USER MANUAL - Zika Industries LTD
Contents
1. Chart 14 Malfunction display of overheating protection 21 22 4 3 Welding environment and safety 5 Environment a D 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 5 Safety norms b c 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 rate standard welding machine will stop working automatically Because that will be damage to welding machine user must pay attention to following The working area is adequately ventilated Our welding machine is powerful machine when it is being operated it generated by high currents and natural wind can t be satisfied with machine cool demands So there is a fan in inter machine to cool down machine Make sure the intake is not in block or covered it is 0 3 meter 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 selected2. 4 5 3 2 Wire diameter mm 0 8 0 9 0 8 0 9 0 8 0 9 0 8 0 9 1 0 1 2 1 0 1 2 1 2 1 2 Welding gun Current Voltage Welding Wire Gas flow vertical speed extension rate angle A V cm min mm L min 10 60 70 16 17 40 45 10 10 15 30 80 90 18 19 45 50 10 10 15 30 90 100 19 20 45 50 10 10 15 47 100 130 20 21 45 50 10 10 15 47 120 150 20 21 45 50 10 10 15 47 150 180 20 22 35 45 10 15 20 25 47 200 250 24 26 45 50 10 15 20 25 47 220 24 150 15 15 47 300 26 250 15 15 34 Appendix Circuit diagram FRONT kel cower PANEL CONTROL CIRCUIT 35 Appendix lll Components figure and list Structure Chart of MIG 300GD ON h ISO ANNA pei fh z A Em ANI 36 Major parts list of MIG 300GD olvlojlalsloln NIMINININMI NIN A BS a i a i alla all all OI STIOlUAIBRIOIN SIOlIOlIOISTIOlAIRI OINVI O Item Air switch Fuse seat Fan cover Supporting of radiator Push lock button Socket Heater board Absorption board Capacitor Transformer Reactor commutate module radiator radiator Fan board Fan net Silicon single wheel Crater Automatic line lock button Discal axis plastic switch Hinge Main control board Control panel Front panel Panel preventive cover Supporting of argon cylinder Machine chassis Quantity No tem auant 1 a hand f ae el nmo Ji al ams JI at
3. duty cycle Keep welding current is not exceed max duty cycle current Over load current will damage and burn up 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 in allowable range If power voltage is exceeding allowable range limited it is damaged to 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 reliable with cable which section is over 6 square millimeters in order to prevent from static electricity and accidents because of electricity leaking 4 4 Welding problems and resolution The phenomenon listed below may happen due to relevant accessories used welding material surroundings and power supply Pleas improve surroundings and avoid these problems Arc starting difficulty Arc interruption happens easily Examine whether grounding wire clamp contacts with the work pieces well Examine whether each joint has improper contact The output current fails to reach rated value The deviation of power voltage from rated value may cause that the output current does no accord with adjusted value When the power voltage is lower than rated value the maximum output current may be lower than rated value The current can not keep stable
4. small regulating rate and low speed 7 Gas check 15 16 8 Multifunctional data display 9 Burn back Polarity conversion joint This machine has the polarity conversion There are positive output terminal and negative output terminal between wire feeder and wire spool When use solid wire with gas protection torch socket should be connected to the positive output terminal ground cable should be connected to the negative output terminal When use flux cored wire the two connected cable should be exchanged 4 2 Operation instruction 4 2 1 Welding display 5 The starting up display Switch on the welding power source the front panel displays as Chart 1 After the Multifunctional data display or any key or knob on front panel flashes for 5 seconds the machine enters into the welding mode that saved in the last shutdown 1 0mm 1 2mm MIG300GD Chart 1 the starting up display interface 5 Operation instruction under MMA mode a When welding stops Press the STICK LIFT TIG MIG switch key the STICK indicator lights up and it turns into STICK mode b When under STICK mode pressing the VRD 2T 4T switch key VRD function is enabled when the indicator lights up and displays in multifunctional data display Or the VRD function isn t enabled if the indicator is off Chart 2 Chart 3 MIG300GD MIG300GD Chart 2 under MMA mode preset current Chart 3 under MMA mode pres
