SifWeld Evolution MTS200 SYN, Operation Manual

Page 1: ...ration Manual www sifweld com Peters House The Orbital Centre Icknield Way Letchworth Garden City Hertfordshire SG6 1ET Tel 44 0 345 130 7757 MIG Approved TIG MMA TSXE1D200MTS SifWeld Evolution MTS200 SYN ...

Page 2: ... EEA has been used in the design EN60974 1 Arc welding equipment Part 1 Welding power sources EN60974 10 Arc welding equipment Part 10 Electromagnetic Compatibility EMC requirements Additional information restrictive use Class A equipment intended for use in locations other than residential By signing this document the undersigned declares as manufacturer or the manufacturer s authorised represent...

Page 3: ... as damp environments wearing wet clothing and metal structures Try to avoid welding in cramped or restricted positions Ensure that the equipment is well maintained Repair or replace damaged or defective parts immediately Carry out any regular main tenance in accordance with the manufacturer s instructions Safety against fumes and welding gases Locate the equipment in a well ventilated position Ke...

Page 4: ...r the cutting welding area Remove all flammable and combustible materials from the cutting welding zone and surrounding areas Do not cut weld fuel and lubricant containers even if empty These must be carefully cleaned before they can be cut welded Always allow the cut welded material to cool before touching it or placing it in contact with combustible or flammable material Do not work in atmospheres...

Page 5: ...ment that has reached its end of life must be collected separately and returned to an environmentally compatible recycling facility Handling of Compressed gas cylinders and regulators All cylinders and pressure regulators used in welding operations should be handled with care Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face ...

Page 6: ...y 12 2 2 Lift TIG Display 13 2 3 MIG Manual Display 16 2 4 MIG SYN Display 18 2 5 Spool Gun Display 20 2 6 System Setting Panel 21 3 Installation MMA MIG TIG 22 3 1 Wire Feed Roller 29 3 2 Wire Intallation and setup 30 3 3 MIG Totch liner Types 32 4 Operation 33 4 1 Spool Gun 34 5 Troubleshooting 37 6 Maintenance 38 7 Warranty 39 Contents ...

Page 7: ...nsult an authorised SifWeld dealer or visit the SifWeld web site at www sifweld com The specifications presented in this manual are subject to change without prior notice Important notes Items in the manual that require particular attention in order to minimise damage and personal harm are indicated with the NOTE notation Read these sections carefully and follow their instructions Disclaimer While...

Page 8: ... all welding parameters Active PFC technology for increased duty cycle and energy efficiency Multi voltage input can use with long extension lead 230V or 110V MIG MAG with Synergic programs for aluminum mill steel stainless steel and CuSi 2T 4T S4T Spot Weld welding mode function parameter adjustment MMA function Stick electrode Hot start improves electrode starting Adjustable Arc Force DC TIG Lif...

Page 9: ...10 120 130 10 Diameter mm 50 60 36 6 27 6 40 140A 60 115A 100 90A Fe 0 6 0 8 0 9 1 0 SS 0 8 1 0 Flux Cored 0 6 0 8 0 9 1 0 MIG 1 220 230 240 10 25 6 20 2 30 4 40 100A 60 85A 100 65A Al 1 2 0 99 TIG MIG MIG TIG MIG 27 9 4 0 3 0 5 9 4 6 7 0 3 1 25 140 10 140 25 200 10 100 40 200A 60 165A 100 130A Protection class Circuit breaker Dimensions mm Weight Kg Power Factor IP21S JD03 A1 30A 540 245 390 17 8...

Page 10: ...g power output connection socket 5 TIG torch gas connector 6 Power switch 7 Gas inlet connector 8 Input power cable Rear View 6 Power switch 7 Gas inlet connector 8 Input power cable Wire Feeder of machine 9 Spool holder 10 Spool Gun Switch 11 MIG Torch Polarity Change Power Connection 12 Wire feed tension adjustment 13 Wire feed tension arm 14 Wire feeder inlet guide 15 Wire drive roller ...

Page 11: ...ess it to check whether the machine isn t air connected or the gas passage isn t smooth 4 Left parameter knob Press it to select parameters and rotate it to adjust values such as welding current In function interface rotate it to select parameters 5 Function button Press it to select parameters or enter the function interface 6 Right parameter knob Press it to select parameters and rotate it to ad...

Page 12: ... electrode and arc length the welding voltage varies to keep the current constant This can cause instability in some welding conditions as MMA welding electrodes will have a minimum voltage they can operate with and still have a stable arc Arc Force control boosts the welding power if its senses the welding voltage is getting too low The higher the arc force adjustment the higher the minimum volta...

Page 13: ... interface rotate it to select parameters such as trigger mode and Post Flow time 3 Right parameter knob Rotate it to adjust Down Slope time or other parameters 4 Function button Press it to enter the function interface that require a short arc length such as out of position welds FUNCTION INTERFACE 1 Motion Trigger mode 2T 4T Spot weld 2 Post Flow 0 10s ...

