SifWeld TSXE1T200ACP Operation Manual

www.sifweld.com
Peters House
The Orbital Centre
Icknield Way
Letchworth Garden City
Hertfordshire
SG6 1ET
Tel. +44 (0) 345 130 7757
TIG
SifWeld Evolution TS200ACDC
MMA
Approved
Operation Manual
TSXE1T200ACP
DECLARATION OF CONFORMITY
The Low voltage Directive 2006/95/EC of 12 December 2006, entering into force 16 January 2007
The EMC Directive 2004/108/EC, entering into force 20 July 2007
The RoSH Directive 2011/65/EC, entering into force 2 January 2013
Type of Equipment
Welding power source for TIG/TAG, MMA welding
Brand name or trade mark
SifWeld® Evolution
Type designation etc.
TS200ACDC
Manufacturer or his authorised representative established within the EEA
Name, address, telephone no, fax no
Weldability Sif
Peters House, The Orbital Centre
Icknield Way, Letchworth
Hertfordshire, SG6 1ET
United Kindom
Phone: +44 (0)845 130 7757 Fax: +44 (0)800 970 7757
The following harmonised standard in force with the EEA has been used in the design:
EN60974-1- Arc welding equipment- Part 1: Welding power sources
EN60974-10 Arc welding equipment - Part 10: Electromagnetic Compatibility (EMC) requirements
Additional information: restrictive use, Class A equipment, intended for use in locations other than residential
By signing this document, the undersigned declares as manufacturer, or the manufacturer’s authorised
representative established within the EEA, that the equipment in question complies with the safety
requirements stated above.
Place and Date
Letchworth, UK
01-04-2015
Signiture
Keith Mullan
WEEE Directive & Product Disposal
At the end of its serviceable life, this product should not be treated as household
or general waste. It should be handed over to the applicable collection point for
the recycling of electrical and electronic equipment, or returned to the supplier for
disposal.
2
Position
Quality Manager
Weldability Sif
Safety Guidelines
These general safety norms cover both arc welding machines and plasma cutting machines unless
otherwise noted. The equipment must only be used for the purpose it was designed for. Using it in any
other way could result in damage or injury and in breach of the safety rules. Only suitably trained and
competent persons should use the equipment. Operators should respect the safety of other persons.
Prevention against electric shock
The equipment should be installed by a qualified person and in accordance with current standards in
operation. It is the user’s responsibility to ensure that the equipment is connected to a suitable power
supply. Consult with your utility supplier if required. If earth grounding of the work piece is required,
ground it directly with a separate cable. Do not use the equipment with the covers removed. Do not
touch live electrical parts or parts which are electrically charged. Turn off all equipment when not in use.
Cables (both primary supply and welding) should be regularly checked for damage and overheating. Do
not use worn, damaged, under sized or poorly jointed cables. Ensure that you wear the correct protective clothing, gloves, head and eye protection. Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work ground. Never touch the
electrode if you are in contact with the work ground, or another electrode from a different machine.
Do not wrap cables over your body. Ensure that you take additional safety precautions when you are
welding in electrically hazardous conditions such as damp environments, wearing wet clothing, and
metal structures. Try to avoid welding in cramped or restricted positions. Ensure that the equipment is
well maintained. Repair or replace damaged or defective parts immediately. Carry out any regular maintenance in accordance with the manufacturer’s instructions.
Safety against fumes and welding gases
Locate the equipment in a well-ventilated position. Keep your head out of the fumes. Do not breathe
the fumes. Ensure the welding zone is in a well-ventilated area. If this is not possible provision should be
made for suitable fume extraction. If ventilation is poor, wear an approved respirator. Read and understand the Material Safety Data Sheets (MSDS’s) and the manufacturer’s instructions for metals, consumable, coatings, cleaners, and de-greasers. Do not weld in locations near any de-greasing, cleaning, or
spraying operations. Be aware that heat and rays of the arc can react with vapours to form highly toxic
and irritating gases. Do not weld on coated metals, unless the coating is removed from the weld area,
the area is well ventilated, and while wearing an air-supplied respirator. The coatings on many metals
can give off toxic fumes if welded.
Prevention against burns and radiation
Arc rays from the welding process produce intense, visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Wear an approved welding helmet fitted with a proper shade of filter lens
to protect your face and eyes when welding or watching. Wear approved safety glasses with side shields
under your helmet. Never use broken or faulty welding helmets. Always ensure there are adequate
protective screens or barriers to protect others from flash, glare and sparks from the welding area. Ensure
that there are adequate warnings that welding or cutting is taking place.
3
Wear suitable protective flame resistant clothing. The sparks and spatter from welding, hot work pieces,
and hot equipment can cause fires and burns. Welding on closed containers, such as tanks, drums, or
pipes, can cause them to explode. Accidental contact of electrode to metal objects can cause arcs,
explosion, overheating, or fire. Check and be sure the area is safe and clear of inflammable material
before carrying out any welding.
Protection against noise
Some welding and cutting operations may produce noise. Wear safety ear protection to protect your
hearing.
Protection from moving parts
When the machine is in operation, keep away from moving parts such as motors and fans. Moving
parts, such as the fan, may cut fingers and hands and snag garments. Protections and coverings may
be removed for maintenance and controls only by qualified personnel, after first disconnecting the
power supply cable. Replace the coverings and protections and close all doors when the intervention
is finished, and before starting the equipment. Take care to avoid getting fingers trapped when loading
and feeding wire during set up and operation. When feeding wire be careful to avoid pointing it at other
people or toward your body. Always ensure machine covers and protective devices are in operation.
