MAX ARC MAX-ARC 250 Instruction Manual

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OPERATION INSTRUCTIONS

D I G I T A L A C / D C T I G W E L D I N G M A C H I N E

Used for the MAX-ARC 250 AC/DC, with input power of 220/230/240V,50/60HZ.

CONTENT

1. SAFETY PRECAUTIONS

2. MAIN USAGE AND THE RANGE OF USAGE

3. OPERATION CONDITIONS AND WORK SURROUNDING

4. MAIN TECHNICAL SPECIFICATIONS

5. SKETCH MAPS OF THE PANELS

6. DESCRIPTION OF THE CONNECTIONS

7. SPECIAL FEATURES, DEFINITIONS & GLOSSARY

8. METHOD OF THE OPERATION

9. MAINTENANCE

10. TROUBLES AND REFERENCE SOLUTIONS

11. SCHEMATIC BLOCK DIAGRAM

1.SAFETY PRECAUTIONS

! WARNING

PROPOSITION AND WARNINGS

For Diesel Engines: Diesel engine exhaust and some of its constituents are known to the State of California (USA) to cause cancer, birth defects, and other reproductive harm.

For Gasoline Engines: The engine exhaust from this product contains chemicals known to the State of

California (USA) to cause cancer, birth defects,or other reproductive harm.

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD

CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of "Safety in Welding & Cutting " from the Local Welding Society.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTANANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

! FOR ENGINE

POWERED EQUIPMENTS

1) Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

2) Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

3) Do not add 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. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.

4) Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from Vbelts, gears, fans and all other moving parts when starting, operating or repairing equipment.

5) In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

6) 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.

7) To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

8) To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

1.SAFETY PRECAUTIONS

ELECTRIC AND MAGANETIC FIELDS

MAY BE DANGEROUS

1) Electric Current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding Current creates EMF fields around welding cables and welding machines.

2) EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

3) Exposure to EMF fields in welding may have other health effects which are now not known.

4）All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

a. Route the electrode and work cables together. Secure them with tape when possible. b. Never coil the electrode lead around your body. c. Do not place your body between the electrode and work cables. If the electrode cable is on your

right side, the work cable should also be on your right side.

ELECTRIC SHOCK CAN KILL

1)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.

2)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. In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:

Semiautomatic DC Constant Voltage (Wire) Welder. DC Manual (Stick) Welder. AC Welder with Reduced Voltage Control.

3) In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically "hot".

4)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.

5)Ground the work or metal to be welded to a good electrical (earth) ground.

6)Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.

7)Never dip the electrode in water for cooling.

8)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.

1.SAFETY PRECAUTIONS

9)When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

ARC RAYS CAN BURN

1)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. Head-shield and filter lens should conform to ANSI Z87. I standards.

2)Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.

3)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.

FUMES AND GASES

1)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.

2)Do not weld in locations near chlorinated hydrocarbon vapors coming from 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.

3)Shielding 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.

4)Read and understand the manufacturer's instructions for this equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer's safety practices. MSDS forms are available from your welding distributor or from the manufacturer.

WELDING SPARKS CAN CAUSE FIRE OR

EXPLOSION

1)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.

2)Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to "Safety in Welding and Cutting" (Standard) and the operating information for the equipment being used.

3)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.

1. SAFETY PRECAUTIONS

4)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". For information, purchase "Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances".

5)Vent hollow castings or containers before heating, cutting or welding. They may explode.

6)Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless 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.

7)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.

8)Don't use this machine to defrost pipes

CYLINDER MAY EXPLODE IF DAMAGED

CAN BE DANGEROUS

1)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.

2)Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

3)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.

4)Never allow the electrode, electrode holder or any other electrically "hot" parts to touch a cylinder.

5)Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

6)Valve protection caps should always be in place and hand tight except when the cylinder is in use

or connected for use.

7)Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA

publication P-l, "Precautions for Safe Handling of Compressed Gases in Cylinders," available from the Compressed Gas Local Association.

FOR ELECTRICALLY POWERED EQUIPMENT

1)Turn off input power using the disconnect switch at the fuse box before working on the equipment.

2)Install equipment in accordance with the National Electrical Code, all local codes and the manufacturer's recommendations.

