Top Gun MULTIMIG 160 Bedienungsanleitung

INTRODUCTION

ISO9001:2000

2015.10

MULTIMIG

series inverter

INVERTER MIG Arc Welding Machine

IMPORTANT: Read this Owner’s Manual Completely before attempting to use this

equipment. Save this manual and keep it handy for quick reference. Pay particular

attention to the safety instructions we have provided for your protection. Contact your

distributor if you do not fully understand this manual.

OPERATORS’MANUAL

CONTENT

- Ⅳ-

CONTENT

1 Safety ..........................................................................................1

§1.1 Signal Explanation....................................................................................................... 1

§1.2 Arc Welding Damage................................................................................................... 1

§1.3 The knowledge of Electric and Magnetic Fields....................................................... 5

§2 Overview.......................................................................................7

§2.1 Brief Introduction........................................................................................................ 7

§2.2 Working Principle........................................................................................................ 8

§2.3 Volt-Ampere Characteristic........................................................................................ 8

§3 Installation andAdjustment.....................................................10

§3.1 Parameters ................................................................................................................. 10

§3.2 Duty cycle and Over-heat...........................................................................................11

§3.3 Equipment Connection...............................................................................................11

§4 Operation....................................................................................15

§4.1 Layout for the front and rear panel......................................................................... 15

§4.2 Welding operation...................................................................................................... 17

§4.3 Welding parameters................................................................................................... 18

§4 .4Operation environment............................................................................................. 18

§4.5 Operation Notices...................................................................................................... 19

§5 Maintenance & Troubleshooting .............................................20

§5.1 Maintenance............................................................................................................... 20

§5.2 Troubleshooting ......................................................................................................... 21

§5.3Electrical schematic drawing..................................................................................... 22

SAFETY

- 1 -

1 Safety

§1.1 Signal Explanation

The above signals mean warning! Notice! Running parts and getting an electric

shock or thermal parts will take damage for your body or others. The corresponding

notices are as follows. It is quite a safe operation after taking several necessary

protection measures.

§1.2 Arc Welding Damage

The following signals and word explanations are to some damages for your body

or others happening on the welding operation. While seeing these, please remind of

yourself or others to be dangerous.

Only ones who are trained professionally can install, debug, operate, maintain and

repair the equipment.

During the operation, non-concerned people should be lift, especially for children.

After shut off the machine power, please maintain and examine the equipment

according to §5 because of the DC voltage existing in the electrolytic capacitors.

ELECTRIC SHOCK CAN KILL.

Never touch electrical parts.

Wear dry, hole-free gloves and clothes to insulate yourself.

Insulate yourself from work and ground using dry insulation. Make certain the

insulation is large enough to cover your full area of physical contact with work and

ground.

Take carefully when using the equipment in small place, falling-off and wet

circumstance.

Never close the machine power before installation and adjustment.

SAFETY

- 2 -

Ensure to install the equipment correctly and ground the work or metal to be welded

to a good electrical (earth) ground according the operation manual.

The electrode and work (or ground) circuits are electrically “hot” when the welder

is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry,

hole-free gloves to insulate hands.

In semiautomatic or automatic wire welding, the electrode, electrode reel, welding

head, nozzle or semiautomatic welding gun are also electrically “hot”.

Always be sure the work cable makes a good electrical connection with the metal

being welded. The connection should be as close as possible to the area being

welded.

Maintain the electrode holder, work clamp, welding cable and welding machine in

good, safe operating condition. Replace damaged insulation.

Never dip the electrode in water for cooling.

Never simultaneously touch electrically “hot” parts of electrode holders connected

to two welders because voltage between the two can be the total of the open

circuit voltage of both welders.

When working above the floor level, use a safety belt to protect yourself from a

fall should you get a shock.

FUMES AND GASES CAN BE DANGEROUS.

