6 - Manual for MultiMIG350P 500P 英文说明书
6 - Manual for MultiMIG350P 500P 英文说明书
6 - Manual for MultiMIG350P 500P 英文说明书
MultiMIG 350P/500P
OPERATING MANUAL
380 3
V PHASE
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new GREEWELD product. We are proud to have you
○
R
as our customer and will strive to provide you with the best service and reliability in the
industry. This product is backed by our extensive warranty and outstanding service network.
This Operating Manual has been designed to instruct you on the correct use and operation
of your GREEWELD product. Your satisfaction with this product and its safe operation is our
ultimate concern. Therefore please take the time to read the entire manual, especially the
Safety Precautions. They will help you to avoid potential hazards that may exist when work-
ing with this product. We have made every effort to provide you with accurate instructions,
drawings, and photographs of the product(s) while writing this manual. However errors do
occur and we apologize if there are any contained in this manual.
Due to our constant effort to bring you the best products, we may make an improvement
that does not get reflected in the manual. If you are ever in doubt about what you see or
read in this manual with the product you received, then ask for a newer version of the
manual from relevant staff or contact our customer support for assistance.
We strive to improve your production, efficiency and welding performance to make your
process more excellent.
Above all, we are committed to achieve a safer working environment for industry operators.
Your satisfaction with this product and its safe operation is our ultimate concern. Therefore
please take the time to read the entire manual, especially the Safety Precautions.
0-1
WARNING
Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the
equipment.
While the information contained in this Manual represents the Manufacturer’s best judgment, the Manufacturer assumes no
liability for its use.
The publisher does not assume and hereby disclaims any liability to any
party for any loss or damage caused by any error or omission in this
Manual, whether such error results from negligence, accident, or any
other cause.
WARNING
Protective measures should be taken to avoid injury or death. Children should be kept away from
operating area. Pacemaker wearers should also keep away until consulting the doctor. Read
operating manual carefully before installing, operating or servicing this equipment.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the
operator does not strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through
study and training before using this equipment. Some of these practices apply to equipment connected to power lines; other
practices apply to engine driven equipment. Anyone not having extensive training in welding and cutting practices should not
attempt to weld.
1-1
5. Use approved ear plugs or ear muffs if noise level is
high.
6. NEVER wear contact lenses while welding.
Refer to GB9448 (ANSI/ASC Z49.1) for selection of 7. Do not weld on closed containers such as tanks or
shade number: drums.
8. Connect work cable to the work as close to the
welding area as practical to prevent welding current from
Welding Arc Minimum Recommended
Shade No. travelling long, possibly unknown paths and causing
Method Current Shade No.
<60 7 —— 9. Do not use welder to thaw frozen pipes.
Manual Metal
60-160 8 10 10. Remove stick electrode from holder or cut off welding
Arc Welding
(MMAW) 160-250 10 12 wire at contact tip when not in use.
250-550 11 14
Gas Metal Arc <60 7 ——
Welding
(GMAW) (MIG) 60-160 10 11 CYLINDERS
and 160-250 10 12
Flux-cored Arc CYLINDERS can explode if damaged.
Welding 250-500 10 14
(FCAW) Shielding gas cylinders contain gas under high pressure. If
<50 8 10 damaged, a cylinder can explode. Since gas cylinders are normally
Gas Tungsten
Arc Welding part of the welding process, be sure to treat them carefully.
(GTAW) (TIG)
50-100 8 12
150-500 10 14 1. Protect compressed gas cylinders from excessive heat,
<500 10 12 mechanical shocks, and arcs.
Air – Carbon 2. Install and secure cylinders in an upright position by
Arc Gouging 500- chaining them to a stationary support or equipment cylinder
11 14
1000 rack to prevent falling or tipping.
<20 4 4 3. Keep cylinders away from any welding or other electrical
20-40 5 5 circuits.
Plasma - Arc 40-60 6 6 4. Never allow a welding electrode/ wire to touch any
Cutting cylinder.
60-80 8 8 5. Use only correct shielding gas cylinders, regulators,
80-300 8 9
300-400 9 12 maintain them and associated parts in good condition.
400-800 10 14 6. Turn face away from valve outlet when opening cylinder
* These values are applicable for places where the actual arc is clearly
valve.
visible. Experience shows that when the work piece can block the arc 7. Keep protective cap in place over valve except when
cylinder is in use or connected for use.
