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Summary of Contents for FY-TECH FYMIG270X
- Page 1 Instruction Manual FYMIG270X Our equipment is approved by the following car manufacturers(China)
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Page 2: Table Of Contents
CONTENTS 1. Safety Precautions Symbols 2. Symbols and Descriptions 3. Installation 3.1 Specifications 3.2 Duty Cycle and Overheating 3.3 Machine Installation 3.4 Selecting a Location 3.5 Installing Gas Supply 3.6 Connecting Input Power 3.7 Threading Welding Wire 3.8 Changing Drive Roll 3.9 Typical MIG Process Connection 3.10 Welding Gun Installation of Aluminum Welding Gun... -
Page 3: Safety Precautions Symbols
1. SAFETY PRECAUTIONS SYMBOLS To protect yourself and others from injury, read and follow these precautions before installation and operation. Electric shock can kill: Read instructions. 1. Do not touch live electrical parts. 1. Read the manual before using or 2. -
Page 4: Symbols And Descriptions
2. SYMBOLS AND DESCRIPTIONS Symbols and Definitions Gas Metal Arc Amperes Welding (GMAW) Percent Volts Wire Feed Increase Protective Earth Rated Welding Degree of Protection Line Connection (Ground) Current Power Rating, Products Single Phase No / Do Not Do This Loose Shield Cup of Voltage and Current Adjust Air/Gas... -
Page 5: Installation
3. INSTALLATION 3.1 Specifications FYMIG270X Model AC 380 Input Voltage Three Phase Frequency 50/60 (Hz) Rated Input Power 10.5 (KW) Rated Input Current Rated Output Current Output Voltage 15.2-35 No-load Voltage Welding Wire Diameter 0.6, 0.8, 0.9, 1.0 (mm) Duty Cycle... -
Page 6: Duty Cycle And Overheating
3. INSTALLATION 3.2 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 7: Machine Installation
3. INSTALLATION 3.3 Machine Installation 1. Open the package and find out the 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. -
Page 8: Selecting A Location
3. INSTALLATION 3.4 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 6mm2. 3. Do not move or operate unit where it could tip. 4. -
Page 9: Installing Gas Supply
3. INSTALLATION 3.5 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 (Make sure the surface is vertical while installing.) 5. -
Page 10: Connecting Input Power
3. INSTALLATION The power supply must have a ground connection. The welder must also be connected to circuit breaker. 3.6 Connecting Input Power 1. Input power cord (not less than 6mm copper cord). 2. Over-current protection. 3. Disconnect device line terminals. 4. -
Page 11: Threading Welding Wire
3. INSTALLATION 3.7 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 12: Changing Drive Roll
3. INSTALLATION 3.8 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. -
Page 13: Typical Mig Process Connection
3. INSTALLATION 3.9 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 14: Welding Gun
3. INSTALLATION 3.10 Welding Gun 1. Shield cup C012 2. Contact tip C004 3. Front adaptor C010 4. Gooseneck (15/24AK) C020/C018 5. Trigger 6. Spanner Page 12... -
Page 15: Installation Of Aluminum Welding Gun
11、Installation of Aluminum Welding Gun Loosen the fastening bolts of the bass tube Pull out the guide wire Tools :Cutter and hex wrench Install into welding gun Cut off the guide wire from the bottom of 3-5mm Cut off the extended part 11.3mm of the guide wire. Use cutter and hex wrench Loosen the fastening bolts of the bass tube Pull out the guide wire... -
Page 16: Operation
Operation 1. Data display screen 2. Data adjustment 3. Data type selector 4. Data indicator 5. A/B indicator 6. Welding material indicator and selector 7. Pulse/Standard mode indicator and selector 8. Wire diameter indicator and selector 9. Welding mode indicator and selector 10.Alarm Setting welding data instruction:... -
Page 17: Holding And Positioning Welding Gun
OPERATION 4.2 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 rest hand on workpiece 0°-15° 90° 90° End view of work angle Side view of gun angle GROOVE WELDS 0°-15°... -
Page 18: Conditions That Affect Weld Bead Shape
