INVERTER WELDER OPERATOR S MANUAL ARC200D(Z225)/ARC250D(Z226)/ARC250(Z227)

Transcription

1 INVERTER WELDER OPERATOR S MANUAL MODEL: ARC0(Z69)/ ARC00(Z0)/ARC00(Z76) ARC00D(Z5)/ARC50D(Z6)/ARC50(Z7)

2

3 FORWARD SHENZHEN JASIC TECHNOLOGY CO., LTD. Address: No., Qinglan st Road, Pingshan District, Shenzhen, Guangdong, China Postcode: 588 Fax: Tel: Website: sales jasictech.com Version: A0

4 SAFETY Precautions for installation Beware of electric shock! Install grounding device according to application standard. Do not touch live parts with naked skin, wet gloves or wet clothes. Be sure you are insulated from ground and workpiece. Cover the cover plate of the machine before power on to avoid an electric shock. Confirm the safety of your working position. Beware of fire hazard! Please install the machine on non-combustible materials to avoid a fire. Make ensure there are no inflammables near the welding position to avoid a fire. Beware of explosion! Do not install the machine in an environment with explosive gas to avoid an explosion. Replacing the components can be dangerous. Only professionals can replace the components of the machine. Make sure there are no foreign bodies such as wire leads, screws, gaskets and metal bars falling into the machine inside when replacing the components. Make sure the connecting wires inside the machine are correctly connected after replacing the PCBs, and then the machine can be run. Otherwise, there is a risk of damage to property.

5 Precautions for operation Precautions for discard Smoke-may be harmful to your health! Keep your head away from the smoke to avoid inhalation of waste gas in welding. Keep the working environment well ventilated with exhaust or ventilation equipment when welding. Arc radiation-may hurt your eyes and burn your skin! Use proper welding mask and wear protective clothing to protect your eyes and body. Use proper mask or curtain to protect onlooker from being injured. Magnetic field can make cardiac pacemaker a bit wonky! People with cardiac pacemaker should consult the doctor before carrying out welding. Stay away from the welding source to reduce the affect of magnetic filed. Improper use and operation may result in a fire or an explosion! Welding spark may result in a fire, so please make ensure there are no inflammables near the welding position, and pay attention to fire safety. Ensure there is fire extinguisher nearby, and make sure someone has been trained to operate the fire extinguisher. Do not weld closed container. Do not use this machine for pipe thawing. Hot workpiece can cause severe scald! Do not touch hot workpiece with bare hands. Cool the welding torch for a while after continuously working. Excessive noise does great harm to people s hearing! Wear ear covers or other hearing protectors when welding. Give warning to onlooker that noise may be potentially hazardous to hearing. Moving parts may injure your body! Please keep away from moving parts (like fan). Each door, panel, cover, baffle plate, and protective device the like should be closed and located correctly. Seek professional support when trouble strikes! When trouble strikes in installation and operation, please inspect according to related contents in this manual. If you still cannot understand fully, or you still cannot solve the problem, please contact the dealer or the service center of JASIC to obtain professional support. Pay attention to the following when discarding the welding machine: Burning the electrolytic capacitors in the main circuit or on the PCBs may cause an explosion. Burning the plastic parts such as the front panel may produce poisonous gas. Dispose it as industrial waste.

