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TIME Inverter Welding Machine

TDN 3500/5000
MAG/MIG/CO2 Power source

Instruction manual

Beijng TIME Technologies Co., Ltd


Operation instruction of TDN 5000 MAG/MIG/CO2 power source Contents

CONTENTS
1. SAFETY PRECAUTIONS .......................................................................................................................1
1.1 Description of safety signs .........................................................................................................1
1.2 Safety signs.................................................................................................................................1
1.3 Electromagnetic field .................................................................................................................5
1.4 Electromagnetic compatibility....................................................................................................5
2. OVERVIEW .........................................................................................................................................8
3. DEFINITION DECLARATION .............................................................................................................. 11
3.1 Nameplate ................................................................................................................................ 11
3.2 Symbol description ...................................................................................................................12
4. STRUCTURE AND NAMES OF MAIN COMPONENTS .............................................................................13
5. HANDLING, INSTALLATION SITE AND POWER EQUIPMENT .................................................................15
5.1 Handling...................................................................................................................................15
5.2 Installation site.........................................................................................................................15
5.3 Power equipment......................................................................................................................16
5.4 Installation method...................................................................................................................17
6. FUNCTION AND OPERATION .............................................................................................................19
6.1 Function description of control panel ......................................................................................19
6.2 Operating instruction of control panel.....................................................................................22
6.3 Connection before welding operation ......................................................................................34
6.4 Terminal definition on the automatic welding port: ..............................................................37
6.5 Operation before and after welding .........................................................................................38
6.6 Description of operation mode.................................................................................................39
7. PRINCIPLE AND PARAMETERS ..........................................................................................................41
7.1 Functional block diagram ........................................................................................................41
7.2 Technical parameters ...............................................................................................................43
7.3 Wiring diagram ........................................................................................................................44
8. LIST OF MAIN COMPONENTS ............................................................................................................45
9. MAINTENANCE ................................................................................................................................46
9.1 Daily inspection .......................................................................................................................46
9.2Routine inspection.....................................................................................................................47
10. FAULT AND ELIMINATION ...............................................................................................................49
10.1 Fault code ..............................................................................................................................49
10.2 Inspection items during welding failure .................................................................................52
11. TRANSPORTATION, STORAGE AND AMBIENT CONDITIONS ...............................................................54
12. QUALITY COMMITMENT................................................................................................................. 54

I
Operation instruction of TDN 5000 MAG/MIG/CO2 power source Safety precautions

1. Safety precautions

Before installing, adjusting and operating machine, it shall ensure to learn all
safety regulations.
Although all safety performances have been evaluated during design and
production, still be sure to observe safety regulations because welding operation
involves in high voltage, electric arc, smoke dust, poisonous gas, metal dust and
splashing.

1.1 Description of safety signs

Warning sign shows sudden injury possibly occurs. Linked signs indicate injuries
possibly occur.
This group of signs indicates: be careful of
danger like personal injury caused by electric
shock, movable components and hot objects.
Please refer to safety signs and corresponding safety regulations to avoid injury.

1.2 Safety signs

Following safety signs used in this manual intend to remind the danger to catch attention.
When you see safety signs, you shall be careful and observe corresponding safety regulations to
avoid injury.
Only professionals can adjust, maintain, care and repair this machine.
During maintenance, other unconcerned persons, especially for children, shall be far away
from it.

Injury caused by electric shock


  Do not touch components with voltage.
  Turn off the switch of machine and use breaker and cut off switch to shut off
the power or pull out of wiring plug.
  During operation, stand on dry insulation cushion so that operator self is
insulated from the ground. Wear dry insulated gloves. Please not use wet or
damaged gloves.
  If it requires operating the machine under the voltage, only professionals

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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Safety precautions

familiar with safety regulations can operate it.


  During inspecting the machine under the voltage, it shall observe regulation
of “one-hand operation”. Do not stretch your hands into the machine. It shall
keep the other hand outside of machine.
  Before moving the machine, it shall cut off the power.
  If it requires opening the housing, please cut off the power firstly and wait
for at least one minute and carry out operation.
  Be sure to use the cables whose the cross section is more than that of input
end to ground the housing reliably.
After the power of inverter welding machine is cut off, there is still DC
high voltage.
  Before touching components, please turn off the inverter welding machine,
cut off the power and discharge capacitance according to regulations related to
part 7: maintenance.

Static electricity damages circuit board

  Before moving circuit board and components, be sure to wear anti-static


wristlet (ring) that is grounded reliably.
  Use proper anti-static bag (box) to store, move and transport circuit board.
Fire/explosion danger
  Please not place the machine on or near flammable surface.
  Please let combustibles be far away from the site. Do not weld near
combustibles.

  Do not weld in closed vessel.


  Prohibit using machine for defrosting of the pipe
Splashed metal damages possible eye
  Please wear glasses with side mask and mask during maintenance and test.

Wear weld cap and use proper filter glass


  Wear helmet, safety gloves, safety shoe and earplug, buckle collar, wear
weld cap, select proper filter glass and wear full set of protective clothing.

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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Safety precautions

Hot work pieces can cause severe scald


  Do not touch hot work pieces with bare hands.
  During using welding gun continuously, it shall have a period of cooling
time interval.

Component explosion can cause injury


  When inverter-welding machine is power up, failure components explode
possibly or cause other components to explode.
  During maintaining inverter-welding machine, it shall wear mask and
clothes with long sleeve.

Possibly be subject to electric shock during test


  Before measuring lead wire, it shall shut off the power of welding machine
firstly.
  Use the instrument whose at least one lead wire is with retaining clip (e.g.
spring clamp) to measure it.
  Read operation instruction of test equipment.
Reference notes
  Refer to safety precautions related to welding safety.
  Only use quality goods during replacing components.

Magnetic field influences cardiac pacemaker


  Before seeing the doctor, operator of cardiac pacemaker shall be far away
from the welding machine site.

Falling objects cause possibly machine damage and personal injury


  Support the machine by the equipment with enough loads;
  If the machine is placed on the inclined plane, pay attention to preventing it
from being tilted.
  It must use proper trolley to move the machine.
  The handle must be used to lift the machine.

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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Safety precautions

Movable components cause possibly personal injury


  It shall avoid movable components (e.g. fan).
  All guard devices like doors, panels, covers and baffles etc shall be closed
tightly and placed in position.

Excessive operation causes overheating of machine


  It shall cool down the machine for a period of time and observe regulation
of rated duty cycle.
  Before restarting welding machine and beginning welding, it requires
reducing welding current and working time.
  Please not block airflow entering into the machine. Do not air flow resistance
due to filtering of airflow.
High-frequency radiation causes interference
  High frequency interferes possibly radar navigation, computer and
communication equipment.
  Installing, adjusting and maintaining high frequency generating components
shall be carried out by professionals familiar with electronic equipment.
  If the interference problem occurs due to the installation, the customers
shall be responsible for solving it. The problem shall be solved by means of
qualified professionals.
  If government department informs of communication interference, it shall stop
operation at once.
  It shall detect and maintain equipment regularly.
  Minimize possibility of interference with grounding and shielding device
Smoke dust endangers possibly person health
  Let the head be far away from smoke dust;
  Remove smoke dust with forced ventilation and smoke suction device;
  Remove smoke dust with ventilation fan;
  During removing smoke dust, it shall observe relevant regulations of
protecting environment.
Arc light injures possibly eyes and skin
  Wear cap and safety glasses, use earplug and buckle collar tightly. Wear
weld cap and use proper filter glass. Wear a full set of protective clothing and
helmet.

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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Safety precautions

1.3 Electromagnetic field

Pay attention to influence of welding and low frequency electromagnetic field. When
welding current is through cable, electromagnetic field is produced. International blue-collar
committee cannot still judge exposing to power electromagnetic field will harm personal health
after research of more than 500 cases in past 17 years. But it still keeps on research. Before
drawing final conclusion, it had better reduce the time of exposing to this electromagnetic field
during welding and cutting.
It shall use following methods to reduce electromagnetic field at job site:
1. Centralize cable as far as possible not to scatter it by wrapping or binding tapes;
2. During routing, lay cable on the side that is far away from operators as far as possible;
3. Do not wind cable on the body or drop it from the body;
4. Welding power and cable are far away from operators as far as possible;
5. The ground clip is clamped on the place that is near the welding point as far as possible.

About cardiac pacemaker:


Operators of cardiac pacemaker shall consult with the doctor firstly. If doctor considers it is
harmless, it suggests observing above methods to reduce the influence of electromagnetic field.

