SKYARC ULTRA 3140 Inverter DC MMA Arc Welding Machine
Contents
1. adopts the latest pulse width modulation PWM technology and the insulated gate bipolar transistor IGBT power module It can change work frequency to medium frequency so as to replace the traditional hulking work frequency transformer with the cabinet medium frequency transformer Thus it is characterized with portable small size low consumption and etc SKYARC ULTRA 3140 ULTRA POWER have excellent performances constant current output makes welding arc more stable fast dynamic response speed reduces the impact from the arc length fluctuation to the current accurate step less current adjustment and pre setting function There are also some automatic protection functions for under voltage over current over heat etc inside the welders when the problems listed before occurred the alarm on the front panel is light and at the same time the output current will be cut off It can self protect and prolong the using life and greatly improved the reliability and practicability of the welders SKYARC ULTRA 3140 ULTRA POWER welders can also realize TIG operation While MMA operation if the electrode touches workpiece over two seconds the welding current will drop to the minimum current automatically to protect the electrode While TIG operation the minimum current will be outputted firstly until the arc is ignited by lifting method the output current will rise to the preset value which can protect the electrode At the same time the arc fo2. 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 A 4 DO adds the 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 VE WELDING SPARKS can cause fire or explosion Remove fire hazards 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 3 SAFETY inside They can cause an explosion even though they have been cleane
3. 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 e Shielding 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 e Read and understand the manufacturers instructions for this equipment and the consumables to be used including the material safety data sheet and follow your employer s safety practices SAFETY IN RL ARC RAYS CAN BURN e 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 e Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays e 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 Are SELF PROTECTION e 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 e Do not
4. 0 The relation between the welding current l factor K electrode diameter d I Kxd Carbon electrode Electrode 1 6 2 2 5 3 2 diameter mm 14 OPERATION CONTROL AND CONNECTORS Factor K 20 25 25 30 30 40 Notice the above parameters originate from Welding Dictionary P66 P67 Volume 1 of Edition 2 Electrode should be drying according to user manual before using For reducing the hydrogen of the molten pool and welding seam and avoiding the blowhole and cold crack n the welding process the arc must not be too long otherwise it will cause unstable arc burning large spatter light penetration undercut blowhole etc If the arc is too short it will cause electrode stick In MMA welding the arc length is usually equal to 0 5 1 0 time of the electrode diameter The basic electrode s arc length is not beyond the electrode diameter it s better to choose the short arc welding the acid electrode s arc length is equal to the electrode diameter 84 5 Arc Welding Defect and Prevent Method Defect name Caused reasons Prevent methods Welding seam doesn t meet the requirement The groove angle is not proper The root face and assembly gap is not equal Welding technics parameters are unreasonable The welder s operation skill is lower Choosing the proper groove angle amp assembly gap improve the assembly quality Choosing the proper we
