USER`S MANUAL
Contents
1. 3 Make sure the input voltage is 3 phase Check if all kinds of components of machine are poor contact Meter is normal fan is working no Check if connector of output terminal is broken or damaged welding output Check if the control board is damaged contact with the supplier or manufacturer 1 IGBT is damaged Abnormal indicator is on fan is 2 Rectifier of quick recovery is damaged working meter is normal 3 Control board is broken 4 The feedback circuit is in fault Please contact with the supplier or manufacturer ae spatter during MMA Output terminal polarity connection is wrong So please change the polarity Erratic welding output current or 1 The potentiometer is damaged out of control of potentiometer 2 All kinds of connectors are poor contact especially plugs Check them 1 Power switch is broken Power switch doesn t work 2 Three phase rectifier bridge is broken replace it 3 Check if there is any short circuit of inner machine USER MANUAL 172. acidity alkalescence and fibre It can apply in high altitude the open air and inside and outside decoration Compared with the same products of home and abroad it is compact in volume light in weight easy to install and operate Thanks for purchasing the product and hope for your precious advice We will dedicate to produce the best products and offer the best service WARNING The machine is mainly used in industry It will produce radio wave so the worker should make fully preparation for protection USER MANUAL D TECHNICAL PARAMETERS TABLE USER MANUAL Model Parameters I DC500 II Power voltage V Three phase AC380V 15 Frequency Hz 50 60 Rated input current A 38 4 No load voltage V 93 Output current A 40 500 Rated output voltage V 40 Force range A 0 100 Hot starting range CA 0 135 Duty cycle 60 No load loss W 100 Efficiency 85 Power factor 0 93 Insulation grade H Housing protection grade IP21 Weight kg 47 Dimensions mm 650x310x640 10 INSTALLATION INSTRUCTION The machine is equipped with power voltage compensation equipment When the power voltage fluctuation is betweent15 of rated voltage it still can work normally When use long cable in order to prevent voltage form going down bigger section cable is suggested If the cable is too long it may affect the performance of the
3. 0 65 0 66 0 Current 70 100A 110 1604 170 2204 230 2804 260 300 Hot starting 1 3 3 7 7 10 7 10 4 Hot starting adjustment knob You can adjust this knob below pre set current 200A which can make arc striking more easy 5 Knob of arc striking drive is use to adjust welding function specially in low current range that is cooperated with knob of welding current adjustment they may adjust current of arc striking and be out of control of knob of welding current adjustment So machine can gain powerful energy and push current can achieve effect 6 If welding machine has been coordinated remote control device 1 Make sure the switch position of remote control device before operation If switch is on OFF position that is out of remote control Switch is on ON position that is using remote control device 2 Insert plug of remote control in socket of remote control correctly and tighten firmly in order to prevent poor contact If remote control device is not be used make sure the switch is on OFF position or welding current will not be adjusted on panel 3 In removing the welding machine some users bumped the remote control switch into wrong place accidentally so that the adjustment doesn t function properly However they mistake it for fault in machine Please pay attention 7 Ifthe VRD equipment is installed in the machine When the switch of front panel is put ON position the VRD indi
4. In this situation you don t have to pull the plug let the fan cool the machine When the indicator light is off and the temperature goes down to the standard range it can weld again USER MANUAL 14 QUESTIONS TO BE RUN INTO DURING WELDING Fittings welding materials environment factor supply powers maybe have some impact in welding User must try to improve welding environment A 1 2 3 Arc striking is difficult and easy to pause Make sure quality of tungsten electrode is high If the electrode is not dried it will cause unstable arc welding defect increases and the quality is down If use extra long cable the output voltage will decrease so please shorten the cable Output current is not to rated value When power voltage departs from the rated value it will make the output current not matched with rated value when voltage is lower than rated value the max output may lower than rated value C Current is not stabilizing when machine is being operated This may be caused by the following factors Electric wire net voltage has been changed There is harmful interference from electric wire net or other equipment Too much spatter during MMA welding Maybe current is too heavy while welding rod diameter is too small Output terminal polarity connection is wrong The positive connection should be applied at the normal technique that is to say welding rod connects with the negative polarity wh
