IGBT CO2 Manuel utilisateur

Full Digital Heavy Duty IGBT CO2/MAG/MMA Carrier

Intelligent Multifunctional Inverter Welder

User Manual

Version: V1.4

No.: R33010063

Shenzhen Megmeet Electric Co., Ltd. provides comprehensive technical support for customers,

covering but not limited to, CAN communication, welder network monitors, robot collaboration,

welding process database software upgrade, and after-sale service. Users can contact the nearest

Megmeet's offices or customer service centers, or directly contact Megmeet headquarters.

Shenzhen Megmeet Electric Co., Ltd.

Address: 5th Floor Block B, Ziguang Information Harbor, Langshan Road, Shenzhen, 518057,

China

Zip code: 518057

Website: www.megmeet.com

Customer service hotline: 4006662163

Email: Welder.4S@megmeet.com

Preface

Thank you for choosing Megmeet's full digital heavy duty IGBT CO2/MAG/MMA carrier intelligent

multifunctional inverter welder (hereinafter referred to as the welder).

This document covers the precautions on installation and cabling, parameter setup, troubleshooting,

and daily maintenance. To ensure that the welder is installed and operated properly and can

achieve its optimal performance, read this user manual before installation. This document must be

kept properly and delivered to users of the welder.

Safety Precautions

Safe Definition

Danger

Follow instructions to perform operations. Failing to do so may result in death or serious

injuries.

Note

Follow instructions to perform operations. Failing to do so may result in medium or slight

injuries or property damages.

●Read this document before using the welder to ensure proper use.

●Although this welder is designed and manufactured with safety considerations, pay attention to

the precautions specified in this document when using the welder, so as to ensure the safety of

you and related personnel and prevent serious accidents.

●Misuse of this welder may cause injuries.

Safety Precautions

Danger

●Before moving the welder, cut off the input power of the distribution box.

●When using a crane to move the welder, make sure that the hoist ring has been tightened and

the housing and cover plates of the welder have been installed.

●If a crane is required to move the welder, use two lifting belts and the included angle of each

lifting belt and the vertical direction must be less than 15 degrees.

●Do not lift the welder and other objects at the same time.

●Install the welder on non-inflammable objects to prevent fire risks.

●Do not place inflammable objects near the welder; failing to do so may result in fires.

●Do not install the welder in an environment with explosive gas; failing to do so may result in

explosion risks.

●Cabling must be performed by certified personnel; failing to do so may result in electric shock.

●Before cabling, make sure that the power input has been disconnected completely; failing to do

so may result in electric shock.

●Before connecting the power supply, connect the grounding terminal of the welder properly;

failing to do so may result in electric shock.

●Before connecting the power supply, install the cover plate; failing to do so may result in electric

shock.

●Do not touch terminals when the power supply is connected; failing to do so may result in electric

shock.

●Do not operate the welder with wet hands; failing to do so may result in electric shock.

Danger

●Perform maintenance 5 minutes only after the power supply is disconnected, the power indicator

is completely off, and the voltage of the positive and negative bus bars is lower than 36 V; failing

to do so may result in electric shock.

●Parts can be replaced only by professionals. Do not leave cable stubs or metal objects in the

welder; failing to do so may result in fires.

●After replacing the control board, set the parameters correctly before using the welder; failing to

do so may result in property damages.

●Use insulation tapes to wrap the copper noses that connect to cables; failing to do so may result

in electric shock.

Note

●Do not impose force on the control panel and cover plates when moving the welder; failing to do

so may cause the control panel and cover plates to fall off and lead to damages of properties.

●When moving the welder using a forklift truck, fix the casters of the welder.

●Install the welder only at the place where the welder can be held stably. Otherwise, falling of the

welder may result in injuries or property damages.

●Do not install the welder at the place where water spray may occur; failing to do so may result in

property damages.

●Prevent bolts, washers, or metal rods from dropping into the welder. They may result in fires and

property damages.

●If the welder is damaged or incomplete, do not install or use it; failing to do so may result in fires

and injuries.