5. 120 15 20 Plate Wire Current Voltage Welding Wire Gas flow rate thickness diameter speed extension A V L min mm mm cm min mm 0 8 0 9 60 80 16 17 40 50 10 10 0 8 0 9 g0 100 19 20 40 55 10 10 15 1 0 1 2 120 160 20 22 35 45 10 15 10 15 1 0 1 2 150 180 21 23 30 40 10 15 20 25 Plate Wire Welding gun Current Voltage Welding Wire Gas flow thickness diameter vertical speed extension rate angle A V mm mm cm min mm L min 5 1 0 0 8 0 9 45 70 80 17 18 50 60 10 10 15 1 2 0 9 1 0 45 85 90 18 19 50 60 10 10 15 amp 1 6 1 0 1 2 45 100 110 19 20 50 60 10 10 15 2 2 1 0 1 2 45 115 125 19 20 50 60 10 10 15 2 2 3 1 0 1 2 45 130 140 20 21 50 60 10 10 15 S 1 0 1 2 45 150 170 21 22 45 50 15 15 20 3 4 5 1 0 1 2 45 140 200 22 24 45 50 15 15 20 a 1 2 45 230 260 24 27 45 50 20 15 20 F 89 1216 50 270 380 29 35 45 50 25 20 25 g 1 2 1 6 50 400 32 36 35 40 25 20 25 1 0 0 8 0 9 45 140 19 20 160 10 15 S 0 8 0 9 45 130 150 19 20 120 10 15 F 0 e 1 6 1 0 1 2 45 180 22 23 120 10 15 20 2 a 2 1 2 45 210 24 120 15 20 8 2 3 1 2 45 230 25 110 20 25 3 2 1 2 45 270 27 110 20 25 4 5 1 2 50 290 30 80 20 25 6 1 2 50 310 33 70 25 25 33 mu Buipjam jai EIUOZLOH paads Bulpjam Mo7 peeds Buipjam UD Plate thickness mm 0 8 1 2 1 6 2 3 3 2
6. of the gas cylinder will lead to high pressure gas eruption and cause human hurt Never let fingers hair clothes or etc near the moving parts such as the fan The wire shoot out of the torch may stab eyes face and other naked parts Never stand in front of the swang equipment or under it or it may fail and cause injury A DANGER Please follow the rules below to avoid heavy accidents Never use the equipment to do other things but welding Follow related regulations for the construction of the input driven power source choice of place usage of high pressure gas storage configuration safe keeping of workpiece after welding and disposal of waste etc Nonessentials do not enter the welding area People using heart pacemaker is not allowed to get close to the welding machine or area without doctor s permission The magnetism created by energizing the welding machine can have a bad effect to the pacemaker Install operation check and maintain the equipment by profession personnel Understanding the contents of the user manual for safety A DANGER Please follow the rules below to avoid electric shock Keep away from any electric parts Earth the machine and workpiece by professional personnel Cut off the power before installation or checking and restart 5 minutes later The capacitance is chargeable device Please ensure it has no voltage before start again even if the power source is
7. MIG 300GD WLEDING MACHINE USER MANUAL Preface This manual includes hardware description and operation introduction of MIG 300GD equipment For your and other people s safety please read the manual carefully Pay attention Pay attention to the words after the signs below Sign Description The words after this sign means there is great potential danger paNncer which may cause major accident damage or even death if it is not followed The words after this sign means there is some potential danger A WARNING which may cause hurt or property lose if it is not followed The words after this sign means there is potential risk which may ATTENTION cause equipment fault or break if it is not followed Version Version YF 41H A1 Released at 19th 7 2012 The contents of this manual are updated irregularity for updating of product The manual is only used as operation guide except for other promises No warranties of any kind either express or implied are made in relation to the description information or suggestion or any other contents of the manual CONTENTS 1 SATETY WARNING EE 4 A tee E 10 PM Sa sn 10 2 2 Technical at AN A AA AAAA SAANA ANATA A ANSA 11 Se WAS Tea EE EE 12 ASTANA as AG eel SAE a ci lect A 15 AT TROIA ETEINEN e EE 15 4 2 Operation Neie EE 16 4 3 Welding environment and safety A 22 4 4 Welding problems and resolution aaaaaaaaaaassanssaasaaassaansnannn
8. and wire sending Pressure wheel CABLE Position Checking keys If torch cable over bended Remarks Cause poor wire sending If the metal connecting point of mobile plu loreh l sen TE pig 1 Unstable arc if cable cable over bended Wearing out of the cable insulated material For lif d Cable connecting head naked insulation 9 SE Si Output damage or loosen the end of power supply Stable welding adopt cable and cable of main material connecting point suitable method to check according to If the connect of power supply input protective worming plete equipment input and the output end fixed or not Simple check If the security equipment cable reliably dail Input connected ay r Careful and cable If the power input end cable fixed medeni check If the input cable is worn out and bares the p conductor on fixed period If the earth cable that connects the power To prevent creep age Ga supply is broken and connect tightly i ari If the earth cable that connects the main part is en Security cable please make daily broken and connects tightly check 27 6 Trouble shooting and fault finding Notes The following operations must be performed by qualified electricians with valid certifications Before maintenance you are suggested to contact local distributor to verify qualification Malfunctions and
