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1: Tungsten burning away quickly

Possible Reason

Suggested Remedy

Incorrect Gas

Check that pure Argon is being used

No gas

Check the gas cylinder contains gas and is connected and the torch gas valve is open

Inadequate gas flow

Check the gas is connected, check hoses, gas valve and torch are not restricted. Set

the gas flow between 21-30cfh flow rate

Back cap not fitted correctly

Make sure the torch back cap is fitted so that the o-ring is inside the torch body

Torch connected to DC +

Connect the torch to the DC- output terminal

Incorrect tungsten being used

Check and change the tungsten type if necessary

Tungsten being oxidised after weld

is finished

Keep shielding gas flowing 10–15 seconds after arc stoppage. 1 second for each 10

amps of weld current.

2: Contaminated tungsten

Possible Reason

Suggested Remedy

Touching tungsten into the weld

pool

Keep tungsten from contacting weld puddle. Raise the torch so that the tungsten is off of

the work piece 1/8-1/4in

Touching the filler wire to the tung-

sten

Keep the filler wire from touching the tungsten during welding, feed the filler wire into the

leading edge of the weld pool in front of the tungsten

Tungsten melting into the weld pool

Check that correct type of tungsten is being used. Too much current for the tungsten

size so reduce the amps or change to a larger tungsten

3: Porosity - poor weld appearance and colour

Possible Reason

Suggested Remedy

Incorrect Gas

Check that pure Argon is being used

Inadequate gas flow / gas leaks

Check the gas is connected, check hoses, gas valve and torch are not restricted. Set

the gas flow between 21-30cfh flow rate. Check hoses and fittings for holes, leaks etc.,

Moisture on the base metal

Remove all moisture from base metal before welding

Contaminated base metal

Remove materials like paint, grease, oil, and dirt, including mill scale from base metal

Contaminated filler wire

Remove all grease, oil, or moisture from filler metal.

Incorrect filler wire

Check the filler wire and change if necessary

4: Yellowish residue / smoke on the alumina nozzle & discoloured tungsten

Possible Reason

Suggested Remedy

Incorrect Gas

Use pure Argon gas

Inadequate gas flow

Set the gas flow between 21-30cfh flow rate

Alumina gas nozzle too small for size

of tungsten being used

Increase the size of the alumina gas nozzle

5: Unstable Arc during DC welding

Possible Reason

Suggested Remedy

Torch connected to DC +

Connect the torch to the DC- output terminal

Contaminated base metal

Remove materials like paint, grease, oil, and dirt, including mill scale from base metal.

Tungsten is contaminated

Remove 10mm of contaminated tungsten and re grind the tungsten

Arc length too long

Lower torch so that the tungsten is off of the work piece 2 - 5mm

The following chart addresses some of the common problems of DC TIG welding. In all cases of equipment malfunction, the

manufacturer’s recommendations should be strictly adhered to and followed.

TIG WELDING TROUBLE SHOOTING

Trouble Shooting

Summary of Contents for 8619470

Page 1: ...on manual carefully before the installation and operation of this equipment OPERATING MANUAL 145 Multi System MIG ARC TIG Multi Process Welder 8619470 180 Multi System MIG ARC TIG Multi Process WelderWelder 8611311 YEARS Warranty Power Source 3 ...

Page 2: ... specialist welders that have a proven history of welding knowledge and expertise giving vital input towards ensuring that our machines deliver control and performance to the utmost professional level We employ an expert team of profes sional sales marketing and technical personnel that provide us with market trends market feedback and customer comments and requirements Secondly they provide a cus...

Page 3: ...Set up Guide 16 Installation Operation for Gasless MIG Welding for Pro Point 145 180 17 18 MIG Torch Liner Installation 19 MIG Torch and Wire Feeder Set Up Guide for Aluminum Wire 20 21 Installation Operation for MIG Welding with Spool Gun 22 23 Basic MIG Welding Guide 24 29 Installation Operation for DC TIG Welding 30 31 TIG Fusion Technique 32 Tungsten Electrodes Preparation 33 34 TWECO 2 MIG We...

Page 4: ...put power cable for wear and tear replace the cable immediately if damaged bare wiring is dangerous and can kill Do not use damaged under sized or badly joined cables Do not drape cables over your body We recommend RCD safety switch is used with this equipment to detect any leakage of current to earth Fumes and gases are dangerous Smoke and gas generated whilst welding or cutting can be harmful to...