●Firmly connect the main loop terminal to the copper nose; failing to do so may result in property

damages.

Usage Precautions

Danger

●To ensure safety, welding must be performed by personnel who understand safe operations and

possess welding skills.

●Do not use the welder for purposes other than welding.

●Installation, commissioning, and maintenance of the welder can only be performed by

professional personnel.

●People using heart pacemakers are not allowed to get close to the welder and welding sites

without doctors' permission.

●Do not touch the live parts; failing to do so may result in electric shock.

●Do not use cables with insufficient cross-sectional areas, cables with exposed conductors, and

Danger

cables with damages.

●Do not remove the housing or cover plates when the welder is in use.

●Wear insulation gloves with good insulation performance and without damages.

●Take safety measures when doing tasks at high places.

●Disconnect the power supplies of the welder and distribution box when the welder is not used.

●When performing welding in narrow or confined space, adopt supervision and ensure good

ventilation or use respiratory protection tools; failing to do so may result in asphyxia due to

hypoxia.

●Hazardous smoke, dust, and gas may be generated during welding. Ensure good ventilation or

use respiratory protection tools; failing to do so may result in injuries.

●Do not weld pressure vessels that contain gas, such as air pipes and seal pots.

●Do not move hot workpieces close to combustible materials.

●Do not perform welding near combustible materials.

●Deploy fire extinguishers near welding sites.

●Fix gas cylinders using only dedicated stands; failing to do so may result in injuries when the gas

cylinders fall down.

●Do not connect electrodes with gas cylinders.

●Follow instructions to correctly use pressure reducing valves.

●Only professional personnel are allowed to disassemble and repair pressure reducing valves.

●Do not touch the rotating parts such as the fan and wire feeder when the welder is in use; failing

to do so may result in injuries.

●When performing or supervising welding, use protective equipment with sufficient shading

degree to prevent arc from harming eyes or skin.

●Use protection gears, such as welding-dedicated protection leather gloves, clothes with long

sleeves, foot protection, aprons, and goggles, to protect against arc, spatters, and welding slag.

●Set up protective barriers around welding sites to prevent arc from injuring others.

●Use soundproof devices to prevent noise hazards.

Note

●Do not use this welder for tasks other than welding.

●Do not place heavy objects on the welder.

●Do not seal or block the air vents of the welder.

●Place the welder at places where metal objects such as spatters are unable to enter the welder.

●Keep the welder at least 30 cm away from walls and other welder.

●Use screens to prevent wind from directly blowing against arc.

Note

●Fix the casters to prevent the welder from sliding.

●To prevent electromagnetic hazards, implement electromagnetic shielding for cables and

welding sites.

●The slope of the surface must be less than 15 degrees to prevent the welder from falling down.

●The protection class of the welder is IP23S and is applicable in the following conditions:

Operating temperature range: -10°C- +40°C

Transportation and storage temperature range: -40°C - +70°C

Operating humidity range: ≤ 75% RH at 40°C; ≤ 95% RH at 20°C

Altitude: ≤ 2000 m

The operating environment must not have significant mechanical vibration or mechanical impact.

The welder must not be tilted more than 15°.

The content of dust, metal dust, and corrosive gas must not exceed the normal level.

Avoid the welder from rain and prevent the fan from taking in rain.

Scrapping Precautions

Pay attention to the following when scrap the welder:

●The electrolytic capacitors on the main circuit and the PCB may explode when getting burnt.

●Toxic gases may be emitted when plastic parts such as the front panel are burnt.

●Dispose the welder as industrial waste.

