Yeswelder CT2050 Operator'S Manual Download

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MULTl-PROCESS IGBT INVERTER WELDER & CUTTER(AC/DC TIG, AC/DC

PULSE TIG, STICK, PLASMA CUT WITH OUTER AIR AND BUILT-IN AIR)

OPERATOR'S MANUAL

Please read this manual before using your new CT2050 welding and cutting machine

Summary of Contents for CT2050

Page 1: ...T INVERTER WELDER CUTTER AC DC TIG AC DC PULSE TIG STICK PLASMA CUT WITH OUTER AIR AND BUILT IN AIR Copyright YesWelder OPERATOR S MANUAL Please read this manual before using your new CT2050 welding and cutting machine ...

Page 2: ... new YesWelder product YesWelder creates quality products at dis counted prices to make welding affordable to everyone To help us serve you better and for further questions visit www yeswelder com Thank you for your purchase ...

Page 3: ...VIEW 06 FUNCTION OVERVIEW 07 PERFORMANCE CHARACTERISTICS 08 INSTALLATION 09 ACCESSORIES 10 DESCRIPTION 11 18 OPERATION 19 34 CAUTION 35 BASIC KNOWLEDGE OF WELDING 36 43 OPTIONAL ACCESS OPERATION DESCRIPTION 43 44 MAINTENANCE 45 TROUBLESHOOTING 46 51 WIRING DIAGRAM 52 ...

Page 4: ... breathing zone and the general area IN A LARGE ROOM OR OUTDOORS natural ventilation may be adequate if you keep your head out of the fumes See be low USE NATURAL DRAFTS or fans to keep the fumes away from your face If you de develop unusual symptoms see your supervisor Per haps the welding atmosphere and ventilation system should be checked WEAR CORRECT EYE EAR BODY PROTECTION PROTECT your eyes a...

Page 5: ...fuel is spilled wipe it up and do not start engine until fumes have been eliminated 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repair ing equipment 1 e In some cases it may be necessary to remove safety guards to perform required maintena...

Page 6: ...orm to ANSI Z87 I standards 4 b Use suitable clothing made from durable ﬂame resistant material to protect your skin and that of your helpers from the arc rays 4 c Protect other nearby personnel with suitable non ﬂammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal ARC RAYS CAN BURN FUMES AND GASES CAN BE DANGEROUS 5 a Welding ma...

Page 7: ...he welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create ﬁre hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c 6 I Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy M...

Page 8: ...lease take care of our environment SMART Function Input Voltage Remote Control Mode or Torch Control Mode AC TIG Mode DC TIG Mode Stick Mode CUT Outer Air Power ON Power OFF Arc force current Ground Connection Current Frequency Percentage Time Pulse Frequency Width of Pulse Peak Gas Parameters of Welding CUT Built in Compressor Air S Hz A WARNING 05 ...

Page 9: ... prove the duty cycle The unique air channel heat dissipation efﬁciency can effectively prevent damage to the power devices and control circuits resulting from the dust absorbed by the fan and greatly improve the welder s reliability thereby The overall streamlined design with a big arc transition perfectly integrates front and back panels forming the most coherent and natural joints of the machin...

Page 10: ... in pressurized arc ignition circuit support HF pilot TIG arc ignition Ÿ No HF pilot arc start CUT support no HF pilot arc ignition when going plasma cutting Ÿ Intelligent fan automatic cooling fan which works though temperature control and prolong the fan s lifespan Ÿ Auto saving and recovery of welding parameters the welder will auto save the parameters for sudden power off and will re covery Ia...

Page 11: ...ormation the welder will restart when the network voltage is stable The welder will shut off in case of over heat or other abnormalities and display the according failure information Multi protections largely prolong the welder s lifespan Excellent consistency and performance Ÿ This product adopts intelligent digital control technology which is not sensitive to component parameters change certain ...

Page 12: ... 68V 68V with VRD 7V 12 25A 10 160A 5 160A 12 45A 10 200A 5 200A 10 2 18V 20 4 28V 84 8 98V 10 2 16 4V 20 4 26 4V 84 8 90V 312V Read the entire installation section before you start the installation INSTALLATION WARNIG ELECTRIC SHOCK can kill Ÿ Only qualiﬁed personnel should per form this installation Ÿ Only personnel reading and under standing the CT2050 Operator s Man ual should install and oper...