Page 14: ...to the minimum welding current from the setting current Iw or Ib and then arc is turned off 7 t4 t5 Post gas time after the arc is turned off You can adjust it 0 0 10s through turnning the knob on the front panel 8 t5 Electromagnetic gas valve turned off the shield gas stops to flow and welding is finished 4T Mode This is known as latching mode The trigger is pulled once and released to activate t...

Page 15: ... Iw or Ib the upslope time can be adjusted 6 t3 t4 Welding process During this period the gun switch is loosen Note Select the pulsed output the base current and welding current will be outputted alternately otherwise output the setting value of welding current 7 t4 Press the torch switch again the welding current will drop in accordance with the selected down slope time 8 t4 t5 The output current...

Page 16: ... function interface rotate it to select parameters 3 Right parameter knob rotate it to adjust Inductance or other parameters 4 Function button Press it to enter the function interface 5 Gas check button 6 Manual wire feed button PANEL FUNCTIONS DESCRIPTIONS 1 panel 0 0 10S 12 t7 Electromagnetic valve is closed and stop argon flowing Welding is finished 3 2 4 MIG Manual display introduction 1 Weldi...

Page 17: ...stant after welding Range 0 10 Slow feed This function is used to regulate the start speed of wire feeding increasing Range 0 10s Spot Weld trigger mode 1 cannot keep up with which makes the welding wire and workpiece disconnected T phenomenon is called burn back This function is to ensure the welding seam is beautiful after welding Range 0 10 Slow feed This function is used to regulate the speed ...

Page 18: ...t parameters 3 R parameter knob Rotate it to adjust parameters 4 Functional button 5 Manual shield gas check button 6 Manual wire feed button The operator simply sets the welding current like MIG welding and the machine calculates the optimal voltage and wire speed for the material type wire type and size and shielding gas being used Obviously other variables such as welding joint type and thickne...

Page 19: ...Manual wire feed button FUNCTION INTERFACE 1 Trigger mode 2T 4T S4T Spot weld No Spot weld in MIG Dual Pulse 2 Wire material SS solid cored Fe solid cored Fe flux cored Al Mg solid cored CuSi 3 Wire diameter 0 6 1 6mm 4 Shield gas CO2 and Ar CO2 20 5 Pre flow time 0 10s PANEL FUNCTIONS DESCRIPTIONS 1 Function interface 1 Trigger mode 2T 4T S4T Spot weld No Spot weld in MIG Dual Pulse 2 Wire materi...

Page 20: ...nal parameter interface rotate it to select parameters 3 R parameter knob Rotate it to adjust parameters 4 Functional parameter button 5 Manual shield gas check button 6 Manual wire feed button Function interface PANEL FUNCTIONS DESCRIPTIONS 1 3 2 6 Spool Gun display introduction 1 Welding mode button Press it to select Spool Gun welding mode 2 L parameter knob Rotate it to adjust wire feeding spe...

Page 21: ...arameter key and hold it for 3s to enter the system interface Here you can adjust the language the unit and the brightness setting by L parameter knob and R parameter knob Press the functional parameter key and hold it for 3s to enter the system interface Here you can adjust the language the unit and the brightness setting by L parameter knob and R parameter knob ...

Page 22: ...able Details of the machine requirements can be found on the rating plate of the machine or in the technical parameters shown in the manual The equipment should be connected by a suitably qualified competent person Always ensure the equipment has a proper grounding Never connect the machine to the mains supply with the panels removed Output connections In general when using manual arc welding elect...

Page 23: ...e electrode against the work piece to create and arc and hold the electrode steady to maintain the arc INSTALLATION OPERATION 1 4 Installation Operation 4 1 Installation Operation for MMA Electrode Welding 4 1 1 Set Up Installation Two sockets are available on this welding machine One Positive and one Negative polarity to connect MMA Electrode holder cable and earth clamp cable Various electrodes ...

Page 24: ...g current will show on display Set down slope time as required The down slope time will show on the digital display INSTALLATION OPERATION 5 Strike the electrode against the work piece to create and arc and hold the electrode steady to maintain the arc 4 2 Installation Operation for TIG Welding 4 2 1 Set Up for TIG Welding 1 Insert the earth cable plug into the positive socket on the front of the ...

Page 25: ...n TIG torch to start the gas flow 14 With a small movement rotate the gas cup forward so that the tungsten electrode touches the work piece 15 Now rotate the Gas Cup in the reverse direction to lift the Tungsten electrode from the work piece to create the arc 16 Release the trigger to stop the welding IMPORTANT It is recommended that you check for gas leaks prior to operation and that the operator...

Page 26: ...ing machine with the outlet on electrical box INSTALLATION OPERATION 4 3 Installation Operation for MIG Welding 4 3 1 Set up installation for MIG Welding Gas shielded wire 1 Insert the earth cable plug into the Negative socket and twist to tighten 2 Plug the MIG welding gun into MIG torch euro connector on the front panel and tighten locking nut securely 3 Connect the MIG polarity change power con...

