Joint 315A/350A/400A/500A/630A

Digital inverter welding machine

Operation manual

Shanxi Nebula Welding Equipment Co., Ltd.

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3. Description of the control panel

3.1 Joint A series welding machine panel operating instructions

Figure 3.1 Joint A series welding machine operation panel

3.1.1 Choosing welding process

Press to choose welding process orderly from MMA, TIG, Pulse TIG, Spot TIG,

MIG, Pulse MIG, Double Pulse MIG and Gonging.

3.1.2 Choosing start switch function

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Press to choose start switch function orderly from 2T, 4T, S2T, S4T and spot

welding, which only work for TIG, Pulse TIG, MIG, Pulse MIG, and Double Pulse MIG

welding processes.

Job is for storing the welding parameters.

3.1.3 Choosing welding material

Press and to choose welding material and matched protect gas as following

form.

Joint A series welding machine support 13 kinds of material.

Only work for MIG, Pulse MIG, Double pulse MIG welding processes.

No. Material Protect gas Welding Wire (AWS)

1 Steel 100% CO2 Carbon Steel wire

2 Steel 80% Ar + 20% CO2 Carbon Steel wire

3 CrNi 18 8 6 98% Ar + 2% CO2 ER307 SS solid wire

4 CrNi19 9 98% Ar + 2% CO2 ER308 SS solid wire

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5 Rutil 80% Ar + 20% CO2 Acid/Rutil flux-cored wire

6 Basic 80% Ar + 20% CO2 Basic flux-cored wire

7 Metal 80% Ar + 20% CO2 Metal flux-cored wire

8 CrNi 80% Ar + 20% CO2 CrNi flux-cored wire

9 Al99.5 100% Ar ER1050 Al wire

10 AlSi 5 100% Ar ER4043 AlSi wire

11 AlMg 5 100% Ar ER5356 AlMg Wire

12 CuSi 3 100% Ar ER Cu Si wire

13 CuAl 9 100% Ar ER Cu Al wire

3.1.4 Choosing welding wire diameter

Press to choose welding wire diameter orderly from 0.8mm, 1.0mm, 1.2mm,

and 1.6mm.

Only work for MIG, Pulse MIG and Double pulse MIG welding processes.

3.1.5 Use of gas test

If you press the gas test button, the gas will flow without pressing gun trigger. Gas flow

can be measured by the CO2 or Argon flow meter. Gas flow will be stopped when

release the button.

Only work for TIG, Pulse TIG, Spot TIG, MIG, Pulse MIG and Double pulse MIG

welding processes.

3.1.6 Wire Inch

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If you press the wire inch button, the motor of the wire feeder will start run without

pressing gun trigger. The wire speed will be 3m/min but can be adjusted in startup

setting (see section 3.3).

Only work for MIG, Pulse MIG and Double pulse MIG welding processes.

3.1.7 Welding current adjustment

For MIG, Pulse MIG, Double Pulse MIG welding process, press to choose the

display value as for current, for wire feed speed, or for thickness of

plate. Turn to adjust the current (A), wire feed speed (m/min) or thickness of

plate (mm) value. Due to the built-in synergic adjustment model, anyone of

parameters (current, wire feed speed and thickness of plate) has been adjusted; the

others will be matched automatically.

For MMA, TIG, Pulse TIG, Spot TIG, Gonging welding processes, only current can

be adjusted.

3.1.8 Welding Voltage adjustment

Press to choose the display value as for voltage, for inductance/arc

force, for job and for other parameters.

When the display value is voltage, Turn to adjust the voltage value（V）.

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Only work for MIG, Pulse MIG, and Double Pulse MIG welding process.

Note : For new version, due to the synergic function, the voltage value

automatically matches with the adjusted current. So the display value is zero. But

it can be adjusted within the rang ±50% of the matched voltage value.

When the display value is inductance/arc force, Turn to adjust the

inductance/arc force value. 1) For MIG welding process: the inductance value 0 is recommended reference

range. Value less than 0 give a rougher arc and increased stability. Value greater than 0 give a smoother arc and less spatter.

2) For pulse MIG welding process: The droplet transfer force will be increased according the inductance value changed from less than 0 to greater than 0.

3) For MMA welding process: the arc force value 0 means soft and spatter small arc, value 100 means hard and stable arc.

When the display value is Job, the welding parameter can be stored and recalled.

Please refer to the details on section 3.2

3.1.9 Indicator

WORK: The indicator light when under welding process. HOLD: The indicator light when under no-load working. Error: The indicator light when the welder has some trouble wrong. Robot: The indicator light when connect with the Device net. COM:The indicator light when welding machine communicate with other

equipment.

3.1.10 Menu

The key has two purposes: store the welding parameters and startup Settings menu .

