MIGALL SERIES SINGLE-UNIT

Transcription

1 MIGALL SERIES SINGLE-UNIT OPERATION MANUAL MODEL MIGALL - SERIAL No AE00- Date ANTECH ELECTRONICS LTD

2 SAFETY PRECAUTIONS WARNING: These safety precautions are for your protection. Before performing any installation or operating procedures, be sure to read and follow the safety precautions listed below. Failure to observe these. Safety precautions can result in personal injury or death. 1.PERSONAL PROTECTION Skin and eye burn resulting from body exposure to the electric arc rays or hot metal of MAG welding, or other welding processes can be more severe than sunburn. Therefore: A. Use a protect face shield fitted with the correct filter and cover plates to proper your eyes, face, neck, and ears from sparks and arc rays when operating or observing welding. Warn bystanders not to watch the arc nor expose themselves to the electric arc rays or to hot metal. B. Wear flameproof gauntlet type gloves, heavy long-sleeve shirt, cuff less trousers, high topped shoes and a welding helmet or cap for hair protection to protect the skin from arc rays and hot sparks or hot metal. A flameproof apron may also be desirable as protection against radiated heat and sparks. C. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs,or pockets. Sleeves and collars should be kept buttoned, and pockets eliminated from the front of clothing. D. Protect other nearby personal from arc rays and hot sparks with a suitable non-flammable partition. 1

3 E. Always wear safety glasses or goggles when in a welding area. Use safety glasses with side shields or goggles when chipping slag or grinding. Chipped slag is hot and may travel considerable distances. Bystanders should also wear safety glasses or goggles. 2.FIRE PREVENTION Hot slag or sparks can cause serious fires when in contact with combustible solids, liquids, or gases. Therefore: A. Remove all combustible materials well away from the welding area or completely cover the materials with a non-flammable covering. Such combustible materials include wood, clothing, sawdust, gasoline, kerosene, paints, solvents, natural-gas, acetylene, propane, and similar combustible articles. B. Hot sparks or hot metal can fall into cracks in floors or wall opening and cause a hidden smouldering fire. Make certain that such opening are protected from hot sparks and metal. C. DO not weld on used barrels, drums, tanks or other containers until they have been completely cleaned so that there are no substances in the container which might produce flammable or toxic vapors. D. For fire protection, have fire extinguishing equipment handy for instant use, such as a garden hose, water pall, sand bucket, or portable fire extinguisher. E. After completing operation, inspect the work area to make certain there are no hot sparks or hot metal which could cause a later fire. 3.ELECTRICAL SHOCK Exposed hot conductors or other bare metal in welding circuit or in ungrounded, electrically hot equipment can fatally shock a person whose body becomes a conductor. Do not stand, sit, lie, lean on, or touch a wet surface when welding without suitable protection. 2

4 A. Never allow live metal parts to touch bare skin or any wet clothing. Be sure gloves are dry. B. When standing on metal or operating in a damp area, make certain that you are well insulated by wearing dry gloves and rubbersoled shoes and standing on a dry board or platform. C. Always ground the welding machine by connecting a ground wire between the machine and a good electrical ground. D. Do not use worn or damaged cables. Do not overload the cable. Use well maintained equipment. E. When not operating, turn off the equipment. Accidental grounding can cause overheating and create a fire hazard. Don t coil or loop the welding cable around parts of the body. F. Be sure the ground cable is connected to the work piece as close to the operating area as possible. Grounds connected to building framework or other remote locations from the operating area increase the possibility of the output current passing through lifting chains, crane cables or various electrical paths. G. Keep everything dry, including clothing, work area, cables, electrode holder and welding machine. Fix water leaks immediately. 4.VENTILATION Welding fumes, particularly in confined spaces, can cause discomfort and physical harm if breathed over an extended period of time. Therefore: A. At all times provide adequate ventilation in the operating area by natural ventilation or mechanical ventilation means. Do not weld on galvanized, ventilation is provided to prevent breathing fumes from these materials. B. Do not weld or cut in locations close to chlorinated hydrocarbon vapors coming from degreasing or spraying operations. The heat or arc rays can react with solvent vapors to from phosgene, A highly toxic gas, and other irritant gases. 3

