TIG200 User Manual
Contents
1. more is not always better as too high of a current setting will burn the tungsten electrodes and welded material For Clearance Effect Knob 6 it is for shifting the heat either to the work piece or to the Tungsten Electrode Turning the knob toward will induce more heat to the material you are welding While turning the knob toward will induce more heat to the torch and gives less penetration to the work piece So turn the knob towards if the welding voltage is more than 150A and turn the knob towards if the welding voltage is less than 100A For Tungsten Electrodes please refer to ww w uwelding com for proper equipment for different types of welding For non aluminum Tig welding please sharpen the tungsten tip For aluminum Tig welding please hold the torch 1 8 from the aluminum surface Depress and hold foot pedal at the Y position for 4 seconds then go to 34 to full as required to form a ball on the tungsten This is necessary to achieve a smoother and higher quality aluminum Tig welding gt INSTALLATION DIAGRAMS TROUBLESHOOTING REPAIR SHOULD ONLY BE PERFORMED BY TRAINED PERSONNEL FOR YOUR SAFE PLEASE OBSERVE ALL SAFETY INFORMATION THROUGHOUT THIS MANUAL PLEASE READ AND UNDERSTAND THIS ENTIRE SECTION SERVICE AND 44 WARNING ELECTRIC SHOCK can be fatal AN Service and Repair should only be performed by a Trained Personnel Have a qualified electri2. other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to arc rays to hot spatter or metal HOT METAL will burn gt Electric welding operations cause sparks and heats metal to temperatures ee that will cause severe burns gt Use protective gloves and clothing when performing any welding ANI RA EAA operations gt Always wear long pants long sleeved shirts and leather welding gloves gt Make sure that all persons in the welding area are protected from heat sparks and ultraviolet rays gt Use additional face shields and flame resistant barriers as needed gt Never touch a work piece until it has completely cooled FUMES AND WELDING GASES can be dangerous gt Do not breathe fumes that are produced by welding operation These 3 fumes are dangerous gt Shielding gases used for welding can displace air and cause injury or death 40 Always work in a properly ventilated area M Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer WELDING SPARKS can cause a fire or an explosion E gt Remove fire hazards from the cutting area If this is not possible cover them gt lt a to prevent the weldi
3. the ground clamp to the piece to be welded and as close to the weld area as possible This will give the least resistance and best weld gt Maintain the welding torch work clamp power cable and welding machine in good safe operating condition Replace damaged insulation gt Always wear dry protective clothing and leather welding gloves and insulated footwear You have to the wear the welding gloves and auto darkening welding helmet to protect your hands and eyes from harmful arc Please check www uwelding com for proper tig welding helmet gt Always operate the welder in a clean dry well ventilated area Do not operate the welder in humid wet rainy or poorly ventilated areas gt NOT touch the torch head when the button is depressed It will cause a serious shock and burn gt The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or clothing gt Due to high frequency keep all cell phone cameras and other electronic devices at least 7 feet away from the machine and torch ARC RAYS can be dangerous gt Usea shield with the proper filter a minimum of 11 to protect your eyes from sparks and rays of when welding or observing open arc L welding 2 gt Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays gt Protect
4. use the tool if any switch does not turn on and off properly Guard against electric shock Prevent body contact with grounded surfaces such as pipes radiators ranges and refrigerator enclosures Replacement parts and accessories When servicing use only identical replacement parts Use of any other parts will void warranty Only use accessories intended for use with this welder Approved accessories are availabl from www uwelding com Do not operate tool if under the influence of alcohol or drugs Read warning labels on prescriptions to determine if your judgment or reflexes are impaired while taking drugs If there is any doubt do not operate the welder Maintenance For your safety service and maintenance should be performed regularly by a qualified technician Use proper size and type extension cord If an extension cord 15 required it must be of the proper size and type to supply the eotrect current to the welder without heating up Otherwise the extension cord could melt and catch fire or cause electrical damage to the welder This welder requires use of an extension cord of 20 amps minimum capability up to 30 feet with a wire size rated at 12 AWG Longer extension cords require larger size wire If you are using the welder outdoors use an extension cord rated for outdoor use signified by WA on the jacket Performance of this welder may vary depending on condition in local line voltage Extension cord usage may also aff