3.2 Welding parameters storage and recall

The storage capacity of Joint A series welding machine can store 100 sets of welding

parameters (Job0—Job99). The suitable welding parameters value for different welding

application can be stored at any time. Its very convenience to recall the stored welding

parameter when use it next time. No need to preset and adjust the welding parameter

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value each time before welding.

Figure 3.2 Set up storage JOB number

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.

2) Turn to adjust the Job number as 0.

3) The LED will be display the welding parameter which has been used last time.

For Job 1-99, it’s used for manual storage, Operation process as follow:

1) LED displays the welding parameters which will be stored.

2) Press to choose the display value as job.

3) Press , the front of the Job number will display "－", see Figure 3.2.

4) Turn to choose the Job number as “X”.

5) Press , the LED will display "Finished", means the parameter has been

stored to the Job number “X”.

Operation process of recall as follow:

1) Press to choose the display value as job.

2) Turn to choose the Job number as “X”.

3) The LED will be displayed the welding parameters which has been stored in

Job “X”.

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3.3 Joint A series welding machine startup Settings.

Some welding parameters of JOINT A series welding machine could be adjusted

through the startup Settings menu, and the operation process as following：

Figure 3.3 startup Settings menu

1) Press on menu key, and turn on the power switch of the machine at the same

time.

2) After few seconds, it enters the Startup Settings Menu, and LED display "Preg" as

Figure 3.3.1.

3) Press to choose , then the left part of the LED display the parameter

name, and right part of the LED display the parameter value.

4) Turn the left side to choose the parameter name, turn the right side to

adjust the parameter value.

5) Press , the LED will display "Finished", means the parameter has been reset

and stored. Then restart the machine and weld.

Adjustable parameters name of startup Settings as following:

1) Pre-gas flow time (PreG): 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.

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 welding process.

4) Inch wire feed speed (Infd) : Adjustable from 1-22 m/min. 5) Master station MACID (NetP) : Master station MACID of Devicenet: 0-63. 6) Slave station MACID (NetS) : Slave station MACID of Devicenet: 0-63. 7) Device net baud rate (Netb) : 0-125 k, 1-250 k, 2-500 k

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8) System Set 1 (Set1) : Bit0 = 1 means allow the simulation remote control, 0 means banned.

9) System Set 2 (Set2) : temporary undefined. 10) Wire feed machine coefficient (Fdp), wire feed machine constant (Fdc) :

according the different wire feed motor, setting up different coefficient. First Type, 24V, 22M/Min, 5A motor: Fdp = 400; Fdc = 426; Second Type, 24 v, 22 m, 3.5 A motor: Fdp = 371; Fdc = 400;

11) Setting up Password (Pas1, Pas2, Pas3, Pas4) : function password settings.

Figure 3.4 storage success indicator

3.4 Joint A series welding machine status display

JOINT A series welding machine can display some information and status of the welder.

After startup welding, the LED will display the company LOGO, hardware, software

version, welding process, expert database material type and whether support

DEVICENET and WIFI one by one.

Figure 3.5 Company LOGO after startup the welder

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:

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Figure 3.6 Machine internal temperature is 26℃

Figure 3.7 Hardware version for V23, software version for V1.4

Figure 3.8 Machine serial number as XY000030

Figure 3.9 Actual wire feed speed in 8.5 m/min

4. Installation, Debugging and operation

4.1 Safety Tips

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4.2 Joint A series welding machine front panel and structure

Figure 4.1 Joint A series welding machine front-panel diagram

A Current knob B Socket for Fast plug “-” C Membrane switch D TIG torch connector

E Argon gas outlet F Voltage knob

4.3 Joint A series welding machine rear panel

A B C D E F

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Figure 4.2 Joint A series welding machine rear panel diagram

A Power socket for heating CO2 regulator B Fiber converter C Analog control connector D Devicenet communication interface E Wire feeder connector F Air circuit breakers G Three-phase power lines H Argon gas inlet I Power supply socket for water tank J Power socket for water pressure switch K Socket for fast plug”+” L CO2 regulator heating fuse

B C D G E

H JK

F

L K

A

F

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Figure 4.3 MMA welding connection diagram

4.5.2 Debugging and operation for MMA

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Figure 4.4 manual welding panel diagram

Adjust the parameter as following steps 1, 2, 3.

1. Use welding process buttons to select MMA welding method. 2. Twist the knob A to adjust the current. 3. Twist Knob M to set the arc force. 4. Begin to weld All the parameters in steps 1.2.3 could be saved automatically when the machine is working and remain the same even if the machine is killed halfway. The MMA welding has seven adjustable parameters: 1. Current: The range (10A ~ rated current) is welding current, please choose the proper

current according to welding technology.