5. 315A 40 250A 40 315A 40 250A 45 315A 40 315A u cle wee in 60 177A 60 130A 60 267A 60 204A 60 267A 60 204A 60 267A 60 223A min 100 140A 100 100A 100 207A 100 158A 100 207A 100 158A 100 207A 100 173A No Load 70 15 VRD Voltage V Welding Current 5 200 5 200 5 315 5 250 5 315 5 250 5 315 5 315 Range A Efficiency 28096 28096 28096 28096 Power Factor 0 98 0 98 0 9 0 9 Electrode 2 5 3 2 7 5 etc diameter Electrode Type 6010 6011 6013 7018 etc Net Weight Kg 21 8 Dimensions mm 535x235x435 Protection Class IP23S Insulation Class F Cooling AF Note The above parameters are subject to change with the improvement of machines INSTALLATION AND ADJUSTMENT 83 2 Duty cycle 8 Over heat The letter X stands for duty cycle which is defined as the proportion of the time that a machine can work continuously within a certain time 10 minutes The rated duty cycle means the proportion of the time that a machine can work continuously within 10 minutes when it outputs the rated welding current The relation between the duty cycle X and the output welding current I is shown as the following figure If the welder is over heat the IGBT over heat rotection unit inside it will output an instruction to cut output welding current and brighten the over heat pilot lamp on the front panel At this time the machine should be relaxed for 15 minutes to cool the fan When oper
6. INTRODUCTION OPERATORS MANUAL Inverter DC MMA Arc Welding Machine 1509001 2000 SKYARC ULTRA 3140 MV scuweisstecianix SWEISS 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 2012 09 INTRODUCTION CONTENT STSAFETY ON 1 S1 T SIGNAEEXPEANATION attinet ee cedo e eite AN cede cene 1 81 2 ARC WELDING DAMAGE A 1 1 3 THE KNOWLEDGE OF ELECTRIC AND MAGNETIC FIELDS sesscssssccssssccssscccssscecssecesssccesssccssusccesusecesusecssscesnsecesusecesaseced 4 82 SUMMARY A RN 6 52 T BRIEF INTRODUCTION caco 6 52 2 WORKING PRING PLE i 7 52 3 VOLT AMPERE CHARACTER Criada 7 83 INSTALLATION amp ADJUSTMENT cs0ssesonsssonsssonnssnnnsennnnenonnnnonnssnnnnsnnnsennnnsnnnnnsnnnssnnnsennnnennnnnnen 7 83 T PARAMETERS svccccccscccsasscousccaesccessvescncectnccsecsonasseseussounscsucnsousuesesesecurssesavecusesecsesdonssesesoseunossesesese 7 53 2 DUTY TNA A AO 8 83 3 WELDING POLARITY CONNECTION WAY A 9 93 351 is 9 NSE e RAN 10 84 OPERATION CONTROL AND CONNECTORS sccssccsscscsccscsccsescsccsccsssccsesccsesccssscscsssseseseeees 11 54 1 LAYOUT FOR FRONT amp REAR PANEL ssssssccssseccssscccssecesssecesssecesssccesssccc
7. al necessary protection measures 81 2 Arc Welding Damage e The following signals and word explanations are to some damages for your body or others happening on the welding operation While seeing these please remind of yourself or others to be dangerous e Only ones who are trained professionally can install debug operate maintain and repair the equipment e During the operation non concerned people should be lift especially for children e After shut offthe machine power please maintain and examine the equipment according to 85 because of the DC voltage existing in the electrolytic capacitors AN 2 ELECTRIC SHOCK CAN KILL Never touch electrical parts Wear dry hole free gloves and clothes to insulate yourself e 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 e Take carefully when using the equipment in small place falling off and wet circumstance Never close the machine power before installation and adjustment Ensure 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 eThe electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to SAFETY insulate hands e In semiautoma
8. anger to user Only professional maintenance personal who is authorized by our company could overhaul the machine Guarantee to shut off the arc welding machine s power before turn on the outline of the equipment If there is any problem and has no the authorized professional maintenance personal of our company please contact local our company agent or the branch company 17 MAINTENANCE AND TROUBLESHOOTING If there are some simple troubles of SKYARC ULTRA 3140 ULTRA POWER welding machines you can consult the following overhauling chart S N Troubles Reasons Solutions Turn on the power source and fan The power light damaged or connection is Test and repair the inside circuit of 1 works but the power light is not hot good power light Pr3 on Power PCB failures Repair or change power PCB Pr2 Turn on the power source and the There is something in the fan Clear out 2 power light is on but fan doesn t work The fan motor damaged Change fan motor No input voltage Check whether there is input voltage Turn on the power source and the 3 power light is not on and fan Overvoltage Input voltage is too much or Check input voltage doesn t work not 4 No no load voltage output There is trouble inside the machine Check the main circuit Pr1 and Pr2 Welding cable is not connected with the Connect the welding cable to the two output of the weld
