Sua ionTig 200 AC/DC Operation Manual Download

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ionTig 200 AC/DC

CONTENT

1. SAFETY

.................................................................................................................................................... 3

1.1 Signal Explanation

....................................................................................................................................... 3

1.2 The Knowledge of Electric and Magnetic Fields

........................................................................................... 6

2. Overview

................................................................................................................................................... 7

2.1 Brief Introduction

........................................................................................................................................ 7

2.3 Volt-Ampere Characteristic

........................................................................................................................ 10

3. Installation and Adjustment

..................................................................................................................... 11

3.1 Parameters

................................................................................................................................................ 11

3.2 Duty cycle and Over-heat

........................................................................................................................... 12

3.3 Movement and Placement

.......................................................................................................................... 12

3.4 Power supply input connection

................................................................................................................. 13

3.5 Polarity Connection (MMA)

........................................................................................................................ 13

3.6 Assembling the equipment (TIG)

................................................................................................................ 13

4. Operation

................................................................................................................................................ 14

4.1 Layout for the panel

................................................................................................................................... 14

4.2 Control panel

............................................................................................................................................. 15

4.3 Remote control

.......................................................................................................................................... 20

4.3.1 Pedal switch control

............................................................................................................................... 20

4.3.2 Remote box control

................................................................................................................................. 21

4.3.3 Gun switch control current

..................................................................................................................... 22

4.4 Argon Arc Welding Operation

.................................................................................................................... 22

4.4.1 TIG welding

（

4T operation

）

............................................................................................................... 22

4.4.2 TIG welding (2T operation)

...................................................................................................................... 24

4.5 Welding Parameters

................................................................................................................................... 26

4.5.1 Joint forms in TIG/

MMA

......................................................................................................................... 26

4.5.2 The explanation of welding quality

.......................................................................................................... 26

4.5.3 TIG Parameters Matching

........................................................................................................................ 27

4.6 Operation Environment

.............................................................................................................................. 30

4.7 Operation Notices

...................................................................................................................................... 31

5. Maintenance & Troubleshooting

.............................................................................................................. 31

5.1 Maintenance

.............................................................................................................................................. 31

5.2 Troubleshooting

........................................................................................................................................ 33

5.3 Electrical principle drawing:

...................................................................................................................... 36

Summary of Contents for ionTig 200 AC/DC

Page 1: ...TION MANUAL IMPORTANT Read this Owner s Manual Completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection Contact your distributor if you do not fully understand this manual ...

Page 2: ...sembling the equipment TIG 13 4 Operation 14 4 1 Layout for the panel 14 4 2 Control panel 15 4 3 Remote control 20 4 3 1 Pedal switch control 20 4 3 2 Remote box control 21 4 3 3 Gun switch control current 22 4 4 Argon Arc Welding Operation 22 4 4 1 TIG welding 4T operation 22 4 4 2 TIG welding 2T operation 24 4 5 Welding Parameters 26 4 5 1 Joint forms in TIG MMA 26 4 5 2 The explanation of weld...

Page 3: ...hrottle control rods while the engine is running Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed ...

Page 4: ...ed hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products Shielded gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manu...

Page 5: ...rode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never ...

Page 6: ... not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuff less trousers high shoes and a cap over your hair Wear ear plugs w...

Page 7: ...2 1 Brief Introduction ionTig 200 AC DC arc welding machine adopts the latest pulse width modulation PWM technology and insulated gate bipolar transistor IGBT power module which can change work frequency to medium frequency so as to replace the traditional hulking work frequency transformer with the cabinet medium frequency transformer Thus it is characterized with portable small size light weight...

Page 8: ...when the problems listed before occurred the alarm lamp on the front panel will be on and the output current will be cut off It can self protect and prolong the using life Double purpose AC inverter TIG MMA and DC inverter TIG MMA Excellent performance on Al alloy carbon steel stainless steel titanium According to choosing the front panel functions the following six welding ways can be realized I ...

Page 9: ...int 5 High frequency arc is suitable for high welding speed to improve the productivity IV For AC MMA magnetic flow caused by invariable DC polarity can be avoided V For AC TIG rectangle wave arc is more stable than Sine AC TIG At the same time you can not only obtain the max penetration and the min tungsten pole loss but also obtain better clearance effect ionTig 200 AC DC welding machine is suit...

Page 10: ...er can be adjusted continuously and steplessly to meet with the requirements of welding craft Rectif ier Invert er Trans forme r Rectif ier Hall devic e Current feedback control Single phase AC DC AC DC 220V 50Hz AC Invert er AC or DC Control signal AC or DC 2 3 Volt Ampere Characteristic ionTig 200 AC DC welding machine has an excellent volt ampere characteristic whose graph is shown as the follo...

Page 11: ...ange of start current A TIG MMA AC D C AC DC HF LIFT 5 weldi ng curre nt 10 welding current 30 welding current Adjustment range of welding current A 10 200 30 200 5 200 10 170 5 170 Adjustment range of Crater arc current A 10 200 30 200 5 200 10 170 5 170 Adjustment range of downslope time S 0 10 Pre gas time S 0 1 1 Adjustment range of post gas time S 0 1 10 Clearance effect 15 50 Efficiency Duty...