Contents

Chapter 1 Product Overview ..................................................................................................................................... 1

1.1 Model Description.......................................................................................................................................... 1

1.2 Technical Specifications................................................................................................................................. 1

1.3 External Dimensions and Gross Weight.......................................................................................................... 4

1.4 System Components and Configuration.......................................................................................................... 5

1.4.1 System Components........................................................................................................................... 5

1.4.2 Configuration...................................................................................................................................... 6

1.5 System Features.......................................................................................................................................... 9

Chapter 2 Installation and Cabling...........................................................................................................................12

2.1 Installation Requirements..............................................................................................................................12

2.2 Transportation Precautions ...........................................................................................................................12

2.3 Power Supply Specifications .........................................................................................................................13

2.4 Open-Package Inspection.............................................................................................................................14

2.5 Preparing the Cable Bundle...........................................................................................................................14

2.5.1 Packing List for the Cable Bundle Component Box..............................................................................14

2.5.2 Cable Bundle Preparation Description.................................................................................................15

2.6 Electric Connections .....................................................................................................................................16

2.6.1 Welder Output Cables........................................................................................................................17

2.6.2 Connecting the Gas Cylinder..............................................................................................................18

2.6.3 Connecting the Wire Feeder...............................................................................................................19

2.6.4 Connecting the Welding Torch............................................................................................................20

2.6.5 Connecting the Welding Power Cable (Grounding Cable) on the Workpiece Side.................................21

2.6.6 Connecting the Power Cable on the Power Input Side.........................................................................21

2.7 Welding Preparation......................................................................................................................................22

2.7.1 Safety Measures................................................................................................................................22

2.7.2 Installing the Welding Wire.................................................................................................................23

2.7.3 Turning on the Power Switch..............................................................................................................23

2.7.4 Adjusting the Gas Flow.......................................................................................................................24

2.7.5 Wire Inching.......................................................................................................................................24

2.7.6 Welding Conditions............................................................................................................................25

2.8 Post-welding Tasks.......................................................................................................................................30

Chapter 3 Welder Operation Description .................................................................................................................31

3.1 Welder Control Panel Structure.....................................................................................................................31

3.1.1 Front Control Panel............................................................................................................................31

3.1.2 Remote Control Box of the Wire Feeder..............................................................................................33

3.2 Buttons and Knobs........................................................................................................................................33

3.3 Screens and LED Indicators..........................................................................................................................34

3.4 Control Panel Functions................................................................................................................................35

3.4.1 Gas Shielded Arc Welding..................................................................................................................35

3.4.2 Spot Welding .....................................................................................................................................35

3.4.3 Welding Without Ending Arc...............................................................................................................37

3.4.4 Welding with Ending Arc.....................................................................................................................38

3.4.5 Welding with Repeated Ending Arc.....................................................................................................40

3.4.6 Synergic/Manual................................................................................................................................41

3.4.7 Arc Dynamic ......................................................................................................................................42

3.4.8 Detect Gas.........................................................................................................................................43

3.4.9 Wire Inching.......................................................................................................................................44

3.4.10 SAVE and LOAD..............................................................................................................................45

3.4.11 Lock.................................................................................................................................................47

3.4.12 Internal Menu...................................................................................................................................56

3.4.13 Welder Network Monitors .................................................................................................................57

3.5 Welding Electrode.........................................................................................................................................57

3.6 Intelligent Function Description......................................................................................................................57

3.6.1 Energy Conservation Function of the Fan............................................................................................57

3.6.2 Safety Protection Function for the Welding Torch................................................................................58

3.6.3 Slow Wire Inching ..............................................................................................................................58

3.6.4 Connecting a Robot............................................................................................................................58

3.7 Restoring Factory Settings............................................................................................................................62

Chapter 4 Maintenance.............................................................................................................................................63

4.1 Daily Inspection ............................................................................................................................................63

4.2 Regularly Inspection......................................................................................................................................64

4.3 Troubleshooting............................................................................................................................................66

4.3.1 Welder Fault Indicator ........................................................................................................................66

4.3.2 Welder Error Codes and Solutions......................................................................................................66

4.3.3 Rectifying Welder Faults and Welding Process Issues.........................................................................69

4.4 After-Sale Service.........................................................................................................................................70

Appendix I Technical Specifications........................................................................................................................71

Appendix II Electric Connections of Ehave CM250/350...........................................................................................73

Appendix III Electric Connections of Ehave CM500/500H........................................................................................74

Appendix IV Components.........................................................................................................................................75

Appendix V Detailed Component List ......................................................................................................................76

Chapter 1 Product Overview 1

Ehave Series Full Digital IGBT CO2/MAG/MMA Multifunctional Inverter Welder User Manual

Chapter 1 Product Overview

This chapter describes the model, appearance, dimensions, system components, system

configuration, technical specifications, and system features of the Ehave full digital heavy duty

IGBT CO2/MAG/MMA carrier intelligent multifunctional inverter welder.

1.1 Model Description

Figure 1-1 describes the welder model code format.

500: nominal current 500A

350: nominal current 350A

250: nominal current 250A

Ehave

500

DR: digital robot

100% duty cycle

Welder series

CO2/MAG

AR: analog robot

T: customized

Figure 1-1 Model description

1.2 Technical Specifications

Table 1-1 describes the welder technical specifications.

Table 1-1 Technical specifications

Item

Description

Ehave CM250/350

Ehave CM500/500H

Input

Rated

voltage/frequency

Three-phase without neutral line, 380 V

50 Hz

Three-phase without neutral line,

380 V 50 Hz

Working voltage

range

Voltage: 285 V - 475 V; voltage

unbalance rate: < ±5%; frequency: 30

–80 Hz

Voltage: 285 V - 475 V; voltage

unbalance rate: < ±5%; frequency:

30 –80 Hz

Static tolerant

input voltage

Phase-to-phase voltage 520 V AC

Rated input power

factor

0.94

0.93

2Chapter 1 Product Overview

Ehave Series Full Digital IGBT CO2/MAG/MMA Multifunctional Inverter Welder User Manual

Item

Description

Ehave CM250/350

Ehave CM500/500H

Output

Rated open circuit

voltage

63.7 V

73.3 V(Ehave CM500)/75 V(Ehave

CM500H)

Rated output

current/voltage for

gas shielded

welding

30 A/15.5 V - (250) 350 A/(26.5) 31.5 V

30 A/15.5 V –500 A/39 V

Rated output

current/voltage for

manual welding

30 A/21.2 V - (250) 350 A/(30) 34 V

30 A/21.2 V –500 A/40 V

Rated duty cycle

350 (250) A@ 60% @ 40°C / 271 (193)

A@ 100% @ 40°C

350 (250) A@ 100% @ 25°C

Ehave CM500:

500 A@ 60% @ 40°C / 390 A@

100% @ 40°C

500 A@ 100% @ 25°C

Ehave CM500H:

500 A@ 100% @ 40°C

Change rate of

rated output

voltage

< ±5% (cold and hot states; 10% input

voltage fluctuation)

< ±5% (cold and hot states; 10%

input voltage fluctuation)

Line regulation

Output

characteristics

CV/CC

Output voltage

range

Adjustment range: 12 - (34) 38 V

Adjustment range: 12 –45 V

Output current

range

Adjustment range:

CO2/MAG: 30 - (300) 400A

MMA: 30 - (300) 400A

Instant short-circuit peak current: >

550 A

Adjustment range:

CO2/MAG: 30 –500 A

MMA: 30 –500 A

Instant short-circuit peak current:

> 550A

Adjustment range

of ending arc

voltage

Adjustment range: 12 - (34) 38 V;

step: 0.1 V

Adjustment range: 12 –45 V; step:

0.1 V

Adjustment range

of ending arc

current

Adjustment range: 30 - (300) 400 A;

step: 1 A

Adjustment range: 30 –500 A;

step: 1 A

Total positive and

negative output

cable length

Rated input; 15m/35mm2; (250) 350 A

60% normal operation/(193) 271 A

100% normal operation

Ehave CM500: rated input;

30m/50mm2; 500 A 60% normal

operation/ 390 A 100% normal

operation

Ehave CM500H: rated input;

30m/50mm2; 500 A 100% normal

operation

Main control

functions

LED screen

Sets welding voltage and current

values, and displays welding voltage

and current values and error codes.

Sets welding voltage and current

values, and displays welding

voltage and current values and

error codes.

Ce manuel convient aux modèles suivants

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