9. ated if the arc welding machine has the above problems it should be fastened or changed Observe that Whether the current output cable is damaged If it is damaged it should be wrapped up insulated or changed 16 MAINTENANCE AND TROUBLESHOOTING Using the dry compressed air to clear the inside of arc welding machine Especially for clearing up the dusts on radiator main voltage transformer Monthly inductance IGBT module the fast recover diode and PCB etc examination Check up the bolt in arc welding machine if it is loose please screw down it If it is skid please replace If it is rusty please erase rust on bolt to ensure it works well Quarter Whether the actual current accords with the displaying value If they does yearly not accord they should be regulated The actual current value can be examination measured by the adjusted plier type ampere meter Yearly examination Measure the insulating impedance among the main circuit PCB and case if it below 1MO insulation is thought to be damaged and need to change and need to change or strengthen insulation 85 2 Troubleshooting Before arc welding machines are dispatched from the factory they have already been debugged accurately So forbid anyone who is not authorized by our company to do any change to the equipment Maintenance course must be operated carefully If any wire becomes flexible or is misplaced it maybe potential d
10. ating the machine again the welding output current or the duty cycle should be xA x A The relation between duty cycle and welding current for GM 3150 a 60 di ba The relation between duty cycle and welding current for GM 3150 100 100 60 30 5 gt 25 gt 59 0 140 177 250 ICA 0 100 130 200 ICA Input single phase 220V TIG Input single phase 220V MMA reduced The relation between duty cycle and The relation between duty cycle and welding current for GM 3150 welding current for GM 3150 100 100 60 60 43 40 gt P 0 207 267 315 ICA 0 158 204 250 ICA Input single phase 380V TIG Input single phase 3830V MMA INSTALLATION AND ADJUSTMENT 4 The relation between duty cycle and welding current for GM 3150 7 100 60 43 0 Input three phase 220V TIG 4 The relation between duty cycle and welding current for GM 3150 Pa 100 60 43 Input three phase 380V TIG 83 3 Welding polarity connection way 83 3 1 MMA M Ur A ND workpiece DCEN The relation between duty cycle and welding current for GM 3150 100 60 40 Input three phase 220V 4 The relation between duty cycle and welding current for GM 3150 100 60 30 Input three phase 380V SKYARC workpiece DCEP C
11. ch the arc in unprotected eyes e Ensure good ventilation of the machine to improve duty ratio Turn off the engine when the operation finished to economize energy sources e When power switch shuts off protectively because of failure Don t restart it until problem is resolved Otherwise the range of problem will be extended eIn case of problems contact your local dealer if no our authorized maintenance man SWEISS 17 MAINTENANCE AND TROUBLESHOOTING 85 Maintenance amp Troubleshooting 85 1 Maintenance In order to guarantee that arc welding machine works high efficiently and in safety it must be maintained regularly Let customers understand the maintenance methods and means of arc welding machine more enable customers to carry on simple examination and safeguarding by oneself try one s best to reduce the fault rate and repair times of arc welding machine so as to lengthen service life of arc welding machine Maintenance items in detail are in the following table e Warning For safety while maintaining the machine please shut off the supply power and wait for 3 minutes until capacity voltage already drops to safe voltage 36V Date Maintenance items Daily examination Observe that whether panel knob and switch in the front and atthe back of arc welding machine are flexible and put correctly in place If the knob has not been put correctly in place please correct If you can t correct or
12. d e Vent hollow castings or containers before heating cutting or welding They may explode e 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 ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area e 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 chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail AR 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 e Cylinders should be located Away from areas where they may be struck or subjected to physical damage 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 oth
