Related Manuals for FY-TECH FY-4180/2E
Summary of Contents for FY-TECH FY-4180/2E
- Page 1 Owner’s Manual FY-4180/2E The equipment is approved by a number of car manufacturers(China)
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Page 2: Table Of Contents
CONTENTS 1.Safety Precautions Symbols 2. Symbols And Descriptions 3.Accessories And Spare Parts 4.Installation 4-1. Specifications 4-2. Duty Cycle And Overheating 4-3. Machine Installation 4-4. Selecting A Location 4-5. Installing Gas Supply 4-6. Connecting Input Power 4-7. Threading Welding Wire 4-8. Changing Drive Roll 4-9. -
Page 3: Safety Precautions Symbols
Safety Precautions Symbols Protect yourself and others from injury, read and follow these precautions before installation and operation. Electric shock can kill: 1、Do not touch live electrical parts。 Read instructions. 2、Wear dry,hole-free insulating gloves 1、Read owner's Manual before using or and body protection. -
Page 4: Symbols And Descriptions
Symbols And Descriptions Symbols And Definitions Gas Metal Arc Amperes Welding(GMAW) Percent Wire Feed Volts Increase Degree Of Protective Earth Line Connection Protection Rated Welding (Ground) Current No--Do Not DO Power Rating,Products Single Phase Loose Shield Cup Of Voltage And Current This Adjust Air/Gas Duty cycle... -
Page 5: Accessories And Spare Parts
Accessories And Spare Parts Accessories And Spare Parts List Pressure Regulator NO.C001 Adjustment Switch NO.C002 European Connector NO.C003 Contact Tip NO.C004 Ouput Cable NO.C005 Spool Spindle NO.C006 Collect Body NO.C008 NO.C009 Welding Gun NO.C007 Wire Guide NO.C011 Shield Cup NO.C012 Front Adaptor NO.C010 Trigger Potentiometer NO.C013... - Page 6 Installation Instruction Side panel Gun holder 6" torx screw Rubber mat Fender panel Caster bracket Side plate 6" torx screw Caster Wheel washer 6" nut Wheel cap 8" inner- hexangular screw Wheel axle Wheel Install the gun holer to the side panel; install the side plates to the fender panel; install the wheel axle and wheels to the fender panel;...
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Page 7: Installation
INSTALLATION Specifications Model FY-4180/2E Parameter Voltage AC 380V/3ph Frequency 50 / 60 (Hz) Rated Max 10.8 Input Current Max Effective Input Current No-load Voltage 20-30 Welding Current 35-220A Duty Cycle Output 35A/17V- Current/Voltage 220A/24V Insulation Grade Mild Steel Solid Wire Wire Diameter 0.8/1.0mm... -
Page 8: Duty Cycle And Overheating
2.Duty Cycle And Overheating 1.Overheat protection is installed on the aluminium board of main transformer and rectifier.The unit products heat while welding. 2.If unit overheats ,output stops, and cooling fan runs. 3.Wait fifteen minutes for unit to cool.Reduce amperage or voltage, or duty cycle before welding. -
Page 9: Machine Installation
3.Machine Installation 1.Open the package and find out the Owner's Manual. 2.Check the details of accessories according to packing list that attached to this manual. 3.Properly install this equipment as following diagram.Inspect the unit for any damage. If so,contact your local distributor or service agency. -
Page 10: Selecting A Location
4、Selecting a Location 1)Select a correct location to place the unit。 2)Determine input power cord length according to its actual operation requirement.Input power cord must have a minimum inside diameter of 6mm。 3)Do not move or operate unit where it could tip。 4)Use cart or unit handle to move unit .Do not pull the cords to move unit. -
Page 11: Installing Gas Supply
5、Installing Gas Supply 1)、Cap 2)、Cylinder valve (Remove cap,stand to side of valve,and open valve slightly.Gas flow blows dust and dirt from vavle.Close vavle) 3)、Cylinder 4)、Regulator/Flowmeter (Install so face is vertical) 5)、Flow Adjust (Typical pressure is 0.05-0.15MPa) 6)、Hose 7)、Hose Connection (Connect gas hose between regulator/flowmeter and the unit) 8)、Regulator/Flowmeter heating socket (For low temperature worksite,please plug the regulator/flowmeter to the socket for heating.) -
Page 12: Connecting Input Power
6、Connecting Input Power power supply must have ground connection. welder must also connected circuit breaker. 1. Input power cord (not less than 6mm copper cord). 2. Over-current protection. 3. Disconnect device line terminals. 4. Ground wire L1/L2 input conductors National and Local standards(Circuit breaker must be installed).Only qualified persons are allowed to make this installation. -
Page 13: Threading Welding Wire
7、Threading Welding Wire 1 、Wire spool spindle 2 、Welding Wire 3 、Pressure adjustment knob 1.Open wire spool spindle;install wire spool;release pressure adjustment knob;pull and hold wire. Push wire thru guides into drive roll.Close wire spool spindle tightly to prevent slipping (Feed wire to check wire spool installation). -
Page 14: Changing Drive Roll
8、Changing Drive Roll 1、Drive roll securing nut 2、Drive roll 3、Pressure adjustment knob 4、Press device Changing Drive roll: 1、Release pressure adjustment knob .Press wire device springs open. 2、Loosen securing nut ,Remove drive roll. 3、The drive roll consists of two different sized grooves.Reinstall the desired wire sized groove close to the motor shaft. -
Page 15: Typical Mig Process Connection