Precautions against fire and explosion
Avoid causing fires due to sparks and hot waste or molten metal. Ensure that appropriate fire safety
devices are available near the cutting / welding area. Remove all flammable and combustible materials
from the cutting / welding zone and surrounding areas. Do not cut/weld fuel and lubricant containers,
even if empty. These must be carefully cleaned before they can be cut/welded. Always allow the cut/
welded material to cool before touching it or placing it in contact with combustible or flammable
material. Do not work in atmospheres with high concentrations of combustible fumes, flammable gases
and dust. Always check the work area half an hour after cutting to make sure that no fires have begun.
Risks due to magnetic fields
The magnetic fields created by high currents may affect the operation of pacemakers or electronically
controlled medical equipment. Wearers of vital electronic equipment should consult their physician
before beginning any arc welding, cutting, gouging or spot welding operations. Do not go near welding
equipment with any sensitive electronic equipment as the magnetic fields may cause damage.
RF Declaration
Equipment that complies with directive 2004/108/EC concerning electromagnetic compatibility (EMC)
and the technical requirements of EN60974-10 is designed for use in industrial buildings and not those
for domestic use where electricity is provided via the low voltage public distribution system. Difficulties
may arise in assuring class A electromagnetic compatibility for systems installed in domestic locations
due to conducted and radiated emissions. In the case of electromagnetic problems, it is the
responsibility of the user to resolve the situation. It may be necessary to shield the equipment and fit
suitable filters on the mains supply.
4
LF Declaration
Consult the data plate on the equipment for the power supply requirements. Due to the elevated
absorbency of the primary current from the power supply network, high power systems affect the
quality of power provided by the network. Consequently, connection restrictions or maximum
impedance requirements permitted by the network at the public network connection point must be
applied to these systems. In this case the installer or the user is responsible for ensuring the equipment
can be connected, consulting the electricity provider if necessary.
Materials and their disposal
The equipment is manufactured with materials, which do not contain any toxic or poisonous
materials dangerous to the operator. When the equipment is scrapped, it should be dismantled
separating components according to the type of materials. Do not dispose of the equipment with
normal waste. The European Directive 2002/96/EC on Waste Electrical and Electronic Equipment states
the electrical equipment that has reached its end of life must be collected separately and returned to an
environmentally compatible recycling facility.
Handling of Compressed gas cylinders and regulators
All cylinders and pressure regulators used in welding operations should be handled with care.
Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.
Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
Always secure the cylinder safely. Never deface or alter any cylinder.
!
The following signs and explanations are to remind the user of the potential
risks involved and the dangers of misuse or mistreatment of the welding
machine.
RUNNING PARTS MAY BE DANGEROUS!
Keep away from running components,
including the fan.
ELECTRIC SHOCKS CAN KILL!
Never touch electrical parts. Keep the
equipment in good condition, replace
damaged parts, undertake regular
maintenance according to the instructions.
BE AWARE OF SPARKS AND SPATTER
Wear protective clothing, such as leather
gloves, Flame retardant overalls, boots and
eyewear.
DO NOT TOUCH THERMAL COMPONENTS!
Thermal components may cause severe burns
when in contact with unprotected skin.
5
Contents
1.
Preface7
1.1
1.2
1.3
1.4
General7
Introduction8
Technical Specifications9
Overview of Machine10
2.
2.1
2.2
2.3
2.4
2.5
Control Panels11
MMA Display12
HF/Lift TIG Display13
Pulse TIG Display14
TIG SPOT Display15
JOB Programme15
3.
3.1
3.2
Installation 18
Wireless Foot Pedal22
Pedal switch Control23
4.
Operation24
5.
Troubleshooting25
6.
Maintenance26
7.
Warranty27
6
1. Preface
1.1 General
Congratulations on choosing your SifWeld Evolution TS200ACDC welding machine.
Used correctly, SifWeld products can significantly increase the productivity of your welding, and provide
years of economical service. This operating manual contains important information on the use,
maintenance and safety of your SifWeld product. Please read the manual carefully before using the
equipment for the first time. For your own safety and that of your working environment, pay particular
attention to the safety instructions in the manual.
For more information on SifWeld products, consult an authorised SifWeld dealer, or visit the SifWeld web
site at www.sifweld.com. The specifications presented in this manual are subject to change without prior
notice.
Important notes
Items in the manual that require particular attention in order to minimise damage and personal harm
are indicated with the ’NOTE!’ notation. Read these sections carefully and follow their instructions.
Disclaimer
While every effort has been made to ensure that the information contained in this guide is accurate and
complete, no liability can be accepted for any errors or omissions. We reserve the right to change the
specification of the product described at any time without prior notice. Do not copy, record, reproduce
or transmit the contents of this guide without prior permission.
7
1.2 Introduction
The advanced Sifweld Evolution Aerotech range of AC/DC TIG machines have features normally only
available on high end Aerospace specific TIG welding machines, including: Four power levels of HF ignition
strength, fully adjustable cleaning and welding current levels on both the positive and negative parts of
the AC Square Wave Cycle.
A professional, microprocessor-controlled inverter welding power source for AC TIG, DC TIG & MMA
applications. The use of IGBT technology providing a compact and lightweight machine including the
advanced Aerotech features, high speed pulse and the complete range fully adjustable parameters
normally expected on a professional TIG welding machine. Multimodal for TIG HF / TIG Lift / MMA process.
Features
• PFC Technology: Power factor more than 0.99. Multiple advantages such as energy saving and welder
input voltage. Input voltage, works with single-phase: 110V/230V.
• Fully adjustable Cleaning and Welding current levels on the Negative and Positive parts of the AC
Square Wave.