Page 13: ...P 26 TIG Torch with Amperage Control KDP35 50 Electric Connector M16 1 5 Gas Connector 5 pin Control Cable 3 8 Gas Hose with 5 8 18 RH 4 13 Air Tube 5 Air Compressor Regulator Filter 6 220V 110V Power Adapter 7 10 Work Clamp Cable 8 10 Electrode Holder Cable 9 Manual 2 1 3 4 5 6 8 7 10 9 ...

Page 14: ... off and adjust welding amperage Connect the 5 pin connector present on the welding torch to the recepta cle 6 Negative Output Receptacle Permits attaching an elec trode holder or TIG welding torch electric connector 7 Value Adjusting Function Knob Permits selecting and ad justing parameters 1 8 9 7 2 3 4 5 6 8 Trademark 9 Handle 10 CNC Arc Voltage Connector 11 CNC Signal Control Connector 12 Inte...

Page 15: ... Parameter Value or Error Code 2 Current Indicator 3 Time Indicator 4 AC Balance Clearance Width or Duty Cycle Pulse Width 5 AC Frequency or Pulse Frequency 1 2 1 Input Voltage 2 Power LED Fig 2 Digital Display Fig 3 Input Voltage 1 2 3 4 5 6 7 1 Welding Process Selection 2 Outer Air LED 3 CUT Built in Compressor Air 4 CUT Outer Air 5 Stick 6 DC TIG 7 AC TIG Fig 4 Weld Mode Select 1 2 3 4 1 Torch ...

Page 16: ...3 2mm 6 3 16 5 0mm 1 2 3 4 5 6 1 2 1 SMART Button 2 SMART LED Fig 8 SMART Selection 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 Pre ﬂow 2 Initial Current 3 Upslope Time 4 Peak Current Output Current 5 Pulse Frequency 6 Downslope Time 7 Crater Current 8 Post Flow 9 Arc Force Current 10 Hot Start Current 11 Pulse Width Duty Cycle 12 Background Current 13 AC Frequency 14 Clearance Width AC Balance Fig 9 Param...

Page 17: ...Control Fig 12 Torch Operation Selection Welding Process Selection 14 Press and hold the Value Knob for 3s to turn Pulse on off Operation Modes Mode No Operation Torch Trigger Operation and Current Curve 1 Standard 2T mode 1 Push the torch trigger arc is ignited and current rises gradually 2 Release the torch trigger current drops gradually and arc stops If push the torch trigger again before arc ...

Page 18: ...elding Angle Overhead Welding Angle When under SMART mode one can press to select aluminum plate thickness 18GA 1 0mm 16GA 1 3mm 16GA 1 6mm 1 8 3 2mm 3 16 5 0mm 15 SMART Mode Selection When under AC AC Pulse TIG mode press to select SMART mode Please see below AC TIG SMART Fig 13 Operation Selection AC TIG SMART AC TIG SMART SMART OFF SMART ON ...

Page 19: ...iddle of welding without affecting welding Welding Mode Torch Switch Mode Pre ﬂow Initial Current Up Slope Time Peak Current Background Current Pulse Frequency Pulse Width Stick NO DC TIG 2T 4T Foot Pedal DC Pulse TIG 2T 4T Foot Pedal AC TIG 2T 4T Foot Pedal AC Pulse TIG 2T 4T Foot Pedal CUT Built in compressor Air 2T 4T CUT Outer Air 2T 4T Adjusting Direction DESCRIPTION 16 ...

Page 20: ... welder must rest and be cooled Duty cycle is expressed as a percentage of 1 O minutes and represents the maximum welding time allowed The balance of the 1 0 minute cycle is required for cooling For ex ample a welder has a duty cycle rating of 30 at the rated output of 90A With that machine you can weld at 90 A output for three 3 minutes out of every 10 min with the remaining seven 7 minutes requi...

Page 21: ... new welder it is necessary to Ÿ Read the safety precautions at the front of this manual Ÿ Prepare an organized well lit work area Ÿ Protect the eyes and skin of the operator and bystanders Ÿ Attach the work clamp to the bare metal to be welded ensuring good contact Ÿ When for TIG Welding ensure opening the gas cylinder valve for 100 Argon and adjust the gas pressure regulator to the correct ﬂow r...

Page 22: ...ch the work clamp to the workpiece that needs welding Ÿ Put the TIG torch away from all conductive materials Ÿ Install the gas hose into the Inlet for Argon Gas and connect to the gas pressure regulator 100 Argon only Ÿ Open the gas cylinder valve and adjust the gas pressure regulator to the correct ﬂow rate Recommend 20 35CFH Ÿ Plug the power cable into a suitable power outlet recommend NEMA6 50R...

