SWP 9104H Operator's Manual
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SWP 9104H Operator's Manual

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OPERATOR'S MANUAL
MIG 315 INVERTER
Part No. 9104H
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 315 INVERTER Part No. 9104H 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.

  • Page 3: 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··································································································11 §2.5 Working Principle ·············································································································12 §2.6 Volt-Ampere Characteristic ······························································································12 §3 Panel Functions & Descriptions ·················································································· 13 §3.1 Machine Layout Description ····························································································13 §3.1.1 Front and rear panel layout of welding machine ···································································...
  • Page 4 CONTENT §5 Maintenance & Troubleshooting ················································································ 59 §5.1 Maintenance ······················································································································59 §5.2 Troubleshooting ···············································································································60 §5.2.1 MIG welding trouble shooting ································································································ 61 §5.2.2 MIG wire feed trouble shooting ······························································································ 62 §5.2.3 DC TIG welding trouble shooting ···························································································· 63 §5.2.4 MMA welding trouble shooting ······························································································ 65 §5.3 List of error code···············································································································66...

  • Page 5: 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 6 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 7 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 8 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 9 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 10 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 11 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 12 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 13: 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 Manual and SYN function: -Synergic programs for aluminum, mill steel, stainless steel and CuSi - 2T/ 4T welding mode...

  • Page 14: Brief Introduction

    OVERVIEW §2.2 Brief Introduction BT MIG 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 15: Technical Data

    OVERVIEW §2.3 Technical Data Models BT MIG 315 Parameters Input Voltage (V) 3~400±10% Frequency (HZ) 50/60 Input Current (A) 22.5 17.0 18.5 Input Power (kVA) 15.6 11.8 12.8 Welding Current (A) 30~315 10~300 10~250 No-load Voltage (V) 75.5 71.5 75.5 40% 315A 40% 300A 40% 250A...

  • Page 16: Working Principle

    OVERVIEW §2.5 Working Principle The working principle of BT MIG series welding machine is shown as the following figure. Three-phase 400V 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 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. Negative (-) welding power output connection socket. 2. Remote connection plug. 3. MIG Torch Polarity Change Power Connection. 4.

  • Page 18: Right Layout Of Welding Machine

    PANEL FUNCTIONS & DESCRIPTIONS Right layout of welding machine §3.1.2 10. Spool holder. 11. Wire feed tension adjustment. 12. Wire feed tension arm (2x). 13. Wire feeder roller (2x) 14. Wire feeder inlet guide. 15. Wire drive roller. 16. Toolkit.

  • Page 19: Front Panel Functions And Descriptions

    PANEL FUNCTIONS & DESCRIPTIONS §3.2 Front Panel Functions and Descriptions §3.2.1 MMA control panel 1. Welding mode button: Press it to select MMA welding mode. 2. L parameter knob: Rotate it to adjust welding current. 3. R parameter knob: Press it to select Hot start or Arc force and rotate it to adjust value.

  • Page 20: Tig Lift Control Panel

    PANEL FUNCTIONS & DESCRIPTIONS §3.2.2 TIG Lift control panel 1. Welding mode button: Press it to select TIG Lift welding mode. 2. L parameter knob: Rotate it to adjust welding current. In functional parameter interface, rotate it to select parameters. 3.
  • Page 21 PANEL FUNCTIONS & DESCRIPTIONS 1. Trigger mode: 2T or 4T. 2. Post flow time: 0~10s. Trigger mode select:  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 22 PANEL FUNCTIONS & DESCRIPTIONS (8) t5: Electromagnetic gas valve turned off, the shield gas stops to flow, and welding is finished.  4T Mode This is known as ’latching’ mode. The trigger is pulled once and released to activate the welding circuit, pulled and released again to stops the welding circuit.

  • Page 23: Mig Manual Control Panel

    PANEL FUNCTIONS & DESCRIPTIONS (10) t6: Loosen the gun switch, stop arc and keep on argon flowing; (11) t6～t7: Post-gas time can be set by post-gas time adjustment knob on front panel; (12) t7: Electromagnetic valve is closed and stop argon flowing. Welding is finished. §3.2.3 MIG Manual control panel 1.

  • Page 24: Mig Syn Control Panel

    PANEL FUNCTIONS & DESCRIPTIONS 1. Trigger mode: 2T/ 4T. 2. Pre flow time: 0~5s. 3. Post flow time: 0~10s. 4. Burnback: 0~10. 5. Slow feed: 0~5. 6. Spool gun: ON/OFF. 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 25 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 Inductance or other parameters. 4.

