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TOP GUN WELDING MULTIMIG 355F Operator's Manual

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INTRODUCTION
OPERATORS' MANUAL
MULTIMIG 355F/MULTIMIG 515F
INVERTER Based Welding Machine
IMPORTANT: Read this Owner's Manual Completely before attempting to use this
equipment. Save this manual and keep it handy for quick reference. Pay particular
attention to the safety instructions we have provided for your protection. Contact your
distributor if you do not fully understand this manual.
Ⅰ I

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  • Page 1 INTRODUCTION OPERATORS’ MANUAL MULTIMIG 355F/MULTIMIG 515F INVERTER Based Welding Machine IMPORTANT: Read this Owner’s Manual Completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. Contact your distributor if you do not fully understand this manual.

  • Page 2: Table Of Contents

    CONTENT CONTENT §1 Safety....................§1.1 Symbols Explanation ...................... §1.2 Machine Operating warnings! ..................§1.3 EMC device classification ....................§1.4 EMC measure........................§1.5 Warning label ........................§2 Overview ..................§2.1 Features ........................... §2.2 Technical Data ......................... §2.3 Brief Introduction ......................§2.4 Duty cycle and Over-heat ....................§2.5 Working Principle ......................
  • Page 3 CONTENT §4.1.2 MMA Welding ......................... §4.1.3 MMA Welding Fundamentals ....................§4.2 Installation & Operation for TIG Welding ..............§4.2.1 Set up installation for TIG Welding ..................§4.2.2 DC TIG Welding ........................§4.2.3 TIG Welding Fusion Technique ....................§4.2.4 Tungsten Electrodes ........................ §4.2.5 Tungsten Preparation .......................

  • Page 4: Safety

    SAFETY §1 Safety Welding and cutting equipment can be dangerous to both the operator and people in or near the surrounding working area, if the equipment is not correctly operated. Equipment must only be used under the strict and comprehensive observance of all relevant safety regulations.
  • Page 5 SAFETY ELECTRIC SHOCK CAN KILL. Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and internal machine circuits are also live when power is on. In Mig/Mag welding, the wire, drive rollers, wire feed housing, and all metal parts touching the welding wire are electrically live.
  • Page 6 SAFETY to two welders because voltage between the two can be the total of the open circuit voltage of both welders.  When working above the floor level, use a safety belt to protect yourself from a fall should you get an electric shock! FUMES AND GASES CAN BE DANGEROUS.
  • Page 7 SAFETY ARC RAYS: Harmful to people’s eyes and skin. Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin.  Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding.
  • Page 8 SAFETY WELDING SPARKS can cause fire or explosion. Welding on closed containers, such as tanks, drums, or pipes, can cause them to explode. Flying sparks from the welding arc, hot work piece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire.
  • Page 9 SAFETY chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail. Rotating parts may be dangerous.  Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used.
  • Page 10 SAFETY  Insure cylinders are held secure and upright to prevent tipping or falling over.  Never allow the welding electrode or earth clamp to touch the gas cylinder, do not drape welding cables over the cylinder.  Never weld on a pressurised gas cylinder, it will explode and kill you. Open the cylinder valve slowly and turn your face away from the cylinder outlet valve and gas regulator.

  • Page 11: Emc Device Classification

    SAFETY  Connect the work cable to the workpiece as close as possible to the area being welded.  The people with heart-pacemaker should be away from the welding area. Noise can damage hearing. Noise from some processes or equipment can damage hearing. You must protect your ears from loud noise to prevent permanent loss of hearing.

  • Page 12: Emc Measure

    SAFETY hanker welding machines belong to Class A. §1.4 EMC measure In the special situation, The specified area may be affected, the standard of radiation limit value has been complied with (eg: The device, which is easy effected by electromagnetism, is used at the installation location, or there is radio or TV near the installation location).

  • Page 13: Warning Label

    SAFETY  Shield the whole welding machine §1.5 Warning label The device with a warning label. Do not remove、 destroy or cover this label. These warnings are intended to avoid incorrect device operations that could result in serious personal injury or property damage. -10-...

  • Page 14: Overview

    OVERVIEW §2 Overview §2.1 Features  New PWM technology and IGBT inverter technology.  MIG/MAG with Pulse SYN/Dual pulse SYN/Manual and SYN function -Synergic programs for aluminum, mill steel, stainless steel and CuSi -JOB mode (Save and call 100 different job records) - 2T /4T/S4T/Spot Weld welding mode - function parameter adjustment...

