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Hanshen MP350 Series Operation Manual

Dsp multifunction pulse welding machine
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DSP MULTIFUNCTION PULSE
A T T E N T I O N :
Be sure that all installation, operation, maintenance and repair
procedure are performed only by qualified individuals.
Read this operation manual completely before using this equipment.
Save this manual and keep it handy for quick reference pay more
attention to the safety instructions.
OPERATION
MANUAL
WELDING MACHINE
MP350/500 series
1

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Summary of Contents for Hanshen MP350 Series

  • Page 1 OPERATION MANUAL DSP MULTIFUNCTION PULSE WELDING MACHINE MP350/500 series A T T E N T I O N : Be sure that all installation, operation, maintenance and repair procedure are performed only by qualified individuals. Read this operation manual completely before using this equipment. Save this manual and keep it handy for quick reference pay more attention to the safety instructions.

  • Page 2: Table Of Contents

    CATALOGUE 1 、 S A F E T Y R U L E S … … … … … … … … … … … … … … … … … … 3 2 、 S P E C I F I C A T I O N … … … … … … … … … … … … … … … … … 8 3 、...

  • Page 3: Safety Rules

    1、 SAFETY RULES S a f e t y R u l e s Please read the manual carefully before using the machine and  operating it correctly on this basis This manual only for the installation, operation and maintenance ...
  • Page 4 O v e r h e a t e d p a r t s m a y i n j u r e t h e s k i n  Do not touch the overheated welding position  Do not touch with bare hands the welding cable or welding clamp due to the heat produced during operation.
  • Page 5 When the welding wire emerges from the torch, there is a high risk of injury (the wire may pierce the welder’s hand. injure his face and eyes) For this reason, when feeder-inching etc., always hold away from your body (machines with wire feeder) ...
  • Page 6 ● The electromagnetic fields may have some interference with radio waves, computer, communications equipment and some other telecoms equipment, the owner/operator is obliged to take all necessary measures to prevent such interference. To prevent the risk of scalding from accidental discharge of hot coolant, before unplugging the connectors of coolant flow, switch off the cooling unit first.
  • Page 7  The machine may only be used for jobs as defined by the “Intended purpose”： - The machine may only be used for the welding processes stated on rating plate. Utilisation for any other purpose, or in any other manner, shall be deemed to not be in accordance with the intended purpose, the manufacturer shall not be liable for any damage resulting from such improper use.
  • Page 8 2、 SPECIFICATIONS Hanshen MP series DSP welding machines are fully digitally controlled inverter power source. Its core is the digital signal processor (DSP). The DSP centrally deals with the welding data, controls and monitors the welding process, which gives a reliable, premium performance and welding quality.
  • Page 9 3、TECHNICAL SPECIFICATIONS Table 1：Specifications Specification MP350 MP500 Power source AC 3 phase 380V10% 50Hz voltage/frequency Rated power input 16.5KVA 24KVA Rated input current Rated duty cycle Range of rated output 20--350A 20-500A current adjusting Range of rated output 11--34V 11-40V voltage adjusting Output open circuit voltage...
  • Page 10 4、EQUIPMENT INSTALLATION & CONNECTION 4.1 Connection diagram (for example: melting pole welding)
  • Page 11 connection diagram Fig.1：...
  • Page 12 4.2 Safety tips Please strictly stick to the following steps for installation and debugging  Note: The operation of connecting the gas cylinders can only start after turning  off the power switch of distribution box. Electric shock Welding process may cause fire may injure or explosion Warning...
  • Page 13 5、FUNCTION INTRODUCTION 5.1 MP front panel structure Fig 2：MP-500 front panel diagram Table 2： Item Function Adjust parameters, function selection, etc. read instructions for Operation panel operation manual of MP series welding machine panel Cathode output Through the output cable to connect the welding workpieces (gas connector metal arc welding) Control cable interface...
  • Page 14 Fig3：MP-500 back panel diagram Table 3 Item Function Input power supply box Used to connect the welding machine to 380V power supply Air switch This switch can automatically turn off power to protect the welding machine during the overload or failure. In general, this switch should be kept on Control power fuse When the control circuit short circuit occurs, this fuse will blow...
  • Page 15 Fig4：MP series welding machine operation panel schematic diagram 1）Adjusting knob Adjust the parameter values. When Indicator light is on, it means the knob can be used to adjust the corresponding parameter of the project. 2）Indicator light of adjusting knob When indicator light is on, it means the knob can adjust the parameters 3）Selection key F2 Choose to operate the parameters of the project：...
  • Page 16 6）indicator light of welding speed When indicator light is on, the display screen on the right shows the preset welding speed (cm/min) 7）indicator of welding voltage When indicator light is on, right display shows preset or actual welding voltage 8）indicator light of arc length correction When indicator light is on, the display screen on the right shows arc length correction value —...
  • Page 17 When indicator light is on, the display screen on the left shows the preset base metal thickness 16）indicator light of welding angle When indicator light is on, the display screen on the leftshows welding angle size ‘a’ 17）indicator light of F1 When indicator light is on, it means that F1 key has been selected and it can adjust the parameters 18）selection key F1...
  • Page 18 29）welding torch operation mode button Select the welding torch operation mode Table 4：welding torch operation mode Mode Remark Two steps Normal operation mode Four steps Locked operation mode Special four steps Up, crater arc adjustable model Spot welding Automatically control working time 30）indicator light of welding method When indicator light is on, it means the corresponding welding method is selected...
  • Page 19 Use the wire diameter selection button (23) and choose to modify the content. Use the adjusting knob (1) to adjust to parameter values. P05, P06 item are available for F2 key switch to display current percentage, arc length offsets, and can also use (1) to modify the parameter values.

