Headux TitanMig Pulse 2700, TitanMig Pulse 5000, TitanMig Pulse 3500, TMP3500, TMP5000 Operation Manual

TitanMig Pulse 2700/3500/5000

Operation Manual

Operating manual EN

Brugsanvisning DA

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

TitanMig Pulse 2700/3500/5000 MIG/TIG/Stick Welder

Model No. TMP2700, TMP3500, TMP5000 Issue. A 05/16

TitanMig Pulse 2700/3500/5000 Operators Manual

Issue. A 0516

Welcome:

Thank you for your purchase of your new Weldtronic product. The Weldtronic product range provides
you with quality and reliability.

This product is supported by our extensive service network. In the unlikely event of a problem occurring
please call your local distributor.

Please record below the details from your product as these will be required for warranty purposes and to
ensure you get the correct information should you require assistance or spare parts.

Date purchased: ________________________________________________________________________

From where: ___________________________________________________________________________

Serial No: ____________________________________________________________________________

(The serial number will be located on the equipment data plate underneath or on the rear panel)

This Operating manual has been designed to instruct you on the correct use and operation of your
Weldtronic product. Information is a guide and we assume no liability for its use.

Please take the time 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 repair agent as appointed by Weldtronic.
 Warranty does not cover abuse, misuse, accident, theft or general wear & tear.
 New product will not be supplied unless Weldtronic International P/L has inspected product

returned for warranty and agrees to replace the product.

 Product will only be replaced if repair is not possible.
 Warranty will be considered void if the 15 Amp primary power Input Plug is modified or replaced

to fit a domestic 10A primary power input Plug.

 Warranty will be considered void if the equipment is powered from an unsuitable engine driven

generator.

 Warranty will be considered void if no proof of purchase can be provided.
 Warranty will be considered void if this product has been altered, tampered or used in any

manner contrary to customary usage or application.

 Full warranty details and conditions supplied with this product are shown in the back of this

manual.

TitanMig Pulse 2700/3500/5000 Operators Manual

Issue. A 0516

Contents

SAFETY PRECAUTIONS………………….……………………………………………………………..……1

1.0 Preface…………………………………………………………………………………………………11

1.1 General…………………………………………………………………………………………………11

1.2 Introduction………………………………………………………………….………………………12

1.3 Technical Specifications…………………………………………………………..……………13

1.4 Important Notes before use………………………………………………………………...14

1.5 Overview of Power Source……………………………………………………………………15

1.6 Overview of Wire Feeder……………………………………………………………………..16

1.7 Welding Panel , Storage & Recall………………………………………………………….20

1.8 Welding Machine Setup……………………………………………………………………….21

1.9 Welding Machine Status Display…………………………………………………………..22

2.0 Installation……………………………….…………………………………………………………23

3.0 Operation …………………………………………………………………………………………..25

3.1 GMAW (MIG) Welding…………………………………………………………………………26

3.2 MMAW (Stick) Welding……………………………………………………………………….42

3.3 GTAW (TIG) Welding………………………………………………….………………………..44

3.4 Software Updates……………………………………………………………………………….47

3.5 Add Funtions………………………………………………………………………………………54

4.0 Trouble Shooting…………………………………………………………………………………55

4.1 Mig Trouble Shooting………………………………………………………………………….55

4.2 MMAW (Stick) Trouble Shooting…………………………………………………………57

4.3 GTAW (TIG) Trouble Shooting……………………………………………………………..58

4.4 Electrical Trouble Shooting………………………………………………………………...59

5.0 Maintenance…………………………………………………………………………………..….60

6.0 Electrical Diagram……………………………………………………………………………….61

7.0 Warranty Terms & Conditions……………………………………………………………..62

TitanMig Pulse 2700/3500/5000 Operators Manual

Issue. A 0516

SAFETY PRECAUTIONS – READ BEFORE USING

These general safety norms cover both arc welding machines and plasma cutting machines unless
otherwise noted.
The equipment must only be used for the purpose it was designed for. Using it in any other way could
result in damage or injury and in breach of the safety rules. Only suitably trained and competent persons
should use the equipment. Operators should respect the safety of other persons.

Prevention against electric shock

 The equipment should be installed by a qualified person and in accordance with current standards

in operation. It is the user’s responsibility to ensure that the equipment is connected to a suitable
power supply. Consult with your utility supplier if required.

 If earth grounding of the work piece is required, ground it directly with a separate cable.
 Do not use the equipment with the covers removed.
 Do not touch live electrical parts or parts which are electrically charged.
 Turn off all equipment when not in use.
 Cables (both primary supply and welding) should be regularly checked for damage and

overheating. Do not use worn, damaged, under sized, or poorly jointed cables.

 Ensure that you wear the correct protective clothing, gloves, head and eye protection.
 Insulate yourself from work and ground using dry insulating 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 structures. Try to avoid
welding in cramped or restricted positions.

 Ensure that the equipment is well maintained. Repair or replace damaged or defective parts

immediately. Carry out any regular maintenance in accordance with the manufacturer’s

instructions.

Safety against fumes and welding gases

 Locate the equipment in a well-ventilated position.
 Keep your head out of the fumes. Do not breathe the fumes.
 Ensure the welding zone is in a well-ventilated area. If this is not possible provision should be

made for suitable fume extraction.

 If ventilation is poor, wear an approved respirator. Read and understand the Material Safety Data

Sheets (MSDS’s) and the manufacturer’s instructions for metals, consumable, coatings, cleaners,

and de-greasers.

 Do not weld in locations near any de-greasing, cleaning, or spraying operations. Be aware that

heat and rays of the arc can react with vapours to form highly toxic and irritating gases.

 Do not weld on coated metals, unless the coating is removed from the weld area, the area is well

ventilated, and while wearing an air-supplied respirator. The coatings on many metals can give off
toxic fumes if welded.

TitanMig Pulse 2700/3500/5000 Operators Manual

Issue. A 0516 1

Prevention against burns and radiation

 Arc rays from the welding process produce intense, visible and invisible (ultraviolet and infrared)

rays that can burn eyes and skin.

 Wear an approved welding helmet fitted with a proper shade of filter lens to protect your face

and eyes when welding or watching

 Wear approved safety glasses with side shields under your helmet.
 Never use broken or faulty welding helmets.

 Always ensure there are adequate protective screens or barriers to protect others from flash,

glare and sparks from the welding area. Ensure that there are adequate warnings that welding or
cutting is taking place.

 Wear suitable protective flame resistant clothing. The sparks and spatter from welding, hot work

pieces, and hot equipment can cause fires and burns

 Welding on closed containers, such as tanks, drums, or pipes, can cause them to explode.
 Accidental contact of electrode to metal objects can cause arcs, explosion, overheating, or fire.
 Check and be sure the area is safe and clear of inflammable material before carrying out any

welding.

Protection against noise

 Some welding and cutting operations may produce noise.
 Wear safety ear protection to protect your hearing.

Protection 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 intervention is finished, and

before starting the equipment.