Page 5: ...ecause gas cylinders are normally part of the welding process be sure to treat them carefully CYLINDERS can explode if damaged Protect gas cylinders from excessive heat mechanical shocks physical damage slag open flames sparks and arcs Insure cylinders are held secure and upright to prevent tipping or falling over Never allow the welding electrode or earth clamp to touch the gas cylinder do not dr...

Page 6: ...ature inside the equipment The machine will be ready for use again when the internal temperature reaches safe level 2 3 Over Voltage Supply Regarding the power supply voltage range of the machine please refer to Main parameter table This equipment is of automatic voltage compensation which enables the maintaining of the voltage range within the given range In case that the voltage of input power s...

Page 7: ...ellent MIG welding with CO2 gas mixed gas Euro style MIG and TIG torch connection Internal wire feeder with solid construction Adjustable Burn Back Spool Gun Connection Stepless voltage and wire feed control Wire Inch Smart Set functionality Dual voltage 115 230V Hot Start Anti Stick Digital Readout Solid case construction IP21S rating and CSA CAN Approved Complete withTorch Regulator return and A...

Page 8: ...n allows you to dial in your preferred wire size and gas mixture and you are ready to start welding The machine comes complete with Torch Regulator Adaptor and Arc lead set A real workhorse with a hight duty Cycle Input voltage V Single phase AC230V 115V 15 50 60Hz Welding wire diameter 0 025 0 03 0 035 in ARC Input 115V 20A Rated input current 27 5A Output 10A 20 4V 100A 24V X 25 60 100 I2 100A 6...

Page 9: ... TIG Torch Connector MIG MAG 9 Output terminal 10 SpoolGun Power Supply Connection BACK PANEL LAYOUT 11 Power switch 12 Gas Inlet 13 Fan 14 Input power cable 15 Data Plate 14 12 15 11 INTERNAL PANEL LAYOUT 16 Spoolgun Standard selector switch 17 Inch wire feed button 18 Gas Check button 19 Spool holder assembly 20 Geared Wire feed assembly 17 20 19 13 18 16 1 2 3 6 5 4 7 8 9 10 Front Back Internal...

Page 10: ...t socket 2 Turn the power source on and select the ARC function with the MIG TIG ARC selector switch 3 Set the welding current relevant to the electrode type and size being used as recommended by the electrode manufacturer 3 Set the welding current using the amperage control dial and adjust arcforce if required 6 Hold the electrode slightly above the work maintaining the arc while travelling at an...

Page 11: ...olten pool and becomes the deposited weld metal The deposit is covered and protected by a slag which comes from the electrode coating The arc and the immediate area are enveloped by an atmosphere of protective gas Core wire Flux coating Base metal Protective gas Arc Slag Weld pool Manual metal arc stick electrodes have a solid metal wire core and a flux coating These electrodes are identified by t...

Page 12: ... to have an arc length no greater than the diameter of the core wire Electrode Angle The angle that the electrode makes with the work is important to ensure a smooth even transfer of metal When welding in down hand fillet horizontal or overhead the angle of the electrode is generally between 5 and 15 degrees towards the direction of travel When vertical up welding the angle of the electrode should...

Page 13: ...ned setting based on Gas and wire used The machine will preselect Voltage and wire speed allowing the user to quickly find the best welding parameters for a given metal 5 Set torch operation 2T 4T When 2T operation is selected press trigger Arc starts release trigger Arc stops burnback operation is automatic and preset When 4T operation is selected press and release trigger Arc starts press and re...

Page 14: ...ween 11 21cfh 16 Set the welding parameters using the wire feed and voltage control knobs 17 Or use Smartset Smartset is a predefined setting based on Gas and wire used The machine will preselect Voltage and wire speed allowing the user to quickly find the best welding pa rameters for a given metal 12 Press and hold the inch wire button to feed the wire down the torch cable through to the torch he...

Page 15: ...essure roller to avoid de forming the shape of the wire too much tension will push the wire out of shape and cause it to catch in the contact tip Flux Core Gasless Wire these wires are made up of a thin metal sheath that has fluxing and metal compounds layered onto it and then rolled into a cylinder to form the finished wire The wire cannot take too much pressure from the top roller as it can be c...

Page 16: ...ing nut and screw to hold the new position NOTE MIG 180 145 not geared 4 Snip the wire carefully be sure to hold the wire to prevent the spool uncoiling Carefully feed the wire into the inlet guide tube of the wire feed unit 5 Feed the wire through the drive roller and into the outlet guide tube of the wire feeder NOTE MIG 180 145 not geared 6 Lock down the top pressure roller and apply a medium a...