5. A safe distance from arc welding or cutting operations and any other source of heat sparks or flame gt Never allow any electrically hot parts to touch a cylinder gt Keep your head and face away from the cylinder valve outlet when opening the cylinder valve gt Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use ELECTRICALLY POWERED EQUIPMENT can be dangerous e gt Turn off input power using the disconnect switch at the fuse box before working on the equipment gt Install equipment in accordance with the local codes and manufacturer s recommendations gt Ground the equipment accordance with the manufacturer s recommendations MOVING PARTS can cause injury Keep away from moving parts such as fans Keep all doors panels covers and guards closed and securely in place qe Please read this Operation Manual carefully and thoroughly before attempting to operate this machine Keep this manual handy for quick reference Pay close attention to the safety instructions provided for your own protection SPECIFICATIONS GENERAL DESCRIPTION This compact dual voltage versatile TIG200 offers user a simple array of controls to accurately set the welder to perform under a wide variety of situations Its square wave inverter enables accurate welding of fine aluminum It allows user to easily switch from 220v to 110v with t
6. LOTOS TIG200 TIG Stick Welder TABLE OF CONTENTS SAFETY eere 4 SPECIFICATIONS VEM Lue nnt 9 General Description deus AA serres 9 What s IncludedMl B B B 0 9 9 Power Supply Rating idees cese uuo us ho ex eS PAESE EN RR FAR VERAS CUP ERA RS 1 What You Need to Operate This 6 12 Control Panel Intormatiolk esvvsss sisse ka kola en koke ke ges las 12 Machine Rear i disa al vr a w oi 13 Front Control Panel JAN MY 13 5 M 14 Before Installation O A occcocococccoconocccconanononanoso 14 Setup Instructions isis 15 Installation Diagllims 16 TROUBLESHOOTIN Gir rat pa nie 17 How to Use the Troubleshooting 17 Common Pro D AS tia poo on aaa ko aye aa kaa CREER ERR FERES Pan kai 17 Troubleshooting uses baba ki ate eo 18 OTHER ACCESSORITES AIEED 20 TIG200 TIG WELDER Save this Manual You will need the manual for safety warnings and precautions assembly instructions operating and maintenance procedures parts list and diagram Keep your invoice with this manual Write the invoice nu
7. Observe work area conditions Do not use machines or power tools in damp or wet locations Do not expose to rain Keep work area well lighted Do not use electrically powered tools in the presence of flammable gases or liquids Keep children away Children must be never be allowed jin the work area Do not let them handle machines tools or extension cords Store idol equipment When not in use tools must be stored in a dry location to inhibit rust Always lock up tools and keep them out of the reach of children Do not force tool It will do the job better and safer at the rate for which it was intended Do not use inappropriate attachments in an attempt to exceed the tool capacity Use the right tool for the job Do not attempt to force a small tool or attachment to do the work of a larger industrial tool There are certain applications for which this welder was designed Do not modify this welder and do not use this welder for any other purposes for which it was not intended Dress properly Do not wear loose clothing or jewelry as they can be caught in moving parts Protective flame retardant electrically non conductive clothing and non skid footwear are recommended when working Wear restrictive hair covering to contain long hair Use eye and ear protection Always wear ANSI approved arc shaded impact safety face shield welding helmet Always use a full face shield when welding Always wear ANSI approved eyewear under face shield and while
8. cian install and service this equipment HOW TO USE THE TROUBLESHOOTING GUIDE This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machin symptom Step 3 RECOMMENDED ACTION This column provides a course of action for the Possible Cause If you do not understand or are unable to perform the Recommended Course of Action safely contact your dealer COMMON PROBLEMS BLACK WELDING SPOT It might have been caused by an over oxidized welding spot Please make sure there is sufficient gas flow Make sur that the valve of Argon Tank has been opened with enough gas pressure If the pressure is lower than 0 5MPa then itis necessary to refill the cylinder ARC CANNOT BE STARTED OR DISCONTINUOUSARC 1 Make sure the Tungsten Electrode is the right type for your welding material 2 Tungsten tip should be sharpened for non aluminum welding and should be formed to a ball shape for aluminum welding gt OUTPUT CURRENT CANNOT REACH RATED VALUE Deviation of p