 Take care to avoid getting fingers trapped when loading and feeding wire during set up and

operation.

 When feeding wire be careful to avoid pointing it at other people or toward your body.
 Always ensure machine covers and protective devices are in operation.

Precautions against fire and explosion

 Avoid causing fires due to sparks and hot waste or molten metal
 Ensure that appropriate fire safety devices are available near the cutting / welding area.
 Remove all flammable and combustible materials from the cutting / welding zone and

surrounding areas

 Do not cut/weld fuel and lubricant containers, even if empty. These must be carefully cleaned

before they can be cut/welded.

 Always allow the cut/welded material to cool before touching it or placing it in contact with

combustible or flammable material.

 Do not work in atmospheres with high concentrations of combustible fumes, flammable gases

and dust.

 Always check the work area half an hour after cutting to make sure that no fires have begun

TitanMig Pulse 2700/3500/5000 Operators Manual
Issue. A 0516 2

Risks due to magnetic fields

 The magnetic fields created by high currents may affect the operation of pacemakers or

electronically controlled medical equipment.

 Wearers of vital electronic equipment should consult their physician before beginning any arc

welding, cutting, gouging or spot welding operations.

 Do not go near welding equipment with any sensitive electronic equipment as the magnetic fields

may cause damage.

RF Declaration

Equipment that complies with directive 2004/108/EC concerning electromagnetic compatibility (EMC) and
the technical requirements of EN60974-10 is designed for use in industrial buildings and not those for

domestic use where electricity is provided via the low voltage public distribution system. Difficulties may

arise in assuring class A electromagnetic compatibility for systems installed in domestic locations due to
conducted and radiated emissions.
In the case of electromagnetic problems, it is the responsibility of the user to resolve the situation. It may
be necessary to shield the equipment and fit suitable filters on the mains supply.

LF Declaration

Consult the data plate on the equipment for the power supply requirements.
Due to the 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 connected,
consulting the electricity provider if necessary.

Materials and their disposal

The equipment is manufactured with materials, which do not contain any toxic or poisonous materials
dangerous to the operator.
When the equipment is scrapped, it should be dismantled separating components according to the type of
materials.
Do not dispose of the equipment with normal waste. The European Directive 2002/96/EC on Waste
Electrical and Electronic Equipment states the electrical equipment that has reached its end of life must be
collected separately and returned to an environmentally compatible recycling facility.

Handling of Compressed gas cylinders and regulators

All cylinders and pressure regulators used in welding operations should be handled with care.
Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.
Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
Always secure the cylinder safely.
Never deface or alter any cylinder

TitanMig Pulse 2700/3500/5000 Operators Manual

Issue. A 0516 3

EMF Information

Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding
current, as it flows through welding cables, will cause electro-magnetic fields. There has been and still is
some concern about such fields, However, after examining more than 500 studies spanning 17 years of
research, a special blue ribbon committee of the National Research Council concluded that: "The body
of evidence, in the committees judgment, has not demonstrated that exposure to power-frequency
electric and magnetic fields is a human-health hazard." However studies are still going forth and evidence
continues to be examined. Until the final conclusions of the research are reached, you may wish to
minimize your exposure 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 to the weld as possible.

Limitations of warranty declaration regarding machine use

▲ The welding machine(s) described in this manual are designed exclusively for electrical arc welding

with shielding gases Argon, CO2 or Ar + CO2 mixture(s) employing MIG or MAG technology. Using
this machine for other purposes is not allowed. Using this machine in opposition with instructions
can put the welder in danger. Damage can occur to the welding machine if not operated according
to this manual. Failures and accidents due to such actions are not covered by warranty, nor can the
producer be held responsible

TitanMig Pulse 2700/3500/5000 Operators Manual

Issue. A 0516 4

Symbol usage

This group of symbols means Warning! Watch
Out! Possible ELECTRIC SHOCK, MOVING PARTS,
and HOT PARTS hazards.
Consult symbols and related instructions below for
necessary actions to avoid the hazards.

Means Warning! Watch Out! There are possible hazards with this procedure! The possible
hazards are shown in the adjoining symbols.

▲ Marks a special safety message.

Arc Welding Hazards

▲ The symbols shown below are used throughout this manual to call attention to and identify

possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid
the hazard. The safety information given below is only a summary of the more complete safety
information found in the Safety Standards. Read and follow all Safety Standards.

▲ Only qualified persons should install, operate, maintain, and repair this unit.

▲ During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and
work circuit is electrically live whenever the output is on. The input power circuit and
machine internal circuits 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 insulating mats or covers big enough to prevent any

physical contact with the work or ground.

 Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling.
 Use AC output ONLY if required for the welding process.
 If AC output is required, use remote output control if present on unit.
 Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input

power according to Safety Standards.

 Properly install and ground this equipment according to its Owner’s Manual and national, state, and local

codes.

 Always verify the supply ground — check and be sure that input power cord ground wire is properly

connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded
receptacle outlet.

TitanMig Pulse 270/3500/5000 Operators Manual
Issue. A 0516 5

 When making input connections attach proper grounding conductor first - double-check connections.
 Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged —

bare wiring can kill.

 Turn off all equipment when not in use.
 Do not use worn, damaged, undersized, or poorly spliced cables.
 Do not drape cables over your body.
 If earth grounding of the work piece is required, ground it directly with a separate cable.
 Do not touch electrode if you are in contact with the work, ground, or another electrode from a different

machine.

 Use only WeII-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to

manual.

 Wear a safety harness if working above floor level.
 Keep all panels and covers securely in place.
 Clamp work cable with good metal-to-metal contact to work piece or worktable as near the weld as

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 touching any parts.

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous
to your health.

 Keep your head out of the fumes. Do not breathe the fumes.
 If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases.
 If ventilation is poor use an approved air-supplied respirator.
 Read the Material Safety Data Sheets (MSDSs) and the manufacturers’ instructions for metals,

consumables, coatings, cleaners, and degreasers.

 Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always

have a trained watch-person nearby. Welding fumes and gases can displace air and lower the oxygen level
causing injury or death. Be sure the breathing air is safe.

 Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can

react with vapours to form highly toxic and irritating gases.

 Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is

removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied
respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

TitanMig Pulse 270/3500/5000 Operators Manual

Issue. A 0516 6

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense visible and invisible (ultraviolet and
infrared) rays that can burn eyes and skin. Sparks fly off from the weld.

 Wear a welding helmet fitted with a proper shade of filler to protect your face and eyes when welding or

watching (see Safety Standards).

 Wear approved safety glasses with side shields under your helmet.

 Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc.
 Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot

protection.

WELDING can cause fire or explosion.

Welding on closed 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.
 Do not weld where flying sparks can strike flammable material.
 Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them

with approved covers.

 Be alert that welding sparks and hot materials from welding can easily go through small cracks and

openings to adjacent areas.

 Watch for fire, and keep a fire extinguisher nearby.
 Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.
 Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared

according to Safety Standards.