Page 17: ...wer lead to Negative socket 4 Turn the power source on and select the MIG function with the MIG TIG MMA selector switch 5 Set torch operation 2T 4T When 2T operation is selected press trigger Arc starts release trigger Arc stops burnback operation is automatic and preset When 4T operation is selected press and release trigger Arc starts press and release trigger Arc stops burnback operation is aut...

Page 18: ...ch button when the wire exits the torch neck 13 Fit the correct sized contact tip and feed the wire through it screw the contact tip into the tip holder of the torch head and nip it up tightly 14 Fit the gas nozzle to the torch head 15 Set the welding parameters using the wire feed and voltage control knobs 15 Set welding parameters using the voltage and wire feed controls 10 Apply a medium amount...

Page 19: ...he liner approximately 1 8in past the end of the torch neck 8 Place the tip holder over the end of the liner and screw into the torch neck trimming it up tight 9 Screw down the liner nut the remaining 1 2 and trim it up tight This method compresses the liner inside the torch cable assembly preventing it moving during use and ensures good wire feed 2 Remove the liner retaining nut 3 Carefully pull ...

Page 20: ...torch lead and tighten the liner retaining nut 9 Install a U groove drive roller of the correct size to match the wire diameter being used 2 Remove the liner retaining nut 3 Carefully pull out and completely remove the liner 4 Carefully unravel the new liner 8 Push the liner firmly into the torch lead and tighten the liner retaining nut 5 Carefully feed in the new liner in short forward movements ...

Page 21: ...g used 17 Fit the remaining front end parts to the torch neck ready for welding 17 Fit the remaining front end parts to the torch neck ready for welding 11 Install a U groove drive roller of the correct size for the diameter wire being used NOTE MIG 180 145not geared 7 Place aluminum wire onto spool holder Feed the wire through the inlet guide tube on to the drive roller NOTE MIG 180 145 not geare...

Page 22: ... Hand thread Hold and snip the wire from the spool being sure to hold the wire to prevent rapid uncoiling 3 Connect earth lead to 1 Set Standard Spoolgun selector switch inside door to Spoolgun 5 Connect the gas line to the regulator and connect to the gas cylinder 6 Set MIG TIG MMA selector switch to MIG IMPORTANT When connecting the torch be sure to tighten the connection 2 Connect Spool Gun to ...

Page 23: ...ylinder valve and set the flow rate to between 21 30cfh 17 Set the welding parameters using the wire feed and voltage control knobs 9 Carefully feed the wire through the inlet guide tube onto the drive roller through into the outlet guide tube Squeezing the tension arm adjustment knob to release the pressure of the tension arm will allow the wire to be guided through the drive roller easily 10 Che...

Page 24: ...uit also known as dip transfer globular transfer spray transfer and pulsed spray each of which has distinct properties and corresponding advantages and limitations To perform MIG welding the basic necessary equip ment is a welding gun a wire feed unit a welding power supply an electrode wire and a shielding gas supply Short circuit transfer is the most common used method whereby the wire electrode...

Page 25: ...e of the arc flattens out the droplet into the weld pool The heat of the arc melts the end of the wire slightly as it feeds towards the base metal The wire feed speed overcomes the heat of the arc and the wire again approaches the work to short circuit and repeat the cycle droplet separates arc flattens the droplet cycle repeats BASIC MIG WELDING GUIDE MIG METAL INERT GAS WELDING Short Circuit Tra...

Page 26: ...eld bead profile and degree of weld penetration Push Technique The wire is located at the leading edge of the weld pool and pushed towards the un melted work surface This technique offers a better view of the weld joint and direction of the wire into the weld joint Push technique directs the heat away from the weld puddle allowing faster travel speeds providing a flatter weld profile with light pe...

Page 27: ...good bead shape prevents undercut uneven penetration poor gas shield and poor quality finished weld Correct angle Not enough angle Too much angle good level of control over the weld pool even flat weld less control over the weld pool more spatter poor control unstable arc less penetration lots of spatter Stick Out Stick out is the length of the unmelted wire protruding from the end of the contact ...

Page 28: ... resulting in a weld deposit of poor quality cold lap lack of fusion lack of joint penetration porosity large wide bead Too Slow Travel Speed Correct Travel Speed The correct travel speed keeps the arc at the leading edge of the weld pool allowing the base metal to melt sufficiently to create good penetration fusion and wetting out of the weld pool producing a weld deposit of good quality good toe...

