OPERATING INSTRUCTIONS - Topgun Welding Australia
Contents
1. A e Suo AS Abela Aina Ay UAI A e gS Jl ai Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas e N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes e N o opere com os paineis abertos ou guardas removidas ONAPI ANUALES CBRE LETH EY CRRA MRLARS SRE e EO Sel Sele Si O AB ALAYI culs I jiqall lia gadi Yo Aj Cul a jaja Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Japanese te SR Arabic LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANGA DO EMPREGADOR B gt BKANBHOX 1 DBETRRESLI RA Sierra ALTRHOREMEL HO TTEN RA EE RA SA At TE E UR BO A EE JA KISRA A MIS IRAMRRBMAMAE Ss oot ol Aol AIIM SASHA FAH Set VISAS ETEMI BRELIOR Jarl ala GU dl sde el y Wisel a Aal y Galant odgh EU ghall lach sl 3 gaat 1 i2. Connect input power for the welder then switch on the power The Data Display Meter 2 light will switch on 2 Select 10 onto the position MMA 3 Select right welding current select empiric formula I 40d d is dia of the electrode 4 Notice positive and negative connections during welding A NEGATIVE CONNECTION select 7 onto the position DC B POSITIVE CONNECTION select 7 onto the position DC WELDER ELECTRODE HOLDER WORKPIECE 5 Pay attention to the rated welding current and the rated duty cycle of the welder Overload is not allowed 6 After the welding operation is finished let the welder cool down for a few minutes before cutting off the power switch VI SVSTEMATIC BLOCK DIAGRAM Inverse OUTPUT 3x380 415V Circuit Rec tifier 2x25KHz Control Circuit This product is sold subject to the understanding that if any defects in manufacture or material shall appear within 12 months from date of consumer purchase sale the manufacturer will arrange for such defects to be rectified without charge on the sales invoice and warranty card except for damage caused by neglect General Troubles and Problem Solving Trouble Causes Problem Solving Power lamp not lit 1 No electricity input 2 Switch of welder fails 1 Check incoming line 2 Replace the switch Fan not rotating 1 Fan power line is off 2 Enclosure blocks the fan due to distortion 3 The fan
3. ROEAMA RSBMICE IVEN WOMNEWZE e HIW Yogi PERE TUB ELTFAW e XARA XU DEA UR TIPO ARES e FEM 2423 de Si 478 ga Saal DWAR e 2x2 HIE ax OAR Ae Un ey Gill ja qual Y dese Zen AN d oll ell All Lal sual JAS dang e VE gua Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo e Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos SRAPTUSOOM TOBE MMIC L TRAV ERA OLA ASM TEM elses 202 Ha AFA PHL Aen CASA JUE AA oh gt aca Wear eye ear and body protection e Prot jase los ojos los o dos y el cuerpo e Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz e Use prote o para a vista ouvido e corpo o E FRUSHICRBBELTE EAR RM HRARAHRRAR ex 4 Sal 25478 Es AR idi dijo de y palas ll ma o a 5 READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LE
4. fails 1 Reconnect the line 2 Reform the enclosure 3 Replace the fan Warning lamp lights 1 Over heat yellow lamp lights 2 Over current Green lamp lights 1 Weld after cooling 2 Increase input voltage No output of welder Output decreased current 1 Over current protection 2 Welder fails 1 Input Voltage is low 2 Input line is too thin 1 Over load using 2 Maintenance in manufacturer or service center 1 Power line is thickened Current cannot be regulated 1 Connecting line of the potentiometer is off 2 Potentiometer for current regulation fails 1 Reconnect the line 2 Replace potentiometer High frequency cannot be generated arc 1 The switch fails 2 Interval of high frequency discharging i4 too big 3 Proximity of torch and work pieces too great 4 High frequency 1 Replace torch switch 2 Regulate discharging interval to 0 8 1 0mm 3 Put torch tungsten electrode close to material 4 Replace high frequency arc generator Arc of argon welding is broken or tungsten electrode is burnt 1 Argon gas flow is not regulated well 2 Tungsten electrode fails 3 Value of current does not match with dial of tungsten electrode 4 After flow time is too short 1 Regulate well 2 Replace or sharpen 3 Select the electrode dial and current correctly 4 Increase the time Welding overheat torch 1 Cannot use the water cooling when the current is more than 160A