Page 23: ...e material thickness see Settings Chart Thread the correct Ceramic Nozzle onto Collet Body Ÿ Insert Collet into Collet Body Insert tungsten Electrode into Collet Ÿ Lock Electrode in place with Back Cap The electrode should protrude 1 8 to 1 4 beyond the Ceramic Nozzle 3 1 4 5 6 7 2 20 1 Pyrex Glass Cup 2 Stubby Gas Lens 3 Temperature Resistant O ring 4 Collet 5 Insulator Torch Body 6 Torch Head 7 ...

Page 24: ...ding Current DCEN A AC A 1 16 70 150 60 120 3 32 150 250 100 180 1 8 250 400 160 250 5 32 400 500 200 320 Welding Material Recommendation Process Welding Material Tungsten Diameter Metal Thickness 110V 220V AC TIG Aluminum Aluminum Alloy Magnesium Alloy etc 1 16 3 32 1 8 5 32 1 25 5 32 mm 1 25 3 16 mm AC Pulse TIG DC TIG Carbon steel stainless steel copper titanium alloy etc DC Pulse TIG ...

Page 25: ...gnition The pre ﬂow time should be increased if the gas hose is long Ÿ Post ﬂow Time It indicates the time from the welding current being cut off to the gas valve inside the machine being closed If it is too long it will lead to a waste of argon gas if it is too short it will result in the oxidation of weld bead When in AC TIG or for spe cial materials the time should be longer Ÿ Upslope Time tr I...

Page 26: ...Ÿ Pulsed Frequency 1 T T Tp Tb It should be adjusted according to users technical requirements Ÿ Pulse Duration Ratio Pulse Width 100 Tp T The percentage peak current time holding in pulse period It should be ad justed according to users technical requirements Upslope Welding Current I1 Initial Preset Downslope Pilot arc O tp tb T Ib I5 Ip t I DC TIG Parameters DC Pulse TIG 23 The actual parameter...

Page 27: ...welding when taking the electrode as an anode the current is called cathode current Its main function is to break up the oxidized layer of the workpiece and the cleaning strength is the percentage of cathode current holding in the AC period This parameter is 10 40 commonly When the value is smaller the arc is concentrative the molten pool is narrow and deep and when it is bigger the arc is dispers...

Page 28: ...e corresponding contents in DC pulsed TIG welding The pulse frequency 1 T is a little low and it can be adjusted between 0 5Hz and 5Hz The pulse duration ratio Tp T can be adjusted between 10 and 90 tc Cathode Current time tp AC Period Tp Pulsed Peak Current Time T Pulse Period tu Tp T tc tp td Process Parameter Description 220V 110V Default AC Pulse TIG PRE GAS Pre ﬂow 0 1 15s 0 1 15s 0 3s Istart...

Page 29: ...Istart Initial Current 10 15 20 25 30 SLOPE UP UpSlope Time 0 0 0 0 0 I1 Peak Current 20 40 55 95 160 I2 Background Current 10 10 10 10 25 SLOPPE DOWN Downslope Time 0 0 0 0 0 Istop Crater Current 20 20 20 20 20 POST GAS Post ﬂow 5 5 5 5 5 AC Hz AC Frequency 85 85 85 85 85 AC BALANCE Clearance Width 30 30 30 30 30 PULSE Hz Pulse Frequency 0 2 200 0 2 200 0 2 200 0 2 200 0 2 200 DUTY CYCLE I1 I2 Pu...

Page 30: ...t and air compressor Ÿ Set the air pressure to 60 90PSI Ÿ Attach the work clamp to the workpiece that need cutting Ÿ Put the cutting torch away from all conductive materials Ÿ Plug the power cable into a suitable power outlet recommend NEMA6 50R Ÿ Turn on the power source and select Plasma Cut Built in Compressor Air Plasma Cut Outer Air process with the Welding Process Selection Ÿ Trigger the tor...

Page 31: ...Cutting Torch Assembly 1 Spacer Guide 2 Outside Nozzle 6 holes 3 Nozzles Tips 4 Electrodes 5 Diffuser 6 Torch Head Plasma Cutting Torch Accessory 1 5 3 2 6 28 4 ...

