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TitanMig Pulse 2700/3500/5000 Operators Manual

Issue. A 0516

4.2 MMAW (Stick) Welding Trouble Shooting

The following chart addresses some common problems during MMAW Welding.
In the event of equipment malfunction, contact an authorized service agent.

Possible Reason

Suggested Solution

No Arc

Incomplete welding circuit

Check Earth & Work leads connected

Wrong Mode Selected

Check the MMA/Stick switch is selected

Porosity

Arc length too long

Shorten arc length

Contaminated base metal

Remove any paint , grease, oil & dirt

Damp or Contaminated Electrodes

Dry Electrode or replace

Lack of Penetration

Insufficient heat input

Increase amperage

Contaminated base metal

Remove any paint , grease, oil & dirt

Excessive Spatter

Amperage set to high

Reduce Amperage

Arc length too long

Shorten arc length

Excessive penetration

Amperage set to high

Reduce Amperage

Incorrect travel speed

Increase travel speed

Distortion

Excessive heat input

Reduce Amperage

Poor joint preparation

Check joint design and fit up

Содержание TitanMig Pulse 2700

Страница 1: ... de instrucciones ES Käyttöohje FI Manuel d utilisation FR Manuale d uso IT Gebruiksaanwijzing NL Bruksanvisning NO Instrukcja obsługi PL Manual de utilização PT Инструкции по эксплуатации RU Bruksanvisning SV 操作手册 CN TitanMig Pulse 2700 3500 5000 MIG TIG Stick Welder Model No TMP2700 TMP3500 TMP5000 Issue A 05 16 ...

Страница 2: ...TitanMig Pulse 2700 3500 5000 Operators Manual Issue A 0516 ...

Страница 3: ...ime to read the entire manual paying particular attention to the Safety Precautions They will help you to avoid potential hazards that may exist when working with this product 2 Year Warranty Statement This product is covered by a 2 Year Warranty Parts Labour Warranty This warranty does not cover freight or goods that have been interfered with All goods in question must be repaired by an authorize...

Страница 4: ...g Panel Storage Recall 20 1 8 Welding Machine Setup 21 1 9 Welding Machine Status Display 22 2 0 Installation 23 3 0 Operation 25 3 1 GMAW MIG Welding 26 3 2 MMAW Stick Welding 42 3 3 GTAW TIG Welding 44 3 4 Software Updates 47 3 5 Add Funtions 54 4 0 Trouble Shooting 55 4 1 Mig Trouble Shooting 55 4 2 MMAW Stick Trouble Shooting 57 4 3 GTAW TIG Trouble Shooting 58 4 4 Electrical Trouble Shooting ...

Страница 5: ...lating mats or covers big enough to prevent any physical contact with the work ground Never touch the electrode if you are in contact with the work ground or another electrode from a diﬀerent machine Do not wrap cables over your body Ensure that you take additional safety precautions when you are welding in electrically hazardous conditions such as damp environments wearing wet clothing and metal ...

Страница 6: ...otection from moving parts When the machine is in operation keep away from moving parts such as motors and fans Moving parts such as the fan may cut ﬁngers and hands and snag garments Protections and coverings may be removed for maintenance and controls only by qualiﬁed personnel after ﬁrst disconnecting the power supply cable Replace the coverings and protections and close all doors when the inte...

Страница 7: ...to the elevated absorbance of the primary current from the power supply network high power systems aﬀect the quality of power provided by the network Consequently connection restrictions or maximum impedance requirements permitted by the network at the public network connection point must be applied to these systems In this case the installer or the user is responsible for ensuring the equipment c...

Страница 8: ...xposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures Keep cables close together by twisting or taping them Arrange cables to one side and away from the operator Do not coil or drape cables around your body Keep welding power source and cables as far away from operator as practical Connect work clamp to work piece as close...

Страница 9: ...ive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard Do not touch live electrical parts Wear dry hoIe free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground Do not use AC ...

Страница 10: ...inverters Turn off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use exhaust at the a...

Страница 11: ... the area is safe before doing any welding Protect yourself and others from flying sparks and hot metal Do not weld where flying sparks can strike flammable material Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings t...