  • Page 26: System Setting Panel

    PANEL FUNCTIONS & DESCRIPTIONS 4. Shield 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. §3.2.5 System setting panel Press the functional parameter button and hold it for 3s to enter the system interface. Here you can adjust the language, the unit and the brightness setting by L parameter knob and R parameter knob.

  • Page 27: 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 28: Mma Welding

    INSTALLATION & OPERATION §4.1.2 MMA Welding One of the most common types of arc welding is manual metal arc welding (MMA) or stick welding. An electric current is used to strike an arc between the base material and a consumable electrode rod or ‘stick’. The electrode rod is made of a material that is compatible with the base material being welded and is covered with a flux that gives off gaseous vapours that serve as a shielding gas and providing a layer of slag, both of which protect the weld area from atmospheric contamination.

  • Page 29: Mma Welding Fundamentals

    INSTALLATION & OPERATION ● producing a protective gas around the weld area ● providing fluxing elements and deoxidizer ● creating a protective slag coating over the weld as it cools establishing arc characteristics ● adding alloying elements Covered electrodes serve many purposes in addition to filler metal to the molten pool.
  • Page 30 INSTALLATION & OPERATION 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 31: Installation & Operation For Tig Welding

    INSTALLATION & OPERATION §4.2 Installation & Operation for TIG Welding §4.2.1 Set up installation for TIG Welding (1) Insert the earth cable plug into the positive socket on the front of the machine and tighten it. (2) Plug the welding torch into the negative socket on the front panel, and tighten it. (3) Connect the control cable of torch switch to aero socket on the front of the machine.
  • Page 32 INSTALLATION & OPERATION  When 4T operation is selected press and release trigger Gas starts, touch and lift arc start, press and release trigger Gas and Arc stops. (11) Select water cooling mode on the front panel. 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 33: Dc Tig Welding

    INSTALLATION & OPERATION (3) Lay the outside edge of the cup on (4) With a small movement rotate the gas work piece with the tungsten Electrode cup forward so that the tungsten electrode 1-2mm from the work piece. Press and touches the work piece.
  • Page 34 INSTALLATION & OPERATION side. This needs to be understood because it determines what terminal the TIG torch will be connected to (this rule applies to all the other forms of DC welding as well). DC TIG welding is a process in which an arc is struck between a TUNGSTEN electrode and the metal work piece.

  • Page 35: Tig Welding Fusion Technique

    INSTALLATION & OPERATION tungsten touches gas flow the work established TIG arc arc ignition tungsten off the work Lay the nozzle on the Rock the torch sideways Rock the torch back in Lift the torch to job without the tungsten that tungsten the opposite direction,...

  • Page 36: Tungsten Electrodes

    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 37 INSTALLATION & OPERATION color-coded at the end for easy identification. Below are the most commonly used tungsten electrodes found in the New Zealand and Australian market. Thoriated Thoriated tungsten electrodes (AWS classification EWTh-2) contain a minimum of 97.30 percent tungsten and 1.70 to 2.20percent thorium and are called 2 percent thoriated.
  • Page 38 INSTALLATION & OPERATION have excellent arc starts at low amperages and become popular in such applications as orbital tube welding, thin sheet metal work. They are best used to weld carbon steel, stainless steel, nickel alloys, and titanium, and in some cases it can replace 2 percent thoriated electrodes.

  • Page 39: 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 40 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 41: Installation & Operation For Mig Welding

    INSTALLATION & OPERATION §4.3 Installation & Operation for MIG Welding §4.3.1 Set up installation for MIG Welding As shown is for gas shielded welding (1) A- Insert the earth cable plug into the Negative (-) socket and twist to tighten. ( shielded wire) B- Insert the earth cable plug into the Positive (+) socket and twist to tighten.
  • Page 43 INSTALLATION & OPERATION (10) Close down the top roller bracket and clip the pressure arm into place with a medium amount of pressure applied. (11) Remove the gas nozzle and (12) Press and hold the manual wire button contact tip from the front end of to feed the wire down the torch cable the MIG torch.

  • Page 44: Wire Feed Roller Selection

    INSTALLATION & OPERATION (15) Carefully open the gas cylinder valve and set the required gas flow rate. (16) Press the welding mode button to select MIG welding mode. (17) Select torch trigger mode: 2T or 4T. (18) Select water cooling mode. (19) Select the required welding parameters using the knobs and buttons.

