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SWP MULTIMIG 200 PRO Owner's Manual

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THANK YOU FOR USING OUR PRODUCTS
OPERATORS' MANUAL
MULTIMIG 200 PRO
Inverter Based Welding Machines
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.

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Summary of Contents for SWP MULTIMIG 200 PRO

  • Page 1 THANK YOU FOR USING OUR PRODUCTS OPERATORS’ MANUAL MULTIMIG 200 PRO Inverter Based Welding Machines 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...

  • Page 2: Table Of Contents

    CONTENT CONTENT §1 Safety ..............................1 §1.1 Symbols Explanation .......................... 1 §1.2 Machine Operating warnings! ......................1 §1.3 EMC device classification ........................7 §1.4 EMC measure ............................8 §1.5 Warning label ............................9 §2 Overview .............................. 10 §2.1 Features ..............................10 §2.2 Technical Data ............................
  • Page 3 CONTENT §4.3 Installation & Operation for MIG Welding ................. 44 §4.3.1 Set up installation for MIG Welding ...................... 44 §4.3.2 Wire Feed Roller Selection ........................46 §4.3.3 Wire Installation and Set-Up Guide....................... 47 §4.3.4 MIG Torch Liner Types and Information ..................... 49 §4.3.5 Torch &...

  • Page 4: Safety

    SAFETY §1 Safety Notice: The instructions are for reference only. The manufacturer reserves the right to explain the differences between the description and the product due to product changes and upgrades! 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.

  • Page 5: Electric Shock Can Kill

    SAFETY  After shutting off the machine power, please maintain and examine the equipment according to §7 because of the DC voltage existing in the electrolytic capacitors at the output of the power supply! 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.
  • Page 6 SAFETY 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 Smoke and gas generated whilst welding or cutting can be harmful to people’s health.
  • Page 7 SAFETY and that of your coworkers from the arc rays.  Protect other nearby personnel with suitable, non-flammable screening and /or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.
  • Page 8 SAFETY  When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.  Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside.

  • Page 9: Electric And Magnetic Fields

    SAFETY  Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.  Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use. Gas Cylinders.

  • Page 10: Noise Can Damage Hearing

    SAFETY  Route the electrode and work cables together – Secure them with tape when possible.  All cables should be put away and far from the operator.  Never coil the power cable around your body.  Make sure welding machine and power cable to be far away from the operator as far as possible according to the actual circumstance.

  • Page 11: Emc Measure

    SAFETY §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 12: Warning Label

    SAFETY §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.

  • Page 13: Overview

    OVERVIEW §2 Overview §2.1 Features  New panel design: More trendy and humanized.  LCD screen for accurate setting & feedback of welding output.  New PWM technology and IGBT inverter technology.  Active PFC technology for increased duty cycle and energy efficiency. ...

  • Page 14: Technical Data

    OVERVIEW §2.2 Technical Data Models MULTIMIG 200 PRO Parameters Input Voltage (V) 1-110±10% 1-230±10% Frequency (HZ) 50/60 Input Current (A) 37.0 34.9 35.4 38.3 39.9 27.4 21.7 21.9 28.6 31.4 Input Power (KW) Welding Current (A) 30~140 10~160 10~130 30~200...

  • Page 15: Duty Cycle And Over-Heat

    OVERVIEW perfect arc ignition every time and a remarkably smooth stable arc produces high quality TIG welds. TIG functionality includes adjustable Down Slope & Post Gas as well as being gas solenoid-valve equipped. The stick welding (MMA) capability delivers easy electrode welding with high quality results, including cast Iron, stainless and low hydrogen.

  • Page 16: Working Principle

    OVERVIEW panel. In that case, the machine should not be welding for 10~15 minutes to cool down with the fanrunning. When operating the machine again, the welding output current or the duty cycle should be reduced. §2.5 Working Principle The working principle of BT MIG series welding machine is shown as the following figure.
  • Page 17 OVERVIEW...

  • Page 18: Panel Functions & Descriptions

    PANEL FUNCTIONS & DESCRIPTIONS §3 Panel Functions & Descriptions §3.1 Machine Layout Description Front and rear panel layout of welding machine 1. Positive (+) welding power output connection socket. 2. Polarity change power connection. 3. MIG torch euro connector. 4. 9 core air socket 5.

