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THYRISTOR CO2/MAG ARC WELDER
OPERATION MANUAL
DO NOT INSTALL, OPERATE OR MAINTAIN THIS MACHINE WITHOUT READING
THIS MANUAL AND PLEASE ALWAYS THINK BEFORE YOU ACT.
www.worldwel.com
■ TECHNICAL SPECIFICATIONS
- Stable and excellent welding by new control circuit
- Easy to maintain and repair by simple and firm structure design
- High duty cycle by sufficient capacity of all parts and quality cooling fan
- Adjustable crater voltage and current
ITEM UNIT SPECIFICATION
Input Voltage V 220, 380, 440, 3 Phase
50/60Hz
Rated Output Current A 600
Input Current @ rated
output
220V
KVA 43
380V
440V
No Load Voltage V 75
Output Current Range A 60 ~ 600
Output Voltage Range V 12 ~ 48
Duty Cycle @ rated output % 100
Dimension (W×D×H) mm 500 × 740 × 900
Weight kg 195
General Safe Practices
■ Wear approved safety glasses with side shields under your welding helmet or face shield and at all
times in the work area.
■ When working above floor level, use a safety belt to protect yourself from a fall should you get a
shock.
■ Do not install or place machine on or over combustible surfaces.
■ Be sure that all installation, operation, maintenance and repair procedures are performed only by
qualified persons.
Electric shock can kill.
■ Wear Dry, hole-free insulating gloves and body protection. Do not touch electrode with bare hand. Do
not wear wet or damaged gloves.
■ Do not touch live electrical parts.
■ Never dip the electrode in water for cooling.
■ Properly install and ground all equipment.
■ Protect yourself from electric shock by insulating yourself from work and ground. Use non-flammable,
dry insulating material if possible, or use dry rubber mats, dry wood or plywood, or other dry insulating
material big enough to cover your full area of contact with the work or ground, and watch for fire.
■ Turn off input power using the disconnect switch at the fuse box before working on the equipment.
■ Frequently inspect input power cord for damage or bare wiring and repair or replace cord immediately
if damaged.
Fumes and gases can be dangerous.
■ Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.
When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to
keep fumes and gases away from the breathing zone.
■ Use enough forced ventilation or local exhaust (forced suction) at the arc to remove the fumes from
your breathing area.
■ Use a ventilating fan to remove the fumes from the breathing zone and welding area.
Arc rays can burn eyes and skin.
■ Use welding helmet with correct shade of filter to protect your eyes from sparks and the rays of the
arc.
■ Wear welders cap and safety glasses with side shields. Use ear protection when welding out of
position or in confined spaces. Button shirt collar.
■ Wear complete body protection. Wear oil-free protective clothing such as leather gloves, heavy shirt,
cuffless pants and high boots.
Welding sparks can cause fire or explosion.
■ Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding
sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go
through small cracks and opening to adjacent areas. Avoid welding near hydraulic lines.
■ When not welding, make certain no part of the electrode circuit is touching the work or ground.
Accidental contact can cause overheating and create a fire hazard.
■ Do not weld on drums, tanks, or any closed containers unless a qualified person has tested it and
declared it or prepared it to be safe.
■ Connect the work cable to the work as close to the welding area as practical. Work cables connected
to the building framework or other locations away from the welding area increase the possibility of the
welding current passing through lifting chains, crane cables or other alternate circuits. This can create
fire hazards or overheat lifting chains or cables until they fail.
■ INSTALLATION
● The welding machine shall be installed at a place ;
free from the inflammables
less humidity, dirt and dust
protecting from influence of direct sunlight, wind and rain
not generated oil vapor and corrosive gas
operating temperature range is from -10℃ to 40℃
least 30㎝ away from wall and other welding machine
● Input Connection (Rear of the machine)
Be sure the voltage, phase and frequency of the input power is as specified on the name plate
located on the rear panel of the machine.
To connect the power cables, turn the power switch OFF
Verify the voltage to be supplied from main power.
Connect the power cable to the power input cable on the rear of the machine.
For grounding the machine, connect a ground wire to the ground terminal marked with the symbol is
located on the rear panel of the machine.
● Output Connection (Front of the machine)
Connect the work cable to the "METAL" terminal.
To connect the Wire feeder, connect a electrode cable from wire feeder to the "TORCH" terminal and a
Remote control cable from the wire feeder to the "REMOTE CONTROL" receptacle and a gas hose from inert
gas tank to the gas input receptacle of wire feeder.
