Tig200 DC Digital Tig Welder Operating Instructions - R
Contents
1. Before any Warranty work is undertaken the customer must provide proof of purchase and serial number of the equipment in order to validate the Warranty The parts replaced under the terms of the Warranty remain the property of R Tech Welding 29 7 0 Recommended Safety Guidelines Some safety precautions R Tech Welding recommends are as follows Repair or replace defective cables immediately Keep fire extinguishing equipment at a handy Never watch the arc except through location in the shop lenses of the correct shade Keep primary terminals and live parts In confined spaces adequate ventilation effectively covered and constant observation are essential Never strike an electrode on any gas cylinder Leads and cables should be kept clear Never use oxygen for venting containers of passageways Diagram and safety explanation Diagram and safety explanation Electrical safety alert Welding electrode causing electric shock Fumes and gases coming from welding process Welding arc rays Read instruction manual Become trained 30 Wear dry insulated gloves Insulate yourself from work and ground Disconnect input power before working on equipment Keep head out of fumes Use forced ventilation or local exhaust to remove fumes Use welding helmet with correct shade of filter Notes 31 Notes 332. ne PFC SERIES www r techwelding co uk Email sales r techwelding co uk Tel 01452 733933 Fax 01452 733939 Tig200 DC Digital Tig Welder Operating Instructions Ce Important Notice This document has been prepared by R Tech Welding Ltd as general information and does not contain and is not to be taken as containing any specific recommendation The document has been prepared in good faith and is professional opinion only Information in this document has been derived from third parties and though R Tech Welding Ltd believes it to be reliable as at the time of printing R Tech Welding makes no representation or warranty as to the accuracy reliability or completeness of information in this document and does not assume any responsibility for updating any information or correcting any error or omission which may become apparent after the document has been issued Neither R Tech Welding nor any of its agents has independently verified the accuracy of the information contained in this document The information in this document is commercial in confidence and is not to be reproduced The recipient acknowledges and agrees that it must make its own independent investigation and should consider seeking appropriate professional recommendation in reviewing and evaluating the information This document does not take into account the particular circumstances of the recipient and the recipient should not rely on this document in making a
3. 1ph AC 230V 15 50 60 16 Stick 10 150 TIG 5 200 62 35 0 95 1P23 10 430 x 160 x 310 3 Years 6 0 Warranty Information 6 1 Terms of Warranty R Tech Welding provides a Warranty for the TIG200DC PFC sold by it against defects in manufacture and materials Valid for 12 months from date of purchase Only R Tech Welding must carry out Warranty repairs Freight packaging and insurance costs are to be paid for by the claimant No additional express Warranty is given unless in writing signed by an authorised manager of R Tech Welding This Warranty is in addition to any other legal rights you may have Welding leads which include the electrode holder and the work clamp are not covered in these Warranty terms 6 2 Limitations on Warranty The following conditions are not covered non compliance with operating and maintenance instructions such as connection to incorrect faulty voltage supply including voltage surges outside equipment specs and incorrect overloading natural wear and tear and accidental damage transport or storage damage The Warranty is void if changes are made to the product without the approval of the manufacturer repairs are carried out using non approved spare parts a non authorised agent carries out repairs 6 3 Warranty Repairs R Tech or their Authorised Service Agent must be informed of the Warranty defects and the product returned within the Warranty Period
4. Connection MMA Operation TIG Welding Operation Technical Specifications Warranty Terms of Warranty Limitations on Warranty Warranty Repairs o oo ogo 12 13 17 21 22 23 24 25 25 26 28 28 28 28 29 32 33 33 33 1 0 Recommended Safety Precautions 1 1 Health Hazard Information The actual process of welding is one that can cause a variety of hazards All appropriate safety equipment should be worn at all times i e headwear respiratory hand and body protection Electrical equipment should be used in accordance with the manufacturers recommendations Eyes The process produces ultra violet rays that can injure and cause permanent damage Fumes can cause irritation Skin Arc rays are dangerous to uncovered skin Inhalation Welding fumes and gases are dangerous to the health of the operator and to those in close proximity The aggravation of pre existing respiratory or allergic conditions may occur in some workers Excessive exposure may cause conditions such as nausea dizziness dryness and irritation of eyes nose and throat 1 2 Personal Protection Respiratory Confined space welding should be carried out with the aid of a fume respirator or air supplied respirator as per AS NZS 1715 and AS NZS 1716 Standards You must always have enough ventilation in confined spaces Be alert to this at all times Keep your head out of the fumes rising from the arc Fumes from the weldi
