USER MANUAL
Contents
1. and hope for your precious advice We will dedicate to produce the best products and offer the best service A WARNING The machine is mainly used for industrial purpose It will cause radio interference indoor operators shall take fully preventative measures TECHNICAL PARAMETERS TABLE Parameters Rated input current A No load voltage V Rated output voltage V 0 10 PANEL FUNCTION INSTRUCTION Front panel layout 6 Basic curentadjusmnent 17 Torch swich socket Remote contol swioh 19 Negative outptterminal Pulse requenay wien 20 Puse wid adusiment pas el 11 INSTALLATION INSTRUCTION Equipment is equipped with power voltage compensation equipment When power voltage fluctuates between 15 of rated voltage it still can work normally When use long cable in order to prevent voltage form going down bigger section cable is suggested If cable is too long it may affect the performance of the power system So cables of configured length are suggested 12 Make sure intake of the machine is not blocked or covered lest cooling system could not work Make good connection of shielded gas source Gas supply passage includes cylinder argon decompress flow meter and pipe Connecting part of pipe should use hoop or other things to fasten lest argon leaks out and air gets in Put the fasten plug of the cable to fasten socket of terminal at the front pane2. high 2 Grind end of the tungsten electrode to taper JI tungsten electrode is not grinded that will be difficult to strike arc and cause unstable arc C Output current not to rated value When power voltage departs from the rated value it will make the output current not matched with rated value When voltage is lower than rated value the max output may lower than rated value D Current is not stabilizing when machine is being operated It has something with factors as following 1 Electric wire net voltage has been changed 2 There is harmful interference from electric wire net or other equipment E stick is burnt out Pulse duty is too high which lead to over heat of stick F When welding aluminum can not break oxidized film 1 Wrong welding value 2 Pulse duty too low 3 Twice inverter MOSFET broken 18 TROUBLESHOOTING AND FAULT FINDING Fault symptom and solutions Power indicator is not lit fan does not work and no welding output Power indicator is lit fan does not work or revolve several circles and stopped no welding output Fan is working abnormal indicator is not lit sound of HF arc striking cannot be heard wiping arc welding can not strike arc Abnormal indicator is not lit sound of HF arc striking can be heard no welding output Power switch is damaged Make sure the electric wire net connecting to input cable is working alright Make sure if input cable h
3. replace it 2 If abnormal indicator is off a Maybe transformer on middle board is damage measure primary inductance volume and Q value of main transformer by inductance bridge L 0 9 1 6mH Q gt 35 If value is too low please replace it b Maybe secondary rectifier tube of transformer is damaged find out faults and replace rectifier tube with same model Maybe feedback circuit is open When welding aluminum 1 Wrong welding value can not break oxidized 2 Pulse duty too low film Twice inverter MOSFET broken Stick is burnt out Pulse duty is too high reduce it
4. trunks boilers cabins etc Please accept the supervisor s inspection when operating in narrow space Air the room and wear breathe preventive facilities Never operate in degrease washing or spray space Using breathe preventive facilities when weld shielded steel for it will cause poisonous dust and gas A WARNING The arc spark residue and noise are harmful to health please wear protective appliance Eye protection against arc is recommended when welding or supervise welding Please wear preventive spectacles Welder s gloves welders goggles long sleeve clothes leather apron and other standard protection equipments must be worn for welding operation A screen to protect other people against the arc must be set in the welding place A WARNING Please follow the notes below to avoid gas cylinder toppling over or broken Use the gas cylinder correctly Use the equipped or recommended gaseous regulator Read the manual of gaseous regulator carefully before using it and pay attention to the safety notes Fix the gas cylinder with appropriative holder and other relative parts Never put the cylinder under high temperature or sunshine environment Keep your face away from the gas cylinder exit when opening it Put on the gas shield when it is not used Never put the torch on the gas cylinder The electrode can not meet the gas cylinder A WARNING Any touch of the switch part will cause injury please note the followin
5. Aiki l TIG 200AC DC II WELDING MACHINE USER MANUAL Ole _ _ BAS aN ON i TN a eas i Sa Preface This manual includes hardware description and operation introduction of the equipment I TIG 200AC DC Il For your and other people s safety please read the manual carefully Pay attention Pay attention to the words after the signs below a Ca eee The words after this sign means there is great potential danger LO ANGER which may cause major accident damage or even death if it is not followed A The words after this sign means there is some potential danger WARNING which may cause hurt or property lose if it is not followed f The words after this sign means there is potential risk which may ATTENTION cause equipment fault or break if it is not followed Version Version YF 01A AO Released at 14th 11 2012 The contents of this manual are updated irregularity for updating of product The manual is only used as operation guide except for other promises No warranties of any kind either express or implied are made in relation to the description information or suggestion or any other contents of the manual The images shown here are indicative only If there is inconsistency between the image and the actual product the actual product shall govern CONTENTS SAFRE E WARNING EE 4 TEGA NICACPARAMETERS Ee 10 PANEL PUNGTIOINSINS HAW CMON ME 11 INS TAELATIONIINGERUG TION WE 12 MAINTENAN