13. ent Unusual current in the main circuit Test and repair the main circuit and drive PCB Pr1 19 MAINTENANCE AND TROUBLESHOOTING 85 3 Electrical principle draw 20 NOTES 21 NOTES 22 NOTES 23 NOTES 24
14. er welder s output Wrap repair or change the welding 5 N inth Idi Welding cable is broken o current output in the welding cable Earth cable is not connected or loosen Check the earth clamp The plug loosen or connect not well Check and tighten the plug Not easy to start arc in the Oilor dust covered the workpiece Check and clear out welding or easy to cause sticking MMA TIG welding selection is wrong Selecting the MMA welding 7 atc Sek inthe welding The arc force is too small Increase the arc force process The welding current can not be The welding current potentiometer in the 8 front panel connection not so good or Repair or change the potentiometer adjusted damaged The welding current adjusted too low Increase the welding current 9 The penetration of molten pool is not enough MMA The arc force adjusted too small Increase the arc force Airflow disturbance Use the shelter from airflow Adjust the electrode angle The electrode eccentricity Change the electrode Incline the electrode to the opposite oe way of the magnetic blow Change the position of earth clamp Magnetic effect or add earth cable in the two side of workpiece Use the short arc operation Over welding current Induce the welding current output Over heat gt 11 The alarm light is on Working time too protection long Induce the duty cycle interval work 18 MAINTENANCE AND TROUBLESHOOTING Over protection curr
15. er electrically hot parts to touch a 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 81 3 The knowledge of Electric and Magnetic Fields Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF The discuss on the effect of EMF is ongoing all the world Up to now no material evidences show that EMF may have effects on health However the research on damage of SAFETY 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 e All cables should be put away and far from the operator e Never coil the power cable around your body e Make sure welding machine and power cable to be far away from the operator as far as possible according to the actual circumstance e Connect the work cable to the workpiece as close as possible to the area being welded e The people with heart pacemaker should be away from the welding arc SUMMARY 52 Summary This operation manual is suitable for the models of SKYARC ULTRA 3140 ULTRA POWER 82 1 Brief Introduction SKYARC ULTRA 3140 ULTRA POWER welders are general MMA arc welder which
16. es that the maximum current is 250A 4 SKYARC 3140 Imax P L 12 98 Ee e E A A OSMEISS aan O d i f DOE Sem 14 um unus li O _ 9 P gt I Welding current display The welding current display shows the welding current now Maximum current pilot lamp This pilot lamp when lit Maximum current pilot lamp This pilot lamp when lit Maximum current pilot lamp This pilot lamp when lit indicates that the maximum current is 315A Power Supply Voltage V Imax A 1 220 200 MMA 1 380 3 220 250 3 380 315 1 220 250 TIG 1 380 3 220 315 3 380 315 11 OPERATION CONTROL AND CONNECTORS 5 6 VRD pilot lamp Choose the switch as shown below to choose VRD model Model Condition No load on turn on o loa off turn off MMA on turn off Choose 1 Welding off turn on TIG No load Weldi an o load Weldin mg off turn off Choose on MMA TIG No load Welding on of
17. f turn off 7 Power pilot lamp This pilot lamp when lit indicates that the machine is on 8 Alarm pilot lamp When the machine less voltage over current or over heat This pilot lamp indicates when lit that the protection of the machine has been activated 9 12 Rod electrode welding key Parameter Setting range Arc force 0 10 Hot start 1 10 Arc length 1 10 13 Conversion switch Choose TIG 14 Connector The welder s positive polarity output 12 OPERATION CONTROL AND CONNECTORS 15 Welding current regulation Set welding current 16 Connector The welder s negative polarity output 17 Power source input connect power source 18 Power switch Choose ON power through Choose OFF power cut off 84 2 Welding current adjustment SKYARC ULTRA 3140 welder has the function of welding current pre setting Before welding adjusting welding current the welding current display will show the ampere Itis convenient to set parameters and adjust accurately 84 3 Welding operation 84 3 1 Striking arc way Knocking arc take the electrode upright to touch the workpiece after forming short circuit quickly lift up about 2 4 mm and arc will be ignited This method is difficult to master But in the welding for the brittle or hard steel it is better to use knocking way electrode electrode electrode upright EUM por up workpiece workpiece touch workpiece JIN 274mm Take the electrode u
