MTS 200 User Manual TSX1D200MTS SWMTS001

Transcription

1 MTS 200 User Manual SWMTS001

2 DECLARATION OF CONFORMITY The Low voltage Directive 2006/95/EC of 12 December 2006, entering into force 16 January 2007 Type of Equipment Welding power source for MIG/MAG, TIG/TAG, MMA welding Brand name or trade mark Sif Type designation etc. SifWeld MTS200 Manufacturer or his authorised representative established within the EEA Name, address, telephone no, fax no Weldability Sif, Peters House, The Orbital Centre, Icknield Way, Letchworth, Hertfordshire,. SG6 1ET Phone: Fax: The following harmonised standard in force with the EEA has been used in the design: EN Arc welding equipment- Part 1: Welding power sources Additional information: restrictive use, Class A equipment, intended for use in locations other than residential By signing this document, the undersigned declares as manufacturer, or the manufacturer s authorised representative established within the EEA, that the equipment in question complies with the safety requirements stated above. Place and Date Signature Position Letchworth Quality Director Weldability Sif Keith Mullan WEEE Directive & Product Disposal At the end of its serviceable life, this product should not be treated as household or general waste. It should be handed over to the applicable collection point for the recycling of electrical and electronic equipment, or returned to the supplier for disposal

3 1 SAFETY 2 INTRODUCTION 3 TECHNICAL DATA 4 INSTALLATION 4.1 MIG Installation 4.2 TIG Installation 4.3 MMA Installation 5 OPERATION 5.1 Connection and Control Devices 5.2 Display Function Diagram 5.3 Operating Functions 5.4 MIG Function Set Up 5.5 TIG Function Set Up 5.6 MMA Function Set Up 6 RECOMMENDED WELD PARAMETERS 7 DAILY CHECKLIST & ROUTINE MAINTENANCE 8 PARTS LIST & CIRCUIT DIAGRAM 9 FAULT TRACING & TROUBLESHOOTING 10 ACCESSORIES - 3 -

4 1 Safety Weldability Sif does not accept any liability for damage to the product or personal injury caused by ignoring the safety instructions in this manual, or by negligence during installation, use, maintenance, and repair of the product mentioned on the cover of this document and any corresponding accessories. Specific working conditions or used accessories may require additional safety instructions. Immediately contact your supplier if you detect a potential danger when using the product. The user of the product is always fully responsible for observing the local safety instructions and regulations. Observe all applicable safety instructions and regulations. All work must be carried out by a trained personnel well-acquainted with the operation of the equipment. Incorrect operation of the equipment may lead to hazardous situations which can result in injury to the operator and damage to the equipment. WARNING Arc welding and cutting can cause injury to yourself and others. Take necessary precautions when welding and cutting, ensuring you use adequate protection. Ask for your employer s safety practices which should be based on manufactures hazard data. ELECTRIC SHOCK- Can Kill Install and earth the unit in accordance with application standards Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing Insulate yourself from earth and the workplace Ensure your working stance is safe FUMES AND GASES - Can be dangerous to health Keep your head out of the fumes. Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone and the general area ARC RAYS - Can injure eyes and burn skin Protect your eyes and body. Use the correct welding screen and filter lens, and wear protective clothing Protect bystanders with suitable screens or curtains FIRE HAZARD Sparks (spatter) can cause fite. Make sure therefore that there are no flammable materials nearby NOISE- Excessive noise can damage hearing Protect your ears. Use ear defenders or other hearing protection Warn bystanders of the risk MALFUNCTION- Call for expert assistance in the even of malfunction If you incur any difficulties curing the installation, please check the manual If you are unable to resolve your issue, please contact our Technical Department Read and understand the instruction manual before installing or operating - 4 -

