SWP Stealth Cobra MIG DP 5006 Operator's Manual
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SWP Stealth Cobra MIG DP 5006 Operator's Manual

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OPERATOR'S MANUAL
MIG DP 5006 INVERTER
Part No. 9114H
IMPORTANT
Read this Operator'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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  • Page 1 OPERATOR’S MANUAL MIG DP 5006 INVERTER Part No. 9114H IMPORTANT Read this Operator’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 §2 Overview ························································································································ 9 §2.1 Features ······························································································································· 9 §2.2 Brief Introduction ·············································································································10 §2.3 Technical Data ···················································································································11 §2.4 Duty cycle and Over-heat··································································································12 §2.5 Working Principle ·············································································································12 §2.6 Volt-Ampere Characteristic ······························································································13 §3 Panel Functions & Descriptions ·················································································· 14 §3.1 Machine Layout Description ····························································································14 §3.1.1 Front and rear panel layout of welding machine ···································································...
  • Page 3 CONTENT §4.3 Installation & Operation for MIG Welding·······································································45 §4.3.1 Set up installation for MIG Welding························································································ 45 §4.3.2 Wire Feed Roller Selection ····································································································· 48 §4.3.3 Wire Installation and Set Up Guide ························································································ 49 §4.3.4 MIG Torch Liner Types and Information ················································································ 52 §4.3.5 MIG Welding ····························································································································...

  • 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! The device is manufactured using state-of-the-art technology and according to recognised safety standards. If used incorrectly or misused, however, it can cause: ...
  • Page 5 SAFETY Excessive ambient temperature will cause the machine heat dissipation is not smooth, so that the internal components of the machine heat seriously. Usually the maximum operating temperature is 104°F (40°C). Low temperature may lead to performance degradation or damage of components inside the product, resulting in ice inside the water tank.
  • Page 6 SAFETY Many harmful phenomena, such as noise, bright light and harmful gas, will inevitably occur in the welding process. In order to avoid harmful By product phenomena causing harm to the human body, it is necessary to make corresponding preparations in advance. Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin.
  • Page 7 SAFETY Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.  Do not breathe the smoke and gas generated whilst welding or cutting, keep your head out of the fumes. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone.
  • Page 8 SAFETY 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.  Welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
  • Page 9 SAFETY cylinder outlet valve and gas regulator. 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. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.
  • Page 10 SAFETY maintenance. Don’t sling cables or leads around either the body or parts of the body. The electrode (rod electrode, tungsten electrode, welding wire, etc) must  Never be immersed.  Never be touched when current is flowing. When the machine is connected to the power supply, there is electricity inside the machine.
  • Page 11 SAFETY  Shield off entire welding installation. Radiation Class A Device.  Only can be used in the industrial area.  If it is used in other area, it may cause connection and radiation problems of circuit. Radiation Class B device. ...

  • Page 12: Overview

    OVERVIEW §2 Overview §2.1 Features  New appearance and new panel design: More trendy and humanized.  LCD screen for accurate setting & feedback of welding output.  New PWM technology and IGBT inverter technology.  MIG/MAG with Pulse SYN/ Dual pulse SYN/ Manual function: -Synergic programs for aluminum, mill steel, stainless steel and CuSi -JOB mode (Save and call 10 different job records) - 2T/4T/S4T/ Spot Weld welding mode...

  • Page 13: Brief Introduction

    OVERVIEW §2.2 Brief Introduction BT MIGDP series of welding machines adopts the latest Pulse Width Modulation (PWM) technology and the Insulated Gate Bipolar Transistor (IGBT) power modules. It uses switching frequencies in the 20KHz~50KHz range so as to replace the traditional line-frequency transformer type welding machines.

