YJHB-2 Micro Repair Welder
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1 MANUAL YJHB-2 Micro Repair Welder We appreciate that you have chosen our YJHB-2 Micro Repair Welder. Customer satisfaction is our priority. We strive to provide the most efficient machine, and a good after-sales service. Kindly contact us, if you need any assistance in operating the machine. We welcome all suggestions that can improve the machine performance. Before using the welder, pls read through this manual, to enable you a smooth start and a satisfactory performance. Contact Information: Yuyao Yijing Electric Co., Ltd. Simen West Industrial Estate, Yuyao City, , Zhejiang Province, P.R. China Tel: Fax: oversea@chinayijing.com Website:
2 WARNINGS Misuse of the welder may cause danger to the users. Therefore, the equipment will be used only in compliance with relevant safety regulations. Special attention should be paid to the following: Electric Shock: - Welding equipment must be installed properly. - Isolate yourself from the ground and weld the topic (eg use of footwear with rubber sole). - Ensure proper maintenance of welding equipment. Never work with damaged cables or insulation. - Repair and maintenance of the equipment shall be made by a person with the necessary technical insight. Strong Arc Light: - Protect your eyes. Use the supplied welding screen or the like, which can protect your eyes from the blazing light. Even a brief exposure can cause permanent damage to eyesight. Pls BE CAREFUL - Protect your body against the light from the arc while the skin can be damaged by radiation. Use protective clothing that covers all parts of the body. - If possible, shielded the total working area, to protect others from the light from the arc; at least warn them. Welding Fumes and Gas - Smoke and gases generated by welding is dangerous to breathe. Ensure appropriate exhaust and ventilation. Fire - Radiation from the arc and sparks can cause fires. Flammable objects are removed from the welding site. - Work clothes should also be protected from sparks and splashes from the arc. Please review this manual carefully before equipment is installed and put into use! Preface
3 General introduction YJHB-2 is a micro repair welder with TIG-like welding pulses. The welder can generate very precise welding pulse to produce fine-sized and positioned welding spots. The machine can weld a variety of materials incl. all types of steel and iron, Aluminum, copper, brass, bronze. It can weld even very small details with very thin fillers, and weld fast with thicker fillers. Although the machine is easy to use, it still requires some manual dexterity. We recommend you use some time to practice, with support from the tips in this manual. Technical data 1: The machine can weld in Fe, Cu, Al. The machine can not be used for welding: Sn, Zn. 2: The machine can be used: Repair of worn and faulty details in the form tool for pressure casting, injection molding, blow molding, etc.. Defects in castings, such as pinhole, sand holes etc.. Other small and precise welding tasks as a normal TIG welder can not perform. 3: Electric Input: 220V, 50Hz. 4: Power consumption W. 5: Maximum instant output is 40kW. 6: Mode: TIG power mode 1-4. power (current): 1-99, time (hours): Set Filler mode: power (current): 1-99, Filler diameter of 0.1-1mm. 7:ns frequency: 1Hz (mode4), 2Hz (mode3), 3Hz (Mode2), 5Hz (Mode1) 7: Machine dimensions: 380 x 150 x 220 mm. 8: Weight: 9 kg. Welding Screen The welding screen is controlled by the welder machine and can shield the arc light simultaneously. You need to install the screen as shown in the picture blow and plug its wire on the back of the machine. You must TEST the screen before welding. Page 1
4 Front Panel : Mode buttons. 2: Set Filler Mode button 3: a pulse or continuously by pressing the foot pedal switch. 4: currency display and setting. 5: time display and setting. 6: On-Off. 7: Foot pedal connection. 8: TIG Welding torch connections. 9: Ground cable connections. 10: Set-Filler welding cable connections. Page 2
5 Tungsten Tip In the welding torch, there is a mounted tip, which is made of tungsten. The design of the tip varies as the welding task changes. Pls see the following pictures. *NOTE: 1. Dull pin is the most stable shape of tungsten pin. We suggest the use of this shape as much as possible. 2. If the dull pin cannot fit, try the sharp pin. 3. The protect glue is a special-made heat-resistance glue. It can protect the tungsten pin and prolong its service life. 4. The round pin best prevent pin-stuck. It is highly recommended for welding of aluminum, copper and brass. 5. Normally, we use pins of Φ1.6mm. If repairing large output, change the pin to Φ2.0mm, to prolong its service life. Filler We generally recommend that you use filler of the same type as the workpiece that is welded on. For iron, we recommend filler with low Wc%. Set Filler Mode This function is a very useful aid, when you need weld on very delicate, complicated positions. You can pre-weld the filler with set filler mode, and then you use the TIG mode to re-weld the filler thoroughly onto the position. This function can free your hand from the traditional tiresome way of feeding the fillers. You can stable the TIG welding torch by both your hands and get much better welding quality. This function can also be used to prevent potential damage to surrounding areas. To use Set-Filler Mode, you must make sure: 1) The ground cable is firmly fastened on the front panel; 2) The ground plate is in good contact with the workpiece; 3) The area to be welded is clean and free of stain, grease, etc.. During setting fillers, you need to press down hard on the filler. For filler dia. of 0.3mm, we suggest pulse currency value 30. For filler dia. of 1.0mm, we suggest pulse currency value 99. Page 3
6 Welding on Flat Surface Theoretically the arc is formed between the tungsten tip and the workpiece, while the nearby filler is melt and drawn to cover the spot. So it is important that the tungsten tip is in a precise position, and it should always be closer to the surface and farther from the filler. Pls see the following pictures. Machine Settings: Filler DIA (mm) TIG MODE Currency Time V mm L mm Ø Ø Ø Ø Ø Ø Ø Ø Ø Page 3
7 Welding multiple seams The pin-filler distance should be about the filler diameter. The filler should be put tightly against the privous seam. Set Filler Function: To get an even and flat welded surface, we can pre-weld the fillers, as shown in the left picture. There should be a distance about the filler diameter, between two neighboring fillers. During TIG welding, the fillers will melt and fill the spot between two neighboring fillers. Welding on Corners and Edges The Start of a Corner Welding on corners and edges is a more difficult task than to weld on a flat. The most common problem is that there is undercut (workpiece molt more than welded on) at startup. We shall give a few guidelines that can be used. Page 4
8 The rest of a Corner Set Filler Function: To get an more stable welding result, we suggest that you use the Set Filler Function to pre-weld the filler precisely on top of the edge of the corner. Hence you can free your hand from stabilizing the filler and especially helps if the space is narrow. Machine Settings: Filler DIA (mm) TIG MODE Currency Time L mm Ø Ø Ø Ø Ø Ø Ø Welding in Interior Corners When welding in interior corners, we need to use sharp tungsten pin. First of all, we need TIG weld without any fillers. This is to prepare for the next steps. When the interior corners is round, it is much easy to weld. Set-filler Function is also very useful here, especially when the space is limited. Using set-filler, we can skip the TIG-weld-withou- any-filler-step. We directly pre-weld the filler into the corner and then TIG the filler thoroughly Pls see the pictures next page. Page 5
9 Machine Settings: How much needs to be repaired (mm) TIG MODE Currency Time V mm 0.3MM MM MM MM MM MM
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