Operation and Maintenance Manual

TORNADO 401

ADOR FONTECH LIMITED

 CONTENTS

1. Warning……………………………………………………………………… 2

2. General Description………………………………………………………… 3

3. Main Parameter………………………………………………………….…. 4

4. Installation & Operation………………………………………………….… 5

5. Caution………………………………………………………………………. 7

6. Maintenance………………………………………………………………… 8

7. Troubleshooting…………………………………………………………….. 9

8. Spare Parts List…………………………………………………………….. 10

EC DECLARRATION OF CONFORMITY

Hereby we declare that our machines for industrial and professional use of
Tornado 401 Machine

Conform the EMC Directives: 73/23/EEC and 89/336/EEC

European Standard: EN/IEC60974

Please read and understand this instruction manual carefully before the
installation and operation of this equipment.

This instruction manual is issued on 1st September 2005

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 WARNING
Welding and cutting is dangerous to the operator, people in or near the
working area, and the surrounding, if the equipment is not correctly operated.
Therefore, the performance of welding/cutting must only be under the strict and
understand this instruction manual carefully before the installation and operation.
• The switching of function modes is possibly damaging to the equipment, while the
welding operation is performed.
• Do disconnect the electrode - holder cable with the equipment, before the
performance of welding.
• A safety switch is necessary to prevent the equipment from electric-leakage.
• Welding tools should be of high quality.
• Operators should be qualified.

Electric shock: it may be fatal

• Connect the earth cable according to standard regulation.
• Avoid all contact with live components of the welding circuit, electrodes and wires with
bare hands. It is necessary for the operator to wear dry welding gloves while he
performs the welding task.
• The operator should keep the working piece insulating from himself/herself

Smoke and gas generated wile welding or cutting: harmful to people’s health.
• Avoid of breathing the smoke and gas of welding or cutting.
• Keep the working area in good ventilation.

Arc light-emission: harmful to people’s eyes and skin

• Wear the welding helmet, anti-radiation glass and work clothes while the welding
operation is performed.
• Measures also should be taken to protect people in or near the working area.

Fire hazard
• The welding splash may cause fire, thus remove flammable material away from the
working place.

Noise: possiable harmful to people’s hearing

• Surface noise is generated while welding/cutting, the hearing aids is necessary in some
cases.

Machine Fault:
• Consult this instruction manual.
• Contact your local dealer or supplier for further advice.

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 GENERAL DESCRIPTION
This welding machine is manufactured with advanced inverter technology. With power
component IGBT and PWM technology, the inverter converts DC Voltage, which is rectified
from input AC Voltage, to high frequency AC Voltage, as a consequence, the voltage is
transformed and rectified. Therefore, the result is more small-sized of the main transformer
and lighter in weight of the inverter welder, which rates the performance of welding by 30%.
The high frequency oscillation, which enables the output of high frequency DC, is employed in
the arc-starting system. The features of this product are as following: stable of current,
reliable, completely portable, efficient and low noise generated while the welding operation is
performed.

The features of MMA serial are: efficiency, energy saving, portable of excellent
dynamic characteristics, and stable arc, of relatively low no-load voltage, and with
compensation of power force, and able to meet various welding requirements.

Guarantee of maintenance for main engine is one year, excluding other spare parts.

During the guarantee maintenance period, all maintenance is free of charge, not including
the deliberated damage to this welding equipment.

Only qualified technician are authorized to carry out the repair task of this welding
equipment in case of machine fault.