9. b during welding can realize the synergic manipulation of welding voltage and feeding speed which displays in multifunctional data display The 0 8mm wire adjustable range is 16 2V 3 0m min 27V 15 0m min 91 0mm wire adjustable range is 16 5V 2 2m min 30 3V 12m min 91 2mm wire adjustable range is 18 1V 2 2m min 29 4V 9 0m min Press the data selection key for the first time the multifunctional data display displays as Chart 8 which means the welding voltage is adjustable and the adjustment range of preset voltage is 20 Press the data selection key for the second time the multifunctional data display displays as Chart 9 which means the inductance is adjustable and its adjustment range is 10 Press the data selection key for the third time it would turn back to preset welding voltage and wire feeding speed Chart 8 fine adjustment display of voltage Chart 9 Fine adjustment display of Inductance presetting range under MIG mode range under MIG mode 3 seconds later after setting the welding parameters the multifunctional data display would flashes for one time which means the data has been saved The panel displays as Chart 10 when perform welding which means the welding voltage is 18 2V and the current is 82A Releasing the torch switch and stopping welding the panel displays as Chart 11 Moreover HOLD flashes for 3 seconds and quenched which means the welding stops 2 seconds later mu
10. cut off Do not use wire with inadequate section surface or damage insulation sleeve or even exposed conductor Do ensure well isolation of wire connection Never use the device when the enclosure is removed Never use broken or wet insulation gloves Use firenet when work at high position lt Check and maintain regularly don t use it until the broken parts are fixed well Turn off the power when not in used Follow the national or local related standard and regulations when using the AC welding machine at narrow or high position A DANGER Please follow the below notes to avoid fire and explode etc No combustible in welding area Keep off combustible when welding Keep hot workpiece after welding away from flammable gas Do move away the combustible around when weld the dooryard ground and wall The wire connection of base metal should be as close to the welding place as possible Never weld those facilities with gas pipe or airtight slot Put fire extinguisher around the welding area to prevent fire WARNING The gas and fumes are harmful to health please wear protective device according to regulations Wear exhaust equipment and breathe preventive facilities to prevent gas poisoning or choke Use suggested part exhaust equipment and breathe preventive facilities to prevent hurt or poisoning by gas and other powder please To prevent oxygen deficiency air out the gas filled room which is full o
11. d sd nd d Reason of poor wires sending and unstable arc please change Block caused by dirt in the tube and the remains of the wire plating lay Reason of poor wire sending and unstable arc use kerosene to wipe or change new one Wire sending tube broken O 1 Pyrocondensation tube broken circle wear out change new tube 2 Change new O circle May lead to vice splash because of poor gas shield torch body get burned arc in the torch please handle Forget to insert or the hole Gas bypass blocked or different factory component WIRE SENDING MACHINE Position Checking keys Remarks O If put the arm to the suitable indicating Pressing level notes not to damage wire less Lead to unstable arc and arm than 61 2mm wire sending O lf powder or residue store up inthe mouth Clean the residue and of the tube check the reason and solve it O Wire diameter and the tube inner diameter match or not lf nol match leads to unstable arc and residue O Ifthe tube mouth center matches the wire If unmatched lead to wheel slot center or not unstable arc and residue O Lead to unstable arc Wire diameter matches the wheel s and residue and requirement block wire tube E If the wheel slot blocked Change new one of necessary Check the stability of its move and wearing out of pressed wire the narrowing of its contact surface Lead to unstable arc
