PART LIST
No Part Q'ty No Part Q'ty
1Main PCB 1 9Input bridge diode / PCB 1
2Capacitor 1 10 FRD / PCB 1
3Circuit Breaker 1 11 Output terminal 2
4Auxiliary transformer 1 12 Choke transformer 1
5Volume knob 1 13 Main transformer 1
6Switch 1 14 FAN 1
7Temp sensor 1 15 Cable lock 1
8IGBT / PCB 1 16 MF Capacitor 1

200LD PART LIST
No Part Q'ty No Part Q'ty
1Main PCB 1 9Input bridge diode / PCB 1
2Capacitor 1 10 FRD / PCB 1
3Circuit Breaker 1 11 Output terminal 2
4Auxiliary transformer 1 12 Choke transformer 1
5Volume knob 1 13 Main transformer 1
6Switch 1 14 FAN 1
7Temp sensor 1 15 Cable lock 1
8IGBT / PCB 1 16 MF Capacitor 1

200LD2 PART LIST
No Part Q'ty No Part Q'ty
1Main PCB 1 9FRD / PCB 1
2Capacitor 1 10 Output terminal 2
3Circuit Breaker 1 11 Choke transformer 1
4Auxiliary transformer 1 12 Main transformer 1
5Volume knob 1 13 FAN 1
6Temp sensor 1 14 Cable lock 1
7IGBT / PCB 1 15 MF Capacitor 1
8Input bridge diode / PCB 1

200LD2 PART LIST
No Part Q'ty No Part Q'ty
1Main PCB 1 9FRD / PCB 1
2Capacitor 1 10 Output terminal 2
3Circuit Breaker 1 11 Choke transformer 1
4Auxiliary transformer 1 12 Main transformer 1
5Volume knob 1 13 FAN 1
6Temp sensor 1 14 Cable lock 1
7IGBT / PCB 1 15 MF Capacitor 1
8Input bridge diode / PCB 1

230LD PART LIST
No Part Q'ty No Part Q'ty
1Main PCB 1 9Input bridge diode / PCB 1
2Capacitor 1 10 FRD / PCB 1
3Circuit Breaker 1 11 Output terminal 2
4Auxiliary transformer 1 12 Choke transformer 1
5Volume knob 1 13 Main transformer 1
6Switch 1 14 FAN 1
7Temp sensor 1 15 Cable lock 1
8IGBT / PCB 1 16 MF Capacitor 1

230LD PART LIST
No Part Q'ty No Part Q'ty
1Main PCB 1 9Input bridge diode / PCB 1
2Capacitor 1 10 FRD / PCB 1
3Circuit Breaker 1 11 Output terminal 2
4Auxiliary transformer 1 12 Choke transformer 1
5Volume knob 1 13 Main transformer 1
6Switch 1 14 FAN 1
7Temp sensor 1 15 Cable lock 1
8IGBT / PCB 1 16 MF Capacitor 1

250LD3 PART LIST
No Part Q'ty No Part Q'ty
1Main PCB 1 10 Output terminal 2
2Capacitor 1 11 Choke transformer 1
3Circuit Breaker 1 12 Main transformer 1
4Auxiliary transformer 1 13 FAN 1
5Temp sensor 1 14 MF Capacitor 2
6IGBT 2 15 Input terminal 1
7IGBT Drive PCB 2 16 TNR 1
8Input bridge diode / PCB 1 17 Fuse 1
9FRD / PCB 1

250LD3 PART LIST
No Part Q'ty No Part Q'ty
1Main PCB 1 10 Output terminal 2
2Capacitor 1 11 Choke transformer 1
3Circuit Breaker 1 12 Main transformer 1
4Auxiliary transformer 1 13 FAN 1
5Temp sensor 1 14 MF Capacitor 2
6IGBT 2 15 Input terminal 1
7IGBT Drive PCB 2 16 TNR 1
8Input bridge diode / PCB 1 17 Fuse 1
9FRD / PCB 1

300LD3 PART LIST
No Part Q'ty No Part Q'ty
1Main PCB 1 10 Output terminal 2
2Capacitor 1 11 Choke transformer 1
3Circuit Breaker 1 12 Main transformer 1
4Auxiliary transformer 1 13 FAN 1
5Temp sensor 1 14 MF Capacitor 2
6IGBT 2 15 Input terminal 1
7IGBT Drive PCB 2 16 TNR 1
8Input bridge diode / PCB 1 17 Fuse 1
9FRD / PCB 1

300LD3 PART LIST
No Part Q'ty No Part Q'ty
1Main PCB 1 10 Output terminal 2
2Capacitor 1 11 Choke transformer 1
3Circuit Breaker 1 12 Main transformer 1
4Auxiliary transformer 1 13 FAN 1
5Temp sensor 1 14 MF Capacitor 2
6IGBT 2 15 Input terminal 1
7IGBT Drive PCB 2 16 TNR 1
8Input bridge diode / PCB 1 17 Fuse 1
9FRD / PCB 1

400LD3 PART LIST
No Part Q'ty No Part Q'ty
1Main PCB 1 15 FAN 2
2Auxiliary transformer 1 16 FAN 1
3Input bridge diode 1 17 FRD 2
4Relay 1 18 Resistance 2
5Circuit Breaker 1 19 IGBT Snubber PCB 2
6Meter PCB 1 20 IGBT 2
7Fuse 1 21 IGBT Drive PCB 2
8Volume knob 1 22 Temp sensor 1
9Switch 1 23 Bridge diode 1
10 MF Capacitor 4 24 Main transformer 1
11 MF Capacitor 2 25 Choke transformer 1
12 Capacitor 2 26 Output terminal 2
14 Input selection terminal 1 27 Connector 1

400LD3 PART LIST
No Part Q'ty No Part Q'ty
1Main PCB 1 15 FAN 2
2Auxiliary transformer 1 16 FAN 1
3Input bridge diode 1 17 FRD 2
4Relay 1 18 Resistance 2
5Circuit Breaker 1 19 IGBT Snubber PCB 2
6Meter PCB 1 20 IGBT 2
7Fuse 1 21 IGBT Drive PCB 2
8Volume knob 1 22 Temp sensor 1
9Switch 1 23 Bridge diode 1
10 MF Capacitor 4 24 Main transformer 1
11 MF Capacitor 2 25 Choke transformer 1
12 Capacitor 2 26 Output terminal 2
14 Input selection terminal 1 27 Connector 1