18. fix the knob please replace immediately If the switch is not flexible or it can t be put correctly in place please replace immediately Please get in touch with our company maintenance service department if there are no accessories After turn on power watch listen to that whether the arc welding machine has shaking whistle calling or peculiar smell If there is one of the above problems find out the reason to get rid of if you can t find out the reason Please contact local this area our company agent or the branch company Observe that whether the display value of LED is intact If the display number is not intact please replace the damaged LED If it still doesn t work please maintain or replace the display PCB Observe that whether the min max value on LED accords with the set value If there is any difference and it has affected the normal welding craft please adjust it Check up that Whether fan is damaged and is normal to rotate or control If the fan is damaged please change immediately If the fan does not rotate after the arc welding machine is overheated observe that whether there is something blocked in the blade if it is blocked please get rid of If the fan does not rotate after getting rid of the above problems you can poke the blade by the rotation direction of fan If the fan rotates normally the start capacity should be replaced If not change the fan Observe that whether the fast connector is loose or overhe
19. hoosing the connection of DCEN or DCEP is based on the arc stable burning condition The different electrodes need different connection way Please refer to the electrode manual INSTALLATION AND ADJUSTMENT 83 3 2 TIG Ar O When TIG operation the shielded gas is inputted to welding gun directly and the method of lifting arc is scraping arc N NWelding gun Workpiece DCEN 1 Place the welding 2 Scrape the electrode 3 Lift arc gun aslant with the workpiece CS y Ri A 2 rd 2 4mm Steps of scraping arc Stricking arc of TIG operation when tungsten electrode touches the workpiece the short circuit current is only 28A After generating arc current can rise to the setting welding current If the tungesten electrode touches the workpiece when welding the current will drop to 5A within 2s which can reduce the tungsten spoilage farthestly prolong the using life of the tungsten electrode and prevent tungsten clipping OPERATION CONTROL AND CONNECTORS 584 Operation control and connectors 84 1 Layout for front amp rear panel M M ko Is bo na VAD 1 2 indicates that the maximum current is 200 3 indicat
20. lding parameters Improve the operation skill of welders Over current Arc length is too long Choosing the proper welding current amp speed The arc can t be drawn too long Underc t The electrode angle is wrong The electrode angle should be proper Manipulation of electrode is not proper Manipulation of electrode should be correct The groove angle or gap is too small the root Correctly to choose and process the groove face is too big size Incomplete penetration Welding parameters are not suitable or the assembly is not good The welder s operation skill is lower Correctly to assemble and ensure clearance Choosing the suitable welding current amp speed Improve the operation skill of welders The welding thermal input is too low The arc direction is lean Correctly to choose the welding parameters incomplete There are rust amp dust on the side of groove Operation seriously fusion The slag between the layers is not cleared Enhance the clearness of layers well Choosing parameters based on the welding Overlap The temperature of molten pool is too high different position The liquid metal concretes slowly Strictly to control the molten hole size In the crater electrode should be stayed for a Crater The crater time lasts too short short time or round to manipulate electrode Over current in the welding of thin plate after the molten pool is filled in by metal take to the side for crater There are some dus