12. during operation This situation may relate to the following factors The voltage of electric power network changes Serious interference from electric power network or other electric facilities Gas vent in welds Examine whether the gas supply circuit has leakage Examine whether there is sundries such as oil dirt rust paint etc on the surface 23 5 Daily maintenance and checking 24 5 Daily maintenance a Remove dust regularly with dry compressed air If the welding machine is used in surroundings with heavy smoke and polluted air it is necessary to remove dust at least one time one month b The pressure of compressed air shall fall to required level to prevent damage to small components in the machine c Examine inside electric joints and ensure perfect contact Especially plugs and sockets Fasten the loosing joints In case of oxidation remove oxide film with sand paper and connect again d Prevent water from entering into the machine and prevent the machine from getting moist If any blow and dry Measure the insulation with megohmmeter to make sure it is qualified to use e If the welding machine is not used for a long time pack the machine in original package and store in dry surroundings f Every time the wire feeder operates for 300hours grind the electrical carbon brush and clear up the armature commutator Rinse speed reducer apply 2 Molybdenum Disulfide lubricant to the turbine whirlpool rod and b
13. earing A WARNING The power shall be cut off completely before all maintenance repairing works Make sure to pull out power plug before opening the case 5 Daily checking WELDING POWER SUPPLY Position Checking keys Remarks Switch condition of operation transfer and installation Gonuol an Test the power indicator Check if there is wind and the sound normal If abnormal noise Cooling fan or not and no wind to check the inner When electrified abnormal smell or not When electrified abnormal vibration and buzz or not Power part Color changing and heating or not in appearance Gas pipe broken loosen or not Periphery H Housing and other fixed parts loosen or not WELDING TORCH Position Checking keys Remarks If installment fixed the front distorted Reason for air hole Loophole O Attach splash or not Reason for burning the torch can use splash proof material If installment fixed Reason of torch screw thread damage Electric hole Damage of its head and halablocked narnot Reason of unstable arc and broken arc Have to be changed when less than 6mm when the extended part too small the arc will be unstable Check the extended size of the pipe Wire sending tube Wire diameter and the tube inner diameter match or not Reason of unstable arc please use the suitable tube 26 Partial winding an
14. eed extra preventive measures when the equipment is used in particular location e Before the installation please estimate the potential electromagnetism problems of the environment as follows a Upper and lower parts of the welding equipments and other nearby power cable control cable signal cable and phone cable b Wireless electric as well as TV radiation and reception equipment c Computer and other control equipments d Safety recognition equipment etc Such as supervise of industrial equipments e Health of people around Such as personnel using the heart pacemaker or audiphone f Equipments for adjustment and measurement g Anti disturb capability of other used equipments Users should ensure these equipments and the environment are compatible which may need extra preventive measures h Practical state of the welding and other activities Users should observe the following dos and don ts to decrease radiation interference a Connect the welding equipments to the power supply lines b Maintain the welding equipments regularly c The cable should be short enough to be close to each other and the ground d Ensure the safety of all the welding metal parts and other parts nearby e The workpiece should be well earth f Shield or protect the other cable and equipments to decrease the effects of disturbances The welding equipments can be complete shielded in some special conditions Users are responsible for inter