5. electric shock or burnt 1 Don t touch any electric parts 2 Ask professional person to connect the machine and workpiece to the ground 3 Cut off the power box before the installation or checking and restart after 5 minutes For the capacitance is chargeable please ensure it has no voltage before restart even if the power source is cut off 4 Do not use cable without enough section or with worn out cover or broken conductor 5 Do ensure insulation at the cable joint parts 6 Do not use the machine when the housing is off 7 Do not use broken or wet insulation gloves 8 Use safety net when work at high position 9 Check and maintain regularly don t use it until the broken parts are fixed well 10 Cut off all the input power when not use 11 Follow the national or local related standard and regulations when using the AC DC machine at narrow or high position Danger Please use preventive measures to avoid gas and fumes Gas and fumes are harmful to health a x It may cause choke when operate in narrow space 1 In case of accidents like gas poisoning or choke please use suggested exhaust equipment and breathe preventive facilities 2 In case of hurt and poisoning by gas and other powder please use suggested part exhaust equipment and breathe preventive facilities 3 When operated on trunks boilers cabins etc the CO2 and argon gas will stay in the bottom Please replace gas sufficiently and use g
6. or supervise welding please use preventive facilities with enough shielding 2 Please wear preventive glasses 3 Please wear preventive facilities such as leather gloves coat foot safeguard and apron 4 Set preventive shield screen around the welding area to protect other people from harmful arc rays USER MANUAL 5 VAN Notes Please follow the below notes to avoid gas cylinder toppling over or broken rey Toppling over of the gas cylinder will cause body hurt I Wrong use of the gas cylinder will lead to high pressure gas eruption and cause human hurt 1 Use the gas cylinder correctly 2 Use the equipped or recommended gas adjustment 3 Read the manual of the gas adjustment carefully before using it and pay attention to the safety notes 4 Fix the gas cylinder with appropriative holder and other relative parts 5 Do not put the cylinder under high temperature and sunshine 6 Do not put your face close to the gas cylinder exit when opening it 7 Put on the gas shield when not use 8 Do not put the torch on the gas cylinder or touch the electrode A Notes Any touch of the switch part will cause injury please pay attention to the below y notes Do not put fingers hair clothes etc near to the moving parts such as the fan 1 Do not use the machine when the housing is off 2 Ask professional person to install operate check and maintain the machine 3 Do not put fingers hair clothes etc nea
7. p lt 15 Notes for electromagnetism disturb 1 It may need extra preventive measures when the power is used in some partial space 2 Before the installation please estimate the potential electromagnetism problems of the environment as follows 1 Upper and down parts of the welding equipments and other nearby power cable control cable signal cable and phone cable 2 Wireless electric as well as TV radiation and reception equipment 3 Computer and other control equipments 4 Safety recognition equipment etc Eg supervise of industrial equipments 5 Health conditions of the people around Eg use of the heart pacemaker and audiphone 6 Equipments for adjustment and measurement 7 Anti disturb capability of other used equipments Users should ensure these equipments and the USER MANUAL af environment are compatible and this may need extra preventive measures 8 Practical state of the welding and other activities 3 Users should follow the below notes to decrease radiation disturb 1 Connect the welding equipments to the power supply lines 2 Maintain the welding equipments regularly 3 The cable should be short enough to be close to each other and near to the ground 4 Ensure the safety of all the metal parts and other parts nearby 5 The workpiece should be well connected to the ground 6 Shield or protect the other cable and equipments to decrease the influence of disturb The welding equipments can be fully shie
8. ZIKH USER S MANUAL I DC500 II gt 5 POC 500 N so von USER MANUAL CONTENTS Contents ii ida ares eee des dun ne aaa ei cd otre sent 1 Safety warning nello 2 Machine description A ana 8 Technical parameters table aa A aaa 9 Installation instruction 2 ae A Aa ein 10 Panel function instruction iii 11 Operatlorinstruciiohi salare 12 Notes oripreventive measures nia e 13 Questions to be run into during Welding 14 40 Maintenance a 15 11 Troubleshooting and fault finding 16 USER MANUAL a SAFETY WARNING e Please read this manual carefully before using it e The safety notes listed in this manual is to ensure correct use of the machine and to keep you and other people from being hurt e The machine is safety considered designed please refer to the safety warning listed in the manual when using it in case of bad accidents e Vrong use of the machine will cause different extent of hurt as follows and there will be warning sign and description for remind Warning sign Description Meaning High danger means there is possibility of severe dangerous 1 and may cause dead if not avoid This sign is used in extreme High danger Ce i case which is normally related to body dan
9. as respire facilities in case of oxygen shortage 4 Please accept the supervisor s check when operate in narrow space and ensure enough gas supply USER MANUAL 4 and use breathe preventive facilities 5 Do not weld in degrease washing and spray space 6 Use breathe preventive facilities as it will cause poisonous dust and gas when weld shielded steel Danger Please follow the below notes to avoid accidents like fire and explode DIR Spark and hot workpiece can cause fire It may cause fire if the cable is not connected well or when the current circuit of the steel or other workpiece are not connected completely Do not weld on the case of tinder stuff or it may cause explode Do not weld airtight containers such as slot pipe etc or may break 1 Do not put tinder stuff in welding area 2 Do not weld around tinder gas 3 Do not put heat workpiece near the tinder stuff 4 When weld the dooryard ground and wall do move away the tinder stuff around 5 The cable joint place should be insulated 6 The cable joint of the workpiece should be close enough to the welding place 7 Do not weld those facilities with gas pipe or airtight slot 8 Put fire extinguisher around the welding area in case of fire IN Notes Please wear protective appliance to avoid arc spark residue and noise 28 Arc ray can cause eye inflammation or skin burnt Spark and residue will burn your eyes and skin 1 When welding