5 C. If you develop momentary eye, nose, or throat irritation during the operation, this is an indication that ventilation is not adequate. Stop work and take necessary steps to improve ventilation in the opening area. D. Fumes from the welding operation can be toxic. An adequate suction type ventilating system must always be provided to remove all visible smoke from the vicinity of the operator. 5.EQUIPMENT MAINTENANCE Faulty or improperly maintained equipment can produce poor work. But most importantly it can cause physical injury or death through fires or electrical shock. Therefore: A. Whenever possible, have qualified personnel perform the installation, troubleshooting, and maintenance work on the welding machine. Do not perform any electrical work on the machine unless you are qualified to perform such work. B. Before performing any maintenance work inside the welding machine, disconnect the machine from the electrical power source. C. Maintain cables, grounding wire and connections, power cord and welding machine in safe working order. Do not operate the machine or accessory equipment in a faulty condition. D. Do not abuse the welding machine or accessory equipment. Keep the equipment away from heat sources such as furnaces, wet conditions such as water puddles, oil or grease, corrosive atmospheres and inclement weather. E. Keep all safety devices and cabinet covers in position and in good repair. F. Use welding machine for its intended purpose and do not modify in any manner. Before installation, inspection, or service of equipment switch off and isolate the machine from any power source. 4

6 CONTENTS 1. Welding machine Characteristics Functions Main Features Main Specifications 7 2. Welding machine accessories Standard accessories Customer s accessories 8 3. WM-100 Voltage/Ampere Meter 8 4. Operation instructions of the welding machine Installation External connection Operation of the welding machine 11 5.Maintenance and service 12 Attached Diagraml:Wiring diagram of the welding machine 14 Attached Diagram2:Descriptions of the front panel 15 Appendix 1: Description on operating methods 16 Appendix 2: Features of poor welding 18 Appendix 3: Features of good welding 18 Appendix 4: welding problems and their causes 19 Appendix 5: GoodTorch GT180JS CO 2 /MIG WELDING GUN 21 Appendix 6: GoodTorch GT180ES CO 2 /WIG WELDING GUN 22 5

7 1. WELDING MACHINE CHARACTERISTICS: 1.1 Functions: MIGALL-271 is a 3-phase, tapped flat characteristic Semiautomatic, melt able electrode, gas-shielded welding machine. It can be used mainly for CO 2 welding, MIG and MAG welding, the metals which can be welded with this machine are low-carbon, steel, low-alloy steel, high tensile steel, stainless steel or aluminum. It is used for spot welding, butt welding, angle welding, lap welding etc. The protective gases used are pure CO 2, Ar, CO 2 +Ar or CO 2 +O 2 etc. to achieve stable welding processes. The diameters of the welding wires used in this machine range from f 0.6mm to f 1.2mm. It is an ideal welding equipment for production works and well-received by customers in South-East Asia and China. 1.2 Main features: The main circuit is 3-phase, inductively filtered bridgerectifier Arc-ignition is stable and reliable Wire feeder mechanism employed permanent magnet type DC motor for speed variation, wire feeding is thus stable and reliable Good output characteristic, even if the arc is disturbed, Accurate and steady welding can still be accomplished The machine adapts European plug-in type welding gun, convenient for operation; Spot welding is possible, and the spot welding time can be continuously adjusted For discontinuous welding, welding time and idle time can be continuously adjusted The machine is also protected from being overheated. 6

8 1.3 Main specifications: MODEL RATED INPUT POWER RATED INPUT VOLTAGE RATED FREQUENCY RATED OUTPUT CURRENT MIGALL KVA 380V/,3 50/60Hz 270A RATED DUTY CYCLE 35% VOLTAGE STEPS 10 MACHINE TYPE WIRE DRIVE SYSTEN WIRE-FEEDER MECHANISM WIRE-FEEDER SPEED WIRE SIZE WEIGHT COMPACT ME8720 DOUBLE-WHEELS 1-20m/min 0.6~ 1.2mm 85Kg 2. WELDING MACHINE ACCESSORIES: 2.1 Standard accessories: DESCRIPTION SPECIFICATION Q TY FUSE 10A,250V 1piece FUSE 2A,250V 2pieces FUSE 3A,250V 2pieces Earthing Cable and snap-in plug Earthing clip Gas connector cylinder CSA of the cable :25mm 2 Length of the cable:2meters 1set 1piece 1piece 7