• Lift TIG and HF Start Modes
• Adjustable arc force, hot start & anti stick control for greater control and ease of use when MMA welding.
• Electronic HF TIG arc ignition system for contamination free and easy arc starting with low EMF
interference.
• Four levels of High performance HF Strength for use on ultrathin surfaces with no deformation.
• High Speed Pulse
• 2T/ 4T/ Spot trigger control.
• LCD screen for accurate setting & feedback of welding output.
• Intelligent protection: Over-voltage, over-current, over-heat, when the problems listed before occurred,
the alarm indicator on the front panel will be on and the output current will be cut off. It can self-protect
and prolong the using life.
• Designed to work with diesel generators and to avoid failures due to its voltage spikes.
• Wire/Wireless Foot Pedal available.
8
1.3 Technical Specifications
SifWeld Evolution TS200ACDC
1-110V±10%, 50/60Hz
Power source
1-230V±10%, 50/60Hz
TIG
TIG
MMA
MMA
TIG
TIG
MMA
MMA
AC
DC
AC
DC
AC
DC
AC
DC
39.3
19.8
21.3
28.5
30.8
4.3
4.5
4.9
6.6
7.1
74.8
65.9
Rated input current (A)
32.0
34.5
36.0
Rated input power (KW)
3.5
3.8
4.0
0.99
Power factor
Welding current range (A)
Max no load voltage (V)
10~160
74.5
10~130
10~200
65.9
66
65.9
0~10
Up slope/Down slope (S)
0.1~2.0/ 0.0~10.0
Pre/Post Flow (S)
Pulse Frequency (HZ)
0.5~999
Pulse Width Range (%)
5~95
Efficiency (%)
80
Duty cycle (40oC, 10mins)
30% 130A
35% 200A
60% 160A
60% 95A
60% 200A
60% 145A
100% 125A
100% 75A
100% 155A
100% 110A
Circuit breaker
JD03-A1 30A
Protection class
IP21S
Cooling
AF
Net weight (Kg)
AF
Dimensions (mm)
580 × 245 × 400
9
1.4 Overview of Machine
Front View
Power Source Front Panel Layout
1. Positive output.
2. Negative output
3. Aero socket
4. Shield gas connector
5. Power source switch
Rear View
5. Power source switch.
6. Power source input.
7. Shield gas input joint.
10
INSTALLATION & OPERATION
2. Control Panels
§3.2 Layout for Control panel
§3.2.1 Control panel
1. Welding mode key: Press it to select MMA/ HF TIG/ Lift TIG welding mode.
1. Welding mode key
2. Output waveform key.*
Press it to select MMA/
HF TIG/ Lift TIG welding mode.
3. Trigger mode selecting key: Press it to select 2T or 4T trigger mode.
2. Output waveform
4. key
Welding function key: Press it to select the opening or closing of Pulse mode and
Spot welding mode.
3. Trigger mode selecting key
5. JOB key: Press it for 3s to open JOB program and press it for 1s to save parameters
Press it to select 2T or 4T trigger mode.
into JOB number.
6. key
Function A key.*
4. Welding function
Press it to select the7.opening
or closing
of Pulse
mode
and
welding
mode.
Parameter
A key: Press
it to select
Hot
startSpot
or Balance.
If the
key is not pressed
within 3s, the selection will be automatically removed.
5. JOB key
8. Screen: It will show all welding parameters, such as welding voltage, welding current
Press it for 3s to open JOB program and press it for 1s to save parameters into JOB number.
and other parameters set.
6. Function A key. 9. Parameter B key: Press it to select Arc Force or AC Frequency. If the key is not
pressed within 3s, the selection will be automatically removed.
7. Parameter A key10. Function B key.*
Press it to select Hot11.start
or Balance. If the key is not pressed within 3s, the selection will be
Parameters select/adjust knob.*
automatically removed.
* Denotes more detailed explanation of function to follow.
8. Screen
6
It will show all welding parameters, such as welding voltage,
welding current and other parameters set.
9. Parameter B key
Press it to select Arc Force or AC Frequency. If the key is not pressed within 3s, the selection will be
automatically removed.
10. Function B key
11. Parameters select/adjust knob.
11
INSTALLATION & OPERATION
2.1 MMA§3.2.2
Display
MMA display introduction
1. Welding mode key: Press it to enter MMA welding mode.
1. Welding mode key
2. Out waveform key: Press it to select DC output or AC Square wave output.
Press it to enter MMA
welding mode.
3. Parameter A key: Press it to select Hot start. Setting range: 0 - 10.
4. key
Parameter B key: Press it to select Arc force. Setting range: 0 - 10.
2. Out waveform
knob: wave
Rotateoutput.
it to adjust welding current and value of Hot start
Press it to select 5.
DCParameter
output oradjust
AC Square
and Arc force.
3. Parameter A 6.
keyCurrent display: It displays welding current during welding operation, otherwise
Press it to select Hotshow
start.current
Setting
range: 0 - 10.
selected.
7. Welding voltage display: It displays welding voltage.
4. Parameter B key
Press it to select Arc force. Setting range: 0 - 10.
5. Parameter adjust knob
Rotate it to adjust welding current and value of Hot start and Arc force.
6. Current display
It displays welding current during welding operation, otherwise show current selected.
7. Welding voltage display
It displays welding voltage.
12
8
2.2 HF/LIFT TIG Display
INSTALLATION & OPERATION
§3.2.3 HF/LIFT TIG display introduction
1. Welding mode
key: Press
to enter
HFit TIG
or Lift
mode.