  • Page 14: Technical Data

    OVERVIEW §2.3 Technical Data Models BT MIGDP 5006 Parameters Input Voltage (V) 3-400±10% Frequency (HZ) 50/60 Input Current (A) 40.5 41.5 Input Power (kVA) 28.1 22.8 28.9 Welding Current (A) 20~500 10~500 10~500 No-load Voltage (V) 60% 500A Duty cycle (40°C) 100% 410A PULSE CuSi3: 1.0/1.2...

  • Page 15: Duty Cycle And Over-Heat

    OVERVIEW §2.4 Duty cycle and Over-heat The letter “X” stands for Duty Cycle, which The relation of the welding current is defined as the portion of the time a and duty cycle for BT MIGDP 5006 welding machine can weld continuously with its rated output current within a certain time cycle (10 minutes).

  • Page 16: Volt-Ampere Characteristic

    OVERVIEW §2.6 Volt-Ampere Characteristic BT MIGDP series of welding machines has an excellent volt-ampere characteristic, whose graph is shown as the following figure. The relation between the rated loading voltage U and welding current I is as follows: U =14+0.05I (V).

  • Page 17: Panel Functions & Descriptions

    PANEL FUNCTIONS & DESCRIPTIONS §3 Panel Functions & Descriptions §3.1 Machine Layout Description §3.1.1 Front and rear panel layout of welding machine 1. TIG gun control connector. 2. Positive (+) welding power output connection socket. 3. TIG torch gas connector. 4.

  • Page 18: Front And Rear Panel Layout Of Water Cooling

    PANEL FUNCTIONS & DESCRIPTIONS §3.1.2 Front and rear panel layout of water cooling Water level calibration.* * Intake: From here, water or coolant, antifreeze, etc. can be injected into tank. Backwater inlet for TIG (red).* * Water outlet for TIG (blue).* * Water outlet for MIG (blue).* * Backwater inlet for MIG (red).* * Water cooling control connector.* *...

  • Page 19: Control Connector

    PANEL FUNCTIONS & DESCRIPTIONS Inlet (3) and outlet (4) for TIG The two nozzles on the same side of the intake (2) are used for TIG operation and can be connected to the nozzles on TIG welding torch. Blue corresponds to the outlet: cold water is delivered from the tank;...

  • Page 20: Front Panel Functions And Descriptions

    PANEL FUNCTIONS & DESCRIPTIONS 11. Wire feed tension adjustment. 12. Wire feed tension arm (2x). 13. Wire feeder inlet guide. 14. Wire drive roller (2x). §3.2 Front Panel Functions and Descriptions §3.2.1 MMA control panel 1. Welding mode button: Press it to enter MMA welding mode. 2.

  • Page 21: Lift Tig Control Panel

    PANEL FUNCTIONS & DESCRIPTIONS too low. The higher the arc force adjustment, the higher the minimum voltage that the power source will allow. This effect will also cause the welding current to increase. 0 is Arc Force off, 10 is maximum Arc Force. This is practically useful for electrode types that have a higher operating voltage requirement or joint types that require a short arc length such as out of position welds.
  • Page 22 PANEL FUNCTIONS & DESCRIPTIONS 1. Mode: Trigger mode: 2T/4T. 2. Down slope time: 0~10s. 3. Post flow time: 0~10s.  2T Mode The trigger is pulled and held on to activate the welding circuit, when the trigger is released, the welding circuit stops. This function without the adjustment of start current and crater current is suitable for the Re-tack welding、transient welding、thin plate welding and so on.
  • Page 23 PANEL FUNCTIONS & DESCRIPTIONS (7) t4～t5: Post-gas time, after the arc is turned off. You can adjust it (0.0~10s) through turnning the knob on the front panel. (8) t5: Electromagnetic gas valve turned off, the shield gas stops to flow, and welding is finished.

