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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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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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§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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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
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
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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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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～
％
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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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● 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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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
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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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