6 TABLE OF CONTENTS

7 . Model coding. GENERAL DESCRIPTION ARC XXX X (XXXX). Technical parameters Product code Vacancy: single voltage D: double voltage Code for rated output current Inverter DC MMA welder Figure -: Model coding. GENERAL DESCRIPTION Table -: General technical parameters Items Rated input power supply Rated input capacity ( KVA) Rated input power (KW) ARC0 (Z69) ARC00 (Z0) ARC00 (Z76) Single-phase AC0V 50Hz Models ARC00D(Z5) Single-phase Single-phase AC0V 50Hz AC80V 50Hz ARC50D(Z6) Single-phase AC0V 50Hz ARC50 (Z7) Single-phase -phase AC80V 50Hz AC80V 50Hz Rated input current(a) Rated output (A/V) No-load voltage(v) 0/5.6 70/6.8 00/8.0 60/6. 00/8.0 80/7. 0/9. 50/ Welding current range (A) 0~ 0 0~ 70 0~ 00 0~60 0~ 00 0~ 80 0~ 0 0~ 50 Arc force current range(a) 0~ 00 0~ 60 0~ 60 0~ 60 Cooling mode Air cooling Rated duty cycle(%) 0% 0% 0% 0% 0% 0% Insulation grade F Enclosure ingress protection IPS Power factor Efficiency (%)

8 Z0. Size and weight Table -: Overall size and weight of the machine. GENERAL DESCRIPTION Model Overall size (L*W*H) Weight( Kg) ARC0 (Z69) ARC00 (Z0) ARC00 (Z76) ARC00D (Z5) ARC50D (Z6) ARC50 (Z7) * * 56 0* 68* 0* 68* 0* 68* 0* 68* 0* 68* H W L L OC H W Figure -: Appearance and size of the machine ( Unit: mm)

9 . Composition and configuration of the welding machine system ) Composition. GENERAL 第一章 DESCRIPTION 产品概述 Figure -: Composition of the welding machine system ) Configuration Table -: Configuration of ARC00 ( Z69) Name Welding machine Quick plug Operator s manual Material code Specification Quantity ( pcs) Remark ARC0 (Z69) DKJ6-5(black) ARC series Table -: Configuration of ARC00 (Z0) Name Welding machine Quick plug Operator s manual Material code Specification Quantity ( pcs) Remark ARC00 (Z0) DKJ5-50(black) ARC series Table -5: Configuration of ARC00 (Z76) Name Welding machine Quick plug Operator s manual Material code Specification Quantity ( pcs) Remark ARC00(Z76) DKJ5-50(black) ARC series

10 Table -6: Configuration of ARC00D (Z 5). GENERAL DESCRIPTION Name Welding machine Quick plug Operator s manual Name Welding machine Quick plug Operator s manual Name Welding machine Quick plug Operator s manual Material code Specification Quantity ( pcs) Remark Material code ARC00D(Z5) ARC series Table -7: Configuration of ARC50D (Z 6) ARC50D(Z6) Table -8: Configuration of ARC50 (Z 7) Material code DKJ5-50(black) ARC50(Z7) Specification Quantity ( pcs) Remark DKJ5-50(black) ARC series Specification Quantity ( pcs) Remark DKJ5-50(black) ARC series.5 Functions and characteristics of the welding machine ARC series are inverter welding machines made by our company with advanced inverter technology. These machines are mature models and with stable performance. This series includes several single-voltage and double-voltage models. Advanced VMOS or IGBT inverter technology High inverter frequency greatly reduces the volume and weight of the welding machine. Great reduction in magnetic and resistance loss obviously enhances the welding efficiency and energy saving effect. Working frequency is beyond audiorange, which almost eliminates noise pollution. Leading control mode Advanced control technology meets various welding applications and greatly improves the welding performance It can be widely used in acid and basic electrode welding. Easy arc ignition, little spatter, stable current and good shaping. Common characteristics of MMA welding machines Portable, energy saving, with excellent dynamic characteristics and high efficiency, stable arc, molten pool easy to control, higher no-load voltage, better compensation of power and arc force, able to meet various welding requirements, applicable to aerial work, field work, indoor and outdoor decoration, etc. Characteristics of double-voltage models It adopts automatic switching mode for voltage. Unique circuit design prolongs the service life of the capacitor and IGBT. New air duct design balances the temperature inside the machine and prolongs the service life of the components and machine.