Страница 12: ...elding gas supply when not in use Always ventilate confined spaces or use approved air supplied respirator HOT PARTS can cause severe burns Do not touch hot parts bare handed Allow cooling period before working on gun or torch MAGNETIC FIELDS can affect pacemakers Pacemaker wearers keep away Wearers should consult their doctor before going near arc welding gouging or spot welding operations NOISE ...

Страница 13: ...gulators hoses and fittings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for us FIRE OR EXPLOSION hazard Do not install or place unit on over or near combustible surfaces Do not install unit near flammables Do...

Страница 14: ...ference problem resulting from the installation If notified by the FCC about interference stop using the equipment at once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut Keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference Electromagnetic ene...

Страница 15: ...ntion to the safety instructions in the manual For more information on our products contact us consult an authorized dealer or visit our website The specifications presented in this manual are subject to change without prior notice Important notes Items in the manual that require particular attention in order to minimize damage and personal harm are indicated with the NOTE notation Read these sect...

Страница 16: ... 2700 3500 5000 are used in workshops and industry for manual and automated applications with classical steel galvanised sheets chrome nickel and aluminium The TitanMig Pulse 2700 features an integral 4 roller drive There is no longer an interconnecting hose pack between the power source and wire feed unit Its compact design makes the TMP 2700 particularly suitable for mobile applications on build...

Страница 17: ...t Current 36A 21A 50 A Power Factor 0 85 0 75 Efficiency 90 90 Gas pre flow time Preg 0 15 0s Post flow time Posg 0 15 0s Soft start speed Stfd Auto 0 5 22m min Wire Feeder Type Gear Driven 4 Roll Gear Driven 4 Roll Gear Driven 4 Roll Protection Class IP 21S IP 21S IP 21S Insulation Class H H H Dimensions Power Source LxWxH 685x295x560mm 685x295x560mm 685x295x560mm Weight Power Source 53 Kg 52Kg 3...

Страница 18: ...s caused by misuse Acceptable range of ambient temperature is from 10 40 C Acceptable range of humidity is 20 C at 95 humidity Specifications may change without previous notice Fitted for commissioning Recommended outlet Important Note on TitanMig Pulse 2700 Input Power Supply This unit has been supplied with a downgraded 15 Amp primary supply plug for commissioning purposes only You are advised t...

Страница 19: ...ll vary from model Front View Power Source Front Panel Layout 1 Control panel 2 Welding Cable Connection 3 Earth Cable Connection Rear View 4 CO2 Heating Socket 5 Welding Cable Connection 6 Data Plate 7 Primary Input Cable 8 Primary Power Switch 9 Water Cooler Power Socket 10 Control Cable Connection 1 2 3 4 5 6 7 8 9 10 ...

Страница 20: ...2 Feed Roll 30 10 22 1 0 1 2mm Steel FR3022V1012 Feed Roll 30 10 22 1 0 1 2mm Aluminum FR3022U1012 Feed Roll 30 10 22 0 9 1 2mm Aluminum FR3022U0912 Feed Roll 30 10 22 0 9 1 2mm Flux Cored FR3022K0912 Feed Roll 30 10 22 1 2 1 6mm Flux Cored FR3022K1216 2 3 4 1 5 6 7 8 HF10 Structure 1 Control Box 2 Spool Cover 3 Handle 4 Drive System 5 Gun Connector HF10 Drive System 1 Drive Gear 2 Wire Feed Rolle...

Страница 21: ...is selected 4 Wire feed speed LED lights up when the wire feed speed parameter is selected 5 Sheet thickness LED lights up when the sheet thickness parameter is selected 6 More indicator LED lights up when the other indicator parameter is selected 7 Left parameter selection button 8 Digital display 9 Right parameter selection button 10 Welding voltage LED lights up when the welding voltage paramet...

Страница 22: ...n be stored and recalled Please refer to the details on section 3 2 12 Job no LED lights up when the job number parameter is selected 13 Value indicator LED lights up when the other indicator parameter is selected 14 Adjusting dial for altering welding parameters If the indicator on the adjusting dial is lit up then the selected parameter is one that can be altered 15 Gas test button for setting t...

