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zika MIG300GD User Manual

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MIG 300GD WLEDING MACHINE
USER MANUAL

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Summary of Contents for zika MIG300GD

  • Page 1 MIG 300GD WLEDING MACHINE USER MANUAL...
  • Page 2 Preface This manual includes hardware description and operation introduction of MIG 300GD equipment. For your and other people’s safety, please read the manual carefully. Pay attention Pay attention to the words after the signs below. Sign Description The words after this sign means there is great potential danger, which may cause major accident, damage or even death, if it is not followed.

  • Page 3: Table Of Contents

    CONTENTS 1 SATETY WARNING ........................4 2 Product ............................10 2.1 General ..........................10 2.2 Technical data ........................11 3 Installation ............................. 12 4 Operation ............................15 4.1 Front panel layout ......................... 15 4.2 Operation instruction ......................16 4.3 Welding environment and safety ..................22 4.4 Welding problems and resolution ..................

  • Page 4: Satety Warning

    1 SATETY WARNING The safety notes listed in this manual is to ensure correct use of the machine and to keep you and other people from being hurt. The design and manufacture of welding machine considers safety. Please refer to the safety warning listed in the manual to avoid accidents.
  • Page 5 Please follow the rules below to avoid heavy accidents. ● Never use the equipment to do other things but welding. ● Follow related regulations for the construction of the input-driven power source, choice of place, usage of high-pressure gas, storage, configuration, safe-keeping of workpiece after welding and disposal of waste, etc.
  • Page 6 The gas and fumes are harmful to health, please wear protective device according to regulations. ● Wear exhaust equipment and breathe preventive facilities to prevent gas poisoning or choke. ● Use suggested part exhaust equipment and breathe preventive facilities to prevent hurt or poisoning by gas and other powder, please.
  • Page 7 Any touch of the switch part will cause injury, please note the following. ● Never use the machine when the enclosure is off. ● Install, operate, check and maintain the machine by professional person. ● Keep your fingers, hair, clothes etc. away from the switch parts such as the fan. The wire end may deal damage, please note the following.
  • Page 8 Correct False Lifting way for gas shielded machines Electromagnetic interference needing attention: ● It may need extra preventive measures when the equipment is used in particular location. ● Before the installation, please estimate the potential electromagnetism problems of the environment as follows. a) Upper and lower parts of the welding equipments and other nearby power cable, control cable, signal cable and phone cable.
  • Page 9 ● Users should observe the following dos and don’ts to decrease radiation interference. a) Connect the welding equipments to the power supply lines. b) Maintain the welding equipments regularly. c) The cable should be short enough to be close to each other and the ground. d) Ensure the safety of all the welding metal parts and other parts nearby.

  • Page 10: Product

    2 Product 2.1 General The welding machine applies the most advanced inversion technology in the world. The principle of inversion is to transform the power frequency of 50Hz/60Hz into direct current and invert it into high frequency (24KHz) through high-power device IGBT, then perform voltage-drop and commutation with the output high-power D.C power supply via Pulse Width Modulation (PWM).

  • Page 11: Technical Data

    2.2 Technical data Type MIG 300GD Item 3 phase Power voltage (V) 380V 15% Frequency (Hz) 50/60 18.5 Rated input current (A) 16.8 40-300 Output current adjustment (A) 45-300 MMA 21.6-32 Output voltage (V) MIG 16.2-29 Duty cycle (%) Power factor 0.93 Efficiency (%) Type of wire feeder...

  • Page 12: Installation

    3 Installation The welding equipment is equipped with power voltage compensation device. It keeps the machine work normally when power voltage fluctuating ±15% of rated voltage. When using long cable, in order to reduce voltage drop, big section cable is suggested. If the cable is too long, it will affect the performance of arcing and other system function, it is suggested to use the recommend length.
  • Page 13 ways: positive connection and negative connection. Positive connection: holder connects with “-” terminal, while work piece with the “+” terminal. Negative connection: work piece with the“-” terminal, holder with the “+” terminal. Choose suitable way according to the working situation. If unsuitable choice is made, it will cause unstable arc, more spatters and conglutination.
  • Page 14 Installation drawing of MIG 300GD (MIG): Installation drawing of MIG 300GD (MMA):...

  • Page 15: Operation

    4 Operation 4.1 Front panel layout Front panel instruction MMA/MIG switch key VRD/2T/4T switch Wire diameter selection key(φ0.8mm φ1.0mm φ1.2mm) Data selection key (effective under MIG mode) Store mode selection key(Memory1 Memory2 Memory3) Multifunctional data adjusting knob coarse adjustment by pressing the knob and turning it: big regulating rate and high speed;...

  • Page 16: Operation Instruction

    Multifunctional data display 9 Burn back Polarity conversion joint This machine has the polarity conversion; There are positive output terminal and negative output terminal between wire feeder and wire spool; When use solid wire with gas protection, torch socket should be connected to the positive output terminal, ground cable should be connected to the negative output terminal;...
  • Page 17 Chart 2: under MMA mode, preset current Chart 3: under MMA mode preset current display with VRD enabled display VRD disabled multifunctional data display shows the preset current“080A”, its unit is ampere(A). Adjusting the Multifunctional data adjusting knob can change the welding current during welding process, and displayed in multifunctional data display .
  • Page 18 Under MIG mode, pressing BURN BACK ,the indicator lights up, which can realize high speed wire feeding(Chart 6). multifunctional data display would flash continuously until pressing the torch switch or any key or knob on the panel. Both multifunctional data display and BURN BACK stops flashing, and the wire stops feeding.
  • Page 19 attenuates until to crater value and keep on, then release the torch switch again, burn back and get rid of the ball on the end of wire, then stop feeding gas 3 seconds later. Under MIG mode, operate the wire diameter selection , choose different wire diameter among φ0.8mm φ1.0mm φ1.2mm Adjust Multifunctional data adjusting knob...
  • Page 20 Chart 10 display status when perform welding under Chart 11 Display status after stop welding under MIG mode MIG mode Storage function Press mode selection , can store 3 modes, which are Memory1,Memory2 and Memory3. 4.2.2 Malfunction display Malfunction display of wire feeder The panel displays as Chart 12 when the wire feeder is malfunctioning, and the multifunctional data display flashes continuously, the machine can not work normally.
  • Page 21 Chart 12 malfunction display of wire feeder Chart 13 Malfunction display of over current Malfunction display of overheating protection The panel displays as Chart 16 when overheating, and the multifunctional data display flashes continuously, the machine can not work normally. Only when the temperature of the welding machine falls below 60 , the overheating malfunction would disappear, and the machine work normally without restarting.