15. et current display with VRD enabled display VRD disabled c multifunctional data display shows the preset current 080A its unit is ampere A d Adjusting the Multifunctional data adjusting knob can change the welding current during welding process and displayed in multifunctional data display The welding current range is 10A 300A e 3 seconds later after setting the welding parameters the multifunctional data display would flashes for one time which means the data has been saved f The panel displays as Chart 4 when perform welding which means the welding voltage is 23 2V and the preset current 80A 5 seconds later it returns to the preset current state MIG300GD Chart4 The display status when welding under MMA mode 5 Operation instruction under MIG mode a When welding stops press MMA MIG switch key MIG indicator lights up and the machine enters into MIG mode Chart 5 bi multifunctional data display shows the preset voltage 18 0V its unit is volt V while 05 0m min means the preset wire feeding speed its unit is m min 17 c MIG300GD MIG300GD Under MIG mode pressing BURN BACK the indicator lights up which can realize high speed wire feeding Chart 6 multifunctional data display would flash continuously until pressing the torch switch or any key or knob on the panel Both multifunctional data display and BURN BACK stops flashing and the wire stops feedin
16. f CO2 and argon on the bottom When operating on trunks boilers cabins etc Please accept the supervisor s inspection when operating in narrow space Air the room and wear breathe preventive facilities Never operate in degrease washing or spray space Using breathe preventive facilities when weld shielded steel for it will cause poisonous dust and gas A WARNING The arc spark residue and noise are harmful to health please wear protective appliance Eye protection against arc is recommended when welding or supervise welding Please wear preventive spectacles Welder s gloves welder s goggles long sleeve clothes leather apron and other standard protection equipments must be worn for welding operation A screen to protect other people against the arc must be set in the welding place A WARNING Please follow the notes below to avoid gas cylinder toppling over or broken e Use the gas cylinder correctly e Use the equipped or recommended gaseous regulator Read the manual of gaseous regulator carefully before using it and pay attention to the safety notes Fix the gas cylinder with appropriative holder and other relative parts Never put the cylinder under high temperature or sunshine environment Keep your face away from the gas cylinder exit when opening it Put on the gas shield when it is not used Never put the torch on the gas cylinder The electrode can not meet the gas cylinder WARNING Any touch of the swi
17. ference due to welding 2 Product 2 1 General The welding machine applies the most advanced inversion technology in the world The principle of inversion is to transform the power frequency of 50HZ 60Hz into direct current and invert it into high frequency 24KHz through high power device IGBT then perform voltage drop and commutation with the output high power D C power supply via Pulse Width Modulation PWM Since the switch power inversion technology is adopted the weight and volume decrease greatly while the conversion efficiency increase of more than 30 Additional to MIG the machine added MMA function It adopts full digital panel display which can realize synergic adjustment of feeding speed and welding voltage as well to regulate the welding parameters easily Our CO gas shielded welding machine is equipped with unique electronic reactor circuit which can precisely control the short circuiting transfer and mixed transfer resulted in better performance than other machines Compared with silicon controlled welding machine and tapped welding our products have the following advantages stable wire feed rate portable energy saving electromagnetic noise free Besides our products spatter less easier arc starting deep welding pool high duty cycle etc With high efficiency and electrical saving advantage this equipment is applicable for both multi metal and mutli technology required welding Thank your for choosing our produc
18. g Chart 5 Preset voltage display under MIG mode Chart 6 Burn back display under MIG mode 18 d Under MIG mode press the Gas check the indicator lights up which can realize gas check function chart 7 multifunctional data display would flash continuously until pressing the torch switch or any key or knob on the panel Both multifunctional data display and GAS CHECK stops flashing and the gas stops checking MIG300GD Chart 7 Gas check display under MIG mode Under MIG mode operate VRD 2T 4T switch key to choose the welding mode 2T NORMAL lighting up means 2 step control way press the torch switch feed the gas in advance and perform welding normally release the torch switch burn back and get rid of the ball on the end of wire then stop feeding gas 3 seconds later While 4T LATCH lighting up means 4 step control way press the torch switch for the first time feed the gas in advance and ignite the arc to perform welding then release the torch switch and perform welding normally Press the torch switch for the second time the welding current MIG300GD MIG300GD attenuates until to crater value and keep on then release the torch switch again burn back and get rid of the ball on the end of wire then stop feeding gas 3 seconds later Under MIG mode operate the wire diameter selection choose different wire diameter among 0 8mm 1 0mm 1 2mm Adjust Multifunctional data adjusting kno