Page 32: ...ir and plasma cutting with outer air from an external com pressor The built in compressor makes it easy to take on various outdoor projects and making life for welders on the road that much easier It s able to start cutting without an extra air compressor Access to an external air compressor makes cutting more powerful and with better quality 29 ...

Page 33: ...g valve knob to ﬁx it after the pressure is adjusted Ÿ Loose the ﬁxing nuts on the rear panel to install the bracket Ÿ Place the air ﬁlter regulator on the bracket and ﬁx it Ÿ Connect the Inlet Air In with the ﬁlter regulator outlet nozzle by an air tube and tighten it with a clamping band Ÿ Connect the Inlet Air Out with ﬁlter regulator inlet nozzle by an air tube and tighten it with a clamping b...

Page 34: ...ductor back onto its seat completing the pilot arc circuit The blow back start comes without interference is safe and ideal for general use and is friendly to the surrounding electrical ma chine and human health Cutting Features Non touch Pilot Arc The pilot arc torch efﬁciently cuts through rough painted and rusty surfaces while producing minimal slag Pilot arc technology allows cutter to cut wit...

Page 35: ... 6mm 56 130 83 07 127 30 7 136 36 22 134 5 16 8mm 40 133 54 53 130 21 25 140 27 16 138 3 8 10mm 31 136 36 22 134 12 2 146 15 75 141 1 2 12mm cut from the edge 21 25 140 27 16 138 6 7 152 9 45 147 5 8 16mm 12 2 146 15 75 141 4 33 157 5 71 154 3 4 20mm 6 7 152 9 45 147 1 25mm 4 3 157 5 7 154 Recommended air ﬂow rate pressure 188 I min 400 scfh 5 9 bar 90 psi The actual parameters can be ﬂexibly sele...

Page 36: ...ing up heavy deposits of materal with less penetration and thin sheet welding Note For Stick welding DCEP means the electrode holder is connected to the positive socket while the work clamp workpiece is connected to the negative socket However various electrodes require a different polarity for optimum results Please follow the electrode manufacturer s recommendation on the correct polarity Ÿ Turn...

Page 37: ... the weld start Adjustable Hot Start Electrode Size ø mm Inch Current Range Amps 3 32 or 0 09 2 4mm 60 95 1 8 or 0 125 3 2mm 100 130 11 64 0r 0 15 4 0mm 130 165 13 64 or 0 19 5 0mm 165 260 Built in VRD The voltage reduction device VRD is a hazard reduction device that lowers the welder s open circuit voltage OCV to prevent elec tric shock from welding current A VRD is usually equipped with a stick...

Page 38: ...entilation is of critical importance to the normal performance and lifespan of the machine 2 Over load is forbidden The welder is operated according to the allowable duty circle refer to the corresponding duty cycle Make sure that the welding cur rent should not exceed the max load current An overload could obviously shorten the machine s lifespan or even damage the ma chine 3 Over voltage is forb...

Page 39: ...d helmet type Colored chemical glass is installed on the viewing window of the mask to ﬁlter ultraviolet rays and infrared rays Arc burning condition and weld crater condition can be observed from the viewing window during welding Thus welding can be carried out by operators conveniently c Slag hammer peen hammer for the use of removing slag crust on the surface of the weld joint d Wire brush for ...

Page 40: ...nt movement in which the electrode simultaneously moves in three basic directions the electrode gradually moves along the welding direction the electrode gradually moves toward the weld crater and the electrode transversely swings See Fig 21 Electrode should be correctly manipulated in three movement directions after the arc is ignited In butt welding and ﬂat welding the most important is to contr...

Page 41: ...ead b Arc Extinguishing on the Weld Bead Fig 23 Arc Extinguishing Modes 7 Weldment Cleaning Clean welding slag and spatter with wire brush and tools the like after welding Argon Arc Welding General Description of Argon Arc Welding Argon arc welding is a kind of gas shielded arc welding using argon as shield gas and the process of argon arc welding is shown in Fig 24 Tightly close protective layer ...

Page 42: ...ly suitable for welding chemically active metals and alloys Generally it is used in the welding of aluminum titanium copper low alloy steel stainless steel refractory steel etc With the increase in product structure of non ferrous metals high alloy steel and rare metals common gas welding methods and arc welding methods are difﬁcult to obtain the required welding quality However argon arc welding ...

Page 43: ... inert gas argon does not react with metal chemically even under high temperature Thus the alloying elements will not be oxidized or burned out and problems caused accordingly will be avoided Meanwhile argon is insoluble in liquid metal so air holes can be avoided Argon is a kind of monatomic gas existing in atomic state without molecular decomposition and atomic endotherm under high tempera ture ...