2. Arc force: 1 ~ 100, refers to the slop of current rise in the process of short circuit. It should be settled based on electrode diameter, set current value and welding procedure requirements. The stronger arc force, the faster droplets, the less sticking. However, too strong arc force would increase splashes. The weaker arc force, the lower splashes, the better welding seam, but sometimes, people feel that the arc is soft or cause sticking. So the

Knob A Knob M

MMA

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arc force should be increased when use wide electrode rod (4mm) with small current (120A). The arc force should be 10~50 in general.

3. Hot starting arc current (HotI) : 0 ~ 100%, 20 refers to Hot starting arc current = welding current + 20% * welding current.

The hot starting arc time (Hott) : 0 ~ 1.5 s, refers to the duration of Hot starting arc time. In order to strike arc successfully, the welder would output a high current as striking current, the duration of striking current is determined by the ignition time. The two parameters 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.

4. External characteristics (Slop)

In order to fit different kinds of electrodes, the MMA welding machine own adjustable

external characteristics curve. Adjust the SLOP to change external characteristics.

CC: constant-current characteristic. Arcing current is constant, independent of the welding voltage. Adapted to acid electrode, basic electrode and groove weld.. 1-20 is decreasing characteristic of adjustable slope, the lower the voltage, the greater the current. 20 represents the voltage drops each 1V, the current increases 20A. Adapted to the cellulose electrodes. CP: Constant power characteristics: Output power (I × V) remains the same, especially for cellulose electrodes.

5. Arc-break adjustment

It is for snapping the arc easily when intermittent welding. It can be set as 30V、40V、50V、

60V,The greater the value, the more difficult to pull off the arc, the parameter should be off

when continuous welding.

6. Anti-sticking function (Felt)

When it is on, it can prevent red and failure electrodes caused by striking. The machine

would stop till the striky electrode is away from workpiece. Then the machine would continue

to work.

7. VRD function (VRD)

There are ON and OFF available for VRD function. When it is ON, the main circuit would not work under welder not welding. Only output less than 12V voltage. It can not only avoid no-load voltage injury, but also save electrical energy, reduce noise and increase the life-span.

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4.6 Installation, debugging and operation for TIG/PULSE TIG/SPOT TIG.

4.6.1 Installation of the TIG, Pulse TIG, Spot TIG

1. Connect the TIG torch to the Negative output of the welding machine, insert the plug of the torch to the socket of the TIG torch on the front panel, and connect the Air connector of the TIG torch to the Valve seat on the front panel.

2. Connect the earth wire to the positive output, and Clamp the workpiece with the earth clamp.

3. Connect the Inlet nozzle on the back panel and Argon flow meter with air tube, then open the Cylinder valve.

4. Connect the input power wires as figure 4.5 shown, and turn on the power switch. Note: Be ensure that the welder positive and negative output terminals are

connected reliably; otherwise the outputs will be burned due to the heating of

joint!

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Figure4.5 TIG welding connection diagram

4.6.2 Debugging and operation of TIG/PULSE TIG/SPOT TIG

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Figure 4.6 TIG welding control panel

Adjust the parameter as following steps 1, 2, 3.

1. Use welding process button to select TIG welding method.

2. Twist knob A to adjust welding current.

3. Select the suitable operation mode by the welding process button.

4. Adjust the gas-flow rate of the cylinder after pressing the gas check button.

5. Start welding

All the parameters in steps 1.2.3 could be saved automatically when the machine is working and

remain the same even if the machine is killed halfway.

There are total 13 adjustable parameters for TIG (DC TIG, PULSE TIG, and SPOT TIG)

1.Current: 2～Rated Current

The welding current of DC TIG and Spot TIG, the peak current of the Pulse TIG, please adjust

the suitable current according to the welding technology.

2. Operation Mode:

TIG operation is the operation mode, which use the torch switch to control the welding current

during working of DC TIG and PULSE TIG. There are 5 ways for TIG welding, including 2T, 4T,

Knob A Knob M

welding process

PULSE

TIG SPOT

TIG

TIG

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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

①Press the on/off button, arc strike and upslope ②Loose the on/off button, down slop and arc quench ③If press the on/off button again before arc quenching, it will continue up sloping to the settled parameter, and turn to ②

4T

① Press the on/off button, arc strike and upslope ②Re-press the on/off button, down slop and arc quench

S2T

① Press the on/off button, arc strike and upslope to initial current HotI ②Last Hott time, then down slope to the set current ③Loose the on/off button, down slop to end current EndI ④Last Endt time, then quench arc

S4T

① Press the on/off button, arc strike and upslope to initial current HotI ② Loose the on/off button, down slop to set current ③Re-press the on/off button ,down slop to end current EndI ④Loose the on/off button, quench arc

Spot welding

① Press the on/off button, strike arc to set value ②Last spot time, quench arc.

sptt

Note: graphic means pressing on/off button of the TIG torch, means loosing the on/off

button of the TIG torch, means pressing the on/off button once (press, then loose)

Table 4.1 the operation mode of TIG welding

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3.Upslope time(SLPU): 0～15s

The upslope time means the time, which the current from 0 to set current, it should be set

according to the technological requirements

4.Downslope time(SLPD):0～15s

The downslope time means the time, which the current from the set current to 0, it should be

set according to the technological requirements

5. Arc strike mode(HF): the welder provide two arc strike modes including lift (HF) arc strike and

contact arc strike.