9. ding stops a This knob is to adjust the current descending time b Note If you are using the foot pedal control you should turn this knob counter clockwise to 0 3 Post flow time adjustment knob 3 To prevent the work piece from becoming oxidized let the argon flow for few sec nds after stopping the welding arc This knob is for adjusting the post flow time 4 Foot pedal switch 4 When the switch is on the OFF position the current is adjusted by using the Current adjustment knob 5 when it is on the PEDAL position the current is adjusted dynamically by foot pedal 5 Current adjustment knob 45 Note it only works when switch 4 pedal off is on the OFF position If switch 4 is set on the PEDAL mode the current would be fully controlled by using the foot pedal instead 6 Pulse duty knob 6 During AC aluminum Tig welding Note For an increased welding voltage of more than 150A use pulse duty below 30 or less than 1 For medium voltage from 100A to 150A use pulse 50 0 on knob For voltages less than 100A use pulse duty more than 50 1 to 5 7 Pre flow time adjustment knob 7 For better welding results argon gas should come earlier than the current This knob is to adjust the time between argon start and electric arc start 8 Stick welding Tig Welding Switch 8For Tig welding please switch to Tig Mode For Stick Welding please switch to mode 9 AC DC Switc
10. dry oil free argon Recommended gas nlet flow rate 65ps pressure Input power cable length 6 1 8m Mild Steel Material Stainless Steel Welding Capacity 4 6mm Aluminum Other Metals New Unit 1 Year Warranty Warranty 3 Refurbished Unit 60 Day Warranty Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating 60 duty cycle m Ma y 6 Minutes Welding 4 Minutes Resting T D gt 0 oe Overheating Minutes Reduce Duty Cycle 2 Production weld thickness are the results of Lotos laboratory testing Production speeds are approximately 80 of maximum For optimum weld quality welding speeds may vary based on different welding applications 11 WHAT YOU NEED TO OPERATE THIS MACHINE gt A properly grounded 110 120 50 60 hz Circuit or a 220 240 VAC 50 60 hz 30 50 amp Circuit Remember Machine must be grounded to work properly and safely A clean and well ventilated working place Heavy Duty Welding Gloves An Auto Darkening Welding Mask to provide eye protection A compressed gas cylinder containing pure Argon Stainless steel wire welding brushes for each material to welded A stone grinding wheel or a Tungsten Sharpener to sharpen the tungsten electrode Control Panel Information 1 Power switch 1 is located on the back of the machine 2 Downslope adjustment knob 2 In order to reduce the current gradually before the wel
11. ect welder performance A WARNING The warnings cautions and instructions discussed in this instruction manual cannot cover all possible conditions and situations that may occur It must be understood by the operator that common sense and caution are factors which cannot be built into this product but must be supplied by the operator ARC WELDER SAFETY WARNINGS AND PRECAUTIONS Warning This product when used for welding and similar applications produces chemicals to cause cancer and birth defects or other reproductive liarm 5 ELECTROMAGNETIC FIELDS may be dangerous gt EMF field that is generated during arc welding may interfere with various electrical and electronic devices such as cardiac pacemakers 23 sa gt Anyone using such devices should consult with their physician prior to S performing any electric welding operations dame gt Exposure to EMF fields while welding may have other health effects which are not known 4 ELECTRIC SHOCK can be fatal gt Read all precautions described in this manual to reduce the possibility of electric shock gt Improper use of an electric welder can lead to electric shock injury and death gt power switch should be in the OFF 0 position when installing the work cable and gun and while plugging in the power cord gt The machine must be securely grounded Ground the work metal to be welded to a good electrical earth ground Always attach
12. h 9 For Aluminum welding please switch to AC for non aluminum welding please switch to DC Overheat protection indicator OC light This is to protect the machine if it overheats If the light is on please stop the machine for 4 to 10 minutes before turning it on again 12 MACHINE REAR FRONT CONTROL PANEL AAA POWER QC Ba e 5 Poet ed x ac Zz oc TIG 200AC DC Inverter E 10 111 12 113414 Yo ca The unit is connected to the supply even if the Power Switch is on the OFF position and therefore there are electrically live parts inside the power source Carefully follow the instructions given in this manual REAR COMPONENTS 1 Power Switch 2 Down Slope Time Adjustment 3 Post flow Time Adjustment 4 Foot Pedal Switch 5 Voltage Adjustment 6 Clearance Effect Pulse Width Adjustment T Opening for Ground Cable 8 Stick Welding TIG Welding Switch 9 AC DC Switch 10 Tig Torch Gas Connector 11 Stick Welding Cable Connector 12 Tig Torch Electrical Connector 13 Foot Pedal Connector 14 Ground Cable Connector INSTALLATION PLEASE READ ENTIRE INSTALLATION SECTION BEFORE STARTING INSTALLATION BE SURE THAT ONLY QUALIFIED PERSONNEL SHOULD PERFORM THIS INSTALLATION BEFORE INSTALLATION WARNING ELECTRIC SHOCK can be fatal Turn t