6. CE EE 16 NOTE Oe oad oY oe El LEE 16 NOTES OR PREVENTIVE MEASURE EE 17 QUESTIONS TO BE RUN INTO DURING WELDING 2 0 ccc cc cece cece cece eee eee eeeeeeeeeeeeeeeeeeeeeeaaaaaaaaaneeeeeees 18 TROUBLESHOOTING AND FAULT FINDING GE 19 SAFETY WARNING The safety notes listed in this manual is to ensure correct use of the machine and to keep you and other people from being hurt The design and manufacture of welding machine considers safety Please refer to the safety warning listed in the manual to avoid accidents Different damage would be caused by wrong operation of the equipment as follows Please read the user manual carefully to reduce such damage Any contact of electric parts may cause fatal electric shock or burnt Gas and fumes are harmful to health Operation in narrow space may cause choke Spark and hot workpiece after welding may cause fire Bad connected cable may cause fire Incompletion connection of workpiece side circuit may cause fire Never weld on the case of tinder stuff or it may cause explode Never weld airtight containers such as slot pipe etc or it may break Arc ray may cause eye inflammation or skin burnt Spark and residue will burn your eyes and skin Toppling over of the gas cylinder will cause body hurt Wrong use of the gas cylinder will lead to high
7. achine will stop working automatically Because that will be damaged to welding machine user must pay attention as following 1 The working area is adequately ventilated The welding machine is powerful machine when it is being operated it generated by high currents and natural wind will not satisfy machine cool demands So there is a fan in inter machine to cool down machine Make sure the intake is not in block or covered it is 0 3 meter from welding machine to objects of environment User should make sure the working area is adequately ventilated It is important for the performance and the longevity of the machine Do not over load The operator should remember to watch the max duty current Response to the selected duty cycle Keep welding current do not exceed max duty cycle current Over load current will damage and burn up machine No over voltage Power voltage can be found in diagram of main technical data Automatic compensation circuit of voltage will assure that welding current keep in allowable rangement If power voltage is exceeding allowable rangement limited it is damaged to components of machine The operator should understand the situation and take preventive measures There is a grounding screw behind welding machine there is grounding marker on it Mantle must be grounded reliable with cable which section is over 6 square millimeter in order to prevent from Static electricity and leaking lf welding time i
8. as broken circuit Input cable is possibly connected to 380V power which causes over voltage protection circuit is starting Connect input cable to 220V power then restart the machine Erratic 220V power supply input cable is too thin and long or input cable is connected to electricity network would start overload voltage protection circuit Increase section of input cable or tighten input contact Turn off machine for 2 3 min and restart it Cable that connects switch and power board is loosed tighten it again Turn on and off power switch continuously would start overload voltage protection circuit Turn off machine for 2 3 min and restart it 24V relay of main return circuit on power board is not closed or damaged check 24V power and relay Replace it with same model series if it s damaged Measure voltage of positive and negative electrode from power board to VH 07 insert of MOS board by multimeter which should reads DC 308V a If circuit is broken and silicon bridge is poor contact b If some of four high electrolytic about 470UF 450V of power panel capacitor is leaking There is a green indicator for auxiliary power on MOS board if its not lit auxiliary power is out of work check fault spot and contact with dealer Check if all kinds of connect and insert cable is poor contact Check if there is some problem in control circuit contact with dealer Check if control cable of torch is broken Cable of torch i
