TOP GUN WELDING 2040 5IN1 Manual de usuario

INTRODUCTION

Ⅰ

IMPORTANT: Read this Owner’s Manual Completely before attempting to use this

equipment. Save this manual and keep it handy for quick reference. Pay particular

attention to the safety instructions we have provided for your protection. Contact your

distributor if you do not fully understand this manual.

2040 5IN1

INVERTER Based Welding & Cutting Machines

OPERATORS’ MANUAL

CONTENT

- II -

CONTENT

§1 Safety.............................................................................................1

§1.1 Symbols Explanation................................................................................................... 1

§1.2 Machine Operating warnings!.................................................................................... 1

§1.3 EMC device classification........................................................................................... 8

§1.4 EMC measure............................................................................................................... 9

§1.5 Warning label............................................................................................................. 10

§2 Overview..................................................................................... 11

§2.1 Features .......................................................................................................................11

§2.2 Technical Data............................................................................................................ 13

§2.3 Brief Introduction...................................................................................................... 14

§2.4 Duty cycle and Over-heat.......................................................................................... 15

§2.5 Working Principle...................................................................................................... 15

§2.6 Volt-Ampere Characteristic...................................................................................... 16

§3 Panel Functions & Descriptions...............................................17

§3.1 Machine Layout Description .................................................................................... 17

§3.2 Control Panel of welding machine ........................................................................... 18

§4 Installation & Operation ..........................................................19

§4.1 Installation & Operation for MMAWelding........................................................... 19

§4.1.1 Set up installation for MMAWelding .................................................................................19

§4.1.2 Operation of MMA welding method...................................................................................20

§4.1.3 MMAWelding..................................................................................................................22

§4.1.4 MMAWelding Fundamentals .............................................................................................24

§4.2 Installation & Operation for TIG Welding ............................................................. 25

§4.2.1 Set up installation for TIG Welding ....................................................................................25

§4.2.2 Operation of LIFT TIG/HF TIG/Smart TIG welding method .............................................27

§4.2.3 DC TIG Welding .................................................................................................................28

§4.2.4 TIG Welding Fusion Technique...........................................................................................30

§4.2.5 Tungsten Electrodes ............................................................................................................31

§4.2.6 Tungsten Preparation...........................................................................................................34

§4.2.7 Gun switch control current..................................................................................................36

§4.3 Installation & Operation for MIG Welding............................................................ 37

CONTENT

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§4.3.1 Set up installation for MIG Welding- Gas shielded wire.....................................................37

§4.3.2 Operation of MIG Synergic/MIG Pulse welding method....................................................39

§4.3.3 Wire Feed Roller Selection .................................................................................................41

§4.3.4 Wire Installation and Set Up Guide.....................................................................................42

§4.3.5 Set up installation for MIG Welding- Gasless wire.............................................................44

§4.3.6MIG Torch Liner Installation ...............................................................................................47

§4.3.7 MIG Torch Liner Types and Information ............................................................................49

§4.3.8 Torch & Wire Feed Set Up for Aluminium Wire.................................................................51

§4.3.9 MIG Welding.......................................................................................................................54

§4.3.10 Standard welding programs...............................................................................................62

§4.3.11 Welding parameters...........................................................................................................63

§4.4 Installation & Operation for Cutting....................................................................... 65

§4.4.1 Cutting Guide......................................................................................................................69

§4.4.2 Operating Techniques..........................................................................................................70

§4.5 Operation of Setting .................................................................................................. 73

§4.6 Operation of SAVE/LOAD........................................................................................ 74

§4.7 Welding parameters................................................................................................... 75

§4.8 Operation environment............................................................................................. 77

§4.9 Operation Notices...................................................................................................... 77

§5 Welding trouble shooting..........................................................79

§5.1 MIG welding trouble shooting.................................................................................. 79

§5.2 MIG wire feed trouble shooting ............................................................................... 81

§5.3 TIG welding trouble shooting................................................................................... 82

§5.4 MMAwelding trouble shooting................................................................................ 85

§5.5 MMAwelding trouble shooting................................................................................ 87

§6 Maintenance & Troubleshooting .............................................89

§6.1 Maintenance............................................................................................................... 89

§6.2 Troubleshooting ......................................................................................................... 90

§6.3 List of error code ....................................................................................................... 91

§6.4 Electrical schematic drawing.................................................................................... 93

SAFETY

-1-

§1 Safety

Welding and cutting equipment can be dangerous to both the operator and people in

or near the surrounding working area, if the equipment is not correctly operated.