1.4 Electromagnetic compatibility

This welding machine meets the requirements of the electromagnetic


compatibility in GB15579.10 and IEC.
This welding machine is the A-class machine and not applicable for the
resident environment where the power is provided by the public low-voltage
power supply system. Because of the conduction and radiation harassment, the
electromagnetic compatibility is difficult to be ensured.
This welding machine does not meet the requirements in IEC61000-3-12. If it
requires connecting this welding machine with the public low-voltage power
supply system, the installers or users of this welding machine shall contact with
Electric Power Company (if necessary) to confirm that this welding machine can be
connected.
1.4.1 Environmental assessment
Before installing the arc welding equipment, the users shall assess the potential
problem of the electromagnetic harassment in the ambient environment. The matters

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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Safety precautions

to be considered are as follows:


a) Other power supply cables, control cables, signal & telephone wires and
others around the arc welding equipment;
b)Radio and TV transmitting and receiving equipment;
c) Computer and other control devices;
d)Critical safety equipment, for example, the security monitoring equipment in
the industrial equipment;
e) The health of the operators around the above equipment, for example, if there
are the persons with the hearing aids and the cardiac pacemaker;
f) The equipment used for the calibration or detection;
g)Pay attention to the noise immunity the other surrounding equipment; the
users shall ensure that the other surrounding equipment is compatible each
other, which may require additional protective measures;
h)The welding time or other activities’ execution time in one day;
The considered environmental field depends on the structure of the building and
other activities that are possible to be carried out. This field is possible to be beyond
the building itself.
1.4.2 The method to reduce the emission
1.4.2.1 Public power supply system
The arc welding equipment shall be connected into the public power supply
system according to the method recommended in this operation instruction. If the
interference occurs, the additional preventive measures shall be taken, for example,
the filter of the public power supply system. For the arc welding equipment that is
installed fixedly, the problem that its power cable is shielded shall be considered by
using the metal conduit or other equivalent methods. The electrical continuity shall be
maintained after being shielded. The shielding layer shall be connected with the
housing of the welding power to ensure good electrical contact.
1.4.2.2 Maintenance of arc welding equipment
The arc welding equipment shall be maintained regularly according to the
recommendation in this operation instruction. When the arc welding equipment runs,
it shall close tightly all ports, the access doors and the covers. The arc welding
equipment shall not be changed in any form unless the appropriate change and
adjustment are allowed in this operation instruction. Especially for the gap of the
spark plug on the arc striking and stabilizing devices, it shall be adjusted and
maintained according to the method specified in this operation instruction.

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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Safety precautions

1.4.2.3 Welding cable


The welding cable shall be kept as short as possible and close to each other, abut
against or cling to the ground.
1.4.2.4 Equipotential lapping
The lapping problem of all metal objects in the ambient environment shall be
noticed. When the metal objects are lapped with the work pieces, the risk of the work
will be increased so that the operators may be subjected to the electric shock if they
touch these metal objects and electrodes at the same time. The operators shall be
insulated from the metal objects.
1.4.2.5 The grounding of the work piece
For the reasons like the safe power utilization or the positions, sizes and others of
the work pieces, the work pieces may not be grounded, for example, the hull or the
structural steel-frame. When the work piece is grounded, sometimes, the emission will
be reduced, but not always. Therefore, we must prevent that the risk that the users are
subjected to the electric shock is increased and other electrical equipment is damaged
because the work piece is grounded. If necessary, the work piece shall be connected
directly with the ground, however, the direct connection is not allowed in some
countries and the work piece is connected with the ground only by the selected proper
capacitance according to the regulations in local country.
1.4.2.6 Shielding
The surrounding equipment and other cables are shielded selectively so as to
reduce the electromagnetic interference. In special applications, shielding the whole
welding zone can be considered.

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Operation instruction of TDN 5000 MAG/MIG/CO2power source Overview

2. Overview

TDN 5000 gas-shielded arc welding power is the smart power controlled by fully
digital microprocessor and launched in 2012, based on DSP (hardware main circuit
control) and ARM (panel communication) digital platform, it uses the modular design
concept, fully embodies the characteristics of the digitization, the intelligent, the
automation, the networking and the green to provide the users with a fire-new
experience. It is easy to upgrade the software of the welding machine, under the
condition that the hardware is not changed, through the software upgrade, the welding
machine can add new functions.
(1)TDN 5000 gas-shielded arc welding power possesses the following features:
● Optimized structure design improves the system’s portable performance, the
tightness and the dust proof;
● New manual welding function facilitates more welding application
demands;
● Used digital control panel and friendly human-machine interface are simple,
beautiful, easy for operation, more visual and convenient parameter setup;
● Internally stored unified welding parameters database let the welding
conditions setup be more simple and quick;
● 20 welding conditions can be stored/called to be easy for beginners to use
them;
● The used wire feed motor with the encoder can achieve stable and highly
precise wire feed control;
● Optimized welding process control has excellent performance in aspects of
the welding speed, the weld appearance and the spatter control;
● Various welding control methods can be selected to meet the welding control
requirements for multi-type of welding seams;
● The detailed parameters during welding can be set according to the
individual demand to facilitate the realization of custom-built special welding process.
The set detailed parameters include:pre-flow time, post flow time, low wire feed
speed, burning back voltage, burning back time, thermal arc striking voltage,
penetration adjustment, arc striking current peak factor and arc striking current peak
time factor;
● It possesses the intelligent fault detection function:depending on the fault
reason, the panel display and the fault code corresponding to the fault type, easy to
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Operation instruction of TDN 5000 MAG/MIG/CO2power source Overview

quickly analyze the fault reason and faulty components and eliminate the fault;
● Rich feature expansion interface is easy to achieve the linkage with various
automatic welding equipment (special welding machine and robot etc.) , at the same
time, the centralized control of multi-set of welding machine so as to improve the
work efficiency;
● It can be used for welding within AC 380±10%V input range to improve the
applicability of the welding machine;
● It uses the modular design to improve the product consistency, which is easy
to upgrade, renew and repair the product;
● The air-cooled system uses the temperature control technology to reduce
standby losses and wind noise;
● The criteria of designing, manufacturing and accepting the product :
IEC60974-1, GB15579.1-2004 and GB/T8118;
(2)The welding methods applicable for TDN 5000 gas-shielded arc welding
power:
This arc welding power has two independent welding modes including manual
welding and gas-shielded welding and they can be selected according to different
welding requirements. Main factors determining the welding method include: the base
metal material and welding wire material. Please you select the welding methods
listed in table 1 according to the above two factors and available welding parameters
(shield gas and welding wire diameter):
● TDN 5000 arc welding power in gas-shield mode can select three welding
methods:
(1)CO2 welding (2)MAG welding (3)MIG welding
● The available welding methods of TDN 5000 gas-shielded arc welding power see
the following table:
Base metal Welding wire Welding wire diameter
Shield gas
material material (mm)
1.0
CO2 1.2
1.6
Solid-cored wire
1.0
MAG
1.2
Carbon steel (80% CO2+20% Ar)
1.6
1.0
CO2
1.2
Flux-cored wire
MAG
1.6
(80% CO2+20% Ar)

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Operation instruction of TDN 5000 MAG/MIG/CO2power source Overview

CO2 1.2
MAG
1.2
(80% CO2+20% Ar)
Solid-cored wire
MIG 1.0
(98% Ar+2% O2) 1.2
Stainless steel (97% Ar+3% O2) 1.6
CO2
MAG
(80% CO2+20% Ar)
Flux-cored wire 1.2
MIG
(98% Ar+2% O2)
(97% Ar+3% O2)

Table 1:welding method


Notice: The welding power control system includes the unified welding database
corresponding to the welding methods listed in table 1. If the welding method used by
you is not listed in table 1, in order to ensue the welding quality, please you
respectively set the detailed parameters during welding according to the actual
demand(for the method of setting the detailed welding parameters, refer to the
detailed parameter setup)and store them in the selected channels to facilitate the
future direct call.

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Operation instruction of TDN 5000 MAG/MIG/CO2power source Overview

3. Definition declaration

3.1 Nameplate

Nameplate of TDN 5000 MAG/MIG/CO2 power source

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Operation instruction of TDN 5000 MAG/MIG/CO2power source Overview

3.2 Symbol description

Ampere Voltage Breaker

Three-phase static frequency


converter—
Input
Transformer— rectifier

Panel local
Output Remote control
(control)

Protective
ON OFF
earthling

Positive pole Negative pole AC

Intake air Exhaust DC

Agreed welding
Duty cycle Agreed load voltage
current

Rated input Rated no load


Max. Rated input current
voltage voltage

Rated input Reduced rated no Max. Effective input


I1 current
Ur load voltage current
Level of
Adjust(increase Welding control with the
protection of
/reduce) arc striking function
housing
Welding control
Welding control with the initial
without the arc welding current Timing welding control
striking function and the arc striking
function
Wire feeder
Arc force Channel
Wire feed speed

Increment Decrement Cycle button

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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Structure and names of main components

4. Structure and names of main components

1 、 Negative pole of welding cable


connector
2、Current window knob
3、Voltage window knob
4、Welding parameters display window
5、Handle
6、Wire feeder control aviation socket
7 、 Positive pole of welding cable
connector

Fig. 4.1-1 Front view

8、Ground terminal
9、XS4 socket(automatic welding port,
optional)
10、XS2 socket(CAN port,optional)
11、Power socket of heater
12、Power nameplate
13、USB socket(optional)
14、Fuse holder
15、XS1 socket(CAN port,optional)
16、Breaker
17、Power input cable
18、XS3 socket(DEVICE NET port,
optional)

Fig. 4.1-2 Rear view

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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Structure and names of main components

19、Three-phase input filter


20、Three-phase rectifier bridge
21、Thermostatic switch
22、IGBT radiator
23、Driver board
24、Communication control board
25、Display board
26、Input-output interface board
27、Current sensor
28、High-frequency transformer
29、Filter absorbing plate
30、IGBT module
Fig. 4.1-3 Left view 31、Door polar plate

33、Transparent cover
34、Voltage sampling board
35、Auxiliary power board
36、Power master control board
37、Wire feeder control board
38、Wire feeder transformer
39、Diode radiator
40、Rectifier diode module
41、RC absorption component
42、Reactor

Fig. 4.1-4 Right view

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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Handling, installation site and power equipment

5. Handling, installation site and power equipment

5.1 Handling

During handling this product, the following matters shall be noticed:


①This product is heavier and manual handling may be dangerous.
②It requires lying during transporting this product (the caster is
installed and the hazard may occur if this product is placed slantwise.).
③The handle of this product is used only for handling on the ground
and cannot be used as the hoisting device.
Notice ④During pushing this product forward on the ground by the hands,
please do not turn sharply to avoid severe friction between the caster
and the ground.
⑤Please do not place the weight on the machine to avoid the danger.