9. g Never use the machine when the enclosure is off Install operate check and maintain the machine by professional person Keep your fingers hair clothes etc away from the switch parts such as the fan A WARNING The wire end may deal damage please note the following Never look into the electric conduction hole when checking the wire feeding is normal or not or the shooting wire may stab your eyes and face Keep your eyes face or other naked parts away from the end of torch when feeding the wire manually or pressing the switch A ATTENTION For better work efficiency and power source maintenance please note the following Precautions against toppling over Never use the welding equipment for pipe thawing Lift the power source from side when use the up down forklift truck to avoid toppling over When using the crane for lift tie the rope to the ears with an angle no more than 15 to the vertical direction When lifting the welding machine which equipped with gas cylinder and wire feeder download them from the power source and ensure the horizontal of the machine Do fix the gas cylinder with belt or chain when moving it to avoid body hurt Ensure fastness and insulation when lifting the wire feeder through the swing ring for welding A ATTENTION Electromagnetic interference needing attention It may need extra preventive measures when the equipment is used in particular location Before the installation please esti
10. hnology The development of inverter gas shielded welding equipment profits from the development of the inverter power supply theory and components Inverter gas shielded welding power source utilizes high power component MOSFET to transfer 50 60Hz frequency up to 100KHz then reduce the voltage and commutate and output high power voltage via PWM technology Because of the great reduce of the main transformer s weight and volume the efficiency increases by 30 The appearance of inverter welding equipment is considered to be a revolution for welding industry AC DC series machine are the AC DC and MMA three way machines which are developed by our company newly Its biggest characteristics is that DC function can be used to weld stainless steel alloyed steel carbon steel copper and other color metals and AC function can be used to weld aluminum and aluminum alloy materials such as welding of scooters bicycles AC DC series machine adopts our company s exclusive HF inverter technology Compared with traditional machine it is compact in volume light in weight effective in transfer power saving com pared with imported machine it is low in price strong in power net adaptability What s more it adopts twice inverter technology has characteristics of pure square wave output good arc force wide cleaning range and continuous arc with small current which guarantee excellent welding result Thanks for purchasing our company product
11. l fasten it clockwise and the earth clamp at the other terminal clamps the work piece Correctly connect the arc torch or holder according to the sketch When use MMA welding Make sure the cable holder and fastening plug have been connected with the ground Put the fastening plug into the DU fastening socket at the terminal and fasten it clockwise When use TIG welding Put the gas electricity plug of the welding gun to the joint at the front panel and fasten clockwise Put the air switch on the gun to the relevant joint at the front panel and fasten the screw When use pedal control connect its two core air plug and three core air plug with the relevant air socket at the panel According to input voltage grade connect power cable with power supply box of relevant voltage grade Make sure there is no mistake and the voltage of power supply does not exceed permission range After the above job installation is finished and welding is available Installation diagram TIG Power supply 1Phase 220V 0a Ge Connected to the ground TIG torch Installation diagram MMA Power supply 1Phase 220V e Ca Connected to the Cu AAA ground Earth clamp Ku ZK Z Work piece Electrode holder a 13 OPERATION INSTRUCTION 9 DC TIG welding i 2 Turn on power switch fan begins to wheel Open argon switch and adjust gas flow to rated standard refer to flow tab
12. le Put the welding switch to upper position is TIG WELDING When put the switch to DC position it is DC arc welding which can be for stainless steel iron copper and other metals Set handwork pedal switch according to needs Put the switch to OFF position current is adjusted by panel knob Put the switch to ON position current is adjusted by pedal According to requirement to choose Pulse choosing switch Down position is no pulse Upper position is low frequency 0 5 2Hz and adjust the Pulse adjustment knob to suitable pulse frequency According to requirement to adjust the duty cycle to suitable position When no pulse value is 1 According to requirement to adjust arc initiation current and attenuation time According to thickness set suitable welding current and basic value current When pulse switch is down position no basic value current 10 Press torch switch and electromagnetic valve starts you will hear the sound of electricity releasing HF sparkle and at the same time argon gets out the torch 11 Keep 2 4mm space between tungsten pole and work piece press torch control switch between electrode and work piece HF electricity is released After arc initiation HF sparkle disappears soon and can start to work 12 When finish welding adjust the post flow knob to suitable place in order to protect welding surface 13 When TIG welding for long welding and spot