5. areas away from pedestrian or vehicle thoroughfare 3 Guard cylinders against being knocked violently or being allowed to fall 4Wear safety shoes glasses and gloves when handling and connecting cylinders 5 Always move cylinders securely with an appropriate trolley Take care not to turn the valve on when moving a cylinder 6 Keep in a cool well ventilated area away from heat sources sources of ignition and combustible materials especially flammable gases 7 Keep full and empty cylinders separate 8 Keep ammonia based leak detection solutions oil and grease away from cylinders and valves 9 Never use force when opening or closing valves 10 Don t repaint or disguise markings and damage If damaged return cylinders to your local supplier Cylinder Valve Safety When working with cylinders or operating cylinder valves ensure that you wear appropriate protective clothing gloves boots and safety glasses When moving cylinders ensure that the valve is not accidentally opened in transit Before operating a cylinder valve Ensure that the system you are connecting the cylinder into is suitable for the gas and pressure involved Ensure that any accessories such as hoses attached to the cylinder valve or the system being connected to are securely connected A hose for example can potentially flail around dangerously if it is accidentally pressurised when not restrained at both ends Stand to the side of the cyl
6. main current 11 is Indicator lowered to the final current 2 For tig welding Ending Current 7 Indicator For tig welding Argon In Stopping l 8 Indicator For tig welding 9 Foot Switch Indicator Lights up if foot switch connected 0 Hot Start For MMA welding 1 1 1 Arc Force For MMA welding 12 HF Contact Indicator ON OFF 16 Pulse On Indicator Setup Indicator Lights up if under setting status Lights up if the power source overheats e g because Over heat Indicator the duty cycle has been exceeded For more information on this see the Troubleshooting section Savethe data step Mode Indicator step Mode Indicator MMA Mode Indicator Mode Button Used to select 2 step mode or 4 step mode or MMA Welding Parameter Adjusting Knob N O Used to adjust welding parameter Pulse Selection Button N ON OFF used to select the process depending on the mode that has been chosen HF Contact Button ON OFF w Process Button Display OO w Wl 09 NINININ N N 0 N A NIOS ey N Current Presetting MER Actual Output Current 39 Lacsinetconnecton standardised connection socket for system add ons e g remote contro TIG torch etc 40 Output Nozzle 41 output output _ power switch switching the power source on and off power input shielding gas 45 connection a SS 3939 SS ey SS 3939 SS 1 U Ee a CE ww CE a U I eS E Ss en SS 3
7. of Materials 3 1 Application Summary Material C Mn steel Alloyed steel Copper and Cu alloys Nickel and Ni alloys Titanium andTi alloys Aluminum and Al alloys Magesium and Mg alloys Type of current Direct current Direct current Direct current Direct current Direct current Alternating current Direct current with Helium Alternating current Polarity DC negative DC negative DC negative DC negative DC negative DC negative 17 3 2 C Mn Steel TIG welding may be used for welding carbon steel but because deposition rates are low it is usually only used for welding sheet and thin sections for high quality applications small components and root passes of multipass butt joints in plate and pipe Standard DC TIG equipment is normally suitable and DCEN polarity is usually chosen to provide good workpiece heating Only inert or reducing gases should be used for TIG welding and pure argon is normally recommended as the shielding gas for steel Filler rods are usually selected to match the chemical composition and the mechanical properties of the parent plate The weldability of the steel may impose restrictions on the choice of filler rod Steels with carbon contents above about 0 3 are hardenable and fast cooling will produce a hard HAZ and this is liable to result in hydrogen cracking This form of cracking can be prevented by use of preheat and suitable weldin