Page 12: ...0 minutes when it outputs the rated welding current The relation between the duty cycle X and the output welding current I is shown as the right figure If the welder is over heat the IGBT over heat protection unit inside it will output an instruction to cut output welding current and brighten the over heat pilot lamp on the front panel At this time the machine should be relaxed for 15 minutes to c...

Page 13: ... shorten the welder life span The below measures can be used Change the power supply input net Such as connect the welder with the stable power supply voltage of distributor Induce the machines using power supply in the same time Set the voltage stabilization device in the front of power cable input 3 5 Polarity Connection MMA MMA DC Choosing the connection of DCEN or DCEP according to the differe...

Page 14: ...Balance AC DC DC AC Hz S V A AC DC PULSED TIG WELDER 1 220V ON OFF 1 2 3 4 5 6 7 8 1 Positive output The welder s positive polarity output 2 Aero socket Is connected to torch switch control wire It has 14 leads and lead 8 lead 9 are connected to torch switch control wire 3 Negative output The welder s negative polarity output 4 Shield gas connector Is connected to the gas input pipe of torch 5 Pow...

Page 15: ...gas cylinder 8 Fan It is used for cooling the components and parts inside the welder 4 2 Control panel 1 AC DC selecting key 2 Mode selecting key 3 Gas test key 4 HF high frequency ignition key 5 Pulse key 6 Parameter selection key 7 Parameter selection key 8 Adjusting dial 9 Rod electrode welding key 10 Power Alarm indicator 11 Welding voltage other parameter display ...

Page 16: ...ction 1 AC DC selecting key AC welding DC welding 2 Mode selecting key 2 step mode 4 step mode 3 Gas test key Lights up when Gas test key is pressed after that gas will flow out for 15s Press the key again to stop the gas flow before the 15s are up 4 HF high frequency ignition key Lights up when High frequency key is pressed HF high frequency ignition has been selected 5 Pulse key Lights up when P...

Page 17: ... with 4T Unit A Setting range 5 100 of main current Iw DC 10 100 of main current Iw AC HF 30 100 of main current Iw AC LIFT Factory setting 5 Tup Upslope time Unit S Setting range 0 10 Factory setting 0 Iw Welding current Unit A WSME 160 5 160 TIG DC 10 160 TIG AC HF 30 160 TIG AC LIFT WSME 200 5 200 TIG DC 10 200 TIG AC HF 30 200 TIG AC LIFT 5 170 MMA DC 10 170 MMA AC Tpr Is Tup Iw Ic Tpo Tdown F...

Page 18: ...ge 5 100 Factory setting 5 Important Only selectable when pulse key has been pressed Fp Pulse frequency Unit Hz Setting range 0 5 200 Factory setting 0 5 Important Only selectable when pulse key has been pressed Tdown Downslope time Unit S Setting range 0 10 Factory setting 0 Ic Crater arc current only with 4T Unit S Setting range 5 100 of main current Iw DC 10 100 of main current Iw AC HF 30 100 ...

Page 19: ...up if the power switch on Light up if the welder overheat over voltage or over current At the same time display Err 001 11 Welding voltage other parameter display Indicate the welding voltage or other parameter Before the start of welding the right hand display shows the pre set value of Tpr Tup Dcy Fp Tdown andTpo There is a 3s time lag open circuit voltage is displayed after adjusting those para...

Page 20: ...ry set can t be changed If they are changed the welder may be broken 4 FACTORY TEST When it is ON the welder is on debug state 5 FOOT_REMOTE BOX SELECT When it is ON the pedal control can be used When it is OFF the remote box can be used Gun switch control current can be used both ON and OFF 4 3 1 Pedal switch control When plug the fourteen lead aero socket of pedal switch in it Welder will identi...

Page 21: ...n lead aero socket is pedal adjustable resistance 4 3 2 Remote box control When use the remote box the max welding current can be set by panel welding current Connect to gun switch socket Connect to the welder socket Adjustment knob of welding current Adjustment knob of max welding current Connected to the 14 lead aero socket on the front panel ...

Page 22: ...operation The start current and crater current can be pre set This function can compensate the possible crater that appears at the beginning and end of the welding Thus 4T is suitable for the welding of medium thickness plates Gun switch Adjust current button when it s pushed up the current increase when it s pushed down the current decrease ...

Page 23: ...ess During this period the gun switch is loosen Note Select the pulsed output the base current and welding current will be outputted alternately otherwise output the setting value of welding current t4 Press the torch switch again the welding current will drop in accordance with the selected down slope time t4 t5 The output current slopes down to the crater current The downslope time can be adjust...

Page 24: ...ld it Electromagnetic gas valve is turned on The shielding gas stars to flow 0 t1 Pre gas time 0 1 1s t1 t2 Arc is ignited and the output current rises to the setting welding current Iw or Ib from the min welding current t2 t3 During the whole welding process the gun switch is pressed and held without releasing Note Select the pulsed output the base current and welding current will be outputted al...