OPERATION 4.3 Conditions that Affect Weld Bead Shape 10° Push 10° Drag Perpendicular GUN ANGLES AND WELD BEAD PROFILES Long Short Normal ELECTRODE EXTENSIONS (STICKOUT) Long Short Normal FILLET WELD ELECTRODE EXTENSIONS (STICKOUT) Fast Slow Normal 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 19: Gun Movement During Welding
OPERATION 4.4 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 17... -
Page 20: Poor Weld Bead Characteristics
OPERATION 4.5 Poor Weld Bead Characteristics 1. Large Spatter Deposits 2. Rough, Uneven Bead 3. Slight Crater during Welding 4. Bad Overlap 5. Poor Penetration Page 18... -
Page 21: Good Weld Bead Characteristics
OPERATION 4.6 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 19... -
Page 22: Troubleshooting
5. TROUBLESHOOTING 5.1 Excessive Spatter Scattering of molten metal particles that cool to solid form near weld bead. Possible Causes Corrective Actions Wire feed too high Select lower wire feed speed Voltage too high Select lower voltage range Electrode extension (stickout) too long Use shorter electrode extension (stickout) Workpiece dirty Remove all grease, oil, moisture, rust paint... -
Page 23: Porosity
5. TROUBLESHOOTING 5.2 Porosity Small cavities or holes resulting from gas pockets in weld metal. Possible Causes Corrective Actions Insufficient shielding gas at welding arc Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc Remove spatter from gun nozzle Check gas hoses for leaks Adjust nozzle distance from workpiece Hold gun near bead at end of weld until... -
Page 24: Excess Penetration
5. TROUBLESHOOTING 5.3 Excessive Penetration Excessive Penetration Good Penetration Weld metal melting through base metal and hanging underneath weld. Possible Causes Corrective Actions Excessive heat input Select lower voltage range and reduce wire feed speed Increase travel speed Page 22... -
Page 25: Lack Of Penetration
5. TROUBLESHOOTING 5.4 Lack of Penetration Lack of Penetration Good Penetration Shall fusion between weld metal and base metal. Possible Causes Corrective Actions Improper joint preparation Material too thick. Joint preparation and design must provide access to bottom of groove while maintaining proper welding wire extension and arc characteristic Improper weld technique Maintain normal gun angle of 0 to 15 degrees... -
Page 26: Incomplete Fusion
5. TROUBLESHOOTING 5.5 Incomplete Fusion Failure of weld metal to fuse completely with base metal or a preceeding weld bead Possible Causes Corrective Actions Improper joint preparation Remove all grease, oil, moisture, rust paint under coating, and dirt from surface, before welding Improper weld technique Select higher voltage range and... -
Page 27: Burn Through
5. TROUBLESHOOTING 5.6 Burn Through Weld metal melting completely through base metal resulting in holes where no metal remains. Possible Causes Corrective Actions Excessive heat input Select lower voltage range and reduce wire feed speed Increase and/or maintain steady travel speed Page 25... -
Page 28: Waviness Of Bead
5. TROUBLESHOOTING 5.7 Waviness of Bead Weld metal that is not parallel and does not cover joint formed by base metal. Possible Causes Corrective Actions Welding wire extends too far out of nozzle Do not extend wire too far from nozzle Unsteady hand Support hand on solid surface or use two hands... -
Page 29: Distortion
5. TROUBLESHOOTING 5.8 Distortion Contraction of weld metal during welding that forces base metal to move. Possible Causes Corrective Actions Excessive heat input Use restraint (clamp) to hold base metal in position Make tack welds along joint before starting welding operation Select lower voltage range and/or reduce wire feed speed Increase travel speed... -
Page 30: Other Troubleshooting
5. TROUBLESHOOTING 5.9 Other Troubleshooting Problem Probable Cause Remedy Arc can not weld 1. Not enough power phase 1. Check power source Incomplete fusion 2. Too low welding voltage 2. Select higher voltage range No wire feed 1. Drive roll groove does not 1.
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