 Connect work cable to the work as close to the welding area as practical to prevent welding current from

travelling long, possibly unknown paths and causing electric shock and fire hazards.

 Do not use welder to thaw frozen pipes.
 Remove stick electrode from holder or cut off welding wire at contact tip when not in use.
 Wear oil-free protective garments such as leather gloves, heavy shirt, cuff less trousers, high shoes, and a

cap.

 Remove any combustibles, such as butane lighter or matches, from your person before doing any welding.

TitanMig Pulse 270/3500/5000 Operators Manual

Issue. A 0516 7

FLYING METAL can injure eyes.

 Welding, chipping, wire 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 cooling period before working on gun or torch.

MAGNETIC FIELDS can affect pacemakers.

 Pacemaker wearers keep away.
 Wearers should consult their doctor before going near arc welding, gouging, or spot

welding operations.

NOISE can damage hearing.

Noise from some processes or equipment can damage hearing.

 Wear approved ear protection if noise level is high.

TitanMig Pulse 270/3500/5000 Operators Manual

Issue. A 0516 8

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can
explode. Since gas cylinders are normally part of the welding process, be sure to treat
them carefully.

 Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and

arcs.

 Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent 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 good condition.

 Turn face away from valve outlet when opening cylinder valve.
 Keep protective cap in place over valve except when cylinder is in use or connected for us

FIRE OR EXPLOSION hazard.

 Do not install or place unit on, over, or near combustible surfaces.
 Do not install unit near flammables.
 Do not overload building wiring — be sure power supply system is properly sized, rated,

and protected to handle this unit.

FALLING UNIT can cause injury.

 Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.
 Use equipment of adequate capacity to lift and support unit.
 If using lift forks to move unit, be sure forks are long enough to extend beyond opposite

side of unit.

OVERUSE can cause OVERHEATING

 Allow cooling period; follow rated duty cycle.
 Reduce current or reduce duty cycle before starting to weld again.
 Do not block or filter airflow to unit.

TitanMig Pulse 270/3500/5000 Operators Manual

Issue. A 0516 9

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 rolls.

WELDING WIRE can cause injury.

 Do not press gun trigger until instructed to do so.
 Do not point gun toward any part or the body, other people, or any metal when

threading welding wire.

H.F. RADIATION can cause interference.

 High frequency (HF,) can interfere with radio, navigation, safety services, computers, and

communications equipment.

 Have only qualified persons familiar with electronic equipment perform this installation.
 The user is responsible for having a qualified electrician promptly correct any

interference problem resulting from the installation.

 If notified by the FCC about interference, stop using the equipment at once.
 Have the installation regularly checked and maintained.
 Keep high-frequency source doors and panels tightly 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, keep weld cables as short as possible, close together,

and down low, such as on the floor.

 Locate welding operation 100 meters from any sensitive electronic equipment.
 Be sure this welding machine is installed and grounded according to this manual.
 If interference still occurs, the user must take extra measures such as moving the welding machine, using

shielded cables, using line filters, or shielding the work area

TitanMig Pulse 270/3500/5000 Operators Manual
Issue. A 0516 10

1.0 Preface

1.1 General

Congratulations on choosing TitanMig Pulse welding machine. Used correctly, our products can
significantly increase the productivity of your welding, and provide years of economical service.

This operating manual contains important information on the use, maintenance and safety of our
product. Please read the manual carefully before using the equipment for the first time.

For your own safety and that of your working environment, pay particular attention 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 sections carefully and follow their instructions.

Disclaimer

While every effort has been made to ensure that the information contained in this guide is accurate
and complete, no liability can be accepted for any errors or omissions. We reserve the right to change
the specification of the product described at any time without prior notice.

TitanMig Pulse 270/3500/5000 Operators Manual
Issue. A 0516 11

1.2 Introduction

TitanMig Pulse 2700/3500 and 5000 are CC/CV welding power sources designed for demanding
professional use. They are suitable for synergic Pulsed MIG/MAG, Synergic 1-MIG/MAG,Lift-Tig and MMA
welding in DC current.

TitanMig Pulse 2700/3500/5000 product range offers both technical and commercial welding solutions
matching a wide range of applications from sheet metal fabrication to heavy industry segments.

The TitanMig Pulse 2700/3500/5000 power sources are digitised microprocessor-controlled inverter
power sources.

The TMP-series power sources 2700/3500/5000 are used in workshops and industry for manual and
automated applications with classical steel, galvanised sheets, chrome/nickel and aluminium.

The TitanMig Pulse 2700 features an integral 4-roller drive. There is no longer an interconnecting hose
pack between the power source and wire-feed unit. Its compact design makes the TMP 2700 particularly
suitable for mobile applications on building sites or in repair workshops..

The TMP 4000/5000 power sources are designed for: -- Mechanical engineering - Steel engineering - Crane
construction - Shipbuilding - Boiler manufacture- Automobile and component supply industry - Machinery
and rail vehicle construction - Chemical plant construction - Equipment construction etc.

All models are multiprocess devices: - MIG/MAG welding - TIG welding with touchdown ignition- Manual
metal arc welding

TitanMig Pulse 270/3500/5000 Operators Manual

Issue. A 0516 12

TMP 5000

TMP 3500

TMP 2700

Power Supply / Phases (V-Ph)

AC380V±15%~50/60Hz

240 V 1 Phase

Duty Cycle@40°c to AS/NZ60974

60% @ 500 Amps MIG

60% @ 350 Amps MIG

35% @ 275Amps MIG

60% @ 500 Amps MMA

60% @ 350 Amps MMA

60% @ 194Amps MMA

Rated Output Power Rate

500A/40V

350A/34V

250/26.5V

Rated Input Current

36A

21A

50 A

Power Factor

≥0.85

0.75

Efficiency

90%

90%

Gas pre-flow time (Preg)

0～15.0s

Post-flow time(Posg)

0～15.0s

Soft start speed (Stfd)

Auto，0.5～22m/min

Wire Feeder Type

Gear Driven 4 Roll

Gear Driven 4 Roll

Gear Driven 4 Roll

Protection Class

IP 21S

IP 21S

IP 21S

Insulation Class

H H H

Dimensions Power Source (LxWxH)

685x295x560mm

685x295x560mm

685x295x560mm

Weight Power Source

53 Kg

52Kg

38 Kg

Dimensions Wire Feeder (LxWxH)

630x235x420mm

630x235x420mm

685x295x560mm

Weight Wire Feeder

16 Kg

16 Kg

Length of Interconnecting Cable

5m/10 m/15m

5m/10 m/15m

1.3 Technical Specifications

TitanMig Pulse 270/3500/5000 Operators Manual
Issue. A 0516 13

1.4 Important notes before use

▲ Fitted for commissioning

▲ Recommended outlet

▲ Important Note on TitanMig

Pulse 2700 Input Power Supply

This unit has been supplied with
a downgraded 15 Amp primary
supply plug for commissioning
purposes only. You are advised to
upgrade the input power plug
and lead to a minimum of 32A if
sustained usage at maximum
amperage is desired.