Block Diagram

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 MAIN PARAMETERS

TYPE TORNADO 401

Input Power Voltage (V) Three phase AC 415+10
Input Frequency (Hz) 50 / 60
Rated Input Capacitance (KVA) 18
Rated Input Current (A) 28
Rated Output Voltage (V) 36
Output Current range (A) 40 - 400
Drive Current range (A) 0 - 100
Duty cycle % 60
No-load Voltage (V) 72
No-load loss (W) 200
Efficiency % > 85
Power factor 0.93
Insulation class F
Protection class IP23
Weight (kg) 32

Circuit diagram

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INSTALLATION & OPERATION
1. Remote connection
2. Fast Connectors
3. Power MCB
4. Current Adj. Knob
5. Alarm Indication
6. Arc Force Knob
7. Remote Local selection switch
8. Digital Display

1. Connection of power supply cables

A primary power cable is available for this welding equipment, connect the
power supply cable with required voltage (415V, 3 Phase). The primary cable should
be connected to the correct socket to avoid oxidization. Check whether the voltage
value varies in the given rang with a multi-meter.

2. Connection of output cables

Two Fast connectors are available for this welding equipment, connect the
Male plug with welding cables to female Fast connector on the panel board. There is a
possibly of damaging to both the male and female, if they are incorrectly connected.
The electrode holder cable should be connected to the negative terminal, while the
work piece should be connected to the positive terminal for straight connection.

Serious attention should be paid to the electrode of the wire. Generally, two
modes of connection of DC welding equipment are available:
• Straight polarity connection: electrode holder to “-“, while work piece to “+”;
• Reveres Polarity connection: work piece to “-“, while electrode holder to “+”.

Opt the mode according to practical requirements, and incorrect connection

may cause unstable arc, splash and conglutination of rod and work piece etc. In case
that minimum distance between work piece and this welding equipment is over 50 M,
as a consequence it spells the over-length of the secondary cable including electrode
holder cable and earth cable. Therefore it is necessary to increase the diameter of
cable in order to maintain and improve the performance of voltage output.

3. Power supply switch

While the power supply switch is on, the built-in fan works and current meter
displays the current value.

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4. Welding current output setting
According to practical demand, set the parameters of current output by the
operation of “welding current knob”. Generally, the required output welding currents
with respect to Welding Electrode Diameter are listed as following:
Ø2.5: 70-100A; Ø3.2: 110-160A; Ø4.0: 170-220A; Ø5.0: 230-280A

5. Pilot Lamp
If the pilot lamp is on, it indicates that this welding equipment is of over heating
protection status, which possibly is the consequence of duty over-loading. This
welding equipment automatically restarts when the temperature inside the machine
drops to required degree, meanwhile the pilot lamp is off.

6. ARC Force adjust

Arc – Force knob” is available for the improvement of arc-starting, especially in
case of low current input and non down hand welding.

7. Remote Control

7a.Remote Switch: If remote switch is on, remote control is available; remote switch
off, remote control unavailable.

7b. Remote socket: Connect remote plug with remote socket. Setting output current
is unavailable in case that the remote switch is on. Machine fault of remote control
possibly occurs due to the rough handling during transportation.

Operatable duty cycle

The welding operation of this welding equipment should be strictly according to
stipulation. Please refer to the table of Main Parameter.
A sudden halt may occur while the welding operation is carried out while this welding
machine is of over-load status. Under this case, built-in fan work to bring down the
temperature inside this welding equipment, therefore it is unnecessary to disconnect
the input of welding machine.

8. Current Meter
Digital meter indicates welding current.

Before Welding Check whether

This welding equipment is connected with earth cable;

All the connection are available. Particular attention should be drawn to the
connection of earth clamp and work piece;

The output terminal of electrode holder and earth cable is short-circuited;

The pole of output terminal is correct;

In case that leaking switch is opted, the maximum output of leaking electricity is
less than 30Ma.

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 CAUTIONS
1. Working Environment
1.1 The location in which this welding equipment is installed should be of little dust,
corrosive chemical gas, flammable gas or materials etc, and of maximum 80%
humidity.

1.2 Avoid the operation of welding in the open air unless the working area sheltered
from the sun shining, rain water and snow etc; the temperature of working
environment should be maintained within -10°C to +40°C.

