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PowerMaster205

DC INVERTER

AC/DC TIG/DC STICK/CUT

4IN1 MACHINE

(Suitable for 1x220V)

Operators’s Manual

Safety, Setup and General Use Guide

REV.2 0 00146-16
Issue Date: May. 10, 2016
Manual No.: 0-1536

EMPRESAS CARBONE S.A.

Calle 5ta. Rio Abajo, Panamá, Panamá
Telefonos: (507) 3916309 / 3916313

www.empresascarbone.com

Summary of Contents for PowerMaster205

Page 1: ...4IN1 MACHINE Suitable for 1x220V Operators s Manual Safety Setup and General Use Guide REV 2 0 00146 16 Issue Date May 10 2016 Manual No 0 1536 EMPRESAS CARBONE S A Calle 5ta Rio Abajo Panam Panam Tel...

Page 2: ...erformance Should you have an issue or question concerning your unit please contact performance technical support available through the main company headquarters available in your country For best ser...

Page 3: ...________ Where Purchased _____________________________ Whenever you request replacement parts or information on this equipment please always supply information you have recorded above This product is...

Page 4: ...e information please contact our Support The warranty does not cover improper use maintenance or consumables Do not attempt to alter or defeat any piece or part of your unit particularly any safety de...

Page 5: ...tection is available exclude them from the work area Even brief expo sure to the rays from the welding arc can damage unprotected eyes Always wear hearing protection because welding and cutting can be...

Page 6: ...s nose or throat are signs that you need to increase ventilation Stop immediately and relocate work if necessary until adequate ventilation is ob tained Stop work completely and seek medical help if i...

Page 7: ...materials including rags and spare clothing away from area Keep all flammable fuels and liquids stored separately from work area Visually inspect work area when job is completed for the slightest trac...

Page 8: ...mitations B 2 Control Panel B 3 Controls and Settings 2 Step and 4 Step Tig Sequence B 3 B 6 Operating steps B 7 Welding in Tig mode B 7 Welding Polarity B 7 DC Electrode Negative Polarity B 7 DC Elec...

Page 9: ...Rated Duty Cycle 60 AMP Adjusting Range 5 200A Rated Duty Cycle 60 Current Up slope Time 0 10S Current Down slope Time 0 25S pulse Base AMP Current Ratio 5 95 Pluse Time On 0 1 0 9 Pluse Frequency 0 5...

Page 10: ...1 National Electric Code Use a Super Lag type fuse or circuit breaker with a delay in tripping action Models with NEMA 6 50P plug may be used with a 50 amp protected 6 50R receptacle or with a maximum...

Page 11: ...of the equipment Never make the cargo pass or leave it suspended over people or things Neither let the equipment or the single unit fall nor put it down with force Once it has been removed from the p...

Page 12: ...to an earth ground close to the work clamp using one of the following methods a A metal underground water pipe in direct contact with the earth for ten feet or more b A 3 4 19mm galvanized pipe or a 5...

Page 13: ...or defeat the purpose of the power cord ground pin RECONNECT PROCEDURE The Inverter machine auto reconnects to either 115V or 230V supply Fuse the input circuit with time delay fuses or delay type1 ci...

Page 14: ...er procedure on grounding the work clamp and work piece SHIELDING GAS CONNECTION Obtain the necessary inert shielding gas usually argon Connect the cylinder of gas with the pressure regulator and flow...

Page 15: ...der electrically hazardous conditions such as welding in wet areas or on or in the workpiece FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust at the arc or both...

Page 16: ...ll as many industry standard items such as TIG torches adapted for Twist Mate hoses PROCESS LIMITATIONS The Precision TIG machines are not recommended for arc gouging due to it s limited output capaci...

Page 17: ...rthing column 26 2 steps 4 steps switch 27 220v receptacle 28 PreFlow29 Start Amps 30 End Amps 31 Pulse On Off 32 warning indicating light 34 Pilotarc CONTROL FUNCTIONALITY 1 DIGITAL METER A 3 digit L...

Page 18: ...gative wave at full CW rotation setting to Max Cleaning 70 positive wave at CCW rotation This setting position feature automatically provides the proper amount of cleaning and penetration for normal A...

Page 19: ...p mode which is selected with the Trigger Mode Push Button 2 Step Sequence With the Trigger Mode switch in the 2 step position the following welding sequence will occur This sequence is shown in 2 ste...

