WSM 315.400IGBT Pro Inverter Pulse TIG Welding Mahcine Manual
WSM 315.400IGBT Pro Inverter Pulse TIG Welding Mahcine Manual
MANUAL
INSTRUCTION
Huayuan arc welding and cutting equipment are designed and built with ample safety consideration. However, proper installing and
operating the machine can increase your safety.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT CASUALLY WITHOUT READING THIS MANUAL THROUGHOUT.
1.BE SURE TO AVOID THE WELDING MACHINE FALLING DOWN WHEN IT IS PLACED ON THE GRADIENT GROUND.
2. IT’S FORBIDDEN UNFREEZING THE PIPELINE BY THE WELDING MACHINE.
3. THE SHIELD RANK OF THIS SERIAS OF WELDING MACHINES IS IP21S, SO WORKING IN RAIN IS NOT SUTABLE.
4. The rated duty cycle of this welding machine is 35%, there is protection function when the machine is
overloading used. When it’s protected and no power output, must wait and after the temperature back to
normal, then use again.
5. When welding current is lower than 200A, the argon gas flow is 4-8L/min, when welding current is higher
than 200A, the argon gas flow is 8-15L/min.
6. The Electromagnetic compatibility classification of this welding machine is A.
Purchase Date:
Serial Number:
Machine Type:
Purchase Place:
Arc and arc rays can hurt.
Cautions
All performing welding workers ought to have health qualification from the authority
organization to prevent you and others from arc radiation and burn, it should be prevented
for children to enter into dangerous area as well.
Be careful reading the following important items and the welder safety byelaw from the
authority organization. Be sure that qualified professionals perform all installation,
maintenances and repair procedures.
1 Electric shock: The welding circuits are not insulated when welding. If you touch the
two output electrodes of the machine with your bare skin at the same time, it will lead to
electric shock, sometimes even fatal dangers. Users need to follow the items below to avoid
electric shocks:
If possible, lay some insulating materials, which are dry and large enough, in your working field.
Otherwise, use the automatic or semiautomatic welding machine, DC welding machine as possible as
you can.
Components in the automatic and semiautomatic welding machine such as the welding wire reel, feed
wheel, contact tip and welding head are all electriferous.
Always be sure the machine has been connected perfectly to the work piece with the work cables and
should be as close as possible to the working area.
The work piece should be grounded perfectly.
Make sure that the insulating material of the electrode holder, the grounding clamp, the welding cable
and the welding head are not affected by damp, mildewed or spoilt, and be replaced momentarily.
Never dip the electrode in water for cooling.
Never touch electriferous parts of two welding machines at the same time, because this voltage is
supposed to be two times of welding voltage while the grounding mode is not clear.
While working high above the ground or other places having the risk of falling, please be sure to wear
safety belt to avoid losing balance caused by electric shock.
2 Arc: Use an arc welding mask to protect your eyes and skin from sparks and the rays of
the arc, pay special attention to the filter glass, which must be conformable to the national
standard.
Use clothing made from durable flame-resistant material or sailcloth to protect your
skin from hurting by the arc rays.
Remind other nearby personnel before working lest arc rays hurt them by accident.
3 Fumes and Gases: Welding may produce fumes and gases hazardous to health. Avoid
breathing these fumes and gases. While working in limited room, use enough ventilation
and/or exhaust to keep fumes and gases away from the breathing zone, or use the
respirator. Do not weld at the same time when using of degreasing, cleaning or spraying
operations. The heat and rays of the arc can react with these gases to form phosgene, a highly toxic gas,.
Some protective gases used in welding might displace the oxygen in the air, and can lead to hurt or even
death.
Read and understand the manufacturer’s instructions for this equipment, and validate the health
certification of consumptive materials, make sure they are asepsis and innocuity.
4 Spatter: Spatter can cause fire or explosion.
Remove fire hazards from the welding area. Remember that spatter from welding can
easily go through small cracks and touch fire hazards. Keep the safety of all kinds of lines
going though welding area, including hydraulic lines in the wild.
Where compressed gases are to be used in the field, special precautions should be used to prevent
explosion.
When not welding, make certain that no electriferous part is touching the work piece or the work stage.
Accidental contact can create a fire hazard.
Do not weld containers or lines, which are not proved to be innocuity.