5.2 Installation site

Select installation site:


●This machine is only fit for being used in industrial area. Applying in residential
area is possible to cause the electromagnetic interference etc.
●In order to ensure the ventilation and heat emission conditions of the arc welding
power, no obstacle shall be within 300mm at the air inlet and outlet of the arc welding
power.
●This machine shall be placed in the room avoiding direct shine and rain with
small humidity and dust (-10℃~40℃ room temperature).
●The installation site shall ensure that this machine is used for welding operation in
the windless place, if necessary, the measures to prevent from the wind shall be taken.
● It does not recommend using this product in the place
possibly affected by the rain.
● When this product is used outdoors, please take
measures to prevent from the rain and the spatter.
● During operating this product, the conductive foreign
Notice matter shall avoid entering into the welding power.

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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Handling, installation site and power equipment

When this product is dampened by the rain or the water drop drips inside the
power, the serious accident possibly occurs. If such condition occurs, it must ask the
professionals to inspect and maintain it or contact with the professionals to guide the
inspection and maintenance.

5.3 Power equipment

This power is only applicable for three-phase four-wire power supply


system whose neutral point is grounded.
3-phase AC380V±10% 50Hz/60Hz
Input power
three-phase four-wire
Equipment Applicable power 35kVA
capacity Engine generator More than twice 24 KVA
Input protection Fuse 50A*
device Breaker 63A*
Arc welding
Cross-section 4×6mm2 and above
power input
area of cable
Arc welding
(Copper 60mm2 and above
power output
conductor)
Ground wire 60mm2 and above
*The capacity of the fuse and breaker shown in the table is only for reference.
Notice: Please use correctly this arc welding power according to the following
regulations, or else, it may cause the equipment fault and endanger the personal
safety:
● The permissible fluctuation range of the input power is ±10% rated input
voltage;
● During using the generating equipment, please use the generating equipment that
has the capacity more than twice rated input capacity of welding power and the
compensating coil;
● When the work place is relatively wet and the arc welding power is used on the
iron plate and stand, in order to protect the personal safety, please install the
electric leakage protector;
● The power distribution type the breaker (or electric leakage protector) shall be
selected, for example, used by the welding machine, the motor and the
transformer etc.;

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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Handling, installation site and power equipment

5.4 Installation method

Notice:As the figures 5.1 and 5.2 show, two installation methods including
manual welding and gas-shielded arc welding are respectively shown. Therein, the
distribution box, the gas cylinder, the air duct and the flow meter are the devices
self-prepared by the users. The figure 5.1 shows DC straight polarity method of
manual welding, if DC reverse polarity method is used, please exchange the welding
tongs with the cable plug of the ground clamp and insert them into the output
terminals of the welding machine. In general, the basic welding rod recommends
using DC reverse polarity method (i.e. the welding rod is connected with the positive
pole.) and the acid welding rod has not special regulation. The picture does not
represent the actual object that is based on the product in the packing box.

distribution box

power cable

Ground wire

work piece
Power source

Electrode holder

Fig. 5.1 Installation sketch of manual welding (MMA)

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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Handling, installation site and power equipment

Heater cable

distribution box

gas

Gas hose cylinder

Wire feeding

Wire control cable Input cable

feeder

torch

Earth clamp
Power source
cable
Output cable

Work piece

Fig. 5.2 Installation sketch of gas-shielded arc welding

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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Function and operation

6. Function and operation

6.1 Function description of control panel

Current window Voltage window Welding Welding Shield Output Operation


knob knob wire wire gas control
material diameter mode

6.1.1 Panel resource description


This panel includes 35 LED indicator lamps, 8 nixie tubes, 16 buttons and 2
knobs, therein, 8 nixie tubes are divided into three groups, respectively for the current
display window, the voltage display window and the arc force display window.
The functions of LED indicator lamps see table 1. The functions of the buttons
and knobs see table 2.
Table 1 Function table of LED indicator lamps
No. Name Function
1 Power Power-on indication
2 Alarm Fault indication
3 Remote control Remote controller switching-in indication
4 Network Connection indication of the host computer
5 USB Connection indication of USB
6 Lock Panel lock indication
Indicate the display value in the current display window is the
7 Current(A)
current
Indicate the display value in the current display window is the
8 Wire speed(m/min)
wire speed

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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Function and operation

Indicate the display value in the voltage display window is the


9 Voltage(V)
voltage
Indicate the display value in the voltage display window is the
10 Spot welding time(s)
spot welding time
Arc force Indicate the display value in the voltage display window is the
11
arc force
Indicate the display value in the arc force display window is
12 Channel(CH)
channel No.
Indicate the display values in the current and voltage display
13 Initial period
windows are the initial period values

Indicate the display values in the current and voltage display


14 Welding
windows are the welding values

Indicate the display values in the current and voltage display


15 Arc suppression
windows are the arc suppression values
16 Gas inspection Gas inspection indication
17 Wire inspection Wire inspection indication
18 Carbon steel Indicate the welding wire material is carbon steel
19 Flux-cored carbon Indicate the welding wire material is flux-cored carbon steel
steel
20 Stainless steel Indicate the welding wire material is stainless steel
Flux-cored stainless
21 Indicate the welding wire material is flux-cored stainless steel
steel
22 0.8 Indicate the welding wire diameter is 0.8mm
23 1.0 Indicate the welding wire diameter is 1.0 mm
24 1.2 Indicate the welding wire diameter is 1.2 mm
25 1.6 Indicate the welding wire diameter is 1.6 mm
26 CO2 Indicate the shield gas is CO2
27 MAG Indicate the shield gas is MAG
28 MIG Indicate the shield gas is MIG
Indicate the current welding mode is manual welding rod arc
29 MMA
welding.
Indicate the output control is unified, i.e. the unified database
30 Unified
is used

Indicate the output control is separate, i.e. the unified database


31 Separate
is not used
Indicate the operation mode is two-step 「welding control
32 Two-step
mode without the arc suppression」
Indicate the operation mode is four-step「welding control
33 Four-step
mode with the arc suppression」
Four-step
with initial Indicate the operation mode is four-step with initial period
34 period welding current「welding control mode with initial period
welding welding current and the arc suppression」
current
Spot Indicate the operation mode is spot welding「timing spot
35
welding welding control mode」

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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Function and operation

Table 2 Function table of buttons and knobs


No. Name Function
Current/wire Select the current or the wire feed speed to be shown in the
1 feed speed current display window, or special operation
During spot welding, select the voltage or the spot welding
Voltage/spot time to be shown in the voltage display window, or special
2 welding time operation
3 Increment Increase the display value in the arc force window
4 Decrement Decrease the display value in the arc force window
During four steps with initial period welding current, after
selecting to display and adjust initial period values, initial
5 Initial period period indicator lamp is ON.
After selecting to display and adjust the welding values, the
6 Welding welding indicator lamp is ON.
During four steps and initial period four steps, after selecting
Arc to display and adjust the arc suppression values, the arc
7 suppression suppression indicator lamp is ON.
Gas After pressing it for the first time, the gas inspection begins;
8 inspection after pressing it again, the gas inspection is ended.
Wire After pressing it for the first time, the wire inspection begins;
9 inspection after pressing it again, the wire inspection is ended.
Enter into the channel call operation and confirm the channel
10 Call call operation
Enter into the channel storage operation and confirm the
11 Store channel storage operation
Welding wire
12 material Switch to select the welding wire material
Welding wire
13 diameter Switch to select the welding wire diameter
Switch to select the shield gas; it is pressed together with the
14 Shield gas output control at the same time to select MMA
15 Output control Select if the unified database is used
Operation
16 mode Switch to select the operation mode
Current
adjusting
17 knob Adjust the values in the current display window
Voltage
adjusting Adjust the values in the current display window
18 knob

6.1.2 Function description of panel

After turning on the power of the machine, firstly, the machine is through the
start-up process before entering into the work process. During start-up process, firstly,
the display interface verification is carried out on the panel and the nixie tube and
LED are respectively ON; later, the panel version number “Pxx.xxx”, master control
version number“H xx.xxx” and the machine capacity “CAP 500” are shown in turn;
finally, enter into main interface of the work process to indicate the start-up process is

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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Function and operation

finished smoothly. Its panel functions see table 3.


Table 3 Panel function table
Function Function Remarks
type
Abnormal When the machine is abnormal, the alarm indicator lamp is ON
display and the error code is shown.
Real-time data During welding, the welding real-time data is shown.
display
Detection Check if the gas supply is normal in the standby state of the
Gas inspection gas-shielded arc welding
Check if the wire feed is normal in the standby state of the
Wire inspection gas-shielded arc welding
Welding modes Select the welding mode in the standby state
setup
Parameter Welding The welding parameters are set directly on main interface.
setup conditions setup
Detailed The welding parameters are set further by using combination
parameters key.
setup
Factory setup During start-up, the channel parameters and some system
recovery parameters are restored into the factory defaults.
System CAN address Set CAN address of this machine
setup setup
Machine The actual value of the calibration current (voltage) is
calibration consistent with its display value.
Call the parameters of some channel into the working channel
Channel Call in the standby state of the gas-shielded arc welding
operation Store the parameters of the working channel into some channel
Store in normal state of the gas-shield arc welding
Panel When the panel is locked, the lock indicator lamp is ON and
lock Panel lock the panel cannot be operated.

