SifWeld Evolution MTS500 DP, Operation Manual

Page 1: ...eration Manual www sifweld com Peters House The Orbital Centre Icknield Way Letchworth Garden City Hertfordshire SG6 1ET Tel 44 0 845 130 7757 MIG Approved TIG MMA TSXE3D500MTS SifWeld Evolution MTS500 DP ...

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 representa...

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: ... 16 2 4 MIG Manual Display 19 2 5 MIG SYN Display 20 2 6 Spool Gun Display 21 2 7 JOB programme Display 22 2 8 System Setting Panel 23 3 Installation 24 3 1 Torch switch Control 27 3 2 Remote Torch Control 28 3 3 Pedal Switch Control 29 3 4 Wire Feed Roller 33 3 5 Wire Installation 34 3 6 MIG Torch Liner 36 4 Operation 37 4 1 Spool Gun 38 5 Troubleshooting 41 6 Maintenance 42 7 Warranty 43 Content...

Page 7: ...onsult 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 Whil...

Page 8: ... aluminium Featuring IGBT technology and providing a lightweight multi process machine a separate feed system with full feature control Features 500A Three phase MIG welding machine with separate wire feed unit Synergic features including Dual Pulse programs for steels aluminium and mig brazing Very high duty cycle 100 at 400A 60 at 500A Perfect machine for high production environment Programmable...

Page 9: ... MTS500 DP Input Voltage V Diameter mm 50 60 40 9 58 1 Fe 0 6 0 9 1 0 1 2 1 6 SS 0 8 0 9 1 0 1 2 1 6 Flux Cored 0 6 0 8 0 9 1 0 1 2 1 6 3 400 10 42 3 92 9 Al 1 0 1 2 1 6 0 75 MIG TIG 32 9 28 4 28 9 22 9 15 500 10 500 92 8 60 500A 100 400A Protection class Circuit breaker Dimensions mm Weight Kg Power Factor IP21S D32A 620 x 260 x 430 33 8 10 500 MMA No load Voltage V ...

Page 10: ... Connect the inlet of TIG gun 3 TIG gun control connector 4 Positive Output When TIG mode this polarity must conne 5 Gas Inlet Connect the gas conduit 6 Positive Output Used to connect to the welding cable of w 7 Wire feeder connector Used to connect to the control cab 8 Water Cooler connector To connect water box 9 Power source input To connect power source 10 Power switch Turn on power supply cl...

Page 11: ...ater inlet for MIG red Wire feeder 1 MIG gun connector 2 9 core Gas Socket for Spool gun 3 Water outlet 4 Water inlet 5 Gas connector 6 Control anode 7 Positive output anode 8 Water inlet Water outlet 9 Wire reel Shaft 10 Wire Feed Motor 11 Wire feed tension adjustment 2x 12 Wire feed tension arm 2x 13 Wire feeder inlet guide 14 Wire drive roller 2x PANEL FUNCTIONS DESCRIPTIONS 6 Front and rear pa...

Page 12: ... for electrode types that have a higher operating voltage requirement or joint types that require a short arc length such as out of position welds 1 Welding mode button Press it to select MMA welding mode 2 L parameter knob Rotate it to adjust welding current 3 R parameter knob Press it to select Hot start or Arc force and rotate it to adjust value Setting range 0 10 Hot start Hot start provides e...

Page 13: ...unctional parameter button 5 Cooling mode button Press it to select water cooling mode TIG functional parameter interface 1 Trigger mode 2T or 4T 2 Down slope time 0 10s 3 Post flow time 0 10s 1 Welding mode button Press it to select TIG Lift welding mode 2 L parameter knob Rotate it to adjust welding current In functional parameter interface rotate it to select parameters 3 R parameter knob Rotat...