Table 1-1
MOVING PARTS
FIRE AND EXPLOSION MOVING PARTS can cause injury. Moving parts, such as fans, rotors,
1-2
SECTION 2: EQUIPMENT INTRODUCTION
2.01 How To Use This Manual
NOTE
CAUTION
A procedure which, if not properly followed, may cause damage to the equipment.
! WARNING
WARNING
2.02 Equipment
-
2.03 Symbol
MMA Welding
MIG/MAG Welding
Table 2-1
2.04 User Responsibility
-
-
ing leads) should not be used. Parts that are broken, plainly worn, distorted or contaminated, should be replaced immediately.
Should such repairs or replacements become necessary, it is recommended that such repairs be carried out by appropriately
2-1
Methods
The equipment is equipped with a handle and foot wheel for carrying purposes.
WARNING
ELECTRIC SHOCK can kill. DO NOT TOUCH live electrical parts. Disconnect input power conductors from de-energized
supply line before moving the welding power source.
! WARNING
FALLING EQUIPMENT can cause serious personal injury and equipment damage.
Table 2-2
Model
Nominal Input Voltage (V) 3 phase, 380V 50/60Hz
Nominal Input Current (A) 29.5 48.5
! WARNING
2-2
SECTION 3: INSTALLATION, OPERATION AND SETUP
requirement.
•
upright on horizontal surface.
! WARNING
CAUTION
3-1
3.04 Front and Rear Panel
350P
Figure 3-1
3-2
500P
Figure 3-2
3-3
1. Inching Feeding
2. Save
channel currently displayed for future reference.
NOTECH
This mode is not available for MMA (STICK) welding (No. 28).
CH
3. Channel
which will be changed between 0 and 9.
4. Call
saved number in the channel as the current parameter.
NOTE
1. This mode is not available for MMA (STICK) welding (No. 28).
2.
3. If there is a need to change the welding current and welding voltage of the current channel when the call indicator
t
②
NOTE
value depending on the welding mode, the wearing parts and gas mixture used, the welding level of operator, and the
arc transfer form (such as short circuit transfer or spray transfer). If the output value needs to be set accurately (used
3-4
A
7. Crater current
① -
② -
t
8. Spot Welding Time
value depending on the welding mode, the wearing parts and gas mixture used, the welding level of operator, and the
arc transfer form (such as short circuit transfer or spray transfer). If the output value needs to be set accurately (used
15. Purging
and 10.
18. Parameter
-
3-5
19. Mode Switch
NOTE
1. This mode is not available for MMA (STICK) welding (No. 28).
2. The DC welding is defaulted by system in case of the Carbon Steel + CO2 GMAW (No. 28), and the impulse welding
mode cannot be selected.
Press (No. 19) to select the impulse welding or DC welding mode, and the indicator of the mode selected will be on. See
Press (No. 21) to select the synchronous or manual mode and the indicator of the mode selected illuminates.
①
NOTE
1.
voltage value depending on the welding mode, the wearing parts and gas mixture used, the welding level of operator,
and the arc transfer form (such as short circuit transfer or spray transfer), so as to meet the requirement of welding
process.
2. The expert system mode is defaulted in case Carbon Steel + Mixed Gas GMAW (No. 28) and the impulse welding
3. The expert system mode is defaulted in case Stainless Steel + Inert Gas GMAW (No. 28) and the impulse welding
(No. 20) mode are selected, and the synchronous or manual mode cannot be selected, with both indicators gone out.
4. This mode is not available for MMA (STICK) welding (No. 28).
Press (No. 23) to select the 2T, 4T or spot welding mode, and the indicator of the mode selected will be on.
①
switch and welding stops.
②
NOTE
This mode is not available for MMA (STICK) welding (No. 28).
NOTE
welding wires. Therefore, the indicator (No. 26) of corresponding welding wire must be illuminated according to the
current wire diameter.
3-6
26. Wire Diameter
Press (No. 25) to select the current wire diameter and the indicator of the selected mode illuminates.
350P: Φ0.8, Φ1.0, Φ1.2
500P: Φ1.0, Φ1.2, Φ1.6
NOTE
This mode is not available for MMA (STICK) welding (No. 28).
Press (No. 27) to select the MMA (STICK) welding and GMAW (including ① Carbon Steel + CO2 GMAW, ② Carbon Steel +
Mixed Gas GMAW, ③ Stainless Steel + Inert Gas GMAW) modes, and the indicator of the selected mode will be on.