5. 2 The argon flow is the low current 1 Use water cooling 2 Increase the argon flow IX ACCESSORIES SEE PACKING LIST PLEASE PACKING LIST OOOO model quantity remark note AC DC315D Welding machine 1 Welding Holder 1 Ground clamp 1 TIG welding torch 1 Adjustable foot control 1 optional accessory gas inlet pipe 1 Operation instructions 1 Certificate of quality 1 No Certificate of quality Name of product AC DC PULSE TIG WELDING Type of product _AC DC315D Packing No Test results of this welder fulfils technical requirements and its release from the works is granted Inspector Date Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Japanese EA BIA Korean 2 i e Do not touch electrically live parts or electrode with skin or wet clothing e Insulate yourself from work and ground e No toque las partes o los electrodos bajo carga con la piel o ropa moja da e Aislese del trabajo y de la tierra e Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension e Isolez vous du travail et de la terre e Ber hren Sie keine stromfiihrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung e Isolieren Sie sich von den Elektroden und dem Erdboden e N o toque partes el tricas e elec trodos com a pele ou roupa molha da e Isole se da peca e terra GA
6. E EYE PIECE when welding Arcs may cause blindness Wear a protective cap underneath the helmet 13 WHEN WELDING OVERHEAD BEWARE OF HOT METAL DROPPINGS Always protect the head hand feet and body 14 KEEP A FIRE EXTINGUISHER CLOSE BY AT ALL TIMES 15 DO NOT EXCEED THE DUTY CYCLE OF THE MACHINE The rated cycle of a welding machine is the percentage of a ten minute period that the machine can operate safely at a given output setting 16 KEEP ALL CHILDREN AWAY FROM WORK AREA When storing equipment make sure it is out of reach of children 17 GUARD AGAINST ELECTRIC SHOCK Do not work when tired Do not let body come in contact with grounded surfaces L MAIN USAGE AND THE RANGE OF USAGE AC DC315D Welder is a triple functional machine used as DC MMA AC TIG DC PULSE TIG Welder All ferrous metals copper aluminium titanium and stainless steel material can be welded from all positions The welding current is stable and the stepless is adjustable Few spatter and low noise occurs during welding The welder is compact light in weight and easy to move It is suitable for pressure vessel building shipping and petrochemical industries It is the priority product to replace the NSA series welding machine IT MAIN TECHNICAL SPECIFICATIONS MODEL AC DC315D INPUT Voltage 3xAC 380 415V 50Hz DC No load Voltage 70V MMA Base current Adjusting Range 10 250A Rate
7. SEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN e Keep your head out of fumes e Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases e Gardez la t te l cart des fum es e Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie fiir gute Be und Entliiftung des Arbeitsplatzes Mantenha seu rosto da fumaga e Use ventilac o e exhaust o para remover fumo da zona respirat ria LEE CET A Feu AROHALL SERELTFEL eR EM ES OCF R Bik Hi ARE e YE 271242 golstzdAs e SENOR FE SIE HAPI sie 22H IL ELE ASSIJAR a ye Jun dhul dg TJAN gaal h jiga A Aa al arte Agel alt vill MG ye gaa aa st Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig fi nen Maschine anhalten e N o opere com as tampas removidas e Desligue a corrente antes de fazer servico e N o toque as partes el tricas nuas e 5 TFT HEAR PART EFBRATY FE dis TFN
8. THANKS FOR PURCHASING OUR PRODUCT DC INVERTER ACIDC315D iresi OPERATING INSTRUCTIONS SUITABLE FOR 3x380V 415V SAFETY PRECAUTIONS Follow these precautions carefully Improper use of any welder can result in injury or death 1 ONLY CONNECT WELDER TO A POWER SOURCE FOR WHICH IT WAS DESIGNED The specification plate on the welder lists this information When welding outdoors only use an extension cord intended for such use 2 ONLY OPERATE WELDER IN DRY LOCATIONS and on concrete floor Keep area clean and uncluttered 3 KEEP ALL COMBUSTIBLES AWAY FROM WORK SITE 4 DO NOT WEAR CLOTHING THAT HAS BEEN CONTAMINATED with grease or oil 5 KEEP CABLES DRY AND FREE FROM OIL AND GREASE and never coil around shoulders 6 SECURE WORK WITH CLAMPS or other means don t over reach when working 7 NEVER STRIKE AN ARC ON A COMPRESSED GAS CYLINDER 8 DON T ALLOW THE INSULATED PORTION OF THE ELECTRODE HOLDER TO TOUCH THE WELDING GROUND WHILE CURRENT IS FLOWING 9 SHUT OFF POWER AND UNPLUG MACHINE WHEN REPAIRING OR ADJUSTING Inspect before every use Only use identical replacement parts 10 FOLLOW ALL MANUFACTURER S RULES on operating switches and making adjustments 11 ALWAYS WEAR PROTECTIVE CLOTHING when welding This includes long sleeved shirt leather sleeves protective apron without pockets long protective pants and boots When handling hot materials wear asbestos gloves 12 ALWAYS WEAR A WELDER S HELMET WITH PROTECTIV
