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DYNA TIG 201AC/DC Operating Manual

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Summary of Contents for DYNA TIG 201AC/DC

Page 1: ... 04 DC pulse TIG welding 17 5 05 AC pulse TIG welding 18 6 0 BASIC TIG WELDING GUIDE 19 6 01 Electrode Polarity 19 6 02 Tungsten Electrode Current Ranges 19 6 03 Tungsten Electrode Types 19 6 04 Guide for Selecting Filler Wire Diameter 20 6 05 Shielding gas selection 20 6 06 TIG welding parameters for low carbon low alloy steel pipe 21 6 07 Welding parameters for Aluminum 21 6 08 Welding parameter...

Page 2: ...SEC Seconds Remote outputs control Panel Remote Percent Remote Function DC Direct Current Arc Control SMAW AC Alternating Current t2 Gas Post Flow Time 2T GTAW t1 Gas Pre Flow Time 4T GTAW VRD Voltage Reduction Device Circuit Repeat Function GTAW Negative Spot Function GTAW Positive High Frequency Starting GTAW Gas Input Lift Start GTAW Gas Output ...

Page 3: ...negligence strict tort or under any warranty or otherwise shall not except as expressly provided herein exceed the price of the goods upon which such liability is based No employee agent or representative of FCW is authorized to change this warranty in any way or grant any other warranty PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN FCW S SOL...

Page 4: ...ing process can be dangerous and hazardous to your health z Keep all fumes and gases from the breathing area Keep your head out of the welding fume plume z Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases z The kinds of fumes and gases from the arc welding cutting depend on the kind of metal being used coatings on the metal and the different processes You...

Page 5: ... and trapped under aluminum workpieces when they are cut underwater or while using a water table Do not cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dissipated Trapped hydrogen gas that is ignited will cause an explosion NOISE Noise can cause permanent hearing loss Arc welding cutting processes can cause noise levels to exceed safe limits You must...

Page 6: ... Disconnect input power conductors from de energized supply line before moving the welding power source WARNING FALLING EQUIPMENT can cause serious personal injury and equipment damage z Lift unit with handle on top of case z Use handcart or similar device of adequate capacity z If using a fork lift vehicle place and secure unit on a proper skid before transporting ...

Page 7: ...s in the near vicinity of the operator which can cause increased hazard have been insulated Installation Location Be sure to locate the welder according to the following guidelines z In areas free from moisture and dust z In areas not subjected to abnormal vibration or shock z In areas free from oil steam and corrosive gases z Place at a distance of 304 79mm or more from walls or similar that coul...

Page 8: ...The input voltage must match one of the electrical input voltages shown on the input data label on the unit nameplate Contact the local electric utility for information about the type of electrical service available how proper connections should be made and inspection required The line disconnect switch provides a safe and convenient means to completely remove all electrical power from the welding...

Page 9: ...rence Interference may be transmitted by a high frequency initiated or stabilized arc welding machine in the following ways Direct Radiation Radiation from the machine can occur if the case is metal and is not properly grounded It can occur through apertures such as open access panels The shielding of the high frequency unit in the Power Source will prevent direct radiation if the equipment is pro...

Page 10: ...erheating and damage to the unit If the welding amperes decrease the duty cycle increases If the welding amperes are increased beyond the rated output the duty cycle will decrease WARNING Exceeding the duty cycle ratings will cause the thermal overload protection circuit to become energized and shut down the output until has cooled to normal operating temperature Continually exceeding the duty cyc...

Page 11: ...rating Manual 3 0 OPERATOR CONTROLS 3 01 DYNA TIG 201AC DC controls Figure 2 1 Process Selection Stick HF TIG 2 7 Pin Socket Used for the TIG torch switch only Figure 3 Pin Function 2 TIG torch switch 3 TIG torch switch Table 4 ...

Page 12: ...Hz Low frequency pulse the pulse frequency can output 2Hz 8 Down Slope Time Control 9 Post Flow Time Control 10 Gas Outlet 11 Positive Socket TIG connect the work lead MMA connect the electrode holder 12 Negative Socket TIG connect the TIG torch MMA connect the work lea 13 Input Power Cable 3 meter 14 Input Gas Fitting Size 5 8 18RH female 15 Ground screw Ground cable 16 AC Balance 17 Digital disp...

Page 13: ... choice pulse mode this pulse width is fixed Pulse Freq When choice pulse mode this pulse frequency from 2Hz to 250Hz depend on peak current AC Balance This parameter is used for aluminium AC TIG mode and is used to set the penetration to cleaning action for the AC weld current Generally AC BALANCE is set to 50 for AC STICK welding The AC BALANCE control changes the ratio of penetration to cleanin...