1. Welding
modeit key:
Press
to enter
HFTIG
TIGwelding
or Lift TIG
welding mode.
2. Outputkey:
waveform
PressDC
it tooutput
select DC
output
or output.
AC wave output.
2. Output waveform
Press itkey:
to select
or AC
wave
3. Trigger mode
key: Press
it key:
to select
4T trigger
3. Trigger
mode
Press2Tit or
to select
2T ormode.
4T trigger mode.
4. Welding function
key:
Press it key:
to select
Noit Pulse/
Pulse/
Spot welding
function.
4. Welding
function
Press
to select
No Pulse/
Pulse/ Spot
welding function.
(Here is no Spot(Here
function
in Lift TIG welding mode and AC mode.)
is no Spot function in Lift TIG welding mode and AC mode.)
5. Parameter
key: Press Ait key:
to select
Balance.
Setting
range:
-5 torange:
+5. -5 to +5.
5. AParameter
PressAC
it to
select AC
Balance.
Setting
9
13
6. Parameter B key
Press it to select AC Frequency. Setting range: 50 - 250Hz.
7. Function A key
Press it to select Pre-gas time, Start arc current and Up slope time.
INSTALLATION & OPERATION
8. Function
A key B key: Press it to select AC Frequency. Setting range: 50 - 250Hz.
6. Parameter
Press it7.to Function
select Down
slope
time,itEnd
arc current
and
Post-gas
time.
A key:
Press
to select
Pre-gas
time,
Start arc
current and Up slope time.
8. Function
A key: Press
9. Parameters
select/adjust
knobit to select Down slope time, End arc current and Post-gas
Press it to time.
select welding current and other parameters. Rotate it to adjust parameters’ value.
9. Parameters select/adjust knob: Press it to select welding current and other
10. Current display
Rotate
it to adjust
parameters’
It displays parameters.
welding current
during
welding
operation,value.
otherwise show current selected.
10. Current display: It displays welding current during welding operation, otherwise
11. Welding voltage display.
show current selected.
11. Welding voltage display.
2.3 Pulse TIG Display
§3.2.4 TIG Pulse display introduction
1. Peak current
It is 5%1.to Peak
100%current:
of the main
current.
It iswelding
5% to 100%
of the main welding current.
2. Base current: It is 5% to 100% of the main welding current, but less than Peak
2. Base current
It is 5% to current.
100% of the main welding current, but less than Peak current.
3. Pulse frequency: 0.5 - 999Hz.
3. Pulse frequency
4. Pulse width: 5 - 95%.
0.5 - 999Hz.
4. Pulse width
5 - 95%.
14
1
2.4 TIG Spot Display
INSTALLATION & OPERATION
§3.2.5 TIG Spot display introduction
INSTALLATION & OPERATION
§3.2.5 TIG Spot display introduction
1. Current display:
10-200A.
1. Current
display: 10-200A.
2. 0.1
Ton- display:
2. Ton display:
1.0s. 0.1 - 1.0s.
1. Current display: 10-200A.
3. Toff display: off - 10.0s.
3. Toff display:
- 10.0s.
2. Ton off
display:
0.1 - 1.0s.
3. Toff display: off - 10.0s.
§3.2.6 JOB Program introduction
2.5 JOB Programme
§3.2.6 JOB Program introduction
1. Welding mode display: Here are selected welding states.
2. Parameters display: Here are all selected parameters values.
1. mode
Welding
mode Here
display: Here
are selected welding
states.
1. Welding
display
3. JOB
number: A are
totalselected
1-10 JOBwelding
numbersstates.
can store or call the selected parameters
2. Parameters display: Here are all selected parameters values.
by JOB Here
key. are all selected parameters values.
2. Parameters display
3. JOB number: A total 1-10 JOB numbers can store or call the selected parameters
4. Load/ Delete display: Press Function A/B key to call/delete parameters setting for
3. JOB number
A total
by JOB
key.1-10 JOB numbers can store or call the selected parameters by JOB key.
the selected JOB number.
Load/
Delete display: Press Function A/B key to call/delete parameters setting for
4. Load/ 4.
Delete
display
1
the selected JOB number.
Press Function
A/B key to call/delete parameters setting for the selected JOB number.
1
15
INSTALLATION & OPERATION

2T Mode
2T MODE
The trigger is pulled and held on to activate the welding circuit, when the trigger is
The trigger is pulled and held on to activate the welding circuit, when the trigger is released, the
released,
thestops.
welding
stops.
welding circuit
Thiscircuit
function
without the adjustment of start current and crater current is suitable
for the
Re-tack
welding,
welding,ofthin
plate
welding
and socurrent
on.
This
function
withouttransient
the adjustment
start
current
and crater
is suitable for the
Re-tack welding、transient welding、thin plate welding and so on.
Introduction:
Introduction
(1) 0: Press the gun switch and hold it. Electromagnetic gas valve is turned on. The
1. 0: Press the gun switch and hold it. Electromagnetic gas valve is turned on. The shielding gas stars to
shielding gas stars to flow.
flow.
(2)
Pre-gas
time (0.1~2.0s)
2. 0~t1:0～t1:
Pre-gas
time (0.1~2.0s)
3. t1~t2:
Arc isArc
ignited
and the
current
rises to
theto
setting
welding
current
(Iw or(IIb)
from the
(3) t1～t2:
is ignited
andoutput
the output
current
rises
the setting
welding
current
w or
min welding current.
from the
min
welding
current.
Ib) During
4. t2~t3:
the
whole
welding
process, the gun switch is pressed and held without releasing.
