Product Manual for * KENDE WSE160 Tig Welder

Product Manual for * KENDE WSE160 Tig Welder
 a WS-160A \
\ WS-250A J
Л\ NT Please read the User’s Manual carefully before use the machine.
e The symbols are being used to identify potential risks.
* When seen a safety symbol in the manual, it must be understood that
there is an injury risk and following instructions must be read carefully to
avoid potential risks.
© While welding, keep the third persons and especially the children away from
the work area,
Read carefully the manual and the labels and the safety warnings.
© [earn to operate the machine and how to make the controls properly.
e Operate your machine in convenient work areas. Improper modifications affect
the safefy of your machine negatively and shorten its lifetime.
1.4 Environmental conditions 9
2,2 WORK AREA raiterieterre retten EEE stems eevee ee aeren asses sm ss sss sa sodas reste sess earsons rite etree Kanne 10
2.4.1 Connect The Machine To Power Suppiy A | 1
2.4.2 Connect Qutput(—) and Output( +) … 12
2.4.3 Connect The Gas Cylinder .. 12
N N 14
3.3 Arc starting for TIG welding process ous 14
3.5 About MMA process and welding knowledge .. 15
4.3 BASIC TROUBLESHOOTING. ..... pene 20
Installation procedure must comply with national electricity standards and other
relevant regulations and ensure that installation is performed by qualified persons.
@ Wear dry, hole-frec insulating gloves and body protection.
@ Do not touch electrode with bare hand. Do not wear wet or damaged gloves and
body protection.
@ Do not touch live electrical parts,
@ Never touch electrode while in contact with working surface, ground or another
electrode which is connected toa different machine.
O Protect yourself from electric shock by insulating yourself from work and ground.
Use non-flammable, dry insulating material if possible, or use dry rubber mats, dry
wood or plywood, or other dry insulating material big enough to cover your full area
of contact with the work or ground, and watch for fire.
@ Never connect up more than | electrodes or wires to the machine.
& Turn offthe machine, when notin use,
@ Disconnect input plug or posver before working on machine.
@ Frequently inspect input power cord for damage or bare wiring - repair or replace
cord immediately if damaged.
NT В @ Be surc input ground wire is properly connected to a ground terminal in disconnect
box or receptacle.
Inhaling fumes and gases over a long period of time, generated during welding is dangerous and
@ Irritation of the eyes, nose and throat are symptoms of inadequate ventilation. Take
immediate steps to improve ventilation. Do not continue welding if symptoms
@ Install anatura! or forced air ventilation system in the work area.
@ install an adequate ventilation system: in the welding and cutting area, if needed
install a system that can remove the fume and vapor accumulated in the entire work
area, ta prevent pollution use adequate filtration in discharge.
Sin the event of welding in small, confined places, or welding lead, beryllium,
cadmium, zine, zinc coated or painted materials; also wear a fresh air supplied
respirator in addition to the above mentioned rules.
@ Always have a trained watchperson nearby, while working in smail confined places,
Avoid working in such confined places if possibie.
@ If gas cylinders are grouped in a different area, make sure that it is a well-ventilated
arca. When not being used, turn off the cylinder valve .
© Shielding gasses such as argon is denser than air and when being used in confined
places, can be inhaled in place of air, and this is dangerous for your health.
@ Do not perform welding operations near chlorinated hydrocarbon vapors produced
by degreasing or painting,
® Usc adequate welding helmet with correct shade of filter (4 or 13 considering TS EN
379) to protect your eyes and face.
© Protect open parts of your body (arms, neck and cars) from arc rays by adequate
protective clothing.
6 To protect others by arc rays and hot metals, surround the working arca with flame
proofcurtains which are higher than eye level and put up warning boards.
E Weiding cause sparks and flying metai.
@ To prevent injuries wear appropriate safety glasses with side shields even under your welding helmet.
€ Noise from certain industrial processes or equipments can damage hearing,
8 Wear approved ear protection ifnoise level is high.
@ Do not touch hot parts.
8 Allow cooling time before servicing.
® If needed to hold hot parts, use appropriate tool, insulating gloves and fireprooficiothes.
@ Keep away from moving parts.
@ Keep al! doors, panels, and guards closed and secured.
@ Wear shoes with metal protection over the fingers.
@® While welding and cutting in small, confined places, always have a trained watchperson nearby.
@® Avoid working in such confined places.
& Do not point the gun toward any part of a human body, other persons orany type of metal when unwinding
welding wire.
& While extracting the wire from the spool by hand, it may spring suddenly and injure you or a nearby person,
protect especially your eyes and face,
© Make sure that there is no one close.
© Never weld near flammable material, It may canse fire or explosions.