5 ENVIRONMENT The welding environment should be dry, where humidity is below 90% The environment temperature should range between 10 C and 40 C Protect the machine against heavy rain, or in hot environments out of direct sunlight Do not allow the machine to come into contact with water Keep the environment free of dust, acid and corrosive gases Ensure the environment is free from drafts The SifWeld MTS200 welding machine has been installed with a pressure, flow and overheating protection circuit. When the network voltage, output current and machine temperature exceeds a set standard, the machine shall automatically stop working. However, excessive use (such as high voltage) can still lead to damage of the welding machine, therefore you shall need to pay attention to the following: Ensure Good Ventilation The SifWeldMTS 200 is a small sized welding machine which has an internal cooling fan to regulate operating temperature during use. For optimum ventilation, the operator must ensure there is sufficient space between the machine and surrounding objects, this must be a minimum of 30cm. It is vital to keep the machine serviced and maintained on a regular basis. Duty Cycle The operator should always consider duty cycles for the current they are welding at, ensuring the duty cycle is not exceeded. Should the duty cycle be exceeded, the Thermal Cut Out will engage therefore halting welding operation. At the same time the overheating signal on the front panel shall activate and light up. In this instance do not unplug the machine, however allow the fan to cool the machine to the required temperature to start welding again. Current overload will reduce the service life, and could result in damage of the machine and even burning out of the thermal inverter. Mains Input Supply Refer to the Recommended Weld Parameters within this manual for your chosen application. Use the correct voltage input for your application, and ensure this is not exceeded. Voltage above the maximum permitted voltage may cause damage to the welding machine. Make sure the earth cable is connected correctly prior to using the machine to remove necessary residual voltage. 2 Introduction The SifWeld MTS200 is an inverter welder which adopts the latest Insulated Gate Bipolar Transistor (IGBT) technology. The working principle is to use a single tube IGBT switching device rectifying input power into a DC output then inverted to a high frequency, then stepped-down through the pulse width modulator (PWM) to produce the welding output. Using a digital liquid crystal (LCD) display panel, weld parameters can be adjusted via the MCP (Mono Control Point) easily and accurately. The feedback circuit gives precise control of the welding arc, therefore providing excellent welding characteristics. The SifWeld MTS200 is an easily portable, multi-functional machine suitable for both on-site and workshop use. Boasting stable wire feed speed, no electromagnetic noise, good arc force, molten pool and low spatter along with high duty cycle. This unit is also energy efficient and is suitable for the welding of various materials

6 3 Technical Data Item Model SifWeld MTS200 Power Voltage (V) 1ph AC 230/240V Frequency (Hz) 50/60 Rated Input Current (A) I-1max 40.6 Rated Input Current (A) I-1eff 20.3 Rated MIG Current Range TIG (A) MMA Recommended Fuse Rating 32A No Load Voltage 63 Output Voltage (V) MIG TIG MMA Duty Cycle (%) 40 C 10min 25% Efficiency 0.73 Wire Feed Speed (m/mm) Wire Diameter (mm) 0.6/0.8/1.0 Protection Class Insulation Class IP23S F Weight (Kg) 15 Dimensions (mm) 439x214x

7 4 Installation The SifWeld MTS200 is equipped with a network voltage compensation device, this ensures that when the network voltage changes within the 15% range, the machine can still continue to work. The cross-sectional area of any extension cable must be above the cross-sectional area of the machines mains input cable to minimise voltage drop. Prior to installation, check the following: Confirm both air-vents are no covered, obstructed or blocked otherwise this could result in failure of the cooling system Ensure the machine is connected to a suitable grounded mains supply Installation for MIG Applications 1. Connect to a suitable cylinder with required regulator and gas hose. 2. Select desired polarity via the quick-connect sockets on the front of the machine. 3. Select the MIG function via the switch inside the machine. Fit the correct wire feed roll, and screw into place

8 4. Install wire spool, by unscrewing the plastic retainer and placing the wire spool onto the spool hub. 5. Release the pressure arm. 6. Feed the wire into the guide tube, and through the wire feed roll. Set the correct pressure on the arm, and fit back into place. Ensure that the pressure is enough to hold the wire in place, however not too much as this will deform the wire. 7. Insert the MIG gun onto the front of the machine, and feed the wire through into the gun

9 Diagram for Installation for MIG Applications - 9 -

10 Installation for Spool-On Gun MIG Applications 1. Connect to a suitable cylinder with required regulator and gas hose. 2. Select desired polarity via the quick-connect sockets on the front of the machine. 3. Select the Spool-on Gun function via the switch inside the machine. Plug the spool-on torch into the front of the machine. 4. Insert the control plug into the silver control plug socket

11 5. Open the spool gun and mount the wire spool onto the spindle. 6. Secure the spool with the retaining screw. 7. Feed wire into the guide tube. 8. Release the pressure of the feed rolls, and feed the wire through into the tip of the torch