  • Page 45: Wire Installation And Set Up Guide

    INSTALLATION & OPERATION deforming the shape of the wire, too much tension will push the wire out of shape and cause it to catch in the contact tip. Flux Core/ Gasless Wire - these wires are made up of a thin metal sheath that has fluxing and metal compounds layered onto it and then rolled into a cylinder to form the finished wire.
  • Page 46 INSTALLATION & OPERATION (1) Remove the spool retaining nut. (2) Note the tension spring adjuster and spool locating pin. (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.

  • Page 47: Set Up For Mig Welding- Aluminum Or Silicone Bronze Wire

    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 48: Mig Torch Liner Installation

    INSTALLATION & OPERATION (1) Repeat all steps as listed in 4.3.1. (2) Fit the correct size U-groove drive roller for soft wires. (3) Change shield gas to 100% Argon. §4.3.5 MIG Torch Liner Installation (1) Remove MIG torch front end parts. (2) Remove the liner retaining nut.

  • Page 49: Mig Torch Liner Types And Information

    INSTALLATION & OPERATION (7) Snip the liner off 3mm past the end of the (8) Replace the front end parts. torch neck. (Remove any burrs) (9) Fully screw down the liner retaining nut and tighten. §4.3.6 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.
  • Page 50 INSTALLATION & OPERATION Small diameter welding wires, 0.6mm through 1.0mm have relatively low columnar strength, and if matched with an oversized liner, can cause the wire to wander or drift within the liner. This in turn leads to poor wire feeding and premature liner failure due to excessive wear.

  • Page 51: Mig Welding

    INSTALLATION & OPERATION 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. Neck Liner §4.3.7 MIG Welding Definition of MIG Welding...
  • Page 52 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 53 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 54 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 55 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 56 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 57 INSTALLATION & OPERATION shielding gas the weld produced would contain defects like porosity, lack of fusion and slag inclusions. Additionally some of the gas becomes ionized (electrically charged) and helps the current flow smoothly. The correct gas flow is also very important in protecting the welding zone from the atmosphere.

  • Page 58: 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 59 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 60: 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 61: 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 (MM) G (MM) (MM) (CM/MIN) (L/MIN) 60-70 16-16.5 50-60 75-85 17-17.5...

  • Page 62: 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℃.

  • Page 63: Maintenance & Troubleshooting

    MAINTENANCE & TROUBLESHOOTING §5 Maintenance & Troubleshooting §5.1 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 64: Troubleshooting

    MAINTENANCE & TROUBLESHOOTING §5.2 Troubleshooting  Before the welding machines are dispatched from the factory, they have already been tested and calibrated accurately. It is forbidden for anyone who is not authorized by our company to do any change to the equipment! ...

  • Page 65: Mig Welding Trouble Shooting

    MAINTENANCE & TROUBLESHOOTING Output cable is connected Screw it down or change it No striking arc and no incorrectly or loosen output voltage Control circuit damaged Check the circuit Check over-voltage, over-current, Welding stops, and alarm Machine has self-protection over-temperature, lower-voltage light is on and over-temperature, and solve it The potentiometer damaged...

  • Page 66: Mig Wire Feed Trouble Shooting

    MAINTENANCE & TROUBLESHOOTING Missing or damaged gas diffuser Replace the gas diffuser MIG torch euro connect O-ring Check and replace the O-ring missing or damaged Bring the torch closer to the work and Holding the torch too far away maintain stick out of 5~10mm Wire stubbing during welding Welding voltage set too low...

  • Page 67: Dc Tig Welding Trouble Shooting

    MAINTENANCE & TROUBLESHOOTING 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 Voltage setting incorrect...
  • Page 68 MAINTENANCE & TROUBLESHOOTING Check and change the tungsten type if Incorrect tungsten being used necessary Keep shielding gas flowing 10~15 Tungsten being oxidized after seconds after arc stoppage. 1 second weld is finished for each 10amps of welding current. Keep tungsten from contacting weld Touching tungsten into the puddle.

  • Page 69: Mma Welding Trouble Shooting

    MAINTENANCE & TROUBLESHOOTING rate Check and change the size and or the Incorrect tungsten size or type tungsten if required Loose connection Check all connectors and tighten Earth clamp not connected to Connect the earth clamp directly to the work work piece wherever possible §5.2.4 MMA welding trouble shooting The following chart addresses some of the common problems of MMA welding.

  • Page 70: List Of Error Code

    MAINTENANCE & TROUBLESHOOTING joint design sure the material is not too thick. Seek 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 characteristic §5.3 List of error code Error Type...

This manual is also suitable for:

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