QUATRO 450 OPERATOR S MANUAL

Transcription

1 QUATRO 450 OPERATOR S MANUAL IMPORTANT DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY SECTION CONTAINED INSIDE THIS MANUAL STARWELD WELDING SOLUTIONS WEBSITE: TEL: FAX:

2 1 Table of Contents 1 Table of Contents Safety Installation SPECIFICATIONS DUTY CYCLE SELECTING LOCATION WELD CABLE SIZES STICK WELD CONNECTION MIG WELD CONNECTION TIG WELD CONNECTION CONNECTING INPUT POWER Operation CONNECTIONS Power Output Terminals way Socket LIFT TIG Advanced Features VOLT-LOC Maintenance and Troubleshooting ROUTINE MAINTENANCE TROUBLESHOOTING Electrical Diagrams Parts Warranty Starweld Quatro 450 Operator s Manual 2

3 2 Safety Only qualified persons should install, operate, maintain, and repair this unit. During operation, keep everybody, especially children, away. Electrical Hazards Electric shock from welding can kill or cause severe burns. The electrode and work circuit is electrically energized whenever the output is on. The input power circuit and unit internal circuits are also electrically energized when the mains power is on. When MIG welding, the wire, drive rolls, and all other metal parts touching the wire are electrically energized. Incorrectly installed or improperly grounded equipment presents a shock hazard. Read the instruction manual before installing, operating, or servicing the unit. Have all installation, operation, maintenance, and repair work performed only by qualified people. Do not touch live electrical parts. Wear dry, insulating in good condition and protective clothing. Insulate yourself from the workpiece and ground by wearing rubber-soled shoes or standing on a dry insulated mat or platform. Use fully insulated electrode holders. Never dip the holder in water to cool it or lay it on conductive surfaces or the work surface. Do not touch holders connected to two welding machines at the same time or touch other people with the holder or electrode. Do not use worn, damaged, undersized, or poorly spliced cables, welding gun cables, and torch cables. Make sure all connections are tight, clean, and dry. Do not wrap cables carrying welding current around your body. In confined spaces or in electrically hazardous locations due to water or perspiration, do not use a welder with AC output unless it is equipped with a voltage reducer and remote output control. Use equipment with DC output. Turn off all equipment when not in use. Disconnect the power to equipment if it will be left unattended or out of service. Wear a safety harness to prevent falling in a potentially hazardous area. Keep all covers secured in place. Welding Fumes and Gases Many welding processes produce fumes and gases, which may be harmful to your health. Keep your head out of the fumes. Do not breathe the fumes. If inside, use ventilation or an exhaust at the arc to remove welding fumes and gases. Starweld Quatro 450 Operator s Manual 3

4 If ventilation is poor, use an approved respirator. Do not weld near degreasing, cleaning or spraying booths. The heat and rays from the arc can react with the gases from those processes to form toxic fumes. Do not weld on coated metals, such as galvanized, lead or cadmium plated steel, unless the coating is removed. The coatings can give off toxic fumes if welded. Arc Rays Arc rays from the welding process produce intense rays that can burn skin and eyes. Wear a welding helmet fitted with correct shade of filter lens when welding in order to protect eyes and face. Use protective screens or barriers to protect passer-bys, warn others not to watch the arc. Wear protective clothing made from durable and flame-resistant material as well as foot protection. Protect exposed skin on hands with leather gloves. Fire and Explosion Welding processes produce molten metal, sparks and hot work surfaces. These can cause fire or explosion if precautionary measures are not followed. Welding on closed containers can them to explode. Check and make sure the work area is safe before doing any welding. Remove any combustible material from the work area. Remove or make safe all combustible materials for a radius of 10m around the work area. If this is not possible then cover materials with approved flame-resistant covers. Do not weld where sparks can strike combustible material. Do not weld on a container that has held an unknown substance or a combustible material whose contents, when heated, can produce flammable or explosive fumes. Do not weld on a workpiece covered by an unknown substance or whose coating can produce flammable, toxic, or reactive fumes when heated. Do not use welder to thaw frozen pipes. Do not weld on closed containers such as drums unless they are correctly prepared. Always keep a fire extinguisher close by. Hot Surfaces / Flying Metal / Noise Starweld Quatro 450 Operator s Manual 4

5 Do not touch hot parts without gloves. Allow cooling period before working on a gun or torch. Welding, grinding and chipping can cause sparks and flying metal. Wear approved safety glasses with side shields even under the welding helmet. Wear approved ear protection if noise level is too high. Pacemakers Electric arc welding processes produce intense electric and magnetic fields. Persons with a pacemaker should not go near welding operations until they have consulted their doctor and obtained information from the manufacturer of the device. Starweld Quatro 450 Operator s Manual 5