6.2 Operating instruction of control panel

6.2.1 Detection function


The detection function includes the abnormal indication, the real-time data
display, the gas inspection and the wire inspection.
1、Abnormal indication
Check if the panel works normally to determine the panel is in normal state or
abnormal state; when the panel is in abnormal state, the alarm indicator lamp is ON
and “Err” is shown in the current display window and the three-bit error code is
shown in the voltage display window. The definition of the error code refers to 10.1
Fault code.

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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Function and operation

When the start-up process is abnormal, the panel is in abnormal state and the
start-up process is stopped.
When the work process is abnormal, the panel is in abnormal state and the panel
cannot be operated.
2、Real-time data display
During welding, the real-time welding current (or the real-time wire feed speed)
is shown in the current display window and the real-time welding voltage is shown in
the voltage display window and three indicator lamps for the initial period, the
welding and the arc suppression flash according to the current welding process.
In the standby state, depending on the indicator lamps, the corresponding
parameters are shown in the current display window and the voltage display window.
3、Gas inspection

In the standby state of the gas-shielded arc welding, press “ ” button for the
first time to begin the gas inspection, after releasing the button for 15s, the gas

inspection is automatically stopped; before stopping the gas inspection, press“ ”


button again to end the gas inspection.
4、Wire inspection

In the standby state of the gas-shielded arc welding, press “ ” button for the
first time to begin the wire inspection, after releasing the button for 15s, the gas

inspection is automatically stopped; before stopping the gas inspection, press“ ”


button again to end the wire inspection.
6.2.2 Parameter setup
The welding parameters setup includes the welding modes setup, the welding
conditions setup and the detailed parameters setup.
1、Welding modes setup
TDN 5000 gas-shielded arc welding machine includes two basic welding modes
like the gas-shielded arc welding and the manual welding and the default welding
mode is selected when the machine enters into main interface of the work process.
In order to switch to the manual welding mode, firstly, it shall ensure that the
detailed parameters H00 of manual welding are in ON state and the specific operation

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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Function and operation

mode sees the detailed parameters setup.


a. Switch the gas-shielded arc welding to the manual welding

In gas-shielded arc welding state, the combination key of “ ” in “shield gas”

column and “ ” in “output control” column is pressed at the same time to switch

the gas-shielded arc welding into the manual welding.


b. Switch the manual welding to the gas-shielded arc welding

In manual welding state, press “ ” button in “shield gas” column to be

switched into the gas-shielded arc welding.


2、Welding conditions setup
Gas-shielded arc welding
When the welding conditions are set, if the current welding process parameter is
included in the process database, the parameter value will be shown normally on the
panel, or else, “nOP ---” is shown on the panel.
1. Operation mode switching

In the standby state of the gas-shielded arc welding, press “ ” button in

“operation mode” column to be switched among four operation modes; the indicator
lamp beside the two-step, the four-step, the four-step with initial period welding
current or the spot welding will be ON to indicate this operation mode is selected.
2. Output control switching

In the standby state of the gas-shielded arc welding, press“ ” button in

“output control” column to be switched between the unified and the separate; the
indicator lamp beside the unified or the separate is ON to indicate the unified or the
separate is selected.
The unified output control mode:The welding voltage is automatically set after
setting the welding current. [in the unified output control mode, by adjusting the
voltage knob on the control box of the wire feeder and “voltage window knob” on the
front panel, the welding voltage can be adjusted finely in the unified state and the fine
adjustment range is:±5.0V]

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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Function and operation

The separate output control mode:The welding current and voltage are adjusted
separately.
3. Shield gas switching

In the standby state of the gas-shielded arc welding, press “ ” button in

“shield gas” column to be switched among three types of gas including CO2, MAG
and MIG; the indicator lamp beside CO2, MAG and MIG is ON to indicate this gas is
selected.
4. Welding wire diameter switching

In the standby state of the gas-shielded arc welding, press “ ” button in

“welding wire diameter” column to be switched among four types of wire diameters
including 0.8, 1.0 and 1.2; the indicator lamp beside 0.8, 1.0 and 1.2 is ON to indicate
this wire diameter is selected.
5. Welding wire material switching

In the standby state of the gas-shielded arc welding, press “ ” button in

“welding wire material” column to be switched among four types of wire materials
including the carbon steel, the flux-cored carbon steel, the stainless steel and the
flux-cored stainless steel; the indicator lamp beside the carbon steel, the flux-cored
carbon steel, the stainless steel and the flux-cored stainless steel is ON to indicate this
wire material is selected.
6. Spot welding time adjustment

In the standby state of the gas-shielded arc welding, in “ ” operation mode,

after pressing “ ” button under the voltage display window, the indicator lamp of
the spot welding time is ON and the spot welding time value is shown in the voltage
display window and changed by adjusting “voltage window knob”.
7. Arc force adjustment
In the gas-shielded arc welding state, the arc force indicator lamp is ON; press

“ ” button under the arc force window to increase the arc force; press “ ”

button under the arc force window to decrease the arc force.

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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Function and operation

8. Initial period current adjustment


In the gas-shielded arc welding state, in “ ” operation mode, after pressing

“ ” button under the current display window to be switched into the current, the

current indicator lamp is ON; after pressing “ ” button to be switched into the
initial period, the initial period indicator lamp is ON; the initial period current value is
shown in the current display window and changed by adjusting “current window
knob”.
The wire feed speed is corresponding to the current and the wire feed speed is
also adjusted.
9. Initial period voltage adjustment
In the gas-shielded arc welding state, in “ ” operation mode, if the output

control is “separate”, after pressing “ ” button under the voltage display window”
to be switched into the voltage, the voltage indicator lamp will be ON; after pressing

” button to be switched to the initial period, the initial period indicator lamp will
be ON; the initial period voltage value will be shown in the voltage display window
and changed by adjusting “voltage window knob”.
If the output control is “unified”, the initial period voltage offset will be changed

by adjusting “voltage window knob”; after pressing “ ” button again, the initial
period voltage offset value will be shown in the voltage display window.
10. Welding current adjustment

In the gas-shielded arc welding state, after pressing “ ” button under the
current display window to be switched to the current, the current indicator lamp is ON;

after pressing “ ” button to be switched to the welding, the welding indicator lamp
is ON and the welding current value is shown in the current display window. Under
the condition that the wire feeder is not connected, the gas-shielded arc welding
parameters are adjusted by using “current window knob” on the panel; under the
condition that the wire feeder is connected, the gas-shielded arc welding parameters

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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Function and operation

are adjusted on the terminal of the wire feeder.


The wire feed speed is corresponding to the current and the wire feed speed is
also adjusted.
11. Welding voltage adjustment
In the gas-shielded arc welding state, if the output control is “separate”, after

pressing “ ” button under the voltage display window to be switched to the voltage,

the voltage indicator lamp is ON; after pressing “ ” button to be switched to the
welding, the welding indicator lamp is ON and the welding voltage value is shown in
the voltage display window. Under the condition that the wire feeder is not connected,
the gas-shielded arc welding parameters are adjusted by using “voltage window knob”
on the panel; under the condition that the wire feeder is connected, the gas-shielded
arc welding parameters are adjusted on the terminal of the wire feeder.
If the output control is “unified”, the welding voltage offset will be adjusted;
after pressing “welding” button again, the welding voltage offset value will be shown
in the voltage display window.
12. Arc suppression current adjustment
In the gas-shielded arc welding state, in “ ” or “ ”operation mode, after

pressing “ ” button under the current display window” to be switched into the

current, the current indicator lamp will be ON; after pressing “ ” button to be
switched to the arc suppression, the arc suppression indicator lamp will be ON; the
arc suppression current value will be shown in the current display window and
changed by adjusting “current window knob”.
The wire feed speed is corresponding to the current and the wire feed speed is
also adjusted.
13. Arc suppression voltage adjustment
In the gas-shielded arc welding state, “ ” or “ ”operation mode, if the

output control is “separate”, after pressing “ ”button under the voltage display
window” to be switched into the voltage, the voltage indicator lamp will be ON; after

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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Function and operation

pressing “ ” button to be switched to the arc suppression, the arc suppression


indicator lamp will be ON; the arc suppression voltage value will be shown in the
voltage display window and changed by adjusting “voltage window knob”.
If the output control is “unified”, the arc suppression voltage offset will be

adjusted by using “voltage window knob”; after pressing“ ” button again, the arc
suppression voltage offset value will be shown in the voltage display window.
Manual welding
a. Welding current adjustment
In manual welding state, the current indicator lamp is ON and the welding
current is changed by adjusting “current window knob”.
b. Arc force adjustment

In manual welding state, the arc force indicator lamp is ON; press“ ” button

under the arc force window to increase the arc force; press “ ” button to decrease
the arc force.
3、Detailed parameters setup
In standby state of the machine, the entries of the detailed parameters related to
the welding are called by using the combination key and adjusted.
Gas-shielded arc welding
In standby state of the gas-shielded arc welding, press the combination key of

“ ” and “ ” at the same time to call the detailed parameters of the gas-shielded
arc welding. The parameter code “Pxx” is shown in the current display box and the
parameter value is shown in the voltage display box. The parameter entry is switched
by using “current window knob” and the parameter value is adjusted by using
“voltage window knob”. Press any key to quit the detailed parameters adjustment.
The content of the detailed parameters of the gas-shielded arc welding:
The
Factor
Setting mini
Item Purpose y Remarks
range mum
setting
unit
P00 Pre-flow time 0~10.0s 0.1 0.2 The welding gun is turned on and the time

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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Function and operation

from the starting of the gas supply to the


starting of the welding is set.
The welding gun is turned off and the time
P01 Post flow time 0~10.0s 0.1 0.2 from arc suppression to the end of the gas
supply is set.
Low wire feed
P02 -20~20 1 0 Low wire feed speed is adjusted finely.
speed *1
Burning back The voltage within the burning back time
P03 *2 -20~20 1 0
voltage is adjusted finely.
Burning back
P04 -20~20 1 0 The burning back time is adjusted finely.
time
Thermal arc
The voltage value during arc striking is
P05 striking voltage -20~20 1 0
*3 adjusted finely.