6.End current(EndI):0～200%, it means the percent of the set current, it is used for filling the

crater.

7.Initial current(HotI):0～200%, it means the percent of the set current.

The initial current is the current after arc ignition; it should be set according to the

technological requirements. The higher initial current, the easier arc striking, but it is 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 init ial current, in order to

heat up the workpiece or lighting.

8. Initial time (Hott): it means the last time of the initial current, it is only valid in the S2T.

9. End time (Endt): it means the duration of the end current, it is only valid in the S2T.

10.Spot time: 0.1～2s

Spot welding time is the time of the SPOT TIG; it should be confirmed according to the

technological requirements.

11. Base current: it is the base current of the PULSE TIG, the peak current is the set current

12. Duty ratio: it is the ratio of the peak time and cycle in the Pulse TIG.

13. Frequency: it is the frequency of the pulse TIG. These three parameters are for the PULSE

TIG only, see the diagram below:

Figure 4-9 Current curve of PULSE TIG

In the figure the I1 is initial current, IB is base current, IP is peak current(set current), I2 is end

current. T1 is upslope time, T2 is downslope time. TP is the duration of the peak current, TB is

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the duration of the base current, TP+TB is the pulse cycle, the pulse frequency is the c reciprocal

of the cycle: 1/(TP+TB), the duty ratio is the percentage of the duration of peak current in the

pulse cycle: 100*TP/(TP+TB), changing the pulse frequency and duty ratio could adjust the TP

and TB value.

4.7 Installation, debugging and operation for MIG/PULSE MIG/DOUBLE PULSE

MIG.

4.7.1The installation of MIG, PULSE MIG&DOUBLE PULSE MIG 1. Connect the combined cable to the positive output of the welder and the socket of control cable, and the other sides connect to the wire feeder. 2. Connect the earth cable to the negative output of the welder, and clamp the workpiece with the earth clamp. 3. Please insert the power line of the gas heater into the socket of heater power on the back panel, if use CO2 regulator. 4. Insert the gas tube to the air inlet of the wire feeder, the other side to the Vacuum meter of the gas cylinder 5. Connect the power line according to figure 4.5, turn on the switch. After finishing the above work, the MIG welding is done now, put on the welding wire

according to the instruction of wire feeder and welding torch in chapter 8, connect the

power, close the breaker on the back panel, adjust the welding parameters, open the gas

valve then start welding.

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Figure 4.7 Connection diagram of the MIG welding

4.7.2 The debugging and operation of MIG, PULSE MIG&DOUBLE PULSE MIG

Press welding process button to choose (MIG, PULSE MIG or double pulse mig), then

adjust the other parameters.

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Figure4.8 Control panel of MIG welding

The adjustable parameter of MIG welding and PULSE MIG welding

1. Current, wire feed speed and thickness: these three parameters are linked, if you adjust one of them, the others will be matched automatically due to there is a Highly intelligent expert database in welding machine.The user just need to select the welding process, operation mode, type of material, wire diameter and any one of (current, wire speed, thickness), the machine will find the best combinated parameters from the expert database.

2. 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.

3. 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: Get hard and steady arc, =0: medium arc, >0: soft arc, small splash

Pulse MIG: <0: Reduce the droplet transfer force, =0: medium droplet transfer

force,>0:increase the droplet transfer force

4. Type of material: the user could select the suitable type of material according to the base

metal dand welding wire, details in section 4.10 (expert database of MIG, PULSE MIG, &

DOUBLE PULSE MIG).

5. Wire diameter: setting the diameter directly according to the actual used welding wire.

6. Operation mode: there are 5 kinds of torch operation mode as following diagram:

Knob A Knob M

MIG PULSE MIG DOUBLE

PULSE MIG

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Note: Arrow means press the on/off button of gun, means loose the on/off button,

means press on the on/off button. Figure 4.9 2T Operation mode

Note: Arrow means press the on/off button of gun, means loose the on/off button. Figure 4.10 4T Operation mode

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Figure 4.11 S2T Operation mode

Note: Arrow means press the on/off button of gun, means loose the on/off button,

mean press on the on/off button. Figure 4.12 S4T Operation mode

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Note: Arrow means press the on/off button of gun, means loose the on/off button.