8. 1 Used with high frequency AC good cleaning action higher welding speed increased penetration Reduces penetration during surfacing minimising dilution Stable arc Low fume Stable and easy to control arc Stable and easy to control arc Can be used for copper nickel to steel Increased heat input Stable arc Good penetration Stable arc Lower penetration Stable arc Manual operation High speed automated welding Stable arc Good penetration High speed automatic welding Deeper penetration Small concentrated HAZ Used with continuous high frequency AC Good arc stability Good cleaning action Good penetration Good arc stability Deeper penetration Stable arc High speed welding 2 5 Consumable Selection a Welding wire The following table includes the recommended welding consumable for the most commonly welded materials Base Material Consumable C Mn and low Carbon steels Mild steel TIG wire Low Alloy steels 1 25Cr 0 5Mo CrMo1 2 5Cr 1Mo CrMo2 Stainless Steel 304 304L 308L 316 316L 316L 309 309 C Mn 309L 321 Stabilised grades 347L Aluminium 1000 series 1100 5000 series 4043 4047 5356 6000 series 4043 4047 5356 Filler rod diameter mm Thickness of metal mm 2 0 5 2 3 2 5 4 5 8 4or5 8 12 5 or6 12 or more 2 6 Welding Techniques Welding techniques 2 The suggested electrode and welding rod Vertical 7 angles for welding a bead on plate The same angles are used when m
9. 800 2 4 0 800 2 4 1 100 3 2 1 100 3 2 1 500 12 Constant included angle degrees Current range A 12 2 15 20 5 30 25 8 50 30 10 70 35 12 90 45 15 150 60 20 200 90 25 250 2 9 Joint Preparation All measurements in mm All measurements in mm gt 0 5 2 50 Bal 2 3 5 b 4 a I lt gt oO _ gt oO u 1 5 3 PE Roll direction Troubleshooting guide Problem Excessive electrode consumption Erratic Arc Inclusion of tungsten or oxides in weld Porosity in Weld Deposit Cause I Inadequate gas flow 2 Improper size electrode for current required Operating of reverse polarity Electrode contamination Excessive heating inside torch Electrode oxidising during cooling N BD GH KR bw Shield gas incorrect Incorrect voltage arc too long Current too low for electrode size Electrode contaminated Joint too narrow OM KR LU N gt Contaminated shield gas Dark stains on the electrode or weld bead indicate contamination 6 Base metal is oxidised dirty or oily I Poor scratch starting technique 2 Excessive current for tungsten size used 3 Accidental contact of electrode with puddle 4 Accidental contact of electrode to filler rod 5 Using excessive electrode extension 6 Inadequate shielding or excessive drafts 7 Wrong gas 8 Heavy surface oxides not
10. 93939 GG Emm u 3939 SS EEE Ls Se ee Se 4 5 1 For Direct current DC TIG Welding Select the correct size and type of non consumable tungsten and shielding gas for the application See selection chart at the end of the application section For DC most commonly used polarity connect the TIG torch to the negative Dinse plug connector and the work return lead to the positive dinse plug connector ce GTAW with DCEN produces deep penetration because it concentrates the heat in the joint area No cleaning action occurs with this The heat generated by the arc using this polarity occurs in the work thus a smaller electrode can be used as well as a smaller gas cup and gas flow The more concentrated arc allows for faster travel speeds For DC applications connect the TIG torch to the positive Dinse plug connector and the work return lead to the negative dinse plug connector In this mode most of the heat is generated within the non consumable tungsten and the heat input into the plate is reduced resulting in lower penetration depths Larger tungstens are normally selected for this application Ensure that the process selector switch 3 is switched to TIG Select 4T 2T on the trigger selector switch 5 26 Depress the contactor switch on the torch and hold this down for the entire weld Selecting the 2T function will disable the Start current 9 and the process will immediately rise to the selecte
11. aking a butt weld The torch is held 60 75 from the metal surface This is the same as holding the torch 15 30 from the vertical Welding Rod 60 75 Shield gas Take special note that the rod is in the shielding gas during the welding process amp Dir ection of travel III 1 1 1 1 1 1 1 1 1 1 1 1 1 11111 11111111 2 7 Torch Movement During Welding Tungten Without Filler Rod Welding direction SE N e m u ET T TT _ XZ Form pool Tilt torch Move torch to front of pool Repeat process Tungten With Filler Rod Welding direction Se aE wa 15 Se Ey u Form pool Tilt torch Add filler metal Remove rod Move torch to front of pool Repeat process 2 8 Positioning Torch Tungsten for Various Weld Joints 20 40 7 Lap Joint e ButtWeld and ce TJoint Stringer bead ia b Non consumableTungstens Tungsten Electrode Selector Chart Base metal type Thickness range Aluminium alloys and All Magnesium alloys Copper alloys Cu NI alloys and Nickel alloys Mild Steels Carbon Steels Alloy Steels Stainless Steels and Titanium alloys 10 Only thin sections Only thick sections All Only thin sections Only thick sections All Only thin sections Only thick sections Desired results General purpose Control penetration Increase penetration or travel speed General purpose Control penetration Increase pen