21. pright The Electrode touch the workpiece Lift up for about 2 4mm e Lifting arc take the electrode to scrape the workpiece for striking arc But it may cause the arc scratch so must to lift arc in the groove 13 OPERATION CONTROL AND CONNECTORS 84 3 2 Manipulation of electrode In MMA welding there are three motions to being matched in the end of ER electrode the electrode moving to the molten pool along axes the electrode gt swing right and left the electrode moving P 2 BE gt 7 1 electrode moving 2 the electrode swing right amp left 3 the electrode move along weld along welding way The operator can choose the manipulation of electrode based on welding joint shape welding position electrode spec welding current and operation skill etc The details please refer to Welding Dictionary P69 Volume 1 of Edition 2 54 4 Welding parameters 84 4 1 Joint form in MMA In MMA welding the common basic joint form butt joint lap joint corner joint amp T joint OC OL corner joint lap joint er butt joint PASEJO p Jor T joint 84 4 2 Electrode selection The electrode diameter selection is based on the workpiece thickness welding position joint form welding layer etc Please refer to the following table The welding current reference for different electrode diameter Electrode 1 6 2 0 2 5 3 2 diameter mm Welding current A 25 40 40 60 50 80 100 13
22. pt the basic electrode Three reasons will cause cold crack Adopt loi hydrogen type basicelectrode Bake under the instruction before use The structure turned from the marten site Remove the feculence before use reduce the Cold crack The residual stress caused by big restraint intensity The residual hydrogen in welding gap percentage of hydrogen Adopt appropriate parameters and heat input After welding do dehydrogenation at once 84 6 Operation Environment e Height above sea level is below 1000m Operation temperature range 10 C 409C e Relative humidity is below 90 20 C e Preferably site the machine some angles above the floor level the maximum angle does not exceed 15 e Protect the machine against heavy rain or in hot circumstance against direct sunshine e The content of dust acid corrosive gas in the surrounding air or substance can not exceed normal standard e Take care that there is sufficient ventilation during welding There is at least 30cm free distance between the machine and wall 84 7 Operation Notices Read 81 carefully before attempting to use this equipment e Connect the ground wire with the machine directly eIn case closing the power switch no load voltage may be exported Do not touch 16 OPERATION CONTROL AND CONNECTORS the output electrode with any part of your body Before operation no concerned people should be left Do not wat
23. rce and hot start will be provided with MMA operation SKYARC ULTRA 3140 Characteristics Input voltage from 110 440 15 1 3 Anti sticking Arc force hot start adjustable arc length MCU control system and IGBT technology Current preset and real time display Fan on demand MMA Lift TIG VRD selectable Intelligent protection Over voltage Low voltage Over current Over heat 6 SUMMARY O Protected 8 compatible POWER GENERATOR No single phase de rating PFC ZVS technology Power factor more than 0 98 Compact light weight portable high efficiency Low input current MMA Manual Metal Arc welding PWM Pulse Width Modulation IGBT Insulation Gate Bipolar Transistor TIG Tungsten Inert Gas welding 82 2 Working Principle The working principle of SKYARC ULTRA 3140 ULTRA POWER welder is shown as the following figure Single phase 208V 460V 10 work frequency 50 60 Hz AC is rectified into DC three phase 208v 460V 10 work frequency 50 60 Hz AC is rectified into DC then by PFC circuit DC about 750V is converted to medium frequency AC about 20KHz by inverter device IGBT module after reducing voltage by medium transformer the main transformer and rectified by medium frequency rectifier fast recovery diodes and is outputted by inductance filtering The circuit adopts current feedback control technology to insure current output stably Meanwhile the welding current parameter can be adju