6 3 Installation 3.1 Specifications Input Voltages 380V Input 43A Rated Output Maximum Input Current Duty Cycle Output Amperes Volts at Rated Output Amperes Input Amperes 380V Stick 100% 450A 38V 43A TIG 100% 450A 28V 32A MIG 100% 450A 37.5V 43A Output Output Current Range Open Circuit Voltage Type of Output A 55V DC Physical Dimensions Height Width Depth Weight 370mm 350mm 500mm 33kg Environmental Operating Temperature Range Storage Temperature Range Relative Humidity -10C to +40C -50C to +80C Up to 50% at 40C Up to 90% at 20C Altitude Above Sea Level Up to 1800m 3.2 Duty Cycle Duty cycle is the percentage of ten minutes that the unit can weld at selected current without overheating. If the unit was used at 450A (Maximum Current) then the unit could weld continuously, that is no time is needed in order to let the unit cool. 3.3 Selecting Location The air is blown from the rear of the unit through the heatsink and out the front of the unit, therefore adequate thought needs to be considered about the location of the unit. The unit should be spaced at least 15cm away from a wall at the rear of the machine, this will allow adequate airflow into the unit. Starweld Quatro 450 Operator s Manual 6

7 Front of Unit Unit 15cm Wall Figure 1: Location of Unit Starweld Quatro 450 Operator s Manual 7

8 3.4 Weld Cable Sizes Turn off power before connecting to unit output terminals Do not use worn, damaged, and undersized cables Minimum welder cable size (mm 2 ) Welding Amperes (A) Total Cable Length (m) Figure 2: Cable Area vs. Cable Length This chart serves only as a general guide, if the unit tends to trip early on overtemp or the cables become warm then the next size cable should be used. If one wants to weld at 150A 60% duty cycle with the total cable length, that is earth cable and electrode cable, of 100m then the cable size should be 70mm Stick Weld Connection Stick welding requires positive polarity, that is the electrode holder is connected to the unit s positive output socket (red connector) and the earth clamp is connected to the unit s negative output socket (black connector). 3.6 MIG Weld Connection MIG welding requires positive polarity, that is the earth clamp is connected to the unit s negative output socket, the separate wire feeder unit is connected to the positive terminal through an interconnecting cable, the wire feeder control cable also needs to be connected to the female 14 way socket. 3.7 TIG Weld Connection TIG welding requires negative polarity, that is the electrode holder is connected to the unit s negative output socket and the earth clamp is connected to the unit s positive output socket. Starweld Quatro 450 Operator s Manual 8

9 The Starweld Quatro 450 does not include a gas solenoid inside the unit, therefore a TIG torch needs to be used with a gas valve built into it. The gas line from the torch is then connected straight to the flowmeter on the gas cylinder. 3.8 Connecting Input Power Turn off power before connecting unit to mains Do not use worn, damaged, and undersized cables or plugs The unit is supplied with usually a five meter trailing cable (other lengths are available on request). If no plug is supplied with the unit then the connections are the following: Green/Yellow - Represents the earth wire Brown - Represents Phase A Blue - Represents Phase B Black - Represents Phase C The Quatro 450 is designed to work on a three phase with earth system only. Starweld Quatro 450 Operator s Manual 9

10 4 Operation CONTROL PANEL MODE BUTTON LOCAL/REMOTE BUTTON ENCODER This button is used when selecting the Welding Process to be used. With each press of the button, one scrolls down through the modes. An accompanying LED indicates the selected mode. Used to select the input reference. Either from the main encoder (local) or from a suitable remote controlling device. When in the TIG and Stick modes the remote device will control from 0 local setting. This control is used to select the required Amperage or Voltage to be used. The Encoder is also used to set values in Menu Settings. (To be discussed later) Starweld Quatro 450 Operator s Manual 10

11 DIGITAL DISPLAYS In the MIG mode the preset welding voltage is displayed before welding commences, once welding the actual voltage is displayed. All other modes displays the actual voltage. Before welding the preset welding current is displayed, once welding the actual current is displayed. MENU BUTTON This button allows for the setting of the various welding parameters, subject to the selected mode. MENU OPERATION METHOD PARAMETERS OPTIONS MIG Process SLOPE 1. Push the Menu Button twice. 2. Use the Encoder to select the parameter to be set. (This will appear on the Voltage Display) 3. Push the Menu Button a second time. 4. The parameter in the Voltage Display will begin to flash, indicating that this has been selected for change. 5. Use the Encoder to now adjust this parameter. 6. After the desired value is selected, press the Menu Button again, to exit. Setting: 1 10 This is an inductance control that sets the speed at which the current picks up, after each short of the arc. A high setting is recommended for Aluminium and a low setting for Steels. FCAW-SS Nothing Stick Process DIG Setting: 1 10 Controls the amount of added current during the deposition of welding material to prevent freezing of the puddle. Lift TIG Process Nothing The higher the setting, the greater the added current. 4.1 Connections Power The circuit breaker at the rear of the unit switches the unit on and off. Starweld Quatro 450 Operator s Manual 11

