SanRex SANARG 180AP Operator'S Manual Download Page 32

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MAINTENANCE & TROUBLESHOOTING

S/N

Troubles

Reasons

Solution

Turn on the power source, and

fan works, but the power pilot

lamp is not on.

The power light damaged or connection is

not good

Check and repair Pr7

The transformer of power is broken

Repair or change the transformer

Control PCB failures

Repair or change the control Pr4

Turn on the power source, and

the power lamp is on, but fan

doesn’t work

There is something in the fan

Clear out

The start capacitor of fan damaged

Change capacitor

The fan motor damaged

Change fan

Turn on the power source, the

power lamp is not on, and fan

doesn’t work

No power supply input

Check whether there is power supply

The fuse inside the machine damaged

Change it (3A)

The number on the display is not

intact.

The LED in the display is broken

Change the LED

The

max

and

min

value

displayed doesn’t accord with

the set value.

The max value is not accordant (refer to

§3.1)

Adjust potentiometer Imin on the power

board.

The min value is not accordant (refer to

§3.1)

Adjust potentiometer Imaxin the current

meter.

no-load

voltage

output

(MMA)

The machine is damaged

Check the main circuit and the Pr4.

Arc can not be

ignited (TIG)

There is spark

the

igniting board.

The welding cable is not connected with the

two output of the welder.

Connect the welding cable to the

welder’s output.

The welding cable damaged.

Repair or change it.

The earth cable connected unstably.

Check the earth cable.

The welding cable is too long.

Use an appropriate welding cable.

There is oil or dust on the workpiece.

Check and remove it.

There is not

spark on the

igniting

board.

The HF igniting board does not work.

Repair or change Pr8

The malfunction of the welding gun switch.

Check the welding gun switch, control

cable and aero socket.

No gas flow (TIG)

Gas cylinder is close or gas pressure is low

Open or change the gas cylinder

Something in the valve

Remove it

Electromagnetic valve is damaged

Change it

Gas always flows

The gas-test on the front panel is on

The gas-test on the front panel is off

Something in the valve

Remove it

Electromagnetic valve is damaged

Change it

Summary of Contents for SANARG 180AP

Page 1: ...anual Completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection Contact your distributor if you do not fully understand this manual OPERATOR S MANUAL ...

Page 2: ...1 3 6 ASSEMBLING THE EQUIPMENT TIG 12 4 OPERATION 13 4 1 LAYOUT FOR THE PANEL 13 4 2 CONTROL PANEL 14 4 3 REMOTE CONTROL 18 4 3 1 Pedal switch control 18 4 3 2 Gun switch control current 19 4 4 ARGON ARC WELDING OPERATION 19 4 4 1 TIG welding 4T operation 19 4 4 2 TIG welding 2T operation 21 4 5 WELDING PARAMETERS 23 4 5 1 Joint forms in TIG MMA 23 4 5 2 The explanation of welding quality 23 4 5 3...

Page 3: ... equipment according to 5 because of the DC voltage existing in the electrolytic capacitors ELECTRIC SHOCK CAN KILL Never touch electrical parts Wear dry hole free gloves and clothes to insulate yourself Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground Take carefully when using t...

Page 4: ...welding with electrodes which require special ventilation such as stainless or hard facing or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precaut...

Page 5: ...ore refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated WELDING SPARKS can cause fire or explosion Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Rememb...

Page 6: ...e hazards or overheat lifting chains or cables until they fail Rotating parts may be dangerous Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position ...

Page 7: ... minimize exposure to EMF as few as possible In order to minimize EMF we should use the following procedures Route the electrode and work cables together Secure them with tape when possible All cables should be put away and far from the operator Never coil the power cable around your body Make sure welding machine and power cable to be far away from the operator as far as possible according to the...

Page 8: ...e success ratio of igniting arc the reverse polarity ignition ensures good ignition behavior in TIG AC welding Avoid AC arc break with special means even if arc break occurs the HF will keep the arc stable TIG DC operation If the tungesten electrode touches the workpiece when welding the current will drop to short circuit current to protect tungsten Intelligent protection over voltage over current...

Page 9: ...r AC TIG rectangle wave arc is more stable than Sine AC TIG At the same time you can not only obtain the max penetration and the min tungsten pole loss but also obtain better clearance effect SANARG 180AP welding machine is suitable for all positions welding for various plates made of stainless steel carbon steel alloyed steel titanium aluminum magnesium cuprum etc which is also applied to pipe in...

Page 10: ...ly Meanwhile the welding current parameter can be adjusted continuously and steplessly to meet with the requirements of welding craft Rectif ier Invert er Trans forme r Rectif ier Hall devic e Current feedback control DC AC DC AC Invert er AC or DC Control signal AC or DC t 120 240V 50 60HZ single phase AC PFC DC 2 4 Volt Ampere Characteristic SANARG 180AP welding machine has an excellent volt amp...