Figure 4.13 Spot Welding operation mode

7. End current(EndI): as figures shown, its function is to fill the crater.

8. Initial current(HotI) : as figures shown, its function is to increase the heat input when start to

weld and avoid the welding defects during the arc strike.

9. Burn time: it is to adjust the effect of ball cutting when finish welding.

10. Spot time(Sptt): the duration of the spot welding.

11. Initial time(Hott): the duration of the initial current, it is only suitable for S2T.

12. End time(Endt): the duration of the end current, it is only suitable for S2T.

13. Slop time(SLOP): the switching time between two currents, such as the initial current and

welding current.

14. Double pulse frequency (Freq): as figures shown

15. The arc length of double pulse (AL2): as figures shown, it is the High arc length value of the

double pulse MIG, The lowe arc length decided by corresponding arc in the indicator lamp I

16. The scope of the double pulse(Fd2) , as 4.17 figures shown, it is the rangeability of wire

speed for double pulse.

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Note: Arrow means press the on/off button of gun, means loose the on/off button,

mean press on the on/off button. Figure 4.14Diagram of Double pulse MIG

4.8 The details of expert database for MIG, Pulse MIG and double pulse MIG

Serial

No.

material AWS

specification Protective gas

welding

machine

series

1 Steel:G 3/4 Si 1 CO2% F,G,H,J

2 AlMg4,5Mg ER5083 Ar+50%He H

3 AlSi 5 ER4043 Ar 100% F,G,H,J

4 AlMg 5 ER5356 Ar 100% F,G,H,J

5 Al99.5 ER1050 Ar 100% F,G,H,J

6 AlSi12 ER4047 Ar 100% H

7 CuAl 9 ER Cu Al Ar 100% F,G,H,J

8 CuSi 3 ER Cu Si Ar 100% F,G,H,J

9 NiCr 21 Mo 9 Nb ER NiCrMo Ar 100% H

10 CrNi 18 8 6 ER307 Ar 97.5% CO2 2.5% F,G,H,J

11 CrNi19 9 ER308 Ar 97.5% CO2 2.5% F,G,H,J

12 CrNi 22 12 ER 309 Ar 97.5% CO2 2.5% H

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13 CrNi 25 20 ER 310 Ar 97.5% CO2 2.5% H

14 CrNi 19 12 3 ER 316 Ar 97.5% CO2 2.5% H

15 CrNi 13 4 ER 410 Ar 97.5% CO2 2.5% H

16 CrNb 16 ER 430 Ar 97.5% CO2 2.5% H

17 CrNi 22 9 ER 2209 Ar 82% CO2 18% H

18 CrNi 19 12 3 ER 316 Ar 82% CO2 18% H

19 CrNi 13 4 ER 410 Ar 82% CO2 18% H

20 CrNi Flux cored Ar 82% CO2 18% F,G,H,J

21 Rutil Flux cored Ar 82% CO2 18% F,G,H,J

22 Basic Flux cored Ar 82% CO2 18% F,G,H,J

23 Metal Flux core Ar 82% CO2 18% F,G,H,J

24 Steel:G 3/4 Si 1 Ar 82% CO2 18% F,G,H,J

25 Hard facing Ar 82% CO2 18% H Table 4.2 the details of expert database

4.9 Installation, debugging and operation of Carbon Arc gouging

Figure 4.15 The connection of carbon arc gouging diagram As figure 4.18 shown

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1. Connect the earth cable to the negative output of the welding machine. 2. Connect the torch to the positive output of the welding machine, and connect the compressed air. 3. Connect the power line and turn on the switch

Figure 4.16 control panel of carbon arc gouging

Select the Carbon arc gouging, adjust the current, turn on the compressed air, then start to

work.

4.10 Alarming

When the welding machine is over heating, it would stop and display “Over Temp”, as figure 4.20 shown. The “Over Temp” would disappear and resume to work after cooling.

Figure 4.17 Over-heating alarm(welder temperature is higher than set temperature value)

Knob A Knob M

carbon arc

airair

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Figure 4.18 Over-current alarm(welder primary current is too large)

Figure 4.19 the master control panel data is uninitialized(The procedure of master control panel is uninitialized)

Figure 4.20 No water alarm(water-cycling system is failure)

Figure 4.21 Lack phase alarm(Three phase input voltage lack phase)

Figure 4.22 Over-voltage alarm(three phase input voltage is too high)

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Figure 4.23 Low-voltage alarm(three phase input voltage is too low)

Figure 4.27 Over-current of the wire feeder alarm(the resistance of the wire feeder is too high)

5. Upgrade software and add functions

5.1 software upgrade

It is the most important advantage that the software can be upgraded for digital 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”

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a, Long press this button and turn on the switch.

b, Press the , Make it on “More”

c, Twist the button on the left. You will find Pas 1, Pas 2,Pas 3, Pas4.(See below pictures)

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d, Twist the button on the right to make the numbers the same as the codes.

e, Press the button again. The screen would show “Finished”. Turn off the switch. Note: The softdog and password need to buy from sellers. Please contact the vendor.

