Nielsen CT4973 Operation instructions

PROCESSES

MIG/MAG Welding MMA welding

Description

Arc Welding Power Source

INVERTER MIG/MAG, FLUX, MMA

CT4973

ORIGINAL INSTRUCTION

Cannon Tools Limited

Address: 20 Station Road, Rowley Regis, West Midlands, B65 0JU.U.K

Work like a Pro! Pros weld and cut safely.

Please read the User’s Manual carefully before using the machine.

EC DEC LARATION OF CONFORMITY

We CANNON TOOLS LTD

20 Station road,Rowley Regis,West Midlands,B65 0JU.U.K.

Declare that the following machine complies with the appropriate basic

safety and health requirements of the EC Directive based on its design and

type, as brought into circulation by us.

In case of alteration of the machine, not agreed upon by us, this declaration

will lose its validity.

Product description: INVERTER MIG/MAG, FLUX, MMA

Model: CT4973

Applicable EC Directives:

EC Low Voltage Directive 2014/35/EU

EC Directive of Electromagnetic Compatibility 2014/30/EU

Harmonized standards

EN 60974-1：2012

EN 60974-10：2014/A1：2015

20 Station Road,Rowley Regis,West Midlands,B65 0JU.U.K.

Mr. Gurcharan Tony Singh Sanghera

Managing Director

CANNON TOOLS LTD

2018.09.07

CONTENTS

SAFETY RULES.......................................................... .................................................................................................2

IDENTIFYING SAFETY INFORMATION

●These symbols are being used to identify potential risks.

●When seen a safety symbol in the manual, it must be understood that there is an injury risk and following

instructions must be read carefully to avoid potential risks.

●While welding, keep the third persons and especially the children away from the work area.

UNDERSTANDING THE SAFETY WARNINGS

Read carefully the manual and the labels and the safety warnings on the machine.

●Make sure that the warning labels positioned on your machine are in good order. Renew the damaged and the

missing labels.

●Learn to operate the machine and how to make the controls properly.

●Operate your machine in convenient work areas. Improper modifications affect the safety of your machine

negatively and shorten its lifetime.

ELECTROMAGNETIC COMPATIBILITY（EMC）........................................................................................ ...... 6

1. TECHNICAL INFORMATIONS........................................................ ..................................................................7

1.1 GENERAL EXPLANATIONS.................................................. .....................................................................7

1.2 APPLICATION AREA ........................................................ ...........................................................................7

1.3 SYMBOL AND MEANING ON DATA PLATE............................................................................................7

1.4 TECHNICAL SPECIFICATIONS................................................. ....................................................... ..........8

2. INSTALLATION..................................................................................... ..................................................... .......9

2.1 UPON RECEIPT AND CLAIMS........................................................... ..................................................... ...9

2.2 WORK AREA ........................................................................................... .............................................. .......9

2.3 INSTALLATION AND USAGE OF THE MACHINE ................................................ ................................. 9

2.3.1 CONNECT THE MACHINE TO POWER SUPPLY............................................................. ... ........10

2.3.2 CONNECT THE ELECTRODE HOLDER FOR MMA..................................................... ... ........10

2.3.3 CONNECT THE EARTH WELDING CABLE TO THE MACHINE....................... ... ....................10

2.3.4 CONNECT THE EARTH CLAMP......................................................................................... ... .......10

2.3.5 CONNECT THE GAS CYLINDER...................................................................................... ... .........12

2.3.6 THREAD THE WELDING WIRE.................................................................................... ... ..............12

3. USAGE INFORMATION.......................................................................................................................... ... ......13

3.1 THE POWER SOURCE FRONT PANEL ............................................................................................... ... .......13

3.2 THE POWER SOURCE BACK PANEL ............................................................................................... ... .......13

3.3 ADJUSTING THE GAS FLOW.......................................................................................................... ... .......13

3.4 ALIGNING DRIVE ROLLS FOR APPROPRIATEWIRE DIAMETER.................................................. ....13

3.5ADJUSTING THE FREE WIRE LENGTH ,WELDING CURRENT AND VOLTAGE ...................... .......13

3.6 THE FUNCTIONS OF THE GUN SWITCH ...................................................................................... ... ......14

3.7 SETTINGS FOR ALUMINUM WELDING........................................................................................ ..........14

4. MAINTENANCE AND TROUBLESHOOTING........................................................................................ ........15

4.1 PERIODIC MAINTENANCE................................................................................................................ ... ....15

4.2 NONPERIODIC MAINTENANCE.................................................................................................... ... .......16

4.3 BASIC TROUBLESHOOTING ..................................................................................................... ... ...........16

-1-

SAFETY RULES

ELECTRICAL SHOCK COULD BE FATAL

Installation procedure must comply with national electricity standards and other

relevant regulations and ensure that installation is performed by qualified persons.