  • Page 22: Welding Environment And Safety

    4.3 Welding environment and safety Environment The machine can perform in environment where conditions are dry with a dampness level of max 90%. Ambient temperature is between -10 to 40 degrees centigrade. Avoid welding in sunshine or drippings. Do not let water enter the gas Avoid welding in dust area or the environment with corrosive gas.

  • Page 23: Welding Problems And Resolution

    4.4 Welding problems and resolution The phenomenon listed below may happen due to relevant accessories used, welding material, surroundings and power supply. Pleas improve surroundings and avoid these problems.. Arc starting difficulty. Arc interruption happens easily: Examine whether grounding wire clamp contacts with the work pieces well. Examine whether each joint has improper contact.

  • Page 24: Daily Maintenance And Checking

    5 Daily maintenance and checking Daily maintenance Remove dust regularly with dry compressed air. If the welding machine is used in surroundings with heavy smoke and polluted air, it is necessary to remove dust at least one time one month. The pressure of compressed air shall fall to required level to prevent damage to small components in the machine.
  • Page 25 Daily checking WELDING POWER SUPPLY Position Checking keys Remarks Switch condition of operation, transfer and installation. Control panel Test the power indicator. If abnormal noise Check if there is wind and the sound normal or not. Cooling fan and no wind, to check the inner.
  • Page 26 Partial winding Reason of poor wires sending and extended unstable arc, please change. Block caused by dirt in the Reason of poor wire sending and tube, and the remains of the unstable arc, (use kerosene to wire plating lay. wipe or change new one.) 1.
  • Page 27 CABLE Position Checking keys Remarks Cause poor wire If torch cable over bended. sending. If the metal connecting point of mobile plug Torch Unstable arc if loosen. cable cable over bended. Wearing-out of the cable insulated material. For life security and Cable connecting head...

  • Page 28: Trouble Shooting And Fault Finding

    6 Trouble shooting and fault finding Notes: The following operations must be performed by qualified electricians with valid certifications. Before maintenance, you are suggested to contact local distributor to verify qualification. Malfunctions and solutions of MIG 300GD: Malfunctions Solution 1. Confirm the power switch is on. The meter show nothing;...
  • Page 29 INITIAL PROBLEMS DIAGNOSE Even the machine comes up with abnormal phenomenon such as welding unable, arc unstable or bad welding effect, it is still early to judge that there is malfunction on the machine. The above-mentioned abnormal phenomenon may be caused by some reasons. For example: tight parts loosen, forgetting to switch on, wrong set up, cable broken and gas rubber pipe cracked, etc.
  • Page 30 1. Turn on gas supply 2. Residual Amount of Gas in the Gas Cylinder and Cylinder Gas Regulator 3. Set value for flow 4. Connection joint loose Gas supply hose (the whole line from 1. Connection joint loose the high pressure 2.
  • Page 31 1. Loose connection of conductive tip, nozzle and nozzle contactor Body of weld gun 2. Contactor of weld gun body is not plunged in or tightened well Power supply 1. Break off (bending fatigue) cable of weld gun 2. Damaged by weighted drop as well as cable of switch control Surface Condition...

  • Page 32: Appendix Welding Parameter List

    Appendix Welding parameter list Generally, welding current is adequate to welding electrode according with as following. Electrode φ2.5 φ3.2 φ4.0 φ5.0 specification Welding current 70-100A 110-140A 170-220A 230-280A Welding variables when use MIG welding The values listed in the following table are the general specification values under standard condition.
  • Page 33 Plate Wire Welding Wire Current Voltage Gas flow rate thickness diameter speed extension L/min cm/min 0.8,0.9 60 80 16 17 40 50 0.8,0.9 80 100 19 20 40 55 10 15 1.0,1.2 120 160 20 22 35 45 10 15 10 15 1.0,1.2 150 180...
  • Page 34 Plate Wire Welding gun Welding Wire Gas flow Current Voltage thickness diameter vertical speed extension rate angle(°) L/min (cm/min) 0.8,0.9 60 70 16 17 40 45 10 15 80 90 18 19 45 50 10 15 0.8,0.9 90 100 19 20 45 50 10 15 0.8,0.9...

  • Page 35: Appendix Circuit Diagram

    Appendix Circuit diagram...

  • Page 36: Appendix Components Figure And List

    Appendix Components figure and list Structure Chart of MIG 300GD...
  • Page 37 Major parts list of MIG 300GD Item Quantity Item Quantity Air switch Horizontal clapboard Fuse seat Erect clapboard Fan cover Handle Supporting of radiator Right cover Push/lock button Left upper cover Socket Left down cover Heater board Chassis of the kit Absorption board upper cover of the kit Capacitor...

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