  • Page 15: Technical Data

    OVERVIEW §2.2 Technical Data Models MULTIMIG 355F MULTIMIG 515F Parameters Input Voltage（V） 3~415±10% 3~415±10% Frequency (HZ) 50/60 50/60 Input Current（A） MIG 19 TIG 15 MMA 21 MIG 33 TIG 27.5 MMA 35 Input Power（KW） MIG 12.8 TIG 10 MMA 14 MIG 21.5 TIG 18 MMA 23...

  • Page 16: Duty Cycle And Over-Heat

    The letter “X” stands for Duty Cycle, Relation of welding current and duty cycle for which is defined as the portion of the time MULTIMIG 355F a welding machine can weld continuously with it’s rated output current within a certain time cycle (10 minutes).

  • Page 17: Working Principle

    OVERVIEW §2.5 Working Principle The working principle of MULTI-GMAW series welding machine is shown as the following figure. Three-phase 380V work frequency AC is rectified into DC（530V）, then is converted to medium frequency AC (about 20KHz) by inverter device (IGBT), after reducing voltage by medium transformer (the main transformer) and rectifying by medium frequency rectifier (fast recovery diodes), and is outputted by inductance filtering.

  • Page 18: Panel Functions & Descriptions

    OPERATION §3 Panel Functions & Descriptions §3.1 Machine Layout Description §3.1.1 Front and rear panel layout of welding machine 1. “-” Output terminal 2. Gas outlet 3. TIG gun control connector 4. “+” Output terminal 5. Gas Inlet 6. “+” Output terminal 7.

  • Page 19: Internal Panel Layout Of Wire Feeder

    OPERATION 9. Water outlet connector (red) §3.1.3 Internal panel layout of wire feeder 1. Spool holder assembly 2. Wire feed assembly §3.1.4 Front and rear panel layout of water cooling 1.Water inlet 2. Water Inlet connector (blue) 3. Water outlet connector (red) 4.

  • Page 20: Operating Process Of Wire Feeder

    OPERATION 10.Air check key 18. Material thickness 11. No water LED 19. Inductance LED 12. Spool Gun LED 20. voltage feedback LED 13. Alarm Led 21. The digital meter 14. JOB LED 22. Welding voltage LED 15. Welding current LED 23.
  • Page 21 OPERATION 4T mode Self Locking Function Gun Switch Gas Supply Wire Feed Output Voltage Output Current End Current conditions Welding conditions S4T mode Transition Time Gun Switch Burn back Time Gas Supply Wire Feed Output Voltage Output Current Initial conditions Welding conditions End Current conditions -18-...
  • Page 22 OPERATION Spot weld Gun Switch Gas Supply Wire Feed Output Voltage Output Current Spot Weld Time 3) Cooling mode selection (press the selector switch(3) to select, the corresponding indicator light) 4) Synergic programs selection by the adjustment knob（4），it will show on the digital meter （7），refer to§...

  • Page 23: Implicit Parameter Adjustment (Fn)

    OPERATION §3.2.3 Implicit parameter adjustment (Fn) 1) Implicit parameter menu and parameter adjustment method for import and export Press the function key （3） ， the indicator  light that into the implicit function parameter adjusting mode.  Select the parameter code that needs to be modified by the knob （...

  • Page 24: Job Mode

    OPERATION §3.2.4 JOB mode In the JOB mode, 100 different JOB records can be stored and called , improve the quality of welding process. Save the JOB programs Welding machine before leaving the factory did not save the JOB programs, to be called before, you must first save the JOB programs ...

  • Page 25: Mma Function - Front Panel Description

    OPERATION setting is changed. To reset the voltage for a synergic program back to factory default, change to another program and back again The synergic programs are given a number from 1-23, this is accessed on the L display (21) using the L knob (1), indicator 'P'.
  • Page 26 OPERATION 8. Air Check Select 9. Current/ Wire Speed / Material Thickness Display 10. Programs Numbers/ Voltage/ Arc length/ Inductance Display MIG-MAG Manual Function 1. Voltage/ Inductance Set 2. Material thickness /Current/ Wire Speed Set 3. MIG-MAG Manual Function Select 4.

