TITANTIG 200 DC PULSE PRO Operating Manual Download Page 36

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TitanTIG 200 DC Pulse

Pro

Operators Manual

Issue. A 0516

5.0 Trouble Shooting

5.1 MMAW (Stick) Welding Trouble Shooting

The following chart addresses some common problems during MMAW Welding.
In the event of equipment malfunction, contact an authorized service agent.

Possible Reason

Suggested Solution

No Arc

Incomplete welding circuit

Check Earth & Work leads connected

Wrong Mode Selected

Check the MMA/Stick switch is selected

Porosity

Arc length too long

Shorten arc length

Contaminated base metal

Remove any paint , grease, oil & dirt

Damp or Contaminated Electrodes

Dry Electrode or replace

Lack of Penetration

Insufficient heat input

Increase amperage

Contaminated base metal

Remove any paint , grease, oil & dirt

Excessive Spatter

Amperage set to high

Reduce Amperage

Arc length too long

Shorten arc length

Excessive penetration

Amperage set to high

Reduce Amperage

Incorrect travel speed

Increase travel speed

Distortion

Excessive heat input

Reduce Amperage

Poor joint preparation

Check joint design and fit up

Summary of Contents for 200 DC PULSE PRO

Page 1: ...A Gebrauchsanweisung DE Manual de instrucciones ES Käyttöohje FI Manuel d utilisation FR Manuale d uso IT Gebruiksaanwijzing NL Bruksanvisning NO Instrukcja obsługi PL Manual de utilização PT Инструкции по эксплуатации RU Bruksanvisning SV 操作手册 CN English TitanTig 200 DC Pulse Pro TIG Stick Welder Model No TTIG200DCP Issue A 05 16 ...

Page 2: ...TitanTig 200 DC Pulse Operators Manual Issue A 0516 ...

Page 3: ...to read the entire manual paying particular attention to the Safety Precautions They will help you to avoid potential hazards that may exist when working with this product 2 Year Warranty Statement This product is covered by a 2 Year Warranty Parts Labour Warranty This warranty does not cover freight or goods that have been interfered with All goods in question must be repaired by an authorized re...

Page 4: ...re use 20 1 5 Overview of Power Source 21 2 0 Installation 22 3 0 Operation 24 3 1 MMAW Stick Welding 25 3 2 GTAW TIG Welding 26 3 3 Panel Layout Functions 28 4 0 Welding Parameters 33 5 0 Trouble Shooting 36 5 1 MMAW Trouble Shooting 36 5 2 GTAW Trouble Shooting 37 5 3 Electrical Trouble Shooting 38 6 0 Maintenance 40 7 0 Electrical Principle Diagram 41 8 0 Warranty Terms Conditions 42 ...

Page 5: ...g mats or covers big enough to prevent any physical contact with the work ground Never touch the electrode if you are in contact with the work ground or another electrode from a diﬀerent machine Do not wrap cables over your body Ensure that you take additional safety precautions when you are welding in electrically hazardous conditions such as damp environments wearing wet clothing and metal struc...

Page 6: ...ion from moving parts When the machine is in operation keep away from moving parts such as motors and fans Moving parts such as the fan may cut ﬁngers and hands and snag garments Protections and coverings may be removed for maintenance and controls only by qualiﬁed personnel after ﬁrst disconnecting the power supply cable Replace the coverings and protections and close all doors when the intervent...

Page 7: ...e elevated absorbance of the primary current from the power supply network high power systems aﬀect the quality of power provided by the network Consequently connection restrictions or maximum impedance requirements permitted by the network at the public network connection point must be applied to these systems In this case the installer or the user is responsible for ensuring the equipment can be...

Page 8: ...posure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures Keep cables close together by twisting or taping them Arrange cables to one side and away from the operator Do not coil or drape cables around your body Keep welding power source and cables as far away from operator as practical Connect work clamp to work piece as close ...

Page 9: ...uits are also live when power is on In semi automatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard Do not touch live electrical parts Wear dry hoIe free insulating gloves and body protection Insulate yourself from work and ground using dry insula...