29. Grounding Bolt
It’s used to earth equipment dependably.
30. 3-phase Power Cord Terminal Box
It’s used to connect 3-phase input power cord
31. 3-phase Power Supply Breaker
The circuit breaker has two functions. Turn on/off the power in normal circumstance. In the event of a serious fault, it automati-
cally trips and cuts off the power.
32. Shielding Gas Regulator Heating Socket
It’s used to connect shielding gas regulator heating plug.
CAUTION
The socket is not intended for other applications, or it may cause damage to the equipment.
(8A)
33. Fuse
The fuse burns out in the event of heating flowmeter fault.
(8A)
34. Fuse
The fuse burns out in the case of circuit fault of wirefeeder.
(2A)
35. Fuse
The fuse burns out in the event of fan and control transformer fault.
36. 3-phase Power Supply Tension Disc
It’s used to fix the 3-phase input power cord to the housing of welding power source.
! WARNING
Input power cord must be tightened and fixed to the housing, or there is a risk of leakage.
37. Power Output Positive Terminal (+)
The welding power source outputs welding current through the connector. Connector should be connected to this terminal, to
ensure a stable connection.
38. Control Socket
7-pin socket is used to connect wirefeeder.
39. Power Output Negative Terminal (-)
The welding power source outputs welding current through the connector. Connector should be connected to this terminal, to
ensure a stable connection.
CAUTION
Loose output terminal connection may cause overheat and connector burn.
.
3-7
3.05 Wirefeeder Guide
350P Wirefeeder
Figure 3-3
1 6 Feeding Roll
Table 3-2
3-8
500P Wirefeeder
Figure 3-4
Table 3-3
Enclosed Water-cooled Wirefeeder (Op�onal)
Figure 3-5
3-9
1.
2. Insert one end of wire into guide wire, and push the wire through the guide wire.
3. Pass the welding wire through the groove of the feed roll, and connect it to the welding torch through the output guide
tube and the welding torch socket. Make sure the size of the feed roll matches the wire diameter.
4. Lower the pressure roll and reset the adjustment handle.
5.
6. Supply power to the welding power source and wirefeeder, set the control speed of the wire to a moderate level, re-
! WARNING
Do not wear gloves during wire feeding or wire spool changing. When the welding wire is passing through the torch,
do not observe the wire in the front, in case of injury.
! WARNING
Only special welding grade shielding gas can be used.
Safety
This regulator is designed to reduce and control high pressure gas from a cylinder or pipeline to the working pressure required for
the equipment using it.
1. NEVER subject the regulator to inlet pressure greater than its rated inlet pressure.
2.
-
der pressure, gas can dangerously propel a loose part.
3.
high and low pressure chambers.
4.
5.
CAUTION
-
ing any other gas.
With the regulator connected to cylinder or pipeline, and the adjustment screw/knob fully disengaged, pressurize as follows:
1. Stand to one side of regulator and slowly open the cylinder valve. If opened quickly, a sudden pressure surge may dam-
age internal regulator parts.
2. With valves on downstream equipment closed, adjust regulator to approximate working pressure. It is recommended
water.
3.
Figure 3-6
3-10
3.07 Setup for MIG (GMAW) Welding
Equipment Connection
1. Remove all packaging and ensure that the front and rear vents are unobstructed.
2. Connect the work cable to the negative terminal (No.20). The welding current is output from the equipment through
the output terminal. Connect the connector to the terminal and ensure stable connection.
CAUTION
Loose output terminal connection may cause overheat and connector burn.
! WARNING
Before connecting the negative cable to the work and inserting the electrode in the TIG torch make sure the Mains
power supply is switched off.
Secure the welding grade shielding gas cylinder in an upright position by chaining it to a suitable stationary support
to prevent falling or tipping.
3. Place the cylinder on the rear bracket of the equipment and secure it between brackets with a chain. If the equipment is
not equipped with a rear bracket, fixed it with a column or wall shelf, or fixed it upright.
Wirefeeder Connection
1. Connect the wirefeeder welding cable to the positive terminal of the equipment.
2. Connect the wirefeeder control cable to 7-pin socket of the equipment.
3. Assemble the air regulator to the cylinder. Connect the rear air tube of the wirefeeder to the gauge outlet.
4. Wirefeeder is equipped with built-in double-groove feed roll. Feed roll should match with the wire.
5. Install the wire spool on wire spool roller. Place stop pin into wire spool roller to fix the wire spool. Wire comes out from
the bottom of the wire spool.