6 Before starting to weld, move Нат mables away or protect them with flame-proof
@ Do not weld on and cut closed tubes or pipes,
@Before welding on closed containers, open and cicar them entirely. Welding
operations on these parts must be performed with the utmost caution,
O Never weld containers ar pipes containing or which have contained substances
that could give rise to explosions,
Welding equipments warms up so never position them on flammable surfaces,
@ Welding sparks can cause fire. For that reason, keep extinguishing means, such as fire
extinguishers, water and sand casy reach.
@ Have and maintain security valves, regulators and other valves on the Nammabie,
explosive and compressed gas circuits in good condition by periodical controls,
used for welding and cutting operations,
Wrong positioned power source or other equipment may cause serious injury to persons
or damage to objects,
& While repositioning the power source always carry by using the lifting eye. Never pull cable, hose or Gun,
Always carry the gas cylinders separately,
@Before carrying the welding and cutting equipment, disassemble all the connections between and
separatciy carry the small ones by handerips and the big ones by lifting eyes or by using appropriate
vehicles like forklifts,
© Instalt your machine on flat piatforms having maximum 19° slope that it does not fall over. Instail it on well
ventilated, non-confined places away from the dust, also avoiding the risk of falling caused by cables and
hoses. For gas cylinders not to fail over, attach it to the mobile machine or to the wall with a chain.
© Ensure that operators casily reach the controls and connections on themachine.
@ Electrical devices should not be repaired by unqualified persons. Improper repairs can cause serious
injuries or even death during applications.
& The components of the gas circuit works under pressure. The service given by unqualified persons may
cause explosions and operators can be injured seriously.
@ Allow cooling period; foilow rated duty cycle.
@ Reduce current orreduce duty cycle before starting to weld again.
@ Do not block airflow to unit.
© Do not filter airflow to unit without the approval ef manufacturer
@ Electromagnetic energy arising during welding and cutting operations can interfere with
sensitive electronic equipment such as microprocessors, computers, and computer-driven equipment such
as robots,
@ Be sure all equipment in the welding arca is electromagnetically compatible.
© To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on
the floor.
@To avoid possible EMC damages, locate welding operation as far as possible (100 meters) from any
sensitive electronic equipment.
@ Be sure this welding machine is installed and grounded according to this manual.
® If interference stili occurs, the user must take extra measures such as moving the welding machine, using
shielded cables, using line filters, or shielding the work area ,
& Puit on grounded wrist strap before handling boards or parts.
@ Use proper static-proof bags and boxes to store, move, or ship PC boards.
@ Do not expose the welding machine to rain, protect from water dropsand vapour.
B® The lifetime determined by Ministry of Industry and Trade is 10 years.
e All electrical equipment generates small amounts of electromagnetic emission due to current transferring in the
equipment, Electrical emission may be transmitted through power lines or radiated through space, similar toa
radio transmitter. When emissions are received by other equipment, electrical interference may result .
Electrical emissions may affect not only welding machines but also many kinds of electrical equipment
like radio and TV reception, numerical controlled machines, telephone systems, computers lc.
o Welding and cutting machines have been designed to work for professional and industriai use; for other
applications to contact the manufacturers,
The user is responsible for installing and using the equipment according to the manufacturer’s instructions, If
electromagnetic disturbances are detected then it shall be the responsibility of the user of the equipment 10
resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may
be as simple as carthing the welding the welding circuit, in other cases it could involve constructing an
electromagnetic screen enclosing the power source and the work compiete with associated input filters. In all
cases eicctromagnetic disturbances must be reduced to the point where theyareno longer troublesome.
e The circuit may or may not be carthed for safety reasons, Changing the earthing arrangements should only be
authorized by a person who is competent to assess whether the chan ges will increase the risk of injury, e.g. by
allowing parallel welding current return paths which may damage the earth circuits of other equipment.
» Extra precaution may be required when the welding power source is used in a domestic establishment.
® Special measures shall be taken to achieve compliance with welding power source including HF frequency for arc
ignition and stabilizing: it may be required use of shielded cables and in any case to resolve the particular
implementation (e.g. with robot, computer and any other electrical and electronic equipment connected to
welding power source} to call the technical assistance ofthe manufacturer,
e Einstufung nach EMV Richtlinie: Klasse A gemäß CISPR 11
Warnung: Als Klasse A eingestufte Geräte sind für den Einsatz im industriellen Bereich vorgesehen. Beim
Einsatz in anderen Bereichen kann die clektromagnetische Vertäglichkeit unter Umständen nicht
gewährleistet werden, bzw, es kann zu Störfälien kommen.
Before installing the welding equipment, the user shall make an assessment of potential electromagnetic
problems in the surrounding area. The following shall be taken into account if needed arrange the
working hours that not coincide with those.
eOther suppiy cables, control cables, signaling and telephone cables; above, below and adjacent to the
welding equipment,
© Radio and television transmitters and receivers,
e Computer and other control equipment,
e Safety critical equipment,
e Presence of heart beat regulators, heart cells, hearing devices or etc, nearby,
e Equipment used for calibration or measurement,
* The immunity ofother equipment in the environment.