  • Page 27: Installation & Operation

    OPERATION §4 Installation & Operation §4.1 Installation & Operation for MMA Welding §4.1.1 Set up installation for MMA Welding (1) Connection of Output Cables Connection of Output Cables Two sockets are available on this welding machine. For MMA welding the electrode holder is shown be connected to the positive socket, while the earth lead (work piece) is connected to the negative socket, this is known as DCEP.

  • Page 28: Mma Welding

    OPERATION (5) Place the electrode into the electrode holder and clamp tight. (6) Strike the electrode against the work piece to create and arc and hold the electrode steady to maintain the arc. §4.1.2 MMA Welding One of the most common types of arc welding is manual metal arc welding (MMA) or stick welding.

  • Page 29: Mma Welding Fundamentals

    OPERATION Manual metal arc ( stick) electrodes have a solid metal wire core and a flux coating. These electrodes are identified by the wire diameter and by a series of letters and numbers. The letters and numbers identify the metal alloy and the intended use of the electrode.
  • Page 30 OPERATION Electrode Size The size of the electrode generally depends on AverageThickness MaximumRecommended the thickness of the section being welded, and of Material Electrode Diameter the thicker the section the larger the electrode 1.0-2.0 mm 2.5 mm required. The table gives the maximum size of 2.0-5.0 mm 3.2 mm electrodes that maybe used for various...

  • Page 31: Installation & Operation For Tig Welding

    OPERATION Electrode Angle The angle that the electrode makes with the work is important to ensure a smooth, even transfer of metal. When welding in down hand, fillet, horizontal or overhead the angle of the electrode is generally between 5and 15 degrees towards the direction of travel. When vertical up welding the angle of the electrode should be between 80 and 90 degrees to the work piece.
  • Page 32 OPERATION (8) Connect the gas line to the machine inlet gas connector via the quick push lock connector located on the rear panel. Check for Leaks! (9) Connect the power cable of welding machine with the output switch in electric box on site. NOTE: Air cooling mode without cooling device，and the water pipe is not needed for the air cooling mode.
  • Page 33 OPERATION (10) Carefully open the valve of the gas (11) Select TIG function using the key. cylinder, set the required gas flow rate. (12) Select 2T, 4T Trigger as required using (13) Select gas / water cooling mode . the key. LIFT ARC DC TIG Operation Lift Arc ignition allows the arc to be started easily in DC TIG by simply touching the tungsten to the work piece and lifting it up to start the arc.
  • Page 34 OPERATION 2mm from the work piece. Press and hold the torch switch to activate to gas flow and welding power. (17) With a small movement rotate the Gas Cup forward so that the Tungsten Electrode touches the work piece. (18) Now rotate the Gas Cup in the reverse direction to lift the Tungsten electrode from the work piece to create the arc.

  • Page 35: Dc Tig Welding

    OPERATION (18) Now rotate the Gas Cup in the reverse (19) Release the trigger to stop the welding. direction to lift the Tungsten electrode from the work piece to create the arc. IMPORTANT! - We strongly recommend that you check for gas leaks prior to operation of your machine.
  • Page 36 OPERATION the TIG arc and can be as hot as 19,000°C. It is a very pure and concentrated arc which provides the controlled melting of most metals into a weld pool. TIG welding offers the user the greatest amount of flexibility to weld the widest range of material and thickness and types. DC TIG welding is also the cleanest weld with no sparks or spatter.

  • Page 37: Tig Welding Fusion Technique

    OPERATION §4.2.3 TIG Welding Fusion Technique Manual TIG welding is often considered the most difficult of all the welding processes. Because the welder must maintain a short arc length, great care and skill are required to prevent contact between the electrode and the work piece. Similar to Oxygen Acetylene torch welding, Tig welding normally requires two hands and in most instances requires the welder to manually feed a filler wire into the weld pool with one hand while manipulating the welding torch in the other.