12 Diagram for Installation for Spool-On Gun MIG Applications

13 Installation for TIG Applications 1. Connect to a suitable cylinder with required regulator and gas hose. 2. Screw gas adaptor onto the gas fitting. 3. Insert the TIG adaptor into the negative polarity socket, and screw onto the gas fitting. 4. Connect the TIG torch into the adaptor, and connect the control cable into the silver control plug socket. Insert the control plug of the earth clamp into the positive polarity socket, and connect the earth clamp to the work piece

14 Diagram for Installation for TIG Applications

15 Installation for MMA Applications 1. Insert the electrode holder control plug into the desired polarity socket for application. 2. Insert the earth clamp control plug into the desired polarity socket for application. The SifWeld MTS200 machine allows for two welding modes, DC + and DC -. In DC positive applications, ensure the electrode holder is connected to the positive polarity socket. In DC negative applications, ensure the electrode holder is connected to the negative polarity socket

16 Diagram for Installation for MMA Applications

17 5 Operation Connection and Control Devices 1. LCD Display 6. Gas Socket 2. MCP- Mono Control Point 7. Input Hose 3. Welding Current Connectors 8. Mains Switch 4. Euro Block 9. Mains Input Cable 5. Control Socket 1 2 WELD 3 MTS200 4 Display Function Diagram 1. Mains Supply Switch 2. Overheating Indicator 3. MCP (Mono Control Point) Adjustment Knob 4. LCD Display

18 Operating Fuctions 1. Switch the SifWeld MTS 200 machine on via the mains plug, and then the switch on the rear on the machine. 2. Upon turning on, the welcome screen will display on the front panel, showing the SifWeld logo, and then turning into welding standby mode after 5 seconds. WELD 3. The last weld parameters used shall be shown on screen. 4. Select the desired function (MIG, TIG or MMA) and follow the instructions below how to change the weld parameters for your application. In the weld parameters settings interface, using the MCP (Mono Control Point) adjustment knob, by rotating it left or right to select the parameter you wish to edit. Select the parameter by pressing the MCP knob and adjust as necessary, pressing the knob again to save your setting. You can set other parameters under each function mode by using the More button to view further settings. If you wish to save your value for next time, once you are finished editing the required parameters, move the cursor down to OK button and press the knob to save these settings. If you do not wish to save these values, move to cursor to the Cancel button and press the knob, then your settings will not be saved for next time

19 MIG Function Set Up The settings parameters for MIG welding include: 1. Wire speed The adjusting range of wire speed depends on different types of machine 2. Welding Voltage 3. Inductance 4. Trigger Speed 5. Pre Gas Time In default situations, the pre-gas time and post-gas time should be 0.1 second and the max value 5 seconds. 6. Post Gas Time In default situations, the pre-gas time and post-gas time should be 0.1 second and the max value 5 seconds. Trigger Pre Gas Post Gas MIG SetUp... 2T 0.1S 0.1S Ok Cancel More 7. Burn Back 8. Gas Test The gas test is mainly to confirm whether the gas circuit is free. 9. Wire Test The wire test is mainly to confirm whether the machine can produce wire, and during installing wire you can select the wire test option to feed the wire through the liner on the MIG torch

20 Burn Back Gas Test Wire Test Ok MIG SetUp Medium 1 OFF OFF Cancel TIG Function Set Up The settings parameters for TIG welding include: 1. Current Upon adjustment of the welding current, the voltage will change, however you are unable to change the voltage independently. 2. Welding Voltage The voltage is unable to be changed independently. 3. Down Slope Time 4. Trigger 5. Pre Gas In default situations, the pre-gas time and post-gas time should be 0.1 second and the max value 5 seconds. 6. Post Gas Time In default situations, the pre-gas time and post-gas time should be 0.1 second and the max value 5 seconds

21 7. Gas Test The gas test is mainly to confirm whether the gas circuit is free. MMA Function Set Up The settings parameters for TIG welding include: 1. Current Upon adjustment of the welding current, the voltage will change, however you are unable to change the voltage independently. 2. Voltage The voltage is unable to be changed independently. 3. Arc Force The size of the Arc force will be changed with the current, and it gets from the percentage of present welding current setting value. Current Voltage ARC Force MMA SetUp... 10A 20.4V 0%

