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AC/DC GTAW

WELDING MACHINE

CONTENTS

INTRODUCTION OF TIG WELDING MACHINE ........................................................................................ 1

SAFETY INSTRUCTIONS ......................................................................................................................... 3

INSTALLATION & COMMISSIONING OF AC/DC TIG WELDING MACHINE ............................................. 8

OPERATING INSTRUCTION .................................................................................................................. 13

COMPONENT DETAILS OF WELDING PLANT ..................................................................................... 15

WELDING PARAMETER SELECTION AND SETTING [FRONT PANEL] ................................................ 16

MAINTENANCE ...................................................................................................................................... 21

TROUBLE SHOOTING .......................................................................................................................... 24

TIG WELDING TORCH DETAILS ........................................................................................................... 28

10. ARGON FLOWMETER REGULATOR DETAILS ..................................................................................... 30

11. WATER COOLING UNIT DETAILS ......................................................................................................... 32

12. TECHNICAL SPECIFICATION OF MACHINE ......................................................................................... 34

13. BASIC WELDING TECHNIQUE .............................................................................................................. 37

Содержание SI-TIG-300

Страница 1: ...AC DC GTAW WELDING MACHINE MANUAL Vavdi Survey no 28 Shivam Industrial Area Street No 3 Plot No 7 Near Sunny Raj Metal Rajkot 360004 Gujarat India Email us sohamlathe gmail com ...

Страница 2: ...OPERATING MANUAL AC DC GTAW WELDING MACHINE MODEL SI TIG 300 Works Soham Impex Vavadi survey no 28 Plot no 7 Near Sunny Raj Metal Rajkot City Gujarat 360004 ...

Страница 3: ...G MACHINE 8 4 OPERATING INSTRUCTION 13 5 COMPONENT DETAILS OF WELDING PLANT 15 6 WELDING PARAMETER SELECTION AND SETTING FRONT PANEL 16 7 MAINTENANCE 21 8 TROUBLE SHOOTING 24 9 TIG WELDING TORCH DETAILS 28 10 ARGON FLOWMETER REGULATOR DETAILS 30 11 WATER COOLING UNIT DETAILS 32 12 TECHNICAL SPECIFICATION OF MACHINE 34 13 BASIC WELDING TECHNIQUE 37 ...

Страница 4: ...tomatic intelligent combination of parameters To achieve beautiful ripple pattern of welding seam with the function of Pulse TIG Perfect functions of starting arc and reducing melting ball while stopping arc Special 4 step mode is suitable for welding metal with good thermal conductivity with perfect welding quality when starting arc and stopping arc Multiple protection functions TIG torch with qu...

Страница 5: ...cool down Reduce amperage or duty cycle before welding Applications This series of machines have many welding processes and can weld most of the metal materials including carbon steel stainless steel aluminum and Al Mg alloy copper and alloy etc Recommended areas of use as follows Automobile and car manufacture industry Chemical structure and engineering Boiler pressure vessel manufacture Shipbuil...

Страница 6: ...nce with the intended purpose The manufacturer shall not be liable for any damage resulting from such improper use Safety signs All the safety instructions and danger warnings on the machine must be kept in legible condition not removed not be covered pasted or painted cover Safety inspection The owner operator is obliged to perform safety inspection at regular intervals The manufacturer also reco...

Страница 7: ...on Replace damaged part immediately Electric and magnetic fields EMF may be dangerous If electromagnetic interference is found to be occurring the operator is obliged to examine any possible electromagnetic problems that may occur on equipment as follow minas signal and data transmission leads IT and telecoms equipment measurement and calibration devices Wearers of pacemakers Measures for minimizi...

Страница 8: ... contact can cause sparks explosion overheating or fire Make sure the area is safe before doing any welding Welding and cutting on closed containers such as tanks drums or containers can cause them to blow up Make sure proper steps have been taken When pressure gas is used at the work site special precautions are required to prevent hazardous situations Connect work cable to the work as close to t...

Страница 9: ...r or any other electrically hot parts Do not drape welding cables or welding torches over a gas cylinder Use only correct compressed gas cylinders regulators hoses and fittings designed for the process used maintain them and associated parts in good condition Use only compressed gas cylinders containing the correct shielding gas for the and properly operating regulators designed for the gas and pr...