  • Page 38: Tungsten Electrodes

    OPERATION joint. The filler metal is introduced to the leading edge of the weld pool. The filler wire is usually held at about a 15° angle and fed into the leading edge of the molten pool, the arc will melt the filler wire into the weld pool as the torch is moved forward. Also a dabbing technique can be used to control the amount of filler wire added, the wire is fed into the molten pool and retracted in a repeating sequence as the torch is moved slowly and evenly forward.
  • Page 39 OPERATION however is a low-level radioactive hazard and many users have switched to other alternatives. Regarding the radioactivity, thorium is an alpha emitter but when it is enclosed in a tungsten matrix the risks are negligible. Thoriated tungsten should not get in contact with open cuts or wounds.
  • Page 40 OPERATION Lanthanated (Color Code: Gold) Lanthanated tungsten electrodes (AWS classification EWLa-1.5) contain a minimum of 97.80 percent tungsten and 1.30percent to 1.70 percent lanthanum, and are known as 1.5 percent lanthanated. These electrodes have excellent arc starting, a low burn off rate, good arc stability, and excellent re-ignition characteristics.

  • Page 41: Tungsten Preparation

    OPERATION §4.2.5 Tungsten Preparation Always use DIAMOND wheels when grinding and cutting. While tungsten is a very hard material, the surface of a diamond wheel is harder, and this makes for smooth grinding. Grinding without diamond wheels, such as aluminium oxide wheels, can lead to jagged edges, imperfections, or poor surface finishes not visible to the eye that will contribute to weld inconsistency and weld defects.
  • Page 42 OPERATION Electrode Included Angle/Taper - DC Welding Tungsten electrodes for DC welding should be ground longitudinally and concentrically with diamond wheels to a specific included angle in conjunction with the tip/flat preparation. Different angles produce different arc shapes and offer different weld penetration capabilities. In general, blunter electrodes that have a larger included angle provide the following benefits：...

  • Page 43: Gun Switch Control Current

    OPERATION §4.2.6 Gun switch control current UP/DOWN GUN Adjust current button, when it’s pushed up, the current increase, when it’s pushed down, the current decrease. Gun switch Remote Control Socket Socket Pin Function Not connected Not connected Not connected Not connected Not connected The button of "UP"...
  • Page 44 OPERATION REMOTE GUN Adjust current roller wheel, when it’s roll upwards, the current increase, when it’s roll downwards, the current decrease. Gun switch Remote Control Socket Socket Pin Function Not connected Not connected 10k ohm (maximum) connection to 10k ohm remote control potentiometer Wiper arm connection to 10k ohm remote control potentiometer Zero ohm (minimum) connection to 10k ohm remote control potentiometer Not connected...

  • Page 45: Pedal Switch Control

    OPERATION §4.2.7 Pedal switch control ● When plug the twelve-lead aero-socket of pedal switch in it. Welder will identify the pedal switch, the welding current knob on the front panel will can’t use，and only 2T can be selected. ● When use the adjustment knob of max-welding current beside the pedal ,can set the max-current you want.

  • Page 46: Installation & Operation For Mig Welding

    OPERATION Socket Pin Function Be shorted with 2 Be shorted with 1 20k ohm (maximum) connection to 20k ohm remote control potentiometer Wiper arm connection to 20k ohm remote control potentiometer Zero ohm (minimum) connection to 20k ohm remote control potentiometer Not connected Not connected Trigger Switch Input...
  • Page 47 OPERATION (9) Connect the control cable of cooling water with the aero socket on the rear panel of welding machine. (10) Connect the power cable of welding machine with the output switch in electric box on site. -44-...
  • Page 48 OPERATION NOTE: Air cooling mode without cooling device，and the water pipe is not needed for the air cooling mode. (11) Place the Wire Spool onto the Spool Holder. Snip the wire from the spool being sure to hold the wire to prevent rapid uncoiling. Feed the wire into the wire feeder inlet guide tube through to the drive roller.
  • Page 49 OPERATION (11) Place wire onto spool holder - (spool retaining (12) Feed wire over the drive roller into nut is left hand thread ) Feed the wire through the the outlet guide tube, Push the wire inlet guide tube on to the drive roller. through approx 150mm.
  • Page 50 OPERATION (17) Fit the gas nozzle to the torch head. (18) Carefully open the gas cylinder valve and set the required gas flow rate. (19) Select torch switch mode 2T/ 4T (20) Select your preferred MIG-MAG /Spot Weld function. (20) Select program number using the knob , (21) Select the required welding parameters it will show on the digital meter .

  • Page 51: Wire Feed Roller Selection

    OPERATION §4.3.2 Wire Feed Roller Selection The importance of smooth consistent wire feeding during MIG welding cannot be emphasized enough. Simply put the smoother the wire feed then the better the welding will be. Feed rollers or drive rollers are used to feed the wire mechanically along the length of the welding gun.