6. Connect the GMAW welding torch connector to the copper interface of the wirefeeder. Screw the nut clockwise to fix
the torch. Connect remote control cable of the torch to the remote control socket of the wirefeeder.
7. Lift the wirefeeder pressure arm, connect the wire to the torch through input guide tube, feed roll, middle guide tube
and output guide tube.
! WARNING
Do not wear gloves during wire feeding or wire spool replacement.
8. Put down the pressure arm. Sort out torch wire. Thread the wire into the torch. Choose the right contact tip. For ex-
ample, if the wire size is 1.2 mm, the diameter of contact tip should also be 1.2 mm.
9. Push the “inch feeding” button to thread the wire through the torch.
② Press (No. 25) to illuminate the corresponding welding wire according to that currently used.
③ Press (No. 23) to select the 2T / 4T / spot welding mode as required by welding process.
a) In 2T mode, turn the “current adjustment” and “voltage adjustment” buttons (located on the wirefeeder) to adjust
the output current and output voltage values.
b) In 4T mode, turn the “current adjustment” and “voltage adjustment” buttons (located on the wirefeeder) to adjust
A
the output current and output voltage values; press the crater current (No. 7) and crater voltage (No.
17) gently to illuminate the corresponding indicators, and turn the parameter adjusting button (No. 18) to adjust
the crater current and crater voltage values.
c) In spot welding mode, turn the “current adjustment” and “voltage adjustment” buttons (located on the
t
wirefeeder) to adjust the output current and output voltage values; press the spot welding time (No. 8) gen-
tly to illuminate the corresponding indicators, and turn the parameter adjusting button (No. 18) to adjust the spot
welding time.
3-11
④ Press (No. 21) to select the synchronous / manual mode as per the requirements of welding
(located on the wirefeeder) to adjust the output current and output voltage values. If the synchronous mode is se-
increase.
⑤ (No. 16) gently to illuminate the corresponding indicator. Turn the parameter adjust-
NOTE
2
GMAW.
② Press (No. 25) to illuminate the corresponding welding wire according to that currently used.
③ Press (No. 23) to select the 2T / 4T / spot welding mode as required by welding process.
a)
the output current and output voltage values.
b)
A
the output current and output voltage values; press the crater current (No. 7) and crater voltage (No. 17)
④ Press (No. 21) to select the synchronous / manual mode as per the requirements of welding
(located on the wirefeeder) to adjust the output current and output voltage values. If the synchronous mode is se-
increase.
⑤ Press (No. 19) to select the impulse welding or DC welding mode as per the requirements of weld-
⑥ (No. 16) gently to illuminate the corresponding indicator. Turn the parameter adjust-
NOTE
1. 2
2. The expert system mode is defaulted in case the selected Carbon Steel + Mixed Gas GMAW (No. 28) and the impulse
welding (No. 20) mode are selected, and the synchronous or manual mode cannot be selected, with both indicators
gone out.
② Press (No. 25) to illuminate the corresponding welding wire according to that currently used.
③ Press (No. 23) to select the 2T / 4T / spot welding mode as required by welding process.
a)
the output current and output voltage values.
3-12
b)
A
the output current and output voltage values; press the crater current (No. 7) and crater voltage (No.
④ Press (No. 21) to select the synchronous / manual mode as per the requirements of welding
(located on the wirefeeder) to adjust the output current and output voltage values. If the synchronous mode is se-
increase.
⑤ Press (No. 19) to select the impulse welding or DC welding mode as per the requirements of weld-
⑥ (No. 16) gently to illuminate the corresponding indicator. Turn the parameter adjust-
NOTE
The expert system mode is defaulted in case Stainless Steel + Inert Gas GMAW (No. 28) and the impulse welding (No.
Figure 3-7
3-13
3.08 Setup for STICK (MMAW) Welding
1. Remove all packaging and ensure that the front and rear vents are unobstructed.
2. Connect electrode holder to the positive terminal of the equipment. Any problem, please consult the manufacturer of
electrode. Welding current is output from the welding power source through output terminal. Connect the connector
to the terminal and secure it with wrench, to ensure stable connection.
3. Connect the work cable to the negative output terminal. The welding current is output from the equipment through
output terminal. Connect the connector to the terminal and secure it with wrench, to ensure stable connection.