  • Page 19: Layout For Control Panel

    PANEL FUNCTIONS & DESCRIPTIONS §3.2 Layout for Control panel §3.2.1 Control panel 1. Welding mode button: Press it to select Stick DC/ Stick AC/ TIG HF/ TIG Lift/ MIG Manual/ MIG Synergic welding mode. 2. Trigger mode button: Press it to select 2T or 4T trigger mode. 3.

  • Page 20: Mma Ac/Dc Display Introduction

    PANEL FUNCTIONS & DESCRIPTIONS §3.2.2 MMA AC/DC display introduction 1. Welding mode button: Press it to select Stick DC or Stick AC welding mode. 2. L parameter knob: Turn it to welding current. 3. R parameter knob: Press it to select Hot Start or Arc Force and turn it to adjust values.

  • Page 21: Tig Hf/Lift Display Introduction

    PANEL FUNCTIONS & DESCRIPTIONS §3.2.3 TIG HF/Lift display introduction 1. Welding mode button: Press it to enter TIG HF or TIG Lift welding mode. 2. Trigger mode button: Press it to select 2T or 4T trigger mode. 3. Function button: Press it to enter the function interface. 4.

  • Page 22: Function Interface

    PANEL FUNCTIONS & DESCRIPTIONS tungsten size, to prevent the tungsten overheating. Increased forward cycle bias will give the opposite effect, less cleaning effect, greater weld penetration and less heat in the tungsten. AC Frequency Only be available in AC welding mode. Increasing AC frequency will focus the shape of the arc, resulting in a tighter, more controlled arc causing increased penetration and less heated affected area for the same current setting.
  • Page 23 PANEL FUNCTIONS & DESCRIPTIONS 9. Pulse Frequency: 0.5~999Hz. (Only available in Pulse mode.) * 10. Duty Cycle: 5~95%. (Only available in Pulse mode.) * 11. Down Slope: 0~10s. 12. Post Current: 10~200A. 13. Post Flow: 0~10s. *Denotes more detailed explanation of function to follow. Further Controls Explained 2T Mode (3) The trigger is pulled and held on to activate the welding circuit, when the trigger is...
  • Page 24 PANEL FUNCTIONS & DESCRIPTIONS alternately; otherwise, output the setting value of welding current; (5) t3: Release the gun switch, the welding current will drop in accordance with the selected down-slope time. (6) t3～t4: The current drops to the minimum welding current from the setting current (I or I ), and then arc is turned off.

  • Page 25: Pulse Frequency

    PANEL FUNCTIONS & DESCRIPTIONS (5) t2～t3: The output current rises to the setting value (I or I ), the upslope time can be adjusted; (6) t3～t4: Welding process. During this period, the gun switch is loosen; Note: Select the pulsed output, the base current and welding current will be outputted alternately;...
  • Page 26 PANEL FUNCTIONS & DESCRIPTIONS Function interface of Spot weld: 1. Post Flow: 0.1~2s. 2. Welding current: 10~200A. 3. T time: 0.2~1s. 4. T time: 0~10s. 5. Post Flow: 0.1~10s. Spot Weld trigger mode: Spot weld Gun Switch Gas Supply Wire Feed Output Voltage Output Current Spot Weld Time...

  • Page 27: Mig Manual Display Introduction

    PANEL FUNCTIONS & DESCRIPTIONS §3.2.4 MIG Manual display introduction 1. Welding mode button: Press it to select MIG Manual welding mode. 2. Trigger mode button: Press it to select 2T or 4T trigger mode. 3. Function button: Press it to enter the function interface. 4.