1.SAFETY PRECAUTIONS

3)Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer's

recommendations.

ELECTROMAGNETIC DISTURBANCES MAY BE

TRANSMITTED THROUGH H.F.

ASSESSMENT OF AREA

Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account:

1）other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the welding equipment; 2）radio and television transmitters and receivers; 3）computer end other control equipment; 4）safety critical equipment, e.g., guarding of industrial equipment; 5）the health of the people around, e.g., the use of pacemakers and hearing aids; 6）equipment used for calibration or measurement; 7）the immunity of other equipment in the environment. The user shall ensure that other equipment being used in the environment is compatible. This may require additional protection measures; 8）the time of day that welding or other activities are to be carried out.

INSTALLATION, USE AND AREA EXAMINATION

1）The user is responsible for the installation and use of the equipment according to the manufacturer's instructions. 2）If any electromagnetic disturbance is noticed, the user must soave the problem, if necessary with the

manufacturer's technical assistance. 3）In any case electromagnetic disturbances must be reduced until they are not a nuisance any longer. 4）Before installing this apparatus, the user must evaluate the potential electromagnetic problems that may arise in the surrounding area, considering in particular the health conditions of the persons in the vicinity, for example of persons fitted with pacemakers or hearing aids.

! WARNING

ELECTROMAGNETIC COMPATIBILITY (EMC)

1)CONFORMANCE

Products displaying the CE mark are in conformity with European Community Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility (89/336/EEC). It was manufactured in conformity with a national standard that Implements a harmonized standard: EN 50 199(EN60974-10) Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with our Electric equipment. It is designed for industrial and professional use.

Introduction

All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be transmitted through power lines or radiated through space, similar to a radio transmitter. When

1.SAFETY PRECAUTIONS

emissions are received by other equipment, electrical interference may result. Electrical emissions may affect many kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment.

Installation and Use

The user is responsible for installing and using the welding equipment according to the manufacturer's instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases it could involve constructing an electromagnetic screen enclosing the power source and the work complete with associated Input filters. In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome.

Note: The welding circuit may or may not be earthed for safety reasons according to national codes.

Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury, e.g., by allowing parallel welding current return paths which may damage the earth circuit of other equipment.

Assessment of Area

Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account: a)other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the welding equipment; b)radio and television transmitters and receivers;

c)computer end other control equipment; d)safety critical equipment, e.g., guarding of industrial equipment; e)the health of the people around, e.g., the use of pacemakers and hearing aids; f)equipment used for calibration or measurement; g)the immunity of other equipment in the environment. The user shall ensure that other equipment being used in the environment is compatible. This may require additional protection measures; h)the time of day that welding or other activities are to be carried out.

2.EMISSION REDUCTION METHODS Mains Power Supply

The welding power source must be connected to the supply mains according to the manufacturer's instructions. In case of interference, it may be necessary to take further precautions like the filtering of the mains power supply. It is also necessary to consider the possibility to shield the power supply cable.

Welding Power Source Maintance

The welding power source needs routine maintenance according to the manufacturer's instructions. When the equipment is working, all the access and operating doors and covers must be closed and fixed. The welding power source must not be modified in any way.

Welding and Cutting Cables

The welding cables must be kept as short as possible, positioned near one another and laid at or approximately at ground level.

Equipotential Connection

The earth connection of all the metal component in the welding installation and near it must be taken in consideration. However, the metal component connected to the work-piece will increase the risk of electric shock for the operator, if he touches said metal component and the electrode at the same time. shock for the operator, if he touches said metal component and the electrode at the same time. Therefore,

1.SAFETY PRECAUTIONS

the operator must be insulated from all the earthed metal components. The equipotential connection must be made according to the national regulations.

EARTHING THE WORKPIECE

When the workpiece is not earthed for electrical safety reasons or due to its size and position, Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to other electrical equipment. the earthing of the workpiece may reduce the emissions in some，but not all instances. It is important to remember that the earthing of the workpiece should neither increase the risk of accidents for the operators, nor damage other electric equipment. The earthing must be made according to the national regulations.

SCREENING AND SHIELDING

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire welding installation may be considered for special applications.