Page 29: ... welding zone from the atmosphere Too low flow will give inadequate coverage and result in weld defects and unstable arc conditions Too high flow can cause air to be drawn into the gas column and contaminate the weld zone Use the correct shielding gas Co2 is good for steel and offers good penetration characteristics the weld profile is narrower and slightly more raised than the weld profile obtain...

Page 30: ...press and release trigger Gas starts touch and lift arc start press and release trigger Gas and Arc stops When 4T operation is selected with downslope time of either 1 to 10 seconds press and release trigger Gas starts touch and lift arc start Press and hold trigger after 1 to 10 seconds depending on the downslope time selected Arc crater fill downslopes crater fill operation is automatic to facto...

Page 31: ...ctrode 1 16 inm from the work piece Press the trigger button on TIG torch to start the gas flow 11 With a small movement rotate the Gas Cup forward so that the Tungsten Electrode touches the work piece 12 Now rotate the Gas Cup in the reverse direction to lift the Tungsten electrode from the work piece to create the arc 10 Lay the outside edge of the Gas Cup on the work piece with the Tungsten Ele...

Page 32: ... pool Travel direction Angle torch Add Tig filler wire Retract the filler wire Move the torch forward to the front of the weld pool Repeat the process gas shield TIG WELDING FUSION TECHNIQUES Manual TIG welding is often considered the most difficult of all the welding processes Because the welder must maintain a short arc length great care and skill are required to prevent contact between the elec...

Page 33: ...e Ceriated Color Code Orange Ceriated tungsten electrodes AWS classification EWCe 2 contain a minimum of 97 30 percent tungsten and 1 80 to 2 20 percent cerium and are referred to as 2 percent ceriated Ceriated tungstens perform best in DC welding at low current settings They have excellent arc starts at low amperages and become popular in such applications as orbital tube welding thin sheet metal...

Page 34: ...ing crosswise is grinding against the grain If electrodes are ground crosswise the electrons have to jump across the grinding marks and the arc can start before the tip and wander Grinding longitudinally with the grain the electrons flow steadily and easily to the end of the tungsten tip The arc starts straight and remains narrow concentrated and stable grind longitudinal on the grinding wheel don...

Page 35: ... next page Wear parts next page 1 2 3 5 6 14 12 13 18 15 16 17 19 20 21 8 7 9 10 11 4 Torch Model Description Part Number 15ft Welding Torch c w Euro Fitting TWC2 15FTE TWC2 Air Cooled Mig Welding Torch Rating 200A CO2 150A mixed gas EN60974 7 60 duty cycle 0 6 to 1 2mm 0 023 to 0 047 wires TWC2 STYLE MIG TORCH Spare Parts Part Number Description 1 PWGA32 Adjustable Nozzle Insulator 2 U62J60 TW No...

Page 36: ...djustable 16mm 5 8 QTY2 QTY2 TWC2 Torch Nozzle Fixed Nozzle Insulator QTY2 Nozzle fixed 13mm 33 67 Nozzle fixed 16mm 5 8 QTY2 Nozzle fixed 13mm 33 67 Nozzle fixed 16mm 5 8 QTY2 QTY2 QTY2 TWC2 Gas Diffuser Gas Diffuser QTY2 Gas Diffuser to suit fixed nozzle QTY2 TWC2 Contact Tips H D Contact H D tip 0 8mm 0 030 Contact H D tip 0 9mm 0 035 Contact H D tip 1 0mm 0 040 Contact H D tip 1 2mm 0 045 Cont...

Page 37: ... Suspension Screw 9 Drive Roll Assembly 10 Wire Nipple 11 Spool Shaft 12 Right Gun Case 13 Upper Gun Case 14 Switch Description 15 Potentiometer 16 Push Roll 17 Conducting Board 18 Conducting Tube 19 Welding Cable 20 Spring Support Back 21 Adaptor Support 22 Adaptor Support Nut 23 Adaptor 24 4 Pin Plug 200 AMP Spool Gun Parts Breakdown Part Number 8612517 Sold Seperately ...