●Wear dry, hole-free insulating gloves and body protection.

●Do not touch electrode with bare hand. Do not wear wet or damaged gloves and

body protection.

●Do not touch live electrical parts.

●Never touch electrode while in contact with working surface, ground or another

electrode which is connected to a different machine .

●Protect yourself from electric shock by insulating yourself from work and ground.

Use non-flammable, dry insulating material if possible, or use dry rubber mats, dry

wood or plywood, or other dry insulating material big enough to cover your full area

of contact with the work or ground, and watch for fire.

●Never connect up more than 1 electrodes or wires to the machine.

●Turn off the machine, when not in use .

●Disconnect input plug or power before working on machine.

●Frequently inspect input power cord for damage or bare wiring - repair or replace

cord immediately if damaged.

●Be sure input ground wire is properly connected to a ground terminal in disconnect

box or receptacle.

BREATHING WELDING FUMES CAN BE HAZARDOUS TO YOUR HEALTH

Inhaling fumes and gases over a long period of time, generated during welding is dangerous and

forbidden .

●Irritation of the eyes, nose and throat are symptoms of inadequate ventilation. Take immediate

steps to improve ventilation. Do not continue welding if symptoms persist.

●Install a natural or forced air ventilation system in the work area.

●Install an adequate ventilation system in the welding and cutting area, if needed

install a system that can remove the fume and vapor accumulated in the entire work

area, to prevent pollution use adequate filtration in discharge.

●In the event of welding in small, confined places, or welding lead, beryllium,

cadmium, zinc, zinc coated or painted materials; also wear a fresh air supplied

respirator in addition to the above mentioned rules .

●Always have a trained watch-person nearby, while working in small confined places.

Avoid working in such confined places if possible.

●If gas cylinders are grouped in a different area, make sure that it is a well-ventilated

area. When not being used, turn off the cylinder valve .

●Shielding gasses such as argon is denser than air and when being used in confined

places, can be inhaled in place of air, and this is dangerous for your health.

●Do not perform welding operations near chlorinated hydrocarbon vapors produced

by degreasing or painting.

-2-

SAFETY RULES

ARC RAYS CAN BURN EYES AND SKIN

●Use adequate welding helmet with correct shade of filter (4 or 13 considering TS EN

379) to protect your eyes and face.

●Protect open parts of your body (arms, neck and ears) from arc rays by adequate

protective clothing.

●To protect others by arc rays and hot metals, surround the working area with flame

proof curtains which are higher than eye level and put up warning boards.

FLYING METALS CAN INJURE EYES

●Welding, wire brushing and grinding cause sparks and flying metal.

●To prevent injuries wear appropriate safety glasses with side shields even under your welding helmet .

NOISE CAN DAMAGE HEARING

●Noise from certain industrial processes or equipment can damage hearing.

●Wear approved ear protection if noise level is high.

HOT PARTS CAN CAUSE SEVERE BURNS

●Do not touch hot parts.

●Allow cooling time before servicing.

●If needed to hold hot parts, use appropriate tool, insulating gloves and fireproof clothes.

MOVING PARTS CAN CAUSE INJURY

●Keep away from moving parts.

●Keep all doors, panels, and guards closed and secured.

●Wear shoes with metal protection over the fingers.

WORKING IN SMALL AND CONFINED PLACES CAN BE DANGEROUS

●While welding and cutting in small, confined places, always have a trained watch-person nearby.

●Avoid working in such confined places.

-3-

SAFETY RULES

WELDING WIRE MAY CAUSE INJURY

●Do not point the gun toward any part of a human body, other persons or any type of metal when unwinding

welding wire.

●While extracting the wire from the spool by hand, it may spring suddenly and injure you or a nearby person,

protect especially your eyes and face.

●Make sure that there is no one close.

WELDING CAN CAUSE FIRE OR EXPLOSION

●Never weld near flammable material. It may cause fire or explosions.

●Before starting to weld, move flammables away or protect them with flame-proof

covers.

●Do not weld on and cut closed tubes or pipes.

●Before welding on closed containers, open and clear them entirely. Welding

operations on these parts must be performed with the utmost caution.

●Never weld containers or pipes containing or which have contained substances

that could give rise to explosions.

Welding equipment warms up so never position them on flammable surfaces.

●Welding sparks can cause fire. For that reason, keep extinguishing means, such as fire

extinguishers, water and sand easy reach.

●Have and maintain security valves, regulators and other valves on the flammable,

explosive and compressed gas circuits in good condition by periodical controls,

used for welding and cutting operations.