  • Page 20: S P E C I F I C A T I O N

    Fig 6：Implicit parameter operation schematic diagram (electrode MMA welding ) 5.5 Modify the content and the corresponding parameters as shown in table 6 Gas shielded welding way implicit parameter is as follows： Individual-use Factory Item Function Setting range Unit setting Back to the burning time 0.01-2.00s 0.01s...
  • Page 21 length correction Double pulse speed offset 0-2m 0.1m Strong pulse group duty 10-90% ratio Fixed frequency mode OFF/U1 ―― fan control time 5-15min 1min 15min Arc starting slowly rise 0.1-10s 0.1s time arc down time 0.1-10s 0.1s Electrode manual welding method implicit parameter is as follows: 1-100％...
  • Page 22 3) Use knob (1) to select the storage location or not to change the current storage location. 4) Press the storage key (21), the left screen shows ‘Pro’ meaning operation parameters are being stored selected storage location Note: if the selected storage location already has operation parameters, it will be covered by the new parameters, the old parameters will not be able to recover.
  • Page 23 3) Gently press the invoking key again (19), the invocation Light is off，exit the invoking operation mode Fig8：Invoking operation schematic diagram 6、WELDING OPERATION Preparation: distribution wiring 1.Ground the yellow and green cables. 2.Losen the screws of the junction box cover, take off junction box upwards. 3.Remove the three OT on the cable terminal, press tightly the OT terminal on same side of three-phase power supply cable 4.Put OT connected on cables terminal fixed on the welding machine wiring terminals with...
  • Page 24 6.3 Melting polar gas shielded welding machine debugging and operation 1.Selection of welding methods: pulse (including double pulse), gas shielded welding, welding electrode manual welding, argon arc welding, carbon arc air gouging. 2.Selection of operation mode: 2step, 4step, special 4 steps and spot welding. 3.
  • Page 25 1.2～ 230～260 24～26 40～50 15～20 0～1.2 300～350 30～35 30～40 15～20 0～0.8 380～420 37～38 40～50 15～20 0～1.2 420～480 38～41 50～60 15～20 Table8:welding process of low carbon steel with solid wire CO2 angle welding reference welding Welding Welding Welding wire Gas flow thickness current voltage...
  • Page 26 welding distance Welding Welding Welding Welding wire between nozzle thick current voltage speed flow Note position ness diameter and workpiece (cm/min) (L/min) (mm) (mm) 80～100 19～21 40～50 12～15 10～15 90～100 19～21 40～50 13～16 13～15 Butt 150 ～ 22～25 40～50 14～17 15～17 joint 150～...
  • Page 27 240～ 24～27 45～55 17～22 20～24 60～80 16～18 60～80 13～16 15～20 ～2 100～ 22～26 35～45 13～16 15～20 angle ～3 100～ 19～21 40～60 13～17 15～20 joint ～3 120～ 20～22 50～70 15～20 15～20 150～ 20～23 50～70 18～22 18～22 ～4 ～4 160～ 22～24 35～50 18～22 16～18 220～...
  • Page 28 Gas tube interface Wire feeder control socket Welding cable connector Fig 9：Wire feeding machine diagram Fig 10：Wire feeding machine control panel diagram Analog panel uses A knob to adjust the given current, use V knob to adjust the given arc length.
  • Page 29 6.4.3 Wire feeding roller specification and installation Wire feeding pressure calibration is carved in pressure handle, for different materials and diameter of the wire feeder will have different pressure relation, as shown in table 11 and figure 12. The value in table is only for reference, the actual pressure specification adjustment must be according to the welding torch cable length, type of welding torch, wire feeding conditions, and correspondingly adjust welding wire type.
  • Page 30 case the wire reel stalling and wire scattered; Braking force cannot be too big, otherwise it will increase the motor load. Generally the faster the wire feed speed, the larger the braking force needed. Fig12：Adjustment diagram 6.4.5 Manual feeding wire and gas detection Press manual feeding wire button and the wire feeding machine start to work, only the wire feed motor will work, then feed welding wire.
  • Page 31 match wire type. Steel wire hose is suitable for hard wire, such as solid carbon steel, stainless steel wire. Teflon hose is suitable for soft wire, such as aluminium and its alloys, copper and its alloy welding wire. Wire feeding tube is too tight or too loose, can increase the wire resistance and effect wire feeding instability.
  • Page 32 Teflon wire feeder tube installation shown in figure 16： Teflon wire Teflon hose feeding hose （to wire feeding roller） Fig 16：Teflon wire feed tube diagram 6.5 Wire feeder connection Refer to figure 1: the equipment connection diagram (gas molten welding),connection of the tube, control cable and welding cables.
  • Page 33 2. After finishing using the welding machine, please make sure to turn off the power switch. 3. In the places with poor ventilation, continuously sending shielding gas may lead to suffocation from hypoxia. 6.6 Alarm code Welding machine has the function of automatic protection when an exception occurs, the alarm code, phenomenon, causes and solutions as shown in table 12.
  • Page 34 other workpiece, reopen the power supply. 1) the control cables break Wire feeder given 1)check cables 2) wire feeder current, voltage abnormal 2)replace it potentiometer given bad. 1) the wire is used up 1)replace new wire 2) the wire feed motor over- Wire feeder overload 2)check motor current, stuck or damage...
  • Page 35 6.7 Welding torch operating mode instruction: Table13 Mode Operation mode Welding torch switch and current curve 1）press the torch switch, start welding step 2）Turn off switch, stop welding 1) press the torch switch, start welding 2) turn off switch, keep the welding state 3) press the torch Four...
  • Page 36 1）press the torch switch, arc current welding 2）turn off switch, keep the welding state 3) press the Special torch switch four again, the step transition to the arc welding current 4) turn off switch, stop welding 1) press the torch switch, began to welding, set continuous spot...
  • Page 37 Pulse Φ1.6 L1—L5、 welding 1060、1035、 Pure aluminium 1100、1200、1370 LT1、4A11、 aluminium- silicon alloy 4043、4047 304、308、309、 97.5%Ar Φ0.8、 316 Such as stainless steel +2.5%CO2 austenitic stainless Φ1.0、 steel welding wire Φ1.2、 82%Ar Φ1.6 carbon steel +18%CO2 Φ1.2、 silicon bronze HS211 100%Ar Φ1.6 Φ1.0、...
  • Page 38 8、DAILY MAINTENANCE 1. Do not open the welder case except the MP maintenance and  professional electrician Note： 2. Please turn off the switch of welding machine and distribution box before opening the case An electric shock can be fatal！ 警告...