It is very dangerous to heat, cut or weld tanks or containers at entry holes. Does not start work until the
proper steps have been taken to insure that there are no flammable or toxic gases there.
Spatter might cause burn. Wear leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over
your hair to prevent from burning by spatter. Wear the ear shield when performing sideways or face up
welding. Always wear safety glasses with side shields when being in a welding area.
The welding cables should be as close to the welding area as possible, and the short, the better. Avoid
welding cables going through the building framework, lifting chains, AC or DC cables of other welding
machines and appliances. The welding current is strong enough to damage them while having short
circuit with them.
Do not add fuel near to fire or during engine starting or welding. When not working, add
fuel after engine is cooling down; otherwise, the evaporation of hot fuel would result in dangers.
Do not splash fuel out of the fuel tank, and do not start the engine until complete evaporation of
the outside fuel.
Make sure that all the safeguard equipments, machine cover and devices are all in a
good condition. Be sure that arms, clothes and all the tools do not touch all the moving and
rotating components including V belt, gear and fan etc.
Sometimes having to dismantle some parts of the device during maintenance, but must
keep safety awareness strongly every time.
Do not put your hand close to fans and do not move the brake handle while operating.
Please remove the connection between the engine and the welding equipment to avoid sudden starting
during maintenances.
When engine is hot, it is forbidden to open the airtight cover of the radiator water tank to avoid hurt by
the hot vapor.
8 Electromagnetic: Welding current going though any area can generate electromagnetic,
as well as the welding equipment itself.
Electromagnetic would affect cardiac pacemaker, the cardiac pacemaker users should
consult one’s doctor first.
The effect of electromagnetic to one’s health is not confirmed, so it might have some negative effect to
one’s health.
Welders may use following method to reduce the hazardous of electromagnetic:
a. Bundle the cable connected to the work piece and the welding cable together.
b. Do not enwind partially or entirely your body with the cable.
c. Do not place yourself between the welding cable and the ground (work piece) cable, if the welding
cable is by your left side, then the ground cable should be by your left side too.
d. The Welding cable and the ground cable are as short as possible.
e. D e. Do not work near to the welding power source.
9 Lift equipment: carton or wooden boxes package the welding machines supplied by
Huayuan. There is no lifting equipment in its wrapper. Users can move it to the prospective
area by a fork-lift truck, then open the box.
If having rings, the machine can be transited using rings. While Huayuan Welding
Machine Manufacture reminds users, there is possible risk to damage the welding machine.
It is better to push the welding machine moving in use of its rollers unless special situations.
Be sure that the appurtenances are all removed off when lifting.
When lifting, make sure that there is no person below the welding machine, and
remind people passing by at any moment.
Do not move the hoist too fast.
10 Noise: Huayuan Welding Machine Manufacture reminds users: Noise beyond the limit
(over 80 db) can cause injury to vision, heart and audition depending on oneself. Please
consult local medical institution. Use the equipment with doctor’s permission would help to
keeping healthy.
Content
1. Overview………………………………………………………………………………1
3. Models description………………………………………………………………………1
6. System description……………………………………………………………………3
7 . S t r u c t u r e d e s c r i pt i o n … …… … …… … … … … … … … … …… … … … … … … … … …… 3
8. Installation ……………………………………………………………………7
9. Operation…………………………………………………………………8
10.Maintenance…………………………………………………………… ………………8
1 1 .Tr o u b l e s h o o t i n g … … … … … … … … … … … … … … … … … … … … … … … … … 9
12.Packing list……………………………………………………10
3 Model description
W S M —□□□ IGBT
4 Symbol description
Read the manual Ground connect
Parameter+/- Current
MMA Voltage
TIG
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Isolation Grade - F
Ingress Protection - IP21S
Dimension (L*W*H) mm 520×260×495
Net Weight Kg 23 26
6 System description
6.1 Working principal:
WS(M)-315、400IGBT(Pro)series welding machine adopts IGBT as the main circuit switch. The
three-phase AC input power inverted to 20KHz mid-frequency current through the rectify of the full
bridge. Then through the filter and current negative feedback control to get the constant adjustable
welding current.
The control circuit will control the output current through the adjusting of the pulse width. The
negative feedback signal, which is the real welding current get from the output current sensor, put into
the special PWM circuit after compared with the current adjust signal, then output the driving pulse to
control the IGBT, so that the output current will keep stable to get descending external characteristic.