▲ WARNING

With the 15A plug supplied it is
recommended that the operator
does not exceed more than
180Amps, as use of higher
amperages over this amount may
lead to failure and overheating of
the 15A plug and circuit, which
may result in electrical supply
component damage and
ultimately electrical fires.

▲ Do not operate or install this equipment without thoroughly reading this manual and the safety

precautions contained throughout.

 Save this manual and keep it handy for reference.
 Disconnect mains of the semi-automatic welding machine after finishing work or before a long break.

▲ DO NOT make any modifications to the machine. It may cause changes in the features and

deterioration of technical data.

▲ Any adaptations to this machine are prohibited and may void the warranty.
▲ Warranty is void if any damage to the machine is 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.

TitanMig Pulse 270/3500/5000 Operators Manual
Issue. A 0516 14

1

2

3

4

5

6
7
8
9

10

1.5 Overview of Power Source

TitanMig 500 Shown (details will vary from model)

Front View

Power Source Front Panel Layout

1. Control panel

2. Welding Cable Connection

3. Earth Cable Connection

Rear View

4. CO2 Heating Socket

5. Welding Cable Connection

6.Data Plate

7. Primary Input Cable

8. Primary Power Switch

9. Water Cooler Power Socket

10. Control Cable Connection

TitanMig Pulse 270/3500/5000 Operators Manual
Issue. A 0516 15

1.5 Overview of Wire Feeder (TMP3500/5000 Only)

1 2

3

4 5

Feed Roll Size & Type

Part Number

Feed Roll 30/10/22 – 0.6/0.8mm Steel

FR3022V0608

Feed Roll 30/10/22 – 0.8/1.0mm Steel

FR3022V0810

Feed Roll 30/10/22 – 0.9/1.2mm Steel

FR3022V0912

Feed Roll 30/10/22 – 1.0/1.2mm Steel

FR3022V1012

Feed Roll 30/10/22 – 1.0/1.2mm Aluminum

FR3022U1012

Feed Roll 30/10/22 – 0.9/1.2mm Aluminum

FR3022U0912

Feed Roll 30/10/22 – 0.9/1.2mm Flux Cored

FR3022K0912

Feed Roll 30/10/22 – 1.2/1.6mm Flux Cored

FR3022K1216

2

3

4

1

5

6

7

8

HF10 Structure

1. Control Box

2. Spool Cover

3. Handle

4. Drive System

5. Gun Connector

HF10 Drive System

1. Drive Gear

2. Wire Feed Rollers

3. Pressure Rollers

4. Pressure Rocker Arm

5. Pressure Adjustment Screw

6. Feed Housing

7. Inlet Guide

8. Drive Motor

HF10 Spare Feed Rollers

TitanMig Pulse 270/3500/5000 Operators Manual
Issue. A 0516 16

1.6 Description of the control panels

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

16 17 18 19 20 21

Control Panel

1. Feeder inching button

for feeding the wire electrode into the torch-hosepack without any flow of gas or curren

2. Adjusting dial for altering welding parameters.

If the indicator on the adjusting dial is lit up, then the selected parameter is one that can be altered.

3. Welding current LED

lights up when the welding current parameter is selected

4. Wire feed speed LED

lights up when the wire feed speed parameter is selected

5. Sheet thickness LED

lights up when the sheet thickness parameter is selected

6. More indicator LED

lights up when the other indicator parameter is selected

7. Left parameter selection button

8. Digital display

9. Right parameter selection button

10. Welding voltage LED

lights up when the welding voltage parameter is selected.

11. Droplet detachment correction/arc force dynamic correction/arc force dynamic LED

lights up when the Droplet detachment correction/arc force dynamic correction/ arc force dynamic

TitanMig Pulse 270/3500/5000 Operators Manual
Issue. A 0516 17

parameter is selected

1) For MIG welding process: the inductance value 0 is recommended reference range. Value less than
0 give a rougher arc and increased stability. Value greater than 0 give a smoother arc and less spatter.

2) For pulse MIG welding process: The droplet transfer force will be increased according the
inductance value changed from less than 0 to greater than 0.

3) For MMA welding process: the arc force value 0 means soft and spatter small arc, value 100 means
hard and stable arc. When the display value is Job, the welding parameter can be stored and
recalled. Please refer to the details on section 3.2

12. Job no. LED

lights up when the job number parameter is selected

13. Value indicator LED

lights up when the other indicator parameter is selected

14. Adjusting dial for altering welding parameters.

If the indicator on the adjusting dial is lit up, then the selected parameter is one that can be altered

15. Gas test button

for setting the required gas flow rate on the pressure regulator. Gas will flow out for 30 s after
pressing the gas test button. Press the button again to stop the gas test flow before the end of this
period.

16. Wire diameter button

for selecting the diameter of the wire to be used. Parameter SP is reserved for additional wire
diameters. When a wire diameter is selected, the LED behind the relevant wire diameter lights up.

TitanMig Pulse 270/3500/5000 Operators Manual
Issue. A 0516 18

17. Material button

for selecting the filler metal and shielding gas to be used. Parameters SP1 and SP2 are reserved for
additional materials. When a material is selected, the LED behind the relevant filler metal lights up.

18. Mode button

for selecting the mode

2-step mode

4-step mode

Special 4-Step Mode

Special 4-Step Mode

Spot welding mode

For storing the welding parameters

Special Mode 1

Special Mode 2

19. Process button(s)

for selecting the welding process

Manual metal arc welding

Lift-TIG welding

Pulse Lift-TIG welding

TitanMig Pulse 270/3500/5000 Operators Manual
Issue. A 0516 19

MIG/MAG standard synergic welding

MIG/MAG single pulse synergic welding

MIG/MAG double pulse synergic welding

When a process is selected, the LED on the relevant symbol lights up.

20. Save Button:

For two purposes: store the welding parameters and startup Settings menu

21. Function

Lights up when under welding process.

lights up when under no-load working

lights up if an error has occurred

Lights up when connecting Robot

Lights up when connecting other equipments

1.7 Welding parameters storage and recall

TMP series can store 100 sets of welding parameters (Job0—Job99). The suitable welding parameters
value for different welding application can be stored at any time. Its very convenience to recall the stored
welding parameter when use it next time. No need to preset and adjust the welding parameter value each
time before welding.
For Job 0, it’s specially used for automatically memory storage, which can store the last welding parameter
automatically. The last welding parameter can be recalled from Job 0 when restart the welding machine.
Operation process of recall as follow:

1) Press to choose the display value as job. 23

2) Turn to alter the Job number as 0.

3) The LED will be display the welding parameter which has been used last time.

For Job 1-99, it’s used for manual storage, Operation process as follow:

1) LED displays the welding parameters which will be stored.

2) Press to choose the display value as job.

3) Press , the front of the Job number will display "－"

4) Turn to choose the Job number as “XX”.

5) Press , the LED will display "Finished", means the parameter has been stored to the Job number
“XX”.
Operation process of recall as follow:

1) Press to choose the display value as job.