Page 11: ...5 100 10 200 5 200 10 170 5 170 Crater Current Range A 10 140 5 140 10 100 5 100 10 200 5 200 10 170 5 170 Up Slope Time S 0 10 Down Slope Time S 0 10 Pre Flow S 0 1 10 Post Flow S 1 10 Pulse Frequency Hz 0 5 200 Pulse Width Range 5 100 AC Frequency Hz 50 250 Clearance Effect 15 50 Are Force 0 10 Hot Start 0 10 Are Length 0 10 Duty Cycle 40 10min 40 140A DC 35 100A AC 40 100A DC 25 200A AC 30 200A...

Page 12: ...front panel At this time the machine should be relaxed for 15 minutes to cool the fan When operating the machine again the welding output current or the duty cycle should be reduced 3 3 Movement and placement Please take care for the welder when moving it and do not make it sloped It also can be moved by the handle on the top of the welder Place the welder well when moving it to the right position...

Page 13: ...shorten the welder life span The below measures can be used Change the power supply input net Such as connect the welder with the stable power supply voltage of distributor Induce the machines using power supply in the same time Set the voltage stabilization device in the front of power cable input 3 5 Polarity Connection MMA MMA DC Choosing the connection of DCEN or DCEP according to the differen...

Page 14: ...f welding machine and welding torch is connected to the negative electrode which is called DC POSITIVE CONNECTION otherwise that is called DC NEGATIVE CONNECTION Generally it is usually operated in DC POSITIVE CONNECTION in TIG welding mode The control cable of torch switch consists of 2 wires pedal control of 3 wires and the aero socket has 14 leads Consumable parts for TIG torch such as tungsten...

Page 15: ... output The welder s positive polarity output 5 Shield gas input joint To connect one head of the gas hose while the other head of which is connected to argon gas cylinder 6 Power source switch Switch to ON the welder is turned on while switch to OFF the welder is turned off 7 Power source input To connect power source 8 Fan When the electric welding machine is over heat the fan operates It is use...

Page 16: ...Control panel 1 AC DC selecting key 5 Welding current adjust 4 Power Alarm indicator 6 Welding current display 3 Gas test key 9 Pulse key 7 HF high frequency ignition key 2 Mode selecting key 8 Rod electrode welding key ...

Page 17: ...s in the following section 1 AC DC selecting key 2 Mode selecting key 4 Power Alarm indicator Light up if the power switch on Light up if the welder overheat over voltage or over current At the same time display Err 001 5 Welding current adjust Before the start of welding you can use this potentiometer adjust welding current 6 Welding current display Display the pre set or the actual welding curre...

Page 18: ...slope time Unit S Setting range 0 10 Factory setting 0 Iw Welding current Unit A MAGIC AC GTIG 200P 5 200 DC 10 200 AC Ib Base current Unit A MAGIC AC GTIG 200P 5 200 DC 10 200 AC Important Only selectable when pulse key has been pressed Dcy Ratio of pulse duration to base current duration Unit Setting range 5 100 Factory setting 5 Important Only selectable when pulse key has been pressed Fp Pulse...

Page 19: ...w time Unit S Setting range 1 10 0 Factory setting 3 AC frequency only with TIG AC Unit Hz Setting range 50 250 Iw 70A 50 200 70A Iw 100A 50 150 100A Iw 140A 50 120 140A Iw 170A 50 100 170A Iw Balance only with TIG AC Balance adjustment is mainly used to set the adjustment of eliminating metal oxide such as Aluminium Magnesium and its alloy while AC output Unit Setting range 15 50 Factory setting ...

Page 20: ...th ON and OFF 4 3 1 Pedal switch control When plug the fourteen lead aero socket of pedal switch in it Welder will identify the pedal switch the welding current knob on the front panel will can t use and only 2T can be selected When use the adjustment knob of max welding current beside the pedal can set the max current you want The eighth and ninth of the fourteen lead aero socket is gun switch Th...

Page 21: ... TIG long welding 4T t s 0 I A Loosen the switch t1 t5 t7 Striking success Stop arc t3 t4 Base current setting value t2 t6 Loosen the switch Repress down the switch Start current Crater current Welding current peak current setting value Press and hold the welding gun switch Introduction Adjustment knob of welding current Connected to the 8 lead aero socket on the front panel Adjustment knob of max...

Page 22: ...ent is DC current t4 Repress down the gun switch the output current slopes down to crater current if the output pulse function is turned on the slope down current is pulsed t4 t5 Down slope time adjustment rang of down slope time 0 10 0S t5 t6 Crater current holds time adjustment range of crater current 5 200A t6 Loosen the gun switch stop arc and keep on argon flowing t6 t7 Post flow time adjustm...

Page 23: ... t1 t2 Striking success the output current slopes up to the setting current from minimum current 5A if the output pulse function is turned on the slope up current is pulsed t2 t3 During the whole welding process the gun switch is pressed and held without releasing Note If the output pulse function is turned on the output current is pulsed If the output pulse function is turned off the output curre...