This machine has functions of gas pre send, gas post cut off, HF arc striking, current up-slope,
currentdown-slope. All these functions are controlled by the digital signal controller automatically.
6.2Working circuit diagram:
7 Productstructure description
This machine is composed of inner part, cover, handle, supporting base.
7.1 Front panel description and function:
Take WSM-IGBT(Pro) as example, the front panel is divided into six areas according to the
function:
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A B C D
A. A.1st digital display meter: it is used to display welding/preset current, pulse/AC frequency,
pulse width ratio/clean width, pre-gas time etc.
B. B.Display type indicator of 1st digital display meter: when the 1st digital display meter is
displaying welding current, this indicator is on.
C. C.2nd digital display meter: it is used to display welding voltage, pass no. etc.
D. D.Display type indicator of 2nd digital display meter: when the 2nd digital display meter is
displaying voltage, this indicator is on.
A B C D E F G H I J K L M N O P
At one time, there is only one indicator light on in this area, which indicates current displayed&
adjusted parameter, and the parameter value is displayed on 1st digital display meter, adjusted by
encoder. WS-IGBT(Pro) display the welding current in default; When WSM-IGBT(Pro) work as MMA or
TIG without pulse, it displays the welding current, when work with pulse, it displays the peak current in
default.
The current displayed or adjusted parameter can be selected through pressing the left or right
selection key.
A. Left selection key: press the key, the lighted parameter indicator will move to left, it moves one
after press key one time;
B. Gas pre-flow time: adjusting the gas pre-flow time;
C. Arc striking current: it is the current when the arc is started;
D. Up-slope time: current is transited from arc striking current to welding current(when there is
no pulse)/peak current and base current (when there is pulse)time;
E. Welding current: it is the current when there is no pulse working;
F. Arc force current: the arc force current of MMA;
G. Hot start current: the hot start current of MMA;
H. Rotary encoder: it is used to adjust current displayed parameter;
I. PWM ratio: when there is pulse working, the ratio between peak current time and pulse cycle;
only WSM-IGBT(Pro) has this function;
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J. Pulse frequency: when there is pulse working, it is pulsed working frequency (the inverse of
pulse cycle), only WSM-IGBT(Pro) has this function;
K. Peak current: it is pulsed peak current when there is pulse working; only WSM-IGBT(Pro) has
this function;
L. Base current: when there is pulse working, it is the base current of pulse, only WSM-IGBT(Pro)
has this function;
M. Down-slope time: the time of current transited from welding current(pulse on)/peak current
and base current(pulse off) to crater arc current;
N. Crater arc current: the current during the arc ending;
O. Gaspost-flow time: it is gaspost-flow time;
P. Right selection key: press the key, the lighted parameter indicator will move to right, it moves
one after press key one time.
7.1.3Functionselection area:
A B C
A. Two steps: when this indicator is on, the welding machine is the non self-lock status of TIG
welding;
B. Four steps: when this indicator is on, the welding machine is the self-lock status of TIG
welding;
C. MMA: when this indicator is on, the welding machine is working as MMA;
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D. Operation mode selection key: this key is used to shift the operation modes of welding
machine.
7.1.5 Storage and parameter selection area:
A B C
A. Channel key: first time press the :channel key”, the voltage meter displays the present channel
number, the current meter displays the present present stored welding parameter; Press the
right/left selection key to display other stored parameters; Press the “storage” key to store the
present welding parameter to the channel; Press “parameter selection” key to select a stored
parameter to use; Press “Channel” key to turn to next channel; It quits the channel if there is
no action within 5 seconds.