2) Turn to choose the Job number as “XX”.

3) The LED will be displayed the welding parameters which has been stored in Job “XX”.

TitanMig Pulse 270/3500/5000 Operators Manual
Issue. A 0516 20

1.8 TMP welding machine startup Settings.

Some welding parameters of TMP series welding machine could be adjusted through the startup Settings
menu, and the operation process as following：

1) Press on key, and turn on the power switch of the machine at the same time.

2) After few seconds, it enters the Startup Settings Menu, and LED display "Preg" as Figure 3.3.1.

3) Press to choose , then the left part of the LED display the parameter name, and
right part of the LED display the parameter value.

4) Turn the left side to choose the parameter name, turn the right side to adjust the
parameter value.

5) Press , the LED will display "Finished", means the parameter has been reset and stored. Then
restart the machine and weld.

Adjustable parameters name of startup Settings as following:

1) Pre-gas flow time (PreG): Adjustable from 0-15s, the default value is 0.1s. It works for MIG, Pulse
MIG, Double Pulse MIG, TIG, Pulse TIG and Spot TIG.

2) Post-gas folw time (PosG) : Adjustable from 0-15s, the default value is 0.1s. It works for MIG, Pulse

MIG, Double Pulse MIG, TIG, Pulse TIG and Spot TIG welding processes.

3) Soft start wire feed speed (Stfd) : Adjustable from 1-22 m/min, and also can be set at automatic. It
works for MIG, Pulse MIG and Double Pulse MIG welding process.

4) Inch wire feed speed (Infd) : Adjustable from 1-22 m/min.

5) Master station MACID (NetP) : Master station MACID of Devicenet: 0-63.

6) Slave station MACID (NetS) : Slave station MACID of Devicenet: 0-63.

7) Device net baud rate (Netb) : 0-125 k, 1-250 k, 2-500 k

8) System Set 1 (Set1) : Bit0 = 1 means allow the simulation remote control, 0 means banned.

9) System Set 2 (Set2) : temporary undefined.

10) Wire feed machine coefficient (Fdp), wire feed machine constant (Fdc) : according the different

wire feed motor, setting up different coefficient. First Type, 24V, 22M/Min, 5A motor: Fdp = 400; Fdc =
426; Second Type, 24 v, 22 m, 3.5 A motor: Fdp = 371; Fdc = 400;

11) Setting up Password (Pas1, Pas2, Pas3, Pas4) : function password settings.

TitanMig Pulse 270/3500/5000 Operators Manual
Issue. A 0516 21

1.9 TMP series welding machine status display

TMP series welding machine can display some information and status of the welder. After startup welding,
the LED will display the company LOGO, hardware, software version, 25 welding process, expert database
material type and whether support DEVICENET and WIFI one by one.
Operation process of the welding machine status display

1) Press to choose the display value as .

2) Turn the left side to show different status of the welding machine as following:

Machine internal temperature is 26℃

Hardware version for V23, software version for V1.4

Machine serial number as XY000030

Actual wire feed speed in 8.5 m/min

TitanMig Pulse 270/3500/5000 Operators Manual
Issue. A 0516 22

2.0 Installation

Worker and working area protection

Fumes and gases produced by welding are dangerous for your health. Ventilation in workplace must be
adequate to remove all harmful fumes and gases but not too strong since it could remove the shielding
gas flowing over work piece. Arc welding rays are dangerous for your eyes. The welder must always use a
welding helmet with a minimum protective shade glass No. 10 for MIG Welding. All personal protective
including working clothes, leather apron, gloves, etc. must always be worn when welding or handling the
work piece.

Unpacking

Check the packaging for any signs of damage. Carefully remove the machine and retain the packaging until
the installation is complete.

Positioning of the machine

Place the machine on a firm, dry and level surface. Where possible, do not allow dust or other 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 against heavy rain and direct sunshine.

NOTE! The machine should not be operated in the rain as the protection class of the machine, IP21S,

allows for outside preserving and storage only.

NOTE! Never aim metallic grinding spray/sparks towards the equipment.

Input connection

Before connecting the machine you should ensure that the correct supply is available. Details of the
machine requirements can be found on the data plate of the machine or in the technical parameters
shown in the manual.

The equipment should be connected by a suitably qualified competent person. Always ensure the

equipment has a proper grounding.
Never connect the machine to the mains supply with the panels removed.

TitanMig Pulse 270/3500/5000 Operators Manual

Issue. A 0516 23

Mains supply – TMP 2700 Only

DO NOT USE FITTED FOR COMMISSION RECOMMEDED TYPE

The INPUT primary cable is supplied with machine. Connect the machine to mains
according to your 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

Mains supply – TMP 3500 / 5000 MTS Only

The INPUT primary cable is supplied with machine. Connect the machine to mains
according to your 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.

 Three phase Plug is not included.
 For 350MTS min 20amp 3 phase plug recommended.
 For 500MTS min 32 amp 3 phase plug recommended

Output connections

Electrode polarity

 In general when using the machine for MMAW (Stick) the electrode holder is connected to the

positive (+) terminal and the work return to the negative (-) terminal.

 In general when using the machine for GMAW (Mig) the MIG Torch should be connected to the

positive (+) terminal (Euro Connector) and the work return to the negative (-) terminal.

 In general when using the machine Gasless Mig the Mig Torch should be connected to the

negative (-) terminal (Euro Connector) and the work return to the positive (+) terminal.

 When using the machine for GTAW (TIG) welding the TIG torch should be connected to the

negative terminal (-) and the work return to the positive (+) terminal

 Always consult the electrode manufacturer’s data sheet if you have any doubts.

TitanMig Pulse 270/3500/5000 Operators Manual
Issue. A 0516 24

3.0 Operation

Duty cycle and overheating

Duty Cycle is percentage of 10 minutes that unit can weld at rated load without
overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan
runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before
welding.

60% Duty 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. In this case the welder must wait until the machine's
temperature drops to normal. Note the machine must be left switched on for the fan
to keep running.

TitanMig Pulse 270/3500/5000 Operators Manual
Issue. A 0516 25

3.1 GMAW (MIG) Welding

 Insert the welding torch into the “Euro connector for torch in MIG” output socket on the front

panel of the wire feed unit, and tighten it.

 Install the wire spool on the spindle adapter of the wire feed unit.
 Connect the cylinder equipped with the gas regulator to the gas inlet of the interconnection cable

set.

 Insert the cable plug with work clamp into the “-” output terminal on the front panel of the

welding machine, and tighten it clockwise.

 Insert the quick plug of the interconnection cable set into the “+” output terminal of the welding

machine, and tighten it clockwise. Connect the other end connection on the rear of the wire feed
unit

 Insert the multi pin plug of the interconnection cable set into the control cable socket of the

welding machine and connect the other connection into the rear of the wire feed unit.