Equipment must only be used under the strict and comprehensive observance of all

relevant safety regulations. Read and understand this instruction manual carefully

before the installation and operation of this equipment.

§1.1 Symbols Explanation

The above symbols mean warning!

Notice! Running parts, getting an electric shock or making contacts with thermal

parts will cause damage to your body and others. The underline message is as

follows:

Welding is quite a safe operation after taking several necessary protection

measures!

§1.2 Machine Operating warnings!

The following symbols and words explanations are for some damages to your body

or others, which could happen during the welding operation. While seeing these

symbols, please remind yourself and others to be careful.

Only people who are trained professionally can install, debug, operate, maintain

and repair the welding equipment covered with this Operator’s Manual!

During the welding operation, non-concerned people should NOT be around,

especially children!

After shutting off the machine power, please maintain and examine the equipment

according to §7 because of the DC voltage existing in the electrolytic capacitors at

the output of the power supply!

SAFETY

-2-

ELECTRIC SHOCK CAN KILL.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode

and work circuit is electrically live whenever the output is on. The input power

circuit and internal machine circuits are also live when power is on. In Mig/Mag

welding, the wire, drive rollers, wire feed housing, and all metal parts touching the

welding wire are electrically live. Incorrectly installed or improperly grounded

equipment is dangerous.

Never touch live electrical parts.

Wear dry, hole-free gloves and clothes to insulate your body.

Be sure to install the equipment correctly and ground the work or metal to be

welded to a good electrical (earth) ground according to the operation manual.

The electrode and work (or ground) circuits are electrically “hot” when the

machine is ON. Do not touch these “hot” parts with your bare skin or wet clothing.

Wear dry, hole-free gloves to insulate hands.

In semiautomatic or automatic wire welding, the electrode, electrode reel, welding

head, nozzle or semiautomatic welding gun are also electrically “hot”.

Insulate yourself from work and ground using dry insulation. Make certain the

insulation is large enough to cover your full area of physical contact with work and

ground.

Be Careful when using the equipment in small places, falling-off and wet

circumstance.

Always be sure the work cable makes a good electrical connection with the metal

being welded. The connection should be as close as possible to the area being

welded.

Maintain the electrode holder, work clamp, welding cable and welding machine in

good, safe operating condition. Replace damaged insulation.

Never dip the electrode in water for cooling.

Never simultaneously touch electrically “hot” parts of electrode holders connected

SAFETY

-3-

to two welders because voltage between the two can be the total of the open

circuit voltage of both welders.

When working above the floor level, use a safety belt to protect yourself from a

fall should you get an electric shock!

FUMESAND GASES CAN BE DANGEROUS.

Smoke and gas generated whilst welding or cutting can be harmful to people’s health.

Welding produces fumes and gases. Breathing these fumes and gases can be

hazardous to your health.

Do not breathe the smoke and gas generated whilst welding or cutting, keep your

head out of the fumes. Use enough ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When welding with electrodes which

require special ventilation such as stainless or hard facing or on lead or cadmium

plated steel and other metals or coatings which produce highly toxic fumes, keep

exposure as low as possible and below the Threshold Limit Values using local

exhaust or mechanical ventilation. In confined spaces or in some circumstances,

outdoors, a respirator may be required. Additional precautions are also required

when welding on galvanized steel.

Do not weld in locations near chlorinated hydrocarbon vapors coming from

degreasing, cleaning or spraying operations. The heat and rays of the arc can react

with solvent vapors to form phosgene, a highly toxic gas, and other irritating

products.

Shielded gases used for arc welding can displace air and cause injury or death.

Always use enough ventilation, especially in confined areas, to insure breathing air

is safe.

Read and understand the manufacturer’s instructions for this equipment and the

consumables to be used, including the material safety data sheet and follow your

employer’s safety practices.

SAFETY

-4-

ARC RAYS: Harmful to people’s eyes and skin.

Arc rays from the welding process produce intense visible and invisible ultraviolet

and infrared rays that can burn eyes and skin.

Use a shield with the proper filter and cover plates to protect your eyes from

sparks and the rays of the arc when welding or observing open arc welding.

Use suitable clothing made from durable flame-resistant material to protect your

skin and that of your coworkers from the arc rays.

Protect other nearby personnel with suitable, non-flammable screening and /or

warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter

or metal.