B. ”Storage” key: to store the present welding parameter to the present channel;
C. “Parameter selection” key : to select a stored parameter to use;
A B
A. Input abnormal indicator: this indicator lights on when input voltage higher than 380±15%
range or lack phase;
B. Over-heating indicator: when the temperature inside the machine is too high, this indicator
lights on;
A F
B G
C
H
D
I
E
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A. Power protection switch: this switch is only for overcurrent protection, please make another
power switch separately;
B. Control signal: to connect the remote control potentiometer and arc striking successful-signal
connector; Only on WS-IGBT(Pro) model;
C. Name plate position;
D. Cooling fan;
E. Air inlet: to connect with the Argon gas reducing valve;
F. Power lead box: to connect the three phase power lead; (User prepare the lead)
G. Ground cable connecting position;
H. 3 phase power lead fixing holder;
I. Serial number position;
A C
8 Installation
The connecting schematic diagram of equipment:
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8.1 The power supply of this machine is 3~380V 50/60HZ, user should prepare the switchboard and
install the air switch (breaker) and ground cable. Connect the green-yellow wire of the three-phase input
cable to the grounding wire on the switchboard reliably according to the below table:
Item Sectional area of power Air switch (A) Sectional area of ground
Model cable (mm2) cable (mm2)
WS(M)-315IGBT (Pro) ≥2.5 25 ≥2.5
9 Operation
9.1 Turn on the power switch, the welding machine start to check by itself, the digital meters and
indicators on panel lights on together for 1.5 seconds and lights off 0.5 seconds, then display normally;
9.2 Press the “Gas control” key, the “check gas” indicator lights on, adjust the argon gas flow according
to different welding technology, then press “gas control” key again and the “automatic” indicator lights
on;
9.3 Set the “pulse on/off” according to different welding technology, press the “Pulse current” key to
do that. If choose “pulse off”, set the welding current by adjusting the encoder; if choose “pulse on”, set
the “peak current”, “PWM ratio”, “Pulse frequency” and “base current”, press left/right selection key to
choose the parameters need to be set.
9.4 Set the “gas pre-flow time”, “arc starting current”, “Up-slope time”, “down-slope time”,”crater
current” and “gas post-flow time” according to different welding technology.
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9.5 Welding operation:
□ Two steps: take the tungsten electrode close to the work-piece about 1~3mm, press the
welding torch switch without loosen, it starts weld normally after current up-slope, when
finish welding, loosen the welding torch switch, the current down-slope to crater current.
After welding, please don’t take away the welding torch at once, should wait the gas
post-flow time finish, to protect the weld crater and tungsten electrode.
□ Four steps: take the tungsten electrode close to the work-piece about 1~3mm, press the
welding torch switch without loosen, after arc striking, find the welding position, then loosen
the welding torch switch, the welding current will increase to the set current, it starts weld
normally , when finish welding, press the welding torch switch again, the current down-slope
to crater current, loosen the torch switch, arc stop and the welding finish. After welding,
please don’t take away the welding torch at once, should wait the gas post-flow time finish,
to protect the weld crater and tungsten electrode.
9.6 MMA: connect the work-piece too “+’”-” according to different welding technology; after
connecting the ground cable and electrode holder, set the welding current/arc force current/hot starting
current according to electrode diameter; before welding, the welding machine output 20V~28V DC
voltage, when the instant moment that electrode touch the work-piece, the welding machine output
welding current and start the normal welding, after arc stop, the open circuit voltage will remain 1
second.
10 Maintenance
For safety, the welding machine should be maintained and checked regularly, when check the inner
or outside connecting terminals, do cut off the power distribution box( or the breaker).
10.1 Daily notes:
10.1.1 Check if there is any abnormal voice, vibration or smell;
10.1.2 Check if there is abnormal heating on the joint of cables;
10.1.3 Check if the cooling fan working well;
10.2 Checking items in 3~6 months period:
10.2.1The electrical connection: check the fastening screws on cables, to find if there is any loosen,
rust or poor connecting and so on;
10.2.2 Grounding cable: check if the welding machine is grounded well;
10.3Clean the dust inside the machine: this work should be done every half a year, with dry compressed
air;
10.4Adjust the high frequency: never touch the spark electrodes (the distance of the spark electrodes
should be 1mm), when the electrode surface is rough or polluted, polish it. Before touching the
electrodes, please discharge them, and then adjust the distance to 1mm.