Page 38: ...045 Contact H D tip 1 4mm 0 052 Contact H D tip 2 0mm 5 64 Contact H D Ali tip 1 2mm 0 045 Contact H D Ali tip 1 6mm 1 16 TWC2 Gas Diffuser Insulator Gas Diffuser Gas Diffuser suit fixed nozzle Insulator TWC2 TORCH Nozzle Nozzle Adjustable 13mm 33 67 Nozzle Adjustable 16mm 5 8 These parts are not original and are offered as replacement parts suitable for TWECO style torches tt 200 AMP Spool Gun Pa...

Page 39: ...S t u b b y G a s L e n s s e r ie s 2 3 6 5 8 7 9 10 11 12 13 4 180A AIR COOLED TIG WELDING TORCH Rating 180Amp DC 125Amp AC 35 duty cycle tt Description 12 Neoprene Cover X 3 2mt Neoprene Cover X 7 2mt 13 Sheath X 12 5ft Inc Leather Cover Sheath X 25ft Inc Leather Cover Description 1 Torch head Torch head flexible 2 Back cap long 3 Medium back cap 4 Short back cap 5 Momentary Kit 6 Trigger Lead ...

Page 40: ...ramic 5 0mm 13 64 Compact Gas Lens Front End Parts Description 1 0mm x 175mm 0 040 x 6 57 64 thoriated tungsten electrode 2 1 6mm x 175mm 1 16 x 6 57 64 thoriated tungsten electrode 2 2 4mm x 175mm 3 32 x 6 57 64 thoriated tungsten electrode 2 3 2mm x 175mm 1 8 x 6 57 64 thoriated tungsten electrode 2 Description 1 0mm x 175mm 0 040 x 6 57 64 zirconiated tungsten electrode 1 1 6mm x 175mm 1 16 x 6...

Page 41: ...ectrode Poor welding technique Use the correct welding technique or seek assistance for the correct technique Poor joint preparation Check the joint design and fit up make sure the material is not too thick Seek assis tance for the correct joint design and fit up 5 Excessive penetration burn through Possible Reason Suggested Remedy Excessive heat input Reduce the amperage or use a smaller electrod...

Page 42: ...lean dry rust free wire Do not lubricate the wire with oil grease etc Gas nozzle clogged with spatter worn or out of shape Clean or replace the gas nozzle Missing or damaged gas diffuser Replace the gas diffuser Mig torch euro connect o ring miss ing or damaged check and replace the o ring 4 Wire stubbing during welding Possible Reason Suggested Remedy Holding the torch too far away Bring the torc...

Page 43: ...into the groove of the drive roller Incorrect drive roller size Fit the correct size drive roller eg 030in wire requires 030in drive roller Wrong type of drive roller selected Fit the correct type roller e g knurled rollers needed for flux cored wires Worn drive rollers Replace the drive rollers Drive roller pressure too high Can flatten the wire electrode causing it to lodge in the contact tip re...

Page 44: ...ur Possible Reason Suggested Remedy Incorrect Gas Check that pure Argon is being used Inadequate gas flow gas leaks Check the gas is connected check hoses gas valve and torch are not restricted Set the gas flow between 21 30cfh flow rate Check hoses and fittings for holes leaks etc Moisture on the base metal Remove all moisture from base metal before welding Contaminated base metal Remove material...

Page 45: ...r of the contents pressure gauge on the regulator if the needle drops away towards zero there is a gas leak Sometimes a gas leak can be slow and to identify it will require leaving the gas pressure in the regulator and line for an extended time period In this situation it is recommended to open the cylinder valve set the flow rate to 21 30cfh close the cylinder valve and check after a minimum of 1...

Page 46: ...female socket 9 rear panel 10 power switch 11 gas inlet Description 12 fan DC24V 13 power cable 14 display pcb 15 plastic packaged solenoid valve 16 silicon bridge plate 17 Control pcb 18 wire feeder motor 19 mainboard 20 Insluation sheet 21 Spool holder 22 Selector switch 23 Wire inch Gas check button 24 wire feeder motor 1 2 3 8 4 5 6 7 tt Spare Parts Identification for Pro Point 145 180 ...

Page 47: ...rised electrical connections Improper installation Use of non authorised non standard parts Abnormal product performance caused by any ancillary equipment interference or other external factors Failure or any breakage caused by overload dropping or abusive treatment or use by the customer Repair modifications or other work carried out on the product other than by an Authorised PRINCESS AUTO Dealer...

Page 48: ...48 NOTES ...

Page 49: ...49 NOTES ...

Page 50: ...50 PRINCESS AUTO LTD Phone 1 800 665 8685 WWW PRINCESSAUTO COM MADE IN CHINA ...

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