Страница 10: ...rsons remove doors panels covers or guards for servicing and maintenance Reinstall doors panels covers or guards when servicing and maintenance is finished and before reconnecting input power Overuse can cause overheating Safety markings Use machine follow duty cycle Reduce current or reduce duty cycle before starting to weld again Allow cooling period Do not block or filter airflow to unit Equipm...

Страница 11: ...rpose The manufacturer shall not be liable for any damage resulting from such improper use Operate inspect and maintain should follow all the instructions given in this manual Machine installation rules Protection degree of this power source is IP23 However the internal key components must be protected from direct soaking The venting duct is very important for safety protections When choosing the ...

Страница 12: ... cables to two windings in reverse direction and overlap them The number of turns for A is same as the number for B Handle the welding cable and ground cable according to above mentioned method Welding cables instruction Connecting to a mains electrical supply THIS MACHINE IS OF AN INDUSTRIAL SPECIFICATION AND MUST BE FITTED TO A MINIMUM of 16AMP 415V MAINS INPUT Connecting to an Engine Driven Gen...

Страница 13: ...ins input cable Fit required plug as per your electrical installation 3 Gas Inlet Input connector Connect input gas hose ensuring connection is tight Gas hose from Flow meter is connected here 4 Main chassis earth bolt If you experience interference you can fit extra earth to this point Not normally used ...

Страница 14: ...bench 3 Gas outlet Quick release type Connect the torch gas hose 4 Torch control socket 7 Pin Connect torch control plug 5 FRONT PANEL All welding Process and Parameter are SET and Operate operated from this panel Its Display will show all values Details of each buttons and is use is elaborated in chapter 6 6 Water Inlet Connect water hose from TIG torch Water input to cool the TIG torch 7 Water o...

Страница 15: ...ap around a point in the top third of the cylinder but never around the neck of the cylinder 2 Take the protective cap off the gas cylinder 3 Gently turn the gas cylinder value anticlockwise and blow off any dust and dirt 4 Screw the pressure regulator onto the gas cylinder and tighten it 5 Connect the shielding gas connector to the pressureregulator Note To avoid a High Frequency shock keep the T...

Страница 16: ...king There are no set rules for pulse welding as this is down to personal choice by the welder Welding in TIG mode with Remote amperage torch 1 Connect the Tig Torch to machine connect earth lead to machine work piece 2 Set to Tig mode pulse OFF or Tig mode pulse ON In welding with pulse in remote torch the foot pedal controls peak main welding amperage 3 Select 2T or 4T torch operation Ensure the...

Страница 17: ...s and application ELECTRODE RATINGS Electrode Diameter mm 2 Thoriated on DC amps Red Tip Grind to point Pure Tungsten on DC amps Zirconiated 0 8 Tungsten on AC amps White Tip No need to grind 1 0mm 0 040 5 80 30 20 60 1 6mm 1 16 40 150 80 40 100 2 4 mm 3 32 140 250 130 80 180 3 2mm 1 8 240 400 180 160 250 4 0mm 5 32 380 500 240 220 320 4 8mm 3 16 500 750 300 280 390 6 4mm 1 4 750 1000 400 360 525 ...

Страница 18: ... gas regulator with flow meter and gas hose Welding cable with Electrode Holder Ground Earthling cable with Clamp Standard tool kit for operating plant Scope of supply by Consignee Input Supply 3 PHASE 340 to 460 VAC 50 Hz Argon gas cylinder Provided by consignee Welding material Electrode wire 5 COMPONENT DETAILS OF WELDING PLANT ...

Страница 19: ...not be save until you save again 2 Save button to save the parameters on control panel 3 Select Parameter selector Button Press this button to scroll from left A to right L to select the machine parameters an adjust the value of the same within 2 seconds or you have to repeat the procedure again as LED will move to its initial D position 4 Parameter Sequence From A to L as explained below A Pre fl...

Страница 20: ...I E if mains amperage is 120A and you set to 50 base amps will be 60A G Pulse Frequency Hz Adjustment This can be adjusted as follows DC Mode 0 1 to 500HzAC Advanced Squarewave 0 1 250HzAC Soft Square Triangular and Sinewave 0 1 10HzAdvanced AC Pulse 0 1 10Hz H AC Balance This sets the of electrode positive used during AC welding to provide a cleaning action as alloys have a oxide layer that has a...