11 Trouble shooting
Problem Possible reasons Trouble shooting
1. When machine Three phase bridge rectifier was may
Replace the rectifier;
energized, the circuit damage
breaker trip IGBT damage Replace IGBT
The control fuse on the back may
2. No output current Replace fuse 1.5A
broken
8
Cooling fan not work, or overload Repair the cooling fan and do not
cause overheat, then temperature overload
relay protect
Temperature relay may damage Replace the temperature relay
Reliably connect the work piece
Machine output terminal not connect
and output terminal
reliably with the work piece
3. No Arc striking
Replace the torch trigger and well
Torch trigger or plug wire may
connect the plug
damage
4. There is no output
voltage, but noise FRD may damage Replace the FRD
from the machine
Workpiece too dirty Clean the workpiece
5. Difficult to strike arc
Tungsten quality not good Replace good tungsten
PW03 damage; Replace PW03;
There are substance in gas valve; Clean the air valve
6. Cannot turn off the Check gas/auto selection switch does Put the switch to auto position;
argon gas. not set to auto position;
The spring in the air valve may have open the air valve and extend the
elastic shortage spring
The voltage of the air valve coil is Check the coil voltage(~36V) or
insufficient or the coil was burnt replace the air valve
7. No argon
PW03 damage; Replace PW03;
8. There is burnt smell Some components was burnet or Replace the damaged components
from the machine there are wires short circuit. or deal with the short circuit parts;
Stop welding, let the machine rest
9. Machine not work, but Machine overload
for 10min without load
the overload indicator
on Cooling fan damage Replace cooling fan
10. Arc break during Water pressure too low or no water Connect water
welding or the machine let in
not work, but the lack
The water checking switch damage Replace the water checking switch
voltage indicator on
11. When use water
cooling torch, machine
not work, but the The input lack-phase or lack voltage Check three phase input
cooling water indicator
on
★ ★Note: if meet some problem can’t solve, please turn off the machine immediately, only the
professional worker can repair the machine.
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12 Standard Packing List
10
V V
C7
11. V4
30. 33.
Gc Ga T A1
15 V
QF1
+5V
-1
O ut
0V
01. L1 04. V1 Ec Ea
1
2
3
4
T M1
02. 05. 12. 15.
Attachment
C5 C8
R1 R2
03. 06. 31. V5
D40
00. C1 C2
Gd Gb
35. L5 21. 34.
C3 Ed Eb *
33.
L4 * THF1
10.
FU1 L3 C9
13. 14.
T A2 34.
Gd Ed Ec Gc Gb Eb Ea Ga
R3 R4 R5 R6
X S3 A
X S3 B
X S3 H
X S3 G
X S4 A
X S4 B
X S4 F
X S4 E
X S1 B
X S1 A
Gd Ed Ec Gc T Aa T Ab
Gb Eb Ea Ga K Ta KD1
XS1C
PT05 过热 K Tb
XS1D
11
55. 54. 53. 52.
11. 10. 62. 65. 67. 64. 66. 63. 78. 77. 76. 75. 92. 93.
XS7A XS7D XS7F XS7C XS7E XS7B XS6F XS6E XS6D XS6C XS2A XS2D
XS9A XS9B XS9C XS9D -15V +15V 给定 END 过热 NC +15V -15V 信号 END
XS1C XS1A
电流信号
74.
脚踏控制接口 网压异常 XS13 A 74. 21. 33.
红白蓝黑 电压反馈 73.
XS13 D 73.
TC1
72.
415V XS13 B 72. 87.
焊枪开关输入 71.
PW06 HFAP1
380V 37. XS13 C 71. 88.
XS3D
110V
引弧成功信
无线网络管理接口 号输出接口
面板通讯 XS2B
70.
高频控制
+5V DGND MISO CL K CS MOSI XZ1A XZ1B +5 V END CS CS1 CLK DAT KEY END1 XS10 A XS10 B
XS2A 69.
1
2
XS5E XS5D XS5F XS5C XS12 A XS12 B XS12 C XS12 D XS12 E XS12 F XS11 A XS11 B XS11 C XS11 D XS11 E XS11 F XS11 G XS11 H XS11 I XS11 J XS4A XS4B XS5A XS5B
SK1
YV1
40. 41. 42. 43. 44. 45. 60. 61. 62. 63. 64. 65. 66. 67. 68. 91. 79. 80. 56. 气阀 57. 58. 59.
08. 07. 18. 17. 1 2
焊枪开关接口
60. 61. 62. 63. 64. 65. 66. 67. 68. 91.
XS4F XS4D XS4C XS4B XS4A XS4A XS4A XS4A XS4A XS4A
C12 XZ1A XZ1B +5 V END CS CS1 CLK DAT KEY END1
EV1
PW02
风扇 WS(M)-IGBT(Pro)整机电气原理图
The final explanation rights reserved to Westweld /Huayuan Company!
If there is any changes in the user’s manual, forgive not to inform separately!
Westweld Ltd
www.westweld.com
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