  • Page 28: Mig Syn Display Introduction

    PANEL FUNCTIONS & DESCRIPTIONS 1. Trigger mode: 2T or 4T. 2. Burnback: 0~10. 3. Pre Flow: 0.1~10s. 4. Post Flow: 0.1~10s. 5. Slow Feed: 0~10. 6. Spool Gun: off/ on. Burnback Short-circuit between welding wire and molten pool leads to the increase of current, which leads to the melting speed of welding wire too fast, and the wire feeding speed cannot keep up with, which makes the welding wire and workpiece disconnected.
  • Page 29 PANEL FUNCTIONS & DESCRIPTIONS 1. Welding mode button: Press it to select MIG Manual welding mode. 2. Trigger mode button: Press it to select 2T or 4T trigger mode. 3. SYN system button: Press it to enter SYN item. Select wire material/ wire diameter and shield gas by using R parameter knob.
  • Page 30 PANEL FUNCTIONS & DESCRIPTIONS Function interface: 1. Trigger mode: 2T or 4T. 2. Burnback: 0~10. 3. Pre Flow: 0.1~10s. 4. Post Flow: 0.1~10s. 5. Slow Feed: 0~10.

  • Page 31: Job Display Introduction

    PANEL FUNCTIONS & DESCRIPTIONS §3.2.6 JOB display introduction 1. JOB button: Press it for 3s to enter JOB programs and press it for 1s to save parameters. 2. Parameters display: Here are all the selected parameter that you settings. 3. JOB number display. 4.

  • Page 32: Installation & Operation

    INSTALLATION & OPERATION §4 Installation & Operation §4.1 Installation & Operation for MMA Electrode Welding §4.1.1 Set-Up Installation Two sockets are available on this welding machine, One Positive (+) and one Negative (-) polarity, to connect MMA/Electrode holder cable and earth clamp cable. Various electrodes require different polarity for optimum results and careful attention should be paid to the polarity, refer to the electrode manufacturers information for the correct polarity.

  • Page 33: Mma/Stick Electrode Welding

    INSTALLATION & OPERATION (4) Place the electrode into the electrode holder and clamp tight. (5) Strike the electrode against the work piece to create and arc and hold the electrode steady to maintain the arc. §4.1.2 MMA/Stick Electrode Welding One of the most common types of arc welding is manual metal arc welding (MMA) or stick welding.

  • Page 34: Mma Welding Fundamentals

    INSTALLATION & OPERATION ● providing fluxing elements and deoxidizer ● creating a protective slag coating over the weld ● establishing arc characteristics ● adding alloying elements Stick electrodes serve many purposes in addition to filler metal to the molten pool. These additional functions are provided mainly by the various coverings on the electrode.
  • Page 35 INSTALLATION & OPERATION rounded profile will be deposited. Too high current is accompanied by overheating of the electrode resulting undercut and burning through of the base metal and producing excessive spatter. Normal current for a particular job may be considered as the maximum, which can be used without burning through the work, over-heating the electrode or producing a rough spattered surface.

  • Page 36: Installation & Operation For Tig Welding

    INSTALLATION & OPERATION mill scale, rust or any other material that will hinder the arc and contaminate the weld material. Joint preparation will depend on the method used include sawing, punching, shearing, machining, flame cutting and others. In all cases edges should be clean and free of any contaminates.
  • Page 37 INSTALLATION & OPERATION display. Set down slope time as required. The down slope time will show on the digital display. (12) Assemble front end parts of the TIG torch, fitting a sharpened tungsten suitable for the material to be welded. (13) Lay the outside edge of the cup on (14) With a small movement rotate the gas work piece with the tungsten Electrode...

  • Page 38: Dctig Welding

    INSTALLATION & OPERATION §4.2.2 DCTIG Welding The DC power source uses what is known as DC (direct current) in which the main electrical component, known as electrons, flow in only one direction from the negative terminal (-) to the positive terminal (+). In the DC electrical circuit there is an electrical principle at work which provides that, in a DC circuit, 70% of the energy (heat) is always on the positive side.

  • Page 39: Tig Welding Fusion Technique

    INSTALLATION & OPERATION Lift Arc is a form of arc ignition where the machine has voltage on the electrode to only a few volts, with a current limit of one or two amps (well below the limit that causes metal to transfer and contamination of the weld or electrode).
  • Page 40 INSTALLATION & OPERATION TIG Welding with Filler Wire Technique It is necessary in many situations with TIG welding to add a filler wire into the weld pool to build up weld reinforcement and create a strong weld. Once the arc is started the torch tungsten is held in place until a weld pool is created, a circular movement of the tungsten will assist is creating a weld pool of the desired size.