9. ans electric arc can obtain greater penetration ability However too much current can cause local melting of tungsten electrode Generally welding current required for DC tungsten argon arc welding uses greater current The arc holding current and base current influences the cooling and crystallizing of the metal in the bath The range is determined by the performance of the welding materials When the sheet is being welded smaller arc holding current base current is usually used in order to reduce the possibility of blowing holes through the sheet material and reduce the possibility of sheet material distortion When pulse width ratio holding time of pulse current and base current is selected both the heat input and features of pulse welding should be considered Usually it can be selected between 10 90 Selection of pulse frequency periodical change time of pulse current mainly depends on the thickness of the sheet and welding speed The customized settings of the operator should also be considered for the pulse width ratio 1 4 AC ARGON ARC WELDING 1 Select 7 onto the position AC connecting the gas inlet pipe to inlet 21 of the welder 2 The method of the connection same as 1 1 3 Select right sp AC Balance SP 4 100 tp the time of l at positive tn the time of In at Negative 4 Select right AC square wave frequency and AC balance 5 The Method of the welding is the same as 1 1 2 Hand welding with electrode 1
10. ch switch to strike an arc Notice 3 During welding with the 12 2T 4T mode on 2T mode the torch trigger should be held at all times and must not be released Otherwise the arc will extinguish 8 When the welding operation is finished close the valve and turn off the power 1 3 PULSE ARGON ARC WELDING Select peak current and base current Select 10 onto the pulse on position and select 7 onto the DC position This will change the frequency between 0 5 25Hz Select peak time on ratio It can be selected between 5 95 Select up slope amp down slope time It can be selected between 0 25 seconds 5 Gas connection testing generating and post flow time use the same procedures as DC arc welding 1 4 PULSE ARGON TUNGSTEN WELDING PROCESS only for reference Ip pulse current CUR A welding process Ib base current tp width time of pulse current th width time of base current tprib T p i tb D pulse width 1 Features and application scope of the process The pulse type argon tungsten welding is different from the continuous DC argon welding The welding current is pulsed The wave form of the current is shown in the sketch above Ip and Ib and their continuous time tp and tb can be regulated according to requirements of the process The amplitude value of electric current changes periodically with certain frequency in case of the pulse current molten base will be formed in the work piec
11. d Output Current 250A Rated Duty Cycle 60 AC No load Voltage 70V TIG Current Adjusting Range 20 315A Initial current crater fill current 20 150A SP AC balance 10 90 AC Square Wave Frequency 20 150Hz Rated Duty Cycle 60 DC BASE PULSE Current Adjusting Range 10 315A Rated Duty Cycle 60 PULSE Current UP Down slope Time 0 25S Pulse freq 0 5 25Hz TIG Pulse width 5 95 Initial current crater fill current 10A 150A Pre gas Flow Time 0 10s Post gas Flow Time 0 25s Arc starting Mode high frequency arc striking Efficiency 280 Mass 25kg Protection Class of enclosure IP21S Outline Dimensions mm 430x200x290 III OPERATING CONDITION AND WORK SURROUNDING 1 Operating condition Voltage of power source 3xAC 380 V 400V 415V Frequency 50 60Hz Reliable grounding protection 2 Work surrounding 1 Relative humidity not more than 90 average monthly temperature not more than 20C 2 Ambient temperature 10C 40C 6 The welding site should be free of harmful gases chemicals molds and flammable explosive or corrosive materials 4 Avoid operating in damp or wet conditions IV OPERATING INSTRUCTIONS 1 Before welding the operator should read the operation instructions 2 Check the welder appearance for any damage before operation 3 To ensure safe operation the welder must be grounded correctly according to your local power supply system using a 4mm fi to connect the welder to the ground 4 Welding opera