Penetration The penetration of the welding seam is


P06 -20~20 1 0
adjustment *4 adjusted finely.
P07 Reserved
P08 Reserved
P09 Reserved
*1 About low wire feed speed
In order to ensure smooth arc striking, the wire feed speed after turning on the welding gun
before normal welding is less than that during normal welding.
*2 About burning back voltage
In order to prevent from the adhesion between the welding wire after turning off the
welding gun and the molten pool that is not cooled down, the arc-burning voltage is applied
to ensure the welding wire burns upward after turning off the welding gun and stopping
feeding the wire and this arc-burning voltage value is relevant to the upward burning
capacity of the welding wire. The excessive burning back voltage will cause the small ball is
formed on the end of the welding wire and have adverse influence on the next arc striking.
*3 About thermal arc striking voltage
The arc-burning voltage value is applied during arc striking. The proper thermal arc striking
voltage can ensure the welding process smoothly enters into the normal welding state from
the arc striking state.

Manual welding
a Functional switch of manual welding
In standby state of the gas-shielded arc welding, press the combination key of

“ ” and “ ” at the same time to call the function switch of manual welding.
The parameter code “H00” is shown in the current display box and “on” or “off” is

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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Function and operation

shown in the voltage display box. “on” is switched into “off” by using “voltage
window knob”. Press any key to quit the function switch of manual welding.
If “on”, the welding mode can be switched between the manual welding and the
gas-shielded arc welding; if “off”, the welding mode cannot be switched.
b General parameters adjustment

In standby state of the manual welding, press the combination key of“ ” and

“ ”at the same time to call the general parameters of manual welding. The
parameter code “Hxx” is shown in the current display box and the parameter value is
shown in the voltage display box. The entries of parameters are switched by using
“current window knob” and the values of parameters are adjusted by using “voltage
window knob”. Press any key to quit the general parameters adjustment.
The content of the detailed parameters of manual welding:
The
Factor
Setting mini
Item Purpose y Remarks
range mum
setting
unit
Functional
on welding mode can be switched
H00 switch of on/off on
off welding mode cannot be switched
manual welding
Arc striking
H01 current of 30~500A 1 100 Arc striking current adjustment
manual welding
H02 Reserved*
H03 Reserved

6.2.3 System setup


The system setup includes the factory setup recovery, CAN address setup and the
machine calibration.
1、Factory setup recovery
The factory setup recovery indicates the operation where the channel parameters
and some system parameters are restored into the factory defaults.

When the panel is turned on, press the combination key of “ ”and “ ”
buttons at the same time for more than 3s; when “rES ...” is shown on the panel, the
factory setup begin to be restored; after the factory setup recovery, continue to the

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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Function and operation

start-up process. At this time, the parameters setup in the power will be restored into
the factory setup and the user-defined parameters of all channels will be cleared.
2、CAN address setup
CAN address is the only home address when the machine is connected to the
hose computer and can be set by using the combination key.

In standby state, press the combination key of “ ”and “ ” at the same time
to call CAN address setup. The parameter code “PP0” is shown in the current
display box and CAN address is shown in the voltage display box. CAN address is
adjusted by using “voltage window knob”. Press any key to quit CAN address setup.
3、Machine calibration
The machine calibration function is the derivation between the current (or
voltage) actual value and display value is corrected so that the current (or voltage)
actual value is consistent with the display value. The corrected value range of the
current value is 125A~550A and the corrected value range of the voltage value is
15.0V~49.5V. During correction, the derivation between the display setting value
and the actual setting value is not more than ±10%. If the derivation is not eliminated
by once correction, it can be eliminated by multiple correction.
Firstly, the current ( or voltage) output value of the machine is measured by
using the multi-meter and recorded as the current (or voltage) actual value, at the
same time, the display value in the current display window (or voltage display
window) of the machine is recorded as the current (or voltage) display value.

Secondly, after holding down the combination key of “ ”and “ ” at the


same time for more than 3s, the panel enters into the calibration state and there are the
readings in the current and voltage display windows and the current indicator lamp
flashes. When the current indicator lamp flashes, it indicates the current correction;
when the voltage indicator lamp flashes, it indicates the voltage correction; the current

correction is selected by using “ ” button and the voltage correction is selected by

using “ ” button.

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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Function and operation

Thirdly, the current correction: after pressing “ ”, the current indicator lamp
flashes, by adjusting “current window knob”, the reading in the current display
window is consistent with the current display value, by adjust “voltage window knob”,
the reading in the voltage display window is consistent with the current actual value,

after pressing “ ” button to confirm the correction, the current indicator lamp
stops flashing.

The voltage correction:after pressing “ ”,the voltage indicator lamp


flashes, by adjusting “current window knob”, the reading in the current display
window is consistent with the voltage display value, by adjusting “voltage window
knob”, the reading in the voltage display window is consistent with the voltage actual

value, after pressing “ ” button to confirm the correction, the voltage indicator
lamp stops flashing.
Finally,press any other key to quit the correction state, or wait for 10s to
automatically quit the correction state.
6.2.4 Channel operation
The channel is the collective storage area of the gas-shielded arc welding
parameters. The different storage areas are marked with the different channel No. and
the range of channel No. of the gas-shielded arc welding is 1~20.
1、Call
The call will copy the welding parameters stored in some channel into the
current welding parameters setup.

Firstly,in standby state of the gas-shielded arc welding, after pressing “ ”


button, the channel indicator lamp is ON and the arc force indicator lamp is OFF,
besides, the channel No. is shown in the arc force window and flashes.

Secondly,press“ ”or“ ” button to adjust the channel No. into the

channel where the parameters are stored.

Finally,after pressing “ ” button again, the channel No. in the arc force

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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Function and operation

window stops flashing to begin to call the channel parameters. 2s later, the channel
indicator lamp is OFF and the arc force indicator lamp is ON to indicate the
successful call.
2、Store
The storage will store the parameters of the working channel that is used directly
into some channel for later use.

Firstly, after pressing “ ” button, the channel indicator lamp is ON and the arc
force indicator lamp is OFF, besides, the channel No. is shown in the arc force display
window and flashes.

Secondly,press “ ”or“ ”button to adjust the channel No. into the

channel to be stored.

Finally,after pressing “ ” button again, the channel No. in the arc force
window stops flashing to begin to store the parameters. 2s later, the channel indicator
lamp is OFF and the arc force indicator lamp is ON to indicate the successful store.
The content of call and store includes the following welding parameters:
No. Welding parameter No. Welding parameter No. Welding parameter
Welding current
1 Operation mode 9 17 Post flow time
setting
Welding wire Welding voltage
2 10 18 Burning back voltage
material setting
Welding wire Arc suppression wire
3 11 19 Burning back time
diameter speed setting
Arc suppression Low wire feed speed
4 Shield gas 12 20
current setting setting value
Initial period wire Arc suppression Thermal arc striking
5 13 21
speed setting voltage setting voltage
Initial period current Spot welding time
6 14 22 Penetration adjustment
setting setting
Initial period voltage
7 15 Output control mode
setting
Welding wire speed
8 16 Pre-flow time
setting
6.2.5 Panel lock
The panel lock function is used by matching with the hose computer or the
remote controller and the panel cannot be self-locked or self-unlocked.
When the panel is locked, the lock indicator lamp is ON and any panel operation
cannot be carried out on the panel; the machine can only work according to the pre-set

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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Function and operation

parameters.

6.3 Connection before welding operation

Danger Any contact with live parts can cause fatal electric shock or
serious burns.
To prevent from personal safety accident, please observe the
following matters.
●Please keep the hands dry during operation.
●Please confirm the powers of the distribution box, this machine and relevant devices
have been turned off before cable connection.
●Check and ensure the reliable insulation of the bare conductor parts, including the input
cable and welding cable etc.
●Please prevent the cable from contacting with the welding parts to avoid damaging the
cable insulation due to high temperature.
●Please prevent the weight from being placed on the cable to avoid damaging the cable
insulation due to the abrasion.
●In order to ensure the safety, please ensure the metal housing of the arc welding power
is grounded reliably.
Notice If the cable is too heating, it will possible to cause the fire and
please observe the following direction for use.
●Please carry out the connection by using the cables with the specified specifications.
●Please ensure that the cable is connected and fixed reliably.
6.3.1 Connection on the output side
The positions and names related to the connection on the output side see the
following figure.

wire feeder socket

6.3.1.1 Connection of base metal cable (ground wire)


●Please select the welding cable or thick rubber insulated cable with more than
50mm2.
●Please install the proper cable terminal on the end of the cable and ensure the
reliable crimp connection.