  • Page 24: Mig Manual Control Panel

    PANEL FUNCTIONS & DESCRIPTIONS (7) t4: Press the torch switch again, the welding current will drop in accordance with the selected down-slope time. (8) t4～t5: The output current slopes down to the crater current. The downslope time can be adjusted; (9) t5～t6: The crater current time;...
  • Page 25 PANEL FUNCTIONS & DESCRIPTIONS Function interface: 1. Mode: Trigger mode: 2T/4T/ Spot weld. 2. Pre flow time: 0~5s. 3. Post flow time: 0~10.0s. 4. Burnback: 0~10. 5. Slow feed: 0~5. 6. Spool gun: On/OFF. 7. Spot welding time: 0.5~10.0s 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 26: Mig (Dual) Pulse Control Panel

    PANEL FUNCTIONS & DESCRIPTIONS Spot Weld trigger mode: Spot weld Gun Switch Gas Supply Wire Feed Output Voltage Output Current Spot Weld Time §3.2.4 MIG (Dual) Pulse control panel 1. Welding mode button: Press it to enter MIG (Dual) Pulse welding mode. 2.
  • Page 27 PANEL FUNCTIONS & DESCRIPTIONS 6. Air check button. 7. Manual wire button. Function interface: 1. Mode: 2T/4T/S4T(4T+) (SPOT for MIG Pulse). 2. Wire material: SS-metal solid-cored/Fe-metal solid-cored/Fe-metal flux-cored/CuSi/ Al-Mg solid-cored/ Al-Si solid-cored/ Al 99.5 solid-cored/ SS-metal flux-cored/ CuAl. 3. Wire diameter: 0.8~1.6mm. 4.
  • Page 28 PANEL FUNCTIONS & DESCRIPTIONS Single Pulse Function Pulse allows the arc to enter spray transfer at lower currents and feed speeds than manual allowing faster welding with high deposition and smaller heat effected zones due to the extra arc energy provided at peak of pulse. Used for stainless or aluminum edge or seam welds.

  • Page 29: Mig Syn Control Panel

    PANEL FUNCTIONS & DESCRIPTIONS S4T trigger mode: S4T mode Transition Time Gun Switch Burn back Time Gas Supply Wire Feed Output Voltage Output Current Initial conditions Welding conditions End Current conditions §3.2.5 MIG SYN control panel The operator simply sets the welding current like MIG welding and the machine calculates the optimal voltage and wire speed for the material type, wire type and size and shielding gas being used.
  • Page 30 PANEL FUNCTIONS & DESCRIPTIONS 1. Welding mode button: Press it to select MIG SYN welding mode. 2. L parameter knob: Rotate it to adjust wire feeding speed. In functional parameter interface, rotate it to select parameters. 3. R parameter knob: Rotate it to adjust parameters. 4.

  • Page 31: Job Program Control Panel

    PANEL FUNCTIONS & DESCRIPTIONS 3. Wire diameter: 0.8~1.6mm. 4. Type of gas: CO /Ar / 98%Ar+2%CO / 80%Ar+20%CO 5. Pre flow time: 0~5s. 6. Post flow time: 0~10s. 7. Burnback: 0~10. 8. Slow feed: 0~5. §3.2.6 JOB Program control panel In the JOB mode, different JOB records can be stored and recalled.

  • Page 32: System Setting Panel

    PANEL FUNCTIONS & DESCRIPTIONS Save/activate/delete memory channels on the device The device has 10 memory channels on which you can save the most-used machine settings. After selecting the appropriate parameters, press the JOB button for 1s. The settings will be saved to the first free channel. Calling up saved memory channels consists of holding the JOB button for 3s.

  • Page 33: Installation & Operation

    INSTALLATION & 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 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 34: Mma Welding

    INSTALLATION & OPERATION (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 35: Mma Welding Fundamentals

    INSTALLATION & OPERATION 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. The Metal Wire Core works as conductor of the current that maintains the arc. The core wire melts and is deposited into the welding pool.
  • Page 36 INSTALLATION & OPERATION Welding Current (Amperage) Correct current selection for a particular Electrode Size Current Range job is an important factor in arc welding. ø mm (Amps) With the current set too low, difficulty is 2.5 mm 60~95 experienced in striking and maintaining 3.2 mm 100~130 astable arc.