(4) t2～t3: During the whole welding process, the gun switch is pressed and held without
Note: Select the pulsed output, the base current and welding current will be outputted alternately;
releasing.
otherwise, output the setting value of welding current.
Note: Select the pulsed output, the base current and welding current will be outputted
5. t3:
Release the
gun switch,
thethe
welding
current
drop in current;
accordance with the selected down-slope
alternately;
otherwise,
output
setting
value will
of welding
time.
(5) t3: Release the gun switch, the welding current will drop in accordance with the
6. t3~t4: The current drops to the minimum welding current from the setting current (Iw or Ib), and
down-slope time.
then arcselected
is turned
off.
(6) t3～t4:
The time,
current
drops
to the
minimum
welding
currentit from
the setting
current
(Iw the knob
7. t4~t5:
Post-gas
after
the arc
is turned
off. You
can adjust
(0.0~10s)
through
turnning
on the or
front
panel.
Ib), and then arc is turned off.
8. t5: Electromagnetic gas valve turned off, the shield gas stops to flow, and welding is finished.
(7) t4～t5: Post-gas time, after the arc is turned off. You can adjust it (0.0~10s) through
turnning the knob on the front panel.
(8) t5: Electromagnetic gas valve turned off, the shield gas stops to flow, and welding is
finished.
1
16
PANEL FUNCTIONS & DESCRIPTIONS
4T MODE
This iswelding
known as
’latching’
mode.
The
trigger isagain
pulledtoonce
andthe
released
to activate
circuit,
circuit, pulled and released
stops
welding
circuit. the
Thiswelding
function
is
pulled and released again to stops the welding circuit. This function is useful to longer welds as the
useful
longer welds
as the
is not TIG
required
held on
continuously.
series
trigger
is nottorequired
to be held
on trigger
continuously.
series to
of be
welding
machines
also hasTIG
more
current
control
options
that
can
be
used
in
4T
mode.
of welding machines also has more current control options that can be used in 4T mode.
Thecurrent
start current
and
cratercan
current
can be
function canthe
compensate
the
The start
and crater
current
be pre-set.
Thispre-set.
functionThis
can compensate
possible crater
that appears at the beginning and end of the welding. Thus, 4T is suitable for the welding of medium
possible crater that appears at the beginning and end of the welding. Thus, 4T is suitable
thickness plates.
for the welding of medium thickness plates.
Introduction:
Introduction
(1) 0: Press and hold the gun switch, Electromagnetic gas valve is turned on. The
1. 0: Press and hold the gun switch, Electromagnetic gas valve is turned on. The shielding gas stars to flow.
shielding
gas
stars to flow;
2. 0~t1: Pre-gas
time
(0.1~2.0S);
3. t1~t2:
Arc
is
ignited
at
and(0.1~2.0S);
then output the setting value of start current;
(2) 0～t1: Pre-gas t1
time
4. t2: Loosen the gun switch, the output current slopes up from the start current;
(3) t1～t2:
Arc current
is ignited
at to
t1 the
andsetting
then output
theorsetting
of start
5. t2~t3:
The output
rises
value (Iw
Ib), thevalue
upslope
time current;
can be adjusted;
6. t3~t4:
Welding
process.
During
this the
period,
the current
gun switch
is loosen;
(4) t2:
Loosen
the gun
switch,
output
slopes
up from the start current;
Note: Select the pulsed output, the base current and welding current will be outputted alternately;
(5) t2～t3:
to the
setting value (Iw or Ib), the upslope time can be
otherwise,
outputThe
the output
setting current
value ofrises
welding
current;
7. t4: Press
the
torch
switch
again,
the
welding
current
will drop in accordance with the selected downadjusted;
slope time.
(6) t3～t4:
Welding
process.
During
period,
the gun
is loosen;
8. t4~t5:
The output
current
slopes down
tothis
the crater
current.
Theswitch
downslope
time can be adjusted;
9. t5~t6: The crater current time;
Note: Select the pulsed output, the base current and welding current will be outputted
10. t6: Loosen the gun switch, stop arc and keep on argon flowing;
11. t6~t7:
Post-gas
time can be
set by
thesetting
post-gas
timeofadjustment
knob on the front
alternately;
otherwise,
output
the
value
welding current;
(7) t4: Press the torch switch again, the welding current will drop in accordance with the
selected down-slope time.
(8) t4～t5: The output current slopes down to the crater current. The downslope time
can be adjusted;
(9) t5～t6: The crater current time;
(10) t6: Loosen the gun switch, stop arc and keep on argon flowing;
(11) t6～t7: Post-gas time can be set by the post-gas time adjustment knob on the front
1
17
3. Installation
Unpacking
Check the packaging for any signs of damage. Carefully remove the machine and retain the packaging
until the installation is complete.
Location
The machine should be located in a suitable position and environment. Care should be taken to avoid
moisture, dust, steam, oil or corrosive gases. Place on a secure level surface and ensure that there is
adequate clearance around the machine to ensure natural airflow.
Input connection
Before connecting the machine you should ensure that the correct supply is available. Details of the
machine requirements can be found on the rating plate of the machine or in the technical parameters
shown in the manual. The equipment should be connected by a suitably qualified competent person.
Always ensure the equipment has a proper grounding. Never connect the machine to the mains supply
with the panels removed.
Output connections
In general when using manual arc welding electrodes the electrode holder is connected to the positive
terminal and the work return to the negative terminal. Always consult the electrode manufacturer’s
data sheet if you have any doubts. When using the machine for TIG welding the TIG torch should be
connected to the negative terminal and the work return to the positive terminal.
18
panel (0.0～10S);
(12) t7: Electromagnetic valve is closed and stop argon flowing. Welding is finished.
