Sweiss SKYARC One FX, SKYARC 2050 FX Operator's Manual

2012 12

．

Inverter DC MMA Arc Welding Machine

OPERATORS’ MANUAL

SKYARC One FX / 2050

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 yo

o not fully understand this manual.

u d

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I

INTRODUCTION

CONTENT

§1 SAFETY ............................................................................................................................................ 1

§1.1 S

§2 SUMMARY ....................................................................................................................................... 6

§3 INSTALLATION & ADJUSTMENT .............................................................................................. 7

§4 OPERATION CONTROL AND CONNECTORS ......................................................................

§5 MAINTENANCE & TROUBLESHOOTING ...............................................................................

IGNAL EXPLANATION .................................................................................................................1

§1.2 A

RC WELDING DAMAGE ..............................................................................................................1

§1.3 T

HE KNOWLEDGE OF ELECTRIC AND MAGNETIC FIELDS ...........................................................4

§2.1 B

RIEF INTRODUCTION .................................................................................................................6

§2.2 W

§2.3 V

ORKING PRINCIPLE ..................................................................................................................7

OLT-AMPERE CHARACTERISTIC ...............................................................................................7

§3.1 PARAMETERS ...............................................................................................................................7

§3.2 D

UTY CYCLE & OVER HEAT.........................................................................................................8

§3.3 W

ELDING POLARITY CONNECTION WAY.......................................................................................8

§3.3.1 MMA (take DM-1600P for an example) .........................................................................

§3.3.2 TIG (take DM-1600P for an example) ............................................................................

§4.1 L

AYOUT FOR FRONT & REAR PANEL (EXAMPLE FOR DM-1600P) ........................................... 10

§4.2 W

§4.3 W

§4. 4 W

ORK PROCESS ....................................................................................................................... 11

ELDING CURRENT ADJUSTMENT ............................................................................................. 11

ELDING OPERATION ............................................................................................................... 12

§4.4.1 Striking arc way ...............................................................................................................

§4.4.2 Manipulation of electrode ...............................................................................................

WELDING PARAMETERS ............................................................................................................. 12

§4.5

§4.5.1 Joint form in MMA ...........................................................................................................

§4.5.2 Electrode selection ..........................................................................................................

RC WELDING DEFECT AND PREVENT METHOD ..................................................................... 14

§4.6 A

§4.7 O

PERATION ENVIRONMENT ....................................................................................................... 15

§4.8 O

PERATION NOTICES ................................................................................................................ 15

§5.1 M

AINTENANCE ........................................................................................................................... 16

§5.2 T

ROUBLESHOOTING ................................................................................................................... 17

§5.3 E

LECTRICAL PRINCIPLE DRAWING ............................................................................................. 20

8
9

10

12
12

12
13

16

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II

§1.1 Signal Explanation

§1 SAFETY

SAFETY

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.

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

to a good electrical (earth) ground according to 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

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1

SAFETY

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 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 wh

ich produc

e 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

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.

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.

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 p

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ractices.

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SAFETY

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 spatte

SELF-PROTECTION

r or metal.

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. Do not spill fuel when filling

tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.

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

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WELDING SPARKS can cause fire or explosion.

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SAFETY

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.

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 discuss 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

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SAFETY

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.

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 arc.

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SUMMARY

§2 Summary

§2.1 Brief Introduction

SKYARC One FX /2050 welders are general MMA arc welder which adopts the

latest pulse width modulation (PWM) technology and the insulated gate bipolar

transistor (IGBT) power module. It uses digital control system. It 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, low c

onsumption and etc.

SKYARC One FX / 2050 have excellent performances: real time display and current

preset makes it convenient to use; fan demand makes the machine save the energy;

constant current output makes welding arc more stable; fast dynamic response speed

reduces the impact from the arc length fluctuation to the current; accurate stepless

current adjustment and pre-setting function. There are also some automatic protection

functions for under voltage, over current, over heat, etc. inside the welders, when the

problems listed before occurred, the alarm on the front panel is light and at the same

time the output current will be cut off. It can self-protect and prolong the using life and

greatly improved the reliability and practicability of the welders.

SKYARC One FX / 2050 welders can also realize TIG operation. While MMA

operation, if the electrode touches workpiece over two seconds, the welding current will

drop to the minimum current automatically to protect the electrode. While TIG operation,

the minimum current will be outputted firstly until the arc is ignited by lifting method, the

output current will rise to the preset value, which can protect the electrode. At the same

time, the arc force and hot start will be provided with MMA operation.