RISK

ANALYSIS

Risks posed by the machine

Solutions adopted to prevent them

Risk of wrong installation.

A manual with the instructions for use has been

Electrical risks.

produced for this purpose.

Application of the EN 60974-1 Standard.

Risks connected with electromagnetic disturbances

Application of the EN 50199(EN60974-10)

produced by the welding power source and induced

Standard.

on the welding power source.

2.MAIN USAGE AND THE RANGE OF USAGE

MAX-ARC 250 AC/DC TIG Welder is a triple functional machine used as MMA, AC TIG, DC TIG (PULSE TIG) Welder. All ferrous metals, copper, titanium, stainless steels, aluminum and alloyed materials can be used for full range of welding in all positions. The Welding Current is very stable, and it is also step-less adjustable. The welding performance is very good and the welding seam is nice, very few spatters and low noise occurs during welding. It's light in weight , compact and portable. It's a double inverter system, heavy duty designed, used ATMEGA SCM controlling system and famous brand IGBT transistors. It's particularly suitable for the welding jobs for the enterprises of pressure tanks, vessel buildings, constructions, petrochemicals etc. It's a premier TIG welder by comparing with the traditional types.

3. OPERATION CONDITIONS AND WORK SURROUNDING

1)Operating Conditions:

√Voltage of power source: AC 220/230/240 V ±10% √Frequency: 50/60Hz √Reliable grounding protections

2)Work Surrounding:

▶Relative Humidity: not more than 90 %(average monthly temperature not more than 20℃). ▶Ambient Temperature: -10℃ ~ 40℃.

▶The welding place should not have harmful gas, chemicals, molds and inflammable matter, explosive

and corrosive medium, and no big vibration and bump to the welder.

▶Avoiding water. Operating in rain is not allowed.

4.MAIN TECHNICAL SPECIFICATIONS

Technical specifications

Item No

Max Arc 200

Max Arc 250

Rated Input Voltage

1PH ~ 230V +15%

Max. Load Power Capacity

TIG: 4.5KVA

TIG: 6.3KVA

MMA: 5.6KVA

MMA: 7.1KVA

Rated Duty Cycle (40℃)60%

TIG: 200A/18V

TIG: 250A/20V

MMA: 160A/26.4V

MMA: 200A/28V

100%

TIG: 160A/26.4V

TIG: 200A/18V

MMA: 130A/25.2V

MMA: 160A/26.4V

Welding Current/Voltage Range

TIG: 5A/10.2V~200A/18V

TIG: 5A/10.2V~250A/20V

MMA:10A/20.4V~160A/26.4V

MMA:10A/20.4V~200A/28V

Open Circuit Voltage

10V

Power Factor

0.73

Efficiency

80%

Peak Current

5A~200A

5A~250A

Pulse

Base Current

5A~200A

5A~250A

Pulse Frequency

0.2Hz~200Hz

Pulse Width (Ratio)

1~100%

AC Frequency Range

20Hz~200Hz

TIG

AC Clean Width (AC Balance)

+40~-40

AC Clean Ratio (AC Bias) %

+30~-50

MIX

MIX Frequency:

0.1Hz~5Hz

TIG

DC Balance: (%)

10~90

Arc-starting Current

10A~160A

10A~200A

Crater-filling Current

5A~200A

5A~250A

Current Up-slope Time

0.1S~10S

Current Down-slop Time

0.1S~15S

Pre-Gas Time

0.1S~10S

Flow-Gas Time

0.1S~15S

Spot Arc Time

0.1S~10S

MMA

Arc Force

10A~100A

10A~160A

Hot Start Time

Hot Start Current

5A~100A

5A~160A

Dimension (LxWxH)

490X230X385mm

Weight (KG)

23KG

Water-cooling Unit: WC-100 (optional)

Operating Voltage

230V 50/60Hz

Rated Power

260W

Cooling Power

1.5KW(1L/MIN)

Maximum Pressure

0.3MPA/60HZ

Recommended Cooling Liquid

20%~40% ethanol/water

Tank Volume

6.5L

5.SKETCH MAPS OF THE PANELS

Panel & connections:

Item

Symbol

Description

Control Panel

Output connectors

Power Switch

Input power cable: 1~ phase 220-240V, 50/60Hz.