12. ases are available to provide specific properties and these include argon hydrogen argon helium mixtures argon helium hydrogen and argon nitrogen mixtures When welding pipes an inert gas purge is required inside the pipe to prevent oxidation on the underside of the weld Gas purging may also be used to protect the root side of butt welds in plate or sheet materials too 3 5 Aluminium Is a high quality process widely used for welding aluminium particularly in section size up to about 6mm The process may be operated with or without filler TIG welding of aluminium can be carried out using any of the three standard operating modes alternating current AC direct current electrode negative DCEN and direct current electrode positive DCEP AC is the most frequently used since with AC cleaning of the oxide film occurs on the electrode positive cycle and heating occurs on the electrode negative cycle With aluminium the surface oxide film must be removed to allow full fusion to take place and AC TIG does this efficiently allowing high quality joints Plate Thickness Tungsten Consumable Size mm Joint type size mm mm Square butt 1 6 1 6 2 Square butt 1 6 3 2 3 Square butt 2 4 3 2 4 Square butt 2 4 3 2 5 Square butt 2 4 3 2 5 V butt 70 3 2 3 2 6 Square butt 3 2 3 2 6 V butt 70 3 2 3 2 to be made High purity argon and argonhelium shielding gas mixtures can be used The AC output may be conventional sine
13. being removed I Entrapped impurities hydrogen air nitrogen water vapour 2 Defective gas hose or loose connection 3 Filler material is damp particularly aluminium A Filler material is oily or dusty Solution v1 Bh WN 6 Do not use ArO or ArCO GMAW MIG gases 8 2 Dry filler metal in oven prior to welding Increase gas flow Use larger electrode User larger electrode or change polarity Remove contaminated portion then prepare again Replace collet Try wedge collet or reverse collet Increase gas flow post time to sec per 10 amps Change to proper gas no oxygen or CO Maintain short arc length Use smaller electrode or increase current Remove contaminated portion then prepare again Open joint groove The most common cause is moisture or aspirated air in gas stream Use welding grade gas only Find the source of the contamination and eliminate it promptly Use appropriate chemical cleaners wire brush or abrasives prior to welding Many codes do not allow scratch starts Use copper strike plate Use high frequency arc starter Reduce the current or use larger electrode Maintain proper arc length Maintain a distance between electrode and filler metal Reduce the electrode extension to recommended limits Increase gas flow shield arc from wind or use gas lens for TIG welding Use ACHF Adjust balance control for maximum cleaning or
14. d welding current For 4T operation Depress the contactor switch on the torch and release it when welding starts Depress the contactor switch again at the end of the weld Selecting the 4T function will enable the start current 9 and the downslope cycle 12 Both start current and downslope cycle time must be manually selected Using a remote control device such as a foot control or remote pendant When using a remote device ensure that the device is properly fitted by connecting it to the remote control outlet connector 21 The remote operating control switch 7 must be set in the on position 4 5 2 For DC Pulse TIG Welding SDC welding of thin material can be enhanced by using the pulse mode When using the pulse mode for DC applications the current will be varied between the welding current and the set background current Additionally the pulse width and pulse frequency can be adjusted By adjusting the pulse frequency and width the optimum heat input for a particular application can be obtained As a general rule increasing the frequency at a given set of welding and background current the heat input into the plate will increase 2 5 0 Technical Specifications Model No Part No Power voltage V Frequency HZ Fuse rating Output Current A No load voltage V Duty Cycle 200A Power Factor Protection Grading Weight kg Dimensions mm Warranty 28 TIG 200DC PFC TIG200DC PFC
15. e Wide current range AC or DC No spitting Consistent arc starts Good stability Best stability at medium currents Good arc starts Medium tendency to spit Medium erosion rate Low erosion rate Wide current range AC or DC No spitting Consistent arc starts Good stability Use on lower currents only Spitting on starts Rapid erosion rates at higher currents Low erosion rate Wide current range AC or DC No spitting Consistent arc starts Good stability Best stability at medium currents Good arc starts Medium tendency to spit Medium erosion rate Low erosion rate Wide current range AC or DC No spitting Consistent arc starts Good stability Lowest erosion rate Widest current range on DC No spitting Best DC arc starts and stability Use on lower current only Spitting on starts Rapid erosion rates at higher currents Low erosion rate Wide current range No spitting Consistent arc starts Good stability Lowest erosion rate Highest current range No spitting Best DC arc starts and stability 11 Tungsten tip preparation DCSP EN or DCRP EP O Diameter Flat varias Dia 4 4 gt lt Taper length 2 3x Dia ACHP General Purpose ZZ Max ball 1x Dia Ball tip by arcing on clean metal at low current DCRP EP then slowly increase current to form the desired ball diameter Return setting to AC Tungsten Extension Standard Parts General purpose 3x Dia Tungsten