Page 14: ...e rotate it to select parameters 3 R parameter knob Rotate it to adjust Down Slope time and other parameters 4 Functional parameter button 5 Cooling mode button Press it to select water cooling mode TIG functional parameter interface 1 Trigger mode 2T or 4T 2 Down slope time 0 10s 3 Post flow time 0 10s 1 Trigger mode 2T or 4T 2 Down slope time 0 10s 3 Post flow time 0 10s ...

Page 15: ...Gas Supply Wire Feed Output Voltage Output Current End Current conditions Self Locking Function 4T mode Latching Pre Gas Time Slow Feed Time Post Gas Time Welding conditions Gun Switch Gas Supply Wire Feed Output Voltage Output Current Burn back Time 2T mode ON OFF Trigger Mode Select ...

Page 16: ... It is mainly used in aluminum alloy welding for strong penetration with narrow bead and smooth surface It can produce the ripple effect of a TIG weld without torch modulation Dual pulse reference waveform as shown below Wire feed Currant Dual Pulse Frequency Set pulse frequency as shown in Figure regulating the value of time T namely ripplepattern of density regulation Higher Hz produces many sho...

Page 17: ...it to adjust parameters 4 Functional parameter button 5 Cooling mode button Press it to select water cooling mode 6 Manual shield gas check button 7 Manual wire feed button 1 Welding mode button Press it to select MIG Pulse or Dual Pulse welding mode 2 Left parameter knob Rotate it to adjust wire feeding speed In functional parameter interface rotate it to select parameters 3 Right parameter knob ...

Page 18: ...er interface 1 Trigger mode 2T 4T Spot weld 2 Pre flow time 0 10s 1 Trigger mode 2T 4T Spot weld 2 Pre flow time 0 10s 3 Post flow time 0 10s 4 Burnback 0 10 5 Slow feed time 0 10s MIG Dual Pulse functional parameter interface Burnback Short circuit between welding wire and molten pool leads to the increase of current which leads to the melting speed of welding wire too fast and the wire feeding s...

Page 19: ...ire feeding speed In functional parameter interface rotate it to select parameters 3 R parameter knob Rotate it to adjust parameters 4 Functional parameter button 5 Cooling mode button Press it to select water cooling mode 6 Manual shield gas check button 7 Manual wire feed button 2 4 MIG Manual control panel ...

Page 20: ...tate it to adjust wire feeding speed In functional parameter interface rotate it to select parameters 3 R parameter knob Rotate it to adjust parameters 4 Functional parameter button 5 Cooling mode button Press it to select water cooling mode 6 Manual shield gas check button 7 Manual wire feed button 2 5 MIG SYN control panel ...

Page 21: ...this variation when the current setting is changed To reset the voltage for a synergic program back to factory default change to another program and back again PANEL FUNCTIONS DESCRIPTIONS Spool Gun control panel 1 Welding mode button Press it to select Spool Gun welding mode 2 L parameter knob Rotate it to adjust wire feeding speed In functional parameter interface rotate it to select parameters ...

Page 22: ... Burnback 0 10 5 Slow feed time 0 10s JOB Program control panel In the JOB mode 100 different JOB records can be stored and recalled When leaving the factory has no saved JOB programs therefore operator must first save a program 1 JOB button Press it for 3s to enter JOB programs and press it for 1s to save parameters 2 Parameters display Here are all the selected parameter that you settings 3 JOB ...

Page 23: ...ss button 5 for three to five seconds then press Button 4 for three to five seconds Supervisor Lock PANEL FUNCTIONS DESCRIPTIONS 1 1 Trigger mode 2T 4T Spot weld 2 Pre flow time 0 10s 3 Post flow time 0 10s 4 Burnback 0 10 5 Slow feed time 0 10s 3 2 7 System setting panel Press the functional parameter key and hold it for 3s to enter the system interface Here you can adjust the language the unit a...

Page 24: ...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 25: ... polarity DCEP Electrode connected to Positive output socket DCEN Electrode connected to Negative output socket 1 Turn the power source on and press the welding mode button to select the MMA function 2 Set the welding current relevant to the electrode type and size being used as recommended by the electrode manufacturer 3 Set the Hot Start and Arc Force using the knob 4 Place the electrode into th...