§3.3 Installation & Operation for MMA welding
§3.3.1 Set up installation for MMA Welding
Connection of Output Cables
MMA Welding
Two socketsTwo
are available
on available
this welding
machine.
Formachine.
MMA welding
the welding
electrode
is shown be
sockets are
on this
welding
For MMA
theholder
electrode
connectedholder
to theispositive
socket,
while to
thethe
earth
leadsocket,
(work piece)
is connected
to thepiece)
negative
shown be
connected
positive
while the
earth lead (work
is socket,
this is known as DCEP. However various electrodes require a different polarity for optimum results and
connected to the negative socket, this is known as DCEP. However various electrodes
careful attention should be paid to the polarity, refer to the electrode manufacturer’s information for the
require a different polarity for optimum results and careful attention should be paid to the
correct polarity.
polarity,
refer to thetoelectrode
manufacturer's
information for the correct polarity.
DCEP: Electrode
connected
“+” output
socket.
DCEN: Electrode
to “-” output
socket.
DCEP:connected
Electrode connected
to “+”
output socket.
MMA (DC): Choosing the connection of DCEN or DCEP according to the different electrodes. Please refer
DCEN: Electrode connected to “-” output socket.
to the electrode manual.
(DC): Choosing
the connection
of DCEN or DCEP according to the different
MMA (AC):MMA
No requirements
for polarity
connection..
electrodes. Please refer to the electrode manual.
MMA (AC): No requirements for polarity connection.
(1) Connect the earth lead to “-”, tighten clockwise;
1. Connect(2)
theConnect
earth lead
“-”, tighten
theto
earth
clamp toclockwise
the work piece. Contact with the work piece must be firm
2. Connect the earth clamp to the work piece. Contact with the work piece must be firm
1
3. Connect the electrode lead to “+”, tighten clockwise
4. Each machine is equipped with a power cable should be based on the input voltage welding power
cable connected to the appropriate position, not to pick the wrong voltage
5. With the corresponding input power supply terminal or socket good contact and prevent oxidation
6. With a multi meter measure the input voltage is within the fluctuation range
7. The power ground is well grounded.
19
TIG Welding
1. Insert earth cable plug into the positive socket on the front of the machine and twist to lock in place.
2. Plug the welding torch into the negative socket on the front panel and twist to lock.
3. Connect the gas line of TIG torch to outlet gas connector on the front of the machine.
4. Connect the control cable of torch switch to 12 pin socket on the front of the machine.
5. Connect the gas regulator to the Gas Cylinder and connect the gas line to the Gas Regulator. Check
for Leaks!
6. Connect the gas line to the machine inlet gas connector via the quick push lock connector located on
the rear panel. Check for Leaks!
NOTE! Air cooling mode without cooling device and the water pipe is not needed for the air cooling
mode.
7. Connect the power cable of welding machine with the output switch in electric box on site. Turn on
the power switch.
8. Carefully open the valve of the gas cylinder, set the required gas flow rate.
9. Select “Lift TIG” or “HF TIG” on the front panel.
10. 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.
• When 4T operation is selected, press and release trigger Gas starts, touch and lift arc start. Press and
release trigger again, Gas and Arc stops.
11. Set current and TIG parameter setting, including Pre Gas, Slow down, etc.
INSTALLATION & OPERATION
20
(8) Carefully open the valve of the gas cylinder, set the required gas flow rate.
(9) Select “Lift TIG” or “HF TIG” on the front panel.
(10) Set torch operation 2T/4T.
Tungsten
Diameter
mm
1.0mm
DC Current Amps
Torch Negative
2% Thoriated
15-80
AC Current Amps
Un-Balanced wave
0.8% Zirconiated
15-80
AC Current Amps
Balanced wave
0.8% Zirconiated
20-60
1.6mm
70-150
70-150
60-120
2.4mm
150-250
150-250
100-180
3.2mm
250-400
225-325
160-250
4.0mm
400-500
300-400
INSTALLATION & OPERATION
300-400
4.0mm
400-500
300-400
200-320
Remote Control Socket
Socket Pin
1
2
3
4
5
6
7
8
9
10
11
12
Function
Not connected
Not connected
Not connected
Not connected
Not connected
The button of "UP" input
The button of "DOWN" input
Trigger Switch Input
Trigger Switch Input
Not connected
The button of "UP"& "DOWN" input
Not connected
§3.4.7 Wireless Foot Pedal Configuration
TIG series of welding machines can be configured to communicate exclusively with
21
wireless foot pedal. This is done by a simple process of synchronising the wireless
remote control and the machine frequencies. Each interface frequency assigned is
unique, so it is possible to use several wireless control systems/ machines in the same
3.1 Wireless Foot Pedal
TIG series of welding machines can be configured to communicate exclusively with wireless foot
pedal. This is done by a simple process of synchronising the wireless remote control and the machine
frequencies. Each interface frequency assigned is unique, so it is possible to use several wireless control
systems/ machines in the same area with no problems. The direct range of the wireless control system is
approximately 100m, this will be affected by the physical location of the machine and the remote control.