16. efore starting any welding operation Refer to the application section for the selection of the correct shielding gas 4 3 TIG Torch Connection TheR Tech TIG200DC PFC machine is rated at 200A 35 duty cycle The matching TIG torch for this machine is the Wp26 torch 1 TheWP26 TIG torch is fitted to the machine by means of the dinse back end For DC TIG operation fit the torch back end to the negative dinse connection similarly for DC fit the torch backend to the positive dinse connection 2 The gas hose is fitted to the gas fitting GAS located on the front bottom panel of the machine 4 4 MMA Operation TheR Tech TIG200DC PFC can be used as a MMA welding machine by fitting a electrode holder and a work return lead to the respective dinse connectors dependant on the type of electrodes being used Please consult the packaging supplied by the manufacturer for the correct polarities 23 Set Current OutputCurrent Set x AZ CE dh e P P Current hia are Le Ses slope amp End mt ee 1 2 em Amps We Set a Hot Arcforce TIG ARC 200MP Description of the control panels No Function Description 1 Argon In Indicator Starting Current Indicator Upslope Time period in TIG welding during which the starting current IS is Indicator increased to the specified main current Welding Current Amps Main current Indicator Downslope Time Period in TIG welding during which the specified
17. electrode tip shapes and current ranges Tungsten Grinding Shape by grinding longitudinally never radially Remove the sharp point to leave a truncated point with a flat spot Diameter of flat spot determines amperage capacity See below The included angle determines weld bead shape and size Generally as the included _N angle increases penetration increases and bead width 4 decreases Use a medium 60 grit or finer aluminium oxide wheel Gas Lens Parts General purpose __ 3x Dia Maximum 6x Dia P lt in draft free areas Thoriated ceriated and lanthanated tungsten electrodes do not ball as readily as pure or zirconiated tungsten electrodes and as such are typically used for DCSP welding These electrodes maintain a ground tip shape much better than the pure tungsten electrodes If used on AC thoriated and lanthanated electrodes often spit Regardless of the electrode tip geometry selected it is important that a consistent tip configuration be used once a welding procedure is established Changes in electrode geometry can have a significant influence not only on the weld bead width depth of penetration and resultant quality but also on the electrical characteristics of the arc Below is a guide for electrode tip preparation for a range of sizes with recommended current ranges Electrode Diameter mm Diameter ar tip mm 1 0 0 125 1 0 0 250 1 6 0 500 1 6 0
18. etration or travel speed General purpose Control penetration Increase penetration or travel speed Welding current ACHF DCRP DCSP DCSP ACHF DCSP DCSP ACHF DCSP Electrode type Pure EW P Zirconiated EW Zr 2 Thoriated EW Th2 2 Ceriated EW Ce2 2 Thoriated EW Th2 2 Ceriated EW Ce2 2 Thoriated EW Th2 2 Ceriated EW Ce2 Zirconiated EW Zr 2 Ceriated EW Ce2 2 Thoriated EW Th2 2 Ceriated EW Ce2 2 Lanthanated EWG La2 Zirconiated EW Zr 2 Ceriated EW Ce2 2 Lanthanated EWG La2 Shielding gas Argon Argon 75 Argon 25 Helium Argon Helium 75 Argon 25 Helium Helium 75 Argon 25 Helium 75 Argon 25 Helium Argon 75 Argon 25 Helium 75 Argon 25 Helium 75 Argon 25 Helium 75 Argon 25 Helium Argon 75 Argon 25 Helium Helium Tungsten performance characteristics Balls easily Low cost Tends to spit at higher currents Used for non critical welds only Balls well Takes higher current with less spitting and with better arc starts and arc stability than pure tungsten Higher current range and stability Better arc starts with lower tendency to spit Medium erosion Lowest erosion rate Widest current range AC or DC No spitting Best arc starts and stability Best stability at medium currents Good arc starts Medium tendency to spit Medium erosion rate Low erosion rat
19. g procedures Plate Tungsten Welding Thickness Joint Number of Electrode Consumable Travel Speed Gasflow mm Type Passes Size mm Size mm Current A cm min l min 0 8 Fillet 1 6 1 5 70 30 5 1 0 Fillet 1 6 1 5 90 30 5 1 5 Fillet 1 6 2 0 110 30 6 2 0 Fillet 2 4 2 5 130 25 6 1 0 Butt 1 6 1 5 80 20 6 1 5 Butt 1 6 2 0 120 20 7 2 0 Butt 2 4 2 5 140 20 7 Shielding gas Argon Consumable ER70S 6 Position Downhand Polarity DC 18 3 3 Alloyed Steel TIG welding may be used for welding alloy steels but because deposition rates are low it is usually only used for welding sheet and thin sections for high quality applications small components and root passes of multipass butt joints in plate and pipe Standard DC TIG equipment is normally suitable and DCEN polarity is usually chosen to provide good workpiece heating Tungsten electrodes with additions of thorium oxide cerium oxide or lanthanum oxide are used for welding steel and they give good arc stability Only inert or reducing gases should be used General welding parameters Plate Thickness Tungsten Electrode Gas Flow mm mm l min 1 0 1 0 3 4 1 5 1 6 3 4 2 0 1 6 4 3 0 1 6 2 4 4 5 5 0 2 4 3 2 4 6 6 0 3 2 4 0 5 6 8 0 4 0 5 6 12 0 4 8 6 4 5 7 Polarity DC for TIG welding and pure argon is normally recommended as the shielding gas for welding alloy steel Filler rods are usually selected to match the chemical composition and t