MMA——Manual Metal Arc welding;

PWM——Pulse-Width Modulation;

IGBT——Insulation Gate Bipolar Transistor;

TIG——Tungsten Inert Gas welding.

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6

U

2

V

（44

Volt-ampere characteristic

）

Working

The relation of the rated loading

voltage&welding current

point

20

0

600

I

2

A

7

（ ）

SUMMARY

§2.2 Working Principle

The working principle of SKYARC One FX / 2050 ULTRA POWER welder is shown as the

following figure. Single phase

then by ULTRA POWER circuit,

frequency AC (about 20KHz) by inverter device (IGBT module), after reducing voltage by

medium transformer (the main transformer) and rectified by medium f

110V 220V±10%work frequency (50/60 Hz) AC is rectified into DC,

DC(about 370V)is converted to medium

－

requency rectifier (fast

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

control technology to insure current output stably. Meanwhile, the welding current parameter

can be adjusted continuously and steplessly to meet with the requirements of welding craft.

§2.3 Volt-Ampere Characteristic

SKYARC One FX / 2050 welders have excellent volt-ampere characteristic, seeing

the following

and welding current I

When I2 ≤600A，U2＝20＋0.04 I2（V）；When I2＞600A，U2＝44（V）.

graph. In MMA welding, the relation between the rated loading voltage U2

2 is as follows:

64

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Models

SKYARC One FX

Parameters

Input power

Single phase,98V-165V,50/60Hz

Single phase,177V-265V, 50/60Hz

TIG

MMA TIG

MMA

Rated input current

A

23

33 15

23.5

Rated input power

KW

2.62

3.75 3.3

5.02

Power factor

0.99

0.99

Welding current range

A

5

125

5

170

Max no-load voltage(V)

71

71

Efficiency

≥80

≥80

Duty

cycle

40

℃

10

50%

125A

30% 125A 40%

160A

40% 160A

（ ）

minutes

see §3.2

）

100%

100A

100%

60A 100%

80A

100%

80A

（

Protection class

（ ）

～

IP23S

Insulation class

F

Dimensions of Machine

400×140×230

L×W×H

mm

Weight

Kg

7.8

（ ，

Note: The above parameters are subject to change with the improvement of machines.

），

）

Models

SKYARC 2050 FX

Parameters

Input power

Single phase 98V-165V

50/60Hz

Single phase 177V-265V

50/60Hz

（

）（

）

TIG

MMA TIG

MMA

Rated input current

A

23

33 23

32

（

）

Rated input power

KW

2.62

3.75 5.24

6.72

Power factor

0.99

0.99

Welding current range

A

5

110

， 5

200

，

Max no-load voltage(V)

52

52

Efficiency

（ ）

≥80

≥80

Duty

cycle

40

℃

10

50%

125A

30% 125A 50%

200A

50% 200A

minutes

see §3.2

）

100%

100A

100%

60A 100%

80A

100%

80A

（

Protection class

（ ）

～

IP23S

Insulation class

F

Dimensions of Machine

400×140×230

L×W×H

mm

Weight

Kg

8

（ ，

INSTALLATION AND ADJUSTMENT

§3 Installation & Adjustment

§3.1 Parameters

％

～

％

％

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7

～

％

INSTALLATION AND ADJUSTMENT

Note: The above parameters are subject to change with the improvement of machines.

§3.2 Duty cycle & Over heat

The letter “X” stands for duty cycle, which is defined as the proportion of the time that a
machine can work continuously within a certain time (10 minutes). The rated duty cycle
means the proportion of the time that a machine

X

can work continuously within 10 minutes when it

100

outputs the rated welding current.

The relation between the duty cycle “X” and

the output welding current “I” is shown as the

right figure.

If the welder is over-heat, the IGBT over-heat

protection unit inside it will output an instruction

to cut output welding current, and brighten

the over-heat pilot lamp on the front panel. At this time, the machine should be relaxed

for 15 minutes to cool the fan. When

operating the machine again, the welding output current or the duty cycle should be

reduced.

Choosing the connection of DCEN or DCEP is based on the arc stable burning condition. The

different electrodes need different connection way. Please refer to the electrode manual.