Page 44: ...e tungsten electrode and molten pool and the gas protective effect will be affected accordingly Be sides the welding speed affects the weld bead shape signiﬁcantly Therefore it is very important to select the appropriate welding speed F Process factors mainly refer to the shape and diameter of the nozzle the distance between the nozzle and workpiece stick out and the diameter of ﬁlling wire etc Al...

Page 45: ...ting torch to the position about 1mm above the workpiece and start cutting Notes for Cutting Operation It is recommended not to ignite the arc in the air if not necessary for it will shorten the electrode s lifespan and the torch s nozzle It is recommended to initiate the cutting from the edge of workpiece unless penetration is needed Ensure spatters ﬂy from the bottom of workpiece while cutting I...

Page 46: ... 5mm 2 Distortion of the nozzle 3 Cutting speed declining arc with green ﬂame 4 Difﬁcult in arc ignition 5 Irregular cut 43 OPTIONAL ACCESS OPERATION DESCRIPTION Pedal remoter control internal structure is composed by inching switch and sliding potentiometer 10K as shown in below Fig 27 Pedal Remoter Operation Fig 27 Pedal Remote Controller The pedal controlling function is only used while it s un...

Page 47: ...le See Fig below YesWelder CT2050 is equipped with an analog control wire drive welding torch 44 Wire drive Welding Torch Operation Analog Regulation Type Torch Socket Interface Fig 30 Ÿ The torch switch mode needs being set to remote when using analog regulation torch function Preset the max weld ing current through front panel and start welding The welding current can be adjusted through torch p...

Page 48: ...G THE CONTACT TIP The purpose of the CONTACT TIP is to transfer welding current to the welding wire while allowing the wire to pass through it smoothly Always use a contact tip stamped with the same diameter as the wire it will be used with 1 If the wire burns back into the tip remove the tip from the gun and clean the hole running through it with an oxygen acetylene torch tip cleaner or tip drill...

Page 49: ...ot power off restart welding when the overheat indicator stop lighting up Under voltage Display error code sound E 2 Permanently close main circuit and need to restart the machine Power grid under voltage lower than 96VAC Please restart the welder if warning still remains If there is a c o n t i n u o u s p o w e r g r i d undervoltage please wait and restart welder when the power grid is back to ...

Page 50: ... tungsten Arc length too long Lower torch so that the tungsten is off of the work piece 5 64 13 64 2 5mm Arc wanders Tungsten incorrect or in poor condition Check that correct type of tungsten is being used Remove tungsten 3 4 from the weld end and re sharpen the tungsten Insufﬁcient gas shielding Check and set the gas ﬂow between 20 30cfh ﬂow rate Contaminated gas or leaks in gas line torch or co...

Page 51: ...e Argon gas and is connected and the torch gas valve is open Set the gas ﬂow between 20 30cfh ﬂow rate Make sure the torch back cap is ﬁtted so that the o ring is inside the torch body Back cap not ﬁtted correctly Check and change the tungsten type if necessary Incorrect tungsten being used Contaminated tung sten Touching the ﬁller wire to the tungsten Keep the ﬁller wire from touching the tungste...

Page 52: ...he consumables for wear and replace worn parts with new YesWelder consumable parts Moisture or oil in air supply Excessive humidity or oil from the compressor may be con taminating the air supply Install a moisture ﬁlter in the air supply line prior to machine Insufﬁcient cut pene tration Workpiece is too thick Check for obstructions blocking air ﬂow and ensure that there are 12 inches of clearanc...

Page 53: ...e Exceeding plasma cutting machine capa bility material too thick Excessive humidity or oil from the compressor may be con taminating the air supply Install a moisture ﬁlter in the air supply line prior to machine Moisture or oil in air supply Improperly assembled or loose Plasma torch consumables Check Plasma torch consumables for proper installation Damaged Plasma torch consumable Check plasma t...

Page 54: ...ely with base metal or a preceeding weld bead Increase amperage Select larger electrode and increase amperage Insufﬁcient heat input Place stringer bead in proper location at joint during welding Improper welding technique Keep arc on leading edge of weld puddle Workpiece dirty changed the word work to electrode to help better exapling angle when welding various positions Momentarily hold arc on g...

Page 55: ...15 WIRING DIAGRAM 52 ...

Page 56: ...www YesWelder com V2 01 ...

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