The user shall ensure that other equipment being used in the environment is compatible. This may
require additional protection measures.
@ Welding equipment should be connected to the mains supply according to the manufacturer's recommendations.
Our welding machines arc filtered against emission according to standards. If interference still occurs, it may be
necessary to take additional precautions such as filtering of the mains supply.
@ The equipment should be routinely maintained according to the manufacturer's recommendations. The
welding equipment should not be modified without the approval of manufacturer.
@ The welding cables should be kept as short as possible and should be positioned close together, running at or
close to the floor level. Power cables and signal cables should be kept separately.
@ Keeping cables in the shape of -8- and taping together reduce emission.
@ Connect earth clamp to workpiece as close to the weld as possible. But the user should be control whether this
situation damage to people and equipment or not.
o This welding machine is manufactured with advanced inverter technology. With high-power component
MOSFETS and by adepting PWM technology. The inverter convert the DC voltage, which is rectified from input
AC voltage, 10 high 100KHz frequency AC voltage. As a consequence, the voltage is transformed and rectified.
Therefore, it results the much more small-sized of the power source and lighter in weight of the inverter welding
machine, which rates the performance of welding by 30%. The high frequency oscitiation, which enables the output
of the high frequency DC, is employed in the arc-starting system. The features of this product are as following:
stable the welding current output , reliable, completely portable, efficient and low noise generated while welding 15
e Both MMA and TiG welding Process are available for WS-200A/250A.
e During the performance of MMA welding, this welding machine is featured with the stability of output, and the
availability of arc force modulation. In case of normal arc input voliage, the stability of welding current output is not
frustrated with variation of arc length, therefore it results in stable performance of welding operation. In case of
unavailable length of arc and low mput voltage, welding output current increases while arc voltage decreases, asa
consequence, the length of arc, which is not sufficient, will automatically compensate and the modulation of arc
force is accessible. In case that the input arc voitage is too low to maintain arc, the output of this welding equipment
descends steeply. which avoid the splash generated due to over current input.
e During the performance of TG welding, this welding equipment is featured with the stability of current output and
that the welding current output does not vary with variation of the length of arc.
e Guarantee of maintenance for main engine is one year, exciuding other spare parts.
e During the guarantee maintenance period, all maintenance is free of charge, excluding the deliberated damage to
this welding equipment.
oe Only qualified technician are authorized to carry out the repairs task of this welding machine in case of machine
eCircuit Block Diagram
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Figure 1: Circuit Block Diagram
@ WS-160A/180A/200A welding machines are single
phase, 50/60Hz, constant curren(CC) output power
sources especially designed for TIG/MMA welding.
e All the controls and adjustment knob of the welding
power source are placed on to the front pane! for casy
e Welding Cable , the torch, Earth Cable and gas hose
can be easy connected to the power source.
@ Output current of the WS-160A welding machine
can be adjusted by a welding current adjustment
knob between “20-160A".
& Output current of the W5-180A welding machine
can be adjusted by a welding current adjustment
knob between “20-1804,
@ Output current of the WS-200A welding machine
can be adjusted by a welding current adjustment
knob between *20-2004A”.
& WS-200A is very good selection for medium
thickness metal (up to 8 mm) welding, itisalsoa very
good choice for stainless steel and metals TTG/MMA
welding. This machine should be selected for high
duty cycle welding applications.
@WS-250A should be selected for very
demanding applications such as very thick metals
(up to 10mm) welding. Itis also a very good choice
for stainless steel and metals TIG/MMA welding.
This machine should be selected for high duty cycle
welding applications.
: / м f SET
———" MMA welding “ TIG welding
Output Characteristics of the welding power source is constant current(CC) output for TIG/MMA.
Norm:Application standards, for example, EN 60974-1:2005 or IEC 60974-1:2005,
Rated AC input voltage of the welding power source
Tima: Max. input current.
ler: Max effective input current.
50Hz or 60 Hz:
Rated frequency of single phase AC power supply .
X: Rated duty cycle.It is the ratio between the load duration time and the fult cycle time.
Note1: This ratio is between G~100%.
Note2: For this standard, one full cycle time is 10min.For example, if the rate is 10%, the loaded time shall be 1
minutes and rest time shall be 9 minutes.
Duty cycle is based on a ten minute period. This means that the arc may be drawn for two minutes out of cach
ten minute period without any danger of overheating If it is used more than two minutes during several
successive ten minutes peiods, it may overheat.
Ug: Non-load voltage
it is the open-circuit output voltage of the welding power source,
E: output current or welding current
Us: Output load voltage or welding voltage.
The reted loaded output voitage U,=20+0.041; for MMA; U.=10+0,041> for TIG.
A/ VA Y: The adjustable range of current and its corresponding load voltage.