  • Page 39: D A I L Y M A I N T E N A N C

    ● Please only allow a professional electrician to open the case ● When carrying out maintenance, please remove the cable from inside the power distribution box 8.1 welding torch, wire feeding machine maintenance and check In order to maximize the machine performance and guarantee the safe and normal operation, daily maintenance and maintenance is very important.
  • Page 40 Wire If can adapt to the wire Produce chip&scrap, feeder types(distinguish aluminum wire and abnormal abrasion of steel wire) wire enter hose Wire enter wire feeding and electric nozzle arc unstable If the hose center fit for groove center Dislocation may cause Wire guiding of wire feeder roller the production of...
  • Page 41 Table16 Abnormal Can not Shield Does Igniting Arc is Weld Adhesive Adhesive Appear ignite gas can the arc edge base welding the arc send hardly stable unclear metal wire and hole flow wire contact welding wire Overhaul parts and repair items Wire 1) pressure regulating feeder...
  • Page 42 board damaged When welding , overheat According to the welder Overload for long time indicator light is on load rate using 1) the wire feeder control cable The welding current can't is broken or controller damage change adjust 2) welding machine control board fault 1) welding specification is 1）adjust specification...

  • Page 43: C I R C U I T D I A G R A

    9. CIRCUIT DIAGRAM 9.1 welding machine circuit diagram C T 8 1 - 1 0 3 P / 3 K V C T 8 1 - 1 0 3 P / 3 K V 2 W / 1 5 K 2 W / 1 5 K S R 1 6 0 S R 1 6 0...
  • Page 44 9.2 wire feeder control circuit diagram 背 面 背 面 电机 气阀 MP-AP2 FH7.820.517B 检气 焊枪开关 检丝...

  • Page 45: 10、Wiring Diagram For Integrated Welding Machine

    10. WIRING DIAGRAM FOR INTEGRATED WELDING MACHINE...

This manual is also suitable for:

Mp500 series