Gas input connector

Ground/Earth connector

6.DESCRIPTION OF THE CONNECTIONS

4 5 6

Item

Symbol

Description

Gas Bottle

power supply/phase 220~240V,50/60Hz

Foot Pedal

Connection socket, "+" welding current

• TIG: Connection for workpiece lead

• MMA: Electrode holder or workpiece lead connection

Connection socket 5-pole: Standard TIG torch control lead Foot pedal control lead

M16X1.5 ” connecting nipple

Shielding gas connection (with yellow insulating cap) for TIG

Connection socket, "-" welding current

 TIG: TIG welding torch connection  MMA: Electrode holder or workpiece lead connection

7.SPECIAL FEATURES, DEFINITIONS & GLOSSARY

Special Features:

Item

Symbol

Description

MIX TIG:

In a cycle time that mixed with EN/EP output (AC TIG) and EN output (DC TIG).

Electrode Dia. selection

Spot Welding Mode

DC +/- converter output arc-starting of AC TIG process MIX TIG process.

AC Wave Type

MIX TIG mode for every pulse cycle.

7.SPECIAL FEATURES ,DEFINITIONS & GLOSSARY

Special Features:

Item Symbol Description

AC Wave Control System:

AC Frequency Control

AC Balance Control

Independent AC Amperage Control

Memory with capacity of 10 sets parameters.

7.SPECIAL FEATURES, DEFINITIONS & GLOSSARY

AC Waveshape Controls

AC Frequency control

Controls the width of the arc cone. Increasing the AC Frequency provides a more focused arc with increased directional control.

Note: Decreasing the AC Frequency softens the arc and broadens the weld puddle for a wider weld bead.

Wider bead,good penetration ideal for buildup work

Wider bead and cleaning acting

Narrower bead for fillet welds and automated applications

Wider bead and cleaning acting

AC Balance Control

Controls arc cleaning action. Adjusting the

Wider bead,good penetration ideal for buildup work

% EN of the AC wave controls the width of

the etching zone surrounding the weld.

Note: Set the AC Balance control for

adequate arc cleaning action at the sides

Wider bead and cleaning action

and in front of the weld puddle.

AC Balance should be fine tuned

according to how heavy or thick

the oxides are.

Wider bead,good penetration ideal for buildup work

Narrow bead, with no visible cleaning

Independent AC

Amperage Control

More current in EP than E N: Sha llower pe netratio n

More cu rrent in EN than E P: De eper p enetra tion

and faster travel speeds

Allows the EN and EP amperage values to be set

independently. Adjusts the ratio of EN to EP

amperage to precisely control heat input to the

work and the electrode. EN amperage controls the

level of penetration, while EP amperage

dramatically effects the arc cleaning action

along with the AC Balance control.

Wider bead and cleaning action

Narrow bead, with no

visibl e clea ning

7.SPECIAL FEATURES, DEFINITIONS & GLOSSARY

MIX TIG Control:

Features of MIX TIG:

The AC current can get a very good clearance, and DC current can get a deeper penetration. Use the MIX TIG we can get an excellent Arc Concentration, can be carried out the excellent welding performance from thin to thick plate.

1) Nice weld appearance, deep penetration.

2) Excellent Arc Concentration.

3) Substantially reduce the electrode consumption.

MIX TIG

AC TIG

MIX TIG Frequency (Hz):

the cycle time of MIX TIG in 1 second. Adjustable range: 0.1-10Hz.

AC DC

(1Hz)

MIX Frequency

MIX TIG Balance (DC) %:

DC Balance (%) = (tad/Tmix) x 100

AC DC

tad

(MIX Cycle Time:1Hz)

7.SPECIAL FEAURES, DEFINITIONS & GLOSSARY

Definitions & Glossary

Item Symbol Description

Process Selection

Tungsten Electrode Dia.

From 2.0mm to >4.0mm

Pulse ON/OFF selection.

2T/4T holding mode or Spot Welding mode selection

7.SPECIAL FEATURES, DEFINITIONS & GLOSSARY

Definitions & Glossary

Item

Symbol

Description

DC +/- converter output arc-starting of AC TIG process MIX TIG process.

Select the AC wave type: square wave or sine wave.