1.3 The minimum distance of this welding equipment and wall should be 30cm.

1.4 Keep the working environment in good ventilation.

2. Safety Tips

2.1 Ventilation. This welding equipment is small-sized, compact in structure, and of

excellent performance in current output. Fans are to abstract heat generated by this
cutting equipment while the operation of welding is carried out.
Cautions: Maintain good ventilation of the louvers of this cutting equipment. The
minimum distance between this welding equipment and any other objects in or near
the working area should be 30 cm. Good ventilation is of critical importance for the
normal performance and service life of this welding equipment.

2.2 Welding operation is forbid while this welding equipment is of over-load. A sudden
halt may occur while the welding operation is carried out while this welding machine is
of over-load status. Under this circumstance, it is unnecessary to restart this welding
equipment. Keep the built-in fan working to bring down the temperature inside this
welding equipment.

2.3 Over-voltage is forbid. Regarding the power supply voltage range of the welding
machine, please refer to “Main parameter” table. This welding equipment is of
automatic voltage compensation, which enables the maintaining of the voltage range
within the given range. In case that the voltage of input power supply current exceeds
the stipulated value, it is possibly damaging to the components of this welding
equipment.

2.4 An earth terminal is available for this welding equipment. Connect with the earth
cable to avoid the static and electric shock.

2.5 It is strongly forbid to contact the output terminal when the welding operation is
performed. An electric shock possibly occurs.

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 MAINTENANCE
Exposure to extremely dusty, damp, or corrosive air is damaging to the welding
machine. In order to prevent any possible failure or fault of this welding equipment,
clean the dust at regular intervals with clean and dry compressed air of required
pressure.

Please note that: lack of maintenance can spell to the unavailability and
cancellation of the guarantee; the guarantee of this welding equipment will be no
longer available in case that it is has been attempted to take the machine apart or
open the factory-made sealing of the machine.

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 TROUBLESHOOTING
Cautions: Only the qualified technicians are authorized to undertake the repair task of
this welding equipment in case of machine fault.

Fault Symptoms Rectification

Connect with power supply, 1. Possible failure of connection of power supply, Check and
however there is no reconnect if necessary.
response 2. If power supply is available, possible damage of four thermal
resistance. Check and replace them if necessary.
3. Possible malfunction of power PCB.
3.1 Possible damage of Rectifier Bridge.
3.2 Power PCB is damaged.
3.3 Check connection of power PCB.
4. Possible failure of secondary power supply. Please contact
dealer or supplier for further advice.
Digital indicator displays 1. Examine connection. Reconnect if necessary.
built-in fan is functioning. 2. Examine control module and drive module. Replace them if
Fault indicator is off. There necessary.
is no output. 3. Check the IGBT, main transformer, diode and connections.
Replace and reconnect if necessary.
Digital indicator displays, 1. It is possibly of over current input protection status.
built-in fan is functioning. Compensate failure if necessary.
However in case to restart 2. It is possibly of over heating protection status. Compensate
this welding equipment, failure if necessary.
fault indicator is on. 3. Possible failure of inverter circuit and PCB of arc starting.
3.1 In case that fault indicator is on, it can be concluded that
fault of inverter is causation. Disconnect the power supply cable
of one of two inverters and the cable-connecting transformer.
Restart this welding equipment. In case that fault indicator is off,
we can conclude this one of two inverters is of fault. Otherwise
the other of two inverters is of fault. Disconnect the power
supply; reconnect the power supply cable of the inverter of fault.
And restart this welding equipment.
3.1.1 In case that the fault indicator is off, it can be concluded
that Middle PCB is of fault.
3.1.1.1 Possible damage of transformer of center PCB.
Replace it if necessary.
3.1.1.2 Possible damage of rectifier of center PCB. Replace it if
necessary.
3.1.2 If fault indicator is on, it can be concluded that top PCB is
of fault.
4. Possible fault of feed back circuit. Please contact your dealer
or supplier for more detailed information.
Excessive welding splash Possible fault connection. Reconnect it if necessary.
generated while welding
operation.

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 SPARE PARTS:

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