24. sted continuously and steplessly to meet with the requirements of welding craft AC Medium AC Medium DC DC PFC gt Inverter gt frequency gt frequency Halldevice transformer rectify Single phase AC DC A 208 460V 50 60Hz Rectify ao Current positive 208 460V 50 60Hz feedback control 82 3 Volt Ampere Characteristic SKYARC ULTRA 3140 welders have excellent volt ampere characteristic seeing the following graph In MMA welding the relation between the rated loading voltage U and welding current l is as follows SUMMARY When 1 lt 600 U 20 0 041 V When gt 600A U 44 V 0 Volt ampere characteristic The relation of the rated loading voltage amp welding current 64 Working point 44 kenn be 20 7 gt 0 600 L A INSTALLATION AND ADJUSTMENT 83 Installation 8 Adjustment 83 1 Parameters Model SKYARC ULTRA 3140 Power Supply Volt V 1 110 208 220 230 240 10 1 380 400 440 460 10906 3 220 230 240 10 3 380 400 440 460 10 oltage Frequency Hz 50 60 50 60 50 60 50 60 TIG MMA TIG MMA TIG MMA TIG MMA Rated input 6 25 7 8 9 9 3 8 9 9 3 8 9 12 8 Power KW Rated input 28 4 31 8 23 4 24 7 23 4 24 7 13 5 19 5 Current A Effective 15 5 15 9 15 3 15 6 15 3 15 6 89 10 6 Current A Duty Cycle 30 250A 30 200A 40
25. susccsssscessuscesssscssssscesusecesusccesusecesusecesusecesuseessusesete 11 54 2 WELDING CURRENT ADJUSTMENT ssssccssssccssssccssscccssececsseccsusecessssccssscesssecesssccesssccssuscesssscesssecssusecesusecesuecessecessseestes 13 54 3 WELDING OPERATION load 13 4 3 1 Striking are WAY iri tette ene REAREA ERAAN 13 4 3 2 Manipulation of electrode eise iii aA i a E aa 14 54 4 WELDING PARAMETERS ninia aeaea E AE A a AAE E EAE aE 14 54 4 1 Joint tornin MMA uite teet tite ene e RR REA ERE Ree aee eee edd 14 54 4 2 Electrode selection RH EORR seas e ERR 14 84 5 ARC WELDING DEFECT AND PREVENT METHOD uenneenssssennsssennsssennsssnnsssnnnsssnnnsssennsssnnusssnnssssnnnsssnnssssnnnsssnnssssnnssssnnsssnnn 15 84 6 OPERATION ENVIRONMENT 16 54 7 OPERATION esc i 16 85 MAINTENANCE amp TROUBLESHOOTING 20ssss0nussonnsennnsennnsenonnsnonnnsnnnsennnnennnssnnnnssnnnssnnnsennnnen 16 651 MAINTENANGE anne 16 55 2 TROUBLESHOOTING osa 17 55 3 ELECTRICAL PRINCIPLE DRAWING seansscrnnssssnssssenessrnnsssenssssunnsssunsssstnnsssennssssnnsssunssessnssesnnesesnnssstnnssssnssssenssssenssssenesssnnesssnne 20 CONTENT SAFETY 81 SAFETY 81 1 Signal Explanation Aya e The above signals mean warning Notice Running parts and getting an electric shock or thermal parts will take damage for your body or others The corresponding notices are as follows It is quite a safe operation after taking sever
26. t like oil rust or water on Clear out the dust around groove for about Blowhole the work piece surface and groove The coating of electrode is damped amp is not 20 30mm 15 OPERATION CONTROL AND CONNECTORS drying Under current or over speed in the welding The arc is too long or lean burning the molten pool protection is not good Over current the coating of electrode falls off and lose protection Manipulation of electrode is not proper Strictly to dry the electrode according to manual Correctly to choose parameters and to operate Using the short arc operation Welding operation in the field should have anti wind protection Don t use the invalid electrode The slag clears bad in the middle layer in the welding process Under current or over speed in the welding Choosing the electrode detachability Strictly to clear the slag in the layers of good slag Welding operation snot Proper Correctly to choose the welding parameters slag The welding material can not match the MM Adjusting the electrode angle and inclusion work piece manipulation The groove design amp processing are not proper In the process of solidification the inter Strictly control the percentage of S and P in isa crystal segregation is seriously caused Atthe welding material same time with the effect of welding stress Adjust the structure of welding material the hot crack is formed Ado
27. tic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 eMaintain 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 e Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders e When working above floor level use a safety belt to protect yourself from a fall should you get a shock FUMES AND GASES CAN BE DANGEROUS e Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume 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 Threshold Limit Values using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be
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