22 4. Hot Start

23 6 Recommended Welding Parameters MIG Welding Parameters Square Butt Joint Normal Welding Speed Plate Thickness (mm) Wire Diameter (mm) Current (A) Voltage (V) Welding Speed (cm/mi) Stick Out (mm) Gas Flow Rate (LPM) High Welding Speed Corner Joint Normal Welding T Joint Speed High Welding Speed Normal T Joint Welding Speed TIG Welding Parameters Plate Thickness (mm) Tungsten Diameter (mm) Wire Diameter (mm) Connection Type Current (A) Gas Flow Rate (LPM) Butt Joint Add Wire MMA Welding Parameters Electrode Size (mm) Welding Current A)

24 7 Daily Checklist and Routine Maintenance Daily Checklist These checks should be performed each time prior to using the SifWeld MTS200 unit, to ensure the unit is it perfect condition to avoid any issues Power Source Section To Check Note Operation Control Panel Cooling Fan Power Section Periphery 1. Switch operation, all connections and general machine are in good condition 2. Check power light turns on and off 1. Check air flow and sound of fan are normal 1. When power is on, check for shaking or buzzing sound 2. When power is on, check for peculiar smell 3. Check for overheating by any colour change on the unit 1. Check whether the gas pipeline is damaged or the connection is loose 1. Check the outer shell and other parts are not loose If the fan does not work, and no sound can be heard the fan needs repair. Welding Gun Section To Check Note Nozzle 1. Whether this is securely fitted 2. Clear of spatter Contact Nozzle 1. Whether this is securely fitted 2. Damage to the tip or if blocked 1. Ensure the correct liner size is chosen for the wire diameter being used 2. Check for kinks in the liner Wire Hose 3. Check for dirt and blockages in the liner 4. Check for kinks in the wire 5. Check for damage to the O-Ring This can cause extra erosion to the liner This can cause leaking gas and effects the weld

25 Internal Unit Section To Check Note Pressure Arm Wire Guide Tube Wire Feed Roll Pressure Roll 1. Ensure the pressure arm is at the correct pressure for the wire diameter used 1. Whether savings have accumulated in the guide tube and wire feed mechanism 2. Whether the guide tube used matches the wire diameter used 3. Ensure the guide tube is in line with the wire feed roll 1. Ensure correct wire feed roll is selected for the wire diameter used 2. Check for blockages or dirt in the wire feed unit 1. Check the pressure roll rotates freely and does not pressurise the wire Sweep away the shavings and investigate the problem This can result in damaging the wire if the pressure is too high Cables Section To Check Note Welding Gun Cable 1. Ensure the welding gun cable is not over bent 2. Ensure the connections of the quick plug are in good condition Welding Cable Mains Input Cable Earth Cable 1. Check the insulation is in good condition 2. Check the fittings and that there is no damage to the installation or bare metal 1. Ensure the mains input is fitted with an appropriately rated fuse 2. Ensure all connections on both the machine end and fuse end are in good condition 3. Ensure the insulation is in good condition and there is no bare metal 1. Ensure the fittings are in good condition and not damaged

26 Routine Maintenance WARNING All maintenance and checks must be performed after shutting off the power supply, and ensure the plug is removed from the mains supply before opening the machine. Using dry compressed air, clear the inside of the welding machine at least once a month, ensuring you use the correct air pressure to avoid damaging the machine Check the internal electrical connections are in good condition, reinforcing any loose parts If there is any corrosion within the internal electrical connections, remove this as required and reconnect Do not use the welder in damp or wet conditions If the welder is not used for a prolonged period, put this in the original packaging and store in a dry place Service the drive motor every 300 hours for this to continue to run smoothly

27 8 Parts List & Circuit Diagram Parts Diagram

28 Parts List Diagram Number Part Name Diagram Number Part Name 1 Plastic rear panel 17 Quick socket 2 Fan 18 Front air connection 3 Wire dish shaft 19 Aviation plug 4 Sheet metal clapboard 20 Sheet metal support article 5 Electromagnetic value 21 Radiator 6 Retifier bridge 22 Plastic support bar 7 Sheet metal clapboard 23 B3 Europe joint 8 Plastic handle 24 Nylon foot pad 9 PCB control panel 25 Plastic baseboard 10 IGBT 26 Wire feeder 11 PCB panel 27 Sheet metal clapboard case 12 Liquid crystal display 28 Hinge 13 Plastic front panel 29 Sheet metal carthweel board 14 Sheet metal panel 30 Plastic gate lock 15 Knob 31 Power switch 16 Quick plug 32 Back air connection