CO2 Torch connection to wire feeder
Connect a wire feeding cable of torch to the wire feeding cable receptacle of wire feeder.
Connect a torch switch connector of torch to the torch switch receptacle of wire feeder.
Connect a gas hose of torch to the gas hose receptacle of wire feeder.
■ FRONT PANEL
1 Power Switch When it is turned on, the cooling fan and all of electrical circuit
inside the machine will be operated.
2 Crater Selection Switch It choose the Crater OFF or Crater ON.
3 Welding mode selection Switch
- Above : Checking the flow of the gas.
- Center : CO2/MAG welding
- Bottom : Gouging
4 Crater Current Volume Adjust the crater current
5 Crater Voltage Volume Adjust the crater voltage
6 Power Lamp It indicates that the machine is on and input voltage is within
acceptable range.
7 Warning Lamp
It indicates the thermal over load or output disabled by any
electrical problems or the failure of program. When it is on, the
machine will not supply power at the output.
8 Motor Fuse (15A) It will be broken by motor problem of wire feeder
9 Control Fuse (5A) It will be broken by any electrical problems
10 Ammeter Indicate the welding current
11 Voltmeter Indicate the welding voltage
■ CRATER SELECTION
CRATER OFF
Press and hold the torch switch, the arc is started at the welding current. When finish
to weld, just release the torch switch.
CRATER ON
Press and hold the torch switch, the arc is started at the welding current. At this time
release the torch switch, the arc is not stopped. When finish to weld, press and hold
the torch switch, the output current will be decreased from the welding current to the
crater current. At this time release the torch switch, the arc is turn off.
■ START UP
Verify the voltage to be supplied from main power and turn on main power
Position the crater switch to CRATER OFF or CRATER ON
Turn on the power switch of machine and then verify that the cooling fan is running.
Position the GAS CHECK switch to "GAS CHECK" and adjust the volume of following gas by the gas
regulator. When start to weld, position to "WELDING".
The welding wire is positioned at end of torch tip by pressing the inching switch of wire feeder for
starting.
Start to weld with adjusting the welding voltage and current of wire feeder and crater voltage and
current if necessary.
① Welding current
② Crater current
■ TROUBLESHOOTING
√ If all recommended action have been checked and the problem persists, please contact our service
center
SYMPTOMS
REASON RECOMMENDED ACTION
Cooling fan does not run when the power switch is
turn on.
No input voltage
Fuse (5A) is blown
Power switch broke down
Cooling fan broke down
Verify input voltage
Replace Fuse (5A)
Replace Power switch
Replace Cooling fan
Welding wire
does not go out
from wire feeder
Welding wire does not go out
when pressing the inching switch
of wire feeder
Fuse (15A) is blown
Wire feeding cable does not
connect perfectly
Motor of wire feeder broke down
Control PCB broke down
Replace Fuse (15A)
Reconnect Wire feeding cable of
torch
Replace Motor of wire feeder
Replace Control PCB
Wire feeding has no problem
when pressing the inching
switch, but Welding wire does
not go out from wire feeder
when pressing the torch switch
of torch
Torch switch connector does not
connect perfectly
Torch switch broke down
Control PCB broke down
Reconnect Torch switch connector
Replace Torch
Replace Control PCB
Gas does not
flow from torch
Gas does not flow from torch
when the GAS CHECK switch is
"GAS CHECK" position
Close the valve of gas tank
Gas check switch broke down
Open the valve of gas tank
Replace Gas check switch
Gas does not flow from torch
when pressing the torch switch
Torch switch connector does not
connect perfectly
Torch switch broke down
Control PCB broke down
Reconnect Torch switch connector
Replace Torch
Replace Control PCB
Gas flows continuous at "WELDING" position of GAS
CHECK switch
GAS CHECK switch broke down
Torch broke down
Control PCB broke down
Replace GAS CHECK switch
Replace Torch
Replace Control PCB
It does not adjust the welding voltage and current on
the wire feeder
Remote control connectors of
wire feeder does not connect
perfectly
Volume broke down
Control PCB broke down
Reconnect Remote control
connectors of wire feeder
Replace Volume
Replace Control PCB
Arc does not started
Torch cable is broke
Torch switch connector does not
connect perfectly
Work cable does not connect
perfectly
Torch broke down
Control PCB broke down
Repair Torch cable
Reconnect Torch switch connector
Reconnect Work cable
Replace Torch
Replace Control PCB
Crater does not work Crater select switch broke down
Control PCB broke down ․ Contact our service center
■ Block Diagram
■ PCB Setting
VR1 Adjust Max. Current
VR2 Adjust Voltage 600TC - 48V(Standard)
VR3 Adjust Motor speed Motor voltage is 26V to measure between #5 and #6 of Connector 10
<DIP S/W>
2 Starting gas Operate about 0.2 seconds when it is “ON"
3 Gauging Select "ON" when needs gauging function
4 Initial value
On factory, 40V(welding voltage)/3V(Wire speed)
Adjust voltage and current of wire feeder when torch is ON. It's saved when DIP S/W is
OFF
5 Magnet S/W
Selection of POWER INPUT
“ON" - If magnet S/W is ON, supply Input Power.