  • Page 52: Wire Installation And Set Up Guide

    OPERATION particles coming of the wire surface. However it is considered that the knurled roller will give a more positive feed of flux core wire without any deformation of the wire shape. §4.3.3 Wire Installation and Set Up Guide Again the importance of smooth consistent wire feeding during MIG welding cannot be emphasized enough.
  • Page 53 OPERATION (3) Fit the wire spool onto the spool holder (4) Snip the wire carefully, be sure to hold fitting the locating pin into the location holeon the wire to prevent the spool uncoiling. the spool. Replace the spool retaining nut tightly. Carefully feed the wire into the inlet guide tube of the wire feed unit.
  • Page 54 OPERATION (7) Check that the wire passes through the centre of the outlet guide tube without touching the sides. Loosen the locking screw and then loosen the outlet guide tube retaining nut too make adjustment if required. Carefully retighten the locking nut and screw to hold the new position. (8) A simple check for the correct drive tension is to bend the end of the wire over hold it about 100mm from your hand and let it run into your hand, it should...

  • Page 55: Mig Torch Liner Installation

    OPERATION §4.3.4 MIG Torch Liner Installation (1) Lay the torch out straight on the ground and remove the front end parts. (2) Remove the liner retaining nut. (3) Carefully pull the liner out of the torch cable assembly. (4) Select the correct new liner and carefully unravel avoiding putting any kinks in the liner, if you kink the liner it will make it no good and will require replacement.

  • Page 56: Mig Torch Liner Types And Information

    OPERATION (3) Carefully pull out and completely remove (4) Carefully unravel the new liner the liner. (5) Carefully feed in the new liner down the torch (6) Fit the liner retaining nut and screw lead all the way to exit the torch neck. only 1/2 way down.
  • Page 57 OPERATION Steel Liners Most MIG gun liners are made from coiled steel wire also known as piano wire, which provides the liner with good rigidity and flexibility and allows it to guide the welding wire smoothly through the welding cable as it bends and flex during operational use. Steel liners are primarily used for feeding of solid steel wires, other wires such as Aluminium, Silicon Bronze etc will perform better using a teflon or Polyamide line.

  • Page 58: Torch & Wire Feed Set Up For Aluminium Wire

    OPERATION with a variety of wire types such as silicon bronze, stainless steel as well as aluminium. A note of caution to careful inspect the end of the welding wire prior to feeding it down the liner. Sharp edges and burrs can score the inside of the liner and lead to blockages and accelerated wear. Polyamide Liners (PA) are made of carbon infused nylon and are ideal for softer aluminum, copper alloy welding wires and push pull torch applications.
  • Page 59 OPERATION (8) Place the tip holder over the end of the liner and screw into the torch neck nipping it up tight. (9) Connect the torch to the machine tighten and secure the torch euro connector to the machine euro connection. (10) Install a U groove drive roller of the correct size to match the wire diameter being used.
  • Page 60 OPERATION (5) Carefully feed in the new liner in short forward (6) Fit the liner collet, liner O-ring and movements down the torch lead all the way to exit liner retaining nut. the torch neck. Be care-full not to kink the liner. (6) Push the liner firmly into the torch lead (7) Snip the liner off 3mm past the end and tighten the liner retaining nut.

  • Page 61: Set Up Installation For Spool Gun

    OPERATION (13) Fit an Aluminium contact tip of the correct (14) Fit the remaining front end parts to size to match the wire diameter being used. the torch neck ready for welding. §4.3.7 Set up installation for Spool Gun (1) Insert the earth cable plug into the Negative socket on the front of the machine and tighten it. (2) Connect the Spool Gun to the Mig torch connection socket on the front panel of the wire feeder, and tighten it.
  • Page 62 OPERATION (9) Select Spool Gun using the Function key and Adjustment knobs. (10) Take the Spool Gun and remove the spool cover . (11) Place the Wire Spool onto the Spool Holder - Hold and snip the wire from the spool being sure to hold the wire to prevent rapid uncoiling.

