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TOP GUN WELDING COMMANDER 2400 User Manual

Acdc pulse mig/tig
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USER MANUAL
COMMANDER 2400 ACDC PULSE MIG/TIG

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  • Page 1 USER MANUAL COMMANDER 2400 ACDC PULSE MIG/TIG...

  • Page 3: Table Of Contents

    Please read carefully this user manual before using this machine Keep it for the future use. MANU SAFETY APPLICATION DESCRIPTION OF THE MACHINE TECHNICAL DATA OF THE DEVICE DEVICE CONNECTION - WELDING POLARITY SETTING PANEL OPERATION-GENERAL -MIG OPERATION -TIG ACDC OPERATION -MMA OPERATION ERROR CODE ELETRICITY SAFETY GUIDLINES...

  • Page 4: Safety

    Safety It is imperative that you read the following signs and safety rules to protect your own and other people's health and life. Read the instructions before starting the device. Use only original equipment supplied by the manufacturer. Some components may explode. Always use a face shield and protective clothing with long sleeves.
  • Page 5 fire protection requirements. Welded parts may burn. The protruding wire from the torch is sharp and can cause skin puncture. Danger of fire and explosion. During welding work, a fire may result. The welding station must be remote and protected against flammable and explosive materials. The magnetic field can disrupt the functioning of pacemakers.
  • Page 6 The heating test was carried out at ambient temperature and the duty cycle (load factor) at 25℃ was determined as a result of the simulation. The device is intended for conducting professional welding works in industrial conditions by personnel having valid qualification certificates in accordance with applicable standards. WARNING: This Class A equipment is not intended for use in residential areas where electricity is supplied through the public low voltage network system.

  • Page 7: Application

    Reliability, a wide range of applications (the ability to carry out work in three welding methods: MIG / MAG, TIG- AC DC, MMA make the device satisfy even the most demanding users. 4. TECHNICAL DATA OF THE DEVICE Characters COMMANDER 2400 Rated input voltage[V] 240V Frequency[Hz]...

  • Page 8: Device Connection - Welding Polarity Setting

    5. DEVICE CONNECTION - WELDING POLARITY SETTING MIG/MAG WELDING Select the correct welding polarity as shown above. Positive polarity welding (MIG / MAG gas shielded solid wire welding) Welder's current plug connected to the positive + socket (EURO) Earth handle connected to the negative socket - Welding with Push and Pull torch Select the correct welding polarity as shown above.
  • Page 9 Welding with negative polarity - （welding with flux cored wire - FCAW) Welder's current plug connected to the negative socket - （EURO） Earth clamp connected to the positive socket + WARNING! To start working with self-shielding wire, change the polarity inside the device - on the wire feeder. BEFORE YOU WORK: Check the voltage, number of phases and frequency of the power supply before connecting the device to the mains.
  • Page 10 Do not place the device on wet ground. Use an electrode wire with diameter and spool weight in accordance with the manufacturer's instructions (D200, max. 15 kg). Check the technical condition of the device and welding cables on an ongoing basis. Welding wire spool assembly: This device is equipped with professional wire feeder, it has 4 rolls feeder enabling work with 2...

  • Page 11: Single Pulse Mode

    A cylinder with a suitable shielding gas must always be properly secured against falling over. If possible, attach to an approved welding carriage with the MIG / MAG device. The trolley is not standard equipment of the set. Connect the semi-automatic machine to the cylinder with a suitable hose. Unscrew the regulator valve before starting to weld.

  • Page 12: Double Pulse Mode

    DOUBLE PULSE MODE Welding with the MIG / MAG method with double pulse we get a high level of face appearance (husk effect). In addition, the use of automatic wire feed affects welding performance. The MIG / MAG method with double pulse allows the regulation of current pulsation (pulse balance) and adjustment of the wire feed speed.