10. ctor is lit and when the switch is put OFF position the VRD indicator is off then the no load voltage is 67V Switch of VRD is put inside the machine with the on condition The no load voltage changes to be less than 15V which is safe for people WARNING Before connecting operation please make sure all the power is turned off The right order is to connect the welding cable and ground cable to the machine first and make sure they are firmly connected and then put the power plug to the power source USER MANUAL 13 NOTES OR PREVENTIVE MEASURES O 1 1 2 3 4 5 2 Environment The machine can perform in environment where conditions are dry with a dampness level of max 90 Ambient temperature is between 10 to 40 degrees centigrade Avoid welding in sunshine or drippings Do not let water enter the gas Avoid welding in dust area or the environment with corrosive gas Avoid gas welding in the environment with strong airflow Safety norms Our welding machine has installed protection circuit of over voltage over current and over heat When voltage output current and temperature of machine are exceeding the rated standard welding machine will stop working automatically Because this will be damage to welding machine user must pay attention to following 1 The working area is adequately ventilated Our welding machine is powerful machine when it is being operated it generated high currents an
11. d natural wind cannot satisfy with machine cool demands So there is a fan inside the machine for its cooling demands Make sure the intake is not in block or covered There should be 0 3 meter distance from welding machine to objects of environment User should make sure the working area is adequately ventilated It is important for the performance and the longevity of the machine Do not over load The operator should remember to watch the max duty current Response to the selected duty cycle Welding current should not exceed max duty cycle current Over load current will damage and burn up the machine No over voltage Power voltage can be found in diagram of main technical data Automatic compensation circuit of voltage will assure that welding current keeps is in allowable range If power voltage is exceeding allowable range limits it can damage the components of machine The operator should understand this situation and take preventive measures There is a grounding screw behind welding machine with a grounding marker on it Before operation welding crust must be grounded reliably with cable which section is over 6 square millimeter in order to prevent from static electricity and accidents because of electricity leaking If welding time is exceeding duty cycle limited welding machine will stop working for protection Because machine is overheated temperature control switch is on ON position and the indicator light is red
12. gerous neither than property loss Danger means there is possibility of dangerous situation and Danger may cause badly hurt if not avoid It can also refer to property loss N This means it may cause body hurt if not avoid Please refer to the otes related description when this sign occurred D 1 Do not use the machine in none welding areas Danger Please follow the rules below in case of bad accidents 2 The machine is safety considered designed please do read the warning notes carefully in case of dead or other bad accidents 3 Follow related regulations for the construction of the input drive force selection of the setup place usage of the high pressure gas storage and configuration safe keeping of the workpiece after welding and management of the offal etc 4 No entry of unrelated person to the welding area 5 People using heart pacemaker cannot get close to the welding machine and area without the doctor s permit The magnetism caused when connecting the machine will cause influence to the pacemaker 6 Ask profession person to install check and maintain the machine USER MANUAL 3 7 Please correctly understand the contents of this manual to ensure safety and ask those professional people with safety knowledge and technique to operate the machine gt Danger Please follow the rules below in case of electric shock Any contact of electric parts may cause fatal
13. ile the work piece with the positive polarity So please change the polarity USER MANUAL 15 MAINTENANCE 1 Remove dust by dry and clean compressed air regularly if welding machine is operating in environment where is polluted with smokes and pollution air the machine needs to be cleaned once a month 2 Pressure of compressed air must be within the reasonable range in order to prevent damaging to small components of inner machine 3 Check internal circuit of welding machine regularly and make sure the circuit connections are connected correctly and tightly especially plug in connector and components If scale and rust are found please clean it and connect again tightly 4 Prevent water and steam from entering into the machine If that happens please blow it dry and check insulation of machine 5 If welding machine will not be used for long time it must be put into the packing box and stored in dry and clean environment USER MANUAL 16 TROUBLESHOOTING AND FAULT FINDING Notes The following operations must be performed by qualified electricians with valid certifications Before maintenance please contact with us for professional suggestion I DC500 II fault symptom and solution Fault symptom Solution Meter doesn t display fan doesn t Make sure power switch is off 2 Make sure the power source connecting to input cable is working alright work no welding output