9 2.2 Customer s accessories: DESCRIPTION Welding gun and its accessories; CO 2 gas and gas cylinder Welding wire and the reel; CO 2 gas-gauge 3. WM-100 Voltage/Ampere Meter: VOLTAGE/AMPERE METER V/A :WELDING VOLTAGE :WELDING AMPERE :MEAN WELDING VOLT. :MEAN WELDING AMP. ANTECH WM-100-XXXX 3.1 Power up the welding machine and it will display ANTECH for awhile during the initialization period.it will then be switched to the Ready mode and the rdy message will be showed on the 3.2 Display: The display will show the welding voltage when the welding gun trigger switch is pressed. For example,the display will show 20.5u if the welding voltage is 20.5 V. The display will be switched to show the welding current if the V/A button is pressed once. For example,it will show 120c if the welding current is 120A. 8

10 3.2.2 The welding machine will be switched back to the Ready mode once the trigger switch is released. In the Ready mode, the display will show the last mean (average) welding voltage that has been observed before the trigger switch is released, once the V/A button is pressed once. For example, if the last average welding voltage is 20.5V, it will be shown as 20.5u on the display. The display will be switched to show the last mean welding current, e.g. 120c for 120 A of welding current, if the V/A button once again. The display will be switched back to the Ready mode if either the V/A button is pressed again or after a 5 seconds time out. Again, the display will show rdy to indicate that it is in the ready mode. 3.3 When the display is in the state showing either the last mean voltage or the last mean current, it will be switched to show the weldingvoltage or current once the trigger switch is pressed for welding to start. 4. OPERATING INSTRUCTIONS OF THE WELDING MACHINE: 4.1 Installation: 3-PHASE POWER SWITCH FLOW METER GAS TANK TANK SUPPORT 50cm 30cm FLOOR CEMENT 9

11 1) Install the welding unit in a low humidity, low dust area; 2) Do not place the machine in open area; 3) Place the machine on a stable and level surface; e. g. concrete floor; 4) The metallic case of the welding machine must be earthed with insulated copper wire with a CSA=25mm 2. 5) Gas tank must be placed behind the machine and anchor it with iron chain to prevent it from toppling. 4.2 External connecting: Weld machine weld torch earthing cable earth clamp workpiece 1) Connect three-phase power supply to the rear input part of the machine. 2) Place the welding-wire reel on to the axis of the wire feeder mechanism. 3) Plug in the welding torch to the snap-in torch connector. 4) Connect the earthing cable with the earthing clamp and plug them into earth connector. 5) Connect the gas hose to the wire feeder. 6) Connect the power supply for the gas-gauge to the socket outlet at the rear of the machine. 7) Thread the welding-wire through the wire-feeding wheel and the welding gun screw in the wire pressing wheel. 8) Do not adjust the voltage during welding. 10

12 Note: 1. Standard power supply for this heater is 220V,voltage supply may differ according to the requirements of the customers. 2. Before threading the welding wire through the wire feeding wheel, the diameter of the welding wire must meet the specification of the wire feeding wheel. 4.3 Operation of the welding machine: 1) Apply a 3 phase 380Vac supply to the welding machine. 2) Turn on the control supply switch on the front panel of the welding machine. The indicator will be lit and the cooling fan will be running when power is connected. 3) Press the trigger switch on the welding gun to thread the welding-wire through the wire-feed mechanism, until the welding wire gets to the electrode tip of the welding gun. Adjust the wire-feed speed control on the front panel for the proper wire speed. 4) Turn on the gas tank and press the trigger switch to check for gas flow. Adjust gas flow accordingly. 5) Adjust for the proper wire-feed speed and select the proper welding voltage, according to the size of the welding wire and the work piece. 6) When spot welding is required, adjust the spot weld time control on the front panel according to the work piece and welding requirement. 11

13 7) Connect the ground wire to the work piece; press the trigger switch and welding arc will be initialized. 8) Normal arc welding can then be carried out. 9) Release the trigger switch at antime to end the welding process. It is suggested to turn off the power to the welding machine and The gas supply when the welding job is finished. 5.Maintenance and service: 1.Daily maintenance: Inspect the electride tip regularly to ensure the proper connection Of the assembly.excessive dust orimproper connections are examples Of bad contacts. It is crucial to remove excessive dust on the heatsink,which would Stop the proper heat dissipation from the rectifier.also Dust around the air gap of the transformer would lower the insolation. It is suggested to clean the interior of the welding machine using Compressed air once every 6 months. 2.Troubleshooting: NO welding wire feed: - Check the wire-feeder speed control if it is turned to zero position. - Check control supply fuse F3. - Check wire feed motor fuse F1. - check the wire feed motor latch, if it is latched properly. - check the wiring of the circuit boards, if the connections are good. 12