MIX TIG adjusting

MIX TIG: Pulse Frequency.

MIX TIG:DC output time (DC Balance).

Push to select AC Freq./AC Balance/Independent EN/EP Amperage for adjusting.

AC Frequency.

AC Balance.

Independent AC Amperage Control (EN/EP Balance %).

Remote: used for foot pedal or Remote torch.

Local: adjusted Currents by face panel.

Memory with capacity of 10 sets parameters.

Function sequence (see next chapter)

7.SPECIAL FEATURES, DEFINITIONS & GLOSSARY

Definitions & Glossary

5 6

Item

Symbol

Description

Gas pre-flow time (TIG)

Absolute setting range 0.1 s to 5.0 s (0.1 s increments).

Ignition current (TIG)

Hotstart current (MMA)

Percentage of the main current. Setting

range 1 % to 100 % (1 % increments).

range 1 % to 150 % (1 % increments).

Up-slope time (TIG)

Hotstart time (MMA)

Setting ranges: 0.00 s to 20.0 s

Setting ranges: 0.00 s to 5.0 s

(0.1 s increments).

The up-slope time can be set separately

for non-latched and latched.

Main current (TIG) / pulse current

Main current (MMA)

I min to I max (1 A increments)

Pulse time

Pulse time setting range: 0.01 s to 9.99 s (0.01 s increments)

TIG pulses

TIG AC Special

The pulse time applies to the main current

The pulse time applies to the AC phase for

phase (AMP) for pulses.

AC special.

Pulse break time

Pulse break setting range: 0.01 s to 9.99 s (0.01 s increments)

TIG pulses

TIG AC Special

The pulse break time applies to the

secondary current phase (AMP%)

DC phase with AC special.

Secondary current (TIG) / pulse pause current

Setting range 1 % to 100 % (1 % increments). Percentage of the main current.

7.SPECIAL FEATURES, DEFINITIONS & GLOSSARY

Item

Symbol

Description

8 Down-slope time (TIG)

0.00 s to 20.0 s (0.1 s increments).

The down-slope time can be set separately for non-latched and latched.

9 End-crater current (TIG)

Setting range 1 % to 100 % (1 % increments). Percentage of the main current.

Gas post-flow time (TIG)

Setting ranges: 0.1 s to 20.0 s (0.1 s increments).

Select welding parameters button

This button is used to select the welding parameters depending on the welding

process and operating mode used.

Select welding parameters button

This button is used to select the welding parameters depending on the welding

process and operating mode used.

8.METHOD OF THE OPERATION

Operation: 1.1 MMA connection

In the MMA process, regularly we have 2 connection method. But the most regular and ideal connection type is, Negtive output connector to Electrode holder and Positive output connector to Earth clamp. At such regular connection method we can get deep Penetration and soft Splash.

4 3

Item

Symbol

Description

Electrode holder

Workpiece

_ Connection socket, “-” welding current

Workpiece lead or electrode holder connection

Connection socket for "+" welding current

Electrode holder or workpiece lead connection

8.METHOD OF THE OPERATION

Operation: 1.2 MMA process

Item

Symbol

Description

Process selection switch: DC MMA.

Main Current indicating lamp (AMP) on the face panel would be light.

Adjust the Encoder switch to proset/change the welding current.

Memory is availabe for all the process.

8.METHOD OF THE OPERATION

Operation: 2.1 TIG connection

5 4 3

Item

Symbol

Description

Welding torch

Welding torch hose package

Connection socket, "-" welding current

Welding current lead connection for TIG welding torch

Connection socket

5-pole: Standard TIG torch control lead

Foot pedal control lead

M16X1.5" connecting nipple

TIG welding torch shielding gas connection

Workpiece

Connection socket for "+" welding current

Workpiece lead connection

Foot Pedal

8.METHOD OF THE OPERATION

Operation: 2.2 DC TIG process

Item

Symbol

Description

1 Select the welding process: DC TIG.

2 Pulse ON/OFF selection.

3 2T/4T holding mode selection.

4 Select and adjust the welding parameters.

5 Used to connect the foot-pedal.

Memory is available for all the process.