13. mate the potential electromagnetism problems of the environment as follows a Upper and lower parts of the welding equipments and other nearby power cable control cable signal cable and phone cable b Wireless electric as well as TV radiation and reception equipment c Computer and other control equipments d Safety recognition equipment etc Such as supervise of industrial equipments e Health of people around Such as personnel using the heart pacemaker or audiphone f Equipments for adjustment and measurement g Anti disturb capability of other used equipments Users should ensure these equipments and the environment are compatible which may need extra preventive measures h Practical state of the welding and other activities Users should observe the following dos and don ts to decrease radiation interference a Connect the welding equipments to the power supply lines b Maintain the welding equipments regularly c The cable should be short enough to be close to each other and the ground d Ensure the safety of all the welding metal parts and other parts nearby e The workpiece should be well earth f Shield or protect the other cable and equipments to decrease the effects of disturbances The welding equipments can be complete shielded in some special conditions Users are responsible for interference due to welding MACHINE DESCRIPTION The welding machine is a rectifier adopting the most advanced inverter tec
14. pressure gas eruption and cause human hurt Never let fingers hair clothes or etc near the moving parts such as the fan The wire shoot out of the torch may stab eyes face and other naked parts Never stand in front of the swang equipment or under it or it may fail and cause injury A DANGER Please follow the rules below to avoid heavy accidents Never use the equipment to do other things but welding Follow related regulations for the construction of the input driven power source choice of place usage of high pressure gas storage configuration safe keeping of workpiece after welding and disposal of waste etc Nonessentials do not enter the welding area People using heart pacemaker is not allowed to get close to the welding machine or area without doctor s permission The magnetism created by energizing the welding machine can have a bad effect to the pacemaker Install operation check and maintain the equipment by profession personnel Understanding the contents of the user manual for safety A DANGER Please follow the rules below to avoid electric shock Keep away from any electric parts Earth the machine and workpiece by professional personnel Cut off the power before installation or checking and restart 5 minutes later The capacitance is chargeable device Please ensure it has no voltage before start again even if the power source is cut off Do not use wire
15. s broken Grounding cable is broken or not connected to work piece There is relaxation between output terminal of positive electrode gas electricity system output terminal and inner machine 19 Primary cable of arc striking transformer is poor contact with power Abnormal indicator is not board tighten it again lit sound of HF arc 2 Arc striking tip is oxidized or distance is too far get rid of film oxide of striking can not be heard burner or adjust the distance between burners to be 1mm wiping welding can strike Switch sticking argon arc welding is damaged replace it arc Some of HF arc striking circuit components is damage find out and replace it Overload current protection may start please turn off machine first then restart it after abnormal indicator is off Overheat protection may start it will become normal in 2 3 min Inverter circuit may go wrong please disconnect the power supply plu 2 the main transformer on MOS board close to insert of fan VH 07 t restart the machine 1 If abnormal indicator is still on turn off machine and disconnect power supply plug of HF arc striking power source close to insert of fan VH 07 then restart machine SE a a If abnormal indicator is still on some fieldistors on MOS board Abnormal indicator is lit are damaged find out and replace them with same model PONS CSL b If abnormal indicator is off up slope transformer of HF arc striking circuit is damaged
16. s exceeded duty cycle limited welding machine will stop working for protection Because machine is overheated temperature control switch is on ON position and the indicator light is red In this situation you don t have to pull the plug in order to let the fan cool the machine When the indicator light is off and the temperature goes down to the standard range it can weld again 17 QUESTIONS TO BE RUN INTO DURING WELDING Fittings welding materials environment factor supply powers maybe have something to do with welding User must try to improve welding environment A Black welding spot Welding spot is not prevented from oxidizing User may check as following 1 Make sure the valve of argon cylinder is opened and its pressure is enough Argon cylinder must be filled up to enough pressure again if pressure of cylinder is below 0 5Mpa 2 Check if the flow meter is opened and has enough flow User can choose different flow according to welding current in order to save gas But too small flow maybe cause black welding spot because preventive gas is too short to cover welding spot We suggest that flow of argon must be kept min L min 3 Check if torch is in block 4 lf gas passage is not air tight or gas is not pure can lower welding quality 5 If air is flowing powerfully in welding environment that can lower welding quality B Arc striking is difficult and easy to pause 1 Make sure quality of tungsten electrode is