CAUTION
Loose output terminal connection may cause overheat and connector burn.
! WARNING
Before connecting the negative cable to the work make sure the Mains power supply is switched off.
Figure 3-8
CAUTION
Generally basic electrode is connected to positive terminal. Please choose the corresponding connecting manner ac-
cording to the type of electrode used and the actual welding requirements.
3-14
SECTION 4: BASIC WELDING GUIDE
4.01 MIG (GMAW) Basic Welding Technique
GMAW is a welding process in which, with a gas (or mixed gases) as shielding gas, an electric
mainly three kinds of transfer forms, i.e., short- circuit transfer, dip transfer and spray transfer.
•
hangs on the end of the welding wire and accumulates, and even connects with the weld pool of
base metal and transfers to it. This is called short- circuit transfer.
Figure 4-1
Table 4-2
4-1
• Dip transfer: It generally produces with long arc and high voltage when the dip is under high spot
pressure, and in CO2 atmosphere it generally fails to transfer to the weld pool along the axial direc-
tion of the welding wire, but deviates from the wire’s axial direction and even goes upward. Since dip
transfer generates large spatter, it is hard to be applied in production.
• Spray transfer: For CO2 GMAW process, spray transfer is a free transfer form, but some also along
with momentary short circuit. Producing with welding wire diameterφ1.2-2.0 and large current, it is
a stable arc process.
Current Range of Spray Transfer for Different Welding Wire Diameters in CO2 GMAW:
Wire Diameter (mm) Welding Current (A)
1.2 250-350
1.6 300-500
2.0 350-550
Table 4-3
NOTE
Short- circuit transfer is generally recommended in the following conditions:
High Voltage 25 - 35V
High Current 200 - 500A
Fine Welding Wire 1.2 mm
Shielding Gas 90%Ar / 10%CO2 or 80%Ar / 20%CO2 or 75%Ar /25%CO2 mixed
gases
Table 4-4
② Affect of CO2+Ar mix ratio. Whether in short-circuit transfer or dip transfer, adding Ar to CO2 can reduce the spatter loss
coefficient. In case of short-circuit transfer, it can have good effect when the content of CO2 is between 50% and 70%; in case of
large- current dip transfer, it can achieve spray transfer when the content of Ar is between 75% and 80%, with stable arc and little
spatter. For weld bead, the bead surface is the smoothest with reduced penetration rate and narrower width when the mix ratio
is 20%CO2 + 80%Ar.
③ Affect of shielding gas flow. The protection is sufficient when the gas flow is large; while since the cooling and compression of
the arc is fierce when the gas flow is too large, too large arc force will disturb the weld pool and affect the bead formation. When
the wire diameter is no larger than 1.2mm, gas flow is generally 6~15L/min; otherwise the gas flow shall be 15~25L/min.
④ Affect of contact tip to welding wire distance: generally called stickout. The larger this distance is, the higher deposition rate
of welding wire can be achieved, for the heat generated by welding wire increases due to wire resistance. However, if the stickout
is too large, the sticked part will become soft due to heat and lead to instable arc process, which should be avoided. Generally
forφ1.2 weldng wire, the stickout shall be maintained at 15-20mm, with specific number determined by welding current.
⑤ Welding torch to work piece distance. If the distance is too large, the deflection of the shielding gas is poor when reaching
the work piece surface, there may be air invasion, and hence the protection effect is poor, with more weld porosity on weld bead.
If the distance is too small, the protection shield may be blocked by spatters, blocking the shield gas flow. The protection shield
needs to be cleaned regularly. Sometimes it even generates large number of porosities, makes weld bead metal oxidize, and
sometimes even short circuit occurs between contact tip and protection shield, burning them and thus raising the replacement
frequency. The proper distance depends on the current.
⑥ Affect of power polarity. When applying DCEP (welding wire to positive and base metal to negative), the electromagnetic
force of arc and the direction transition of dip transfer are strong, and the dip is fine, with stable arc. Otherwise the arc is instable.
⑦ Affect of welding speed. In CO2 GMAW, the affect of welding speed is the same as other arc welding processes: if the welding
speed is too slow, the metal accumulates under the arc in the weld pool and reduces the weld penetration, and since the heat-
affect zone is too wide, the base metal sensitive to heat input is easily to have fusion line and heat-affect zone embrittlement. If
the welding speed is too fast, the cooling speed of the weld pool is too fast, which is not only easy to cause defects such as poor
weld bead formation and porosity, but can also cause delayed crack to base metal sensitive to heat input. Therefore, the welding
speed should be set reasonably according to welding current and voltage selection.