S1: The rated Input Power, KVA
IP: Protection grade . For example, 1P21,approving the welding machine as suitable for use indoors; IP23,. approving
the welding machine as suitable for use outdoors in the rain,
Suitable for hazardous environments,
Class:H Insulation grade.
1.4 Environmental conditions
welding power sources shall be capable of delivering their rated output when the following
environmental conditions prevail:
a) range of the temperature of the ambient air:
during operation: —10 °C to +40 °C;
after transport and storage at ~20 °C to +55 °C;
b} relative humidity of the air:
up to 50 % at 40 °C;
up to 90 % at 20 °C;
c) ambient air, free from abnormal amounts of dust, acids, corrosive gases or substances,
etc. other than those generated by the welding process,
d) altitude above sea level up to 1 000 m;
e) base of the welding power source inclined up to 10°,
© Be sure that you have received all the items that you
have ordered. In case of any items are missing or damaged,
contact your supplier immediately.
@Bc sure that none of the following 6 items are
missing in the box.
Power Source
Earth Clamp and Cable
Switch Cable with TIG Welding Torch
ri User Manual
1 Electrode holder
@Make sure that your line voltage is
single Phase ,220 or 230Y 50/60Hz and you have a
neutral and earth line presentat your work place.
@ in order to cool down the machine and have
an efficient work, keep the machine at least 30
cm away from the surrounding objects. Do not
place any heat source, as oven, to front side of
the machine where the cooling air — is taken from.
&Do not place the machine in small and narrow
places. Beware af excessive dust and dirt,
@Keep your machine away from wet and humid
& Do not operate the machine under direct suniight, rain
and wind, Machines should be operated on lower
capacities when ambient air temperature exceeds 46°C,
O Please use a suitable exhaust system for gases
and cutting vapours. Use breathing apparatus if there is
a risk of inhaling any welding or cutting vapours.
© Avoid welding where air-flow is high. Protect
the welding area with curtains or mobile screens.
@ Transport and place the device on firm and
ievel ground so that it may not fall over. The
maximum permissible angle of inclination
for transport and assemblyis 10°.
O This machine is protected electronically
against overloading. Do not use stronger fuses
than those stated on the type plate of the
@ Ensure that the earth clamp has good and
direct contact near the welding location. Do
not direct welding current over chains, ball
bearings, steel cables, protection conductors
etc., Otherwise they may melt.
@ Ensure that operators can asily reach the
machine controls and equipment connections.
@ Use lifting eyes for lifting the machine.
Do not lift themachine by using a fork-lift or
asimilar vehicle,
Only qualified persons should install use or service this equipment. Protect yourself and others
from possible serious injury or death.
WARNING: Do not operate with covers removed.Disconnect input power before servicing.
Do not touch electicalty live parts,
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@ Before starting the installation,check with the power company to be sure your power supply is adequate
for the voltage,amperes,phase,and frequency specified on the welding machine nameplate, Also be sure the
planned installation will meet all local and nationai code requirements.Some welding machines may be
operated from a single phase line or from one phase of a two or three phase line.
@ Before connecting the input cable to the power supply,check that the power(on-off) switch operates in
the position corresponding to the input voltage that the machine will be connected to.
CAUTION :If the power switch setting does not match the input power voltage, you may burn up the
welding machine!
6 Connect the “PE” or green/yellow grounding wire in the input cord to a system ground per the
applicable national and local codes.
2.4.1 Connect The Machine To Power Supply
@ The connection to the main lines is made by the ead user. It has to be performed by qualified electricians or by
the people trained in thisarea.
6 Power supply cable to the machine must be connected to the main power supply switch. The main power
supply has been labeled inthe nameplate of the machine, for exampie,1 ~, 50Hz. 230VAC.
@ The 3x2.5mm? power supply cable should be used.
© Before turning on the main power supply switch user must check carefully these connections of the power
supply cable and earth cable (Yellow/Green to the machine.
Be sure that connections are fastened tightly. Loose or incorrect fastening may cause
the connection to overheat or burn, Unexpected results may occur if a mistake is made
in the network connection, Pay attention that the connection of the “PE” or green/yellow
grounding wire of the input cord to a system ground.
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Figure 2: The front panel of the welding power source
1- Power supply cable 3-The power supply ON/OFF switch and LED}
4-—The selection switch of TIG or MMA
5--The welding current adjustment knob = 6--Piloi light of LED? for Overheating or Over-current protection
2d—Output(—) for MMA, Connect the workpiece or the Electrode holder
2a-- Output(—) for FIG or connector of the TIG torch Connect it to the TIG torch
2b-- Connector of the torch switch for TIG
2¢-- Qutput{ +), Connect the workpiece or the Electrode holder for MMA; Connect the workpiece for TIG
2.4.2 Connect Output(—) and Output(+)
Positive connection means the workpicee is connected to Qutput( +} of the welding power source,and the
electrode holder or torch is connected to Qutput(—). Negative connection means the workpiece is connected to
Output) of the welding power source,and the electrode holder or torch is connected to Output(-+).
a) T1G welding process
® Positive connection must be selected.