12. e and the molten bath will solidify The welding seam is formed by reciprocal overlaps Welding heat input can be controlled by regulating pulse frequency pulse current amplitude size Of base current continuous time of pulse current and base current and therefore the welding seam size and quality of the zone influenced from heat can be controlled 2 Advantages and application scope of pulse argon gas tungsten arc welding a Precisely control the size of the bath inputting heat to the material to increase penetration resistance of molten seam and preservation of bath It is easy to obtain even fusion deepness b Heating and cooling of each welding point is very fast Therefore the process is applicable for the material with great difference of heat conductivity and thickness c Pulse arc can obtain greater fusion deepness with lower heat input Therefore under the same condition the zone influenced from the welding heat reduces the possibility of distortion from welding This is very important for sheet and ultra thin sheet welding d Fast cooling of the bath metal and short duration time of high temperatures during welding can reduce cracks caused to the thermo sensitive materials during welding Selection of welding parameters Except for pulse current width time width ratio and pulse frequency welding parameters of pulse argon gas tungsten arc welding are the same as general tungsten DC argon arc welding Increasing pulse current me
13. ng column 24 Fan VI METHOD OF THE OPERATION 1 ARGON ARC WELDING TIG a FRONT OF WELDER b BACKOF WELDER a i gas inlet pipe 1 1 CLEAN BEFORE WELDING Tungsten argon welding is very sensitive to surface contamination Therefore ensure material is clean and free from all contaminants including grease paint lubricants and rust Use an appropriate pre cleaner if necessary 1 2 DC ARGON ARC WELDING Select 10 on the pulse off position and select 7 onto the DC position connecting the gas inlet pipe to inlet 21 of the welder Connect gas inlet pipe of the welder torch to argon output of welder 17 Put the control plug of the welding torch in the argon arc control socket 18 Testing the gas turn on the main power and switch on the welder and switch on power setting Regulating the base current knob 13 Select welding current according to the thickness of the material to be welded Select current down slope time and after flow time according to the current Notice 1 The current indicating meter on the front panel is used to display the preset output current level before welding and actual output level while welding A lit display indicates that the input power is turned on Notice 2 When using the Adjustable foot control regulator current will increase gradually when you step on the Adjustable foot control Ensure Tungsten electrode end is 2 3mm away from the welding material Press the tor
14. tion should be carried out in dry and well ventilated areas and conditions Surrounding objects should not be less than 0 5m away from the welder 5 Check the welder output connector for tightness 6 The welder cannot be moved and the cover cannot be opened while the power is on and welding operation is carried out 7 The welder should be cared for used and managed by trained personnel 8 Current of the distribution board not less than 40A V SKETCH SKETCH THE PANEL FUNCTION 1 FRONT PANEL 2 BACK PANEL 11 1 Memory channel LED 2 Data Display meter 3 Parameter Select function 4 Power Indicator 5 A current display indicator S Up amp down slope time amp pre amp post flow time adjustable unit of AC balance amp peak time on Hz unit of pulse frequency amp AC frequency 6 Indicator light for Parameter Select function Pre flow Start current Up slope Welding Amps AC freq AC balance Pulse peak amps peak time on pulse freq base Amps down slope end current post flow 7 AC DC DC selector 8 Warning indicating light 9 MMA AMPS arc force selector 10 Pulse on pulse off MMA selector 11 HF LIFT selector 12 2 steps 4 step selector 13 Data Display Adjustment Knob 15 Output Welding holder 16 Output Ground clamp 17 Argon out 18 argon arc control or remote control 19 Name plate 20 Power switch 21 Argon inlet22 Power supply 23 Safety earthi
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