4-2
2
Table 4-5
Weld Bead Plate Root Opening Wire Current Voltage Welding Speed CO2 Flow
Thickness (mm) Diameter (A) (V) (cm/ min) (l/min)
(mm) (mm)
1.2 2.5-3.0 0.8-1.0 70-100 18-19 50-60 10-15
1.6 2.5-3.0 0.8-1.2 90-120 18-20 50-60 10-15
2.0 3.0-3.5 0.8-1.2 100-130 19-20 50-60 10-15
2.3 3.0-3.5 1.0-1.2 120-140 19-21 50-60 10-15
3.2 3.0-4.0 1.0-1.2 130-170 19-21 45-55 10-15
4.5 4.0-4.5 1.2 190-230 22-24 45-55 10-15
6.0 5.0-6.0 1.2 250-280 26-29 40-50 15-20
9.0 6.0-7.0 1.2 280-300 29-32 35-40 15-20
4-3
Plate Groove Shape Root Root Wire Current Voltage Welding Flow Layer
Thickness Opening Height Diameter Speed (l/min)
12 0-0.5 4-6 1.2 300-350 32-35 30-40 20-25 Front 2
300-350 32-35 45-50 20-25 Back
1.6 380-420 36-39 35-40 20-25 Front
380-420 36-39 45-50 20-25 Back
16 0-0.5 4-6 1.2 300-350 32-35 30-35 20-25 Front 2
300-350 32-35 30-35 20-25 Back
1.6 380-420 36-39 35-40 20-25 Front
380-420 36-39 35-40 20-25 Back
16 0 4-6 1.2 300-350 30-35 30-35 20-25 Front 2
300-350 30-35 30-35 20-25 Back
1.6 380-420 35-40 35-40 20-25 Front
380-420 35-40 35-40 20-25 Back
19 0 5-7 1.2 400-450 25-30 25-30 20-25 Front 2
400-450 25-30 25-30 20-25 Back
1.6 400-420 45-50 45-50 20-25 Front 4
400-420 35-40 35-40 20-25 Back
25 0 5-7 1.6 400-420 40-45 40-45 20-25 Front 4
420-450 30-35 30-35 20-25 Back
Table 4-6
NOTE
4-4
4.03 MIG (GMAW) Basic
Problem Possible Cause
Undercut ① Welding arc voltage too high. ① Reduce voltage or increase feeding speed.
② Wrong welding torch angle. ② Adjust welding torch angle.
③ Too much heat. ③ Reduce voltage or decrease feeding speed to increase
welding torch travel speed and/or reduce welding current.
Porosity
② Impure shielding gas.
③ Dirt on welding wire.
④ Dirt on work surface.
⑤ Arc voltage too high.
③ Use clean and dry welding wire.
large.
work surface.
⑤ Decrease welding current.
⑥ Adjust welding torch to work piece distance.
Incomplete root ① Welding current too low ① Increase feeding speed and voltage, to increase welding
② Opening too narrow, or weld bead too current.
small. ② Increase opening angle or weld bead.
③ Incorrect shielding gas used.
Lack of fusion Voltage too low. Increase voltage.
① Voltage too high. ① Decrease voltage, or increase feeding speed.
② Voltage too low. ② Increase voltage, or decrease feeding speed.
Irregular weld bead shape ① Adjust voltage and speed control knob, to adjust
indicates voltage too low; recession indicates voltage and current.
voltage too high.
② Welding wire deviates. ③ Check shielding gas.
③ Incorrect shielding gas used. ④ Adjust feeding speed or voltage knob.
Broken weld bead ① Weld bead too small. ① Reduce travel speed.
② Decrease current and voltage, increase GMAW torch
deep.
③ Welding stress too large. ③ Increase welding metal strength, or change the design.
④ Voltage too high. ④ Decrease the voltage.
⑤ Cooling rate too high. ⑤ Preheat plate and cool slowly.
as STICK (MMAW).
With electrode and work piece as two poles, when welding the high temperature and blow
force of arc melt part of the work piece, form an oval pit full of liquid metal on the weld
metal, and form weld bead with the move of electrode and the cooling of weld pool.