  • Page 41: Tungsten Electrodes

    INSTALLATION & OPERATION §4.2.4 Tungsten Electrodes Tungsten is a rare metallic element used for manufacturing TIG welding electrodes. The TIG process relies on tungsten’s hardness and high-temperature resistance to carry the welding current to the arc. Tungsten has the highest melting point of any metal, 3,410 degrees Celsius.
  • Page 42 INSTALLATION & OPERATION Ceriated (Orange) Ceriated tungsten electrodes (AWS classification EWCe-2) contain a minimum of 97.30 percent tungsten and 1.80 to 2.20 percent cerium and are referred to as 2% ceriated. Ceriated tungsten performs best in DC welding at low current settings. They have excellent arc starts at low amperages and become popular in such applications as orbital tube welding, thin sheet metal work.

  • Page 43: Tungsten Preparation

    INSTALLATION & OPERATION Tungsten Electrodes Rating for Welding Currents Tungsten DC Current Amps AC Current Amps AC Current Amps Diameter Torch Negative Un-Balanced Wave Balanced Wave 2% Thoriated 0.8% Zirconiated 0.8% Zirconiated 1.0mm 15-80 15-80 20-60 1.6mm 70-150 70-150 60-120 2.4mm 150-250 140-235...
  • Page 44 INSTALLATION & OPERATION Electrode Shape & Angle The shape of the tungsten electrode tip is an important process variable in precision arc welding. A good selection of tip/flat size will balance the need for several advantages. The bigger the flat, the more likely arc wander will occur and the more difficult it will be to arc start.

  • Page 45: Tig Torch Switch Controls

    INSTALLATION & OPERATION  Have a more consistent arc Tungsten Diameter at Constant Included Current Range Current Range Diameter the Tip - mm Angle - Degrees Amps Pulsed Amps 1.0mm .250 05 - 30 05 - 60 1.6mm .500 08 - 50 05 - 100 1.6mm .800...
  • Page 46 INSTALLATION & OPERATION Socket Pin Function Not connected Trigger Switch Input Trigger Switch Input Not connected 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...

  • Page 47: Installation & Operation For Mig Welding

    INSTALLATION & OPERATION §4.3 Installation & Operation for MIG Welding §4.3.1 Set up installation for MIG Welding (1) Insert the earth cable plug into the Negative (-) socket and twist to tighten. (2) Plug the MIG welding gun into MIG torch euro-connector on the front panel and tighten locking nut securely.
  • Page 48 INSTALLATION & OPERATION (8) Feed wire over drive roller into outlet guide wire tube, push wire through approximately 150mm. (9) Close down the top roller bracket and clip the pressure arm into place with a medium amount of pressure applied. (10) Carefully open the valve of the gas cylinder, set the required gas flow rate.

  • Page 49: Wire Feed Roller Selection

    INSTALLATION & OPERATION (18) Set the required welding parameters to suit the material thickness being welded. §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 weld. Feed rollers or drive rollers are used to feed the wire mechanically through the length of the welding gun cable.

  • Page 50: Wire Installation And Set-Up Guide

    INSTALLATION & OPERATION assist to drive it without too much pressure from the top roller. The down side to the knurled wire feed roller on flux cored wire is it will slowly over time bit by bit eat away at the surface of the welding wire, and these small pieces will eventually go down into the liner.
  • Page 51 INSTALLATION & 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 hole the wire to prevent the spool uncoiling. on the spool. Replace the spool retaining Carefully feed the wire into the inlet guide nut tightly.

  • Page 52: Mig Torch Liner Types And Information

    INSTALLATION & OPERATION (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 coil round in your hand without stopping and slipping at the drive rollers, increase the tension if it slips.
  • Page 53 INSTALLATION & OPERATION correct inside diameter and will assist in smooth feeding and prevention of the wire kinking and bird-nesting at the drive rollers. Also bending the cable too tightly during welding increases the friction between the liner and the welding wire making it more difficult to push the wire through the liner resulting in poor wire feeding, premature liner wear and bird-nesting.