INSTALLATION & OPERATION
On-off switch
1. EnsureTo
thesynchronise
welding powerasupply
is switched
off. to a machine, follow these instructions:
Wireless
Foot Pedal
2. Press and hold the parameter select/adjust knob on the front panel of the power supply (2-4 seconds) while at
1) Ensure the welding power supply is switched off.
the same time turning the machine ON using the ON-OFF switch on the back of the welding power supply.
hold
thepanel
parameter
select/adjust
knob release
on the the
front
panelknob.
of the
power
3. When2)
thePress
displayand
on the
front
of the power
supply is blank,
control
Turn
on the remote
control or foot
pedal(2-4
whileseconds)
at the same
timeatpressing
any buttons
on thethe
remote
control
panel
or foot
supply
while
the same
time turning
machine
ON
using
the pedal,
the digital meter on the front panel of the welding power supply flick twice to indicate the synchronization is
ON-OFF switch on the back of the welding power supply.
successful and complete.
theoff
display
on on
theagain
fronttopanel
of the power
supply is blank, release the control
4. Switch3)theWhen
machine
and back
start welding
operation.
5. If the operation
unsuccessful,
repeat steps
1 to 4.
knob.isTurn
on the remote
control
or foot pedal while at the same time pressing any
6. During operation, the front panel control on the power supply is still functional but the remote control panel
buttons on the remote control panel or foot pedal, the digital meter on the front panel
or foot pedal has higher priority level.
the welding
power
supply
flick
twice
is successful
7. When theof
remote
control panel
or foot
pedal
is idles
forto
10indicate
seconds, itthe
willsynchronization
automatically go into
“sleep” mode.
8. Only frontand
panel
control is active
when wirelesshas
remote
control or foot
is in “sleep”
mode. is
Any
operation
complete.(
Synchronization
to accomplish
in pedal
10s after
the display
blank.)
on the wireless remote control panel or foot pedal will “wake it up and resumes control of the machine.
4) Switch the machine off and back on again to start welding operation.
If thethe
operation
unsuccessful,
repeatbox
steps
1 to 4. machine
How to 5)
remove
control is
function
of Foot Pedal
on welding
1. Ensure6)the
welding
power
supply
is
switched
off.
During operation, the front panel control on the power supply is still functional but the
2. Press the encoder on the front control panel of the power supply, meanwhile turn on the machine.
remote control panel or foot pedal has higher priority level.
3. Pressing the encoder about 10 seconds, until the control panel display “rSt”, then it
7) When the remote control panel or foot pedal is idles for 10 seconds, it will
automatically go into “sleep” mode.
22
8) Only front Panel Control is active when wireless remote control or foot pedal is in
“sleep” mode. Any operation on the wireless remote control panel or foot pedal will
“wake it up and resumes control of the machine.
How to remove the control function of Foot Pedal box on welding machine
INSTALLATION & OPERATION
succeed.
Pedal switch
control
3.2 Pedal§3.4.8
Switch
Control
● When plug the twelve-lead aero-socket of pedal switch in it. Welder will identify the
pedal switch, the welding current knob on the front panel will can’t use，and only 2T can
When plug the twelve-lead aero-socket of pedal switch in it. Welder will identify the pedal switch, the
selected.
welding currentbe
knob
on the front panel will can’t use and only 2T can be selected.
●
When
use the
adjustment
knob of max-welding
currentthe
beside
the can
pedal,
the
 When use the adjustment
knob
of max-welding
current beside
pedal,
setcan
theset
max-current
max-current you want.
you want.
Adjustment knob of
welding current
Adjustment knob of
max welding current
Connected to the 12
pin aero socket on
the front panel
Part No.
4.801RM.009
Socket
Pin Pin
Socket
1
2
3
4
5
6
7
8
9
10
11
12
1
Function Function
Be shorted with
2
Be shorted
with 2
Be shorted with 1
2
20k ohm (maximum) connection to 20k ohm remote control potentiometer
Wiper arm connection to 20k ohm remote control potentiometer
Zero ohm (minimum) connection to 20k ohm remote control potentiometer
Not connected
Not connected
Trigger Switch Input
Trigger Switch Input
Not connected
Not connected
Not connected
23
4. Operation
Before starting any welding activity ensure that you have suitable eye protection and protective
clothing. Also take the necessary steps to protect any persons within the area.
Wire types and sizes
Use the correct wire type for the base metal being welded. Use stainless steel wire for stainless steel, aluminum for aluminum and steel wires for steel.
Use a smaller diameter wire for thin base metals. For thicker materials use a larger wire diameter and larger
machine, check the recommended welding capability of your machine. As a guide refer to the “Welding
Wire Thickness Chart” below.
Material Thickness
Recommended Wire Diameters
0.6
0.8
1.0
1.2
1.6
0.8mm
0.9mm
1.0mm
1.2mm
1.6mm
2.0mm
2.5mm
3.0mm
4.0mm
5.0mm
6.0mm
8.0mm
10.0mm
14.0mm
18.0mm
22.0mm
For material thickness of 5.0mm and greater, multi-pass runs or a beveled joint design may be required
depending on the amperage capability of your machine.
24
5. Troubleshooting
Error Type
Thermal relay
Welding machine
Switch
Accessory
Communication
Code
Description
E01
Over-heating (1st thermal relay)
E02
Over-heating (2nd thermal relay)
E03
Over-heating (3rd thermal relay)
E04
Over-heating (4th thermal relay)
E09
Over-heating (Program default)
E10
Phase loss
E11
N/A
E12
No gas
E13
Under voltage
E14
Over voltage
E15
Over current
E16
Wire feeder over load
E20
Button fault on operating panel when switch on the machine
E21
Other faults on operating panel when switch on the machine
E22
Torch fault when switch on the machine
E23
Torch fault during normal working process
E30
Cutting torch disconnection
E31
N/A
E40
Connection problem between wire feeder and power source
E41
Communication error)
25
6. Maintenance
The utilisation level of the power source and its working environment should be taken into
consideration in planning the frequency of maintenance of the machine. Appropriate use and
preventive maintenance guarantee the best trouble-free use of the equipment. This allows you to avoid
interruptions in use and increases the productivity of the machine.