11 .6 System characteristics ) Duty cycle q(%) ARC0(Z69) ARC00(Z0) ARC00D(Z5) ARC00(Z76) ARC50D(Z6) ARC50(Z77). GENERAL DESCRIPTION I(A) Figure -5: Duty cycle ) Output characteristics U(V) U0 External characteristic of maximum output External characteristic of minimum output Relationship with ratedload I(A) Figure -6: Output characteristic curves 5

12 . INSTALLATION AND CONNECTION. INSTALLATION AND CONNECTION. Installation requirements ) Connection of input cable In order to ensure personal safety and avoid electric shock, please ground the machine reliably by connecting the ground wire (yellow-green wire) of the machine to the grounding device in the switching box. A primary power supply cable is available for this welding machine. Connect the power supply cable to the rated input power. The primary cable should be tightly connected to the correct socket to avoid oxidization. Check whether the voltage value varies in acceptable range with a multi-meter. The cross section of the leads used in the switching box should meet the requirements of the maximum input capacity of the machine. ) Connection of output cable Insert the plugs with the cable of the electrode holder and the cable of the earth clamp respectively into the quick sockets on the front panel of the machine, and tighten them to clockwise. Operator can choose DCEN connection according to workpiece and electrode application requirement. Generally, DCEP connection is recommended for basic electrode, while there is no special requirement for acid electrode. DCEN: Connect the electrode holder to - output terminal, and the workpiece to + output terminal. DCEP: Connect the electrode holder to + output terminal, and the work clamp to - output terminal. ) Connection of welding instruments 5 Figure -: Connection of output cable Output cable Rubber sleeve Copper sleeve Bolt 5 Copper connector Figure -: Connection of quick plug 5 Output cable Rubber sleeve Copper sleeve Bolt 5 Electrode holder Figure -: Connection of electrode holder 5 Output cable Copper clip Bolt Nut 5 Iron clip Figure -: Connection of earth clamp 6

13 ) Preset the welding current according to the type and size of the electrode, clip the electrode and then welding can be carried out by short circuit arc starting. For welding parameters, please refer to the table below. Table -: Welding parameters table (for reference only) Electrode dia. (mm) Recommended welding current (A) Recommended welding voltage (V).0 0 ~ ~..6 ~ 8.76 ~ ~ 00. ~ ~ 0. ~ ~ 8. ~ ~ 80.6 ~ ~ 0 0 ~ ~ ~ 0. Note: This table is suitable for mild steel welding. For other materials, consult related materials and welding process for reference.. Precautions. INSTALLATION AND CONNECTION 7

14 . OPERATION. Operation method. OPERATION. Panel functions of ARC0 (Z69) No. Part name Function Power indicator To indicate the machine is powered on when it illuminates. 0 + output terminal To connect the welding output cable. Overheating indicator To indicate the temperature inside the machine is too high and the machine is under overheating protection status when it illuminates. 5 5 Current control knob - output terminal To adjust the output current value. To connect the welding output cable. Figure -: Front panel of Z69 No. Part name Function Power switch Cable Cooling fan To control the ON/OFF of the input power of the machine. For power supply input. For heat dissipation through forced air cooling. Figure -: Back panel of Z69 8

15 Z0. Panel functions of ARC00 ( Z0) Fault 5 No. Part name Function Power indicator Digital meter - output terminal Current control knob To indicate the machine is powered on when it illuminates. To display the welding current. To connect the welding output cable. To adjust the output current value.. OPERATION 5 Abnormity indicator To indicate the machine is under overcurrent or overheating protection status when it illuminates output terminal To connect the welding output cable. Figure -: Front panel of Z0 No. Part name Function Power switch Cable Cooling fan To control the ON/OFF of the input power of the machine. For power supply input. For heat dissipation through forced air cooling. Figure -: Back panel of Z0 9

16 OC. Panel functions of ARC00 ( Z76) 5 No. Part name Function Overcurrent indicator To indicate the machine is under overcurrent protection status when it illuminates. Digital meter To display the welding current.. OPERATION 6 5 Arc force control knob + output terminal Current control knob To adjust the arc force current value. To connect the welding output cable. To adjust the output current value Overheating indicator - output terminal To indicate the temperature inside the machine is too high and the machine is under overheating protection status when it illuminates. To connect the welding output cable. Figure -5: Front panel of Z76 No. Part name Function Power switch Cable Cooling fan To control the ON/OFF of the input power of the machine. For power supply input. For heat dissipation through forced air cooling. Figure -6: Back panel of Z76 0