Страница 23: ... materials When a material is selected the LED behind the relevant filler metal lights up 18 Mode button for selecting the mode 2 step mode 4 step mode Special 4 Step Mode Special 4 Step Mode Spot welding mode For storing the welding parameters Special Mode 1 Special Mode 2 19 Process button s for selecting the welding process Manual metal arc welding Lift TIG welding Pulse Lift TIG welding ...

Страница 24: ...t and adjust the welding parameter value each time before welding For Job 0 it s specially used for automatically memory storage which can store the last welding parameter automatically The last welding parameter can be recalled from Job 0 when restart the welding machine Operation process of recall as follow 1 Press to choose the display value as job 23 2 Turn to alter the Job number as 0 3 The L...

Страница 25: ...ult value is 0 1s It works for MIG Pulse MIG Double Pulse MIG TIG Pulse TIG and Spot TIG 2 Post gas folw time PosG Adjustable from 0 15s the default value is 0 1s It works for MIG Pulse MIG Double Pulse MIG TIG Pulse TIG and Spot TIG welding processes 3 Soft start wire feed speed Stfd Adjustable from 1 22 m min and also can be set at automatic It works for MIG Pulse MIG and Double Pulse MIG weldin...

Страница 26: ...dware software version 25 welding process expert database material type and whether support DEVICENET and WIFI one by one Operation process of the welding machine status display 1 Press to choose the display value as 2 Turn the left side to show different status of the welding machine as following Machine internal temperature is 26 Hardware version for V23 software version for V1 4 Machine serial ...

Страница 27: ... other impurities to enter the machines cooling air flow Preferably site the machine above floor level for example on a suitable carriage unit Notes for positioning the machine The surface inclination should not exceed 15 degrees Ensure the free circulation of the cooling air There must be at least 20 cm of free space in front of and behind the machine for cooling air to circulate Protect the mach...

Страница 28: ... technical data section Direct connection to mains can be done by qualified electrical technician only Three phase Plug is not included For 350MTS min 20amp 3 phase plug recommended For 500MTS min 32 amp 3 phase plug recommended Output connections Electrode polarity In general when using the machine for MMAW Stick the electrode holder is connected to the positive terminal and the work return to th...

Страница 29: ... Duty Cycle at 180A Overheating Welding machine must be used according to technical data from this manual If the machine is overloaded failures may occur that are not be covered by warranty Overload control Thermal protection is built in the machine s main transformer and Inverter Bridge If the machine overheats thermal fuse will prevent further use and control lamp on the front panel will light u...

Страница 30: ...utput terminal of the welding machine and tighten it clockwise Connect the other end connection on the rear of the wire feed unit Insert the multi pin plug of the interconnection cable set into the control cable socket of the welding machine and connect the other connection into the rear of the wire feed unit Ensuring that the groove size in the feeding position on the drive roll matches the conta...

Страница 31: ...lues are displayed on the front panel of the machine When the torch trigger is released welding ends 2 seconds after welding ends the gas supply will be cut oﬀ Installation of wire reel Open the side cover and unscrew reel brake cover Mount the reel in such way that one end of wire hangs downwards Mount brake cover back in position Cut off the bent end of the wire Lead the end of the wire trough i...

Страница 32: ...ined At high currents the transfer mode is globular and significant spatter is produced Carbon Dioxide is less than ideal for use alone as a shielding gas but it is an essential ingredient of most GMAW shielding mixtures High Carbon Dioxide 18 to 23 mixtures are particularly suited to welding steels which are coated with paint primers and other surface contaminants or where higher penetration is r...

Страница 33: ...ing a relatively low heat input fusion defects and porosity can occur when welding heavy sections due to the penetration profile low fluidity and the rapid freezing of the weld pool Carbon Steel Intermediate content CO2 mixtures Intermediate content CO2 mixtures 8 15 CO2 produce a higher heat input giving improved characteristics and broader penetration profile These mixtures are more versatile th...