@ Connect the workpiece to Output( +), not Loose (Figure 2).
& Connect the TIG torch to Qutput{ —) or connector of the TIG torch, not Loose(Fi gure 2).
@ Insert theswitch cable of the TiG torch into Connector of the torch switch , not Loose(Fi gure 2).
@The switch of TIG or MMA must be selected to TIG welding process(Figure 2).
O Connect the gas tube to the copper nozzle of the back panel. The gas supply system, which includes a gas bottie, a
reguiator and a gas outlet, shouid be weil connected in order to keep gas output, which is of critical importance for
TIG welding operation,
© Turn on the power supply ON/OFF switch(Figure 2).
@ The TIG welding process will be carried out by using TIG torch switch.
O Be sure that connections are correct and not Loose.
b) MMA welding process
@ The selection of the positive or negative connection will be depended on the type of the electrode.For the acid
welding electrode, for example E4303 and E6013 , the positive or negative connection are used. For the basic
welding electrode, for example E5015, the negative connection is usually used.
© Connect the workpiece or the electrode holder to Qutput(—), not Loose (Figure 2).
6 Connect the Electrode holder or the workpiece to Output( +), not Laose (Fi gure 2).
9 The switch of TIG or MMA must be selected to MMA welding process(Figure 2}.
& Turn on the power supply ON/OFF switch(Figure 2).
@ The MMA welding process will be carried out.
CAUTION :1)For some the electrode,the workpiece must be connected to Output(—), the Electrode holder
must be connected to Output(+) (Figure 2).
2)Usualiy, for most of the electrodes ,the workpiece may be connected to Output(—}, the
Electrode holder may be connected to Output(+) {Figure 2).
3) Be sure that connections are correct and not Loose,
@Connect the earth clamp firmly to the welding benchor the workpiece
@ To increase the quality of the welding, earth ctamp on the work piece should be clamped tightly and as close to the
welding area as possible,
2.4.3 Connect The Gas Cylinder
© After placing the gas cylinder , fasten it with the chain. To operate safely and get best results use approved gas
@ Briefly open the gas cylinder valve several times in order to blow out any dirt and particles present.
@ Connect the pressure regulator to the shielding gas cylinder.
@ Connect one end of gas hose to the gas supply inlet of the welding power source. The other end is for connecting
the hose to pressure regulator.
@ Screw the gas hose pressure regulator andopen the shiclding gas cylinder.
6 Setting of the gas flow with the adjustment valve. Usually the vaive is about 4-10L/min.
Show gas flow The gas cylinder Open the gas cylinder
Setting of gas flow
with the adjustment
Figure 3: Connection of gas hose and the gas cylinder Figure 4: Open the gas valve and Setting of gas flow
9 On the front control panel of the welding power source,there are Pilot tights, Switchs, Welding current
controller etc(Figure 2).
@ A : Welding current adjustment knob or controller.
6 LEDI: Pilot light of the power supply in the ON/OFF power source switch. The LEDI is iighted when the
switch is ON.
@ ON/OFF Switch of the welding power source
© LED2: Pilot light of Over-heating , Over current or voltage. The LED2 is tighted with thermal overload
protection or over current,
LED2 is on, in case that this welding equipment is of overheating protection status. Overheating arises if this
welding power source is overloaded. This welding equipment automatically restarts when the temperature
inside of this welding equipment has fallen, and pilat lamp is off.
CAUTION :In case that this welding equipment is of over current or voltage protection status, LED? is on. At
this time ,Switch of the weiding power source must be turn off,and then Switch should be turn on, the welding power
source would be able to weld.
3.2 ADJUSTING THE GAS FLOW for TIG welding process
@ The indicators of the regulator shows the flow rate “L/min”.
O Setting of the gas flow with the adjustment valve. Usually, the valve is about 4-10L/min.
3.3 Arc starting for TIG welding process
The distance between the tungsten and the workpiece should be Hmited in the range of 2~4mm. Press the
torch switch, the high frequency(HF} is caused. The arc is made between the work and the tip end of the
tungsten electrode, and welding operation is accessible,
The weiding current is selected according to the thickness of the work piece and diameter of the welding
For MMA, the welding current, L=(25-45Y*D, [the electrode diameter 2.0mm, 2.5mm, 3.2mm,ect.
For TK; veldmgmore detail please refer to the Welding Parameter Selection tabie 1,2 etc.