17 0V 80V 00 Z5.5 Panel functions of ARC00D ( Z5)/A RC50D (Z6) No. Part name Function Digital meter Arc force control knob Overheating indicator + output terminal Voltage indicator Current control knob To display the welding current. To adjust the arc force current value. To indicate the temperature inside the machine is too high and the machine is under overheating protection status when it illuminates. To connect the welding output cable. To indicate 0V is used when it illuminates. To adjust the output current value.. OPERATION 8 7 Voltage indicator To indicate 80V is used when it illuminates. 8 - output terminal To connect the welding output cable. Figure -7: Front panel of Z5/Z6 No. Part name Function Power switch Cable Cooling fan To control the ON/OFF of the input power of the machine. For power supply input. For heat dissipation through forced air cooling. Figure -8: Back panel of Z5/Z6

18 Z7.6 Panel functions of ARC50 ( Z7) 5 No. Part name Function Power indicator To indicate the machine is powered on when it illuminates.. OPERATION 6 5 Digital meter Arc force control knob + output terminal Current control knob To display the welding current. To adjust the arc force current value. To connect the welding output cable. To adjust the output current value Overcurrent indicator - output terminal To indicate the machine is under overcurrent protection status when it illuminates. To connect the welding output cable. Figure -9: Front panel of Z7 No. Part name Function Power switch Cable Cooling fan To control the ON/OFF of the input power of the machine. For power supply input. For heat dissipation through forced air cooling. Figure -0: Back panel of Z7

19 . Daily maintenance. MAINTENANCE WARNING The power of the switching box and the welding machine should be shut down before daily checking (except appearance checking without contacting the conductive body) to avoid personal injury accidents such as electric shock and burns. Table -: Daily checking of the welding machine. MAINTENANCE Items Checking requirements Remarks Front panel Back panel Cover Chassis Routine Whether any of the components are damaged or loosely connected; Whether the output quick sockets are tightened; Whether the abnormity indicator illuminates. Whether the input power cable and buckle are in good condition; Whether the air intake is unobstructed. Whether the bolts are loosely connected. Whether the screws are loosely connected. Whether the machine enclosure has color fading or overheating problems; Whether the fan sounds normal when the machine is running; Whether there is abnormal smell, abnormal vibration or noise when the machine is running. If unqualified, check the interior of the machine, and tighten or replace the components. If unqualified, tighten or replace the components. If abnormal, check the interior of the machine. Table -: Daily checking of the cables Items Checking requirements Remarks Earth cable Welding cable Whether the grounding wires (including workpiece GND wire and welding machine GND wire) break off. Whether the insulating layer of the cable is worn, or the conductive part of the cable is exposed; Whether the cable is drawn by an external force; Whether the cable connected to the workpiece is well connected. If unqualified, tighten or replace the components. Use appropriate methods according to the work site situation to ensure safety and normal welding.

20 . Periodic check. MAINTENANCE Tips: WARNING Periodic check should be carried out by qualified professionals to ensure safety. Thepower of the switching box and the welding machine should be shut down before periodic check to avoid personal injury accidents such as electric shock and burns. Due to the discharge of capacitors, checking should be carried out 5 minutes after the machine is powered off.