Страница 34: ...d bead shaping In the event that the speed is too slow the work piece will be burned through and a good weld bead will be unavailable In practical operation the welding speed should not exceed 50cm min Wire Stick out The increase of the stick out can improve the productivity but too long stick out may lead to excessive spatter wire breaking and unstable welding Generally the stick out should be 10...

Страница 35: ...rs from the expert database Arc length the standard arc length in the expert database is 0 the user could increase or decrease the arc length according to the welding technology Inductance arc force the standard inductance in the expert database is 0 the user could increase or decrease the inductance arc force And the inductance perform different functions in different welding methods MIG MAG 0 so...

Страница 36: ...TitanMig Pulse 270 3500 5000 Operators Manual Issue A 0516 32 4T Special 2T ...

Страница 37: ...the spot welding Initial time Hott the duration of the initial current it is only suitable for S2T End time Endt the duration of the end current it is only suitable for S2T Slop time SLOP the switching time between two currents such as the initial current and welding current Double pulse frequency Freq as figures shown The arc length of double pulse AL2 as figures shown it is the High arc length v...

Страница 38: ...rNi 18 8 6 ER307 A r 97 5 CO2 2 5 11 CrNi19 9 ER308 A r 97 5 CO2 2 5 12 CrNi 22 12 ER 309 A r 97 5 CO2 2 5 Optional 13 CrNi 25 20 ER 310 A r 97 5 CO2 2 5 Optional 14 CrNi 19 12 3 ER 316 A r 97 5 CO2 2 5 Optional 15 CrNi 13 4 ER 410 A r 97 5 CO2 2 5 Optional 16 CrNb 16 ER 430 A r 97 5 CO2 2 5 Optional 17 CrNi 22 9 ER 2209 Ar 82 CO2 18 Optional 18 CrNi 19 12 3 ER 316 Ar 82 CO2 18 Optional 19 CrNi 13...

Страница 39: ...lding technique all determine joint type Around the groove work pieces should be dry and clean free of rust metallic coating dirt colour or grease Joint type Groove shape Weld shape Metal thickness mm Work piece spacing mm Square butt joint single sided up to 1 5 from 1 5 0 to 2 Square butt joint double sided 2 to 4 up to 2 V butt joint 3 to 6 up to 1 3 to 6 up to 1 Square T joint single sided fro...

Страница 40: ...zle and tip of wire positioned correctly on seam 1 Hold torch and control trigger with one hand 2 Work piece 3 Earth clamp 4 Electrode extension Stick out to in 5 Cradle torch with the other hand and rest it on work piece Heat distribution and weld material flow are specific for groove welds and fillet welds Optimal torch position differs from one to another Weld bead shape differs depending on el...

Страница 41: ...more power at higher speeds Dragging the torch results in deeper penetration and narrower weld Arc strength prevents slag to enter the molten material When pushing the torch penetration will be shallower and the weld wider This movement is suitable for thin plates because of smaller heat input 1 Stringer bead steady movement along seam 2 Wave bead side to side movement along seam 3 Wave patterns U...

Страница 42: ...lts and troubleshooting GOOD WELD BEAD 1 Fine spatter 2 Uniform bead 3 Moderate crater during welding 4 No overlap 5 Good penetration into base material POOR WELD BEAD 1 Large spatter deposits 2 Rough uneven bead 3 Slight crater during welding 4 Bad overlap 5 Poor penetration ...

Страница 43: ...ty Small cavities or holes resulting from gas pockets in weld material Possible causes Corrective actions Wrong gas Use welding grade shielding gas change to different gas Welding wire extends too far out of nozzle Be sure welding wire extends no more than in beyond nozzle Work piece dirty Remove all grease oil moisture rust paint undercoating and dirt from work surface before welding Use a highly...

Страница 44: ...g wire extension and arc characteristics Improper welding technique Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration Keep arc on leading edge of weld puddle Be sure welding wire extends no more than in beyond nozzle Insufficient heat input Select higher wire feed speed and or select higher voltage range Reduce travel speed Distortion Contraction of weld metal during weld...