8.METHOD OF THE OPERATION

Operation: 2.3 AC TIG process

Item

Symbol

Description

Select the welding process: AC TIG.

2 Select the Dia. of Tungsten Electrode.

Pulse ON/OFF selection.

2T/4T holding mode selection.

Arc-start position: DC+/DC-.

Select the AC wave type: square wave or sine wave.

8.METHOD OF THE OPERATION

Operation: 2.3 AC TIG process

Item

Symbol

Description

7 Select and adjust the welding parameters.

Push to select AC Freq./AC Balance/Independent EN/EP Amperage for adjusting.

9 Used to connect the foot-pedal.

Memory is available for all the process.

8.METHOD OF THE OPERATION

Operation: 2.4 MIX TIG process

Item

Symbol

Description

Select the welding process: AC TIG.

Select the Dia. of Tungsten Electrode.

2T/4T holding mode selection.

Arc-start position: DC+/DC-.

Select to adjust:MIX TIG Pulse Freq.MIX TIG DC Balance.

Select and adjust the welding parameters.

Used to connect the foot-pedal.

8.METHOD OF THE OPERATION

Operation: 2.4 MIX TIG process

Item Symbol Description

Memory is available for all the process.

8. METHOD OF THE OPERATION

Operation: 3.1 Memory

MEMORY is available for all the MMA & TIG welding process.

Recall the previous setting from Memory:

1) Push to select the memory channel number.

2) Push to recall/use the settings/parameters of this memory channel.

Also it's available to adjust the parameters and re-store the settings into same memory channel or new channel.

Store the settings to Memory:

1) Select a memory channel to store the recent settings/parameters

. (No push if re-store to same channel)

2) Push to store the settings/parameters to this memory channel.

Also it's available to adjust the parameters and re-store the settings into same memory channel or new channel.

9. MAINTENANCE

In order to guarantee that arc welding machine works high-efficiently and in safety, it must be maintained regularly. Let customers understand the maintenance methods and means of arc welding machine more, enable customers to carry on simple examination and safeguarding by oneself, try one's best to reduce the fault rate and repair times of arc welding machine, so as to lengthen service life of arc welding machine. Maintenance items in detail are in the following table.

Warning: For safety while maintaining the machine, please shut off the supply power and wait for 5

minutes, until capacity voltage already drops to safe voltage 36V.

Date

Maintenance items

Observe that whether panel knob and switch in the front and at the back of arc welding

machine are flexible and put correctly in place. If the knob has not been put correctly in

place, please correct; If you can't correct or fix the knob , please replace immediately;

Daily

If the switch is not flexible or it can't be put correctly in place, please replace

immediately; Please get in touch with our company maintenance service department if

examination

there are no accessories. After turn-on power, watch/listen to that whether the arc

welding machine has shaking, whistle calling or peculiar smell. If there is one of the

above problems, find out the reason to get rid of; if you can't find out the reason,

Please contact local this area our company agent or the branch company. Observe

that whether the display value of LED is intact. If the display number is not intact,

please replace the damaged LED. If it still doesn’t work, please maintain or replace the

display PCB. Observe that whether the min/max value on LED accords with the set

value. If there is any difference and it has affected the normal welding craft, please

adjust it.Check up that Whether fan is damaged and is normal to rotate or control. If the

fan is damaged, please change immediately. If the fan does not rotate after the arc

welding machine is overheated , observe that whether there is something blocked in

the blade, if it is blocked, please get rid of ; If the fan does not rotate after getting rid of

the above problems, you can poke the blade by the rotation direction of fan. If the fan

rotates normally, the start capacity should be replaced; If not, change the fan. Observe

that whether the fast connector is loose or overheated. if the arc welding machine has

the above problems, it should be fastened or changed. Observe that Whether the

current output cable is damaged. If it is damaged, it should be wrapped up, insulated or

changed.

Monthly

Using the dry compressed air to clear the inside of arc welding machine. Especially for

clearing up the dusts on radiator, main voltage transformer, inductance, IGBT module,

examination

the fast recover diode and PCB, etc.

Check up the bolt in arc welding machine, if it is loose, please screw down it. If it is

skid, please replace. If it is rusty, please erase rust on bolt to ensure it works well.