13. he included plug adapter and produces AC DC 200 amps for TIG and STICK welding It is perfect for a professional or a weekend enthusiast who is looking to get industrial quality features in a durable and affordable welder Y Y Y Y 200 amp AC DC square wave inverter TIG Stick MMA Welder Automatic dual voltage dual frequency 110 220 volt 50 60Hz HF start hand torch control and precise foot pedal welding heat control Suitable for welding stainless steel mild steel aluminum and other metal materials WHAT S INCLUDED POWER SUPPLY STICK ELECTRODE HOLDER gt Power Supply TIG Torch gt Stick Electrode Holder gt Ground Clamp and Cable gt Pigtail Adapter Type 2 gt Argon Hose gt Argon Regulator gt Foot Pedal Hand Held Shield Wire Brush Etc TIG TORCH GROUND CABLE amp CLAMP PIGTAIL ADAPTER 2 ARGON HOSE ARGON REGULATOR eS HAND HELD SHIELD WIRE BRUSH ETC FOOT PEDAL POWER SUPPLY RATINGS TIG200 Output Power AC DC Input Voltages 110 220V 15 1 PH 50 60Hz Input Current 15A E110V 30A 220V Power Faetor 0 73 Power Efficiency 80 60 Q150A 110V Duty cycle 40 C 104 F 100 110A 110V General 60 190A 220V Specification 100 150A 220V 28 711mm L Dimensions with handle 13 330mm W 17 432mm H Weight w 8 11 2 7 m torch 58165 26 3kg Gas Supply Clean
14. he input power OFF and unplug the machine from the receptacle before working on this equipment Allow machine to sit for 5 minutes minimum to allow the power capacitors to discharge before working inside this equipment N Insulate yourself from the work and ground Always wear dry insulating gloves gt SELECT SUITABLE LOCATION The Inverter will operate in harsh environments Even so it is important that simple preventative measures are followed in order to assure long life and reliable operation The machine must be located where there is free circulation of clean air such that air movement in the back and out the front will not be restricted Dirt and dust that can be drawn into the machine should be kept to a minimum Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdown STACKING TIG200 cannot be stacked TILTING Place the machine directly on a secure level surface The machine may topple over if this procedure is not followed ENVIRONMENTAL AREA Keep the machine dry Do not place it on wet ground or in puddles Avoid rainwater Operating in rain is not allowed SETUP INSTRUCTIONS 44 WARNING ELECTRIC SHOCK can be fatal Have qualified electrician install and service this equipment Turn the input power OFF and unplug the machine from the receptacle before working on this equipment lt N Allow machine to sit for 5 minutes minimum to allow
15. heat by spreading the welding out around the area This can be done by using Stitch Welding techniques and by alternating sides taking your time allowing the pieces to cool between passes Make sure there is no gas leaking adjust the gas flow Torrin shift more negative knob 6 Increase the Tungsten diameter Increase the Post Flow For Tig welding please use 10046 pure argon Contamination in Weld Bead Clean the base metal to make sure to remove any oil coating or debris Remove tungsten from torch and re sharpen the tungsten Arc Cannot Start Make sure the machine is securely grounded Use the right type of Tungsten Make sure there is enough gas flow Make sure the settings is on DC for non aluminum and for aluminum Make sure setting for foot pedal switch is correct Arc Runs Around and Heat Cannot be Concentrated in a Specific Area Check Tungsten type and tip size Adjust the rate of gas flow Make sure Tungst n is not contaminated Make sure the Tungsten is held 1 8 to 1 4 inches off the wofk piece Make sure the machine is securely grounded Make sure the metal piece is not contaminated Shift Knob 6 towards negative OTHER ACCESSORIES The following accessories and consumables can be purchased www uwelding com or call 408 739 2329 to order ACCESSORIES a
16. in the workplace Wear a NIOSH approved dust mask or respirator when working around metal chemical dusts fumes and mists Do not over reach Keep proper footing and balance at all times Do not reach over or across running machines Maintain tools with care Keep tools sharp and clean for better and safer performance Follow instructions for lubricating and changing accessories Inspect tool cords periodically and if damaged have them repaired by an authorized technician The handl es must be kept clean dry and free from oil and grase at all times Disconnect power Unplug tool when not in use Remove adjusting keys and wrenches Check that keys and adjustment wrenches are removed from the welder and work area before plugging in Avoid starting unintentionally Be sure switch 15 the off position when not in use and before plugging in Do not carry any tool with your finger trigger whether it is plugged in or not Stay alert Watch what you are doing Use common sense Do not operate any tool when tired Check for damaged parts Before using any tool any part that appears damaged should be carefully checked to determine that it would operate properly and perform its intended function Check for alignment and binding of moving parts any broken parts or mounting fixtures and any other condition that may affect proper operation Any part that is damaged should be properly repaired or replaced by a qualified technician Do not