Page 10: ...s practical Insulate work clamp when not connected to work piece to prevent contact with any metal object Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters Turn off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touchi...

Page 11: ... containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot work piece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or lure Check and be sure the area is safe before doing any welding Protect yourself and others from flying sparks and hot metal...

Page 12: ...brushing and grinding cause sparks and flying metal As welds cool they can throw off slag Wear approved safety glasses with side shields even under your welding helmet BUILDUP OF GAS can injure or kill Shut off shielding gas supply when not in use Always ventilate confined spaces or use approved air supplied respirator HOT PARTS can cause severe burns Do not touch hot parts bare handed Allow cooli...

Page 13: ...revent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in ...

Page 14: ...period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again Do not block or filter airflow to unit STATIC ESD can damage PC boards Put on grounded wrist strap BEFORE handling boards or parts Use proper static proof bags and boxes to store move or ship PC boards MOVING PARTS can cause injury Keep away from moving parts Keep away from pinch points such as drive r...

Page 15: ...y shut Keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots Be sure all equipment in the welding area is electromagnetically compatible To reduce possible interference kee...

Page 16: ...ttention to the safety instructions in the manual For more information on our products contact us consult an authorized dealer or visit our website The specifications presented in this manual are subject to change without prior notice Important notes Items in the manual that require particular attention in order to minimize damage and personal harm are indicated with the NOTE notation Read these s...

Page 17: ...connection can be chosen according to different electrodes DC TIG DCEP is used normally workpiece connected to positive polarity while torch connected to negative polarity This connection has many characters such as stable welding arc low tungsten pole loss more welding current narrow and deep weld DC Pulsed TIG has the following characters 1 Pulse heating Metal in Molten pool has short time on hi...

Page 18: ...e Single phases work frequency AC 220V 50 Hz is rectified into DC about 312V then is converted to medium frequency AC about 40KHz by inverter device IGBT after reducing voltage by medium transformer the main transformer and rectifying by medium frequency rectifier fast recovery diode and is outputted by inductance filtering The circuit adopts current feedback control technology to insure current o...

Page 19: ...Rated input current A 34 43 Rated input power KW 7 8 9 6 Power factor 0 65 Welding current range A 5 200 Max no load voltage V 89 Efficiency 85 Duty Cycle 40oC to AS NZ60974 35 200A 60 155A 100 120A Protection class IP23 Insulation class H Dimensions of Machine L W H mm 400 145 235 Weight Kg 7 0 Note The above parameters are subject to change with the improvement of machines ...

Page 20: ... caused by misuse Acceptable range of ambient temperature is from 10 40 C Acceptable range of humidity is 20 C at 95 humidity Specifications may change without previous notice Fitted for commissioning Recommended outlet Important Note on TitanTig 200 DC Input Power Supply This unit has been supplied with a downgraded 15 Amp primary supply plug for commissioning purposes only You are advised to upg...

Page 21: ...TitanTIG 200 DC Pulse Pro Operators Manual Issue A 0516 1 5 Overview of machine Front View 1 Control Panel 2 Output terminal 3 Output terminal 4 Control cable connector 5 Gas outlet 1 2 3 4 5 ...

Page 22: ...her impurities to enter the machines cooling air flow Preferably site the machine above floor level for example on a suitable carriage unit Notes for positioning the machine The surface inclination should not exceed 15 degrees Ensure the free circulation of the cooling air There must be at least 20 cm of free space in front of and behind the machine for cooling air to circulate Protect the machine...

Page 23: ... state legislation of where machine is being used Connection can be effected through plug or direct wiring Supply system should be protected at all times by the fuse stated in technical data section Direct connection to mains can be done by qualified electrical technician only Australian 240V Single Phase Plug variants AS NZS 3122 DO NOT USE FITTED FOR COMMISSION RECOMMEDED TYPE ...

Page 24: ...ty Cycle at 180A Overheating Welding machine must be used according to technical data from this manual If the machine is overloaded failures may occur that are not be covered by warranty Overload control Thermal protection is built in the machine s main transformer and Inverter Bridge If the machine overheats thermal fuse will prevent further use and control lamp on the front panel will light up I...