Страница 21: ...just all Arc welding parameter after selecting this function OCV is same as of Power source D STICK WITH VRD Same procedure of ARC Stick Welding with Advance feature VRD Voltage Reduction Device This eliminates the risk of Shock due to High OCV 6 Parameter adjustment Knob Turn this knob to adjust parameter values if you hold the knob in and turn it increase adjustment speed 7 a MMA Arc Force contr...

Страница 22: ... output current will increase from the start min current to base main current in time selected by slope up Release the Tig torch switch to end sequence The machine will now decrease output to finish min current in time set by slope down once at finish min current the machine will stop output and the gas valve will continue to operate for the selected time post flow Possible variations of this stan...

Страница 23: ... your thumb to adjust knob on torch handle This does take some getting used to but is handy when you are welding in a position where a foot pedal is not use able You can use a remote amperage torch in 2T or 4T mode most common is 4T as you press trigger to start weld and then release you can then use thumb finger for torch switch to adjust amperage knob once weld has finished press the torch switc...

Страница 24: ... Before open the machine Maintenance Please follow the instructions as below to ensure normal lifespan of power source Conduct safety check at regular intervals see Safety rules Dismantle machine side panels and clean machine inside with clean and low pressure compressed air by professional technician not less than twice per year Clean the components at a certain distance only If a lot of dust has...

Страница 25: ...or injury to the technician and machine operator and will invalidate your warranty For your safety and to avoid electric shock please observe all safety notes and precautions detailed throughout this manual The troubleshooting guide is provided to help you locate possible machine malfunctions If fault problem is not solved please send complaint to ourcompany Details of our address phone numbers an...

Страница 26: ...c Flutters when TIG welding 1 Tungsten electrode may be too large in diameter for the current setting 2 Tungsten not sharp when in DC mode 3 Gas shielding flow may be low or high check gas flow reduce tungsten stick out beyond ceramic 4 Check for leaks in torch gas hoses Black areas along weld bead 1 Clean any oily or organic contamination from the work piece 2 Tungsten electrode contaminated Repl...

Страница 27: ...to help you locate possible machine malfunctions If fault problem is not solved please send complaint to our company Details of our address phone numbers and E mail id are given in front page of this manual Tig welding problems No output Power light is not lit Check machine on off switch is in the on position Check Input power to machine Check plug wiring Check mains trip fuses No output Fan runs ...

Страница 28: ...ny oily or organic contamination from the work piece 2 Tungsten electrode contaminated Replace or sharpen 3 Check for leaks or contamination on gas hoses connections 4 Gas flow may be insufficient Increase gas flow reduce tungsten stick out from ceramic Weak HF Poor arc striking welding output normal 1 Check torch and earth connections is torch cable insulation in good condition 2 Check for leaks ...

Страница 29: ...le Cause Remedy E01 Over heat protection The welding machine is over heat orTemperature Relay fault Shut down the welding machine and wait for cooling or replace Temperature Relay E02 Over current protection Short circuit of Output Current Sensor fault Check output cable and replace Current Sensor E04 Water cooling is abnormal No circulating water in water cooling system Check water flow and repai...

Страница 30: ... working Check the mains supply lead of Fan make sure that the mains is connected Check Fan is JAM due to dust clean it if still not OK replace it Machine Showing Error code Check Code number and then rectify it as per problem mentioned in code list Welding current can not be regulated Check Potentiometer on torch is ok also check itswiring Check parameter is properly selected or locked Check Pote...

Страница 31: ... 28 9 TIG WELDING TORCH DETAILS ...

Страница 32: ... 29 ...

Страница 33: ... 30 10 ARGON FLOWMETER REGULATOR DETAILS ...

Страница 34: ... 31 ...

Страница 35: ... should be carried out by a suitably qualified person Always use the correct spare parts when completing any repairs DESCRIPTION This Water Cooler is designed for cooling torches for welding applications by means of water re circulation via a closed system The system comprises the following main parts Water Circulating Motor pump Heavy Duty for long life Coolant Tank FRONT VIEW TECHNICAL DATA INPU...