Page 14: ...TIG modes only and is used to adjust the post gas flow time once the arc has extinguished This control is used to dramatically reduce oxidation of the tungsten electrode Table 5 Weld parameter description for DYNA TIG series 3 03 Weld parameter for DYNA TIG 201AC DC Model DYNA TIG 201 AC DC Peak Current 10 200A TIG 10 200A Welding Current STICK 10 160A Pulse Frequency 2Hz 250Hz OFF Down Slope Time...

Page 15: ...to the arc is dependent on the welding arc voltage and as welding arc voltage varies between different classes of electrodes welding current at any one setting would vary according to the type of electrode in use The operator should use the welding current range values as a guide and then finally adjust the current setting to suit the application Figure 5 Set up for DYNA TIG 201 AC DC WARNING Befo...

Page 16: ... Control Selection 2T 4T Function 6 Pulse switch Three kind of choices from the top down in turn is High frequency pulse TIG welding The pulse frequency may output the 250Hz Low frequency pulse TIG Welding The pulse frequency may output the 2Hz DC only 7 Post flow time control 8 Down slope time control 9 Digital display Display welding current 10 Warning indicator Activates under the following con...

Page 17: ...welding z Connect work lead to positive terminal z Connect TIG torch to negative terminal z Switch machine on z Set DC TIG mode z Set welding current control see table 8 5 03 AC TIG welding z Connect work lead to positive terminal z Connect TIG torch to negative terminal z Switch machine on z Set AC TIG mode z Set welding current control see table 9 5 04 DC pulse TIG welding z Connect work lead to...

Page 18: ... A Filler wire diameter mm Argon Gas flow L min 0 3 0 5 1 1 6 5 30 3 8 0 5 1 2 1 6 2 10 50 1 2 1 6 4 8 1 2 2 1 6 2 10 50 1 2 1 6 4 8 1 2 2 1 6 2 30 70 1 6 2 0 6 9 2 4 2 4 60 100 1 6 2 0 7 10 4 6 3 4 100 200 2 0 2 5 10 15 Table 8 Workpiece thickness mm Tungsten diameter mm Welding current A Filler wire diameter mm Argon Gas flow L min 1 1 5 1 6 60 80 0 8 1 0 5 10 1 5 2 2 4 125 145 1 0 1 6 8 10 2 3 ...

Page 19: ... 135 200 130 225 4 0 190 280 190 280 4 8 250 340 250 340 Table 10 Current ranges for varies tungsten electrode sizes 6 03 Tungsten Electrode Types Tungsten type Ground finish Welding Application Features Color code Thoriated 2 DC welding of mild steel stainless steel and copper Excellent arc starting Long life high current carrying capacity Red Zirconated 1 High quality AC welding of aluminium mag...

Page 20: ...5 180 240 4 8 200 350 220 320 Table 12 Filler wire selection guide Notice The filler wire diameter specified in Table 11 is a guide only other diameter wires may be used according to the welding application 6 05 Shielding gas selection Alloy Shielding gas Aluminium alloys Argon Carbon steel Argon Stainless steel Argon Nickel alloy Argon Copper Argon Titanium Argon Table 13 Shield gas selection ...

Page 21: ...oy steel pipe 6 07 Welding parameters for Aluminum Base metal thickness mm AC current for Aluminum Tungsten diameter Electrode mm Filler rod diameter if require mm Argon gas flow rate litres min Joint type 1 0 30 45 35 50 1 0 1 6 5 7 butt corner lap fillet 1 2 40 60 45 70 1 0 1 6 5 7 butt corner lap fillet 1 6 60 85 70 95 1 6 1 6 7 butt corner lap fillet 3 2 125 150 130 160 3 2 2 4 10 butt corner ...

Page 22: ... min Joint type 1 0 35 45 40 50 20 30 25 35 1 0 1 6 5 7 butt corner lap fillet 1 2 45 55 50 60 30 45 35 50 1 0 1 6 5 7 butt corner lap fillet 1 6 60 70 70 90 40 60 50 70 1 6 1 6 7 butt corner lap fillet 3 2 80 100 90 115 65 85 90 110 1 6 2 4 7 butt corner lap fillet 4 8 115 135 140 165 100 125 125 150 2 4 3 2 10 butt corner lap fillet 6 4 160 175 170 200 135 160 160 180 3 2 4 0 10 butt corner lap ...