8

§3.3 Welding polarity connection way

§3.3.1 MMA (take SKYARC one FX for an example)

The relation between duty cycle and

welding current for ONE/2050

Welding holder

electrode

workpiece

Welding holder

electrode

workpiece

DCEN

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DCEP

● When

TIG operation,

the shielded gas is inputted

Welding gun

to welding gun directly, and

the method of lifting arc is

Workpiec e

adopted.

welding

2 Scrape the electrode

3 Lift arc.

Steps of scraping arc

§3.3.2 TIG (take SKYARC for an example)

INSTALLATION AND ADJUSTMENT

SKYARC

Ar

1Plac e theDCEN gun aslant.

Stricking arc of TIG operation when tungsten electrode touches～ the workpiec e，the short-cir cuit current is onl y 10A. After ge nerating arc, c urrent can ris e to the setting welding current .If the tungest en electrode to uches the wor kpiece when welding, the curre nt will drop to 10A within 2s, which ca n reduce the t ungsten spoilage farthestly，pr olong the using li fe of the tu ngsten electrode， and prevent tungsten clipping.

with the workpiece.

2

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OPERATION CONTROL AND CONNECTORS

1) Current display

Display the pre-setting and realtime welding current

2) VRD OFF lamp

This pilot lamp indicates while welding ,or the VRD function

is closed in the MMA mode.

3) VRD ON lamp

This pilot lamp indicates when after welding or the VRD

function is openned in the MMA mode.

4) Alarm lamp

Over-heat or over-current.

5) Power lamp

This pilot lamp indicates when the main switch is

openned

1.

Choose

TIG，refer to§3.3.2.

7)

Welding current regulation Set welding current（5～160A）.

8)

Earth connection

Negative polarity output

§4 Operation control and connectors

§4.1 Layout for front & rear panel (example for SKYARC ONE/2050)

6) Conversion switch Choose ，MMA，refer to§3.3.1.

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10

，

9)

Welding connection

Positive polarity output

10)

Cable clamp

Fastened the mains cable

11)

Mains switch.

§4.2 Work Process

Open the

machine

The fan works,

system

initialize 2s

OPERATION CONTROL AND CONNECTORS

Start

welding?

N

the fan stops,

1 min after

initialization

Y

Fan continuous

works and goes to

welding program

N

Alarm?

Y

N

Welding

finish?

Y

Fan stops

after 8 mins

§4.3 Welding current adjustment

Take example for SKYARC 2050. Welding current

welding current display will show the ampere. It is convenient

A

to set parameters and adjust accurately.

range is 10～200A。

SKYARC 2050 welder has the function of welding current
pre-setting. Before welding, adjusting welding current, the

Inverter stops,

alarming Light is on

and fan works

Y N

Resolved?

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electrode electrode

up

workpiece

touch

workpiece

2 4mm

The Electrode touch the workpiece

Lift up for about 2-4mm

1-electrode moving; 2-the electrode swing right & left; 3-the electrode move along weld

2

§4. 4 Welding operation

§4.4.1 Striking arc way

Knocking arc: take the electrode upright to touch the workpiece, after

forming short circuit, quickly lift up about 2~4 mm, and arc will be ignited.

This method is difficult to master. But in the welding for the brittle or hard

OPERATION CONTROL AND CONNECTORS

steel, it is better to use knocking way.

electrode

workpiece

Take the electrode upright

electrode

upright

Lifting arc: take the electrode to

workpiece

1

weld

2

3

scrape the work piece for striking arc.

But it may cause the arc scratch, so

must to lift arc in the groove.

§4.4.2 Manipulation of electrode

In MMA welding, there are three motions

to being matched in the end of electrode: the
electrode moving to the molten pool

along axes; the electrode swing right and left; the electrode moving along welding

way.

The operator can choose the manipulation of electrode based on welding

～

joint sharp, welding position, electrode spec, welding current and operation skill,
etc. The details please refer to《Welding Dictionary》P69, Volume 1 of Edition 2.

§4.5 Welding parameters

§4.5.1 Joint form in MMA

In MMA welding, the common basic joint form: butt joint, lap joint, corner joint

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Electrode

1.6

2.0

2.5

3.2 diameter/mm

Welding current/A

25 40 40 60

50

80

100 130

The relation between the welding current(I)’ factor(K) & electrode diameter(d) (I K×d: Carbon electrode)

Electrode

1.6

2

2.5

3.2

diameter/mm

Factor/K

20

25

～

30

30

40

25

～ ～

～

～

Notice: the above parameters originate from Welding

Dictionary P66～P67,

Volume 1 of Edition 2.