Страница 45: ... technique Keep arc on leading edge of weld puddle Use correct gun angle of 0 to 15 degrees Insufficient heat input Select higher wire feed speed and or select higher voltage range Burn through Weld metal melting completely through base metal resulting in holes where no metal remains Possible causes Corrective actions Excessive heat input Select lower voltage range and reduce wire feed speed Incre...

Страница 46: ... switch on the back panel to ON Select MMA by switching to the MMA welding mode There is voltage output at both output terminals Set the amperage on the machine suitable for the electrode being used Ensure you check that you have the electrode polarity correct Please see below a guide to amperages required Electrode Diameter mm Welding Current A Electrode Diameter mm Welding Current A 2 0 40 60 4 ...

Страница 47: ...s should be set according to the welding situation the higher striking current and the longer duration the easier ignition But for sheet welding the striking current and duration can not be too high and too long so as not to burn the workpiece In general the striking current should be 1 5 times of welding current and striking time is 0 02 0 05s External characteristics Slop In order to fit differe...

Страница 48: ...tage output at both output terminals After the parameters are set appropriately open the gas valve of the cylinder the gas valve on the torch and adjust the gas regulator to obtain the desired flow rate The arc will start when the tungsten electrode touches the work piece and is lifted off after touching by between 2 4mm The arc will cease when the electrode torch is moved away from the work area ...

Страница 49: ...f DC TIG and PULSE TIG There are 5 ways for TIG welding including 2T 4T S2T S4T and Spot Welding The TIG welding ways should be selected according to the technical requirements and the operation habit of the operator method operation mode TIG torch switch Current Curve 2T Press the on off button arc strike and upslope Loose the on off button down slop and arc quench If press the on off button agai...

Страница 50: ...s not suggest to use when welding the sheet metal Otherwise it will burn out the workpiece easily After ignition arc under some operation mode the current should keep the initial current in order to heat up the workpiece or lighting Initial time Hott it means the last time of the initial current it is only valid in the S2T End time Endt it means the duration of the end current it is only valid in ...

Страница 51: ...ital welding machines And the welding performance can be improved add and change the function by upgrading software It is very easy to operate The steps are as following 1 Insert the USB of UT 850 to computer another side to the welding machine 2 Turn on the computer and welding machine 3 Run the rjsj4 exe in the computer as following a k A Double click rjsj4 ...

Страница 52: ...TitanMig Pulse 2700 3500 5000 Operators Manual Issue A 0516 48 B Choose English C Click Connect D Double click jm132 ...

Страница 53: ...TitanMig Pulse 2700 3500 5000 Operators Manual Issue A 0516 49 ...

Страница 54: ...TitanMig Pulse 2700 3500 5000 Operators Manual Issue A 0516 50 E Copy and paste the Serial Number into Form1 F Click the button Start ...

Страница 55: ...TitanMig Pulse 2700 3500 5000 Operators Manual Issue A 0516 51 G When you can see OK close the small window H Click the Upgrade I Choose the document ...

Страница 56: ...TitanMig Pulse 2700 3500 5000 Operators Manual Issue A 0516 52 J Now data has being transmitted K k Complete ...

Страница 57: ...e cables carefully 2 Something wrong with the USB RS485 converter suggest the UT 850 or change new qualified one 3 Driver of USB RS485 is set wrong need re install If fail to upgrade because of power failure during the process please restart welding machine It will check the correctness of software automatically after each restart if the software isn t correct it cannot work normally but waiting t...

Страница 58: ...case of welding machine find the CFM on the PCB1 pull out the plug with two pins on CFM it s the softdog replace a new one Enter password Enter into the menu of start the machine enter 4 passwords in corresponding options save the passwords and then exit When you restart the welder new processes have been added Details as following steps a e A Long press and turn on the switch B Press Select More ...

Страница 59: ...ting Wrong polarity Set Select the correct polarity for the wire being used Stick out too long Bring the torch closer to the work piece Contaminated base metal Remove any paint grease oil dirt Contaminated MIG Wire Use clear dry rust free wire only Gas Flow too high or too low Check gas is connected Set gas flow between 10 15 l min Protect Weld Zone from wind drafts Porosity Wrong Gas Check that c...

