Professional Documents
Culture Documents
TDN 3500/5000
MAG/MIG/CO2 Power source
Instruction manual
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
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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.
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.
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.
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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Safety precautions
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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Safety precautions
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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Safety precautions
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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Safety precautions
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.
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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Safety precautions
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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Safety precautions
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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)
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Operation instruction of TDN 5000 MAG/MIG/CO2power source Overview
3. Definition declaration
3.1 Nameplate
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Operation instruction of TDN 5000 MAG/MIG/CO2power source Overview
Panel local
Output Remote control
(control)
Protective
ON OFF
earthling
Agreed welding
Duty cycle Agreed load voltage
current
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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Structure and names of main components
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)
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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Structure and names of main components
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
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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Handling, installation site and power equipment
5.1 Handling
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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.
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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Handling, installation site and power equipment
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
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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
Wire feeding
feeder
torch
Earth clamp
Power source
cable
Output cable
Work piece
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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Function and operation
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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Function and operation
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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Function and operation
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
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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
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
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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Function and operation
column and “ ” in “output control” column is pressed at the same time to switch
“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
“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
“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
“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
“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
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
“ ” 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
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
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
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
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.
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.
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.
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.
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.
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.
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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
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Operation instruction of TDN 5000 MAG/MIG/CO2 power source Function and operation
mixer.
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
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.
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
Torch switch
T1: pre-flow time
Output current
welding
Torch switch
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
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
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.
Insulation level Y F
Weight 48kg
43
Operation instruction of TDN 5000 MAG/MIG/CO2 power source Function and operation
Optional
note: 021, 022, 031,
44
Operation instruction of TDN 5000 MAG/MIG/CO2 power source List of main components
45
Operation instruction of TDN 5000 MAG/MIG/CO2 power source Maintenance
9. Maintenance
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.
9.2Routine 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
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.
A. If the fault that can be self-identified by the equipment occurs, the fault code
will be shown on the control panel.
The content shown in the display window when Err 001 fault occurs
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
51
Operation instruction of TDN 5000 MAG/MIG/CO2 power source Fault and elimination
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
53
Operation instruction of TDN 5000 MAG/MIG/CO2 power source Transportation, storage and ambient conditions/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