Page 25: ... has a proper grounding Never connect the machine to the mains supply with the panels removed Output connections Electrode polarity In general when using manual arc welding electrodes the electrode holder is connected the positive terminal and the work return to the negative terminal Always consult the electrode manufacturer s data sheet if you have any doubts When using the machine for TIG weldin...

Page 26: ...0 220 260 Average Thickness of Material mm Suggested Electrode Diameter mm Average Thickness of Material mm Suggested Electrode Diameter mm 1 0 2 0 2 5 5 0 8 0 4 0 2 0 5 0 3 2 8 0 5 0 3 2 GTAW TIG Welding TIG Welding Insert the cable plug with the work clamp into the socket on the front panel of the welding machine and tighten it clockwise Insert the cables plug of the TIG torch into the socket on...

Page 27: ...ameters are set appropriately open the gas valve of the cylinder the gas valve on the torch and adjust the gas regulator to obtain the desired flow rate The arc will start when the tungsten electrode touches the work piece and is lifted off after touching by between 2 4mm The arc will cease when the electrode torch is moved away from the work area TIG guides The recommended size of tungsten nozzle...

Page 28: ...elect 6 Adjusting dial Before starting any welding activity ensure that you have suitable eye protection and protective clothing Also take the necessary steps to protect any persons within the area 1 2 3 4 5 6 Pre flow 0 2s Initial Amps 5 200 Up slope 0 10S Peak Amps5 200 Base Amps 5 200 Down slope 0 10S End Amps 5 200A Post flow 0 10S Pulse off Pulse on Pulse duty 5 95 Pulse frequency 0 5 200Hz ...

Page 29: ... control current Option Example shown only Actual Torch may vary from above TIG mode Connect the TIG torch leads as detailed above Ensure that a suitable inert gas supply is connected Switch the power switch on the back panel to ON Select the TIG welding mode using the selector switch There is voltage output at both output terminals After the parameters are set appropriately open the gas valve of ...

Page 30: ... current t2 t3 The output current rises to the setting value Iw or Ib the upslope time can be adjusted t3 t4 Welding process 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...

Page 31: ...eleasing Note Select the pulsed output the base current and welding current will be outputted alternately otherwise output the setting value of welding current t3 Release the gun switch the welding current will drop in accordance with the selected down slope time t3 t4 The current drops to the minimum welding current from the setting current Iw or Ib and then arc is turned off t4 t5 Post gas time ...

Page 32: ...Check the condition of welding and connection units firstly otherwise there will be malfunction such as ignition spark gas leakage out of control and so on Check that whether there is enough Argon gas in the shield gas cylinder you can test the electromagnetic gas valve through the switch on the front panel Do not let the torch aim at your hand or else of your body When you press the torch switch ...

Page 33: ...oxid Protect effect best better good bad worst TIG Parameters Matching The corresponding relationship between gas nozzle diameter and electrode diameter Gas nozzle diameter mm Electrode diameter mm 6 4 0 5 8 1 0 9 5 1 6 or 2 4 11 1 3 2 Notice the above parameters originate from Welding Dictionary P142 Volume 1 of Edition 2 Gas nozzle and the shield gas flow rate Welding current range A DC positive...

Page 34: ... electrode diameter mm welding wire diameter mm Argon gas flow rate L min 1 welding current DCEP Welding Speed cm min 1 0 8 Butt joint 1 0 1 6 5 20 50 66 1 0 Butt joint 1 6 1 6 5 50 80 56 1 5 Butt joint 1 6 1 6 7 65 105 30 1 5 Corner joint 1 6 1 6 7 75 125 25 2 4 Butt joint 1 6 2 4 7 85 125 30 2 4 Corner joint 1 6 2 4 7 95 135 25 3 2 Butt joint 1 6 2 4 7 100 135 30 3 2 Corner joint 1 6 2 4 7 115 1...