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6. Care and Maintenance

Caution! 1.Do not open the welder case except for professional electrician. 2. Please turn off the welding machine and cut the power before you open the case.

Warning! A n e le c t r i c sho ck ma y be hu r t ev en

f a ta l .

Do not touch the electrified device. Please turn off the welding machine and cut the power before you open

the case.

Note! 转 Turning fan may hurt your body.

Do not close to the turning fan blade. Fix the case before starting up.

1

2

Do not place the welder under the blazing sun for quite a long time. Don’t place the welder under the blazing sun when it is working.

Do not place the welder in the rain. Do not use or deposit the machines in moist environment.。

3

4

nsure that the ventilation holes are not

covered when the welder is working. Welding machines should be used and

Stored in drafty condition

Open the case every six months at least, clean the inside dust and swarf by dry compressed air cleaning machine or vacuum cleaner.

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Make regular inspection for all insulation sleeves, repair or replace new one if damaged.

Make regular inspection for all electric connection parts, and fastening the loose parts. Please take care of all equipments in case they are damaged Open the case by professional electrician. When maintaining the welder, the users must dismantle the 3-phase cable from

distribution box.

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7. Overall wiring diagram

Diagram 7.1 Overall wiring diagram

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8. Instruction of wire feeder

8.1 General remarks

NSA-60 is a closed digital wire feeder, it has speed feedback closed-loop control, can ensure veracity and stationary of wire feed speed, the current and voltage can be adjusted with welding machine at the same time, also the actual current and voltage can be showed on display anytime. It is widely used for the welding of carbon steel, aluminum, copper, stainless steel and flux-cored wire

8.2 Technical data

Model and specifications of motor: 24V, 22m, 5A wire-wound motor Voltage of solenoid valve: DC 24V Range of wire feed speed: 1.5m/min~22m/min Adaptable wire diameter: φ0.8、φ1.0、φ1.2、φ1.6 Adaptable wire reel: diameter of axle: φ50 maximum outside diameter: φ300

width: 103 maximum weight: 20kg Size: length* width * height 485mm×200mm×280mm Net weight: 10.5kg

8.3 Install the Wire feeder

According to the MIG welding connection, connect air tube, control cable and welding cable reliably, also can choose extended cable of 10m, 15m, 20m to extend welding range.

Note: 1.The wire feeder cannot be moved by drag welding gun, cable and air tube.

2. Please turn off the valve when connecting the air tube or do not welding.

Warning: when gas is aspirating continuously in the bad environment, asphyxia maybe

caused by oxygen deficit.

8.4 Installation of welding wire

1. Open the shroud, uplift the hand shank of pressure wire steel. 2. Confirm whether the inlet nozzle adapt for the welding wire, plastic nozzle for aluminum wire, steel nozzle for steel welding wire. 3. Confirm whether the guide wire tube suitable for welding wire, steel guide wire tube for steel welding wire, take off the steel guide wire tube when using aluminum wire, instead by Teflon wire tube or carbon fiber tube. Confirm whether the wire feed rolls suitable for welding wire, U rolls for aluminum welding wire, V rolls for steel and stainless steel welding wire.

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After installation, keep wire feed rolls (groove), inlet nozzle, middle nozzle, utter nozzle in a

straight line.

4. Install the wire reel, install the wire reel on wire reel axis,assemble the catch of wire reel axis, tighten up the screw of handle. 5. Across the welding wire through inlet nozzle, middle nozzle, utter nozzle in order, then reaching to the welding torch. When installing the welding wire, please avoid the welding wire pop up to injury people. 6. Reset the antifriction bearing wheel and pressure regulating handle, exert pressing force, pressing force can be adjusted by turn the handle. When the wire is not slipped, please decrease pressing force. 7. Switch on the power supply, press the “checking wire button on wire feeder, inch the wire feed by manual operation, until 15-20mm wire revealed in the head of torch. Contact tube can be removed when necessary, fix it again after the wire crossing out. Note: wire feed speed cannot be too quick by manual operation, or thin welding wire will be bending easily. Warning: don’t close to contact tube to check whether welding wire is outing. Please cut off the power source after using machine.