～

～

Electrode should

be drying

according to

user

manual

before

using. For

& T joint.

butt joint lap joint corner joint T joint

§4.5.2 Electrode selection

OPERATION CONTROL AND CONNECTORS

The electrode diameter selection is based on the work piece thickness, welding

position, joint form, welding layer, etc. Please refer to the following table.

The welding current reference for different electrode diameter

reducing the hydrogen of the molten pool and welding seam, and avoiding

～

the blowhole and cold crack.

In the welding process, the arc must not be too long; otherwise, it will

cause unstable arc burning, large spatter, light penetration, undercut,

blowhole, etc. If the arc is too short, it will cause electrode stick.

In MMA welding the arc length is usually equal to 0.5~1.0 time of the

electrode diameter. The basic electrode’s arc length is not beyond the

electrode diameter, it’s better to choose the short arc welding; the acid

electrode’s arc length is equal to the electrode diameter.

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Defect name

Caused reasons

Prevent methods

Welding

The groove angle is not proper

Choosing the proper groove angle & assembly

seam

The root face and assembly gap is not equal

gap, improve the assembly quality

doesn’t

Welding

technics

parameters

are Choosing the proper welding parameters

meet the

unreasonable

Improve the operation skill of welders

requirement

The welder’s operation skill is lower

Over current

Choosing the proper welding current & speed

Undercut

Arc length is too long

The arc can’t be drawn too long

The electrode angle is wrong

The electrode angle should be proper

Manipulation of electrode is not proper

Manipulation of electrode should be correct

The groove angle or gap is too small, the root

Correctly to choose and process the groove

Incomplete

face is too big

size

Welding parameters are not suitable, or the

Correctly to assemble and ensure clearance

penetration

assembly is not good

Choosing the suitable welding current & speed

The welder’s operation skill is lower

Improve the operation skill of welders

The welding thermal input is too low

Incomplete

The arc direction is lean

Correctly to choose the welding parameters

There are rust & dust on the side of groove

Operation seriously

fusion

The slag between the layers is not cleared

Enhance the clearness of layers

well

The temperature of molten pool is too high

Choosing parameters based on the welding

Overlap

different position

The liquid metal concretes slowly

Strictly to control the molten hole size

In the crater, electrode should be stayed for a

Crater

The crater time lasts too short

short time or round to manipulate electrode

Over current in the welding of thin plate

after the molten pool is filled in by metal, take

to the side for crater

There are some dust like oil, rust or water on

Clear out the dust around groove for about

the work piece surface and groove

20

30mm

The coating of electrode is damped& is not

Strictly to

dry the

electrode

according to

drying

manual

Under current or over speed in the welding

Blowhole

Correctly to choose parameters and to operate

The arc is too long

or lean burning,

the

Using the short arc operation

molten pool protection is not good

Welding operation

in the field

should

have

Over current, the coating of electrode falls

anti-wind protection

off and lose protection

Don’t use the invalid electrode

Manipulation of electrode is not proper

The slag clears bad in the middle layer in the

welding process

Choosing the electrode of good slag

Inclusion &

Under current or over speed in the welding

detachability

Welding operation is not proper

～

slag

Strictly to clear the slag in the layers

The welding material

can not match

the

Correctly to choose the welding parameters

inclusion

work piece

Adjusting

the

electrode

angle

and

The groove design & processing are not

manipulation way

proper

In the process of solidification, the inter

Strictly control the percentage of S and P in

Hot crack

crystal segregation is seriously caused. At the

welding material.

same time, with the effect of welding stress,

Adjust the structure of welding material.

the hot crack is formed.

Adopt the basic electrode.

Three reasons will cause cold crack:

Adopt low hydrogen type basic electrode.

Bake under the instruction before use.

The structure turned from the marten site

Remove the feculence before use, reduce the

Cold crack

The residual

stress caused by big restraint

percentage of hydrogen

intensity

Adopt appropriate parameters and heat input

The residual hydrogen in welding gap.

After welding, do dehydrogenation at once.

OPERATION CONTROL AND CONNECTORS

§4.6 Arc Welding Defect and Prevent Method

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OPERATION CONTROL AND CONNECTORS

§4.7 Operation Environment

·Height above sea level is below 1000m.

·Operation temperature range:-100C～+400C.

·Relative humidity is below 90 %(+200C).

·Preferably site the machine some angles above the floor level, the maximum

angle does not exceed 150.

·Protect the machine against heavy rain or in hot circumstance against direct

sunshine.