SELF-PROTECTION

Keep all equipment safety guards, covers and devices in position and in good

repair. Keep hands, hair, clothing and tools away from V-belts, gears, fans and all

other moving parts when starting, operating or repairing equipment.

Do not put your hands near the engine fan. Do not attempt to override the governor

or idler by pushing on the throttle control rods while the engine is running.

DO NOT add any fuel near an open-flame welding arc or

when the engine is running. Stop the engine and allow it to cool before refueling to

prevent spilled fuel from vaporizing on contact with hot engine parts and igniting.

Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start

engine until fumes have been eliminated.

SAFETY

-5-

WELDING SPARKS can cause fire or explosion.

Welding on closed containers, such as tanks, drums, or pipes, can cause them to

explode. Flying sparks from the welding arc, hot work piece, and hot equipment can

cause fires and burns. Accidental contact of electrode to metal objects can cause

sparks, explosion, overheating, or fire. Check and be sure the area is safe before

doing any welding

Remove fire hazards material from the welding area. If this is not possible, cover

them to prevent the welding sparks from starting a fire. Remember that welding

sparks and hot materials from welding can easily go through small cracks and

openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire

extinguisher readily available.

Where compressed gases are to be used at the job site, special precautions should

be used to prevent hazardous situation.

When not welding, make certain no part of the electrode circuit is touching the

work or ground. Accidental contact can cause overheating and create a fire hazard.

Do not heat, cut or weld tanks, drums or containers until the proper steps have

been taken to insure that such procedures will not cause flammable or toxic vapors

from substances inside. They can cause an explosion even though they have been

“cleaned”.

Vent hollow castings or containers before heating, cutting or welding. They may

explode.

Sparks and spatter are thrown from the welding arc. Wear oil free protective

garments such as leather gloves, heavy shirt, cuff less trousers, high shoes and a cap

over your hair. Wear earplugs when welding out of position or in confined places.

Always wear safety glasses with side shields when in a welding area.

Connect the work cable to the work as close to the welding area as practical. Work

cables connected to the building framework or other locations away from the

welding area increase the possibility of the welding current passing through lifting

SAFETY

-6-

chains, crane cables or other alternate circuits. This can create fire hazards or

overheat lifting chains or cables until they fail.

Rotating parts may be dangerous.

Use only compressed gas cylinders containing the correct shielding gas for the

process used and properly operating regulators designed for the gas and pressure

used. All hoses, fittings, etc. should be suitable for the application and maintained in

good condition.

Always keep cylinders in an upright position securely chained to an undercarriage

or fixed support.

Cylinders should be located:

-Away from areas where they may be struck or subjected to physical damage.

-At a safe distance from arc welding or cutting operations and any other source

of heat, sparks, or flame.

Never allow the electrode, electrode holder or any other electrically “hot” parts to

touch a gas cylinder.

Keep your head and face away from the cylinder valve outlet when opening the

cylinder valve.

Valve protection caps should always be in place and hand tight except when the

cylinder is in use or connected for use.

Gas Cylinders.

Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can

explode. Because gas cylinders are normally part of the welding process, be sure to

treat them carefully. CYLINDERS can explode if damaged.

Protect gas cylinders from excessive heat, mechanical shocks, physical damage,

slag, open flames sparks, and arcs.

SAFETY

-7-

Insure cylinders are held secure and upright to prevent tipping or falling over.

Never allow the welding electrode or earth clamp to touch the gas cylinder, do not

drape welding cables over the cylinder.

Never weld on a pressurised gas cylinder, it will explode and kill you.

Open the cylinder valve slowly and turn your face away from the cylinder outlet

valve and gas regulator.

Gas build up.

The build up of gas can causes a toxic environment, deplete the oxygen content in

the air resulting in death or injury. Many gases use in welding are invisible and

odourless.

Shut off shielding gas supply when not in use.

Always ventilate confine spaces or use approved air-supplied respirator.

Electric and Magnetic Fields.

Electric current flowing through any conductor causes localized Electric and

Magnetic Fields (EMF). The discussion on the effect of EMF is ongoing in the entire

world. Up to now, no material evidences show that EMF may have effects on health.

However, the research on the effect of EMF is still ongoing. Before any conclusion,

we should minimize exposure to EMF as few as possible.

In order to minimize EMF, we should use the following procedures:

Route the electrode and work cables together –Secure them with tape when

possible.

All cables should be put away and far from the operator.

Never coil the power cable around your body.

Make sure welding machine and power cable to be far away from the operator as

far as possible according to the actual circumstance.

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