8.5 The maintenance and overhaul of welding torch and wire feeder

Warning: the maintenance and overhaul must be conducted under the condition of shut off the distribution box and ensure security. Otherwise, it may cause some major accident such as electric shock, burn and run over. In order to make the most advantage of the machine, to ensure safe and normal operation, the daily maintenance and overhaul is very important. Daily maintenance and overhaul should focus on the abrade and deformation of some spare parts in the welding torch & wire feeder, also the blocking of diverter, do the cleaning and changing when necessary. The part and point need to be examined successively are as follows: Parts for

check the contents for check remarks

Welding torch

nozzles

Whether the installation is firm, the front-end deformation

The reason for causing gas hole

Whether the splash is adhering

The reason of welding torch burning out(the effective method is to use Anti-spatter compound)

Contact tip Whether the installation is firm，

The reason for the damage of welding torch’s thread

The condition of the tip damage, abrasion and blocking of the hole

The reason of Arc unstable or breaking

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Wire feeding hose

Size of wire feeding hose

Short wire feeding hose may lead to wire feeding unstable (select the suitable wire feeder hose to replace)

Whether the wire diameter fit for the inner diameter of wire feed hose

Do not coincide is the cause to unstable arc

Dirt inside the hose, blocking of welding wire residue

May lead to bad wire feeding and unstable arc (clean or change new wire feeding hose)

Partial buckling May lead to bad wire feeding and unstable arc( renew new wire feeding hose)

Damage of wire feeder hose Replace new hose Abrasion of the o-circle Renew

Wire feeder

Pressure regulating handle

Over pressure（damage the welding wire) Wire feeding and electric arc unstable

Wire enter hose Wire guiding hose Wire output hose

Weather fit the welding wire or not( distinguish aluminum wire and steel wire)

Produce chip & scrap, abnormal abrasion of wire enter hose Wire feeding and electric arc unstable

Whether the hose center fit for groove center of wire feeder rolls

Dislocation may cause the production of chip & scrap and unstable electric arc

Whether powder and sweeps stocked in nozzle

Clear chip & scrap, sweeps, find out the reason then exclude it

Wire feed rolls

Whether the welding wire diameter fit for nominal diameter of wire feeder rolls

Result in the production of powder, blocking of wire feed hose and unstable electric arc An exception happened, replace with a new one

Groove of wire feed rolls blocked or not

Antifriction bearing rolls

Damaged or not Result in wire feed and electric arc unstable

cable Whether the connection is reliable and firm

The insulation part is broken or not If there’s disconnection or not

Prevent leakage, ensure safety

Diagram 5.1 maintenance and overhaul of welding torch and wire feeder

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8.6 Exception of early diagnosis

When some abnormal phenomena happened, such as unable to weld, unstable electric arc and bad welding performance don’t make the judgment of fault earlier. Sometimes, the welding machine is work normally, but some external reasons may cause above problems. For example, fusing of fuse tube, tight parts come loose, forget switch, setting wrong parameters, disconnected cable, tracheal rupture and effect of base metal’s surface etc. Before you make the judgment of fault and repair, please first check it, most problems can be solved easily. Regarding the welding torch and wire feeder, please check and maintain according to the diagram.

Diagram 5.2 initial diagnosis of abnormal welding Abnormal items Overhaul parts and repair items

can not ignite the arc

Shield

gas can

not flow out

Do not send w

ire

Igniting the

arc hardly

Arc not stable

Weld edge unclean

Adhesive base metal

and welding w

ire

Adhesive welding w

ire and contact tip

Appear gas hole

Wire feeder

Too tight or loose of pressure regulation handle

Powder stored in the nozzle of wire guide tube Abrasion and blocking of wire feed rolls

●

●

●

●

●

Welding

torch

Too large bending of welding torch cable Adaptability, abrasion, blocking and deformation of contact tip and wire feed tube

●

●

●

●

loose of contact tip, nozzle and nozzle’s joint Bad insertion and fastening of welding gun’s joint

●

●

Disconnected welding torch cable and switch control cable(flexural fatigue, crushing)

● ● ● ● ●

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9.Welding machine structure diagram

9.1 Joint A series welding machine structure diagram

Diagram 9.1 welding machine structure diagram (1)

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Diagram 9.1 welding machine structure diagram (2)

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Diagram 9.1 welding machine structure diagram (3)

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9.2Combined welding achinestructure diagram

Diagram 9.2 combined welding machine structure diagram

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9.3 Installation of combined welding machine

Diagram 9.3 installation diagram of combined welding machine

Installation steps 1. Fix water cooler to trolley through connecting piece II. 2. Fix power source to trolley through connecting piece I. 3. Fix the trolley connection plate and wire feeder support plate through the screw. 4. Fix the wire feeder to cone.