Page 20: ...inish current can be maintained as long or as short as necessary 4 Release the TIG torch trigger The output current of the machine will turn OFF and the gas valve will remain open to continue the flow...

Page 21: ...rn on with the output and remain on continuously until the remote control is released WELDING POLARITY DC Electrode Negative Polarity Direct Current Straight Polarity see FIGURE B 4 While Welding ther...

Page 22: ...gas Considering the fluidity of molten copper the use of backup support may prove useful FILLER MATERIAL In order to avoid the oxidation of the molten material filler materials containing phosphorus...

Page 23: ...2 4 Up to MAX A Up to 160 A Up to MAX A 13 17 6 8 11 15 5 7 1 8 3 2 X Up to MAX A X 15 23 7 11 11 15 5 7 Tungsten electrodes are classified as follows by the American Welding Society AWS Pure EWP gree...

Page 24: ...aces a lot of heat on the tungsten In a balanced wave where both EP and EN are equal in time length 50 penetration is reduced and over cleaning results in wide etch lines running parallel to the side...

Page 25: ...l and service this equipment Turn the input power off at the fuse box disconnect or unplug supply lines and allow machine to sit for five minutes minimum to allow the power capacitors to discharge bef...

Page 26: ...ator may have to turn the cur rent control up and depress the Ampcontrol approximately 1 4 of the way down Depressing the Ampcontrol to its minimum position may not start the arc Also if the current c...

Page 27: ...B 13 OPERATION B 13...

Page 28: ...B 14 OPERATION B 14...

Page 29: ...B 15 OPERATION B 15...

Page 30: ...ver the power switch is turned on 5 Turn the power switch to ON 6 Adjust the Current Control to the desired amps 7 Strike an arc and weld NOTE When the MMA TIG CUT switch is set to MMA the output is a...

Page 31: ...nd automatic amp response needed to maintain the arc when voltage falls below the threshold 6011 Cellulose electrodes may require more arc force control than other rods but each brand and size will we...

Page 32: ...t air pressure If pressure is too low the unit will cease output and the green indicator light next to the pressure gauge will go out to indicate the air pressure is too low to operate safely 4 See to...

Page 33: ...B 19 OPERATION B 19...

Page 34: ...B 20 OPERATION B 20...

Page 35: ...B 21 OPERATION B 21...

Page 36: ...B 22 OPERATION B 22...

Page 37: ...quire no maintenance 7 SPARK GAP ADJUSTMENT The spark gap 020 5mm is set at the factory to a gap of 0 015 inches 0 4mm See Figure D 1 This setting is adequate for most applications Where less high fre...

Page 38: ...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 PO...

Page 39: ...unit to run until the fan cools the unit and the yellow light goes out Machine does not respond no gas flow no high frequency and no open circuit voltage when arc start switch or Ampcontrol is activat...

Page 40: ...ignificantly when AC Balance control knob is set near or at max penetration or when Output control is set near or at full output 1 Input power to machine doesn t have sufficient capacity Try changing...

Page 41: ...2 Tungsten not sharp when welding in DC mode 3 Gas shielding may be insufficient Increase gas flow reduce tungsten stick out beyond gas cup 4 Check for contaminated gas or leaks in the gas line torch...

Page 42: ...k Spark Gap operation and setting 0 5mm High frequency spark is present at tungsten electrode but operator is unable to establish a welding arc Machine has normal open circuit voltage refer to Technic...

Page 43: ...your local welder gas distributor When AC TIG welding the arc is erratic and there is a loss of cleaning of the work piece 1 Tungsten electrode may be too small for process Use a larger diameter tung...

Page 44: ...er diameter electrode 2 Arc too short Excessive spatter 1 Long arc 2 High current Craters 1 Fast movement of the electrode away from piece Inclusions 1 Poor cleanliness or distribution of the Welding...

Page 45: ...1 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual If the diagram is illegible write to the Service Department for a replacement Give the equipme...

Page 46: ...Adjustable foot control 1 Cutting torch 1 Electrode 5 Tip 1 0 5 Ceramic shieid 3 Operation instructions 1 Certificate of quality 1 No Certificate of quality Name of product AC DC TIG DC STICK DC CUT W...

Page 47: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y...

Page 48: ...e Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria Turn power off before servicing Desconectar el cable de ali mentaci...

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