  • Page 37: Installation & Operation For Tig Welding

    INSTALLATION & OPERATION Travel Speed The electrode should be moved along in the direction of the joint being welded at a speed that will give the size of run required. At the same time, the electrode is fed downwards to keep the correct arc length at all times. Excessive travel speeds lead to poor fusion, lack of penetration etc, while too slow a rate of travel will frequently lead to arc instability, slag inclusions and poor mechanical properties.
  • Page 38 INSTALLATION & OPERATION (2) Plug the welding torch into the negative socket on the front panel, and tighten it. (3) Connect the gas line of TIG Gun to outlet gas connector on the front of the machine. Check for Leaks! (4) Connect the control cable of torch switch to 12 pin socket on the front of the machine.
  • Page 39 INSTALLATION & OPERATION (2) Assemble front end parts of the TIG torch making sure they are correctly assembled, use the correct size and type of tungsten electrode for the JOB, the tungsten electrode requires a sharpened point for DC welding. (3) Lay the outside edge of the Gas Cup on the work piece with the Tungsten Electrode 1~2mm from the work piece.

  • Page 40: Dc Tig Welding

    INSTALLATION & OPERATION (5) Now rotate the Gas Cup in the reverse (6) 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 41 INSTALLATION & OPERATION 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. The intensity of the arc is proportional to the current that flows from the tungsten.

  • Page 42: Tig Welding Fusion Technique

    INSTALLATION & 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.

  • Page 43: Tungsten Electrodes

    INSTALLATION & OPERATION 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 44 INSTALLATION & OPERATION 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. The more significant danger to welders can occur when thorium oxide gets into the lungs. This can happen from the exposure to vapours during welding or from ingestion of material/dust in the grinding of the tungsten.
  • Page 45 INSTALLATION & OPERATION Lanthanated tungsten. Lanthanated (Color Code: Gold) Lanthanated tungsten electrodes (AWS classification EWLa-1.5) contain a minimum of 97.80 percent tungsten and 1.30 percent 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 46: Tungsten Preparation

    INSTALLATION & 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 Aluminum 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 47 INSTALLATION & 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.

  • Page 48: 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 on the front of the machine and tighten it. (2) Plug the welding torch into the MIG torch connection socket on the front panel of the wire feeder, and tighten it.
  • Page 49 INSTALLATION & OPERATION (8) Connect the gas regulator to the Gas Cylinder and connect the gas line to the Gas Regulator. Check for Leaks! (9) Connect the control cable of cooling water with the aero socket on the rear panel of welding machine.
  • Page 50 INSTALLATION & OPERATION (15) Press and hold the manual wire button (14) Remove the gas nozzle and to feed the wire down the torch cable contact tip from the front end of through to the torch head. the MIG torch. (16) Fit the correct size contact tip (17) Fit the gas nozzle to the torch head.

  • Page 51: Wire Feed Roller Selection

    INSTALLATION & OPERATION (20) Select torch trigger mode: 2T or 4T.(Refer to §3.2.3/§3.2.4/§3.2.5) (21) Select water cooling mode. (Refer to §3.2.3/§3.2.4/§3.2.5) (22) Select the required welding parameters using the knobs and buttons. (Refer to §3.2.3/§3.2.4/§3.2.5) §4.3.2 Wire Feed Roller Selection The importance of smooth consistent wire feeding during MIG welding cannot be emphasized enough.

  • Page 52: Wire Installation And Set Up Guide

    INSTALLATION & OPERATION finished wire. The wire cannot take too much pressure from the top roller as it can be crushed and deformed if too much pressure is applied. A knurled drive roller has been developed and it has small serrations in the groove, the serrations grip the wire and assist to drive it without too much pressure from the top roller.
  • Page 53 INSTALLATION & OPERATION (3) Fit the wire spool onto the spool holder (4) Snip the wire carefully, be sure to fitting the locating pin into the location hold the wire to prevent the spool holeon the spool. Replace the spool uncoiling.
  • Page 54 INSTALLATION & 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.