21 5. TROUBLESHOOTING Table 5-: Troubleshooting for ARC00 (Z 0) Malfunction Phenomena Cause and Solution The power indicator/meter display does not illuminate; the fan does not work; no welding output. The power indicator/meter display illuminates; the fan does not work; no welding output. a. Make sure that the mains voltage is normal. b. Make sure that the input cable is reliably connected to the power switch, and that the power switch can be switched on or off normally. c. Check whether any of the silicon bridge, MOS tube or rectifier diode are damaged, and whether the gate resistor is burned out. Replace them if necessary. d. Check whether the connecting wires on PCBs are reliably connected. e. Power it on, and switch the digital multimeter to DC 000V. Check if there is 0V DC at both terminals of the DC bus CON on the top PCB. If there is, replace the top PCB. Otherwise, replace the bottom PCB. a. The 0V input power is unstable (the input cable is too thin and too long), which leads to overvoltage protection. Replace the input cable with a larger diameter and tighten the joint. Shut down the machine and restart it after 5~0 minutes, and then it will recover. b. The power switch is continuously switched on and off in a short time, which leads to overvoltage protection. Shut down the machine and restart it after 5~0 minutes, and then it will recover. c. The wire connecting the power switch with the power PCB breaks is loosely connected. Tighten it. d. The V relay on the power PCB is damaged or not closed. Check the V power supply and the relay. Replace the relay if necessary. 5. TROUBLESHOOTING The fan works; the output current is unstable or cannot be controlled by potentiometer when welding. The fan works; the power indicator and meter display are normal; no welding output. a. Make sure that the mains voltage is normal. b. Check if the connecting wires on the control PCB are reliably connected. c. Check if the current adjustment potentiometer is damaged, and replace it if necessary. d. Replace the control module on the top PCB. a. Open circuit or poor contact problems exit at the joints of output terminals. b. There is about DC 0V from the power PCB to CON (VH-07) on the top PCB. Check if the silicon bridge breaks or is not well connected. ) Check if any of the 5 big electrolytic capacitors (70uF/00V) have leakage problem, and replace them if necessary. c. Check if the driving MOSFET ( Z/9Z) for VT7-VT0 on the top PCB is damaged, and replace it if necessary. d. The control circuit fails. Please contact your distributor or JASIC. The fan works; the abnormity indicator illuminates; no welding output. a. Overcurrent protection occurs. Shut down the machine, and restart it after the abnormity indicator does not illuminate, and then it will recover. b. Overheating protection occurs. It will recover automatically after 5~0 minutes. c. The inverter circuit fails. Pull out the power supply socket (near the fan VH-07) for the main transformer on the top PCB, and restart the machine. ) If the abnormity indicator still illuminates, some of the MOSFETs on the top PCB is damaged. Replace it if necessary. ) If the abnormity indicator does not illuminate: The transformer on the center PCB may be damaged. Check the inductance and Q value of the primary of the main transformer. The primary of the transformer is paralleled. For a single main transformer, L=.5~.mH, Q>0. Replace the main transformer when the inductance and Q value is small. Some of the secondary rectifier diodes of the transformer may be damaged. Replace it if necessary. d. The feedback circuit (wire) fails. The electrode holder becomes very hot. Excessive spatter in MMA welding. a. The rated current of the electrode holder is smaller than its actual working current. Replace it with a bigger rated current. b. Check if the screw or wire of the electrode holder is reliably connected. The output polarity connection is incorrect. Exchange the polarity. 5