29 Circuit Diagram

30 9 Fault Tracing & Troubleshooting The faults listed below may relate to either the welding accessories, welding materials, environmental factors or power supply. Ensure that any faults are corrected immediately to avoid machine break down and further problems. Problematic arc starting Check the earth connection is good Check all cable joints Under current Low input voltage results in low output current, therefore check the input supply Unstable welding current Check stability of input voltage Check for interference from the network or other equipment Porosity in the weld Check gas supply for leaks Ensure the workplace is clean from oil,dust, rust and paint Troubleshooting If a fault should occur with the SifWeld MTS200, please check the diagnostic table, and check all options before attempting to repair the unit. This table can be found on the next page. WARNING The following operations require the operator to have competent electrical knowledge, comprehensive safety knowledge, and hold the required qualification to repair this unit. If in doubt, please contact the Weldability Sif Technical Department on Fault Display light is not on, the fan does not work and no welding output Display light is on, the fan is working but no welding output Solution 1. Confirm the unit is switched on. 2. Ensure the power electrical supply is working. 3. Check the fuse. It would seem that the display panel is damaged, therefore please contact Weldability Sif Technical department on Check cables and torch are connected properly. 2. Check they are connected to the correct polarity sockets. 3. Check continuity of torch, able & switch. It would seem that the control circuit is damaged, therefore please contact Weldability Sif Technical department on

31 Display light is on, the fan is working, abnormal indicator light 1. This may be the over-current protection feature, please switch off the unit, waiting for the indicator light to switch off then restart. 2. This may be the over-heating protection feature, keeping the machine on will allow the fan to cool the unit. Therefore after a few minutes you shall be able to resume welding. If neither of the above options work, then it would seem that the inverter is damaged, therefore please contact Weldability Sif Technical department on If the unit is still not working after you have checked all options, please contact the Weldability Sif Technical Department on Initial Diagnostic Table Below is the initial diagnostics table of welding faults. If you experience any faults with the SifWeld MTS200, please refer to this chart initially before any attempt at repair. Check points & maintenance items Fault No arc No gas No wire feed Bad arc start Unstable arc Weld seam edge unclean Wire sticking to metal Conductive contact tip Weld Porosity Fuse Box Input Cable Power Operation Gas Cylinder Connected properly Burnt out fuse Connections not loose Broken cable Connection parts are loose Overheating Connected to mains supply Fuse blown Valve is open Gas in the cylinder Flow settings Loose connections

32 Check points & maintenance items Fault No arc No gas No wire feed Bad arc start Unstable arc Weld seam edge unclean Wire sticking to metal Conductive contact tip Weld Porosity Gas Hose Wire Feeder Welding Gun & Cable Loose connection Damaged gas tube Correct size feed roll & guide tube for wire diameter Clean groove in drive roll Pressure is not too tight, and guide tube is clear of shavings The cable is not over bent Torch consumables are not damaged, and are correct for the application Contact tip, nozzle and nozzle joint are secure Welding Gun Torch fitting is not too tight or loose Gun Power Cable Cables are not broken & Switch Control Cable Cables are not damaged Clean from oil, dirt, rust and paint Material surface & wire length Wire does not need cutting back Output Cables Welding Cable Welding Conditions Good earth connection Cable connections are tight Ensure the cross-sectional area of the cable is sufficient for current required Cable is not coiled Check parameters, torch geometry, welding speed and stick out

33 10 Accessories The SifWeld MTS200 unit is suitable for use in the MIG, TIG and MMA applications. Therefore for ease we have listed a range of useful accessories below. Image Part No Item Description AE3005LX 1S 2G Argon Regulator Single stage, two gauge Argon regulator TWN001COMP Gas Input Hose Mini MIG Hose FXMT2003 SifGun MIG 200A 3m Euro MIG Gun TSX1D200SOG Spool-on MIG Gun 4m Spool-on Gun, accommodates D-100 spools FXTT SifGun TIG 4m TIG Gun with rocker switch FXADF2012 SifLite Olympian ADF 9-13 auto darkening welding helmet DZ10012 Inverter Trolley Black inverter trolley ET001W MIG Helper Pliers Multi-functional MIG pliers ETMTS Magnetic Torch Holder Magnetic MIG & TIG Torch holder