  • Page 55: Mig Torch Liner Types And Information

    INSTALLATION & OPERATION §4.3.4 MIG Torch Liner Types and Information MIG Torch Liners The liner is both one of the simplest and most important components of a MIG gun. Its sole purpose is to guide the welding wire from the wire feeder, through the gun cable and up to the contact tip.
  • Page 56 INSTALLATION & OPERATION Steel Liners Blue - 0.6mm~0.8mm Red - 0.9mm~1.2mm Yellow - 1.6mm Green - 2.0mm~2.4mm Teflon and Polyamide (PA) Liners Teflon liners are well suited for feeding soft wires with poor column strength like Aluminum wires. The interiors of these liners are smooth and provide stable feed ability, especially on small diameter welding wire Teflon can be good for higher heat applications that utilize water-cooled torches and brass neck liners.

  • Page 57: Mig Welding

    INSTALLATION & OPERATION Neck Liner §4.3.5 MIG Welding Definition of MIG Welding MIG (metal inert gas) welding also known as GMAW (gas metal arc welding) or MAG (metal active gas welding), is a semi-automatic or automatic arc welding process in which a continuous and consumable wire electrode and a shielding gas are fed through a welding gun.
  • Page 58 INSTALLATION & OPERATION The pinch causes the forming An arc is created at the wire feed speed droplet to separate and falls separation of the droplet and overcomes the heat of the towards the now creating weld the heat and force of the arc wire again pool.
  • Page 59 INSTALLATION & OPERATION Narrow higher Flat even weld profile Narrower weld profile weld profile more light penetration even penetration penetration 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 than 20°...
  • Page 60 INSTALLATION & OPERATION Angle to Work - The work angle is the forward back angle of the gun relative to the work piece. The correct work angle provides good bead shape, prevents undercut, uneven penetration, poor gas shield and poor quality finished weld. Correct angle Not enough angle Too much angle...
  • Page 61 INSTALLATION & OPERATION correspond with the travel speed, increasing with faster travel speed and decreasing with slower speed. Travel speed needs to match the amperage and will decrease as the material thickness and amperage increase. Too Fast Travel Speed - A too fast travel speed produces too little heat per mm of travel resulting in less penetration and reduced weld fusion, the weld bead solidifies very quickly trapping gases inside the weld metal causing porosity.
  • Page 62 INSTALLATION & OPERATION Correct Travel Speed even shaped bead good toe fusion good penetration good side wall fusion Wire types and sizes - Use the correct wire type for the base metal being welded. Use stainless steel wire for stainless steel, Aluminum wires for Aluminum and steel wires for steel.
  • Page 63 INSTALLATION & OPERATION Gas selection - The purpose of the gas in the MIG process is to protect / shield the wire, the arc and the molten weld metal from the atmosphere. Most metals when heated to a molten state will react with the air in the atmosphere, without the protection of the shielding gas the weld produced would contain defects like porosity, lack of fusion and slag inclusions.

  • Page 64: Set Up Installation For Spool Gun

    INSTALLATION & OPERATION §4.4 Set up installation 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 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 65 INSTALLATION & OPERATION (9) Remove the spool cover by pressing (10) Place a spool of wire inside the button and lifting off the cover. spool holder on post. (12) Pull the trigger to drive the wire down (11) Feed the wire through the drive the neck until it exits the contact tip.

  • Page 66: Spool Gun Control

    INSTALLATION & OPERATION §4.4.2 Spool Gun Control 226 Spool Gun 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.