22 Table 5-: Troubleshooting for ARC0 (Z 69)/A RC00 (Z 76) 5. TROUBLESHOOTING Malfunction Phenomena The power indicator does not illuminate; the fan does not work; no welding output. The fan works; the output current is unstable or cannot be controlled by potentiometer when welding. The fan works; the power indicator is normal; no welding output. The electrode holder becomes very hot. Excessive spatter in MMA welding. Cause and Solution a. Make sure that the mains voltage is normal. b. Make sure that the input cable is reliably connected to the power switch, and that the power switch can be switched on or off normally. c. Check whether any of the silicon bridge, IGBT or rectifier diode are damaged, and whether the gate resistor is burned out. Replace them if necessary. d. Power it on, and switch the digital multimeter to DC V. Check if there is 0V DC at both terminals of the DC bus [] on the top PCB []. If there is, replace the top PCB. Otherwise, replace the bottom PCB []. a. Make sure that the mains voltage is normal. b. Check if the connecting wires on the control PCB are reliably connected. c. Check if the current adjustment potentiometer is damaged, and replace it if necessary. d. Replace the control PCB rectifier PCB. a. Check if the connecting wires on PCBs are reliably connected. b. Open circuit or poor contact problems exit at the joints of output terminals. c. The protection indicator illuminates: Pull out the thermal switch, and check if the protection indicator still illuminates. If so, replace the control PCB. Otherwise,the machine is under overheating protection. In this condition, it is unnecessary to pull out the power plug, and it will recover automatically after 5~0 minutes when the machine is cooled down. d. The protection indicator does not illuminate and there is no output: Pull out the thermal switch, and check if there is no-load voltage. If there is, the thermal switch is damaged. Otherwise, connect the metal part of 785 with the black probe and connect the metal part of IRF9Z or IRFZ with the red probe, the check if the voltage is about 8.V. If it is, replace the center PCB []. Otherwise, replace the top PCB. a. The rated current of the electrode holder is smaller than its actual working current. Replace it with a bigger rated current. b. Check if the screw or wire of the electrode holder is reliably connected. The output polarity connection is incorrect. Exchange the polarity. Notes: [] The DC bus for ARC0 (Z69) is P8, and the DC bus for ARC00 (Z76) is P9. [] The top PCB for ARC0 (Z69) is PM-8, and the top PCB for ARC00 ( Z76) is PM-7. [] The bottom PCB for ARC0 (Z69) is PZ-75, and the top PCB for ARC00 (Z76) is PZ-86. [] The center PCB for ARC0 (Z 69) is PD-7, and the top PCB for ARC00 (Z 76) is PD-5. 6

23 Table 5-: Troubleshooting for ARC00D (Z 5)/A RC50D (Z 6)/A RC50 (Z 7) Malfunction Phenomena The power indicator does not illuminate; the fan does not work; no welding output. The power indicator illuminates; the fan does not work; no welding output. The fan works; the output current is unstable or cannot be controlled by potentiometer when welding. The fan works; the power indicator is normal; no welding output. The 0V indicator illuminates when connecting the machine to AC 80V (only for Z5 and Z6) Excessive spatter in MMA welding. Cause and Solution a. Make sure that the power switch is closed. b. Make sure that the input voltage is normal. a. The wire connecting the power switch with the power PCB breaks is loosely connected. Tighten it. b. The V relay on the power PCB is damaged or not closed. Check the V power supply and the relay. Replace the relay if necessary. a. Check if the current adjustment potentiometer is damaged, and replace it if necessary. b. Check all joints (esp. connectors) for reliable connection. a. Delay circuit is added for this machine to improve the reliability, so there is no output within 5 seconds after the machine is powered on, while the fan and power indicator appear normal. If there is still no output after 0 seconds or a longer time after the machine is powered on, do the following checking. b. Check if the connecting wires inside the machine are reliably connected. c. Open circuit or poor contact problems exit at the joints of output terminals. d. The overheating protection indicator illuminates: ) Themachine is under overheating protection. In this condition, it is unnecessary to pull out the power plug, and it will recover automatically after 5~0 minutes when the machine is cooled down. ) Check if the thermal switch is damaged, and replace it if necessary. e. The protection indicator does not illuminate: Shut down the machine, and check with a multimeter whether the two output terminals are short circuited. If so, check if any of the diode or transformer on the center PCB is damaged or short circuited. Replace them if necessary. a. The mains voltage is below AC 0V. Check if there is any high-power machine working nearby, which leads to the low mains voltage. b. Check if the chip for judging voltage switching IC5 on the top PCB is damaged, and replace it if necessary. The output polarity connection is incorrect. Exchange the polarity. 5. TROUBLESHOOTING 7

24 SHENZHEN JASIC TECHNOLOGY CO., LTD. No., Qinglan st Road, Pingshan District, Shenzhen, Guangdong, China