SWP Stealth Cobra MIG 400 Operator's Manual
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SWP Stealth Cobra MIG 400 Operator's Manual

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OPERATOR'S MANUAL
MIG 400 INVERTER
Part No. 9196H
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 400 INVERTER Part No. 9196H 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··································································································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 3 CONTENT §5.2 MIG wire feed trouble shooting ·······················································································59 §5.3 DC TIG welding trouble shooting ·····················································································60 §5.4 MMA welding trouble shooting ························································································62 §6 Maintenance & Troubleshooting ················································································ 63 §6.1 Maintenance ······················································································································63 §6.2 Troubleshooting ···············································································································64 §6.3 List of error code···············································································································66...

  • 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 Device

    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 Manual and SYN function: -Synergic programs for aluminum, mill steel, stainless steel and CuSi...

  • Page 13: 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 14: Technical Data

    OVERVIEW §2.3 Technical Data Models BT MIG 400 Parameters Input Voltage (V) 3~400±10% Frequency (HZ) 50/60 Input Current (A) 27.0 22.1 28.6 Input Power (kVA) 18.7 15.3 19.8 Welding Current (A) 30-400 10~400 10~400 No-load Voltage (V) 60% 400A Duty cycle (40℃) 100% 310A Fe: 0.8/0.9/1.0/1.2/1.6 SS: 0.9/1.0/1.2...

  • Page 15: 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 16: 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 17: 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 18: Wire Feeder

    PANEL FUNCTIONS & DESCRIPTIONS water is delivered from the tank; red corresponds to the backwater inlet: hot water is flowed into the tank for cooling. Note : Blue outlet and red backwater inlet must not be wrong! Inlet (6) and outlet (5) for MIG The two nozzles on the same side of Control connector (7) are used for MIG operation and can be connected to the nozzles on the wire feeder.

  • 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. 1. R parameter knob: Press it to select Hot Start or Arc Force and rotate it to adjust values.

  • 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 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  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. This function is useful to longer welds as the trigger is not required to be held on continuously. TIG series of welding machines also has more current control options that can be used in 4T mode.

  • Page 23: Mig Manual Control Panel

    PANEL FUNCTIONS & DESCRIPTIONS (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. Welding mode button: Press it to select MIG Manual welding mode. 2.

  • 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 parameters. 4.

  • Page 26: System Setting Panel

    PANEL FUNCTIONS & DESCRIPTIONS 1. Trigger mode: 2T/ 4T 2. Wire material: SS solid-cored/ Fe solid-cored/ Fe flux-cored/ Al-Mg solid-cored/ CuSi. 3. Wire diameter: 0.8~1.6mm for BT MIG 400. 4. Shield gas: CO and Ar+CO 20%. 5. Pre flow time: 0~5s. §3.2.5 System setting panel Press the functional parameter button and hold it for 3s to enter the system interface.

  • 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 gas line of TIG Gun to outlet gas connector on the front of the machine.
  • Page 32 INSTALLATION & OPERATION (10) Carefully open the valve of the gas cylinder, set the required gas flow rate. (11) Select TIG welding mode on the front panel. (12) Set torch operation 2T/4T.  When 2T operation is selected press trigger Gas starts, touch and lift arc start, release trigger Gas and Arc stops.

  • 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 (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 42 INSTALLATION & OPERATION welding machine. (10) 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. (11) Place wire onto spool holder - (spool retaining nut is left hand thread) Feed wire through the inlet guide tube on to the drive roller.
  • Page 43 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 44: Wire Feed Roller Selection

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

  • Page 45: Wire Installation And Set Up Guide

    INSTALLATION & OPERATION surface of the welding wire, and these small pieces will eventually go down into the liner. This will cause clogging in the liner and added friction that will lead to welding wire feed problems. A U groove wire can also be used for flux core wire without the wire particles coming of the wire surface.
  • Page 46 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 47 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 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 49: Mig Welding

    INSTALLATION & OPERATION 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 50 INSTALLATION & OPERATION called short circuit (also known as dip transfer) globular transfer, spray transfer and pulsed-spray, each of which has distinct properties and corresponding advantages and limitations. To perform MIG welding, the basic necessary equipment is a welding gun, a wire feed unit, a welding power supply, an electrode wire, and a shielding gas supply.
  • Page 51 INSTALLATION & OPERATION Basic MIG Welding Good weld quality and weld profile depends on gun angle, direction of travel, electrode extension (stick out), travel speed, thickness of base metal, wire feed speed and arc voltage. To follow are some basic guides to assist with your setup. Gun Position - Travel Direction, Work Angle: Gun position or technique usually refers to how the wire is directed at the base metal, the angle and travel direction chosen.
  • Page 52 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 53 INSTALLATION & OPERATION Correct angle Not enough angle Too much angle Good level of control Poor control, unstable Less control over the over the weld pool, arc, less penetration, lots weld pool more spatter. even flat weld. of spatter. Stick Out- Stick out is the length of the unmelted wire protruding from the end of the contact tip.
  • Page 54 INSTALLATION & OPERATION 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. Undercutting of the base metal can also occur and an unfilled groove in the base metal is created when the travel speed is too fast to allow molten metal to flow into the weld crater created by the arc heat.
  • Page 55 INSTALLATION & OPERATION Too Slow Travel Speed large wide bead porosity lack of fusion cold lap lack of joint penetration 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 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. Too low flow will give inadequate coverage and result in weld defects and unstable arc conditions.

  • Page 57: Set Up Installation For Spool Gun

    INSTALLATION & OPERATION §4.4 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 58 INSTALLATION & OPERATION (9) Remove the spool cover by pressing (10) Place a spool of wire onto the spool button and lifting off the cover. holder. (12) Pull the trigger to drive the wire (11) Feed the wire through the drive through the neck until it exits the contact rolls into the inlet guide tube.

  • Page 59: 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 60: 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 61: 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 62: Mig Wire Feed Trouble Shooting

    WELDING TROUBLE SHOOTING completely with Select a higher voltage range and/or Not enough heat input base metal or a adjust the wire speed to suit proceeding weld Keep the arc at the leading edge of the bead. weld pool. Gun angle to work should be between 5 &...

  • Page 63: Dc Tig Welding Trouble Shooting

    WELDING TROUBLE SHOOTING MIG torch lead kinked or too sharp Remove the kink, reduce the angle or angle being held bend Contact tip worn, wrong size, wrong Replace the tip with correct size and type type Try to clear the liner by blowing out with Liner worn or clogged (the most compressed air as a temporary cure, it is common causes of bad feeding)
  • Page 64 WELDING TROUBLE SHOOTING Keep the filler wire from touching the Touching the filler wire to the tungsten during welding, feed the filler tungsten wire into the leading edge of the weld pool in front of the tungsten Use pure argon. Gas is connected, check hoses, gas valve and torch are Wrong gas / poor gas flow /gas not restricted.

  • Page 65: Mma Welding Trouble Shooting

    WELDING TROUBLE SHOOTING §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 66: 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 67: Troubleshooting

    MAINTENANCE & TROUBLESHOOTING §6.2 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 68 MAINTENANCE & TROUBLESHOOTING Wire reel damaged Change it Wire feed pipe is jammed Repair or change it Tip is jammed because of Repair or change it splash Output cable is connected Screw it down or change it No striking arc and no incorrectly or loosen output voltage Control circuit damaged...

  • Page 69: 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 4009196h

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