Страница 36: ...M POWER SOURCE Periodically check the level of the cooling fluid Add fluid when the level drops below the minimum level indicator Add anti freeze when the room temperature is below 20 C Make sure all the joints are tight and there are noleaks Periodically clean the radiator with clean dry air to eliminate blockages that may affect efficiency IMPORTANT Always use original spare parts which have bee...

Страница 37: ...5 D C 480A 60 DC 600A 100 DC 480A Duty Cycle Torch 35 D C 480A OCV 90V Type of Shielding Gas Argon Type of Cooling Air Cooled Primary Power At 100 DC 20 5 KVA Power factor 0 99 Efficiency 89 Weight 28 Approx Dimensions 560 x 235 x 445 Approx Ambient temp upto 40 degC Thickness of weld metal 6 mm Protection class IP23 Insulation class H Noise Level in db 80 TIG Torch a Type of Cooling GAS WATER b T...

Страница 38: ... value of welding voltage afterwelding 14 Error code display 15 Front Panel Digital Display Welding voltage current 16 Welding Parameter values like gas pre flow time up slope time pulse time ignition current main current down slope time gas post flow time ESSENTIAL FEATURES Digital Control Digital Signal processor Active wave Inbuilt resulting quiet highly stable arc Panel locking features Inbuil...

Страница 39: ...way from the bench where this traditional arrangement can become much more difficult or even impossible to use Fingertip controls are truly invaluable in these cases Being able to control the machine s output with a simple finger motion means there is no need to control your body beyond what is necessary to get your hands near the joint Using a fingertip control also allows for fast tacking while ...

Страница 40: ...be connected to this rule applies to all the other forms of DC welding as well TIG ARC DC TIG welding is a process in which an arc is struck between a TUNGSTEN electrode and the metal work piece The weld area is shielded by an inert gas flow to prevent contamination of the tungsten molten pool and weld area When the TIG arc is struck the inert gas is ionized and superheated changing it s molecular...

Страница 41: ...ngsten inert gas Welding Lift Arc is a form of arc ignition where the machines has low voltage on the electrode to only a few volts with a current limit of one or two amps well below the limit that causes metal to transfer and contamination of the weld or electrode When the machine detects that the tungsten has left the surface and a spark is present it immediately within microseconds increases po...

Страница 42: ...ulating the welding torch in the other However some welds combining thin materials can be accomplished without filler metal like edge corner and butt joints This is known as Fusion welding where the edges of the metal pieces are melted together using only the heat and arc force generated by the TIG arc Once the arc is started the torch tungsten is held in place until a weld pool is created a circu...

Страница 43: ...s introduced to the leading edge of the weld pool The filler wire is usually held at about a 15 angle and fed into the leading edge of the molten pool the arc will melt the filler wire into the weld pool as the torch is moved forward Also a dabbing technique can be used to control the amount of filler wire added the wire is fed into the molten pool and retracted in a repeating sequence as the torc...

Страница 44: ...ding and cutting While tungsten is a very hard material the surface of a diamond wheel is harder and this makes for smooth grinding Grinding without diamond wheels such as aluminium oxide wheels can lead to jagged edges imperfections or poor surface finishes not visible to the eye that will contribute to weld inconsistency and weld defects Always ensure to grind the tungsten in a longitudinal dire...

Страница 45: ...fter welding STICK ARC ARC Ignition Weld pool Protection Slag The arc is initiated by momentarily touching the electrode to the base metal The heat of the arc melts the surface of the base metal to form a molten pool at the end of the electrode The melted electrode metal is transferred across the arc into the molten pool and becomes the deposited weld metal The deposit is covered and protected by ...

Страница 46: ...of Material Maximum Recommended Electrode Diameter 1 0 2 0mm 2 5mm 2 0 5 0mm 3 2mm 5 0 8 0mm 4 0mm 8 0 mm 5 0mm The size of the electrode generally depends on the thickness of the section being welded and the thicker the section the larger the electrode required The table gives the maximum size of electrodes that maybe used for various thicknesses of section base on using a general purpose type 60...

Страница 47: ...tion of travel When vertical up welding the angle of the electrode should be between 80 and 90 degrees to the work piece Travel Speed The electrode should be moved along in the direction of the joint being welded at a speed that will give the size of run required At the same time the electrode is fed downwards to keep the correct arc length at all times Excessive travel speeds lead to poor fusion ...

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