 Ensuring that the groove size in the feeding position on the drive roll matches the contact tip size

of the welding torch and the wire size being used. Release the pressure arm of the wire feeder to
thread the wire through the guide tube, and into the drive roll groove. Adjust the pressure arm,
ensuring no sliding of the wire. Too high pressure will lead to wire distortion, which will affect
wire feeding. Press the wire inch button to thread the wire out of the torch contact tip.

TitanMig Pulse 270/3500/5000 Operators Manual
Issue. A 0516 26

 After being installed according as above, and the power switch on the back panel being switched

on, the machine is started. At this time, the ammeter displays the preset wire feed speed value,
and the voltmeter displays the preset voltage value. Open the cylinder valve, and switch the gas

check switch to the “GAS CHECK” position. Adjust the gas regulator to get the correct gas flow.
After setting, switch the gas check switch to the “Welding” position.

 Before starting the welding it is recommended to make tests and trial runs on scrap material.

 Get the correct arc conditions by adjusting the inductance control knob. Turn the knob

counterclockwise to get lower inductance and harder arc; turn it clockwise to get higher
inductance and softer arc. Generally, select harder arc at lower current, while select softer arc at
higher currents.

 Select the correct welding current and welding voltage by adjusting the current control knob and

voltage control knob on the wire feeder.

 Select 2T or 4T operation mode. In 2T mode, arc is ignited by pushing the torch trigger, and arc

stops by releasing the torch trigger. In 4T mode, welding can be continued when releasing the
torch trigger after arc is ignited, and at this time, welding instructions should be set by adjusting
the current control knob and voltage control knob on the wire feeder. When pushing the torch
trigger again, the machine enters into crater welding, and at this time. Crate parameters should
be set by adjusting the crater/welding current control knob and crater voltage control knob on the
front panel of the machine.

 The actual current and voltage values are displayed on the front panel of the machine. When the

torch trigger is released, welding ends. 2 seconds after welding ends, the gas supply will be cut
off.

Installation of wire reel

Open the side cover and unscrew reel brake cover. Mount the reel in such way that one
end of wire hangs downwards. Mount brake cover back in position.
Cut off the bent end of the wire. Lead the end of the wire trough inlet guide and unclip
pressure handle of feed rollers in order to make the work easier. Ensure both wire inlet
guide and the feeding rollers groove are aligned. Push the welding wire to the inlet of the
torch connection. Replace the pressure handle to re-establish pressure on the wire. If
handle pressure is too strong the wire could be transformed - flattened. If the pressure is

too low the wire could slip in the feeding groove. Use tension knob to adjust this.

Gas selection for Gas Metal Arc Welding (GMAW)

Metal inert gas welding (MIG): Uses Argon (Ar), Helium (He) or Ar-He mixtures as the shield gas, and it
mainly used for welding aluminum and its alloys.

Metal active gas welding (MAG): Uses Argon (Ar) mixed with a certain amount of CO2 / O2 as the shield
gas, and it usually used in short circuit transfer and spray transfer. It can be applicable to flat position
welding, vertical position welding, overhead position welding and all-position welding, and it mainly used
for welding carbon steel, high strength low alloy steel and stainless steel. Welding robots mostly use the
MAG process.

CO2 (carbon dioxide) gas shielded arc welding (CO2 welding): It uses CO2 as the shield gas, and is usually
used in globular transfer and short circuit transfer to implement welding. It can be used to weld in
different positions. As compared with other welding methods, CO2 welding has many advantages, though
it produces more spatters, CO2 welding is widely used for general metal structure welding.

TitanMig Pulse 270/3500/5000 Operators Manual

Issue. A 0516 27

The correct shielding gas can alter productivity in GMAW by contributing to.

 Correct weld sizes, to reduce over welding
 Lower spatter levels, to increase welding speed and reduce clean-up
 Reduced welding defects which reduces rework time
 Reduced fume levels, to improve OH&S and worker comfort, increases productivity

Shielding gases have a strong influence over..

 Stability of the arc
 The shape of the weld bead/face
 Mechanical properties of the weld
 Cost efficiency of the welding process being used
 Control of fume generation rates

Gases used in Shielding Gas Formulations

Argon

 The tendency for argon to produce a “Wine Glass” penetration profile can make it difficult to ensure

complete fusion of the weld especially if “Arc Wander” is occurring.

 For GMAW applications small additions of oxygen or carbon dioxide will assist in eliminating “Arc

Wander” by producing a uniformly oxidized surface for the arc root to “Anchor” to. The addition of

helium produces a broader and deeper fusion profile.

Carbon Dioxide CO2

 The first shielding gas used for GMAW, MIG welding.
 Spray transfer using GMAW cannot be achieved with carbon dioxide.
 At low currents a good dip transfer mode can be obtained.
 At high currents the transfer mode is globular and significant spatter is produced
 Carbon Dioxide is less than ideal for use alone as a shielding gas but it is an essential ingredient of

most GMAW shielding mixtures.

 High Carbon Dioxide (18 to 23%) mixtures are particularly suited to welding steels which are coated

with paint, primers and other surface contaminants, or where higher penetration is required.

Helium

 Rarely used alone as a shielding gas.
 Completely inert.
 Lighter than air therefore less efficient as a shield.
 High ionization potential which can cause arc initiation problems.
 Essential ingredient for many shielding gas mixtures.

 Helium rich shielding gas mixtures provide excellent weld fusion characteristics for GMA welding

applications. The high heat input obtained by using helium produces a hot arc and allows for high
deposition welding.

Oxygen

 Oxygen is never used as a shielding gas on its own.
 Oxygen is a vital component in many mixtures and performs two main functions…
 It aids stability within the arc ionizing at a similar level to argon and influences the arc rooting

characteristics by producing a uniform oxide layer on the electrode and work piece.
It also reduces the surface tension of the metal droplets and the molten weld pool.

 The benefits of these two functions are reduced wire losses as a result of spatter and the more

efficient use of deposited metal due to reduced reinforcement (weld metal build-up).

TitanMig Pulse 270/3500/5000 Operators Manual

Issue. A 0516 28

Penetration Profiles

Base Material considerations

 Base material type or classification
 Base material thickness
 Joint design
 Welding position

Metal transfer mode

 Spray transfer
 Globular transfer
 Dip transfer
 Pulsed current transfer

Quality aspect of the finished weld

 Mechanical and chemical requirement
 Surface finish
 Penetration

Economics of the weld

 Clean up costs (acceptable level of spatter)
 Welding travel speed
 Flow rate of shielding gas
 Cost of shielding gas

Different shielding gas formulations produce quite different and significant changes to the penetration
profile of the weld.

Selecting the Correct Shielding Gas

Carbon Steel - Low content CO2 Mixtures

 Most shielding gases are based on the argon/carbon dioxide/oxygen system for welding carbon steels.
 Low content CO2 mixture (1-7% CO2) produce welds with a “Wine Glass” penetration profile similar to

that produced by pure argon, along with a very stable arc and low spatter levels.

 Due to these mixtures having a relatively low heat input, fusion defects and porosity can occur when

welding heavy sections due to the penetration profile, low fluidity and the rapid freezing of the weld
pool.