Страница 60: ...e being used Incorrect Wire Speed Adjust Speed setting Voltage Setting Incorrect Adjust Volt setting Torch too long Replace with shorter gun Contact tip worn wrong size Replace with correct type Liner worn or clogged Replace with new liner Wrong size liner Replace with correct type Blocked inlet or outlet guide Clean or Replace Incorrect drive roller Fit correct type for wire being used Worn drive...

Страница 61: ...tch is selected Porosity Arc length too long Shorten arc length Contaminated base metal Remove any paint grease oil dirt Damp or Contaminated Electrodes Dry Electrode or replace Lack of Penetration Insufficient heat input Increase amperage Contaminated base metal Remove any paint grease oil dirt Excessive Spatter Amperage set to high Reduce Amperage Arc length too long Shorten arc length Excessive...

Страница 62: ...ol Tungsten Melting Check Type Size Tungsten being used Porosity Incorrect Gas or No Gas Check Pure Argon is in use Insufficient Gas Flow Check gas flow Set to 10 15 l min Contaminated base metal Remove any paint grease oil dirt Contaminated TIG Wire Use clear dry rust free wire only Unstable Arc Torch connected to connection Refit torch to connection Contaminated base metal Remove any paint greas...

Страница 63: ... LED is off The earth cable is not well connected with the work piece Reconnect it The wire feeder cable is not well connected Reconnect it The wire feeder or welding torch fails Repair the wire feeder or welding torch No response when pushing the torch trigger and the protection LED is off The welding torch is not well connected with the wire feeder Reconnect it The control cable of the wire feed...

Страница 64: ...wo minutes after disconnecting the mains cable before removing the machine s case Perform the following cleaning and maintenance at least every six months 1 Clean the interior of the machine and the fan grill s net of any dust and stains for example with a soft brush and vacuum cleaner Do not use pressurized air The stain may become compressed into the grooves of the coolers Do not use a pressure ...

Страница 65: ...TitanMig Pulse 2700 3500 5000 Operators Manual Issue A 0516 61 6 0 Electrical Diagram ...

Страница 66: ...t if original found to be faulty freight free to the customer The obligation of Weldtronic International P L under this warranty is limited to the circumstances set out above and is subject to The customer being able to provide proof of purchase of the product and the purchase price paid for the product The relevant defect in materials or workmanship The product not having been altered tampered wi...

Страница 67: ...ens 3 Month warranty on Helmet shell harness fittings Warranty Returns Exchanges 1 Subject to the conditions of warranty set out in the warranty period Weldtronic International P L warrants that if any defect in any workmanship on any product has occurred then the conditions applicable to the warranty period are a The warranty applies on the basis of the goods being used on the equivalent of singl...

Страница 68: ...dtronic discretion replacing the goods or repairing the goods except where you have acquired goods as a consumer within the meaning of the Trade Practices Act 1974 or the Fair Trading Acts of the relevant state or territories of Australian and is therefore also entitled to at the consumers discretion either a refund of the purchase priceof the goods orrepairofthe goods orreplacementof the goods 7 ...

Страница 69: ...e or other external factors i Failure orbreakage causedbyoverload droppingorabusive treatmentorusebythecustomer j Repair modifications or other work carried out on the product other than by an authorized Weldtronic service dealer 14 This warranty does not cover the following parts a MIG TIG Stick MMA WeldingTorches Consumablessuchas Gas nozzles Gas diffusers contact tip holder contact tip swan nec...

Страница 70: ...TitanMig Pulse 2700 3500 5000 Operators Manual Issue A 0516 66 ...

Страница 71: ...TitanMig Pulse 2700 3500 5000 Operators Manual Issue A 0516 67 ...

Страница 72: ...onal P L ABN 99 149 754 263 42 46 Micro Circuit Dandenong Sth Victoria 3175 Australia P O Box 2096 Rowville Victoria 3178 Australia Tel 03 9702 9366 Fax 03 9702 9766 Email sales weldtronic com au Web www weldtronic com au ...

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