Quarter-

Whether the actual current accords with the displaying value. If they does not accord,

yearly

they should be regulated. The actual current value can be measured by the adjusted

examination

Measure the insulating impedance among the main circuit, PCB and case, if it below

1MΩ, insulation is thought to be damaged and need to change , and need to change or

strengthen insulation.

10. TROUBLES AND REFERENCE SOLUTIONS

Before arc welding machines are dispatched from the factory, they have already been debugged accurately. So

forbid anyone who is not authorized by our company to do any change to the equipment!

Maintenance course must be operated carefully. If any wire becomes flexible or is misplaced,

it maybe potential danger to user!

Only professional maintenance personal who is authorized by our company could overhaul the machine! Guarantee to shut off the arc welding machine’s power before turn on the outline of the equipment! If there is any problem and has no the authorized professional maintenance personal of our company,

please contact local our company agent or the branch company!

Simple troubles and reference solutions:

S/N

Troubles

Reasons

Solutions

Turn on the power source, and

The power light damaged

Test and repair the inside

fan works, but the powerlight

O rconnection is not good

circuit of power light

is not on.

Power PCB

Repair or change power PCB

Turn on the power source,and

There is something in the fan

Clear out

the power light is on, but fan

doesn’t work

The fan motor damaged

Change fan motor

Turn on the power source,and

No input

Check whether there is input

the power light is not on, and

voltage

fan doesn’t work

Overvoltage (Input voltage is too

Check input voltage

much or not)

No no-load voltage output

There is trouble inside the

Check the main circuit

machine

No current output in the welding

Welding cable is not connected

Connect the welding cable to

with the two output of the welder.

the welder’s output

Welding cable is broken

Wrap, repair or change the

welding cable

Earth cable is not connected or

Check the earth clamp

loosen

Not easy to start arc in

The plug loosen or connect not

Check and tighten the plug

The welding, or easy to sticking

well

6.1

(MMA) cause

Oil or dust covered the workpiece Check and clear out

MMA/TIG welding selection is

Selecting the MMA welding

wrong

HF arc start difficult or

Ignition Coil damaged

Change the Ignition Coil

cannot(TIG)

HF discharge gap oxidized

Remove the oxide layer

6.2

carbon deposits.

and carbon deposits, and

adjust the discharge gap to

0.8-1mm.

Torch too far away from the

Make the torch & Tungsten

workpiece.

electrode closer to the

workpiece.

10.TROUBLES AND REFERENCE SOLUTIONS

S/N

Troubles

Reasons

Solutions

6.2

HF arc ignition device

Change the HF arc

damaged.

ignition device.

The arc is not stable in the

The arc force is too small

Increase the arc force

7.1

welding process (MMA)

Argon gas flow improperly

Properly adjust the argon gas

adjusted, or TIG torch damaged. flow rate, or change the torch.

Tungsten electrode damaged. Change the tungsten

electrode or sharpen it.

The arc is interrupted or

7.2

Welding current does not match

Correctly choose the diameter

tungsten electrode consumed

the diameter of tungsten

of tungsten electrode and

too fast (TIG).

electrode.

adjust the welding current

accordingly.

Gas delay time is too short.

Increase the post gas time.

Cleaning width (AC BALANCE)

Re-set the AC BALANCE

setting is incorrectly.

value.

The welding current can not

The welding current potentiometer

Repair or change the

be adjusted

in the front panel connection not

potentiometer

so good or damaged

The penetration of molten pool

The welding current adjusted too

Increase the welding current

is not enough(MMA)

low

The arc force adjusted too small

Increase the arc force

Airflow disturbance

Use the shelter from airflow

The electrode eccentricity

Adjust the electrode angle

Arc blow

Change the electrode

Magnetic effect

Incline the electrode to the

opposite way of the magnetic

blow

Change the position of earth

clamp or add earth cable in

the two side of workpiece

Use the short arc operation

Over heat

Over welding

Induce the welding current

protection

current

output

Working time

Induce the duty cycle

The alarm light is on

too long

(interval work)

Over current

Unusual

Test and repair the main

protection

current in the

circuit and drive PCB

main circuit

11.SCHEMATIC BLOCK DIAGRAM

MAX ARC MAX-ARC 250 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual