Support

User should purchase list of items with welding machine

ARC WELDING MACHINE –

1. Arc-200 A welding m/c  + 25mm2 welding  cable  + holder (400 A) + clamp (400A) + power cable (2.5 mm2 3 core) +  plug (16A) + welding rod (2.5/3.15 mm) + welding helmet

2. Arc-300 welding m/c (1 phase) + 25mm2 welding cable  + holder (600 A) + clamp (400A) + power cable (2.5 mm2 3 core) +  plug (16A) + welding rod (3.15 mm) + welding helmet

3. Arc-300 m/c (3 phase) + 25mm2 welding  cable  + holder (600 A) + clamp (400A) + power cable (2.5 mm2, 4 core) +  plug (20A) + welding rod (3.15 mm) + welding helmet
4. Arc-400 m/c +   35mm2 welding  cable  + holder (1000 A) + clamp (400A) + power cable (2.5 mm2, 4 core) +  plug (20A) + welding rod (4.0mm) + welding helmet
5. Arc-400IJ m/c +    50 mm2 welding  cable  + holder (1000 A) + clamp (600A) + power cable (2.5 mm2, 4 core) +  plug (20A) + welding rod (4,5mm) + welding helmet
6. Arc-630 m/c + 70 mm2 welding  cable  + holder (1000 A) + clamp (600A) + power cable (2.5 mm2, 4 core) +  plug (20A) + welding rod (5,6mm) + welding helmet

TIG/ARC WELDING MACHINE –

1. TIG/Arc -200 welding m/c  + TIG torch gascooled with switch (wp26/gc200)  + 25 mm2 welding  cable  + Electrode Holder (400A) + Earth clamp (400A)+ power cable(2.5mm2 3 core) + 16A plug  + tig rod (1.6 mm) + welding helmet

+ argon regulator + flow mtr +argon cylinder + cylinder key + accessories (gas pipe ,tungsten)

2. TIG/Arc -300 (3phase) welding m/c  +TIG torch gascooled  with switch (wp26/gc200) + 25 mm2 welding  cable  + holder (600A) + earth clamp (400A)+ power cable(2.5mm2, 4 core) + 20A plug  + tig rod (2 mm) + welding helmet

+ argon regulator + flow mtr + argon cylinder + cylinder key  + accessories (gas pipe ,tungsten)

3. Arc -300 (3phase) welding m/c + TIG torch gascooled without switch (gc200) +25 mm2 welding  cable  + holder (600A) + earth clamp (400A) + power cable(2.5mm2, 4 core) + 20A plug  + tig rod (2 mm) + welding helmet

+ argon regulator + flow mtr +argon cylinder + cylinder key  + accessories(gas pipe ,tungsten)

4. Arc -400 welding m/c  +TIG torch watercooled without switch (wc-400) – 8 mtr +35 mm2 welding  cable  + holder (1000A) +  earth clamp (400A) + power cable(2.5mm2, 4 core) + 20A plug  + tig rod (2.4,3 mm) + welding helmet

+ argon regulator + flow mtr + argon cylinder + cylinder key +water pump (0.5HP ) +water tank + accessories(gas pipe ,tungsten)

5. Tig/Arc – 400 IJ welding m/c +TIG torch watercooled with switch (wc-400) with switch – 8 mtr +35 mm2 welding  cable  + holder (1000A) + earth clamp (400A)+ power cable(2.5mm2, 4 core) + 20A plug  + tig rod (3,4 mm) + welding helmet

+ argon regulator + flow mtr + argon cylinder + cylinder key +water pump (0.5HP ) +water tank + accessories(gas pipe ,tungsten)

6. Arc – 630 welding m/c  + TIG torch watercooled without switch (wc-600) – 8 mtr +35 mm2 welding  cable  + holder (1000A) + earth clamp (600A) + power cable(4mm2, 4 core) + 30A plug  + tig rod (4 mm) + welding helmet

+ argon regulator + flow mtr +argon cylinder + cylinder key + water pump (0.5HP ) +water tank + accessories(gas pipe ,tungsten)

 TIG/ARC P AC/DC WELDING MACHINE –

1. Tig/Arc P AC/DC – 315 welding m/c + TIG torch watercooled with switch (wc-400) with switch – 4 mtr + 35 mm2 welding  cable  + holder (1000A) + earth clamp (400A)+ power cable(2.5mm2, 4 core) + 20A plug  + tig rod (2.4, mm) + welding helmet

+ argon regulator + flow mtr + argon cylinder + cylinder key + water pump (0.5HP ) +water tank + accessories(gas pipe ,tungsten)

2. Tig/Arc P AC/DC -500 welding m/c +TIG torch watercooled with switch (wc-600) with switch – 8 mtr + 50 mm2 welding  cable  + holder (1000A) +earth clamp (600A)+ power cable(4mm2, 4 core) + 30A plug  + tig rod (3,4 mm) + welding helmet

+ argon regulator + flow mtr + argon cylinder + cylinder key + water pump (0.5HP ) +water tank + accessories(gas pipe ,tungsten)

MIG/ARC WELDING MACHINE –

1. MIG-250 (1PHASE) Welding Machine + wire feeder +mig torch (15AK/24KD/25AK/PANA250) +  CO2 SET + 25mm2 welding  cable  + earth clamp 400A+ 2.5mm 3core power cable + 16A plug  + mig spool (0.8 mm) +

welding helmet  + co2 cylinder + cylinder key + accessories

2. MIG-250 (3PHASE) Welding Machine + wire feeder + mig torch (15AK/24KD/25AK/PANA250) +  CO2 SET + 25mm2 welding  cable  + earth clamp 400A + 2.5mm 4core power cable + 20A plug  + mig spool (0.8 mm) +

welding helmet  + co2 cylinder + cylinder key + accessories

3. MIG/ARC – 400 A  Welding Machine + wire feeder +mig torch (36KD/PANA350) +  CO2 SET + 35mm2 welding  cable  + earth clamp 400A + holder 1000A + 2.5mm 4core power cable + 20A plug  + mig spool (1.2 mm) +

welding helmet  + co2 cylinder + cylinder key + accessories

4. MIG/ARC – 630 A  Welding Machine + wire feeder + mig torch (40KD/PANA500) +  CO2 SET + 70mm2 welding  cable  + earth clamp 600A + holder 1000A + 4mm 4core power cable + 30A plug  + mig spool (1.6 mm) +

welding helmet  + co2 cylinder + cylinder key + accessories

PLASMA CUTTING MACHINE –

1. CUT-60 Plasma cutting m/c + plasma torch (PT31) + earth clamp 400A + filter regulator + 25mm2 welding cable + 2.5mm2, 4 core power cable + 20A plug + plasma  goggles + air compressor (6kg) + compressore pipe + accessories

2. CUT-100 Plasma cutting m/c + plasma torch (P80) + earth clamp 400A + filter regulator + 35mm2 welding cable + 4mm2, 4 core power cable +30A plug + plasma  goggles +air compressor (8kg) + compressore pipe + accessories
3. CUT-160 Plasma cutting m/c + plasma torch (P80) + earth clamp 600A + filter regulator + 50mm2 welding cable + 4mm2, 4 core power cable + 30A plug + plasma  goggles + air compressor (12kg) + compressore pipe + accessories

TORCH/ACCESSORIES

1. Water cooled 8 mtr torch + tungsten + ceramic
2. CO2 REGULATOR + FLOW MTR + GAS HEATER + 2 CORE 1MM2 CABLE(3 MTR) + PIN (2 NOS.)
3. ARGON REGULATOR + FLOW MTR
4. EURO CONNECTOR 36KD FEEDER SIDE +BACKELITE VISER

                   INSTALLATION KIT

1. MULTI METER
2. AC/DC CLAMP METER
3. SERIES BULB 200W
4. SOLDER SMALL+BIG
5. KALAI (SOLDERING METAL) + COPER PATTI
6. WIRE STRIPPER + WIRE CUTTER
7. PAKKAD + DISMIS (SMALL + BIG) + FIX PANA SET(MM SIZE) + SCREW PANA
8. L TYPE KEY SET

                   INSTALLATION PROCESS

                    ARC-200,300 M/C

1. CONNECT M/C TO 1PHASE/3 PHASE CONNECTION
2. CONNECT HOLDER CABLE WITH MACHINE POSITIVE SIDE & EARTH CLAMP CABLE WITH MACHINE NEGATIVE SIDE

           ARC-400 G/400IJ/630IJ

1. CONNECT M/C TO 1PHASE/3 PHASE CONNECTION
2. CONNECT HOLDER CABLE WITH MACHINE POSITIVE SIDE & EARTH CLAMP CABLE WITH MACHINE NEGATIVE SIDE.
3. SET VRD & REMOTE SWITCH OFF.

IF VRD SWITCH ON THAN VOLTAGE DISPAY SHOW LOW VOLTAGE

     IF REMOTE SWITCH  ON THAN CURRENT DISPAY SHOW 00 AMP

4. SET CURRENT & ARC FORCE.

MIG-250 &  MIG/ARC-400/500/600  M/C

1. CONNECT M/C TO 1PHASE/3 PHASE CONNECTION
2. CONNECT WIRE FEEDER POWER CABLE AND 6 PIN PLUG WITH MACHINE NEGATIVE SIDE & EARTH CLAMP CABLE WITH MACHINE POSITIVE SIDE
3. SET REGULATOR +FLOW MTR+ HEATER ATTACHMENT ON CYLINDER
4. IN MIG -400/500/630 CONNECT GAS PIPE TO CYLINDER REGULATOR +FLOW MTR SET
5. IN MIG-250 CONNECT GAS PIPE WITH M/C
6. IN MIG-250 CONNECT CYLINDER GAS PIPE TO BACK SIDE GAS VALVE NIPPLE ON M/C
7. CONNECT MIG TORCH WITH WIRE FEEDER
8. SET MIG WIRE SPOOL ON WIRE FEEDER
9. SET 2T/4T SWITCH
10. IN MIG-400/500-630 SET MIG/MMA SWITCH IN MIG MODE – SET GAS SWITCH IN OFF MODE –
11. WIRE FEEDER  ITCHING SWITCH IS USEFULL TO CHECK MOTOR                    
12. SET CURRENT AND VOLTAGE PORT ON WIRE FEEDER AT REQUIRED POWER
13. CONNECT HEATER PIN(36V) BACK SIDE ON MIG M/C SOCKET

                          PLASMA CUT M/C

1. CONNECT M/C TO 1PHASE/3 PHASE CONNECTION
2. CONNECT FILTER REGULATOR BACK SIDE ON MACHINE
3. CONNECT PLASMA TORCH TO M/C
4. CONNECT EARTH CLAMP CABLE TO MACHINE
5. CONNECT COMPRESSOR PIPE TO FILTER REGULATOR AND CONNECT FILTER REGULATOR PIPE TO M/C BACK SIDE GAS VALVE NIPPLE.
6. SET PRESSURE 4-6 KG IN FILTER REGULATOR
7. HERE, TORCH AIR PIPE AND POWER CABLE IS MIX

                                               TIG/ARC  M/C

1. CONNECT M/C TO 1PHASE/3 PHASE CONNECTION
2. CONNECT GASCOOLED TORCH TO M/C
3. CONNECT EARTH CLAMP CABLE WITH MACHINE POSITIVE SIDE
4. SET TIG/MMA SWITCH IN TIG MODE.
5. SET VRD & REMOTE SWITCH OFF.
6. SET ARGON REGULATOR + FLOW MTR ON ARGON CYLINDER
7. CONNECT CYLINDER GAS PIPE TO BACK SIDE GAS VALVE NIPPLE ON M/C
8. IN WATERCOOLED TORCH CONNECT TORCH WATER-GAS CONNECTOR TO M/C GAS CONNECTOR SOCKET
9. IN WATERCOOLED TORCH CONNECT TORCH WATER – GAS CONNECTOR WITH WATER PUMP PIPE AND SET TORCH GAS PIPE TO WATER-GAS CONNECTOR
10. IN WATERCOOLED TORCH CONNECT TORCH WATER OUT PIPE WITH WATER TANK.
11. IN WATERCOOLED TORCH ,TORCH WATER IN PIPE AND POWER CABLE ARE MIX.
12. IN GASCOOLED TORCH, TORCH GAS PIPE AND POWER CABLE ARE MIX.
13. IN TIG/ARC P AC/DC 315 AND 500 MACHINE – SET TIG/ARC SWITCH IN TIG MODE                                                                                                                – FOR ALUMINIUM WELDING , SET AC/DC SWITCH IN AC MODE AND SET PULSE/DIRECT SWITCH IN DIRECT MODE AND  SET ONLY CURRENT PORT FOR WELDING                                                                                                                      — FOR PULSE WELDING (<1 MM THK) , SET AC/DC SWITCH IN DC MODE AND SET PULSE/DIRECT SWITCH IN PULSE MODE AND SET START CURRENT PORT, BASE CURRENT PORT, PULSE WIDTH PORT,PULSE FREQUENCY PORT AS PER REQUIREMENT

            ARC M/C + TIG ATTACHMENT

1. CONNECT M/C TO 1PHASE/3 PHASE CONNECTION
2. CONNECT TORCH T CONNECTOR WITH MACHINE NEGATIVE SIDE AND EARTH CLAMP CABLE WITH MACHINE POSITIVE SIDE
3. SET ARGON REGULATOR + FLOW MTR ON ARGON CYLINDER
4. CONNECT TORCH GAS PIPE TO FLOW MTR ON CYLINDER
5. IN WATERCOOLED TORCH ,TORCH WATER IN PIPE AND POWER CABLE ARE MIX.

DESIGN TYPE –

1. ARC WELDING – MOSFET- 200/300/400
2. ARC WELDING – IGBT – 400G/400IJ/500IJ/630IJ
3. MIG – 400 IJ /MIG-630 IJ
4. MIG-250 MOSFET ( MIG-400 IJ + MOSFET 300)
5. PLASMA CUT – 100/CUT-160
6. CUT-40 ( CUT-100 + MOSFET – 200)
7. CUT-60 (CUT-100 + MOSFET-300)
8. TIG MACHINE ( ARC-MOSFET/IGBT + HF )

WELDING MACHINE TYPE –

1. STUD TYPE
2. REGULATOR TYPE
3. DIODE BASED RECTIFIER TYPE
4. THYRISTOR BASED RECTIFIER TYPE
5. INVERTER TYPE

NOTE – ALWAYS TAKE PHOTO OF MACHINE PCB AND PARTS WIRING BEFORE REPAIRE IT.

MOSFET – 200/300/400 SERVICE DATA –

1. MOSFET – 18N50/4107/4108/4109 – VALUE SAME – USE EACH OTHER
2. 3878 –
3. DIODE – D9202 –
4. TRANSFORMER – 21:4 , 21:5 , 10:4 –ALWAYS USE SAME VALUE TRANSFORMER LIKE.

IF 21:4 TRANSFORMER IN M/C THAN REPLACE  BY 21:4, NEVER USE ANOTHER VALUE TRANSFORMER LIKE 21:5,10:4.

IF WE USE ANOTHER TRANSFORMER THAN MOSFET PCB BLAST.

5. TRANSFORMER CHECK – CONTINUITY CHECK BY MULTIMETER.
6. CAPACITOR – CHECK – VISUAL CHECK – DARK ANY AREA , BLAST, SPREAD –
7. CAPACITOR – INSTALL – MATCH (+,-) BOTH PCB AND CAPACITOR
8. MOSFET – CHANGE – ALWAYS CHANGE RESISTOR WITH MOSFET
9. RESISTOR – CHANGE – CHECK COLOUR CODE VALUE – IN SOFTWARE –
10. GENERALLY – 4.6 , 6.8 , OHM RESISTOR USED WITH MOSFET – 10 OHM  RESISTOR USED WITH IGBT DESCRET
11. DIODE PCB – TRANSFORMER – 3 NOS. THAN CONNECTOR PIN ON MOSFET PCB HAVE BLACK WIRE – 3 NOS AND RED WIRE -3 NOS.

 IF DIODE PCB – TRANSFORMER – 4 NOS.  THAN CONNECTOR PIN ON MOSFET PCB HAVE BLACK WIRE – 4 NOS AND RED WIRE – 4 NOS.

12. TRANSFORMER – SHORT – MACHINE OC LIGHT ON – SERIES BULB  FULL – REMOVE CONNECTOR PIN OF MOSFET,DIODE PCB , IF OC LIGHT OFF THAN DIODE PCB IS SHORT MOSTLY TRANSFORMER ARE SHORT.
13. TRANSFORMER – SHORT –FAST REPAIRE –REMOVE BLACK/RED WIRE ONE BY ONE ON CONNECTOR PIN-WHEN WE REMOVE SHORT TRANSFORMER WIRE THAN OC OFF AND SERIES BULD OFF – CUT AND WRAP WIRE TAP OF SHORT TRANSFORMER BLACK/ RED (ANY ONE) WIRE IN CONNECTOR PIN –
14. CONTROL PCB – SHORT – OCV VALUE NOT SHOWN –
15. SHUNT IS IN POSITIVE SIDE OR NAGETIVE SIDE IN DIODE PCB IN ARC-200/300 M/C.
16. IF DODE PCB OR CONTROL PCB –REPLACE IN MACHINE AND WE DON’T GET RESULT THAN SET (+,-) WIRE POSITION OF CONNECTOR PIN OF DIODE ,CONTROL PCB.     

  MINS,IF  (+,-) THAN DO (-,+) AND IF (-,+) THAN DO (+,-) WIRE POSITION.      

 GENERALLY,FIRST WIRE IS RED AND ANOTHER TWO WIRE ARE BLACK AND BLUE.

17. MOSFET 300 AND MOSFET 400 – CONTROL PCB – SAME –
18. IF MOSFET ,DIODE PCB OK THAN CHECK CAPACITOR PCB.
19. RECTIFIER DIODE– CHECK – REMOVE RECTIFIER DIODE PIN ONE BY ONE ON CAPACITOR PCB – IF SERIES BULB FULL – AFTER PIN REMOVE , BULB IS OK – 
20. RECTIFIER DIODE – REPAIRE – CHANGE RECTIFIER DIODE
21. CAPACITOR PCB – RELAY – CHECK – BY RELAY SOUND AND SERIES BULB FULL – SOMETIME RELAY BECOMES HOT
22. CAPACITOR PCB – RELAY –REPAIRE – DIRECT RELAY BY SMALL WIRE
23. POWER IS NOT CONTROLL – CURRENT PORT IS SHORT
24. DISPLAY – SHORT – VOLTAGE/AMP NOT SHOWN BY DISPLAY
25. ON/OFF SWITCH – SHORT – MACHINE IS OFF MINS DISPLAY,FAN,POWER IS OFF –
26. MOSFET – CHECK –SET  MULTIMETER  IN DIODE ARROW –  CHECK MOSFET SHOCK PCB BY MULTIMETER  (+,-) POINT SAME AS GIVEN BELOW – METER READING IS 600-700 –

  IF MULTIMETER READING IS NOT 600-700 AT ANY TWO POINT OF SHOCK PCB THAN THESE SIDE OF MOSFET ARE SHORT. HERE READING IS ZERO GENERALLY.

27. MORE MOSFET ARE SHORT THAN ALSO CHANGE MOSFET SHOCK PCB.
28. MOSFET SHOCK PCB –SHORT – CHECK EVERY MOSFET
29. AFTER REPAIRING MOSFET PCB – CHECK CONTINUTY BETWEEN EVERY TWO MOSFET MIDDLE LEG SO WE CAN KNOW THAT SOLDERING IS DONE PROPERLY ON NOT.

IF SOLDERING IS NOT DONE PROPERLY THAN VOLTAGE CANNOT COME OUTSIDE OF MACHINE.

30. MAIN TRANSFORMER IS SHORT – SERIES BULB FULL – MAIN TRANSFORMER WINDING OPEN – CHECK 15-0-15 AC VOLTAGE IN CONTROL PCB PIN BETWEEN TRANSFORMER AND CONTROL PCB
31. CONTROL PCB – SHORT – CHECK DC VOLTAGE BETWEEN BLACK COLOUR 4 NOS. IRFZ24N/IRF9224N AND TRANSISTOR 7812 STEP BY STEP.

HERE,PUT POSITIVE POINT OF MELTIMETR IS ON IRF AND PUT NEGATIVE POINT ON TRANSISTOR.

IF MULTIMETER SHOW 15V DC, CONTROL PCB IS OK AND IF MULTIMETER SHOW MORE THAN 15V DC, CONTROL PCB IS DAMAGED.

32. CONTROL PCB CHECK DURING MACHINE IS ON BECAUSE IF MACHINE IS OFF MULTIMETER DO NOT SHOW READING.
33. MOSFET PCB CHECK – SECOND METHOD – REMOVE ALL CONNECTOR PIN OF ANOTHER ALL PCB ON MOSFET PCB AND CHECK IT IN SERIES BULB
34. CHECK CONTROL PCB AT LAST BECAUSE IF MOSFET ARE SHORT THAN CONTROL PCB IFR- TRENSISTOR READING IN NOT 13-15 VDC. HERE,READING VALUE IS MORE THAN 15VDC.
35. OUTPUT DIODE – CHECK – SWITCH OFF MACHINE – SET MULTIMETER IN DIODE MODE – CHECK MACHINE (+,-) BY MULTIMETER – IF READING IS AROUND  128-200 THAN OUTPUT DIODE ARE OK – IF READING IS AROUND 0.00-0.012 THAN OUTPUT DIODE ARE DAMAGED –

IGBT 400G/IJ/630IJ  SERVICE DATA

1. IGBT DESCRET – 40T120/40N120 –SAME

                                               – 60T100/60N120 – SAME

                                              – 60T120/60N120 – SAME

2. IGBT MODULE – 50A1200V – 75A1200V- 100A 1200V – 150A 1200V – 200A 1200V
3. IGBT DESRET AND DIODE DESCRET SHOULD NOT TOUCH WITH ALUMINIUM HEATSINK.
4. AFTER REPAIRE CHECK CONTINUITY BETWEEN IGBT/DIODE DESCRET AND HEATSINK.
5. IGBT MODULE AND DIODE MODULE ARE TOUCH WITH ALUMINIUM HEATSINK.THEY ARE SET DIRECTLY ON HEATSINK.
6. IF SINGLE DIODE MODULE IS DAMAGED THEN WE CAN CHANGE SINGLE DIODE MODULE. DIODE MODULE PAIR IS NOT REQUIRED FOR CHANGE LIKE PLASMA MACHINE.
7. IF POWER IS ALWAYS FULL THAN SHUNT IS DAMAGED
8. IF POWER IS DOING HIGH-LOW AND NOT REMAIN CONSTANT THAN CURRENT PORT IS DAMAGED.
9. IGBT MODULE DAMAGED – SERIES BULB FULL- MCB DO TRIP – REMOVE BOTH WIRE (+,-) OR ONLY RED WIRE (+) ON IGBT MODULE WHICH IS COMING FROM BRIDGE DIODE –THANAFTER SERIES BULB IS OK – MCB DO NOT TRIP –

REMOVE IGBT SHOCK PCB ALWAYS WITH IGBT MODULE.

10. IF WELDING ROD IS NOT PROPER MELTING – 3PHASE/1 PHASE POWER IS NOT REACHING TO MACHINE PROPERLY – PHASE POWER CABLE IS IN LOOSE CONDITION –
11. CONTROL PCB CHECK – SAME IN MOSFET
12. CONTROL PCB PULSE IS NOT GOING ON IGBT SHOCK PCB THAN SHOCK PCB LED SHOWS OFF MINS CONTROL PCB IS DAMAGED – HERE MACHINE VRD SWITCH SHOULD BE IN OFF CONDITION .-

 IF VRD SWITCH IS ON THAN SHOCK PCB LED SHOWS OFF, HERE WE CAN NOT CHECK THAT CONTROL PCB IS DAMAGED OR NOT.

12. IF TRANSFORMER ,OUTPUT DIODE,IGBT MODULE IS OPEN , SERIES BULB CAN NOT FIND THIS PROBLEM.

IN THIS CASE, CHECK TRANSFORMER VOLTAGE – REMOVE OUTPUT NPN DIODE FROM MACHINE AND CHECK IT.  – REMOVE IGBT MODULE FROM MACHINE AND CHECK IT. –

13. OUTPUT NPN DIODE – CHECK – SERIES BULB FULL – REMOVE BOTH WIRE ON OUTPUT DIODE – SERIES BULB OK MINS PUTPUT DIODE IS DAMAGED.-

CHECK BOTH OUTPUT DIODE ONE BY ONE.- IF ONE DIODE IS DAMAGED, CHANGE IT. – HERE ONLY CHANGE OUTPUT DIODE – DIODE PCB REMAIN SAME CONDITION – DON’T CHANGE DIODE PCB IF PCB IS NOT DAMAGED

14. VRD – VOLTAGE REDUCTION DEVICE

      REM – REMOTE

     2T – AUTO MODE  – 4T- MANUAL MODE

15. VRD, REMOTE, 2T-4T BLACK SWITCH CHECK –

                        2 –                 ON                                                                                            COMMON    -–

                        1 –                OFF

SWITCH IS ON – CHECK CONTINUITY BETWEEN 1 & COMMON

SWITCH IS OFF – CHECK CONTINUITY BETWEEN 2 & COMMON

16. IF MACHINE PARTS DAMAGED – DURING CONTINUTY METER READING IS ZERO AND CONTINUTY SOUND IS LISTENING.
17. BRIDGE DIODE CHECK – FIRST CHECK OUTPUT DIODE- IF OUTPUT DIODE IS OK AND SERIES BULB FULL THAN REMOVE (+,-) ON BRIDGE DIODE – IF SERIES BULB OK MINS BRIDGE DIODE IS SHORT – REPLACE IT.
18. OUTPUT DIODE – CHECK – SWITCH OFF MACHINE – SET MULTIMETER IN DIODE MODE – CHECK MACHINE (+,-) BY MULTIMETER – IF READING IS AROUND 128-200 THAN OUTPUT DIODE ARE OK – IF READING IS AROUND 0.00-0.012 THAN OUTPUT DIODE ARE DAMAGED –

                 MIG-250 SERVICE DATA

1. MOSFET PCB , DIODE PCB ,CAPACITOR PCB REPAIRE METHOD SAME AS ARC MOSFET MACHINE
2. WIRE FEEDER , TORCH REPAIRE METHODE SAME AS MIG-400 MACHINE.
3. BOTTOM SIDE CONTROL PCB CONTROLS WIRE FEEDER SO IF ANY PROBLEM ON WIRE FEEDER ,CHECK BOTTOM SIDE CONTROL PCB

               MIG- 400/630 SERVICE DATA

1. IGBT MODULE , OUTPUT DIODE , BRIDGE DIODE, CAPACITOR – CHECK –SAME METHOD USED IN ARC IGBT MACHINE.
2. GAS IS NOT COME PROPERLY – GAS VALVE IS DAMAGE OR 24 VDC IS NOT COME PROPERLY FROM CONTROL PCB.

IF 24VDC IS NOT COME PROPERLY FROM CONTROL PCB REPAIRE GAS PRESET ON CONTROL PCB.

3. IF WIRE AND GAS COME DIRECTLY FROM TORCH THAN TORCH SWITCH IS DAMAGED.
4. WIRE FEEDER MOTOR IS NOT WORKING PROPERLY – CHECK 7 CORE CABLE – 7 CORE CABLE IS DAMAGED – REPAIRE IT –
5. WIRE IS NOT COME PROPERLY FROM TORCH – CHECK – TORCH LINER IS DAMAGED OR FEEDER ROLLER SETTING IS VERY TIGHT ,SET IT.
6. MIG/MMA SWITCH IS DAMAGED – MIG MACHINE IS IN ARC MODE MINS WELDING IS DONE WHILE EARTHING BUT WIRE IS NOT COMING OUTSIDE. WIRE COMES OUT WHEN TORCH SWITCH IS ON.
7. POWER REMAINS FULL – CHECK CURRENT SENSOR AND ALSO CHECK OCV ON POWER FEEDBACK WIRE WHICH IS BETWEEN CONTROL PCB AND (+,-) OF MACHINE – IF JUNK ,DUST ON FEEDBACK WIRE THAN POWER REMAINS FULL.

                   CUT-60 SERVICE DATA

1. MOSFET PCB , DIODE PCB ,CAPACITOR PCB REPAIRE METHOD SAME AS ARC MOSFET MACHINE
2. ANOTHER PROBLEM – SEE – CUT-100 SERVICE DATA

                      CUT- 100/160 A SERVICE DATA

1. . IGBT MODULE ,OUTPUT  DIODE , BRIDGE DIODE, CAPACITOR – CHECK – SAME METHOD USED IN ARC IGBT MACHINE.
2. CHANGE OUTPUT DIODE ALWAYS IN PAIR
3. AIR IS LESS – MACHINE SHOWS OC LIGHT ON.
4. SPARK IS NOT COME PROPERLY –

               CHECK NOZZLE & ELECTRODE – ALSO CHECK TORCH HEAD – ALSO CHECK POWER PHASE –ALSO  CHECK TORCH SPARKING CABLE ON METER CONTINUITY MODE – ALSO CHECK MACHINE HF PCB

5. FILTER REGULATOR IS DAMAGED – NOZZLE AND TORCH HEAD ARE DAMAGE EASILY.
6. REMOVE WATER ON FILTER REGULATOR DAILY.
7. THREE PHASE PROBLEM – NOZZLE DAMAGED EASILY
8. IF 510K,5W RESISTOR IN HF PCB DAMAGED THAN REPLACE IT BY ANY 5W OR MORE WATT VALUE RESISTOR. HERE, OHM VALUE IS NOT MORE IMPORTANT.

   TIG – 200, 300,400, 600 SERVICE DATA

1. TIG M/C = ARC M/C + HF
2. TIG M/C REPAIRE METHOD IS SAME AS ARC MOSFET MACHINE AND ARC IGBT MACHINE.
3. HF IS NOT COME PROPERLY – CLEAN HF PCB AND CLEAN HF POINT PROPERLY.

                                 SAW M/C SERVICE DATA

1. IGBT MODULE , OUTPUT DIODE , BRIDGE DIODE, CAPACITOR – CHECK –SAME METHOD USED IN ARC IGBT MACHINE.

                     SIMPLE STEPS  MOSFET M/C REPAIRE   

1. REMOVE CONNECTOR PIN ON MOSFET PCB COMES FROM DIODE PCB – CHECK SERIES BULB
2. PUT MULTIMTR IN DIODE MODE AND CHECK MOSFET SHOCK PCB POINT
3. REMOVE BRODGE DIODE PIN ON CAPACITOR ONE BY ONE – CHECK SERIES BULB
4. CHECK READING OF CONTROL PCB IFR & TRANSISTOR

         SIMPLE STEPS  IGBT  M/C REPAIRE  

1. REMOVE BOTH  BRIDGE DIODE WIRE ON IGBT MODULE – CHECK SERIES BULB
2. REMOVE FOUR WIRES ON OUTPUT DIODE ONE BY ONE – CHECK SERIES BULB
3. TO CHECK CONTROL PCB – CHECK LED ON IGBT SHOCK PCB IS ON OR OFF

                                  PLASMA CNC M/C SERVICE DATA

1. SPARK IS NOT COME PROPERLY –

               CHECK NOZZLE & ELECTRODE – ALSO CHECK TORCH HEAD – ALSO CHECK POWER PHASE –ALSO  CHECK TORCH SPARKING CABLE ON METER CONTINUITY MODE – ALSO CHECK MACHINE HF PCB

2. MACHINE WORKING HEAVILY – IF DRIVE BECOME HOT THAN DRIVE MCB IS TRIPPED SO DRIVE IS OFF ,IN THIS CASE MACHINE IS WORKING ONLY ONE SERVO MOTOR SO WE FEEL THAT MACHINE WORKING HEAVILY.
3. FILTER REGULATOR IS DAMAGED – NOZZLE AND TORCH HEAD ARE DAMAGE EASILY.
4. REMOVE WATER ON FILTER REGULATOR DAILY
5. CUTTING DIMENSION VARIATION PROBLEM – CALIBRATE DRIVE ACCURACY
6. DISPLAY IS DAMAGED – CHECK VISUALLY
7. SOFTWARE DAMAGED – INSTALL NEW SOFTWARE
8. HYPERTHERM DISPAY ERROR PROBLEM – SEE DISPLAY ERROR NO. THAN READ ITS SOLUTION IN HYPERTHERM MANUAL BOOK AND SOLVE IT.

GENERAL STEP – USE BLOWER OR AIR COMPRESSOR AND REMOVE DUST FROM MACHINE

ARC WELDING MACHINE –

1. WELDING ROD NOT MELTING PROPERLY – CHECK 1PHASE/3 PHASE CONNECTION AND TIGHT WIRE /PLUG.

TIG/ARC WELDING MACHINE

1. WELDING ROD NOT MELTING PROPERLY – CHECK 1PHASE/3 PHASE CONNECTION AND TIGHT WIRE /PLUG.
2. HF IS NOT COME PROPERLY – CLEAN HF PCB AND CLEAN HF POINT PROPERLY.
3. HF IS ALWAYS ON – CHECK TIG TORCH SWITCH – CLEAN HF POINT PROPERLY AND KEEP GAP BETWEEN HF POINT PROPERLY IN HF PCB   

MIG WELDING MACHINE

1. WELDING ROD NOT MELTING PROPERLY – CHECK 1PHASE/3 PHASE CONNECTION AND TIGHT WIRE /PLUG.
2. IF WIRE AND GAS COME DIRECTLY FROM TORCH – CHECK TORCH SWITCH IS DAMAGED.REPAIRE IT.
3. WIRE IS NOT COME PROPERLY FROM TORCH – CHECK  TORCH LINER IS DAMAGED  OR FEEDER ROLLER SETTING IS VERY TIGHT ,SET IT.

SAW WELDING MACHINE

1. WELDING ROD NOT MELTING PROPERLY – CHECK 1PHASE/3 PHASE CONNECTION AND TIGHT WIRE /PLUG.

PLASMA  CUTTING MACHINE

1. CUTTING IS NOT PROPERLY DONE – CHECK 1PHASE/3 PHASE CONNECTION AND TIGHT WIRE /PLUG.
2. AIR IS LESS – MACHINE SHOWS OC LIGHT ON.
3. REMOVE WATER ON FILTER REGULATOR DAILY.
4. THREE PHASE PROBLEM – NOZZLE DAMAGED EASILY
5. SPARK IS NOT COME PROPERLY –

              CHECK NOZZLE & ELECTRODE – ALSO CHECK TORCH HEAD – ALSO CHECK POWER PHASE –ALSO  CHECK TORCH SPARKING CABLE ON METER CONTINUITY MODE  (SPARKING CABLE DAMAGE OR OK) – CLEAN HF PCB AND CLEAN HF POINT PROPERLY.

PLEASE,WATCH BELOW VIDEO

PLEASE, WATCH UPPER VIDEO.