SifWeld Evolution MTS500 ROBOT, Operation Manual

Page 1: ...ation 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 TSXE3D500RMTS SifWeld Evolution MTS500 ROBOT ...

Page 2: ...e 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 represen...

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: ...Panels 16 2 1 MMA Display 16 2 2 MIG Display 17 2 3 MIG Dual Pulse SYN Display 18 2 4 MIG Manual Display 19 2 5 MIG MAG SYN Display 20 3 Installation 21 3 1 Wire Feed Roller 26 3 2 Wire Installation 27 3 3 MIG Torch Liner 29 4 Operation 30 4 1 Spool Gun 31 5 Troubleshooting 33 6 Maintenance 34 7 Warranty 35 Contents ...

Page 7: ...consult 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 Whi...

Page 8: ...MIG welding of aluminium Featuring IGBT technology and providing a lightweight multi process machine a separate wire feed system Features 500A Three phase MIG welding machine with separate wire feed unit Synergic features including Dual Pulse programs for steels aluminium and Mig brazing Full digital or analogue robot interface connections Very high duty cycle 100 at 400A 60 at 500A Perfect machin...

Page 9: ... MTS500 ROBOT Input Voltage V Diameter mm 50 60 41 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 41 8 92 9 Al 1 0 1 2 1 6 0 75 MIG TIG 33 1 28 4 28 9 22 9 40 500 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: ...ector Connect to the connector of 5 Wire feeder connector Used to connect to the control cabl 6 Positive output anode Used to connect to the welding cab 7 Power source input To connect power source 8 Power switch Turn on power supply and turn off power sup indicates that it is explained in detail below Robot controlling connector 4 1 User need to connect the robot with the power source acc communi...

Page 11: ...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 panel layout of water cooling 1 Intak...

Page 12: ...rotate it to adjust current or parameters 15 Voltage adjust knob Press down it to select parameters rotate it to adjust voltage or parameters Front Panel Functions 1 Indicated LED Rotate to ON power on rotate to OFF power off 2 Voltage display Display voltage or other parameters 3 Current display Display current or other parameters 4 Function key 5 JOB button 6 Program save delete button 7 Manual ...

Page 13: ... and the JOB LED will illuminate Select the required JOB number by the adjustment Knob 15 as shown on the meter 8 Press the JOB button 16 again and the JOB LED is off that signals exit of JOB mode DISPLAY FUNCTION ADJUSTABLE RANGE MODE PrG PRE GAS 0 5S PoG POST GAS 0 10S SFt SLOW FEED TIME 0 10 bub BURN BACK 0 10 SPt SPOT WELD TIME 0 5 10S dPC DELTA PULSE CURRENT 20 200A DUAL PULSE FdP DUAL PULSE ...

Page 14: ... of the welding machine or further on in this manual Single Pulse Function Pulse allows the arc to enter spray transfer at lower currents and feed speeds than manual allowing faster welding with high deposition and smaller heat effected zones due to the extra arc energy provided at peak of pulse Used for stainless or aluminum edge or seam welds Double Pulse Function Double pulse allows more precis...

Page 15: ...lates 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 thickness air temperature affect the optimal voltage and wire feed setting so the program provides a voltage fine tuning function for the synergic program selected Once the voltage is adjusted in a synergic program it will stay fixe...

Page 16: ...anel Description Function rams select length Inductance ness Current Wire ulse SYN Function Select Spot Weld Select ling Mode Select ct 1 Hot Start Arc Force parameter code display 2 Welding Current Arc Force Hot Start Display 3 Welding current LED 4 MMA Function Select 5 Hot Start Arc Force parameter select 6 Hot Start Arc Force parameter code select 7 Welding Current Arc Force Hot Start Set 2 1 ...

Page 17: ...Check Select 10 Current Wire Speed Material Thickness Display 11 Programs Numbers Voltage Arc length Inductance Display 13 tart Arc Force parameter code g Current Arc Force Hot Start Set ion Front Panel Description se SYN Function gic programs select e Arc length Inductance al thickness Current Wire Set AG Pulse SYN Function al Wire Select S4T Spot Weld Select Air Cooling Mode Select on Select eck...

Page 18: ...nction Voltage Inductance Set Material thickness Current Wire Speed Set MIG MAG Manual Function Select Manual Wire Select 2T 4T Spot Weld Select Water Air Cooling Mode Select Function Select Air Check Select Material thickness Current Wire Speed Display Voltage Inductance Display 1 Synergic programs select 2 Voltage Arc length Inductance Set 3 Material thickness Current Wire Speed Set 4 MIG MAG Du...

Page 19: ...elect Water Air Cooling Mode Select Function Select Air Check Select Material thickness Current Wire Speed Display Voltage Inductance Display 1 Voltage Inductance Set 2 Material thickness Current Wire Speed Set 3 MIG MAG Manual Function Select 4 Manual Wire Select 5 2T 4T Spot Weld Select 6 Water Air Cooling Mode Select 7 Function Select 8 Air Check Select 9 Material thickness Current Wire Speed D...

Page 20: ...pot Weld Select 7 Water Air Cooling Mode Select 8 Function Select 9 Air Check Select 10 Material thickness Current Wire Speed Display 11 Programs Numbers Voltage Inductance Display PANEL FUNCTIONS DESCRIPTIONS tion rams select ctance Set ness Current Wire N Function Select Select pot Weld Select ling Mode Select ct ect ness Current Wire Speed Display mbers Voltage Inductance Display ...

Page 21: ...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 22: ...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 23: ...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 24: ...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 25: ...to 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 ...

Page 26: ...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 27: ...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 28: ...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 29: ...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 30: ...none concerned people should not be around the working area and especially children Do not watch the arc in unprotected eyes Ensure good ventilation of the machine to improve Duty Cycle Turn off the engine when the operation finished for energy consumption efficiency When power switch shuts off protectively because of failure Don t restart it until problem is resolved Otherwise the range of proble...

Page 31: ...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 32: ...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 33: ...ermal relay Over heating 2nd thermal relay E55 E40 E41 Over heating Program default Phase loss No water Communication cord is not connected Communication cord has problem in connected Data transaction is interupted Connection problem between wire feeder and power source Communication error Communication Communication Robot MIG ...

Page 34: ...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 35: ...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 36: ...36 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 ...