Page 26: ...ear panel Check for Leaks 9 Connect the power cable of welding machine with the output switch in electric box on site 10 Carefully open the valve of the gas cylinder set the required gas flow rate 11 Select TIG welding mode on the front panel 12 Set torch operation 2T 4T When 2T operation is selected press trigger Gas starts touch and lift arc start release trigger Gas and Arc stops When 4T operat...

Page 27: ...nected 5 Not connected 6 The button of UP input 7 The button of DOWN input 8 Trigger Switch Input 9 Trigger Switch Input 10 Not connected 11 The button of UP DOWN input 12 Not connected Remote Control Socket 3 1 Torch Switch Control Torch switch Adjust current button when it s pushed up the current increase when it s pushed down the current decrease ...

Page 28: ... control potentiometer 4 Wiper arm connection to 10k ohm remote control potentiometer 5 Zero ohm minimum connection to 10k ohm remote control potentiometer 6 Not connected 7 Not connected 8 Trigger Switch Input 9 Trigger Switch Input 10 Be shorted with 11 11 Be shorted with 10 12 Not connected 3 2 Remote Torch Control Torch switch ...

Page 29: ...3 20k ohm maximum connection to 20k ohm remote control potentiometer 4 Wiper arm connection to 20k ohm remote control potentiometer 5 Zero ohm minimum connection to 20k ohm remote control potentiometer 6 Not connected 7 Not connected 8 Trigger Switch Input 9 Trigger Switch Input 10 Not connected 11 Not connected 12 Not connected When plug the twelve lead aero socket of pedal switch in it Welder wi...

Page 30: ...g machine 6 Connect the cable of wire feeder with the positive output of welding machine 7 Connect the water inlet and outlet pipe of wire feeder with the water inlet and outlet connectors on the rear front of cooling water 8 Connect the control cable of cooling water with the aero socket on the rear panel of welding machine 9 Connect the power cable of welding machine with the output switch in el...

Page 31: ...e through the inlet guide tube on to the drive roller 11 Feed wire over the drive roller into the outlet guide tube push the wire through approx 150mm 10 Place wire onto spool holder spool retaining nut is left hand thread Feed the wire through the inlet guide tube on to the drive roller 11 Feed wire over the drive roller into the outlet guide tube push the wire through approx 150mm 12 Close down ...

Page 32: ...o be used for certain types of welding wire and they have different types of grooves machined 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 s...

Page 33: ...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 34: ...anate from poor set up of the wire into the wire feeder The guide below will assist in the correct setup of your wire feeder DIAGRAM FOR GUN 26 Wire Installation and Set Up Guide Again the importance of smooth consistent wire feeding during MIG welding cannot be emphasized enough The correct installation of the wire spool and the wire into the wire feed unit is critical to achieving an even and co...

Page 35: ...f 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 to the contact tip Steel Liners Most MIG gun liners are made from coiled steel wir 8 ...

Page 36: ...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 37: ...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 38: ...he wire feeder 4 Connect the gas line to gas connector on the rear panel of wire feeder 5 Connect the control cable of wire feeder with the aero socket on the rear panel of welding machine 6 Connect the cable of wire feeder with the positive output of welding machine 7 Connect the gas regulator to the Gas Cylinder and connect the gas line to the Gas Regulator 8 Connect the power cable of welding m...

Page 39: ...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 pressing button an...

Page 40: ...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 41: ...41 Over heating Program default Phase loss No water 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 Water cooler disconnection Connection problem betwee...

Page 42: ...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 43: ...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 44: ...44 Notes ...

Page 45: ...45 Notes ...

Page 46: ...46 www sifweld com Peters House The Orbital Centre Icknield Way Letchworth Garden City Hertfordshire SG6 1ET Tel 44 0 845 130 7757 Fax 44 0 800 970 7757 Email sales weldability sif com www sifweld com ...