Table1:Parameter for Stainless Plate TIG Welding {for reference only)
Plate Weiding ‚
. Tungsten Wire Gas vaive Welding speed
Thickness Connector current
p {mm) ¢ (mm) CL/min) Cem/min)
(mm) CA)
1.0 Butt Joint 2 1.0~1.6 15~25 47-6 10—45
1.2 Butt Joint 2 1.0~1.6 15~30 4~7 16~30
1.5 Butt Joint 2 1.0~1.6 20-40 4—8 10-25
Table2:Parameter for Titanium and ifs Alloy TIG Welding {for reference only)
. Slope Tungsten Wire Welding Nozzle
thickness ‚ Gas volume { L/min) ,
shape radius radius current radius
0.5 1.5 1.0 30-30 67-10 6-5 14—16 1 10
3.0 2.0 10-2.0 | 40-600 8—10 6-8 14—16 | 10
i.5 I-shaped | 2.0 10-70 | 60-80 10-372 | 8—10 14—16 | 10—12
2.0 2.0-3.0 10-20 | 80-110 12-14 10-12 16-20 ¡ 12-14
2.5 20-30 2.0 110-120 17-14 10-12 16-20 | 1214
3.0 3.0 2.0-3.0 1 120-140 12-14 10-12 10-20 | 14-86
4.0 3.0—4.0 2.0--3.0 | 130—150 14—16 12-14 | 20—25 | 18—20
5.0 4.0 3.0 130-150 id— 16 12-14 | 20-25 | 18—20
6.0 4.0 3.0~4.6 | 140~180 187-16 127-18 | 25-28 | 18-20
7.0 4,0 30-40 f 140-180 14—16 12-14 | 25~28 | 20~22
5.0 4.0 30-40 | 140-1809 14—16 127-14 | 23-28 1 20-22
3.5 About MMA process and welding knowledge
No one can learn to weld simply by reading about it .Skiil comes only with practice. The following pages
will help the inexperienced welder to understand welding and develop his skill ‚For more detailed information
order a book on Arc Welding. The operator’s knowledge of arc welding must go beyond the arc itself .He must
known how to control the arc, and this requires a knowledge of welding circuit and the equipment. The
welding circuit begins where the electrode cable is attached to the welding machine and ends where the work
cable 1s attached to the welding machine Current flows through the electrode cable to the electrode holder,
through the electrode and across the arc. On the work side of the arc, the current flows through base metal to
the work cable and back to the welding machine .To weld, the work clamp must be tightly connected to clean
base metal .Remove paint, rust ,etc, as necessary to get a good connection Connect the work clamp as close as
possible to the area you wish to weld. Avoid the welding circuit to pass through hinges, bearings, electronic
components or similar devices that can be damaged.
The electric arc is made between the work and the tip end of a small metal wire, the electrode, which is
clamped in a holder and the holder is held by the welder. A gap is made in the welding circuit by holding the
tip of the electrode 1.5-2.0mm away from the work or base metal being welded. The electric arc is established
in this gap and is held and moved along the joint to be welded, melting the metal as it is moved.
Arc welding 1s manual skill requiring a steady hand, good physical condition, and good eyesight .the
operator controls the welding arc and, therefore, the quality of the weld made,
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Figure 6 The welding arc
Figure 6 illustrates the action that takes place in the electric arc. it closely resembles what is actually seen
during welding .
The “arc stream ”is seen in the middle of the picture .this is the arc created by the current flowing through
the space between the end of the electrode and the work , The temperature of this arc is about 6000° F. ,Which
is more than enough to melt the base metal . The arc is very bright ,as well as hot ,and cannot be looked at with
the naked eye without risking painful injury. The very dark lens, specially designed for arc welding, must be
used with the hand or face shield whenever viewing the arc.
The arc melts the base metal and actually digs into it, much as water through a nozzle on a garden hose digs
into the earth "The moiten metal forms a molten pool or crater and tends to flow away from the arc ‚As it
moves away from the arc, it cools and solidifies. A slag forms on top of the weld to protect it during cooling.
The function of the covered electrode is much more than simply to carry current to the arc The electrode is
composed of a core of metal wire around which has been extruded and baked chemical covering. The core
wire melts in the arc and tiny droplets of molten metal shoot across the arc into the molten pool .The electrode
provides additional filler metal for the joint to £ili the groove or gap between the two pieces of the base metal.
The covering also melts or burns in the arc.It has several functions.It makes the arc steadier, provides a shield
of smoke-like gas around the arc to keep oxygen and nitrogen in the air away from the molten metal, and
provides a fluxe for the molten pool. The flux picks up impurities and forms the protective slag .The principal
differences between the various types of electrodes are in their coatings. By varying the coating, it is possible
to greatly alter the operating characteristics of electrodes. By understanding the differences in the various
coating, you will gain a better understanding of selecting the best electrode for the job you have at hand .In
selecting an etectrode you should consider:
@ The type of deposit you want, e.g. mild steel, stainless, low alloy.
@ The thickness of the plate or base metal you want to weld.
6 The position it must be welded in (down hand, out-of-position).
@ The surface condition of the base metal to be weld.
@ Your ability to handle and obtain the desired electrode.
Four sempie manipulations are of prime importance. Without complete mastery of these four, further
welding is futile .\With compete mastery of the four, welding will be easy.