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9.4 Water cooling structure diagram

Figure9.4 Water cooling structure diagram

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9.5 Wire feeder structure diagram

Diagram 9.5 wire feeder structure diagram

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9.6 Spare parts code list

Table 9.1 Spare parts name code list

Number

Spare parts number

Spare parts name

Number

Spare parts number

Spare parts name

1 03.03.0008 toroidal transformer 41 350201 magnet ring

2 02.03.0131 commutation inductance

42 350203 magnet ring

3 backboard 43 0377021 membrane switch 4 290031 44 0379000 power socket 5 290032 center septum 中心隔 45 0379002 aviation plug with base 6 290036 paster 贴纸 46 0379006 power socket 7 290037 front display panel 47 0379014 aviation plug 8 290038 middle board 48 0379040 aviation plug

9 290039 magnet ting II back-up plate

49 0379051 fast plug(red)

10 290041 back-up plate 50 0379052 fast plug (black) 11 290044 upper cover plate 51 0040301 shunt 12 290045 discharger base plate 52 0004113 NYL 13 290046 back-wheel support

53 0460012 power line 14 290047 axis 54 0490000 coil 15 290048 base plate of diode 55 0490001 coil

16 290049 antenna connector 56 0860055 master control board of 500F

17 290050 side metal plate 57 9900003 plastic panel 18 290051 support of breaker 58 B000028 500semi-finished diode 19 290052 back metal plate 59 B500F01 syntonic inductance 20 290053 front metal plate 60 B500F02 500Fdriver board 21 290056 upper cover plate 61 B500F07 500Freactor

22 290057 4-star electrical support

62 B500F12 filter inductance

23 290058 back display board 63 B500F09 input current common mode choke

24 290063 Accessories of wire feeder support plate

64 B000054 PCB 4 board

25 290067 sensor platen 65 B833003 PCB 3 board 26 0291000 breaker 66 B500F05 generator transformer

27 292001 magnet ring I back-up

67 FF75R12RT4

IGBT

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28 292004 fan support 68 920054 temperature controller

29 292010 magnet ring II back-up

69 0600001 components of base board

30 292022 IGBT radiator 70 0600002 inside insulation board

31 0293002 fuse 71 0600003 wire plate fixed components

32 294003 fuse base 72 0600004 welding torch flapper

33 0293004 fuse 73 0600005 front cover

34 0293005 fuse base 74 0600006 left cover components

35 2930011 main transformer bracket

75 0600007 right cover

36 294003 air cock base 76 0600008 inside riser 37 0297001 temperature sensor 77 0290000 solenoid valve

38 0303100 3 phase rectifier 78 294003 air cork base

39 342228 diode radiator 79

0350209 magnet

40 0343000 fan 80

0353001 pipe clamp

Continued table 9.1

Num

ber

Spare parts

number Spare parts name

Nu

mb

er

Spare parts

number Spare parts name

81 0353003 pipe joint 114 0800106 nut 82 0353004 pipe joint 115 0800108 nut 83 0354004 PU air tube 116 0890003 rubber gloves

84 0352001 front joint of water tank

117 9100035 handle

85 0352003 joint of water tube 118 BSB5001 remote control board

86 0352004 joint of water tube 119 0004065 right angle strain relief bushing

87 0360302 connector 120 0087001 weld assembly of baseboard

88 0360304 connector 121 0087002 upper cover plate 89 0362002 terminal 122 0087003 inside metal plate

90 0370017 OT terminal 123 0087004 support of kettle fixed

91 0376020 NSA-40knob 124 0087005 motor support 92 0376002 button 125 01000005 kettle 93 0377022 membrane switch 126 01000006 water pump

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94 0379003 nine-core socket 127 0342216 cooling fin

95 0379010 nine-core plug 128 0352001 front joint of water tank

96 0379033 fast plug (black) 129 0353001 pipe clamp 97 0004006 Wire box 130

0372000 4m2 plug reed

98 0004014 Wire axis 131 0376023 rocker

99 0004041 hole plugs 132 0377010 water flow switch

100 0004043 motor 133 0379015 aviation plug( with head)

101 0004048 hole plugs 134 0379019 aviation plug( with head)

102 0004115 hinge 135 0460020 380V power line

103 0460000 cable 136 0650508 screw of 6 flower inside

104 0490003 coil 137 0720510 combined screw 105 0490901 (PEF) 138 9900011 plastic panel

106 0005200 European copper head

139 800201 accessories of

base board

107 0005202 flanged housing 140 800202 accessories of stand board

108 0600305 brass stud 141 800203 axis

109 0600310 screw 142 800204 front-wheel

support 110 0720510 combined screw 143 800205 connect plate 111 0720512 combined screw 144 800206 connector I 112 0800104 nut 145 800207 connector II 113 0800105 nut 146