  • Page 54: Torch & Wire Feed Set-Up For Aluminum Wire

    INSTALLATION & OPERATION a floating collet to allow the liner to be inserted all the way to the feed rollers. Teflon Liners Blue-0.6mm-0.8m Red - 0.9mm - 1.2mm Yellow - 1.6mm PA Liner Black-1.0mm-1.6m opper - Brass Neck Liners For high heat applications fitting brass or copper wound jumper or neck liner on the end of the liner at the neck end will increase the working temperature of the liner as well as improve the electrical conductivity of the welding power transfer to the wire.
  • Page 55 INSTALLATION & OPERATION exiting the contact tip. The 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 56 INSTALLATION & OPERATION and direction of the wire into the weld joint. Push technique directs the heat away from the weld puddle allowing faster travel speeds providing a flatter weld profile with light penetration - useful for welding thin materials. The welds are wider and flatter allowing for minimal clean-up and grinding time.
  • Page 57 INSTALLATION & OPERATION Angle 5°- 15° Not enough angle Angle more than 20° Good level of control over Less control over the weld Poor control, unstable arc, the weld pool, even flat pool more spatter. less penetration, lots of weld. spatter.
  • Page 58 INSTALLATION & OPERATION Normal stick out Too short Too long Even arc, good Unstable arc, spatter, Unstable arc, spatter, penetration even over heat contact tip. poor penetration and fusion, good finish. fusion. Travel Speed - Travel speed is the rate that the gun is moved along the weld joint and is usually measured in inches per minute (IPM).
  • Page 59 INSTALLATION & OPERATION 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 out of the weld pool producing a weld deposit of good quality.
  • Page 60 INSTALLATION & OPERATION Argon/CO Penetration Pattern for Steel Argon gas at 100% mixture is good for aluminum and silicone bronze applications. It offers good penetration and weld control. CO is not recommended for these metal alloys. Wire types and sizes - Use the correct wire type for the base metal being welded. Use stainless steel wire for stainless steel, aluminum for aluminum and steel wires for steel.

  • Page 61: Installation & Operation For Spool Gun

    INSTALLATION & OPERATION §4.4 Installation & Operation for Spool Gun §4.4.1 Set up installation for Spool Gun (1) Insert the earth cable plug into the negative (-) socket on the front of the machine and twist to tighten. (2) Plug the Spool Gun into the euro-connect socket on the front panel and tighten. IMPORTANT: When connecting the torch be sure to tighten the adaptor nut completely tight.

  • Page 62: Spool Gun Control

    INSTALLATION & OPERATION (8) Remove the spool cover by pressing (9) Place a spool of wire inside the button and lifting off the cover. spool holder on post. (11) Pull the trigger to drive the wire down (10) Feed the wire through the drive the neck until it exits the contact tip.
  • Page 63 INSTALLATION & OPERATION Gun switch Spool cover switch Adjust current button Remote Control Socket Socket Pin Function Spool gun motor Not connected 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.

  • Page 64: Welding Parameters

    INSTALLATION & OPERATION §4.5 Welding Parameters Process reference for CO butt welding of low carbon steel solid welding wire Process reference for CO corner welding of low carbon steel solid welding wire...

  • Page 65: Operation Environment

    INSTALLATION & OPERATION §4.6 Operation Environment ▲ Height above sea level ≤1000 M. ▲ Operation temperature range 14 ~ 104°F (-10 ~ +40°C). ▲ Air relative humidity is below 90%. ▲ Preferable site the machine some angles above the floor level does not exceed 15°. ▲...

  • Page 66: Diagram For Guns

    DIAGRAM FOR GUNS §5 Diagram for Guns §5.1 MIG Torch...
  • Page 67 DIAGRAM FOR GUNS Part No Description Pack AR0054 Euro Central Adaptor Boby BW0020 Gun Plug Nut BW0195 Back box hole 14 BW0265 Husing for handle BX0020 Tigger BX0024 Long Tigger BX0067 Microswitch BX0068 Microswitch EA0018 Screw EA0064 Screw EA0087 EA0128 O-ring EA0210 O-ring...

  • Page 68: Tig Torch

    DIAGRAM FOR GUNS §5.2 TIG Torch...
  • Page 69 DIAGRAM FOR GUNS...