4-5
No groove 2-3 2 40-50
weld 3-4 3.2 80-110
V groove 5-6 90-120
≥7 90-120
4 120-160
X groove ≥12 3.2 90-120
4 120-160
No groove 2 2 50-55
3-4 3.2 90-120
4 120-160
V groove ≥5 3.2 90-120
4 140-160
X groove ≥14 3.2 90-120
4 140-160
No groove 2 2 50-55
3-5 3.2 80-110
4 120-160
V groove ≥5 3.2 90-120
4 140-160
5 220-260
X groove ≥12 3.2 90-120
5 140-160
5 220-260
Weld Bead Weld Toe Height (mm) Wire Diameter (mm) Current
2 2 55-65
3 3.2 100-130
4
4 160-200
≥5 160-200
5 220-280
2 2 50-60
3-4 3.2 90-120
≥5
≥5 4 120-160
2 2 55-60
weld 3-4 3.2 90-120
≥5 4 120-160
Table 4-8
NOTE
4-6
4.06 STICK (MMAW) Basic
Problem Possible Cause
Welding current changes. Adjust arc force control knob to
improper, causing welding current make welding current stay stable
changes too much when arc length while prevent electrode from
changes.
distance is too small.
① Welding current too low . ① Increase welding current.
② Electrode too large for joint. ② Use smaller diameter electrode.
③ Allow wider gap.
① If bad undercut is present, clean
the weld metal (slag inclusion). trapped in undercut from previous slag out and cover with a run from a
run. smaller diameter electrode.
③ Irregular deposits allow slag to and room for cleaning out the slag.
be trapped. ③ If very bad, chip or grind out
full fusion.
remove all slag from corners
which welding is done. ⑤ Clean joint before welding
⑥ Use electrodes designed for
A groove has been formed in the ① Welding current too high. ① Reduce welding current.
base metal adjacent to the toe of a ② Welding arc too long. ② Reduce the length of the welding
③ Angle of the electrode incorrect. arc.
weld metal (undercut). ③ Electrode should not be inclined
correct electrode angle.
⑤ Electrode too large for joint. ④ Allow more room in joint for
Table 4-9
4-7
SECTION 5: TROUBLESHOOTING AND ROUTINE
MAINTENANCE
Cause Remedy
Main power is turned ON, power ① Turn on MIG (GMAW) mode
indicator lights up, but the power ② Welding torch switch failure ② Repair or replace welding torch switch/ wire
The wirefeeder doesn’t feed wire in ① Welding wire stuck to wire feeding ① Check whether wire feeding tube or contact
GMAW mode
as needed
② 8A fuse blown ② Replace 8A fuse
③ Internal welding power source
③ Have an accredited
○
R
failure
Table 5-1
Maintenance and
! WARNING
R
unless you are repair personnel accredited by GREEWELD . Disconnect the Welding Power Source
from the Mains Supply Voltage before disassembling.
Test and Maintenance
grounding test shall be conducted so as to ensure that the equipment meets the standard.
① Test Schedule:
a) Portable equipment: at least once every 3 months;
b) Fixed equipment: at least once every year.
The customers should record the periodic test result and establish good tagging system (including test date). Portable equipment
5-1
Parts to be tested
resistance (MΩ)
Input circuit (including control circuit connected to it) to welding circuit 5
(including control circuit connected to it)
2.5
Welding circuit (including control circuit connected to it) to any auxiliary 10
circuit exceeding SELV (safety extra-low voltage)
Welding circuit (including control circuit connected to it) to any auxiliary 1
circuit within SELV (safety extra-low voltage)
Independent welding circuit to independent welding circuit 1
Table 5-2
③ Grounding Test
The resistance between equipment grounding metal parts shall not exceed 1Ω. The following parts shall also meet this require-
ment:
The equipment shall be checked periodically by professional serviceman accredited by GREEWELD , to ensure that:
⑤ Accessories
Accessories including output cable, welding clamp, welding torch and wirefeeder should be checked by professional personnel at
⑥ Repair
Any parts damage should be replaced by professional serviceman accredited by GREEWELD .
Equipment
Periodic test should be done on the output of the equipment and accessories, to ensure the lowering level is within limit. Calibra-
Required tests are listed in Table 5-3. They should be conducted by professionals accredited by GREEWELD according to the situ-
Test Requirement
Check output current to ensure the lowering level is within limit
Check output voltage to ensure the lowering level is within limit
Check precision of digital meter to ensure the lowering level is within limit
Table 5-3
-
ity can be used.