19. igh pressure O cylinder to the weld 2 Gas hose damaged gun Initial problems diagnose zee if ig amp EFE V D D 3 g E e o lo amp Ee TI O gt Q ST ST 1 D kel s s D O D o o o Abnormal Items 2 16 o Q 3 5 V o B Z 2 5 e EG Area and Item to be Inspected and Maintained R 5 1 Wire feeding wheel does not match with the diameter of wire in texturing tube 2 Crackle on wire feeding wheel groove Wire Feeding blocked up or defect olololo O Device 3 Too tight or loose of the handle 4 Wire powder accumulated on the inlet of SUS pipe 1 Weld gun cable rolled up or over curved Wees SE 2 Adaptability of conductive tip wire feeding O O able 30 Loose connection of conductive tip nozzle and nozzle contactor Body of weld gun 2 Contactor of weld gun body is not plunged O in or tightened well Power supply 1 Break off bending fatigue cable of weld gun SE db Se as well as cable of 2 9990 9y Weighted crop switch control Surface Condition pe e 1 Oil dirty rust and paint residues of Parent material Se SE O and length that Too long length of wire stretched ou wire stretches out 1 Cross section of cable that connects to parent material is not enough Output Cable 2 Loose connection of output cable 01010 3 Bad electric conductivity of parent material 1 Cross section of cable is not enough Lengthened O O O 2 It is rolled
20. ltifunctional data display redisplays the preset current 19 MIG300GD MIG300GD Chart 10 display status when perform welding under Chart 11 Display status after stop welding under MIG mode MIG mode 5 Storage function 20 Press mode selection can store 3 modes which are Memor Memory and Memory3 4 2 2 Malfunction display 5 Malfunction display of wire feeder The panel displays as Chart 12 when the wire feeder is malfunctioning and the multifunctional data display flashes continuously the machine can not work normally Please restart the machine the panel would display the parameters that were set before malfunction occurrence Malfunction display of over current The panel displays as Chart 13 when over current andthe multifunctional data display flashes continuously the machine can not work normally Restart the machine the panel would display the parameters that were set before malfunction occurrence MIG300GD Chart 12 malfunction display of wire feeder Chart 13 Malfunction display of over current 5 Malfunction display of overheating protection The panel displays as Chart 16 when overheating and the multifunctional data display flashes continuously the machine can not work normally Only when the temperature of the welding machine falls below 60 C the overheating malfunction would disappear and the machine work normally without restarting
21. nnnnnnnnnnnnnnnnnnnnnnnnsnnnnnnnnnnnnanani 23 5 Daily maintenance and checking AA 24 6 Trouble shooting and fault finding AA 28 Appendix Welding parameter list sasssa aaa ha aaa a A ha a 32 Appendix II Circuit diagram scsi een eens 35 Appendix lll Components figure and list ia aaianvaaaanassasasvannasannanaanannanaanannanaanannanaunannanaanannanaananna 36 SATETY WARNING 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 The design and manufacture of welding machine considers safety Please refer to the safety warning listed in the manual to avoid accidents Different damage would be caused by wrong operation of the equipment as follows Please read the user manual carefully to reduce such damage Description Any contact of electric parts may cause fatal electric shock or burnt Gas and fumes are harmful to health Operation in narrow space may cause choke Spark and hot workpiece after welding may cause fire Bad connected cable may cause fire Incompletion connection of workpiece side circuit may cause fire Never weld on the case of tinder stuff or it may cause explode Never weld airtight containers such as slot pipe etc or it may break Arc ray may cause eye inflammation or skin burnt Spark and residue will burn your eyes and skin Toppling over of the gas cylinder will cause body hurt Wrong use