14. lded under special conditions 4 Users are responsible for the disturb problems caused by welding USER MANUAL 8 MACHINE DESCRIPTION The welding machines are rectifiers adopting the most advanced inverter technology The development of inverter gas shielded welding equipment benefits from the development of the inverter power supply theory and components Inverter gas shielded welding power source utilizes high power component IGBT to transfer 50 60Hz frequency up to 15KHz then reduce the voltage and commutate and output high power voltage via PWM technology Because of the great reduce of the main transformer s weight and volume the efficiency increases by 30 The appearance of inverter welding equipment is considered to be a revolution for welding industry The welding power source can offer stronger more concentrated and more stable arc When stick and work piece get short its response will be quicker It means that it is easier to design into welding machine with different dynamic characteristics and it even can be adjusted for specialty to make arc softer or harder MMA welding machine has the following characteristics effective power saving compact stable arc good welding pool high no load voltage and good capacity of force compensation and multi use It can weld stainless steel alloy steel carbon steel copper and other color metal It can apply to electrode of different specifications and materials including
15. power system So cables of configured length are suggested 1 Make sure the intake of the machine is not blocked or covered to avoid malfunction of cooling system 2 Ground the cables with section area no less than 6mm to the housing the way is connecting screw in the back of the power source to ground device 3 Correctly connect the arc torch or holder according to the sketch Make sure the cable holder and fastening plug have been ua connected with the ground Put the fastening plug into the fastening socket at the terminal and fasten it clockwise Put the fastening plug of the cable to fastening socket of terminal at the front panel fasten it clockwise and the earth clamp at the other terminal clamps the work piece p Installation Instruction of I DC500 II 4 Please pay attention to the connecting terminal DC welding machine has two connecting ways positive connection and g ways p Power Supply negative connection Positive connection holder connects with three phase 380V wi terminal while work piece with the polarity Negative de connection work piece with the terminal holder with the terminal Choose suitable way according to working demand s If Connected to unsuitable choice it will cause unstable arc more spatters and ground conglutination If such problems occur please change the polarity of the fastening plug 5 According to input voltage g
16. r to the switch parts such as the fan A Notes Follow the below note as the wire end may cause body hurt A The wire shoot out from the torch can stab eyes face and other naked parts 1 Before feeding the wire do not look into the electric conduction hole or the wire shooted out may stab your eyes and face 2 When feeding the wire manually or press the torch do not put the torch end near to your eyes face and other naked parts A Notes Follow the below notes to ensure better work efficiency and power source S No person under of in front of the machine when swing in case of injury USER MANUAL 6 1 Precautions against toppling over 2 Warning against the use of welding power source for pipe thawing 3 Lift the power source from two sides when use the up down forklift truck in case of toppling over 4 When using the crane for lift tie the rope to the ears with an angle no more than 15 to the vertical direction 5 If the machine is equipped with gas cylinder and wire feeder download them from the power source and ensure the horizontal of the machine Do fix the gas cylinder with gallus or chain when moving it in case of body hurt 6 Ensure fastness and insulation when using the swing ring to lift the wire feeder in welding 7 If the machine is equipped with gallus or handles they are only for hands not for crane fork lift truck or other swing equipments Lifting way for the machines with swing ring on the top
17. rade connect power cable with power supply box of relevant voltage grade Make sure there is no mistake and the voltage of power supply does not exceed permission range After the above job installation is finished and welding is available A If distance of work piece and machine is too far 50 100m and the cables torch cable and earth cable are too long please choose cable of bigger section to minimize the reduction of the voltage USER MANUAL 11 PANEL FUNCTION INSTRUCTION I DC500 II Front Panel Instruction 1 Voltage meter 2 Current meter 3 Abnormal indicator light 4 VRD indicator light 5 VRD switch 6 Remote control switch 7 Welding current adjustment 8 ARC force current adjustment 9 Negative output terminal 10 Remote control 11 Positive output terminal 12 Hot starting adjustment knob The panel picture above is for reference only If any difference with the real machine please follow with the real machine USER MANUAL 12 OPERATION INSTRUCTION 1 Turnonthe power switch screen will show set current value and ventilator is beginning to run 2 Set suitable welding current and arc striking push according to the thickness of work piece diameter of welding rod work position and technics needs 3 Generally welding current is adequate to welding electrode according with as following Specification d 2 5 d3 2 d4
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