20. hallow penetration Nozzle lons Q Electrons DCEN Narrow bead Deep penetration g Nozzle lons Q Electrons Alternating Current with High Frequency m a Welding with alternating current Welding with alternating current combines both direct current characteristics In the positive phase cleaning action occurs in DCEP the weld puddle The DCEP reverse polarity are different from During the negative phase heat is the DCEN in following ways concentrated in the weld puddle High heat is produced on the electrode rather PG ADONE AEE nee PENETANA on the base metal The heat melts the tungsten electrode tip The base metal remains relatively cool AC Average bead Average penetration compared to sing straight polarity f Relatively shallow penetration is obtained Nozzle An electrode whose diameter is too large will reduce visibility and increase arc instability Electrons 2 4 Shielding Gas Selection Material Aluminium Alloys Aluminium Bronze Brass Cobalt based alloys Copper nickel Monel Deoxised copper Nickel alloys Inconel Steel Magnesium Alloys Stainless steel Titanium Shielding Gas Argon Argon Helium Argon Argon Argon Argon Helium Helium 75 Argon 25 Argon Helium Argon Helium Argon Argon Helium Argon Helium Benefits 1 Used with high frequency AC good stable arc good cleaning action
21. he mechanical properties of the parent plate The weldability of the steel may impose restrictions on the choice of filler rod Alloy steels with high carbon equivalents are hardenable and fast cooling will produce a hard HAZ and this is liable to result in hydrogen cracking This form of cracking can be prevented by use of preheat and suitable welding procedures Consumable Size Current A mm 30 60 1 0 70 100 1 5 90 110 1 5 2 0 120 150 2 0 3 0 190 250 3 0 4 0 220 340 4 0 6 0 300 360 4 0 6 0 350 450 4 0 6 0 19 3 4 Stainless Steel Is a high quality process ideally suited for welding of stainless steels particularly thin sheet up to about 5mm thick where weld integrity and good surface finish are critical The process has a high degree of controllability resulting in clean smooth high quality welds with good penetration and strength with very low defect rates Standard TIG equipment is suitable and stainless steels are TIG welded using DCEN polarity A thoriated tungsten electrode is normally used but health concerns have promoted use of ceriated or lanthanated instead The filler rod used depends on the type of stainless being welded but in general is matching for austenitic 20 grades enriched in nickel for duplex grades and may be matching or an austenitic type for ferritic and martensitic grades Shielding gas is conventionally pure argon but other g
22. inal but is most often connected to the negative pole The output characteristics of the power source can have an effect on the quality of the welds produced Shielding gas is directed into the arc area by the welding torch and a gas lens within the torch distributes the shielding gas evenly over the weld area In the torch the welding current is transferred to the tungsten electrode from the copper conductor The arc is then initiated by one of several methods between the tungsten and the workpiece 2 3 Process Variables DCEN When direct current electrode negative straight polarity is used Electrons strike the part being welded ata high speed Intense heat on the base metal is produced The base metal melts very quickly lons from the inert gas are directed towards the negative electrode at a relatively slow rate Direct current with straight polarity does not require post weld cleaning to remove metal oxides Use of DCEN Use of DCEP For a given diameter of tungsten electrode Intense heat means a larger diameter of higher amperage can be used with straight electrode must be used with DCEP polarity Straight polarity is used mainly for Maximum welding amperage should be welding relatively low approximately six times lower Carbon steels than with DCEN Stainless steels Copper alloys The increased amperage provides Deeper penetration Increased welding speed A narrower deeper weld bead DCEP Wide bead S
23. inder so that neither you nor anyone else is in line with the back of the cylinder valve This is in case a back plus is loose or a bursting disc vents The correct stance is shown in the diagram above When operating the cylinder valve Open it by hand by turning the valve hand wheel anti clockwise Use only reasonable force Ensure that no gas is leaking from the cylinder valve connection or the system to which the cylinder is connected DO NOT use ammonia based leak detection fluid as this can 3 damage the valve Approved leak detection fluid can be obtained from a gas supplier When finished with the cylinder close the cylinder valve by hand by turning the valve hand wheel in a clockwise direction Use only reasonable force 1 3 Electrical Shock Never touch live electrical parts Always repair or replace worn or damaged parts Disconnect power source before performing any maintenance or service Earth all work materials Never work in moist or damp areas Avoid electric shock by Wearing dry insulated boots Wearing dry leather gloves Never changing electrodes with bare hands or wet gloves Never cooling electrode holders in water Working on a dry insulated floor where possible Never hold the electrode and holder under your arm 1 4 User Responsibility Read the Operating Manual prior to installation of this machine Unauthorised repairs to this equipment may endanger the technician and operator and wil