  • Page 70: Spool Gun

    DIAGRAM FOR GUNS §5.3 Spool Gun...

  • Page 71: Welding Trouble Shooting

    WELDING TROUBLR SHOOTING §6 Welding Trouble Shooting §6.1 Troubleshooting  Before the welding machines are dispatched from the factory, they have already been tested and calibrated accurately. Do not change settings on the equipment!  Maintenance course must be operated carefully. If any wire becomes flexible or is misplaced, it maybe potential danger to user! ...
  • Page 72 WELDING TROUBLR SHOOTING The drive roll doesn’t fit with the Change the roll diameter of weld wire Wire reel damaged Change it Wire feed pipe is jammed Repair or change it Tip is jammed because of splash Repair or change it Output cable is connected incorrectly Screw it down or No striking arc and no output...

  • Page 73: Mig Welding - Trouble Shooting

    WELDING TROUBLR SHOOTING §6.2 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. Trouble Possible Reason Suggested Remedy Wire feed speed set too high Select lower wire feed speed...
  • Page 74 WELDING TROUBLR SHOOTING during welding maintain stick out of 5~10mm Welding voltage set too low Increase the voltage Wire Speed set too high Decrease the wire feed speed Remove materials like paint, grease, oil, Contaminated base metal and dirt, including mill scale from base metal Select a higher voltage range and /or Not enough heat input...

  • Page 75: Mig Wire Feed - Trouble Shooting

    WELDING TROUBLR SHOOTING §6.3 MIG Wire Feed - Trouble Shooting The following chart addresses some of the common WIRE FEED problems during MIG welding. In all cases of equipment malfunction, the manufacturer’s recommendations should be strictly adhered to and followed. Trouble Possible Reason Suggested Remedy...

  • Page 76: Dc Tig Welding - Trouble Shooting

    WELDING TROUBLR SHOOTING Too much tension on wire spool Reduce the spool hub brake tension Wire crossed over on the spool or Remove the spool untangle the wire or tangled replace the wire Use clean, dry, rust free wire. Do not Contaminated MIG wire lubricate the wire.
  • Page 77 WELDING TROUBLR SHOOTING metal Remove all grease, oil, or moisture Contaminated filler wire from filler metal Check the filler wire and change if Incorrect filler wire necessary Incorrect Gas Use pure Argon gas Yellowish residue / Set the gas flow between 20-40 CFH smoke on the Inadequate gas flow (10-20 l/min) flow rate...

  • Page 78: Mma Welding - Trouble Shooting

    WELDING TROUBLR SHOOTING §6.5 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 79 WELDING TROUBLR SHOOTING movement of base smaller electrode metal during Use the correct welding technique or welding Poor welding technique seek assistance for the correct technique Check the joint design and fit up, Poor joint preparation and or make sure the material is not too thick. joint design Seek assistance for the correct joint design and fit up...

  • Page 80: Maintenance & Troubleshooting

    MAINTENANCE & TROUBLESHOOTING §7 Maintenance & Troubleshooting §7.1 Maintenance The operator must understand the maintenance procedure of inverter welding machine and carry on simple examinations, cleanings and inspections. Do your best to protect the machine from contamination environment and leaving unit ON when not in use to lengthen service life of inverter arc welding machine.
  • Page 81 MAINTENANCE & TROUBLESHOOTING machine has the above problems, it should be fastened or changed. Observe whether the current output cable is damaged. If it is damaged, it should be insulated or changed. Using the dry compressed air to clear the inside of arc welding machine. Especially for clearing up the dusts on aluminium heat-sinks, inductors, IGBT Monthly modules, fast recover diodes, PCB’s, etc.

  • Page 82: List Of Error Codes

    MAINTENANCE & TROUBLESHOOTING §7.2 List of Error Codes Error Type Code Description Over-heating (1st thermal relay) Over-heating (2nd thermal relay) Thermal relay Over-heating (3rd thermal relay) Over-heating (4th thermal relay) Over-heating (Program default) Phase loss No gas Welding Under voltage machine Over voltage Over current...

  • Page 83: Electrical Schematic Drawing

    MAINTENANCE & TROUBLESHOOTING §7.3 Electrical Schematic Drawing...

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