  • Page 13: Panel Operation-General

    PANEL OPERATION A. DESCRIPTION OF THE CONTROL PANEL 1. LCD display 2. Function selection button, to select the previous menu, holding for 5 seconds to save the current setting in memory. 3. Button to return to the previous menu. (additionally held for 5 seconds to return to the factory settings (RESET)).
  • Page 14 B. CHOICE OF WELDING METHOD This page allows you to select welding methods as below: Synergy, MIG, LIFT-TIG, MMA Turn the red knob of the font panel to select the welding mode then press for confirmation. SYNERGY - synergic settings. The user selects the basic welding parameters such as the type of material, thickness of the material to be welded, diameter of the welding wire.
  • Page 15 ARC FORCE - Stabilizes the arc regardless of fluctuations in its length, reduces the amount of spatter. HOT-START - a function that makes welding easier. When the arc strikes, the welding current is temporarily increased to heat up the material and electrode at the point of contact, and to properly shape the penetration and weld face at the initial stage of welding.
  • Page 16 Step 2-Selecting the thickness of the work piece The user chooses the thickness of the welded material. The device automatically selects the intensity on this basis welding current, arc voltage and feeder speed. Step 3 Selecting the welding wire diameter You choose the welding wire diameter you plan to use.

  • Page 17: Mig Operation

    COMMANDER 2400 ACDC PULSE MIG/TIG C. MIG/MAG OPERATION In MIG welding mode, the user sets all welding parameters one after the other. The system suggests the selection of optimal welding parameters by indicating at their adjustment thickness of the welded material (see table - setting the wire feeder speed). This information suggests to the user that the settings are correct.
  • Page 18 COMMANDER 2400 ACDC PULSE MIG/TIG Choice of welded material (and wire) From the list of alloys available in program. Setting the wire feeder speed ATTENTION! It will show automatically the estimated thickness of the welded material in order to select the optimal welding parameter.
  • Page 19 COMMANDER 2400 ACDC PULSE MIG/TIG Adjusting the arc voltage Increasing or decreasing this value will lengthen or shorten the arc length. D. MIG / MAG WELDING WITH PULSE In order to start welding in MIG / MAG PULS mode, the settings should be made as in the previous chapter.
  • Page 20 COMMANDER 2400 ACDC PULSE MIG/TIG Pulse cycle setting Adjusting this parameter causes increasing or reducing the amount of spatter during welding. ATTENTION! The pulse cycle value is automatically selected based on the other welding parameters, there is no need to manually correct it.
  • Page 21 COMMANDER 2400 ACDC PULSE MIG/TIG Double pulse frequency setting In order to achieve optimal welding parameters, it is suggested to set the range from 1 to 2 Hz. Double pulse cycle setting In order to achieve optimal welding parameters, it is suggested to set the range from 30 to 40%.
  • Page 22 COMMANDER 2400 ACDC PULSE MIG/TIG F. SAVE AND RECALL FUNCTION The device is equipped with a memory bank that allows you to save 18 user programs. The method of saving and reading data stored in the device cache is described below:...
  • Page 23 COMMANDER 2400 ACDC PULSE MIG/TIG I. MIG Setting Chart MIG Welding Current-Wire Diameter And Plate Thickness Chart Wire diameter Plate thickness 10.0 Wire speed（M/min） AL-Si1.0/(4043) Welding current (A) (DCEP) Arc voltage 16.0 18.3 19.2 21.0 22.5 23.6 Wire speed（M/min） AL-Si1.2/(4043) Welding current (A) 27.0...