Carbon Steel – Intermediate content CO2 mixtures
 Intermediate content CO2 mixtures (8-15% CO2) produce a higher heat input giving improved

characteristics and broader penetration profile.

 These mixtures are more versatile than the low content CO2 mixtures and sound welds can be

produced over a wide range of material thickness.

 These mixtures usually produce the most stable welding arc characteristics and are normally the best

general purpose shielding gases for Mild, Carbon and Low Alloy Steels.

High content CO2 mixtures
 High content CO2 mixtures (16-23% CO2) allow for further improvements in the fusion characteristics

and the penetration profiles of the weld.

 These mixtures are ideally suited for welding heavy sections especially in multi pass situations.
 The stiff weld pools cool relatively slowly which aids welding and complete fusion to the weld side

walls.

 Any entrapped gas has time to disperse before freezing of the weld pool occurs.
 The arc is less stable than with the low content CO2 mixtures which may result in increased spatter

levels.

TitanMig Pulse 270/3500/5000 Operators Manual

Issue. A 0516 29

Welding current setting

Wire Diameter(mm)

Welding Current Range(A)

Optimal Current(A)

0.8

50-120

70-100

1.0

70-180

80-120

1.2

80-350

100-200

Welding Mode

Welding with thin wire

Welding with thick wire

Welding with thick wire
under high current

Gas Flow(L/m)

5~15

15~20

20~2

Set the welding current after the above preparation. Short circuiting transfer is mainly fit for electrode
wires of diameter 0.6~1.2mm. As a guide for short circuit welding set the welding current according to
the table below.

Welding speed selecting

The welding quality and productivity should be taken into consideration for the selecting of welding speed.
In the case that the welding speed increases, it weakens the protection effect and quickens the cooling. As
a consequence, it is not good for weld bead shaping. In the event that the speed is too slow, the work
piece will be burned through, and a good weld bead will be unavailable. In practical operation, the welding
speed should not exceed 50cm/min.

Wire Stick-out

The increase of the stick-out can improve the productivity, but too long stick-out may lead to excessive
spatter, wire breaking and unstable welding. Generally, the stick-out should be 10 times as the welding
wire diameter.

Shielding Gas flow selection

The protection effect is the primary consideration. Besides, the protection effect of inner-angle welding is
better than that of external-angel welding, so the gas flow in inner-angle welding should be lower. Less or
no shield gas is needed in FCAW. Refer to the table below for the recommended gas flow rates.

TitanMig Pulse 270/3500/5000 Operators Manual
Issue. A 0516 30

3.1 GMAW (MIG) Welding

Use welding process button to select Synergic Mig or Single Pulse Mig or
Double Pulse Mig welding method. then adjust the other parameters.

Current, wire feed speed and thickness: these three parameters are linked, if you adjust one of them,
the others will be matched automatically due to there is a Highly intelligent expert database in welding
machine.The user just need to select the welding process, operation mode, type of material, wire
diameter and any one of (current, wire speed, thickness), the machine will find the best combinated
parameters from the expert database.
Arc length: the standard arc length in the expert database is (=0), the user could increase or decrease the
arc length according to the welding technology.
Inductance/arc force: the standard inductance in the expert database is 0, the user could increase or
decrease the inductance/arc force. And the inductance perform different functions in different welding
methods. MIG/MAG: 0: soft arc, small splash Pulse MIG: 0:increase the droplet transfer force
Type of material: the user could select the suitable type of material according to the base metal dand
welding wire, details in section 4.10 (expert database of MIG, PULSE MIG, & DOUBLE PULSE MIG).

Wire diameter: setting the diameter directly according to the actual used welding wire.
Operation mode: there are 5 kinds of torch operation mode as following diagram:

2T

TitanMig Pulse 270/3500/5000 Operators Manual
Issue. A 0516 31

4T

Special 2T

TitanMig Pulse 270/3500/5000 Operators Manual
Issue. A 0516 32

Special 4T

Spot Welding

End current(EndI): as figures shown, its function is to fill the crater.
Initial current(HotI) : as figures shown, its function is to increase the heat input when start to weld and

avoid the welding defects during the arc strike.

Burn time: it is to adjust the effect of ball cutting when finish welding.
Spot time(Sptt): the duration of the spot welding.
Initial time(Hott): the duration of the initial current, it is only suitable for S2T.
End time(Endt): the duration of the end current, it is only suitable for S2T.
Slop time(SLOP): the switching time between two currents, such as the initial current and welding current.
Double pulse frequency (Freq): as figures shown
The arc length of double pulse (AL2): as figures shown, it is the High arc length value of the double pulse

MIG, The lowe arc length decided by corresponding arc in the indicator lamp I
The scope of the double pulse(Fd2) , as below figures shown, it is the rangeability of wire speed for
double pulse.

TitanMig Pulse 270/3500/5000 Operators Manual
Issue. A 0516 33

No.

material

AWS specification

Protective Gas

Remark

1

Steel:G3/4 Si

CO2%

2 AlMg4,5Mg

ER5083 H

Ar+50%He

Optional

3

AlSi 5

ER4043

Ar 100%

4 AlMg 5

ER5356

Ar 100%

5 Al99.5

ER1050

Ar 100%

6 AlSi12

ER4047

Ar 100%

Optional

7

CuAl9

ER Cu Al

Ar 100%

8 CuSi3

ER Cu Si

Ar 100%

9 NiCr 21 Mo 9 Nb

ER NiCrMo

Ar 100%

Optional

10

CrNi 18 8 6

ER307

A r 97.5% CO2 2.5%

11

CrNi19 9

ER308

A r 97.5% CO2 2.5%

12

CrNi 22 12

ER 309

A r 97.5% CO2 2.5%

Optional

13

CrNi 25 20

ER 310

A r 97.5% CO2 2.5%

Optional

14

CrNi 19 12 3

ER 316

A r 97.5% CO2 2.5%

Optional

15

CrNi 13 4

ER 410

A r 97.5% CO2 2.5%

Optional

16

CrNb 16

ER 430

A r 97.5% CO2 2.5%

Optional

17

CrNi 22 9

ER 2209

Ar 82% CO2 18%

Optional

18

CrNi 19 12 3

ER 316

Ar 82% CO2 18%

Optional

19

CrNi 13 4

ER 410

Ar 82% CO2 18%

Optional

20

CrNi Flux cored

Ar 82% CO2 18%

21

Rutil Flux cored

Ar 82% CO2 18%

22

Basic Flux cored

Ar 82% CO2 18%

23

Metal Flux core

Ar 82% CO2 18%

24

Steel:G 3/4 Si 1

Ar 82% CO2 18%

25

Hard facing

Ar 82% CO2 18%

Optional

The expert database for MIG, Pulse MIG and double pulse MIG

TitanMig Pulse 270/3500/5000 Operators Manual

Issue. A 0516 34

Work piece preparation

Joint type

Groove shape

Weld shape

Metal thickness

[mm]

Work piece

spacing [mm]

Square butt

joint

single sided

up to 1,5

from 1,5

0 to 2

Square butt

joint

double sided

2 to 4

up to 2

V – butt joint

3 to 6

up to 1

3 to 6

up to 1

Square T - joint

single sided

from 0,6

-

Square T - joint

double sided

from 0,6

-

Lap joint

0,6 to 1,5

-

Edge joint

from 1

-

Welding joint describes the welding spot and exact position of work pieces to be welded together. Work
piece preparation, groove form and width, material type and thickness, together with certain welding
technique all determine joint type.

