Longrun 610TC Operating instructions

Brand: Longrun

Model: 610TC

Category: Welding System

Type: Operating instructions

Longrun 610TC

Below you will find brief product information for Longrun 610TC. Please read this manual thoroughly before installing or operating the machine. The Longrun 610TC is a powerful and versatile CO2/MAG arc welder, perfect for a variety of welding applications. With its stable and excellent welding performance, this machine is ideal for both professional welders and hobbyists alike.

Some of the key features of the Longrun 610TC include:

Stable and excellent welding performance, thanks to the new control circuit
Easy to maintain and repair, due to its simple and firm structure design

Longrun 610TC

Some of the key features of the Longrun 610TC include:

Stable and excellent welding performance, thanks to the new control circuit
Easy to maintain and repair, due to its simple and firm structure design

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

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.

Voltage Delay Time

When welding is over, delay output current to avoid wire sticking with material

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

On ▷ Starting gas time [0.4 seconds]

Off ▷ Starting gas time [0 seconds]

On ▷ Gas afer flow time [0.6 seconds]

Off ▷ Gas afer flow time [0.3 seconds]

3 - ▷ No function. Off setting

▷ 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

▷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]

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

Longrun 610TC Operating instructions

Brand: Longrun

Model: 610TC

Category: Welding System

Type: Operating instructions

Longrun 610TC

Some of the key features of the Longrun 610TC include:

Stable and excellent welding performance, thanks to the new control circuit
Easy to maintain and repair, due to its simple and firm structure design

Download PDF

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Longrun 610TC Operating instructions

Longrun 610TC Operating instructions

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