14 No gas output: - Check if the valve of the gas tank is turned open. - Check for proper gas pressure. - Check if the solenoid is working properly. - Check the circuit boards for bad connections. - Confirm that the power cord of the gas tank heater is plugged to the 2-pin power at the rear of the welding machine. Contactor malfunctioning: - Check circuit boards for bad connections. - Check the transformer if it is too hot. Excessive spattering: - Check for the proper adjustments of welding current and voltage. Adjust the wire-feeder speed control and the welding voltage Selector accordingly. - Inspect the 3 phase power supply. Check for any phase loss. CAUTION:Disconnect the power to the welding machine for service And maintenance. 13

15 S/P VALVE t DIAGRAM2:DESCRIPTIONS OF THE FRONT PANEL MIGALL-271 S/P MIGALL 271 ANTECH ELECTRONICS LTD 1.WELDING VOLTAGE SELECTOR AND SWITCH 2.CONTROL SUPPLY SWITCH (C/W INDICATOR) 3.WIRE-FEEDER SPEED CONTROL 4.VOLTAGE/CURRENT METER 5.TORCH CONNECTOR 6.SPOT WELD TIME CONTROL 7.EARTH CONNECTOR 14

16 APPENDIX I:DESCRIPTON ON OPERATING METHODS 1.Nomenclature gas nozzle electrode tip distance between nozzle and woekpiece length of welding wire protrusion distance between electrode and workpiece length of arc 2.Welding operation workpiece workpiece clamp (earth clamp) 1/4" to 1/2" (6.3mm to 12.7mm) Angle of welding gun to Workpiece for butt welding angle of welding gun to workpiece for filet welding 15

17 The pattern of the welded welded line is determined by such conditions as the inclination of the welding gun to the workpiece, direction of advancement of the gun, distance of the nozzle to the workpiece, the speed of the advancement of the welding gun, the thickness of the work piece, the feeder speed and the electric current (voltage)etc. pushing vertical dragging inclination of welding gun to the workpiece distance of nozzle to workpiece 7mm to 13mm too short normal too long short normal too long too slow normal too fast speed of advancement of welding gun method of welding gun advancement straight line advancement zigzag advancement weaving advancement 16

18 APPENDIX?:FEATURES OF POOR WELDING 1 - over splashing 2 - rough or uneven texture 3 - etched edge 4 - poor overlapping 5 - poor penetration APPENDIX?:FEATURES OF GOOD WELDING 1 - limited splashing 2 - even texture 3 - no overlapping 4 - slightly dented edge 5 - good penetration 17

19 APPENDIX IV:WELDING FROBLEMS AND THEIR CAUSES air bubbles in the weld possible causes insufficicnt protective gas incorrect protection gas defective welding wire work piece not clean Protrusion of welding wire too long Counter measures check if gas flow is adequate clean up splashes stuck on the nozzle check if gas hose is leaking avoid over jetting keep distance of nozzle at 6 to 13mm from work piece keep welding gun close to the molten weld until selidifics change to the correct gas use only dry and clean welding wires make sure that no grease contaminates the welding wire in the feeding mechanism clean the surface of the work piece from grease, water, paint and protective coating use welding wires with flux of higher deoxidizing content (please consult flux suppliers). Keep the protrusion less than 13mm over splashing Possible causes countermeasure feed speed to high change to lower feed speos voltage too high choose lower voltage welding wire shorten the wire protrusion protrusion too long work piece not clean the surface of the work piece from grease clean water or paint, and protective coating (if any) insufficient Increase the flow of the protective gas and protective gas prevent the arc from draught welding wire not use only dry and clean welding wires clean make sure that no grease contaminates the welding in the feeding mechanism 18

20 perforated weld possible causes input heat energy too high countermeasures choose lower voltage and/or feeder speed raise the welding gun advancing speed and/or keep the speed stable. joints Twisted weld possible cause welding wire protrusion too long unstable hand Countermeasures keep the protrusion less than 13mm support the hand with suitable objects. Misaligned workpiece Mispositioned workpiece Possible cause input heat energy too high Countermeasures use clamps to fix the workpiece. fix the work piece in place prior to pull welding by giving spaced welding spots on the seam. choose lower voltage and/or feeder speed. carry out the welding in staggered sections so that the workpiece can be cooled in sections. 19