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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Function and operation

●Please connect the ground cable quick plug to the output terminal (-) of the
welding machine and ensure tight connection.
●After reliable connection, please insulate the connection between the bus cable
and this machine.
If there is the interference source near this machine(AC welding
machine or welding machine with high-frequency arc-striking device
etc.), when the same work piece is welded, it is possible to have the
influence on normal operation of this machine and the following
measures can be taken to avoid it.
●The construction operation is carried out at the welding operation point away from
the interference source as far as possible.
●The base metal cable of this equipment is connected directly to the welding
operation point to avoid the crossing-over with the welding circuit of the
interference source.
6.3.1.2 Cable connection on the side of the welding gun
●Please connect the welding cable quick plug of the wire feeder to the output
terminal (+) of the power and ensure tight connection.
●After reliable connection, please insulate the connection between the welding
cable and this machine.
6.2.1.3 Connection of control cable of wire feeder
●Insert the control cable plug led out of the wire feeder into the socket of the wire
feeder, tighten the lock nut on the plug to ensure the reliable connection of the control
cable and prevent the cable drops off.
●Linkage welding of automatic welding device
Please confirm the equipment connection on the socket of the wire feeder. (For
the details, please see 6.3: Terminal definition and connection on the automatic
welding port)
6.3.1.4 Gas heater power
●Insert the power plug of the gas heater into the power output position of the gas
heater shown in the following figure;
●Please select the proper gas heater.

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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Function and operation

Power output of the gas


heater

6.3.2 Connection on the input side


6.3.2.1 Connection of protective ground wire
●The protective ground wire (yellow-green flexible wire) of the input cable is
grounded reliably.
6.3.2.2 Connection of input power lead
Please you configure one special distribution box for each arc welding power
and confirm the distribution is safe before connecting the input power lead.
●Please firstly turn off the switch of the distribution box (user equipment) before
connection;
●Please connect the other end of the input cable to the output terminal on the
switch of the distribution box and ensure reliable connection.
6.3.3 Installation of gas regulator
The gas regulator is a high-pressure gas appliance. Incorrectly using the gas regulator
may be subjected to the direct impact of high-pressure gas in the gas cylinder to
cause the accident that endangers personal safety, therefore, please be sure to read
carefully the operation instruction of the gas regulator before installation.
The power socket of the gas heater is set on the upside of rear panel of welding
power. Please pay attention to the following matters:
●The power of the heater is AC 36V,with the rated output current 5A;
●The power of the heater is only for the gas heater, so do not use it for other;
The used gas quality will directly affect the welding effect. Please pay attention
to the following matters:
●During CO2 welding, please use CO2 specially for welding;
●During MAG welding, please use MAG welding gas mixture (contain 5~20%
CO2,the rest for argon);
●When the argon is used in the gas mixture, please use the welding high purity
argon(the purity is not less than 99.9%);
●When two gases are used after being mixed(argon and CO2),please use the gas

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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Function and operation

mixer.

Water pressure detection signal (water pressure


Gas pressure detection signal (shield gas
detection output signal of water-cooled plant)
pressure detection output signal)

emergency stop signal (output signal during

power emergency stop working)

current detection signal (output signal of


power status signal (power status output
successful arc striking, after the arc striking is
signal, after the power works normally, the
successful, the electronic relay is closed, with the
electronic relay is closed, with the contact
contact capacity DC 60W 0.3A)
capacity DC 60W 0.3A)
Socket on rear panel of the power XS4

6.4 Terminal definition on the automatic welding


port:

Notice:
In standard configuration of TDN 5000 arc welding power, there is not the
socket XS4 of the automatic welding port on rear panel of the power. If you need
connect with special automatic welding machine, please clearly specify it when
ordering to remind us of configuring the plug and socket of the above port for
you and connect internal circuit properly.
During external wiring and operation, please not let all terminals be in short
circuit, or else, it will cause the devices inside the welding machine to be
damaged!

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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Function and operation

6.5 Operation before and after welding

6.5.1 Preparation before welding


●Check the safety protection measures :
The safety protection measures mainly include the measures for the ventilation
system, the arc protection, the splash protection, the noise protection and others in
welding environment and the details refer to relevant content in safety precautions in
P1.
In order to ensure the operators can see clearly the condition in welding
position through the anti-dazzling screen and prevent the arc from injuring the
operators’ eyes, please select the proper anti-dazzling screen. For the selection of the
anti-dazzling screen, please refer to the recommendation in the following table:
Welding
current Less than 100A 100A~300A 300A~500A
Shading
number 9 10 11 12 13 14

● Check and confirmation of connection:


(1)Check the connection of the input cable, the protective ground wire and the
base metal cable;
(2)Check the connection of the welding cable and control cable from the wire
feeder to the arc welding power ;
(3)Check the connection of the welding gun and the shield gas;
●Installation of welding wire:
Please install the welding wire by referring to the relevant requirements in
“Operation instruction of FD90-630N/P wire feeder”.
●Turn on the input power:
After turning on the switch of the distribution box (user equipment), the power
switch on the upper right corner of the rear panel of the arc welding power is turned

on. Tap “ ” key on the control panel of the arc welding power to check the control

circuit of the wire feed motor and tap“ ” key to check the channel of the shield

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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Function and operation

gas.
6.5.2 Operation after welding
●Cut off the shield gas:
Firstly, close main switch of the gas cylinder; then, exhaust the gas remained in
the gas pipe.
●Turn off the input power:
Firstly, turn off the power switch of this machine; then, turn off the switch of the
distribution box (user equipment).
The tip:In order to completely cool down this product after being operated so
as to lengthen the lifetime of the equipment, please keep the input power
turned on for 5 minutes after finishing the welding operation, then, turn
off the input power.

6.6 Description of operation mode

When the gas-shielded arc welding function is used for welding, TDN 5000 arc
welding power offers four welding control modes for selection, as the following
table shows:
Symbol Welding control mode Symbol Welding control mode
Two-step Four-step
「Welding control mode without 「Welding control mode with the arc
the arc striking」 striking」
Four-step with initial period
welding current Spot welding
「 Welding control mode with 「Timing spot welding control
initial period welding current and mode」
the arc striking」

During automatic welding, please select the welding control mode without
the arc striking as the welding control mode of TDN 5000 arc welding power.
6.5.3.1 Welding control mode without the arc suppression
●After turning on the switch of the welding gun, begin welding; after turning off
the switch of the welding gun, stop welding;
●Directly carry out main welding without the initial period welding current and the

39
Operation instruction of TDN 5000 MAG/MIG/CO2 power source Function and operation

arc-striking welding current;


●The time sequence of the welding control mode without the arc striking is shown
as the following figure:

Torch switch
T1: pre-flow time

T2: burning back time


Gas supply
T3: post flow time

Wire feeding Slow feeding t1: arc starting time

t2: arc stopping time


Output voltage

Output current
welding

6.5.3.2 Welding control mode with the arc suppression


●Turning on-off the switch of the welding gun twice is one cycle for controlling the
starting and stopping of the welding;
●The function is to achieve the arc suppression welding after main welding(the arc
suppression welding is mainly used to fill the crater when the welding is ended);
●It is applicable for welding the cut deal;
●The time sequence of the welding control mode with the arc suppression is shown
as the following figure:

Torch switch

T1: pre-flow time


Gas supply
T2: burning back time

T3: post flow time


Wire feeding
Slow feeding
t1: arc starting time

Output voltage t2: arc stopping time

Output current
welding

crater
6.5.3.3 Welding control mode with the initial welding current and the arc suppression
●Turning on-off the switch of the welding gun twice is one cycle for controlling the
starting and stopping of the welding;
●The function is to achieve the welding with initial period welding current before
main welding and with the arc suppression welding current after main welding;
●The time sequence of the welding control mode with initial period welding
current and the arc suppression is shown as the following figure:

40
Operation instruction of TDN 5000 MAG/MIG/CO2 power source Function and operation

T1: pre-flow time


Torch switch
T2: burning back time

Gas supply T3: post flow time

t1: arc starting time


Wire feeding Slow feeding
t2: arc stopping time
Output voltage

Output current
weld

initial crater
6.5.3.4 Timing spot-welding control mode
●When the switch of the welding gun is continuously turned on, the welding is
carried out within the set spot welding time and the arc is automatically stopped
beyond the set spot welding time;
●It is used mainly for the sheet lapping and other welding methods (in order to
ensure the welding quality, please replace the nozzle of the welding gun into the
spot welding nozzle);
●The time sequence of the timing spot welding control mode is shown as the
following figure:
Notice: The switch of the welding gun is turned off before

the set arc spot welding time, at this time, the welding arc

is also stopped.

Torch switch

Gas supply T1: pre-flow time


T2: burning back time
T3: post flow time
Wire feeding Slow feeding t1: arc starting time
t2: arc stopping time
Output voltage

Output current welding

7. Principle and parameters

7.1 Functional block diagram

41
Operation instruction of TDN 5000 MAG/MIG/CO2 power source Function and operation

●It includes four modules like main circuit, control circuit, wire feeder control
circuit and display circuit;
● Main circuit module: three-phase input is outputted through the input filter, the
full-bridge rectifier, the filter module, the inverter module, the transformer and
the rectifier module;
●Control circuit module: all input and output analog values are sent to DSP
through the sampling circuit, after being analyzed and calculated, PWM+PFM
pulse is sent to control the operation of the inverter module, finally, the ideal
output values are obtained and the powerful protection function can ensure the
reliable operation of the power;
● Wire feeder control circuit module:independent wire feeder control circuit
module can optimize the wire feed performance and reliability;
● Display circuit module:ergonomic human-machine interface let the operation
be more convenient and effective and the anti-jamming capability be
strengthened;
●All modules are accordant and become the respective systems so as to be
convenient for upgrading and maintaining the product ;

42
Operation instruction of TDN 5000 MAG/MIG/CO2 power source Function and operation

● The digital control system provides the users with the excellent performance
experience so as to achieve the remote operation and centralized control.