Welding may produce fumes and gases hazardous to health. Avoid breathing these

fumes and gases. When welding, keep your head out of the fume. Use enough

ventilation and/or exhaust at the arc to keep fumes and gases away from the

breathing zone. When welding with electrodes which require special ventilation such

as stainless or hard facing or on lead or cadmium plated steel and other metals or

coatings which produce highly toxic fumes, keep exposure as low as possible and

below Threshold Limit Values using local exhaust or mechanical ventilation. In

confined spaces or in some circumstances, outdoors, a respirator may be required.

Additional precautions are also required when welding on galvanized steel.

Do not weld in locations near chlorinated hydrocarbon vapors coming from

SAFETY

- 3 -

degreasing, cleaning or spraying operations. The heat and rays of the arc can react

with solvent vapors to form phosgene, a highly toxic gas, and other irritating

products.

Shielded gases used for arc welding can displace air and cause injury or death.

Always use enough ventilation, especially in confined areas, to insure breathing air

is safe.

Read and understand the manufacturer’s instructions for this equipment and the

consumables to be used, including the material safety data sheet and follow your

employer’s safety practices.

ARC RAYS CAN BURN.

Use a shield with the proper filter and cover plates to protect your eyes from

sparks and the rays of the arc when welding or observing open arc welding.

Use suitable clothing made from durable flame-resistant material to protect your

skin and that of your helpers from the arc rays.

Protect other nearby personnel with suitable, non-flammable screening and /or

warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter

or metal.

SELF-PROTECTION

Keep all equipment safety guards, covers and devices in position and in good

repair. Keep hands, hair, clothing and tools away from V-belts, gears, fans and all

other moving parts when starting, operating or repairing equipment.

Do not put your hands near the engine fan. Do not attempt to override the governor

or idler by pushing on the throttle control rods while the engine is running.

DO NOT adds the fuel near an open flame welding arc or

when the engine is running. Stop the engine and allow it to cool before refueling to

prevent spilled fuel from vaporizing on contact with hot engine parts and igniting.

SAFETY

- 4 -

Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start

engine until fumes have been eliminated.

WELDING SPARKS can cause fire or explosion.

Remove fire hazards from the welding area. If this is not possible, cover them to

prevent the welding sparks from starting a fire. Remember that welding sparks and

hot materials from welding can easily go through small cracks and openings to

adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily

available.

Where compressed gases are to be used at the job site, special precautions should

be used to prevent hazardous situation.

When not welding, make certain no part of the electrode circuit is touching the

work or ground. Accidental contact can cause overheating and create a fire hazard.

Do not heat, cut or weld tanks, drums or containers until the proper steps have

been taken to insure that such procedures will not cause flammable or toxic vapors

from substances inside. They can cause an explosion even though they have been

“cleaned”.

Vent hollow castings or containers before heating, cutting or welding. They may

explode.

Sparks and spatter are thrown from the welding arc. Wear oil free protective

garments such as leather gloves, heavy shirt, cuff less trousers, high shoes and a cap

over your hair. Wear ear plugs when welding out of position or in confined places.

Always wear safety glasses with side shields when in a welding area.

Connect the work cable to the work as close to the welding area as practical. Work

cables connected to the building framework or other locations away from the

welding area increase the possibility of the welding current passing through lifting

chains, crane cables or other alternate circuits. This can create fire hazards or

overheat lifting chains or cables until they fail.

SAFETY

- 5 -

Rotating parts may be dangerous.

Use only compressed gas cylinders containing the correct shielding gas for the

process used and properly operating regulators designed for the gas and pressure

used. All hoses, fittings, etc. should be suitable for the application and maintained in

good condition.

Always keep cylinders in an upright position securely chained to an undercarriage

or fixed support.

Cylinders should be located:

-Away from areas where they may be struck or subjected to physical damage.

-A safe distance from arc welding or cutting operations and any other source of

heat, sparks, or flame.

Never allow the electrode, electrode holder or any other electrically “hot” parts to

touch a cylinder.