FALLING UNIT CAN CAUSE INJURY

Wrong positioned power source or other equipment may cause serious injury to persons

or damage to objects.

●While re-positioning the power source always carry by using the lifting eye. Never pull cable, hose or Gun.

Always carry the gas cylinders separately.

●Before carrying the welding and cutting equipment, disassemble all the connections between and

separately carry the small ones by handgrips and the big ones by lifting eyes or by using appropriate

vehicles like forklifts.

●Install your machine on flat platforms having maximum 10° slope that it does not fall over. Install it on well

ventilated, non-confined places away from the dust, also avoiding the risk of falling caused by cables and

hoses. For gas cylinders not to fall over, attach it to the mobile machine or to the wall with a chain.

●Ensure that operators easily reach the controls and connections on the machine.

-4-

SAFETY RULES

MAINTENANCE MADE BY UNQUALIFIED PERSONS MAY CAUSE INJURIES

●Electrical devices should not be repaired by unqualified persons. Improper repairs can cause serious

injuries or even death during applications.

●The components of the gas circuit works under pressure. The service given by unqualified persons may

cause explosions and operators can be injured seriously.

OVERUSE CAN CAUSE OVERHEATING

●Allow cooling period; follow rated duty cycle.

●Reduce current or reduce duty cycle before starting to weld again.

●Do not block airflow to unit.

●Do not filter airflow to unit without the approval of manufacturer

ARC WELDING CAN CAUSE INTERFERENCE

●Electromagnetic energy arising during welding and cutting operations can interfere with

sensitive electronic equipment such as microprocessors, computers, and computer-driven equipment such

as robots.

●Be sure all equipment in the welding area is electromagnetically compatible.

●To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on

the floor.

●To avoid possible EMC damages, locate welding operation as far as possible (100 meters) from any

sensitive electronic equipment.

●Be sure this welding machine is installed and grounded according to this manual.

●If interference still occurs, the user must take extra measures such as moving the welding machine, using

shielded cables, using line filters, or shielding the work area .

STATIC (ESD) CAN DAMAGE PC BOARDS

●Put on grounded wrist strap before handling boards or parts.

●Use proper static-proof bags and boxes to store, move, or ship PC boards.

PROTECTION

●Do not expose the welding machine to rain, protect from water drops and vapour.

LIFE TIME

●The lifetime determined by Ministry of Industry and Trade is 10 years.

OBEY ALL THE SAFETY RULES STATED IN THE MANUAL!

-5-

ELECTROMAGNETIC COMPATIBILITY（EMC）

ELECTROMAGNETIC EMISSION

●All electrical equipment generates small amounts of electromagnetic emission due to current transferring in

the equipment. Electrical emission may be transmitted through power lines or radiated through space, similar

to a radio transmitter. When emissions are received by other equipment, electrical interference may result .

Electrical emissions may affect not only welding machines but also many kinds of electrical equipment

like radio and TV reception, numerical controlled machines, telephone systems, computers etc.

●Welding and cutting machines have been designed to work for professional and industrial use; for other

applications to contact the manufacturers.

●The user is responsible for installing and using the equipment according to the manufacturer’s instructions.

If electromagnetic disturbances are detected then it shall be the responsibility of the user of the equipment to

resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may

be as simple as earthing the welding the welding circuit, in other cases it could involve constructing an

electromagnetic screen enclosing the power source and the work complete with associated input filters. In all

cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome.

●The circuit may or may not be earthed for safety reasons. Changing the earthing arrangements should only be

authorized by a person who is competent to assess whether the changes will increase the risk of injury, e.g. by

allowing parallel welding current return paths which may damage the earth circuits of other equipment.

●Extra precaution may be required when the welding power source is used in a domestic establishment.

●Special measures shall be taken to achieve compliance with welding power source including HF frequency for arc

ignition and stabilizing; it may be required use of shielded cables and in any case to resolve the particular

implementation (e.g. with robot, computer and any other electrical and electronic equipment connected to

welding power source) to call the technical assistance of the manufacturer.

●EMC is Class A according to CISPR II.

ASSESMENT OF THE SURROUNDING AREA

Before installing the welding equipment, the user shall make an assessment of potential electromagnetic

problems in the surrounding area. The following shall be taken into account- if needed arrange the

working hours that not coincide with those.

●Other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the

welding equipment,

●Radio and television transmitters and receivers,

●Computer and other control equipment,

●Safety critical equipment,

●Presence of heart beat regulators, heart cells, hearing devices or etc. nearby,

●Equipment used for calibration or measurement,

●The immunity of other equipment in the environment.

The user shall ensure that other equipment being used in the environment is compatible. This may

require additional protection measures.

METHODS OF REDUCING EMISSIONS

●Welding equipment should be connected to the mains supply according to the manufacturer’s recommendations.