7.2 Technical parameters

Input voltage 380V±15% 50/60Hz three-phase AC

Rated input current I1 34A


Rated input power P1 23kW
No-load voltage UO 71V
No-load current IO 0.4 ~ 0.5A
No-load loss PL 300W
Voltage adjustment range U2 15~ 45V
Current output range I2 50 ~ 500A
Manual welding current adjustment
range 30 ~ 500A

Applicable welding wire type Solid-cored / flux cored wire

Applicable welding wire diameter Φ1.0/Φ1.2/Φ1.6

Carbon steel(MS)/ carbon steel _flux-cored(MS_FCW)


Applicable welding wire material
Stainless steel(SUS)/ stainless steel _ flux-cored(SUS_FCW)

CO2 welding CO2:100%

Shield gas MAG welding Ar:80% CO2:20%

MIG welding Ar:98% O2:2%

Duty cycle X 60%(500A\40V)

Efficiency η 80%~ 85%(rated conditions)

Power factor λ λ= 0.7 ~ 0.9

Level of protection of the housing IP23S

Insulation level Y F

Cooling system Temperature-controlled air-cooled

Overall dimension(L×W×H) 715 mm×320 mm×570mm

Weight 48kg

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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Function and operation

7.3 Wiring diagram

Optional
note: 021, 022, 031,

032, 033, 041, 042 and


Optional
043 are copper pillars.

OUT3:Control port of wire feeder XS1、XS2: communication port(CAN communication)


XS3: DEVICE NET port XS4:automatic welding port
For the description for the pin definition on the automatic welding port XS4,
please refer to the article 6.4: terminal definition on the automatic welding port

44
Operation instruction of TDN 5000 MAG/MIG/CO2 power source List of main components

8. List of main components

No. Code Name Specification Remarks


1 Q1 Breaker NDM1-63(C63)
2 EMI Input filter HT535-40-M6-G3 Optional
3 VC1 Three-phase rectifier MDS100(B)-12
bridge
4 IGBT1/IGBT2 Semiconductor power BG150B12LY2-I
device IGBT
5 T1 High-frequency ME05-03
transformer
6 DW1/DW2/DW3/D Fast recovery rectifier DH2F160N4SE-1001
W4 diode module
7 L01 Rectifier output reactor H152-01.9.1
8 OUT1/OUT2 Output connection DKJ70-1 (black)
terminal
9 AC 36V/5A Heater socket AC-12 250V /10A
10 OUT3 Control socket of wire AS28K16Z
feeder
11 XS1/XS2 Communication port AS16K5Z Optional
socket
12 XS4 Automatic welding port AS16K7Z Optional
socket
13 FAN Cooling fan 250FZL8 single phase 380V
14 T2 Control transformer H090-08
15 BA1 Hall current sensor CHF-500B
16 RT1 Self recovery fuse UF600X30
17 FUSE Fuse 10A(5×20)
18 BW1 Temperature relay KSD9700 45 normally opened
19 BW2 Temperature relay KSD9700 80 normally closed
20 RV1 Voltage dependent MYD-14-K-221
resistor
21 R1/R2 Resistor RX21-8W-3R3
22 C1/C2 Capacitance CT81-3KV-472
23 IGBTPCB IGBT Absorption board ME05-01
24 H225-01 board Control power board H225-01
25 ME04-08 board Driver board ME04-08
26 ME04-13 board Voltage sampling board ME04-13
27 ME04-15 board Gas-shielded I/O ME04-15
change-over board
28 ME04-16 board Output CAN interface ME04-16 Optional
board
29 ME04-20 board Control board of wire ME04-20
feeder
30 MS01-01.1 board Main control board MS01-01.1
31 MS01-02.7 board Display control board MS01-02.7
32 MS01-03.1 board Display board MS01-03.1

45
Operation instruction of TDN 5000 MAG/MIG/CO2 power source Maintenance

9. Maintenance

9.1 Daily inspection

Any contact with live parts can cause fatal electric shock or
serious burns.
Warning To avoid the electric shock, burns and other personal injury,
please observe the following matters.
During daily inspection, be sure to turn off the power of this product and distribution
box (user equipment).
(Except for the appearance inspection that does not require contacting with or closing
to the charged body)
●It is of vital importance to adhere to the daily inspection for keeping
high-performance and safety operation of the equipment.
●The inspection is carried out according to the inspection items in the following table;
if required, the cleaning or replacement shall be carried out.
9.1.1 Inspection of welding power
Item Main points of inspection Remarks
● Check if all mechanical appliances are damaged or The regular inspection shall
their installation is loosened. be carried out inside the
● Check if all lower terminal covers are fixed with lower terminal cover.
Front panel
the screws. If abnormal condition
● Check if the air inlet of the cooling fan is blocked occurs, it will require
by the foreign matter. internal inspection, adding,
● Check if the input cable protection cover is fastening or replacing the
installed and the protection cover is damaged or components.
Rear panel loosened.
● Check if the foreign matter is attached to the air
outlet of the cooling fan.
● Check if the fastening bolts are loosened or missing. If abnormal condition
Top cover ● Check if the caster is damaged or not installed firmly. occurs, it will require
Bottom plate ●Check if the air inlet on the side panel is blocked by internal inspection, adding,
Side panel the foreign matter and the side panel is not installed fastening or replacing the
firmly. components.
●Check if there is decolorization or overheating on the If abnormal condition
appearance of the components. occurs, it will require
●Inspection after turning on the power: internal inspection.
Routine
Check if the cooling fan runs smoothly; if there
are the odor, abnormal vibration and noise during
welding the components inside the machine.
9.1.2 Cable inspection
Item Main points of inspection Remarks
Ground ●Check if the ground wire of the input cable drops off In order to avoid personal
cable and is connected reliably. electric shock accident, be
●Check if the base metal ground cable is connected sure to check this item.
reliably.

46
Operation instruction of TDN 5000 MAG/MIG/CO2 power source Maintenance

Cable ●Check if abnormal external force is applied on the In order to ensure personal
cable. safety, please use the proper
●Check if the base metal cable is connected reliably. method for inspection
●Check if the insulating layer of the cable is worn or according to the condition
damaged and if there is bare conductive parts. of the job site.

9.1.3 Relevant inspection


Item Main points of inspection Remarks
Welding gun ●Please check them by referring to relevant If abnormal condition
Wire feeder operation instruction of the product. occurs, it will require taking
the proper treatment
Gas regulator
measures, even replacing
●Check if the gas pipe is worn or damaged. the components.
Gas pipe
●Check if the gas pipe is connected firmly.

9.2Routine inspection

Any contact with live parts can cause fatal electric shock or
serious burns.
Warning To avoid the electric shock, burns and other personal injury,
please observe the following matters.
●In order to ensure the safety, the regular inspection need be finished by the person who possesses
the professional qualification or is skilled in the operation.
●Before inspection, be sure to turn off the power of this product, the distribution box and relevant
devices (those connected with the welding machine).
● Because there is the capacitor discharge inside the arc welding power, please carry out the internal
inspection 5 minutes later after turning off the power.
In order to avoid damaging the semiconductor device and the circuit board
inside this product due to the static electricity, please observe the following
Warning
matters and not touch the parts are irrelevant to the inspection items.
Before touching the semiconductor device inside this product, the static electricity can be
removed by touching the metal parts on the housing with the hands.
●In order to keep long-term stable performance of the equipment, the regular
inspection need be carried out for the equipment.
●The regular inspection mainly includes the inspection and cleaning inside the
product.
●The regular inspection is carried out normally once every six months. (if there is
more fine dust or oily smoke in the workplace of the equipment, the regular
inspection shall be carried out once every three months.)
●The regular inspection plan and record shall be getting done with before putting the
equipment into service formally.
●During the regular inspection, please use the components with the specified
specifications and models during replacement of the components.

47
Operation instruction of TDN 5000 MAG/MIG/CO2 power source Maintenance

●The regular inspection includes the following several points and you can add the
inspection items according to the service condition of the equipment:
(1)Routine inspection
Remove the top cover and the side panel to check if the connecting parts are
loosened and if there are the signs of the odor, the discoloration and the
overheating damage for main components.
(2)Inspection of cable and gas hose
Please carry out the inspection according to the relevant requirements in the
routine inspection, mainly check if the ground wire, the input cable and the output
cable are connected firmly.
(3)Removal of internal dust
Remove the top cover and the side panel to clean up the dirt or the foreign
matter on the circuit board, the radiator and main power devices. During removing
internal dust, please use the dry compressed air to clean it. If the compressed air
with high moisture content is used, it will possible to damage the insulation inside
the machine.
(4)Insulation detection
The insulation detection need be carried out under the guidance of the
professional electrician or the professionals. Please use DC500V insulation mega
meter for detection, mainly check the insulation resistance between the input
circuit and the output circuit of the equipment. If the insulation detection is not
qualified, prohibit continuing to use the equipment to avoid the risk of the electric
shock. The detection indicators shall meet the requirements in the following table:
Insulation
Input——housing Output——housing Input——output
circuit
Acceptable
≥2.5MΩ ≥2.5MΩ ≥5MΩ
range

48
Operation instruction of TDN 5000 MAG/MIG/CO2 power source Fault and elimination

10. Fault and elimination

Any contact with live parts can cause fatal electric shock or
serious burns.
To avoid the electric shock, burns and other personal injury,
Warning
please observe the following matters.
●The fault elimination need be carried out by the person who possesses the professional
qualification or is familiar with the circuit of the welding machine.
●Before operation, it shall ensure that the power switch of this product, the distribution box and
relevant devices (those connected with the welding machine) has been turned off.
● Because there is the capacitor discharge inside the arc welding power, please carry out the
operation 5 minutes later after turning off the power.