24. ition which is weldable These impurities can cause a tendency to crack when hot Lower the travel speed Replace the shielding gas Preheat Increase weld bead cross section size Change weld bead contour Use metal with fewer alloy impurities Reverse direction and weld back into previous weld at edge Use Amprak or foot control to manually down slope current Preheat prior to welding Use pure or non contaminated gas Increase the bead size Prevent craters or notches Change the weld joint design Increase bead size Decrease root opening Use preheat Prevent craters Eliminate sources of hydrogen joint restraint and use preheat Locate and eliminate the blockage or leak Use slower travel speed or carefully increase the flow rate to a safe level below creating excessive turbulence Use a trailing shield cup Set up screens around the weld area 4 Reduce electrode stickout Use a larger size cup Change to gas safer parts or gas lens parts Change to ACHF current Rearrange the split ground connection Reduce weld current and use arc length as short as possible Verify coolant flow direction Return flow must be on the power cable lead Change cup size or type Change tungsten position 3 Ordinary style is split and twists or jams Change to wedge style Do not operate beyond rated capacity Use water cooled model Do not bend rigid torches 3 0 TIG Welding
25. l void your Warranty Only qualified personnel approved by R Tech Welding should perform repairs Always disconnect mains power before investigating equipment malfunctions Parts that are broken damaged missing or worn should be replaced immediately Equipment should be cleaned periodically 4 PLEASE NOTE that under no circumstances should any equipment or parts be altered or changed in any way from the standard specification without written permission given by R Tech Welding To do so will void the Equipment Warranty 2 0 Gas Tungsten Arc Welding GTAW TIG 2 1 Introduction The Tungsten Inert Gas or TIG process uses the heat generated by an electric arc struck between a non consumable tungsten electrode and the workpiece to fuse metal in the joint area and produce a molten weld pool The arc area is shrouded in an inert or reducing gas shield to protect the weld pool and the non consumable electrode The process may be operated autogenously that is without filler or filler may be added by feeding a consumable wire or rod into the established weld pool 2 2 Process Shielding gas Arc TIG filler rod Weld pool Collet g Tungsten Electrode Workpiece Schematic of the TIG welding process Direct or alternating current power sources with constant current output characteristics are normally employed to supply the welding current For DC operation the tungsten may be connected to either output term
26. ng of some metals could have an adverse effect on your health Dont breathe them in If you are welding on material such as stainless steel nickel nickel alloys or galvanised steel further precautions are necessary Wear a respirator when natural or forced ventilation is not good enough Eye protection A welding helmet with the appropriate welding filter lens for the operation must be worn at all times in the work environment The welding arc and the reflecting arc flash gives out ultraviolet and infrared rays Protective welding screen and goggles should be provided for others working in the same area Clothing Suitable clothing must be worn to prevent excessive exposure to UV radiation and sparks An adjustable helmet flameproof loose fitting cotton clothing buttoned to the neck protective leather gloves spats apron and steel capped safety boots are highly recommended Recommended filter shades for arc welding Less than 150 amps Shade 10 150 to 250 amps Shade 11 250 to 300 amps Shade 12 300 to 350 amps Shade 13 Over 350 amps Shade 14 Use one shade darker for aluminium Cylinder Safety Cylinder valve hand wheel Back plug Bursting disc Backview of typical cylinder valve Operator wearing personal protection equipment PPE in safe position Ten Points about Cylinder Safety 1 Read labels and Material Safety Data Sheet MSDS before use 2 Store upright and use in well ventilated secure