Our welding machines are filtered against emission according to standards. If interference still occurs, it may be

necessary to take additional precautions such as filtering of the mains supply.

●The equipment should be routinely maintained according to the manufacturer’s recommendations. The

welding equipment should not be modified without the approval of manufacturer.

●The welding cables should be kept as short as possible and should be positioned close together, running at or

close to the floor level. Power cables and signal cables should be kept separately.

●Keeping cables in the shape of -8- and taping together reduce emission.

●Connect earth clamp to workpiece as close to the weld as possible. But the user should be control whether this

situation damage to people and equipment or not.

-6-

TECHNICAL INFORMATION

1. TECHNICAL INFORMATIONS

1.1 GENERAL EXPLANATIONS

1.2 APPLICATION AREA

1.3 SYMBOL AND MEANING ON DATA PLATE

Single phase input AC power supply, inverter，Rectifier，Transformer，DC current or voltage output

MIG/MAG welding or GMAW process

MMA welding process

With MIG (Metal Inert Gas) or MAG (Metal Active Gas) welding also called Gas-Shielded Metal

Arc Welding (GMAW) an arc is maintained between a continuous solid wire electrode and the work

piece. The arc and weld pool are shielded by a stream of inert or active gas. The process is suitable for

most materials and filler wires are available for a wide range of metals.

MIG/MAG welding is inherently more productive than MMA, where productivity losses occur each time a

welder stops to replace a consumed electrode. Material losses also result from MMA welding when the stub of

each electrode is thrown away. For every kilogram of coated stick electrode purchased, about 65 per cent

becomes part of the weld (the rest being discarded). The use of solid wire and flux cored wire has increased

this efficiency to 80-95 per cent. MIG/MAG welding is a versatile process, which can deposit weld metal at a

very high rate and in all positions. The process is widely used on light to medium gauge steel fabrications and

on aluminium alloy structures particularly where high-rate manual operator production is required. The

introduction of flux cored wires is finding increased application in heavy steel structures.

-7-

●CT4973 welding machines are 1 phase,

constant voltage and current ( CV and CC ) power

sources especially designed for MIG/MAG and

MMA welding.

●All the controls of welding powersourceare placed on

to the front panel for easy operation and monitoring.

●Wire feeding unit is wheel drive and it is installed in

the power source.

●Wire feeder contains motor and drived wheel, etc.

●Output voltage and wire speed or welding current

of the CT4973 welding machine can be adjusted by

a welding voltage and wire speed or welding current

adjustment knobs for MIG/MAG.

●Output welding current of the CT4973 welding

machine can be adjusted by a welding current

adjustment knob for MMA.

●CT4973 is very good selection for welding 1.2~6 mm thickness metal. It is a very good choice for

steel,stainless steel MIG/MAG welding with 0.6-1.0mm welding wires.

●CT4973 is very good selection for welding 2.0~6 mm thickness metal. It is a very good choice for

steel,stainless steel MMA welding with 1.6-4.0mm electrodes.

TECHNICAL INFORMATION

Norm:Application standards,for example,IEC60974,EN60974,etc.

U1：Rated AC input voltage of the welding power source,for example,1~(1 phase),230V.

50 HZ:Rated frequency of single phase AC power supply .

I1max：Max. input current

I1eff：Max. effective input current

X: Rated duty cycle.It is the ratio between the load duration time and the full cycle time.

Note1: This ratio is between 0~100%.

Note2: For this standard, one full cycle time is 10min.For example, if the rate is 40%, the loaded time shall be 4

minutes and rest time shall be 6 minutes.

Duty cycle is based on a ten minute period.This means that the arc may be drawn for two minutes out of

each ten minute period without any danger of overheating .If it is used more than two minutes during several

successive ten minutes periods, it may overheat.

U0：Non-load voltage. It is the open-circuit output voltage of the welding power source.

I2：output current or welding current

U2：Output load voltage or welding voltage.The rated loaded output voltage U2=14+0.05I2

A / V—A / V：The adjustable range of current and its corresponding load voltage.

S1: The rated Input Power, KVA

IP：Protection grade . For example, IP21,approving the welding machine as suitable for use indoors; IP23,. approving

the welding machine as suitable for use outdoors in the rain.

Suitable for hazardous environments.

：Beyond rain.

F or H：Insulation grade.

1.4 THE MAIN TECHNICAL SPECIFICATIONS

CT4973

Input voltage

230VAC±15%, 1 Phase

Frequency

50Hz

Output current

DC 40~180A

Output voltage

DC 16.5~26.4V

Wire Diameter

0.6mm, 0.8mm, 0.9mm,1.0mm

-8-

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