“OFF" - If magnet S/W is ON, supply Input Power when Torch is ON.
6
Voltage Delay Time
When welding is over, delay output current to avoid wire sticking with material
7
No. 6 No. 7 Delay time
OFF OFF 0.3sec
OFF ON 0.5sec
ON ON 1.2sec
ON OFF 0.8sec
■ PCB Setting [New PCB Model]
Adjustable resistance Setting Functions
VR1
CW (Clockwise) No-loading voltage up
CCW
(Counter Clockwise) No-loading voltage down
VR2
CW (Clockwise) Motor voltage up
CCW
(Counter Clockwise) Motor voltage down
▷ DIP S/W
DIP S/W Setting Functions
1
On ▷ Starting gas time [0.4 seconds]
Off ▷ Starting gas time [0 seconds]
2
On ▷ Gas afer flow time [0.6 seconds]
Off ▷ Gas afer flow time [0.3 seconds]
3 - ▷ No function. Off setting
4
On
▷ Starting voltage and Starting motor speed setting (3phases / 380V)
▷ Initial setting on Factory
[Starting voltage = 43V] [Starting Motor Speed = 4V]
▷ You can change Starting voltage and Starting motor speed using adjustable
resistance of voltage and current on wire feeder.
Off
▷Storing Starting voltage and Starting motor speed in memory.
▷You should switch off DIP S/W 4 when finishing setting in order to store in
memory.
5 - ▷ No function. Off setting
6
▷Setting Voltage holding time after welding is over.
DIP S/W 6 =>Off , DIP S/W 7=>Off : 0.1[seconds]
DIP S/W 6 =>On , DIP S/W 7=>Off : 0.3[seconds]
DIP S/W 6 =>Off , DIP S/W 7=>On : 0.5[seconds]
DIP S/W 6 =>On , DIP S/W 7=>On : 0.7[seconds]
7
8On ▷ Control wave form Off
Off ▷ Control wave form On
610TC PARTS LIST
NO.
PART NAME DESCRIPTION QTY.
1FAN Moter IC-9430SDA 1
2FAN 610TC 1
3Control Transformer 11452 1
4Meta DC10V-800A 2
5Volume RV24YN5K 2
6Fuse FH-30 3
7Toggle S/W DJT-3303 4
8NFB 15A 1
9Electric Detect PCB 610TC 1
10 Control Transformer 7630 1
11 Main PCB 610TC 1
12 SCR MTG200A 2
13 Distribution PCB 610TC 1
14 Hole CT TM3A300-04DA15 1
15 Resistor, Discharge 400W/100 1
16 Main Transformer 610TC 1
17 Induction coil 610TC 1
18 Choke Transformer 610TC 1
19 Solenoide Valve AC100V 1
20 Nipple 9/16*1/4 1
21 Connector K25-2R,K25-6R 1
22 Terminal 95*8 2
23 Temp. Switch N85 1
24 Plug HS-002 1
25 Nipple 9/16* 6Φ1
26 Terminal 6M/M 1
27 Magnet CMC-65N 1
Thank you very much for choosing our machine...
Please record your machine identification information below for future reference. This
information can be found on the nameplate of your machine.
Product Name THYRISTOR CO2/MAG ARC WELDER
Model Number LONGRUN 610TC
Date Manufactured
Serial Number
Date Purchased
Where Purchased
Where you use
Whenever you request replacement parts or information on this machine, always
supply the information you have recorded above. The date number is especially
important when identifying the correct replacement parts.
Complete this form, please fax it to our selling agency in your country or us for
warranty statement.
Worldwel Co., Ltd.
11-101, Songlim-dong, Dong-gu, Incheon-city, Korea
TEL : +82-32-876-2114 FAX : +82-32-876-2117
E-mail:sales@worldwel.com http://www.worldwel.com
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