22. onnection holder connects with terminal while work piece with the terminal Negative connection work piece with the terminal holder with the terminal Choose suitable way according to the working situation If unsuitable choice is made it will cause unstable arc more spatters and conglutination If such problems occur please change the polarity of the fastened plug It should adopt negative connection when welding with alkaline electrode while positive connection when welding with acid electrode This procedure shall be operated by electrician Connect proper power cable to the distribution box with corresponding capacity according to the input voltage and current See technical parameter table Do not connect to the inappropriate voltage and make sure that the difference of power supply is within permitted range 13 Installation drawing of MIG 300GD MIG 14 Operation 4 1 Front panel layout 2 gt 21 Noraal AT Latch 0 8mm 1 2mm MIG300GD Front panel instruction 1 MMA MIG switch key 2 VRD 2T 4T switch key 3 Wire diameter selection key 0 8mm 1 0mm 1 2mm 4 Data selection key effective under MIG mode 5 Store mode selection key Memory1 Memory2 Memory3 6 Multifunctional data adjusting knob coarse adjustment by pressing the knob and turning it big regulating rate and high speed fine adjustment only by turning the knob
23. orrect installation of MIG Connect the gas cylinder with CO2 decompression flow mete tightly to CO2 mouth behind the machine via air tube Insert the swift plug of earth cable into socket at the front panel Set the wire wheel with wire on the wheel axis the wheel hole should be matched with the wheel fixer Choose wire slot according to wire size Loosen the screw of wire pressing wheel pit the wire into slot via wire lead tube adjust the wire pressing wheel to keep wire fix from gliding but strength should be suitable in case the wire distorts and affects wire sending Wire roll should turn clockwise rotation to let out wire to prevent wire from gliding wire is usually set to the fixed hole on the wheel side To prevent the bent wire from getting stuck please cut off this part of the wire Put and tighten the torch on the output socket and put the wire into the torch by hand Put the heater plug of the gas meter to the heater socket on the back panel Correct Installation of MMA Make sure cable with electrode holder and quick plug connected well Connect the quick plug to the socket of the machine and fasten it clockwise tightly Connect the quick plug at one end of the cable into the socket of the machine and fasten it clockwise the other end clamps the workpiece Please pay attention to the connecting terminal DC welding machine has two connecting ways positive connection and negative connection Positive c
24. solutions of MIG 300GD Malfunctions Solution The meter show nothing Fan does not rotate No welding output The meter shows Fan works normally No welding output the meter shows Fan works normally Abnormal indicator lights 28 Penh Confirm the power switch is on Power supply available for input cable Check if the commute bridge is damaged There is malfunction occurs in the supplementary power source on control board contact dealers Check if all the sockets in the machine are connected well There is open circuit or badness of connect at the joint of output terminal The control cable on the torch is broken off or the switch is damaged The control circuit is damaged contact to dealers It might be over current protection please turn off the power switch restart the machine after the abnormal indicator light winked It might be overheating protection please wait for about 2 3 minutes until the machine renew without turn off the power switch It might be multifunction of inverter circuit contact dealers INITIAL PROBLEMS DIAGNOSE Even the machine comes up with abnormal phenomenon such as welding unable arc unstable or bad welding effect it is still early to judge that there is malfunction on the machine The above mentioned abnormal phenomenon may be caused by some reasons For example tight parts loosen forgetting to switch on wrong se
25. t up cable broken and gas rubber pipe cracked etc Therefore please test and inspect these factors before deliver it back to the factory because a large number of troubles may be easily solved probably For this reason an initial diagnosis list for general welding troubles is shown below A trouble happened may be found in the column of Abnormal items on up right of the list please inspect and maintain for the corresponding items which have O mark in the column according to the following list respectively Initial problems diagnose 1NO SECH ON uollub oy peg oy a1ge1sun Abnormal Items Du 314 youe ON Hulpse M ON p w 104 sjoumol g weas Dia 10 p3 uo ig Area and Item to be Inspected and Maintained BLI JBUU JU IBq O YONS DIMA di SAHONPUOD 0 HONS M Turn on power supply or not Distribution Boxes Input Protection Fuse burnt out Devices Connection joint loose Examine whether the cable is cut off Input Cable Bead ted Connection joint loose Over heat 1 Turn on power supply or not Welding Power person Phase Lacking 29 pipe and cable diameter Worn blocked up or deformation etc 1 Turn on gas supply 2 Residual Amount of Gas in the Gas Cylinder and Cylinder O Gas Regulator 3 Set value for flow 4 Connection joint loose Gas supply hose the whole line from 1 Connection joint loose the h