Page 24: ...drop a half then if the TIG torch is pressed quickly again the welding current will get back Notices Check the condition of welding and connection units firstly otherwise there will be malfunction such as ignition spark gas leakage out of control and so on Check that whether there is enough Argon gas in the shield gas cylinder you can test the electromagnetic gas valve through the switch on the fr...

Page 25: ... of Ti alloy Welding area color bright argent orange yellow blue purple caesious white powder of titanium oxid Protect effect best better good bad worst 4 5 3 TIG Parameters Matching The corresponding relationship between gas nozzle diameter and electrode diameter Gas nozzle diameter mm Electrode diameter mm 6 4 0 5 8 1 0 9 5 1 6 or 2 4 11 1 3 2 Notice the above parameters originate from Welding D...

Page 26: ...rrent A 1 0 0 125 12 2 15 1 0 0 25 20 5 30 1 6 0 5 25 8 50 1 6 0 8 30 10 70 2 4 0 8 35 12 90 2 4 1 1 45 15 150 3 2 1 1 60 20 200 TIG of stainless steel single run welding Workpiece thickness mm Joint form tungsten electrode diameter mm welding wire diameter mm Argon gas flow rate L min 1 welding current DCEP Welding speed cm min 1 0 8 Butt joint 1 0 1 6 5 20 50 66 1 0 Butt joint 1 6 1 6 5 50 80 56...

Page 27: ...tt welding 4 3 4 180 200 10 15 8 12 Parameters of piping back sealing welding for mild steel DCEP Piping diameter Φ mm Tungsten electrode diameter mm Gas nozzle diameter mm Welding wire diameter mm Welding current A Arc voltage V Argon flow rate L min 1 Welding rate cm min 1 38 2 0 8 2 75 90 11 13 6 8 4 5 42 2 0 8 2 75 95 11 13 6 8 4 5 60 2 0 8 2 75 100 11 13 7 9 4 5 76 2 5 8 10 2 5 80 105 14 16 8...

Page 28: ...f Edition 2 4 6 Operation Environment Height above sea level is below 1000m Operation temperature range 100C 400C Relative humidity is below 90 200 C relative humidity is below 50 400 C The inclination of the power source does not exceed 100 Protect the machine against heavy rain or in hot circumstance against direct sunshine The content of dust acid corrosive gas in the surrounding air or substan...

Page 29: ... concerned people should be left Do not watch the arc in unprotected eyes Ensure good ventilation of the machine to improve duty ratio Turn off the engine when the operation finished to economize energy source When power switch shuts off protectively because of failure Don t restart it until problem is resolved Otherwise the range of problem will be extended ...

Page 30: ...ly Please get in touch with maintenance service department if there are no accessories After turn on power watch listen to that whether the arc welding machine has shaking whistle calling or peculiar smell If there is one of the above problems find out the reason to get rid of if you can t find out the reason Please contact local this area agent or the branch company Observe that whether the displ...

Page 31: ...adjusted plier type ampere meter Yearly examination Measure the insulating impedance among the main circuit PCB and case if it below 1MΩ insulation is thought to be damaged and need to change and need to change or strengthen insulation 5 2 Troubleshooting Before arc welding machines are dispatched from the factory they have already been debugged accurately So forbid anyone who is not authorized by...

Page 32: ...ower board The min value is not accordant refer to 3 1 Adjust potentiometer Imaxin the current meter 6 No no load voltage output MMA The machine is damaged Check the main circuit and the Pr4 7 Arc can not be ignited TIG There is spark on the HF igniting board The welding cable is not connected with the two output of the welder Connect the welding cable to the welder s output The welding cable dama...

Page 33: ...d The max value displayed isn t accordant with the actual value Please refer to 3 1 Adjust potentiometer Imax on the power board 13 The penetration of molten pool is not enough The welding current is adjusted too low Increase the welding current The arc is too long in the welding process Use 2T operation 14 The alarm lamp on the front panel is on Over heat protection Two much welding current Reduc...

Page 34: ...2 J8 J1 12 lead socket R1 R2 TR1 TR2 DRIVE DC24V FAN F P1 9 066 318 A Solenoid Valve 4 OT2 GUN REMOTE 8 PIN SOCKET 2 2 QF HF ACPOUT WVIN 5 DC AC C2 R3 R4 T5 T4 C61 62 3uF C5 C6 C7 C8 C10 R12 C15 R28 2 12 3 2 2 SOFT START AC 120 240V A B SW1 E AC 1 AC 2 V 4 V 3 Q1 EMC AC 1 AC 2 V 4 V 3 Q2 A 1 K 2 D4 A 1 K 2 D3 C10 R187 C12 C11 LT V8 V8 1 PFC drive circuit T1 FD1 FD2 L1 7 731 146 POWER 8 3 POWER JP3...

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