9、Typical MIG Process Connection Regulator/Flowmeter Wire feeder Hose Work clamp and workpiece Shielding gas Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle .Place work clamp as close to the weld as possible. Page.13... -
Page 16: 4-10.Welding Gun
10、 Welding Gun 1、Shield cup C012 2、Contact tip C004 3、Front adaptor C010 4、Gooseneck(15/24AK) C020/018 5、Trigger 6、Spanner Page.14... -
Page 17: Operation
Operation 1、Controls 1. Display 2. Wire speed adjustment 3. Weld time extension 4. Weld current adjustment 5. Indicator light Page.15... -
Page 18: 5-2.Holding And Positioning Welding Gun
2、Holding And Positioning Welding Gun 1、Hold Gun and Control Gun Trigger 2、Workpiece 3、Work Clamp 4、Electrode Extension (Stickout) 5、Cradle Gun and R est Hand on Workpiece 0°-15° 90° 90° Side View Of Gun Angle End View Of Work Angle GROOVE WELDS 0°-15°... -
Page 19: 5-3.Conditions That Affect Weld Bead Shape
3、Conditions That Affect Weld Bead Shape 10° Push 10° Perpendicular Drag GUN ANGLES AND WELD BEAD PROFILES Short Normal Long ELECTRODE EXTENSIONS(STICKOUT) Short Normal Long FILLET WELD ELECTRODE EXTENSIONS(STICKOUT) Slow Normal Fast GUN TRAVEL SPEED Weld bead shape depends on gun angle ,direction of travel,electrode extension(stickout),travel speed, thickness of base metal,wire feed speed(weld current),and voltage. -
Page 20: 5-4.Gun Movement During Welding
4、Gun Movement During Welding 1、Stringer Bead Steady Movement Along Seam 2、Weave Bead Side To Side Movement Along Seam 3、Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode. Page.18... -
Page 21: 5-5.Poor Weld Bead Characteristics
5、Poor Weld Bead Characteristics 1、Large Spatter Deposits 2、Rough ,Uneven Bead 3、Slight Crater During Welding 4、Bad Overlap 5、Poor Penetration Page.19... -
Page 22: 5-6.Good Weld Bead Characteristics
6、 Good Weld Bead Characteristics 1、Fine Spatter 2、Uniform Bead 3、Moderate Crater During Welding 4、No Overlap 5、Good Penetration into Base Metal Page.20... -
Page 23: 6-1.Excessive Spatter
Troubleshooting 1、Excessive Spatter Excessive Spatter: Scattering of molten metal particles that cool to solid form near weld bead. Corrective Actions Possible Causes Wire feed too high Select lower wire feed speed Voltage too high Select lower voltage range Use shorter electrode extension (stickout) Electrode extension (stickout)too long Remove all grease,oil,moisture, rust paint un- Workpiece dirty... - Page 24 2、Porosity Porosity: Small cavities or holes resulting from gas pockets in weld metal. Possible Causes Corrective Actions Increase flow of shielding gas at regulator / flowmeter and/or prevent drafts near welding arc. Insufficient shielding gas at welding Remove spatter from gun nozzle. arc.
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Page 26: 6-4.Lack Of Penetration
4、Lack Of Penetration Lack of Penetration Good Penetration Lack Of Penetration: Shall fusion between weld metal and base metal. Possible Causes Corrective Actions Material too thick.Joint preparation and design must provide access to bottom of groove while mai- Improper joint preparation. ntaining proper welding wire extension and arc ch- aracteristics. -
Page 27: 6-5.Incomplete Fusion
5、Incomplete Fusion Incomplete Fusion: Failure of weld metal to fuse completely with base metal or a preceeding weld bead. Corrective Actions Possible Causes Remove all grease, oil,moisture,rust,paint,underco- Workpiece dirty ating,and dirt from work surface before welding. Select higher voltage range and/or adjust wire Insufficient heat input. -
Page 28: 6-6.Burn-Through
6、Burn-Through Bum-Through: Weld metal melting completely through base metal resulting in holes where no metal remains. Corrective Actions Possible Causes Select lower voltage range and reduce wire feed speed. Excessive heat input. Increase and/or maintain steady travel speed. Page.26... -
Page 29: 6-7.Waviness Of Bead
7、Waviness Of Bead Waviness Of Bead: Weld metal that is not parallel and does not cover joint formed by base metal. Corrective Actions Possible Causes Do not extend wire too far from nozzle. Welding wire extends too far out of nozzle. Support hand on solid surface or use two Unsteady hand hands. -
Page 30: 6-8.Distortion
8、Distortion Distortion: Contraction of weld metal during welding that forces base metal to move. Possible Causes Corrective Actions Use restraint(clamp)to hold base metal in position. Make tack welds along joint before starting welding operation. Excessive heat input. Select lower voltage range and/or reduce wire feed speed. -
Page 31: 6-9.Troubleshooting Guide For Semiautomatic Welding Equipment
9、Troubleshooting Guide For Semiautomatic Welding Equipment 1)Ch eck po wer sourc e. 1)Wi re fee d speed too hi gh. 1) Select low er wire fe ed sp ee d. 2)C onta ct tip da maged . 2)Rep lace con tact tip. 1)Insufficient shielding gas at welding arc. -
Page 32: Exploded View
Exploded View Circuit board Control transformer Output voltage/current adjustment A/C contactor Electromagnetic valve Main transformer Rectifier Left-side view Welding wire Wire feeder Reactor Rectifier Right-side view Page.30... -
Page 33: Electrical Diagram
Circuit Diagram 380V 3ph Page.31... - Page 34 Circuit Diagram 380V 1ph 220V 1ph NO.32...
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