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MAINTENANCE & TROUBLESHOOTING

Monthly

examination

Using the dry compressed air to clear the inside of arc welding machine. Especially for

clearing up the dusts on radiator, main voltage transformer, inductance, IGBT module, the

fast recover diode and PCB, etc.

Check up the bolt in arc welding machine, if it is loose, please screw down it. If it is skid,

please replace. If it is rusty, please erase rust on bolt to ensure it works well.

Quarter-

yearly

examination

Whether the actual current accords with the displaying value. If they does not accord,

they should be regulated. The actual current value can be measured by the 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 our company to do any change to the equipment!



Maintenance course must be operated carefully. If any wire becomes flexible or is misplaced, it maybe

potential danger to user!



Only professional maintenance personal who is authorized by our company could overhaul the machine!



Guarantee to shut off the arc welding machine’s power before turn on the outline of the equipment!



If there is any problem and has no the authorized professional maintenance personal of our company,

please contact local our company agent or the branch company!

If there are some simple troubles of TP-

series

welding machine, you can consult the following

overhauling chart:

S/N

Troubles

Reasons

Solution

Turn on the power source, and

fan doesn’t work, but the power

light is not on.

The power light damaged or connection is

not good

Test and repair the inside circuit of

power light

The transformer of power is broken

Repair or change the transformer

Control PCB failures

Repair or change the control PCB

Turn on the power source, and

the power light 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

Содержание TP Series

Страница 1: ...I TP SERIES Inverter DC Pulsed TIG MMA Arc Welding Machine ...

Страница 2: ... OPERATION 10 4 1 LAYOUT FOR THE FRONT PANEL AND THE REAL PANEL TAKE TP 1600 FOR AN EXAMPLE 10 4 2 LAYOUT FOR THE FRONT PANEL 14 4 3 WELDING OPERATION 15 4 3 1 ARGON ARC WELDING OPERATION 15 4 3 2 STRIKING ARC WAY FOR MMA 17 4 3 3 MANIPULATION OF ELECTRODE 18 4 4 WELDING PARAMETERS 18 4 4 1 JOINT FORMS IN TIG MMA 18 4 4 2 THE EXPLANATION OF WELDING QUALITY 18 4 4 3 TIG PARAMETERS MATCHING 19 4 4 4...

Страница 3: ...se 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 workpiece and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with workpiece and ground Take carefully when using the equipment in small...

Страница 4: ...sing local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highl...

Страница 5: ...eating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from ...

Страница 6: ...nd Magnetic Fields EMF The discussion on the effect of EMF is ongoing all the world Up to now no material evidences show that EMF may have effects on health However the research on damage of EMF is still ongoing Before any conclusion we should 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 Sec...

Страница 7: ...utomatic protection functions with intelligent to over voltage less voltage over current and over heat If any one of the above problems happens the alarm lamp on the front panel will be lighted and output current will be shut off automatically to protect itself and prolong the equipment using life TP series welding machine has MMA operation with hot start and arc force function They are suitable f...

Страница 8: ...while the welding current parameter can be adjusted continuously and steplessly to meet with the requirements of welding craft Rectify Inverter Medium frequency transformer Medium frequency rectify Hall device Current positive feedback control Single phase AC DC AC DC 220 230V 50HZ AC DC 2 3 Volt Ampere Characteristic TP series welding machine has an excellent volt ampere characteristic whose grap...

Страница 9: ...lass F Weight Kg 7 5 8 Dimensions of Machine mm L W H mm 400 140 230 3 2 Duty cycle Over heat The letter X stands for duty cycle which is defined as the proportion of the time that a machine can work continuously within a certain time 10 minutes The rated duty cycle means the proportion of the time that a machine can work continuously within 10 minutes when it outputs the rated welding current The...

Страница 10: ...workpiece DCEN torch front panel Argon gas bottle Gas hose Shield gas input joint gas connecto r Aero socket Return current cable Control cable of torch switch pipe Negative output Positive output Welding cable TP 1600 TP 1600 rear panel Workpiece is connected to the positive electrode of welding machine and welding torch is connected to the negative electrode which is called DC POSITIVE CONNECTIO...

Страница 11: ...ctrical principle drawing for detailed connection Consumable parts for TIG torch such as tungsten electrode tip gas nozzle electrode shield short long please enquire us by mail or phone according to the accessory codes When TP series welding machines are operated in HF ignition method the ignition spark can cause interferences in equipment near the welding machine Be sure to take specially safety ...

Страница 12: ... Hot Start L12 Arc Force L13 Alarm Pilot Light L14 Power Pilot Light L15 Ⅱ The function of welding mode selection switch GAS Gas test function In GAS shelf the gas is given all the time and the welding is stopped 4T_LIFT TIG Lifting arc long welding function 2T_LIFT TIG Lifting arc short welding function 4T_HF TIG HF striking arc long welding function 2T_HF TIG HF striking arc short welding functi...