12 4.1.2 Output Terminals Turn off power before connecting cables to unit One can get shocked by the output terminals if correct care is not exercised Unit s Positive Terminal, normally a red feed through connector, however if the unit has been built using Dinse connectors + then the terminal is marked as such: Unit s Negative Terminal, normally a black feed through connector, however if the unit has been built using Dinse connectors - then the terminal is marked as such: way Socket The 14 way socket is used for the connection of torch triggers, interconnection cables and ancillary equipment Pin Function 1 TIG Trigger 2 TIG Trigger 3 Pot GND 4 Pot Wiper 5 Pot +5V 6 CAN Bus H 7 CAN Bus L VAC Neutral VAC Live 12 Trigger Return (11 to 12) Lift TIG The tungsten must be placed, not scratched on the work and the inverter will supply a preset low current of approximately 100 amps after 100ms. On lifting the tungsten the current will rise to the preset value. In order to break the arc simply pull the torch away from the workpiece NB It is important to remember for TIG welding the electrode is connected to the negative and the earth clamp to the positive. Starweld Quatro 450 Operator s Manual 12

13 5 Advanced Features 5.1 Volt-Loc Volt-Loc is the registered name of the Starweld voltage reducer. Volt-Loc is a free option and is generally fitted as standard. It is used for the stick and TIG modes. The Volt-Loc feature reduces the output voltage to 13 volts until contact resistance below approximately 200 Ohms is made. On contact the full open circuit voltage is applied and welding may continue as long as there is welding current and after an internally set time for tacking. Thereafter the voltage is once more reduced. The time that is allowed for tacking is set to 2s. The use of Volt-Loc provides considerable protection against electrocution. Accidents occur when the equipment is improperly used or maintained and the rules of safe practice for electric arc welding must be observed. Failure to observe these practices may cause serious injury of death. Starweld will not be liable for any claims for injury or death or consequential damage. Starweld Quatro 450 Operator s Manual 13

14 6 Maintenance and Troubleshooting 6.1 Routine Maintenance Turn off power before undergoing maintenance on the unit The unit should be blown out every 6 months to remove dirt and dust build up, depending on site conditions. Worn or damaged machine sockets should be replaced. Damaged mains cable should be replaced. If the unit is used in a dusty environment then the unit should be blown out every 3 months. In order to blow out the machine the cover should be removed and the dust blown out with compressed air. An air pressure of 5 bar will be sufficient to remove any dust buildup. It is important to get all the dust out the heatsink and fan as well. 6.2 Troubleshooting Fault Power LED does not light Power LED on but no weld output Erratic or improper weld output Fan not working Wandering arc Unit not MIG welding Remedy Switch the circuit breaker at the rear of the unit to the on position. Switch the unit on at the wall plug. Make sure the wall plug is correctly wired. Make sure the unit is switched to the stick position. Check for Overtemp error (Err Ot) Make sure unit is in the local mode and not remote. Use proper size and type of weld cable. Clean and tighten all weld connections including the earth connection to the work. Look for something blocking the fan. Send the unit in for service to replace the fan. Use proper size tungsten. Use properly prepared tungsten. Reduce gas flow rate. Check interconnecting cable for any bad connections especially in 14 way socket Check 10A circuit breaker on front panel Starweld Quatro 450 Operator s Manual 14

15 7 Electrical Diagrams Starweld Quatro 450 Operator s Manual 15

16 8 Parts Starweld Quatro 450 Operator s Manual 16

17 Parts List 1 WM000 Control Board 2 200VA Transformer 3 Circuit Breaker 4 HF Transformers 5 WM020 Power Board 6 Input Bridge 7 WM081 Soft Start 8 Output Diodes 9 LEM Module 10 Positive Socket Way Socket 12 10A Circuit Breaker 13 WM010 Firing Board 14 IGBTs 15 Fan 16 WM080 Capacitor Board 17 Negative Socket Starweld Quatro 450 Operator s Manual 17

18 9 Warranty Arc Quip guarantees the product for a period of 24 months (2 years) from date of sale against faulty design material and workmanship, fair wear and tear excepted and excluding misuse and abuse. The equipment must be returned to Arc Quip or its agents. For service repairs and technical assistance contact your STARWELD dealer or the manufacturer. Distributor Starweld Contact Details Arc Quip cc Unit 70D Van Dyk Secure Business Park Cnr Van Dyk & Brakpan rd Boksburg South Africa Po Box 1681 Fourways 2055 Tel: Sales: sales@starweld.co.za Technical: robert@starweld.co.za Starweld Quatro 450 Operator s Manual 18