  • Page 63: Mig Welding

    OPERATION (12) Feed the wire through the drive roller into (13) Pull the trigger to drive the wire through the inlet guide tube. Swing back and clip down the neck until it exits the contact tip holder. the wire tension swing arm (15) Carefully open the gas cylinder valve (16) Set welding parameters using the knobs.
  • Page 64 OPERATION wire touches the work piece and causes a short circuit the wire heats up and begins to form a molten bead, the bead separates from the end of the wire and forms a droplet that is transferred into the weld pool. This process is repeated about 100 times per second, making the arc appear constant to the human eye.
  • Page 65 OPERATION The wire approaches the work The wire cannot support all The current flow creates a piece and touches the work the current flow, resistance magnetic field that begins creating a short circuit between builds up and the wire to pinch the melting wire the wire and the base metal, becomes hot and weak and forming it into droplet.
  • Page 66 OPERATION the wire is directed at the base metal, the angle and travel direction chosen. Travel speed and work angle will determine the characteristic of the weld bead profile and degree of weld penetration Push Technique - The wire is located at the leading edge of the weld pool and pushed towards the un-melted work surface.
  • Page 67 OPERATION Travel Angle - Travel angle is the right to left angle relative to the direction of welding. A travel angle of 5°- 15° is ideal and produces a good level of control over the weld pool. A travel angle greater that 20°...
  • Page 68 OPERATION spatter and over heat the contact tip. Too long stick out will cause an unstable arc, lack of penetration, lack of fusion and increase spatter. Normal stick out Too short Too long Even arc, good Unstable arc, spatter, Unstable arc, spatter, penetration even over heat contact tip.
  • Page 69 OPERATION base metal. This produces a wider weld bead with more deposited weld metal per mm than is required resulting in a weld deposit of poor quality. Too Slow Travel Speed large wide bead porosity lack of fusion cold lap lack of joint penetration Correct Travel Speed - The correct travel speed keeps the arc at the leading edge of the weld pool allowing the base metal to melt sufficiently to create good penetration, fusion and wetting...
  • Page 70 OPERATION WELDING WIRE DIAMETER CHART MATERIALTHICKNESS RECOMMENDED WIRE DIAMETERS 0.8mm 0.9mm 1.0mm 1.2mm 1.6mm 2.0mm 2.5mm 3.0mm 4.0mm 5.0mm 6.0mm 8.0mm 10mm 14mm 18mm 22mm For material thickness of 5.0mm and greater, multi-pass runs or a beveled joint design may be required depending on the amperage capability of your machine.

  • Page 71: Mig Torch /Spool Gun Control

    OPERATION Argon Co2 Penetration Pattern for Steel §4.3.9 MIG Torch /Spool Gun control Spool Gun Gun switch Spool cover switch Adjust current button Remote Control Socket Socket Pin Function Spool gun motor Not connected -68-...

  • Page 72: Standard Welding Programs

    OPERATION Not connected Spool gun motor 10k ohm (maximum) connection to 10k ohm remote control potentiometer. Zero ohm (minimum) connection to 10k ohm remote control potentiometer. Wiper arm connection to 10k ohm remote control potentiometer. Not connected Not connected §4.4 Standard welding programs DISPLAY FUNCTION PRE GAS...
  • Page 73 OPERATION Process reference for CO2 corner welding of low carbon steel solid welding wire Material Wire Welding Welding Welding Gas-flow thickness diameter current voltage speed rate (MM) (MM) (CM/MIN) (L/MIN) 70-80 17-18 50-60 10-15 85-90 18-19 50-60 10-15 1.0/1.2 100-110 18-19.5 50-60 10-15...

  • Page 74: Operation Environment

    OPERATION Welding process of aluminum alloy pulse MIG Material Wire Welding Welding Welding Nozzle and Gas-flow Welding thickness diameter current voltage speed workpiece rate position (MM) (MM) (CM/MIN) spacing(MM) (L/MIN) 60-80 16-18 60-80 12-15 15-20 70-80 17-18 40-50 15-20 80-100 17-20 40-50 14-17...

  • Page 75: Operation Notices

    OPERATION §4.7 Operation Notices ▲ Read Section §1 carefully before starting to use this equipment. ▲Connect the ground wire with the machine directly. ▲ Ensure that the input is three-phase: 50/60Hz, 380V ±10%. ▲Before operation, none concerned people should not be around the working area and especially children.