Page 27: ... spool holder spool retaining nut is left hand thread Feed wire through the inlet guide tube on to the drive roller 6 Place wire onto spool holder spool retaining nut is left hand thread Feed wire through the inlet guide tube on to the drive roller 7 Feed wire over the drive roller into the outlet guide tube push the wire through approx 150mm 8 Close down the top roller bracket and clip the pressu...

Page 28: ...d in them to accommodate the different types of wire The wire is held in the groove by the top roller of the wire drive unit 13 Carefully open the gas cylinder valve and set the required gas flow rate 12 Fit the gas nozzle to the torch head 11 Fit the correct sized contact tip and feed the wire through it screw the contact tip into the tip holder of the torch head and nip it up tightly 11 Fit the ...

Page 29: ...ot less column strength can bend easily and is therefore more difficult to feed Soft wires can easily buckle at the wire feeder where the wire is fed into inlet guide tube of the torch The U shaped roller offers more surface area grip and traction to help feed the softer wire Softer wires also require less tension from the top pressure roller to avoid deforming the shape of the wire too much tensi...

Page 30: ...with MIG welders emanate from poor set up of the wire into the wire feeder The guide below will assist in the correct setup of your wire feeder 1 Remove the spool retaining nut 2 Note the tension spring adjuster and spool locating pin 1 Remove the spool retaining nut 2 Note the tension spring adjuster and spool locating pin INSTALLATION OPERATION 4 Snip the wire carefully be sure to hold the wire ...

Page 31: ...ates an inertia that can cause the spool to run on and the wire loop over the side of the spool and tangle If this happens increase the pressure on the tension spring inside the spool holder assembly using the INSTALLATION OPERAT 4 3 4 MIG Torch Liner Types and Informat MIG Torch Liners The liner is both one of the simplest and most impo sole purpose is to guide the welding wire from the wire up t...

Page 32: ...eads to poor wire feeding and premature liner failure due to excessive wear By contrast larger diameter welding wires 1 2mm through 2 4mm have much higher columnar strength but it is important to make sure the liner has enough internal diameter clearance Most manu facturers will produce liners sized to match wire diameters and length of welding torch cable and most are color coded to suit Teflon a...

Page 33: ...for steel Use a smaller diameter wire for thin base metals For thicker materials use a larger wire diameter and larger machine check the recommended welding capability of your machine As a guide refer to the Welding Wire Thickness Chart below 0 6 Material Thickness Recommended Wire Diameters 0 8mm 0 9mm 1 0mm 0 8 1 0 1 2 1 2mm 1 6mm 2 0mm 2 5mm 3 0mm 4 0mm 5 0mm 6 0mm 8 0mm 10 0mm 14 0mm 18 0mm 22...

Page 34: ...the front of the machine and tighten it 5 Press the Spool gun switch to open Spool Gun welding mode 6 Connect the gas regulator to the gas cylinder and connect the gas line to the regulator 7 Connect the gas line to gas connector on the rear panel 8 Connect the power cord of welding machine with the outlet on electrical box INSTALLATION OPERATION 4 4 Installation Operation for Spool Gun 4 4 1 Set ...

Page 35: ...h the outlet on electrical box 13 Carefully open the gas cylinder valve and set the required gas flow rate 14 Set welding parameters using the knobs as shown on digital displays 11 Feed the wire through the drive rolls and into the inlet guide tube Tighten the wire tension swing arm 12 Pull the trigger to drive the wire down the neck until it exits the contact tip 9 Remove the spool cover by press...

Page 36: ...k ohm remote control potentiometer 7 Wiper arm connection to 10k ohm remote control potentiometer 8 Not connected 9 Not connected Remote Control Socket Gun switch Spool cover switch Adjust current button 4 5 6 7 8 9 Spool gun motor 10k ohm maximum connection to 10k ohm remote control potentiometer Zero ohm minimum connection to 10k ohm remote control potentiometer Wiper arm connection to 10k ohm r...

Page 37: ... E30 E31 E40 E41 Over heating Program default Phase loss N A No gas Under voltage Over voltage Over current Wire feeder over load Button fault on operating panel when switch on the machine Other faults on operating panel when switch on the machine Torch fault when switch on the machine Torch fault during normal working process Cutting torch disconnection N A Connection problem between wire feeder ...

Page 38: ...or of the machine and the fan grills net of any dust and stains for example with a soft brush and vacuum cleaner Do not use pressurised air The stain may become compressed into the grooves of the coolers Do not use a pressure washing device 2 Check the electrical connections of the machine Clean any oxidised connections and tighten the loosened ones Check for the right tension before you start rep...

Page 39: ...scope of the warranty Any warranty repair must be performed by Weldability Sif or an Authorised SifWeld Service Centre The customer is responsible for all shipping costs and risk associated with items that are returned covered under warranty Weldability Sif may opt to refund the purchase price less any costs and depreciation due to use and wear Faults defects found under warranty should be reporte...

Page 40: ...40 www sifweld com Peters House The Orbital Centre Icknield Way Letchworth Garden City Hertfordshire SG6 1ET Tel 44 0 345 130 7757 Fax 44 0 800 970 7757 Email sales weldability sif com www sifweld com ...