Keep your head and face away from the cylinder valve outlet when opening the

cylinder valve.

Valve protection caps should always be in place and hand tight except when the

cylinder is in use or connected for use.

§1.3 The knowledge of Electric and Magnetic Fields

Electric current flowing through any conductor causes localized Electric and

Magnetic Fields (EMF). The discussion on the effect of EMF is ongoing all the

world. Up to now, no material evidences show that EMF may have effects on health.

However, the research on damage of EMF is still ongoing. Before any conclusion,

we should minimize exposure to EMF as few as possible.

In order to minimize EMF, we should use the following procedures:

Route the electrode and work cables together – Secure them with tape when

possible.

All cables should be put away and far from the operator.

SAFETY

- 6 -

Never coil the power cable around your body.

Make sure welding machine and power cable to be far away from the operator as

far as possible according to the actual circumstance.

Connect the work cable to the workpiece as close as possible to the area being

welded.

The people with heart-pacemaker should be away from the welding area.

OVERVIEW

- 7 -

§2 Overview

§2.1 Brief Introduction

MIG SERIES arc welding machine adopts the latest pulse width modulation (PWM)

technology and insulated gate bipolar transistor (IGBT) power module, which can change work

frequency to medium frequency so as to replace the traditional hulking work frequency

transformer with the cabinet medium frequency transformer. Thus, it is characterized with

portable, small size, light weight, low consumption and etc.

MIG SERIES arc welding machine uses Mix gas as shielded gas to realize gas shielded

welding, active gas（Ar+O2、Ar+CO2）as shielded gas to realize MAG welding and inactive gas

（Ar）as shielded gas to realize MIG welding.

MIG SERIES arc welding machine has automatic protection functions with intelligent to

over-voltage, over-current and over-heat. If any one of the above problems happens, the alarm

lamp on the front panel will be lighted and output current will be shut off automatically to protect

itself and prolong the equipment using life.

MIG SERIES Features:

1. Digital control system, real-time display the welding parameters;

2. High performance multifunction power source (MMA/MIG/MAG);

3. Waveform control, stable welding arc;

4. IGBT technology, low power dissipation;

5. Rated duty circle is 40%(40℃).

MULTIMIG 160/200 has another feature: Synergic control of the welding current and voltage.

MIG SERIES arc welding machine is suitable for all positions welding for various plates made

of stainless steel, carbon steel, alloyed steel, copper, titanium, etc, which is also applied to pipe

installment, mould mend, petrochemical, architecture decoration, car repair, bicycle, handicraft

and common manufacture.

MAG--Metal Active Gas Welding

MIG--Metal Insert Gas Welding

OVERVIEW

- 8 -

§2.2 Working Principle

The working principle of MIG SERIES arc welding machine is shown as the following figure.

Single-phase 220V work frequencyAC is rectified into DC（350V）, then is converted to medium

frequency AC (about 40KHz) by inverter device (IGBT), after reducing voltage by medium

transformer (the main transformer) and rectifying by medium frequency rectifier (fast recovery

diodes), and is outputted by inductance filtering. The circuit adopts current feedback control

technology to insure current output stably when MMA or TIG. And adopts voltage feedback

control technology to insure voltage output stably when MIG. Meanwhile, the welding current

parameter can be adjusted continuously and infinitely to meet with the requirements of welding

craft.

Rectifier Inverter Transformer Rectifier Hall

Current

Feedback

control

Single-phase AC DC AC DC

220V 50Hz

AC DC

Welding current

regulate

(Wire feed speed) Wire feeder

motor

PWM signal

CPU control

Voltage

Feedback

control

§2.3 Volt-Ampere Characteristic

MIG SERIES welding machine has an excellent volt-ampere characteristic, whose graph is shown as the

following figure. The relation between the rated loading voltage U2and welding current I2is as follows:

U2=14+0.05I2(V)

Current sensor

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