  • Page 76: Welding Trouble Shooting

    THANK YOU FOR USING OUR PRODUCTS §5 Welding trouble shooting §5.1 MIG welding trouble shooting The following chart addresses some of the common problems of MIG welding. In all cases of equipment malfunction, the manufacturer’s recommendations should be strictly adhered to and followed.
  • Page 77 THANK YOU FOR USING OUR PRODUCTS Check that the correct gas is Wrong gas being used Check the gas is connected, check hoses, gas valve and torch are not restricted. Set the gas flow Inadequate gas flow or too much between 10 - 15 l/min flow rate.

  • Page 78: Mig Wire Feed Trouble Shooting

    THANK YOU FOR USING OUR PRODUCTS Excessive Penetration − Select a lower voltage range weld metal Too much heat and /or adjust the wire speed to melting through suit Increase travel speed base metal Material too thick. Joint preparation and design needs to allow access to bottom of groove while maintaining proper welding wire extension and arc...

  • Page 79: Dc Tig Welding Trouble Shooting

    THANK YOU FOR USING OUR PRODUCTS Be sure to adjust the wire feed and voltage dials for MIG welding. The Adjusting wrong dial amperage dial is for MMA and TIG welding mode Select the correct polarity for the wire Wrong polarity selected being used - see machine setup guide Incorrect wire speed setting Adjust the wire feed speed...
  • Page 80 THANK YOU FOR USING OUR PRODUCTS Trouble Possible Reason Suggested Remedy Use pure Argon. Check cylinder has Incorrect Gas or No Gas gas, connected, turned on and torch valve is open Check the gas is connected, check Inadequate gas flow hoses, gas valve and torch are not restricted.
  • Page 81 THANK YOU FOR USING OUR PRODUCTS Connect the torch to the DC- output Torch connected to DC + terminal Remove materials like paint, grease, Contaminated base metal oil, and dirt, including mill scale Unstable Arc from base metal. during DC welding Remove 10mm of contaminated Tungsten is contaminated tungsten and re grind the tungsten...

  • Page 82: Mma Welding Trouble Shooting

    THANK YOU FOR USING OUR PRODUCTS §5.4 MMA welding trouble shooting The following chart addresses some of the common problems of MMA welding. In all cases of equipment malfunction, the manufacturer’s recommendations should be strictly adhered to and followed. Trouble Possible Reason Suggested Remedy Check earth lead is connected.
  • Page 83 THANK YOU FOR USING OUR PRODUCTS Uneven weld Unsteady hand, wavering Use two hands where possible to appearance hand steady up, practise your technique Reduce the amperage or use a Excessive heat input smaller electrode Use the correct welding technique or Distortion −...

  • Page 84: Maintenance & Troubleshooting

    THANK YOU FOR USING OUR PRODUCTS §6 Maintenance & Troubleshooting §6.1 Maintenance In order to guarantee safe and proper operation of welding machines, they must be maintained regularly. Let customers understand the maintenance procedure of welding machines. Enable customers to carry on simple examination and inspections. Do your best to reduce the fault rate and repair times of welding machines to lengthen service life of arc welding machine.

  • Page 85: Troubleshooting

    THANK YOU FOR USING OUR PRODUCTS Using the dry compressed air to clear the inside of arc welding machine. Especially for clearing up the dusts on radiator, main voltage transformer, Monthly inductors, IGBT modules, fast recover diodes, PCB’s, etc. examinati Check the screws and bolts in the machine.
  • Page 86 THANK YOU FOR USING OUR PRODUCTS Troubles Reasons Solution Breaker damaged Change it Close the breaker, but Fuse damaged Change it the power light isn’t on Input power damaged Change it After welding machine Fan damaged Change it is over-heat, the fan The cable is loose Screw the cable tight doesn’t work...

  • Page 87: List Of Error Code

    THANK YOU FOR USING OUR PRODUCTS §6.3 List of error code Error Type Error code Description Lamp status Yellow lamp(thermal Over-heating(1st thermal relay) protection) always on Yellow lamp(thermal Over-heating(2nd thermal relay) protection) always on Yellow lamp(thermal Thermal relay Over-heating(3rd thermal relay) protection) always on Yellow lamp(thermal Over-heating(4th thermal relay)

  • Page 88: Electrical Schematic Drawing

    THANK YOU FOR USING OUR PRODUCTS §6.4 Electrical schematic drawing -85-...

This manual is also suitable for:

Multimig 515f

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