17. ter into inner machine if them enter into machine please dry inner machine then check insulation of machine If welding machine will not be operated long time it must be put into packing box and stored in dry environment NOTES BEFORE CHECKING WARNING Blind experiment and careless repair may lead to more problems and make formal check and repair more difficult When the machine is electrified the bared parts contain life threatening voltage Any direct and indirect touch will cause electric shock and severe electric shock will lead to death Gi NOTICE In the period of guarantee maintenance if user makes wrong check and repair for malfunction of welding cutting machines without our permission the free maintenance guarantee offered will be invalid 16 1 NOTES OR PREVENTIVE MEASURES Environment 1 2 3 4 5 The machine can perform in environment where conditions are dry with a dampness level of max 90 Ambient temperature is between 10 to 40 degrees centigrade Avoid welding in sunshine or drippings Do not use the machine in environment where condition is polluted with conductive dust on the air or corrosiveness gas on the air Avoid gas welding in the environment of strong airflow Safety norms The welding machine has installed protection circuit of over voltage and current and heat When voltage and output current and temperature of machine are exceeding the rated standard welding m
18. ty above 50 2 When at AC TIG welding the smallest current is not easy for arc initiation please set the current to 20A 5 MMA welding 1 Put the welding switch to Down position at this time Pulse choosing switch 2T 4T switch AC DC switch are out of work only welding current knob can use 2 Set the welding current according to the work piece thickness Attached Relative value for electrode and current Electrode mm Current A 70 100 100 140 Warning kd It is forbidden to pull out or put in the cable or connector during the process of welding which will threat life safety and damage the machine 15 MAINTENANCE WARNING Before maintenance and checking power must be turned off and before opening the housing make sure the power plug is pulled off Remove dust by dry and clean compressed air regularly if welding machine is operated in environment where is polluted with smokes and pollution air the machine need remove dust every month Pressure of compressed air must be inside the reasonable arrangement in order to prevent damaging to small components of inner machine Check internal circuit of welding machine regularly and make sure the cable circuit is connected correctly and connectors are connected tightly especially insert connector and components If scale and loose are found please give a good polish to them then connect them again tightly Avoid water and steam en
19. welding you can choose the 21 4T switch when 21 arc initiation and down slope adjusting function can not work only welding current works 14 When 4T press the torch switch is arc initiation current releasing the switch is welding current pressing again 14 is down slope time adjusting releasing again is off working 2 AC TIG welding 1 When put the switch to AC position it is AC arc welding which can be for aluminum materials 2 Pulse duty knob During AC arc welding current transfers between up side and down side continuously When current goes from tungsten stick to work piece it is positive current time At this moment stick heats slightly and quantity of heat is concentrated which is good for welding When current goes from work piece to stick it is down side current At this moment it can clean oxide at the surface of work force which improve welding result But the stick may be burnt out because of over heat the knob is for adjusting time ratio of positive and reversed current When at O position the ratio is 50 to 50 at gt position ratio is 80 and at 5 position ratio is 20 Turn towards clockwise up side current gets short down side current gets long When turn counter clockwise it is opposite 3 Operating as the10 12 step above Notice 1 Big current should use small pulse duty Above 200A use pulse duty below 30 At small current use big pulse duty below 100A use pulse du
20. with inadequate section surface or damage insulation sleeve or even exposed conductor Do ensure well isolation of wire connection Never use the device when the enclosure is removed Never use broken or wet insulation gloves Use firenet when work at high position Check and maintain regularly don t use it until the broken parts are fixed well Turn off the power when not in used Follow the national or local related standard and regulations when using the AC welding machine at narrow or high position A DANGER Please follow the below notes to avoid fire and explode etc No combustible in welding area Keep off combustible when welding Keep hot workpiece after welding away from flammable gas Do move away the combustible around when weld the dooryard ground and wall The wire connection of base metal should be as close to the welding place as possible Never weld those facilities with gas pipe or airtight slot Put fire extinguisher around the welding area to prevent fire Z wanns The gas and fumes are harmful to health please wear protective device according to regulations Wear exhaust equipment and breathe preventive facilities to prevent gas poisoning or choke Use suggested part exhaust equipment and breathe preventive facilities to prevent hurt or poisoning by gas and other powder please To prevent oxygen deficiency air out the gas filled room which is full of CO2 and argon on the bottom When operating on
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