26. tch part will cause injury please note the following Never use the machine when the enclosure is off Install operate check and maintain the machine by professional person Keep your fingers hair clothes etc away from the switch parts such as the fan A WARNING The wire end may deal damage please note the following Never look into the electric conduction hole when checking the wire feeding is normal or not or the shooting wire may stab your eyes and face e Keep your eyes face or other naked parts away from the end of torch when feeding the wire manually or pressing the switch A ATTENTION For better work efficiency and power source maintenance please note the following Precautions against toppling over Never use the welding equipment for pipe thawing Lift the power source from side when use the up down forklift truck to avoid toppling over When using the crane for lift tie the rope to the ears with an angle no more than 15 to the vertical direction e When lifting the welding machine which 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 belt or chain when moving it to avoid body hurt e Ensure fastness and insulation when lifting the wire feeder through the swing ring for welding False Lifting way for gas shielded machines A ATTENTION Electromagnetic interference needing attention e t may n
27. tet aown cover as Sean Ji al massagen 1 Far Ramcoverotment 1 al Laseanen 1 al tot swpporingerteway 1 al Ah spporng ofthe var 1 Supporting of the front wheels axis r ard gardi gara gar Gard ard gri E N 37
28. ts Please feel free to propose your valuable suggestions we will make efforts to perfect our products and service WARNING The machine is mainly used in industrial fields It will cause radion interference if used indoors Please take through precaution measures 10 2 2 Technical data Type Item 3 phase Power voltage V 380V 15 Frequency Hz 50 60 MMA 18 5 MIG 16 8 MMA 40 300 MIG 45 300 MMA 21 6 32 MIG 16 2 29 Welding wire diameter mm om Rated input current A Output current adjustment A Output voltage V 11 3 12 Installation The welding equipment is equipped with power voltage compensation device It keeps the machine work normally when power voltage fluctuating 15 of rated voltage When using long cable in order to reduce voltage drop big section cable is suggested If the cable is too long it will affect the performance of arcing and other system function it is suggested to use the recommend length 5 D Make sure the intake of the machine is not covered or blocked to avoid the malfunction of the cooling system Use ground cable whose section no less than 6mm to connect the housing and earth The method is to connect the grounded interface in the back to the earth device or make sure the earth end of power interface has been reliably and independently grounded Both ways can be used together for better security MIG 300GD Installation Procedures C
29. up or folded Cable Welding current voltage angle of weld Work Condition gun welding rate and wire length olo o O for Welding stretched out should be confirmed once again 31 Appendix Welding parameter list 5 Generally welding current is adequate to welding electrode according with as following El pein 025 03 2 04 0 05 0 specification Welding current 70 100A 110 140A 170 220A 230 280A 5 Welding variables when use MIG welding The values listed in the following table are the general specification values under standard 32 pee condition Plate Wire Interval Voltage Welding Wire Gas flow rate Hik A Current 4 Ga lckness lameter spee extension mm A V L min mm mm cm min mm 0 8 0 8 0 9 0 60 70 16 16 5 50 60 10 10 1 0 0 8 0 9 0 75 85 17 17 5 50 60 10 10 15 1 2 0 8 0 9 0 80 90 16 16 5 50 60 10 10 15 1 6 0 8 0 9 0 95 105 17 18 45 50 10 10 15 o z 2 0 1 0 1 2 o 0 5 110 120 18 19 45 50 10 10 15 z 5 2 3 1 0 1 2 0 5 1 0 120130 19 19 5 4550 10 1015 a 1 01 2 1 0 1 2 140 150 20 21 45 50 10 15 10 15 D n IS 4 5 1 0 1 2 1 0 1 5 160180 2223 4550 15 15 8 12 1 2 1 6 220 260 24 26 4550 15 1520 D H o 3 1 2 1 6 220 260 24 26 45 50 15 15 20 5 300 340 45 50 15 15 20 Q 300 340 45 50 15 15 20 100 130 10 15 z 110 130 10 15 120 130 10 15 amp 180 130 10 15 Q D
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