  • Page 67: Welding Parameters

    INSTALLATION & OPERATION §4.5 Welding parameters Process reference for CO2 butt welding of low carbon steel solid welding wire Material Root Wire Welding Welding Welding Gas-flow thickness diameter current voltage speed rate (CM/MIN) (L/MIN) (MM) G (MM) (MM) 60~70 16~16.5 50~60 75~85 17~17.5...

  • Page 68: Operation Environment

    INSTALLATION & OPERATION §4.6 Operation environment  Height above sea level ≤1000 M.  Operation temperature range: -10~40°C.  Air relative humidity is below 90% (20°C).  Preferable site the machine some angles above the floor level, the maximum angle does not exceed 15°C.

  • Page 69: Welding Trouble Shooting

    WELDING TROUBLE SHOOTING §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. Trouble Possible Reason Suggested Remedy...

  • Page 70: Mig Wire Feed Trouble Shooting

    WELDING TROUBLE SHOOTING Bring the torch closer to the work and Holding the torch too far away Wire stubbing maintain stick out of 5~10mm during welding Welding voltage set too low Increase the voltage Wire Speed set too high Decrease the wire feed speed Remove materials like paint, grease, Contaminated base metal oil and dirt, including mill scale from...
  • Page 71 WELDING TROUBLE SHOOTING Trouble Possible Reason Suggested Remedy Check that the TIG/MMA/MIG selector Wrong mode selected switch set to MIG position Check that the Wire Feeder/ Spool Gun No wire feed selector switch is set to Wire Feeder Wrong torch selector switch position for MIG welding and Spool Gun when using the Spool gun Be sure to adjust the wire feed and...

  • Page 72: Dc Tig Welding Trouble Shooting

    WELDING TROUBLE SHOOTING §5.3 DC TIG welding trouble shooting The following chart addresses some of the common problems of DC TIG welding. In all cases of equipment malfunction, the manufacturer’s recommendations should be strictly adhered to and followed. Trouble Possible Reason Suggested Remedy Use pure Argon.

  • Page 73: Mma Welding Trouble Shooting

    WELDING TROUBLE SHOOTING Incorrect Gas Use pure Argon gas Yellowish residue/ Set the gas flow between 10~15 l/min smoke on the Inadequate gas flow flow rate alumina nozzle & Increase the size of the alumina gas discolored tungsten Alumina gas nozzle too small nozzle Connect the torch to the DC- output Torch connected to DC+...
  • Page 74 WELDING TROUBLE SHOOTING 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. Check Incomplete welding circuit all cable connections Check the MMA selector switch is No arc Wrong mode selected selected...
  • Page 75 WELDING TROUBLE SHOOTING Check the joint design and fit up, make Poor joint preparation and or sure the material is not too thick. Seek joint design assistance for the correct joint design and fit up Electrode welds with Change the polarity, check the electrode different or unusual arc Incorrect polarity manufacturer for correct polarity...

  • Page 76: Maintenance & Troubleshooting

    MAINTENANCE & TROUBLESHOOTING §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 77: Troubleshooting

    MAINTENANCE & TROUBLESHOOTING Use the dry compressed air to clear the inside of arc welding machine. Especially for clearing up the dusts on radiator, main voltage transformer, inductance, IGBT module, Monthly the fast recover diode and PCB, etc. examination Check up the bolt in arc welding machine, if it is loose, please screw down it. If it is skid, please replace.
  • Page 78 MAINTENANCE & TROUBLESHOOTING No gas in the gas cylinder Change it No output Gas hose leaks gas Change it Press the gas when Electromagnetic valve gun switch, test gas Change it damaged no output shielded gas Output gas Control switch damaged Repair the switch when test Control circuit damaged...

  • Page 79: List Of Error Code

    MAINTENANCE & TROUBLESHOOTING §6.3 List of error code Error Type Error 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 in default) Phase loss No water No gas Welding machine Under voltage Over voltage...

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Stealth cobra bt mig dp 50069114h

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