  • Page 24: Tig Dc Welding

    COMMANDER 2400 ACDC PULSE MIG/TIG TIG Welding In the TIG (Tungsten Inert Gas) method, the electric arc strikes under an inert gas (argon) shield, between the welded element and the non-fusible electrode made of pure tungsten or tungsten with additives.
  • Page 25 AC / DC welding current selection -select DC mode Select operation mode on the right side -select 2T/4T Pulse or continuous current welding description of pulse welding parameters is on page19) Synergic mode / manual mode In synergic mode, the user only need to adjusts the basic welding parameters.
  • Page 26 Control welding parameters panel/remoet control potentiometer in the welding gun or pedal Pre-flow-time before ignition of the arc ATTENTION! The welding arc will catch fire any time after the set gas flow time before welding. For a 4m long handle max. suggested time: 2 seconds Start current - 4 clock mode Take-off current should be 70 to 90% values...
  • Page 27 Peak current Basic welding current. Down slope Time at which the peak welding current will pass to the final current (crater filling). Crater current The final current should be 70 to 90% values of the basic welding current. is used for the correct purpose end of weld in its final phase (crater filling).
  • Page 28 Welding parameters - summary chart The screen shows all parameters welding selected by the user. Saving data in the device's memory Using saved programs TIG DC (direct current) welding is used for welding all types of steel, alloys copper and some non-ferrous metal alloys.
  • Page 29 Polarity Positive (DC+) Negative (DC-) Shallow and Penetration Deep and narrow wide Efficiency heat BAD - high wear Very good electrode Heat 70% - material 30% - material 30% - electrode 70% - electrode distribution WELDING PULSE WELDING – TIG PULSE TIG welding process Lynx 3 -PULSE...
  • Page 30 Select the pulse mode The parameter specifies the time proportion between welding with peak current in relation to the base current. Pulse frequency Parameter specifying the number of changes between the peak current value and the base current value in one second. ALTERNATING CURRENT WELDING–TIG AC TIG AC (AC) welding is used to connect magnesium or aluminum components and their alloys.
  • Page 31 Welding current selection Select a mode AC Selection of the handle button operating mode 2T/4T Pulse or continuous current welding Synergy mode / manual mode synergic mode the user regulates only basic welding parameters. The device constantly checks the correctnessettings, suggesting the user thickness material to be welded (see screen for current).
  • Page 32 Control of welding parameters from the panel / remote control (potentiometer in welding gun or pedal) Selection of AC wave form: Square Wave Sine Wave Triangular 3. Ramp Wave 4. Triangular growing 5. Triangular sloping Trapezoidal wave Pre-flow Attention ! The welding arc will catch fire any time after the set gas flow time before welding.
  • Page 33 AC balance Parameter specifying the heat ratio carried between the electrode tungsten and welded material. It enables welding of thin elements in the case of heat transfer on the electrode or reaching a larger one remelting in a heat transfer situation from the electrode to the workpiece.
  • Page 34 Saving data in the device's memory Using saved programs AC Balances settings AC balance is the ratio of the positive current tbal + to the negative tbal-current in a single cycle Tbal alternating current waveform. The ability to adjust the balance allows you to control the temperature of the electrode and the workpiece, including the welder has an effect on the depth of penetration and the width of the weld.
  • Page 35 Turning the adjustment dial to the left and setting the AC Balances below 50 will reduce the time tbal + duration and proportional extension of the t bal- duration Fig. Turning the control knob to the right and setting AC Balances above 50 will shorten duration duration t i proportional increase in duration bal +...

  • Page 36: Mma Welding

    MMA WELDING Arc welding is also called the MMA (Manual Arc Welding) method and is the oldest and most versatile arc welding method. The MMA method uses a coated electrode, consisting of a metal core covered with a lagging. An electric arc is created between the end of the electrode and the material being welded.

  • Page 37: Arc Force

    Welding current setting Adjust the welding current by spin the knob. HOT-START A function that makes welding easier. When the arc strikes, the welding current is temporarily increased to heat up the material and electrode at the point of contact, and to properly shape the penetration and weld face at the initial stage of welding.

  • Page 38: Error Code

    8. ERROR CODE In special cases, the following messages may appear on the display indicating a problem with the operation of the device. Errors on the display will appear until the defect is removed. Error 001 Over current The device is operated beyond its rated efficiency.

  • Page 39: Working Conditions

    9. ELECTRICITY SAFETY GUIDELINES WORKING CONDITIONS Optimal ambient temperature between -10 ° C and 40 ° C. Avoid welding in sunny conditions and when it is raining, do not allow water to get inside the device. Avoid working in flammable, aggressive or dust environments. WORK SAFETY Properly installed device with over voltage, over current protection and protection against excessive temperature will automatically turn off under conditions beyond those specified as standard.

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