Страница 13: ... on all parameters L1 L11 of TIG can be adjusted If in TIG 2T mode and the output pulse function is turned on the start current and crater current is 5A If the pulse function is closed the parameter of base current L5 pulse frequency L6 and pulse width L7 can not be adjusted TIG parameters adjustment The welding current L4 can be adjusted directly when the welder is tune on Adjust the selection kn...

Страница 14: ... ON the output pulse function is turned on if the digital scale display is OFF the output pulse function is turned off When the pulse LED L11 and digital scale display are twinkling press the selection knob again the output pulsed conditions transform by ON into OFF or transform by OFF into ON Operation flow as follows Step one Welding mode selection switch select TIG 4T or 2T Press the selection ...

Страница 15: ...nction is turned on the pulse pilot light L11 is on If the output pulse function is turned off the pulse pilot light L11 is off In MMA mode the pulse pilot light L11 is off All preset parameters with hold function Adjust the selection knob and select the pulse pilot LED L11 is on Press the selection knob again the pulse pilot LED L11 and digital scale display are twinkling It means the output puls...

Страница 16: ...N ARC FORCE HOT START DC TIG PULSE WELDER DISPLAY 1 Front panel 2 Operation panel 3 Shield gas connector is connected to the gas input pipe of torch 4 Connector the welder s negative polarity output 5 Aero socket is connected to torch switch control wire 3 leads 6 Connector The welder s positive polarity output ...

Страница 17: ...ulse function is turned on the output current is pulsed t2 t3 Output current slopes up to the setting current value adjustment range of up slope time 0 5 0S t3 t4 Welding process During this period the gun switch is loosen Note If the output pulse function is turned on the output current is pulsed If the output pulse function is turned off the output current is DC current t4 Repress down the gun s...

Страница 18: ...ed 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 current is DC current t3 Loosen the gun switch the output current slopes down if the output pulse function is turned on the slope down current is pulsed t3 t4 The output curre...

Страница 19: ...ten electrode and prevent tungsten clipping MMA If the electrode touches workpiece over two seconds the welding current will drop to 0 automatically to protect the electrode Automatically purify gas function When TIG welding turn on the welder and the gas valve is open to output shield gas and maintain 10 seconds Eliminate the air and purify the shield gas of the pipe 4 3 2 Striking arc way for MM...

Страница 20: ... way The operator can choose the manipulation of electrode based on welding joint sharp welding position electrode spec welding current and operation skill etc The details please refer to Welding Dictionary P69 Volume 1 of Edition 2 4 4 Welding Parameters 4 4 1 Joint forms in TIG MMA 4 4 2 The explanation of welding quality The relation of welding area color protect effect of stainless steel Weldi...

Страница 21: ... the above parameters originate from Welding Dictionary P142 Volume 1 of Edition 2 Welding current range A DC positive connection Gas nozzle diameter mm Gas flow rate L min 1 10 100 4 9 5 4 5 101 150 4 9 5 4 7 151 200 6 13 6 8 Tungsten electrode shape and the welding current range DCEP tungsten electrode diameter mm sharpened of the electrode diameter mm angle of cone background current A pulse cu...

Страница 22: ...lection The welding current reference for different electrode diameter Electrode diameter mm 1 6 2 0 2 5 3 2 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 ...

Страница 23: ...here is sufficient ventilation during welding There is at least 30cm free distance between the machine and wall 4 6 Operation Notices Read 1 carefully before attempting to use this equipment Connect the ground wire with the machine directly In case closing the power switch no load voltage may be exported Do not touch the output electrode with any part of your body Before operation no concerned peo...

Страница 24: ... 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 our company agent or the branch company Observe that whether the display value of LED is intact If the display number is not intact please replace the...

Страница 25: ...o is not authorized by our company to do any change to the equipment Maintenance course must be operated carefully If any wire becomes flexible or is misplaced it maybe potential danger to user Only professional maintenance personal who is authorized by our company could overhaul the machine Guarantee to shut off the arc welding machine s power before turn on the outline of the equipment If there ...

Страница 26: ...r or change it 7 No gas flow TIG Gas cylinder is close or gas pressure is low Open or change the gas cylinder No controlling electromagnetic valve signal Repair or change the pulse board Something in the valve Remove it Electromagnetic valve is damaged Change it 8 When welding it is hard to strike arc or easy to stick MMA Connector is loose or connection is not good Check and screw it There is oil...

Страница 27: ... stable power supply Low voltage protection Power supply fluctuates Using the stable power supply Too many machines using power supply in the same time Reduce the machines using power supply in the same time Over current protection Unusual current in the main circuit Check and repair the main circuit and drive PCB Pr2 ...

Страница 28: ...MAINTENANCE TROUBLESHOOTING 26 5 3 Electrical principle drawing Operation panel ...

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