·The content of dust, acid, corrosive gas in the surrounding air or substance

can not exceed normal standard.

·Take care that there is sufficient ventilation during welding. There is at least

30cm free distance between the machine and wall.

§4.8 Operation Notices

·Read §1 §4.2 carefully before attempting to use this equipment.

·Connect the ground wire with the machine directly, and refer to §3.5.

·Input power must be AC as one phase, 50Hz, 220/230V. Forbid working in
lacking any phase。

·In case closing the power switch, no-load voltage may be exported. Do not

touch the output electrode with any part of your body.

·Before operation, no concerned people should be left. Do not watch the arc

in unprotected eyes.

·Ensure good ventilation of the machine to improve duty ratio.

·Turn off the engine when the operation finished to economize energy sources.

·When power switch shuts off protectively because of failure. Don’t restart it until

problem is resolved. Otherwise, the range of problem will be extended.

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MAINTENANCE AND TROUBLESHOOTING

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;

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 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

Daily

number is not intact, please replace the damaged LED. If it still doesn’t work,

please maintain or replace the display PCB.

examination

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.

§5 Maintenance & Troubleshooting

§5.1 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 le

welding machine .Maintenance items in detail are in the following table.

ngthen service life of arc

● 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.

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MAINTENANCE AND TROUBLESHOOTING

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

Especially for clearing up the dusts on radiator, main voltage transformer,

Monthly

inductance, IGBT module, the fast recover diode and PCB, etc.

examination

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

yearly

not accord, they should be regulated. The actual current value can be

examination

measured by the adjusted plier-type ampere meter.

Yearly

Measure the insulating impedance among the main circuit, PCB and case,

if it below 1MX, insulation is thought to be damaged and need to change ,

examination

and need to change or strengthen insulation.

§5.2 Troubleshooting

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 o

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!

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n the

S/N

Troubles

Reasons

Solutions

The power light damaged or

Test and repair the inside

1

Turn on the power source, and fan works,

connection is not good

circuit of power light Pr3

but the power light is not on.

Power PCB failures

Repair or change power PCB

Pr2

2

Turn on the power source, and the power

There is something in the fan

Clear out

light is on, but fan doesn’t work

The fan motor damaged

Change fan motor

No input voltage

Check whether there is input

voltage

3

Turn on the power source, and the power

light is not on, and fan doesn’t work

Overvoltage (Input voltage is

Check input voltage

too much or not)

4

No no-load voltage output

There

is

trouble inside

the

Check

the main circuit,

Pr1

machine

and Pr2

Welding

cable

is

not

Connect the welding cable to

connected with

the

two

the welder’s output

output of the welder.

Welding cable is broken

Wrap,

repair

or change

the

welding cable

5

No current output in the welding

Earth cable is not connected

Check the earth clamp

or loosen

The plug loosen or connect

Check and tighten the plug

not well

Oil

or dust

covered

the

Check and clear out

workpiece

6

Not easy to start arc in the welding, or

easy to cause sticking

MMA/TIG welding selection is

Selecting the MMA welding

wrong

7

The arc is not stable in the welding

The arc force is too small

Increase the arc force

process

The

welding

current

8

The welding current can not be

potentiometer

in

the front

Repair

or

change

the

adjusted

panel

connection

not

so

potentiometer

good or damaged

The welding current adjusted

Increase the welding current

too low

9

The penetration of molten pool is not

The

arc

force

adjusted

too

enough(MMA)

Increase the arc force

small

Airflow disturbance

Use the shelter from airflow

Adjust the electrode angle

The electrode eccentricity

Change the electrode

10

Arc blow

Incline the electrode to the

Magnetic effect

opposite way of the magnetic

blow

MAINTENANCE AND TROUBLESHOOTING

If there are some simple troubles of SKYARC One FX / 2050 welding machines, you can consult the

following overhauling chart:

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Change the position of earth

clamp or add

earth cable in

the two side of workpiece

Use the short arc operation

Over welding

Induce

the

welding

current

Over

heat

current

output

protection

Working time

Induce

the

duty

cycle

11

The alarm light is on

too long

(interval work)

Over

current

Unusual

Test and

repair the main

current in the

protection

circuit and drive PCB (Pr1)

main circuit

MAINTENANCE AND TROUBLESHOOTING

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MAINTENANCE AND TROUBLESHOOTING

§5.3 Electrical principle drawing – SKYARC One FX / 2050

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NOTES

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