5.1 Cables
Check the condition of welding and mains cables daily. Do not use damaged cables. Also make sure that
all extension cables used in the mains connection are in proper condition and compliant with
regulations.
NOTE! The mains cables may be repaired and installed only by electrical contractors and
installers authorised to perform such operations.
5.2 Power source
Make sure the machine is placed away fromany grinding area.
1. Clean the exterior of the machine and the fan grills net of any dust and stains – for
example, with a soft brush and vacuum cleaner.
•
Do not use pressurised air. The stain may become compressed into the grooves of the coolers.
•
Do not use a pressure-washing device.
2. Check the electrical connections of the machine. Clean any oxidised connections, and tighten the
loosened ones.
•
Check for the right tension before you start repairing the connections.
NOTE! Remember that the machine may be repaired only by an electrical contractor or installer
authorised to perform such operations.
5.3 Regular maintenance
Authorised service agents perform regular maintenance by agreement. Tasks included in regular
maintenance:
•
Cleaning of equipment.
•
Inspection and maintenance of the welding gun.
•
Checking of connectors, switches, and control knobs.
•
Checking of electrical connections.
•
Checking of the mains cable and plug.
•
Replacement of damaged or worn parts.
•
Calibration testing, with adjustment of the functions and operational values of the machine, if
necessary.
26
7. Warranty
Weldability Sif warrants its customers that all new SifWeld manual welding and cutting equipment purchased shall be free of failure
from defective materials or production for a period of 2 Years from the date of purchase.
This warranty period can be extended to 5 Years from the date of purchase (including the standard warranty period) for customers
in the United Kingdom and Republic Of Ireland; or to 3 Years from date of purchase for customers in all other countries, subject to
registration of the product at www.sifweld.com within the first year of purchase, and undergoing annual preventative maintenance
servicing with effect from the second year of ownership.
All warranty periods start from the date of purchase from Weldability Sif or an approved SifWeld distributor to the original end user.
The date on the sales invoice is considered the date of purchase for the purpose of the warranty period, or the date of manufacture is
used if proof of purchase is not available. Equipment is warranted to the original owner/user customer, and is not transferable.
Subject to the underlying purchase contract, or, failing such, the Weldability Sif general terms and conditions of sale, both the cost of
replacement parts and Weldability Sif’s labour expense in correcting defects covered by the warranty, will be assumed by Weldability
Sif during the warranty period. Weldability Sif shall in no event be responsible for any direct or indirect damages, third party
expenses, as well as any loss of income/revenue, all of which are specifically excluded under this warranty.
The warranty does not cover : Any defects resulting from normal wear and tear; Improper use; Failure to observe the operating
and maintenance instructions; Connection to an incorrect or faulty mains supply; Overloading during use; Any transport or storage
damage; External damage such as fire, impact or damage due to natural causes, e.g flooding; Use of unapproved spare or wear parts
or replacement parts not supplied by or approved by Weldability Sif; Any modification or alteration of the equipment; or any other
circumstances beyond the control of Weldability Sif. The warranty period is based on a single 8-hour 5-day shift pattern and the
extended warranty is not applicable to units that are purchased for rental or hire. Weldability Sif will submit an invoice for any repair
work performed outside the scope of the warranty.
Any warranty repair must be performed by Weldability Sif or an Authorised SifWeld Service Centre. The customer is responsible for
all shipping costs and risk associated with items that are returned covered under warranty. Weldability Sif may opt to refund the
purchase price (less any costs and depreciation due to use and wear). Faults/defects found under warranty should be reported to
the Weldability Sif Technical team for review. A warranty claim reference number will be issued and details of the most appropriate
Authorised SifWeld Service Centre will be advised, if appropriate. The customer has no claim to any loan or replacement products
whilst repairs are being performed or replacements are being provided.
The decision about repair or replacement of any defective part(s) is made by Weldability Sif. The replaced part(s) remain(s) property of
Weldability Sif. The warranty extends only to the machine power-source, wire-feed unit and parts contained inside. No other warranty
is expressed or implied, including with regard to the fitness of the equipment for any particular application.
Under the terms of the warranty, welding torches, their consumable parts, wire-feed drive-rolls and guide tubes, work return cables
and clamps, electrode holders, connection and extension cables, mains and control leads, plugs, wheels, coolant, etc. are not covered.
The extended warranty is only valid where products have been used strictly in accordance with the operating instructions, all
installation guidelines have been implemented, all legal requirements have been observed, regular preventative maintenance has
been undertaken and a continuous history of annual servicing has been completed and recorded. Failure to register the equipment
online within 1 year of purchase, or to complete the required annual servicing cycle from year 2, will invalidate the extended warranty
period.
Annual preventative maintenance servicing must be arranged and paid-for by the equipment owner/user and carried out by
Weldability Sif or an Authorised SifWeld Service Centre, in order to maintain validity of the extended warranty. Service visits can
be booked online at www.sifweld.com or by calling 0870 330 7757 and will be charged at an average of £65 net per hour of travel/
servicing time. Please allow an average of 2 hours servicing per machine and one hour each way of travel.
Warranty support is facilitated by our network of Authorised SifWeld Service Centres that provide highly experienced capability and
carry-out the professional repair, service and calibration of SifWeld equipment.
27
®
Peters House, The Orbital Centre, Icknield Way, Letchworth Garden City, Hertfordshire, SG6 1ET
Tel. +44 (0) 345 130 7757 | Fax. +44 (0) 800 970 7757 | Email. [email protected] | www.sifweld.com
28
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