27. ny decisions including but not limited to business safety or other operations decisions Except in so far as liability under any statute cannot be excluded R Tech Welding and its affiliates directors employees contractors and consultants do not accept any liability whether arising in contract tort or otherwise for any error or omission in this document or for any resulting loss or damage whether direct indirect consequential or otherwise suffered by the recipient of this document or any other person relying on the information contained herein The recipient agrees that it shall not seek to sue or hold R Tech Welding or their respective agents liable in any such respect for the provision of this document or any other information Contents 1 0 1 1 1 2 1 3 1 4 2 0 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 3 0 3 1 3 2 3 3 3 4 3 5 3 6 3 7 4 0 4 1 4 2 4 3 4 4 4 5 5 0 6 0 6 1 6 2 6 3 Recommended Safety Precautions Health Hazard Information Personal Protection Electric Shock User Responsibility Gas Tungsten Arc Welding GTAW TIG Introduction Process Process Variables Shielding Gas Selection Consumable Selection Welding Techniques Torch Movement During Welding Joint Preparation TIG Welding of Materials Application Summary C Mn Steel Alloyed Steel Stainless Steel Aluminium Balanced Squarewave Copper and Copper Alloys Connection Your R Tech TIG200DC PFC Power Shielding Gas TIG Torch
28. opper alloys Alushield Heavy is ideal for TIG welding copper and some copper 22 alloys particularly in thicker sections Pure argon is the shielding gas used for AC TIG welding TIG consumables are solid filler rods based on pure copper and several copper alloy compositions including aluminium bronzes silicon bronzes and cupro nickels It is normal to try to use a filler material with a similar composition to that of the parent material but this is not always possible and sometimes not desirable Porosity is the main welding problem encountered when TIG welding unalloyed copper and some copper alloys are prone to solidification cracking and porosity Certain alloys are difficult to weld brass will lose zinc if welding is attempted and those containing lead are virtually unweldable 4 0 Connecting your R Tech TIG200DC PFC welding machine A 1 Power The machine is designed to operate on a 240 15 input single phase AC outlet Ensure that there is adequate ventilation around the machine when it is connected to the mains power supply 4 2 Shielding Gas When working the machine in the TIG mode of welding the process requires a shielding gas The shielding gas can be supplied via a pressure regulator to the machine from either a fixed installation or single cylinder of gas If a cylinder of gas is used please ensure that the cylinder is securely fastened refer to the section on cylinder handling and safety b
29. wave or square wave and many electronic power sources allow the AC waveform to be adjusted and also provide facilities for pre and post gas flow and current slope in and slope out 3 6 Balanced Squarewave The balance on squarewave machines can be adjusted to achieve the desired results Greater amounts of EN create a deeper narrower weldbead and better joint penetration This helps when welding thick material and promote faster welding speeds Greater amounts of EP removes more oxides from the surface but also have a shallower penetration Welding Current speed Gas flow A mm min l min 75 26 5 110 21 6 125 17 6 160 15 8 185 14 10 165 14 12 210 8 12 185 10 12 Alternating current Welding position Downhand Pure Aluminium 21 3 7 Copper and Copper Alloys Cleanliness is important when welding copper and all dirt grease and other contaminants must be removed before welding Copper alloys containing aluminium will form a surface oxide film and this must also be removed before welding Preheat will be required for unalloyed copper but some copper alloys can be TIG welded without preheat except on thick sections Standard DC TIG welding equipment is suitable for most copper and copper alloys but aluminium bronze is normally TIG welded using AC current to break down the tenacious oxide film on the surface Pure argon helium or argon helium mixtures are standard shielding gases for DC TIG welding copper and c
30. wire brush and clean the weld joint prior to welding Do not weld on wet material Remove condensation from line with adequate gas pre flow time Check hoses and connections for leaks Replace filler metal 15 Troubleshooting guide Problem Porosity in Weld Deposit Cracking in Welds Inadequate shielding Arc Blow Short parts Life 16 Cause gt ee 3 ee ee Alloy impurities in the base metal such as sulphur phosphorous lead and zinc Excessive travel speed with rapid freezing of weld trapping gases before they escape Contaminated shield gas Hot cracking in heavy section or with metals which are hot shorts Crater cracks due to improperly breaking the arc or terminating the weld at the joint edge Post weld cold cracking due to excessive joint restraint rapid cooling or hydrogen embrittlement Centreline cracks in single pass weld Underbead cracking from brittle microstructure Gas flow blockage or leak in hoses or torch Excessive travel speed exposes molten weld to atmospheric contamination Wind or drafts Excessive electrode stickout Excessive turbulence in gas stream Induced magnetic field from DC weld current Arc is unstable due to magnetic influence Short water cooled leads life Cup shattering or cracking in use Short collet life Short torch head life Solution 5 Change to a different alloy compos
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