When the power switch is automatically turned off, do not turn on the power
switch again and contact with the dealer or after-sales service of our company.
Notice The power switch is the breaker and will be automatically opened if the over-current
is caused for whatever reason. If the power switch is turned on again before eliminating
the fault of the over-current, the accident will be expanded.

10.1 Fault code

A. If the fault that can be self-identified by the equipment occurs, the fault code
will be shown on the control panel.

fault indication fault code

The content shown in the display window when Err 001 fault occurs

B. Classification of the fault types:


Symbol △:It need not turn on the power again (after the fault elimination,
the fault code display will be cleared automatically.)
Symbol ▲:It must turn on the power again (even if the fault is eliminated,

49
Operation instruction of TDN 5000 MAG/MIG/CO2 power source Fault and elimination

the fault code will not be cleared automatically and can be cleared only after turning
on the power again.).
C. After turning on the power, the reasons that the display window on the control
panel cannot work normally include the following several points:
●The display control board (MS01-02.7)is damaged and the fault can be
eliminated by replacing the display control board;
●The display board (MS01-03.1)is damaged and the fault can be eliminated by
replacing the display board ;
●The power of the display control board is abnormal and the reason of abnormal
power supply for the display board is checked so as to eliminate the fault (possibly
caused by the faulty circuit or control power board H225-01) ;
Fault Fault
Fault content Reasons and solution
code type
Internal components are faulty: after turning off the power,
Over-current on check IGBT, fast recovery rectifier diode module,
001 ▲
the primary side high-frequency transformer and primary current
transformer etc. and turn on the power after replacement.
Internal overheating: do not turn on the power before the
Abnormal temperature inside this product falls to be normal;
002 △
temperature eliminate the fault of the overheating (operated beyond the
rated duty cycle, blocked air vent and other reasons).
The input voltage is beyond the permissible range:turn
003 Input overvoltage △ off the power, adjust the input voltage within ±10% rated
input voltage and turn on the input power.
The input voltage is beyond the permissible range:turn
Input
004 △ off the power, adjust the input voltage within ±15% rated
under-voltage
input voltage and turn on the input power.
The input power is in open-phase:turn off the input
power, check the reason the open-phase is caused (the
005 Input open-phase △
faulty input circuit and switch etc.) and turn on the input
power after the fault elimination.
Abnormal the circulating water pressure signal in the
Abnormal cooling cooling water tank:check if the cooling water tank works
006 △
water pressure normally ( for the details, please read the operation
instruction of the cooling water tank.).
Abnormal shield gas pressure signal:check the shield gas
Abnormal shield
007 △ pressure signal and self-restore to be normal after the fault
gas pressure
elimination.
External The terminal connecting to the automatic welding port
008 emergency stop △ receives the emergency stop signal:automatically restore
signal to be normal after clearing the emergency stop signal.
009 Abnormal signal △ Check the signal of turning on the welding gun during

50
Operation instruction of TDN 5000 MAG/MIG/CO2 power source Fault and elimination

of welding gun turning on the input power:automatically restore to be


normal after clearing the signal of turning on the welding
gun.
There is not successful arc striking signal for the arc
striking current output overtime:check if Hall current
Abnormal arc
010 △ sensor works normally; check if the output current
striking
feedback signal is normal; check if master control board
(MS01-01.1) works normally.
The output current feedback signal is detected when the
Abnormal current input power is turned on:check if Hall current sensor
011 △
feedback works normally; check if the output current feedback signal
is normal; check if master control board works normally.
The output voltage feedback signal is detected when the
input power is turned on:check if there is interfering
signal in the welding circuit(the interfering signal possibly
Abnormal voltage
012 △ comes from the adjacent AC welding machine and other
feedback
devices);check if internal output voltage feedback circuit
is abnormal;check if master control board (MS01-01.1)
works normally.
Abnormal wire Check if the wire feeder is connected correctly with the
013 △
feeder welding machine; check the connecting cable.
The reading and writing faults occur for the extended
Abnormal memory unit of the display control board:try to turn on
020 △
memory unit the power again, if the faults occur again, replace the
display control board(MS01-02.7).
Master control board does not respond the request of the
Abnormal display board:check the communication circuit between
021 communication △ the display control board and master control board;turn
response on the power again after replacing the display control board
or master control board.
The slave device connecting with the arc welding power
does not respond normally the response request of the arc
Abnormal slave
022 △ welding power:check if the communication circuit is
response
normal;confirm that the communication protocol between
the host computer and the slave computer is accordant.

51
Operation instruction of TDN 5000 MAG/MIG/CO2 power source Fault and elimination

10.2 Inspection items during welding failure

N N N Po U U Adhes Adhes W
o o o or ns ns ion of ion eld
ar wi ar ta m the betwe in
c a re c bl oo weldin en the g
Welding failure str i fe str e th g wire weldin bl
iki r ed iki ar we and g wire ow
ng s ng c ld the and ho
u ed base the le
p ge metal electro
p de
Inspection items l nozzle
y
●The switch trips or is opened or the fuse blows
Distribution out.
●Input open-phase ▲ ▲ ▲
W box
el ●The switch is connected loosely.
di ●The input cable is broken.
ng ●There is poor contact at the connection of the
Input cable ▲ ▲ ▲
po
input cable.
we
r ● The input switch trips or is opened.
Power body ●The fuse of the wire feed circuit (at rear panel) ▲ ▲ ▲
blows out.
Ga ●Main valve of the gas cylinder is not opened.
s Gas cylinder ●The gas pressure is insufficient.
Gas ●The flow setting value of the gas regulator is ▲ ▲ ▲
regulator wrong.
●Loose connection
●The gas leaks due to the damaged gas pipe or
Gas pipe ▲ ▲
the loose connection.
●The wire feed wheel or the wire guide tube is
not matched with the welding wire size.
●The wire feed wheel is damaged or the groove
is blocked.
Wire feeder ●The inlet of the wire guide tube is blocked by ▲ ▲ ▲ ▲ ▲

the dust.
●The pressing force of the pressure lever is
insufficient.
●The welding cable or the cable of the welding
gun switch is broken.
The cable of the ●The cable of the welding gun is connected ▲ ▲ ▲ ▲ ▲
welding gun loosely with the wire feeder.
●The cable of the welding gun is damaged.
●The cable of the welding gun is bent too much. ▲ ▲ ▲ ▲
Control cable ●The control cable is broken or in short circuit. ▲ ▲ ▲
●The electrode nozzle or the wire guide tube is
not matched with the welding wire size.
Welding gun ●The electrode nozzle is worn seriously. ▲ ▲ ▲ ▲
●The wire guide tube is blocked by the foreign
matter.

52
Operation instruction of TDN 5000 MAG/MIG/CO2 power source Fault and elimination

●The electrode nozzle is installed loosely.


●The welding gun is connected loosely with the ▲ ▲
wire feeder.
●The cross-section area of the cable is
Cable on the side insufficient or the cable is connected loosely. ▲ ▲ ▲
of the base metal
●The base metal has poor conductivity.
●The welding conditions are set improperly.
Welding ●The angle of the welding gun, the welding
▲ ▲ ▲ ▲ ▲
conditions speed or the lever elongation is improper.
●The wave form control is set improperly.
Surface of the ●There is the oil stain, the impurity or the paint
▲ ▲ ▲ ▲ ▲
base metal coating on the surface.

53
Operation instruction of TDN 5000 MAG/MIG/CO2 power source Transportation, storage and ambient conditions/quality commitment

11. Transportation, storage and ambient conditions

● Using standard packaging is to meet the requirements of air transport, sea


transport, rail transport and road transport (national three-level highway or
more).
Notice:During transportation, it shall observe strictly marking on packaging of
products. No inclination, damping, collision and severe vibration are allowed.
●Ambient conditions of transportation, storage and operation
a. Ambient temperature for operation: -10℃~40℃
for transportation and storage:-25℃~55℃
b. Relative humidity at 40℃,≤50%
At 20℃,≤90%
c. Dust, acid and corrosive gases or substances (include such substances
produced during cutting)cannot exceed regular limit.
d. Pay attention to avoiding drench during operating in the open air.

12. Quality commitment

Under the condition that you operate, handle, use and store the welding machine
correctly according to the requirements of operation instruction, our company will
promise one-year warranty for the product. If the quality problem occurs, please
contact customer service center of our company in time.
Customer service center:(010)62978007
400 free telephone :400-660-9391
Fax:(010)62966796
Address:No. 17, Kaituo Road, Shangdi Information and Industry Base, Haidian
district, Beijing City
Postcode: 100085

54