1) The Correct Welding Position
Hlustrated is the correct welding position for right-handed people (For left-handed it is opposite):
6 Hold the electrode holder in your right hand
6 Touch left hand to underside of right hand.
6 Put the left elbow into your left side.
Weld with two the hand whenever possible . This gives complete control over the movements of electrode.
Whenever possible, weld from left to right (if right-hand). This enables you to see clearly what you are
doing.Hold the electrode at a slight angle as shown.
| 80°
side view end view
Figure 7 Correct Welding Position
2yThe Correct Way to Strike An Arc
Be sure the work clamp makes good electrical contract to the work .
Lower your headshield and scratch the clectrode slowly over the metal, and you will sec sparks flying.
While scratching, iift the electrode 3 mm and the arc is established.
NOTE: If you stop moving the electrode while scratching, the electrode wiil stick.
NOTE: Most beginners try to strike the arc by a fast jabbing motion down on the plate ‚Result: They either
stick or their motion is so fast that they break the arc immediately.
3) The Correct Arc Length
The arc length is the distance from the tip of the electrode core wire to the base metal.
Once the arc has been established, maintaining the correct arc length becomes extremely important .The
arc should be short approximately 1.5-3.0 mm long .As the electrode burns off the electrode must be fed to
the work to maintain correct arc length.
The casiest way to tell whether the arc has the correct length is by listening to its sound. A nice,short arc
has a distinctive, “crackling” sound ,very much like eggs frying in a pan. The incorrect, long arc has a hollow,
blowing or hissing sound,
4) The Correct Welding Speed
The important thing to watch while welding is the puddle of molten metal right behind the arc. DO NOT
watch the arc is the appearance of the puddle and the ridge where the molten puddle solidifies that
indicate correct welding speed. The ridge shouid be approximately 10mm behind the electrode.
Ridge where puddle И
Figure 8
Moîten puddie
Most beginners tend to weld too fast, resulting in a thin, uneven, “wormy” looking bead.They are not
watching the molten metal.
IMPORTANT: For general welding it is not necessary to weave the arc; neither forwards and backwards
nor sideways. Weld along at a steady pace. You wiil find it easier.
NOTE: When welding on thin plate, you will find that you will have to increase the welding speed,
whereas when welding on heavy plate ,it is necessary to go more slowly in order to get good penetration.
The best way of getting practice in the four skills that enable you to maintain :
@ Correct Welding Position
O Correct Way to Strike An Arc
O Correct Arc Length
8 Correct Weiding Speed
is to spend a little more time on the following exercise.
Use the following:
Mild Steel Plate: 5 mm or heavier
Elecirode: 1/8" (3.2mm)
Current Setting: 100-130 Amps
Do the following:
@ Learn to strike the arc by scratching the electrode over the plate .Be sure the angle of the electrode is right
and Be sure to use both hands.
© When you can strike an arc without sticking, practice the correct arc length.Learn to distinguish it by its
@ When you are sure that you can hold a short, crackling arc, start moving.l.ook at the moiten puddle
constantly, and look for the ridge where the metal solidifies.
& Run beads on a flat plate.Run them parallel to the top edge (the edge farthest away from you ) .This gives
you practice in running straight welds,and also,it gives you an easy way to check your progress .the 10™ weld
will look considerderably better than the first weld, By constantly checking on your mistakes and your progress,
welding will soon be a matter of routine,
Common Metals
Most metals found around the farm or smail shop are low carbon steel, sometimes referred to as mild steel.
Typical items made with this type of steel include most sheet metal, plate, pipe and rolled shapes such as
channels, angel irons and “1” beams ‚This Type of steel can usually be easily welded without special
precautions.Some steel, however,contains higher carbon. Typical applications include wear plates, axles,
connecting rods, shafts, plowshares and scraper blades. These higher carbon steels cabin be welded
successfully in most cases; however care must be taken to follow proper procedures, including preheating
the metal to be welded and, in some cases, carefully controlling the temperatures during and afier the welding
process ‚For further information on identifying various types of steel and other metals ,and for proper
procedures for welding them ,we again suggest you purchase a book on Arc Welding,
Only qualified persons should install,use or service this equipment. Protect yourself and others
from possible serious injury or death.
WARNING: Do not operate with covers removed.Disconnect input power before servicing,
Do not touch electically live parts.
- Mave an electrician install anc
service this equipment.
= Tarn the input power off at the
fuse box before working on
- Do not touch elecirically hot
WARNING: Before removing any screw on the machine for maintenance, power supply must be
disconnected from the electric lines and enough time should be allowed for capacitor discharging. During
maintenance, pay attention to the moving parts in the machine,
Once every three months
6 Clean the labels on the machine. Repair or replace the worn out labels.
@ Repair or replace the worn out welding cables.
@ Clean and tighten weld terminals.
© Check Gun, earth clamp and their cables.
& Check the main connections inside the machine.