Page 25: ...ode and prevent tungsten clipping 3 MMA operation if the electrode touches work piece over two seconds the welding current will drop to the 0 automatically to protect the electrode 4 Prevent arc break function TIG operation Avoid arc break with special means even if arc break occurs the HF will keep the arc stable Notices Check the condition of welding and connection units firstly otherwise there ...

Page 26: ...above but output polarity changes alternately 4 5 Welding Parameters 4 5 1 Joint forms in TIG MMA 4 5 2 The explanation of welding quality The relation of welding area color protect effect of stainless steel Welding area color argent golden blue red grey grey black Protect effect best better good bad worst The relation of welding area color protect effect of Ti alloy Welding area color bright arge...

Page 27: ...d gas flow rate Welding current range A DC positive connection AC Gas nozzle diameter mm Gas flow rate L min 1 Gas nozzle diameter mm Gas flow rate L min 1 10 100 4 9 5 4 5 8 9 5 6 8 101 150 4 9 5 4 7 9 5 11 7 10 151 200 6 13 6 8 11 13 7 10 201 300 8 13 8 9 13 16 8 15 Notice the above parameters originate from Welding Dictionary P149 Volume 1 of Edition 2 tungsten electrode diameter mm sharpened o...

Page 28: ...3 2 Corner joint 1 6 2 4 7 115 145 25 4 8 Butt joint 2 4 3 2 8 150 225 25 4 8 Corner joint 3 2 3 2 9 175 250 20 Notice the above parameters originate from Welding Dictionary P150 Volume 1 of Edition 2 Parameters of piping back sealing welding for mild steel DCEP Piping diameterΦ mm Tungsten electrode diameter mm Gas nozzle diameter mm Welding wire diameter mm Welding current A Arc voltage V Argon ...

Page 29: ... 9 8 Flange welding 1 5 1 6 2 0 2 50 80 7 9 8 Flange or butt welding by one side 2 2 2 5 2 3 90 120 8 12 8 12 Butt welding 3 2 3 3 150 180 8 12 8 12 V groove butt welding 4 3 4 180 200 10 15 8 12 5 3 4 4 180 240 10 15 10 12 6 4 5 240 280 16 20 14 16 8 4 5 5 100 260 320 16 20 14 16 10 4 5 5 100 150 280 340 16 20 14 16 120 273 2 5 8 10 2 5 110 125 14 16 12 14 5 6 325 2 5 8 10 2 5 120 140 14 16 12 14...

Page 30: ...ing Dictionary P538 Volume 2 of Edition 2 4 6 Operation Environment Height above sea level is below 1000m Operation temperature range 100C 400C Relative humidity is below 90 200C Preferably site the machine some angles above the floor level the maximum angle does not exceed 150 Protect the machine against heavy rain or in hot circumstance against direct sunshine The content of dust acid corrosive ...

Page 31: ... Maintenance In order to guarantee that arc welding machine works high efficiently and in safety it must be maintained regularly Let customers understand the maintenance methods and means of arc welding machine more enable customers to carry on simple examination and safeguarding by oneself try one s best to reduce the fault rate and repair times of arc welding machine so as to lengthen service li...

Page 32: ... the arc welding machine is overheated observe that whether there is something blocked in the blade if it is blocked please get rid of If the fan does not rotate after getting rid of the above problems you can poke the blade by the rotation direction of fan If the fan rotates normally the start capacity should be replaced If not change the fan Observe that whether the fast connector is loose or ov...

Page 33: ...d by us could overhaul the machine Guarantee to shut off the arc welding machine s power before turn on the outline of the equipment If there is any problem and has no the authorized professional maintenance personal please contact local agent or the branch company If there are some simple troubles of WSME series welding machine you can consult the following overhauling chart S N Troubles Reasons ...

Page 34: ...able is not connected with the two output of the welder Connect the welding cable to the welder s output The welding cable damaged Repair or change it The earth cable connected unstably Check the earth cable The welding cable is too long Use an appropriate welding cable There is oil or dust on the workpiece Check and remove it The distance between tungsten electrode and workpiece is too long Reduc...

Page 35: ...entiometer Imin on the power board The max value displayed isn t accordant with the actual value Please refer to 3 1 Adjust potentiometer Imax on the power board 13 The penetration of molten pool is not enough The welding current is adjusted too low Increase the welding current The arc is too long in the welding process Use 2T operation 14 The alarm lamp on the front panel is on Over heat protecti...

Page 36: ... lead socket GD1 GD2 SOU1 HF ACOUT VC SOUIN HFOUT KG AC DRIVER F1 P N DRIVE RECTIFIER PCB1 INVERTER PCB2 MUR PCB3 F2 ST SS K power switch T1 rectifier ST soft start box C1 C2 electrolytical capacitor T2 IGBT B1 m ain transform er T3 fast recovery diode T2 IGBT m odel H Hall L inductance B2 high frequency transform er P positive output N negative output F fuse B3 switch power supply transform er F1...

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