5-2
5.03 Cleaning
! WARNING
○
R
unless you are repair personnel accredited by GREEWELD . Disconnect the Welding Power Source
from the Mains Supply Voltage before disassembling.
slag and loose material. Keep the shunt and lead screw surfaces clean as accumulated foreign material may reduce the equip-
ment output welding current.
CAUTION
NEVER use compressed air to clean the equipment, for the strong force of compressed air may leave the metal grain
between the electric parts and grounding metal parts, causing arc striking between parts and parts damage.
5-3
SECTION 6: SPARE PARTS
350P
Figure 6-1
Table 6-1
6-1
500P
Figure 6-2
Table 6-2
6-2
1 2 3 4 5 6 7 8
GW9-066-014 VD1-4 LEM
+
C1 C3
TR1 A1(+)
TVS1 TVS1 GW6-173-007
G1 G3
R1 R1 R1 R3 GW9-066-011
A U GW9-066-004 BR1 A
S1 ~
E1 E3
GW9-066-030
V C1-3
C13 R5-6 RY1 GW9-066-017 VD6-10
~ GW9-066-017
W
GW9-066-011 A3-1 A3 A2-1(-) A2(-)
~ R4
TVS2 TVS2
SECTION 7: CIRCUIT DIAGRAM
R2
G2 G4 -
R2 R2 L1
C2 C4
E2 E4
FUSE1
2A
E1 G2 E3 G4
B G1 E2 G3 E4 B
G1
G2
G3
G4
E1
E2
E3
E4
D3 D1
1
2
3
4
5
1
2
3
4
5
CN4 CN5
GW9-066-010 CN2
T1 2 73 R1 R2
Figure 7-1
GW6-172-006 1 115
CN3
50 3 D4 D2
CN1
7-1
~19V 51 2
115 1
3
48 2
115 1
~19V
GW9-066-001
415V CT1
12T RJ:JUC-17F-80
C18 ~12V
380V
115
215
51
6 53
50
1 115
33
34
35
220V
2 48
5 54
CN2 4 58
3
2
1
4
C C
3
2
1
3 58
FS ~19V CN6 CN12 CN9 CN5 2 57
215 3 1 57
~19V 20 2 GW9-066-028 NB30
21 1 CN10
CN4 GND 6 115
~27V 5 36
31 2
32 1 CN3 CN7 +15V 4 37
-15V 3 38
Arc Voltage + 2 39
8
7
6
5
4
3
2
1
1
2
3
4
0V Arc Voltage – 1 40
215
27
28
28
29
30
22
23
24
15
15
15
~10V CN2 FUSE3
350P
215
513
512
515
511
511
511
22
23
24
J2
CN4 1 515
2 8A
1
2
3
4
6
5
4
3
2
1
3 505
Circuit of
~15V 2 6 1 Wirefeeder 3 4 5 7
GW9-066-026 GW9-066-019 CN3
FUSE2 1 515
R1 A V 2 515
8A 3 508
1W/10K
TS 4 508
15A502 B502 5 509
QF CN1
D1 D2 6 509
+
DC24V
IPB
3
2
1
IN4007
IN4007
3
2
55 1
4
M
J1
501
SSJ
504
503
502
-
D D
56
R2
24V WUXI GREEWELD
1W/220 TECHNOLOGY CO.,LTD
MAIN CIRCUIT DIAGRAM
NO. GW0-354-005 Name OF MultiMIG 350P
Designed
by Revision V1.0
Approved
by 1 of 1 page
1 2 3 4 5 6 7 8
Figure 7-2
7-2
Arc Voltage +
Arc Voltage –
500P
Circuit of
Wirefeeder
WUXI GREEWELD
TECHNOLOGY CO.,LTD
MAIN CIRCUIT DIAGRAM
NO. Name OF MultiMIG 500P
Designed
by Revision
Approved
by 1 of 1 page
SECTION 8: WARRANTY CARD AND QUALIFICATION
CERTIFICATE
Dear Users,
○
R
Repair Record
Date Reason & Treatment Repair Unit Signature of Repair Personnel
8-1
R Inverter Arc Welding Power Source Professional Manufacturer
WUXI GREEWELD TECHNOLOGY CO.,LTD
Address: A06, U Valley Industrial Park, Xibei Town, Wuxi City
Tel: 0510-83796633
E-mail: [email protected]
Fax: 0510-83793366
Website: www.greeweld.com