17. mber and date of purchase on the inside of the manual Keep the manual and invoice in a safe and dry place for future use Operation Manual Carefully read the operation manual prior to using installing and maintaining the electric welding machine for the purpose of preventing damages such as fire electric shock and etc from occurring Please keep the manual for future reference SAFETY WARNINGS AND PRECAUTIONS 4 PLEASE READ AND UNDERSTAND THE FOLLOWING SAFETY HIGHLIGHTS BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS ARC AND TIG WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING A WARNING WHEN USING THE WELDER ALL BASIC SAFETY PRECAUTIONS SHOULD ALWAYS BE FOLLOWED TO REDUCE THE RISK OF PERSONAL INJURY AND DAMAGE TO EQUIPMENT DRY WORKING PLACE DO NOT WELD IN PLACES WITH HIGH HUMIDITY FOR THE POWER EXTENSION CORD PLEASE MAKE SURE THE WIRE GAUGE IS MORE THAN 11 GAUGE AT 220VAC AND 13 GAUGE AT 110VAC gt USING A NON METALLIC CHAIR PLACED ON A RUBBER MAT WHILE WELDING IS RECOMMENDED USE 20 AMPS CIRCUIT BREAKER FOR 110VAC AND 30 AMPS CIRCUIT BREAKER FOR 220VAC DO NOT USE TRIPLE PHASE INSTEAD USE SINGLE PHASE POWER READ ALL INSTRUCTIONS BEFORE USING THIS WELDER Keep work area clean Cluttered areas invite injuries
18. ng sparks from starting a fire Remember that welding sparks and hot materials from cutting can easily go through small cracks and openings to adjacent areas Avoid cutting near hydraulic lines Have a fire extinguisher readily available Do not operate the electric arc welder in areas where flammable or explosive vapors are present gt Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations gt not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned gt Always keep a fire extinguisher nearby while welding V Use welding blankets to protect painted surfaces dashboards engines etc gt Please make sure there areno combustible items around your welding are 7 CYLINDER may explode damaged gt Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition gt Always keep cylinders in an upright position securely chained to undercarriage or fixed support gt Cylinders should be located Away from areas where they may be struck or subjected to physical damage
19. ower voltage from the rated value will lead to unconformity of output current value with the set value When power voltage is lower than the rated value maximum output current of the welder may also be lower than the rated value gt TUNGSTEN TIP GETS BURNT TOO FAST Reduce the heat of the tungsten tip by twisting knob 6 towards TROUBLESHOOTING WELDING For aluminum Tig welding PROBLEMS RECOMMENDED ACTION Increase the welding heat use 220VAC and use higher Weak Penetration output voltage Twist knob 6 towards to transfer more heat to the work piece Weak Penetration For aluminum Tig welding Increase welding heat use 220VAC and use higher output voltage Tungsten Contaminated Keep Tungsten 1 8 to 1 4 inches from the base metal Re sharpen the Tungsten if the tip is worn Poor Welding Appearance The angle between the filler metal and the torch must be less than 90 degrees Crater at the End of the Weld Bead torch on base metal while the post flow shielding gas flows to protect the metal and tungsten Reduce current with pedal and add more filler at the end of the weld Reduce the heat more times between passes Weld Bead is Cracking T Preheat the base metal and reduce the filler wire size Clamp the work piece tightly Add more tack weldsuntil rigidity and stiffness is developed Material is Warping To reduce
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21. the power capacitors to discharge before working inside this equipment Do not touch electrically hot parts Machine must be plugged into a receptacle that is grounded according to the National Electrical Code and local codes Do not remove or defeat the purpose of the power cord ground pin 10 The machine will automatically detect the power of 110VAC to 220VAC For 110VAC please attach the 220VAC to the 110VAC adapter cord Connect your Argon Tank to Argon Regulator and connect your Argon Regulator to the gas inlet on the back of the machine rear panel Set the gas flow from 12 to 21 scfh For Tig welding set Switch 8 to TIG mode connect your Tig torch to Connectors 10 and 12 If you are using the foot pedal then connect your pedal to Connector 13 and set Switch 4 to Pedal mode If you are not using the foot pedal then set Switch 4 to OFF mode Connect your Ground Cable to Connector 14 and attach your Ground Clamp to your work piece For non aluminum welding please set Knob 9 to the mode For aluminum welding set Knob 9 to the mode For Stick MMA welding you do NOT need gas supply Just hook your Stick Electrode Holder cable to Connect r 11 and hook the Ground Cable to connector 14 and attach your Ground Clamp to the work piece Set Switch 8 to MMA mode Set the machine to mode for aluminum stick welding and DC for non aluminum stick welding Note For output amperage
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