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TOLSEN TOOLS 44002 Instruction Manual

Inverter mma dc welding machine
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44002/44004
INVERTER MMA DC WELDING MACHINE
INSTRUCTION MANUAL
SAVE THIS MANUAL !
You will need this manual for safety instructions, operating procedures and warranty.
Put it and the original sales receipt in a safe dry place for future reference.

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Summary of Contents for TOLSEN TOOLS 44002

  • Page 1 44002/44004 INVERTER MMA DC WELDING MACHINE INSTRUCTION MANUAL SAVE THIS MANUAL ! You will need this manual for safety instructions, operating procedures and warranty. Put it and the original sales receipt in a safe dry place for future reference.

  • Page 2: Important Safety Information

    SAFETY IMPORTANT SAFETY INFORMATION WARNING! OPERATION AND MAINTENANCE OF ARC WELDING EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR HEALTH. To prevent possible injury, read, understand and follow all warnings, safety precautions and instructions before using the equipment. Important Safety Precautions GASES AND FUMES Gases and fumes produced during the Arc welding or cutting process can be dangerous and hazardous to your health.

  • Page 3: Transporting Methods

    SAFETY FIRE AND EXPLOSION Fire and explosion can be caused by hot slag, sparks, or the arc weld. 1. Be sure there is no combustible or flammable material in the workplace. Any material that cannot be removed must be protected. 2.

  • Page 4: Installation Recommendation

    The following Primary Current recommendations are required to obtain the maximum welding current and duty cycle from this Power Supply: Primary supply Minimum primary current Model Current & Duty Cycle lead size circuit size 44002 Minimum 2.5mm2 220V/ 34 A 160A/26. 4V@35% 44004 Minimum 2.5mm2 220V/48.8A 200A/28V@35%...

  • Page 5: Duty Cycle

    SETUP Phase Input Voltage Fuse Size Model 1 phase 220V± 15% AC 40 Amps POWER S-200i 1 phase 220V± 15% AC 60 Amps POWER S-250i Table 2 Notice: Fuse size is based on not more than 200 percent of the rated input amperage of the welding power source (Based on Article 630, National Electrical Code).

  • Page 6: Symbol Legend

    SPECIFICATIONS & SYMBOL LEGEND SPECIFICATIONS & SYMBOL LEGEND MODEL 44002 44004 Input voltage and frequency 220V±15% 50/60Hz 220V±15% 50/60Hz KVA @ max input 8.5 KVA 10.8KVA Max current 160A 200A Output current range MMA 30A-160A 30A-200A Open circuit voltage 100V 103V Duty cycle at 40°C...

  • Page 7: Operator Controls

    SETUP OPERATOR CONTROLS 1. Digital Display 2. Warning Indicator 3. Input Indicator 4. Current Setting 5. Negative (-) Socket. 6. Positive (+) Socket. 7. Input Power Cable 8. Main Power Switch 9. Fan WARNING When the welder is connected to the primary supply voltage, the internal electrical components maybe at primary potential with respect to earth.

  • Page 8: Basic Arc Welding Guide

    SETUP BASIC ARC WELDING GUIDE Electrode polarity Stick electrodes are generally connected to the "+" terminal and the work lend to the "2 terminal but if in doubt consult the electrode manufacturers literature. Effects of stick welding various materials High tensile and alloy steels The two most prominent effects of welding these steels are the formation of a hardened zone in the weld area, if suitable precautions are not taken, the occurrence in this zone of under-bead cracks.

  • Page 9: Maintenance

    MAINTENANCE If this equipment does not operate properly, stop work immediately and investigate the cause of the malfunction. Maintenance work must be performed by an experienced, qualified person only. Any electrical work must be performed by an electrician or other person properly trained in servicing electrical equipment. Do not permit untrained persons to inspect, clean or repair this equipment.

  • Page 10: Troubleshooti

    TROUBLESHOOTI TROUBLESHOOTI WARNING! There are extremely dangerous voltages and power levels present inside this product. Do not attempt to open or repair unless you are an accredited service agent and you have had training in power measurements and troubleshooting techniques. If major complex subassemblies are faulty, then the welding power source must be returned to an accredited service agent for repair.
  • Page 11 TROUBLESHOOTI Description Possible Cause Remedy Excessive bead build-up or poor Increases weld current, and/ or Welding current is too low. faulty joint preparation. penetration or poor fusion at edges of weld. Weld bead too wide and Decreases weld current. Welding current is too high. flat or undercut at edges of weld or excessive burn through.
  • Page 12 TROUBLESHOOTI Stick welding problems Description Cause Remedy Gas pockets or voids in weld 1. Electrodes are damp. 1. Dry electrodes before use. metal (Porosity). 2. Welding current is too large. 2. Reduce welding current. 3. Surface impurities such as: oil, 3.
  • Page 13 TROUBLESHOOTI Power source problems Description Cause Remedy The welding arc can not 1. The Primary supply voltage has not 1. Switch on the primary supply voltage. be established. been switched on. 2. Switch on the welding power source. 2. The welding power source switch is 3.
  • Page 14 TOLSEN TOOLS CO.,LIMITED www.tolsentools.com TOLSEN is a trademark or registered trademark of TOLSEN TOOLS. All rights reserved. MADE IN CHINA...

This manual is also suitable for:

44004

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