Page 35: ... 6 40 84 4 0 140 180 2 0 60 100 5 0 180 220 2 5 80 120 Parameters of piping back sealing welding for mild steel DCEP Piping diamete rΦ mm Tungsten electrode diameter mm Gas nozzle diameter mm Welding wire diameter mm Welding current A Arc voltage V Argon flow rate L min 1 Welding rate cm min 1 38 2 0 8 2 75 90 11 13 6 8 4 5 42 2 0 8 2 75 95 11 13 6 8 4 5 60 2 0 8 2 75 100 11 13 7 9 4 5 76 2 5 8 10...

Page 36: ...ick switch is selected Porosity Arc length too long Shorten arc length Contaminated base metal Remove any paint grease oil dirt Damp or Contaminated Electrodes Dry Electrode or replace Lack of Penetration Insufficient heat input Increase amperage Contaminated base metal Remove any paint grease oil dirt Excessive Spatter Amperage set to high Reduce Amperage Arc length too long Shorten arc length Ex...

Page 37: ...Tungsten Melting Check Type Size Tungsten being used Porosity Incorrect Gas or No Gas Check Pure Argon is in use Insufficient Gas Flow Check gas flow Set to 10 15 l min Contaminated base metal Remove any paint grease oil dirt Contaminated TIG Wire Use clear dry rust free wire only Unstable Arc Torch connected to connection Refit torch to connection Contaminated base metal Remove any paint grease o...

Page 38: ...here is power supply The fuse inside the machine damaged Change it 3A 4 The number on the display is not intact The LED in the display is broken Change the LED 5 The max and min value displayed doesn t accord with the set value The max value is not accordant refer to 3 1 Adjust potentiometer Imin on the power board The min value is not accordant refer to 3 1 Adjust potentiometer Imaxin the current...

Page 39: ...d isn t accordant with the actual value Please refer to 3 1 Adjust potentiometer 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 12 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 o...

Page 40: ...minutes after disconnecting the mains cable before removing the machine s case Perform the following cleaning and maintenance at least every six months 1 Clean the interior of the machine and the fan grill s net of any dust and stains for Example with a soft brush and vacuum cleaner Do not use pressurized air The stain may become compressed into the grooves of the coolers Do not use a pressure was...

Page 41: ...TitanTIG 200 DC Pulse Pro Operators Manual Issue A 0516 7 0 Electrical principle diagram ...

Page 42: ...f original found to be faulty freight free to the customer The obligation of Weldtronic International P L under this warranty is limited to the circumstances set out above and is subject to The customer being able to provide proof of purchase of the product and the purchase price paid for the product The relevant defect in materials or workmanship The product not having been altered tampered with ...

Page 43: ... 3 Month warranty on Helmet shell harness fittings Warranty Returns Exchanges 1 Subject to the conditions of warranty set out in the warranty period Weldtronic International P L warrants that if any defect in any workmanship on any product has occurred then the conditions applicable to the warranty period are a The warranty applies on the basis of the goods being used on the equivalent of single d...

Page 44: ... the meaning of the Trade Practices Act 1974 or the Fair Trading Acts of the relevant state or territories of Australian and is therefore also entitled to at the consumers discretion either a refund of the purchase priceof the goods orrepairofthe goods orreplacementof the goods 7 Returns will only be accepted provided that a You have complied with the provisions outlined above and b Where the good...

Page 45: ...r modifications or other work carried out on the product other than by an authorized Weldtronic service dealer 14 This warranty does not cover the following parts a MIG TIG Stick MMA WeldingTorches Consumablessuchas Gas nozzles Gas diffusers contact tip holder contact tip swan necks trigger handle liners wire guide drive roller neck spring connector block insulator gas nipple cap euro block head a...

Page 46: ...TitanTIG 200 DC Pulse Pro Operators Manual Issue A 0516 ...

Page 47: ...TitanTIG 200 DC Pulse Pro Operators Manual Issue A 0516 ...

Page 48: ... A 0516 Weldtronic International P L ABN 99 149 754 263 42 46 Micro Circuit Dandenong Sth Victoria 3175 Australia P O Box 2096 Rowville Victoria 3178 Australia Tel 03 9702 9366 Fax 03 9702 9766 Email sales weldtronic com au Web www weldtronic com au ...

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