Once every six months
@ Open the covers of the machine and clean with dry air.
NOTE: The above recommended maintenence periods are indicative according to our
general experience, these may vary from work shop to work shop and the conditions of the
welding site,
© The welding power source must be cleaned with dry air.
@ Nozzle on the torch have to be cleaned regularly and changed if required. Contact tips
must be in good condition, longer tips generally give better results.
Exposure to extremely dusty, damp, or corrosive air is damaging to the welding machine. In order to prevent any
possible failure or fault of this welding equipment, clean the dust at regular intervals with clean and dry
compressed air of required pressure.
Please note that: lack of maintenance can speli to the unavailability and cancellation of the guarantee; the guarantee
of this welding equipment will be no longer available in case that it has been attempted to take the machine apart or
open the factory-made scaling of the machine,
Fault Symptoms
1. The welding equipment
is operated, the pilot lamp
is off, no output, the
built-in fan unavailable.
1.Passible function failure of power switch. Compensate it if necessary.
2.Possible unavailability of input. Compensate it if necessary,
3.Possible short circuit of input cable, Compensate it if necessary.
2. While
equipment is operated, the
this welding
i.Possible occurrence of over voltage protection status. Restart ON/OFF Switch .
2.Frequently switching on and off of this welding equipment in a short period leads
this equipment’s being of over-voltage protection, Switch off this welding machine
pilot lamp is on, no | and wait for at least 3 minutes, then restart this welding equipment.
output, the built-in fan | 3.Possible unavailability of the connection of switch and bottom board. Reconnect
unavaiiable, it,
4. The 24 V relay of bottom PCB is possibly damaged. Replace it if necessary.
1.Possible short circuit occurs, and possible unavailability of connection of silicon
bridge with the PCB.
3. While this welding | 2.Possible electricity leakage of capacitors, replace them if necessary.
equipment is operated, the
built-in fan functions, the
fault indicator is off, no
HF electricity releasing,
arc starting unavailable,
3.A green light indicator of secondary power supply of top PCB should be on.
Otherwise, it indicates that the secondary power supply is not functioning. Check the
connection whether 1s available. If fault cannot be rectified, please contact the
supplier for further advice.
4.Possible unavailability of connection inside this welding equipment or malfunction
of control circuit occurs. Check and reconnect if necessary.
5.Possible damage of the welding torch. Replace it if necessary.
4.LED?2 15 off, HF spark
gap is
welding current output is
available, and
I.Possible disconnection of welding torch cable.
2.Possible disconnection of earth cable, or unavailability of connection of the earth
cable and work piece.
3.The connection between positive output terminal or the gas or electricity output
terminal and this welding equipment is possibly unavailable, Reconnect them.
5. While is this welding
equipment is operated, the
fanlt indicator is off, no
electricity releasing, and
the arc starting available.
i. The cable connection between the transformer of arc starting and power PCB is
possibly unavailable. Check and reconnect if.
2.Possible oxidization of the spark gap parts occurs, Or the distance is farger than
the maximum distance available. Remove the oxidization of these parts and adjust
the distance of the spark gap parts to fmm.
3.Possible damage to MMA/TIG switch, Replace them if necessary.
4. HF arc starting circuit are possibly damaged, Check and replace them if
6. While this
equipment 15
fault indicator is on, and
there is no output,
1.1t 1s possible of over-current protection status. Switch off the power supply, wait
till the LED2 is off, and restart this welding equipment.
2.1t ts possible of over-heating protection status, Wait till the LED? is off, and the
welding operation will be available.
3.Possible fault with Inverter circuit. Disconnect the power supply plug (VH-07) of
transformer of MOS PCB. And restart this welding equipment.
4.1f theLED2 is still on. Tum off the power supply of this welding equipment.
Disconnect the power supply plug (VH-03) of HF arc starting.
3.Jf the LED2 is on, MOFESTS of top PCB is possibly defective. Replace it.
6.Possible damage of transformer of center PCB. Replace it if necessary.
1.1f the LED? is off,possible damage of transformer of center PCB. Replace it if
necessary. Measure the inductance value and Q value. L=0.9-1.6mH, Q>35. If both
of the inductance value and Q value are comparatively low, replace them.
8. If the fault indicator is off ,possible damage of secondary rectifier of transformer.
Replace it if necessary.
9.Possible damage of feed back circuit. Replace it if necessary.
7. Unstable current and
the potentiometer is
! Possible damage of I K resistance. Replace it if necessary.
2.The connection of this welding equipment is not available,
Einstufung nach EMV Richtlinie: Klasse A gemäß CISPR 11
Warnung: Als Klasse A eingestufte Geräte sind für den Einsatz im industriellen Bereich vorgesehen.
Beim Einsatz in anderen Bereichen kann die elektromagnetische Vertäglichkeit unter Umständen
nicht gewährleistet werden, bzw. es kann zu Störfällen kommen.
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