Sweiss SKYARC ULTRA 3140, Operator'S Manual

Page 1: ...ad 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 you do not fully understand this manual OPERATORS MANUAL ...

Page 2: ... CONNECTION WAY 9 3 3 1 MMA 9 3 3 2 TIG 10 4 OPERATION CONTROL AND CONNECTORS 11 4 1 LAYOUT FOR FRONT REAR PANEL 11 4 2WELDING CURRENTADJUSTMENT 13 4 3WELDING OPERATION 13 4 3 1 Striking arc way 13 4 3 2 Manipulation of electrode 14 4 4WELDING PARAMETERS 14 4 4 1 Joint form in MMA 14 4 4 2 Electrode selection 14 4 5ARC WELDING DEFECTAND PREVENT METHOD 15 4 6 OPERATION ENVIRONMENT 16 4 7 OPERATION ...

Page 3: ...CONTENT III ...

Page 4: ...t 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 c...

Page 5: ... 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 which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values using local exhaust or mechan...

Page 6: ...rc 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 WELDING SPARKS can cause fire or explosion Remove fire hazards from the welding area If this is not poss...

Page 7: ...orrect 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 physic...

Page 8: ...cure 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 fr...

Page 9: ...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 ULTRA 3140 ULTRA POWER welders can also realize TIG operation While MMA operation if the electrode touches ...

Page 10: ...0KHz by inverter device IGBT module after reducing voltage by medium transformer the main transformer and rectified by medium frequency 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 requ...

Page 11: ...SUMMARY 8 When I2 600A U2 20 0 04 I2 V When I2 600A U2 44 V 64 44 20 0 600 I2 A U2 V Working point Volt ampere characteristic The relation of the rated loading voltage welding current ...

Page 12: ...6 8 9 10 6 Duty Cycle 40 10min 30 250A 60 177A 100 140A 30 200A 60 130A 100 100A 40 315A 60 267A 100 207A 40 250A 60 204A 100 158A 40 315A 60 267A 100 207A 40 250A 60 204A 100 158A 45 315A 60 267A 100 207A 40 315A 60 223A 100 173A No Load Voltage V 70 15 VRD Welding Current Range A 5 200 5 200 5 315 5 250 5 315 5 250 5 315 5 315 Efficiency 80 80 80 80 Power Factor 0 98 0 98 0 9 0 9 Electrode diame...

Page 13: ...truction 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 I A 0 100 140 250 X The relation between duty cycle and welding current for GM 3150 60 30 Input single phase 220V TIG 177 I A 0 100 10...

Page 14: ... 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 I A 0 100 158 250 X The relation between duty cycle and welding current for GM 3150 60 40 Input three phase 220V MMA 204 I A 0 100 207 315 X The relation between duty cycle and welding current for GM 3150 60 43 Input three phase 380V TIG 267 I A ...

Page 15: ...rkpiece the short circuit current is only 28A After generating arc current can rise to the setting welding current If the tungesten electrode touches the workpiece when welding the current will drop to 5A within 2s which can reduce the tungsten spoilage farthestly prolong the using life of the tungsten electrode and prevent tungsten clipping When TIG operation the shielded gas is inputted to weldi...

Page 16: ...t display The welding current display shows the welding current now 2 Maximum current pilot lamp This pilot lamp when lit indicates that the maximum current is 200A 3 Maximum current pilot lamp This pilot lamp when lit indicates that the maximum current is 250A 4 Maximum current pilot lamp This pilot lamp when lit indicates that the maximum current is 315A Power Supply Voltage V Imax A MMA 1 220 2...

Page 17: ...TIG No load Welding on off turn off 7 Power pilot lamp This pilot lamp when lit indicates that the machine is on 8 Alarm pilot lamp When the machine less voltage over current or over heat This pilot lamp indicates when lit that the protection of the machine has been activated 9 12 Rod electrode welding key Parameter Setting range Arc force 0 10 Hot start 1 10 Arc length 1 10 13 Conversion switch C...

Page 18: ...ent to set parameters and adjust accurately 4 3 Welding operation 4 3 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 steel it is better to use knocking way electrode workpiece electrode electrode workpiece ...

Page 19: ...s 4 4 1 Joint form in MMA In MMA welding the common basic joint form butt joint lap joint corner joint T joint 4 4 2 Electrode selection The electrode diameter selection is based on the workpiece thickness welding position joint form welding layer etc Please refer to the following table The welding current reference for different electrode diameter Electrode diameter mm 1 6 2 0 2 5 3 2 Welding cur...

Page 20: ... too long The electrode angle is wrong Manipulation of electrode is not proper Choosing the proper welding current speed The arc can t be drawn too long The electrode angle should be proper Manipulation of electrode should be correct Incomplete penetration The groove angle or gap is too small the root face is too big Welding parameters are not suitable or the assembly is not good The welder s oper...

Page 21: ...trictly control the percentage of S and P in welding material Adjust the structure of welding material Adopt the basic electrode Cold crack Three reasons will cause cold crack The structure turned from the marten site The residual stress caused by big restraint intensity The residual hydrogen in welding gap Adopt low hydrogen type basic electrode Bake under the instruction before use Remove the fe...

Page 22: ... 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 In case of problems contact your local dealer if no our authorized maintenance man SWEISS ...

Page 23: ...ter 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 number is not intact please replace ...

Page 24: ...ure the insulating impedance among the main circuit PCB and case if it below 1MΩ insulation is thought to be damaged and need to change 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 Maintenan...

Page 25: ...air or change the welding cable Earth cable is not connected or loosen Check the earth clamp 6 Not easy to start arc in the welding or easy to cause sticking The plug loosen or connect not well Check and tighten the plug Oil or dust covered the workpiece Check and clear out MMA TIG welding selection is wrong Selecting the MMA welding 7 The arc is not stable in the welding process The arc force is ...

Page 26: ...MAINTENANCE AND TROUBLESHOOTING 19 Over current protection Unusual current in the main circuit Test and repair the main circuit and drive PCB Pr1 ...

Page 27: ...MAINTENANCE AND TROUBLESHOOTING 20 5 3 Electrical principle drawi ...

Page 28: ...NOTES 21 ...

Page 29: ...NOTES 22 ...

Page 30: ...NOTES 23 ...

Page 31: ...NOTES 24 ...