Page 23: ...ections necessary to give proper fusion of weld and base metal Types of Electrodes Arc welding electrodes are classified into a number of groups depending on their applications There are a great number of electrodes used for specialized industrial purposes which are not of particular interest for everyday general work These include some low hydrogen types for high tensile steel cellulose types for...

Page 24: ...o the machine to insure that they are tight and the wires are not frayed or overheated Inspect internal wiring of machine for loose or frayed connections tighten or repair as necessary It would also be advisable to check connections to wire feeders fixtures etc at this time Any damaged cable or hoses should be replaced DANGER HIGH VOLTAGE is present internally even with the control power switch in...

Page 25: ...PCB damage 5 Gas regulator turned off 1 Replace TIG torch 2 Replace gas hose 3 Replace solenoid value 4 Replace power PCB 5 Turn on 4 TIG mode no high frequency starts d Gas flow continues have spark 1 Welding cable disconnected 2 Poor tungsten 1 Reconnect 2 Replace tungsten 5 TIG mode unstable welding Arc 1 Wrong tungsten 2 TIG torch bad contact or damage 3 Gas flow control is improper not pure a...

Page 26: ... is connected to the terminal B No gas flowing to welding region C Torch is clogged with dust D Gas hose is cut E Gas passage contains impurities F Gas regulator turned off G Torch valve is turned off H The electrode is too small for the welding current A Connected the electrode to the terminal B Check the gas lines for kinks or breaks and gas cylinder contents C Clean torch D Replace gas hose E D...

Page 27: ...xides z Arc field in one spot to produce mirror clean weld pool z Move the weld pool around to introduce oxides to the weld pool z Increased cleaning action ie Prolonged oxide emission from a stationary weld pool increases the likelihood of arc flutter z Decrease the cleaning action by turning the WAVE BALANCE to below 50 or move the weld pool around z Accentuated when tungsten running near its cu...

Page 28: ...ed D Lack of penetration with slag trapped beneath weld bead E Rust or mill scale is preventing full fusion F Wrong electrode for position in which welding is done A If bad undercut is present clean slag out and cover with a run from a smaller diameter electrode B Allow for adequate penetration and room for cleaning out the slag C If very bad chip or grind out irregularities D Use smaller electrod...

Page 29: ...o gas flow when the torch trigger switch is depressed A Gas hose is cut B Gas passage contains impurities C Gas regulator turned off A Replace gas hose B Disconnect gas hose from the rear of power source then raise gas pressure and blow out impurities C Turn gas regulator on Table 22 Notice Can move the equipments that the power supply doesn t fixedly mean to link to work with gearing at the some ...

Page 30: ... 30 DYNA TIG 201AC DC Operating Manual 10 0 PARTS LIST ...

Page 31: ... 31 DYNA TIG 201AC DC Operating Manual ...

Page 32: ... 7 Knob 4KYZPN8E20R3 1 8 Knob 4KYZPN8E20R3 1 9 Label control 2LAC8807140 1 10 Switch 4KNX203 1 11 Switch 4KNX202 1 12 Label output o 2LAU8803006 1 13 Cable connector panel 50mm2 2GS50CC001FP 2 14 Adaptor gas kit outlet D 3KITP000113000 1 15 7pin socket 4WP16S5002 1 16 Main swith 4KAMM3R75A 1 17 Fan cover 4FAN001SA1238 1 18 Label input voltage 220V 1ph 2LAM8800005 2 19 NYLON cable gland 4SXJPG29 1 ...

Page 33: ...KIT 1 34 Solenoid valve 4SVAC220 1 35 Heat sink left Ⅰ 2HS7061002 1 36 Fan Motor 4FAN001SA1238 2 37 BOD 60 4EER400111 1 38 AC Drive PCB 3KITP000509005 1 39 AC transform PCB 3KITP000506008 1 40 AC transform PCB 3KITP000506007 1 41 PCB board filter 3KITP002706080 1 42 Diode PCB 3KITP000506021 1 43 Heat sink right Ⅰ 2HS7061003 2 44 Base 2FPB6123018 1 45 Heat sink left Ⅱ 2HS7061039 1 46 Heat sink righ...

Page 34: ... outputting and giving the red candle demonstration warning 11 3 Ambient temperatures high when big electric current long time continuous working the welding machine has stopped because of the heat outputting gets down until the temperature drop only then restores 11 4 When welding machines do not use temporarily its depository should maintain dryly cleanly The environment relative humidity is not...

Page 35: ... 35 DYNA TIG 201AC DC Operating Manual APPENDIX DYNA TIG 201AC DC INTERCONNECT DIAGRAM ...

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