Around the groove work pieces should be dry and clean, free of rust, metallic coating, dirt, colour or
grease.

TitanMig Pulse 270/3500/5000 Operators Manual

Issue. A 0516 35

Positioning the welding torch

Welding wire is energised when the torch button is pressed. Lower your helmet first and then press the
trigger. Wire should be around ½ in past end of nozzle, and tip of wire positioned correctly on seam.

1…….. Hold torch and control trigger with one

hand

2…….. Work piece
3…….. Earth clamp
4…….. Electrode extension (Stick out) ¼ to ½ in
5…….. Cradle torch with the other hand and

rest it on work piece

Heat distribution and weld
material flow are specific for
groove welds and fillet welds.
Optimal torch position differs
from one to another.

Weld bead shape differs
depending on electrode
extension when welding fillet
welds.

TitanMig Pulse 270/3500/5000 Operators Manual

Issue. A 0516 36

Gun movement during welding

Weld bead shape as well as penetration and overall joint quality are affected by torch angle, direction of
travel, electrode extension, travel speed, thickness of base material, wire feed speed, and voltage.

varies with torch travel speed.
For adequate penetration to
be achieved welding source
must provide more power at

Using constant parameters welding material deposit and penetration

1…….. Stringer bead – steady movement along seam
2…….. Wave bead – side to side movement along seam

higher speeds.

Dragging the torch results in
deeper penetration and
narrower weld. Arc strength
prevents slag to enter the
molten material.

When pushing the torch
penetration will be shallower
and the weld wider. This
movement is suitable for thin
plates because of smaller heat
input.

3…….. Wave patterns

Use weave patterns to cover a
wide area in one pass of
electrode.

Normally a single stringer bead
is satisfactory for most narrow
groove weld joints. However for
wide groove weld joints or
bridging across gaps, a weave
bead or multiple stringer beads
work better.

TitanMig Pulse 270/3500/5000 Operators Manual

Issue. A 0516 37

Welding results and troubleshooting

GOOD WELD BEAD

1…….. Fine spatter
2…….. Uniform bead
3…….. Moderate crater during welding
4…….. No overlap
5…….. Good penetration into base material

POOR WELD BEAD

1…….. Large spatter deposits
2…….. Rough, uneven bead
3…….. Slight crater during welding
4…….. Bad overlap
5…….. Poor penetration

TitanMig Pulse 270/3500/5000 Operators Manual

Issue. A 0516 38

Excessive spatter

Scattering of molten metal particles that cool to solid near
weld bead.

Possible causes

Corrective actions

Wire feed speed too high.

Select lower wire feed speed.

Voltage too high.

Select lower voltage.

Electrode extension too long.

Use shorter electrode extension.

Work piece dirty.

Remove all grease, oil, moisture, rust, paint, undercoating, and
dirt from work surface before welding.

Insufficient shielding gas at arc.

Increase flow of shielding gas at regulator and/or prevent
drafts near welding arc.

Dirty welding wire.

Use clean, dry welding wire.
Eliminate pickup of oil or lubricant on welding wire from
feeder or liner.

Porosity

Small cavities or holes resulting from gas pockets in weld
material.

Possible causes

Corrective actions

Wrong gas.

Use welding grade shielding gas; change to different gas.

Welding wire extends too far out of
nozzle.

Be sure welding wire extends no more than ½ in beyond
nozzle.

Work piece dirty.

Remove all grease, oil, moisture, rust, paint, undercoating, and
dirt from work surface before welding.

Use a highly deoxidising welding wire (contact supplier).

Insufficient shielding gas at arc.

Increase flow of shielding gas at regulator and/or prevent
drafts near welding arc.
Remove spatter from gun nozzle.
Check gas hoses for leaks.
Place nozzle ¼ to ½ in from work piece.
Hold gun near bead at end of weld until molten metal
solidifies.

Dirty welding wire.

Use clean, dry welding wire.
Eliminate pickup of oil or lubricant on welding wire from
feeder or liner.

Excessive penetration

Weld metal melting through base metal and hanging
underneath it.

Possible causes

Corrective actions

Excessive heat input.

Select lower voltage range and reduce wire feed speed.

Increase travel speed.

Lack of penetration

Shallow fusion between weld metal and base metal.

Possible causes

Corrective actions

Improper joint preparation.

Material too thick. Joint preparation and design must provide
access to bottom of groove while maintaining correct welding
wire extension and arc characteristics.

Improper welding technique.

Maintain normal gun angle of 0 to 15 degrees to achieve
maximum penetration.

Keep arc on leading edge of weld puddle.

Be sure welding wire extends no more than ½ in beyond
nozzle.

Insufficient heat input.

Select higher wire feed speed and/or select higher voltage
range.

Reduce travel speed.

Distortion

Contraction of weld metal during welding that forces base
metal to move.

Possible causes

Corrective actions

Excessive heat input.

Select lower voltage range and reduce wire feed speed.
Increase travel speed.
Use restraint (clamp) to hold base metal in position.
Make tack welds along joint before starting welding operation.
Weld in small segments and allow cooling between welds.

TitanMig Pulse 2700/3500/5000 Operators Manual

Issue. A 0516 40

Incomplete fusion

Failure of weld metal to fuse completely with
base metal or a preceding weld bead.

Possible causes

Corrective actions

Work piece dirty.

Remove all grease, oil, moisture, rust, paint, undercoating, and
dirt from work surface before welding.

Improper welding technique.

Place stringer bead in correct location(s) at joint during
welding.

Adjust work angle or widen groove to access bottom during
welding.

Momentarily hold arc on groove side walls when using weaving
technique.

Keep arc on leading edge of weld puddle.

Use correct gun angle of 0 to 15 degrees.

Insufficient heat input.

Select higher wire feed speed and/or select higher voltage
range.

Burn-through

Weld metal melting completely through base metal resulting in
holes where no metal remains.

Possible causes

Corrective actions

Excessive heat input.

Select lower voltage range and reduce wire feed speed.

Increase and/or maintain steady travel speed.

Incomplete fusion

Weld metal that is not parallel and does not cover
joint formed by base metal.

Possible causes

Corrective actions

Welding wire extends too far out of
nozzle.

Be sure welding wire extends no more than ½ in beyond
nozzle.

Unsteady hand.

Support hand on solid surface or use two hands.

TitanMig Pulse 2700/3500/5000 Operators Manual
Issue. A 0516 41

3.2 MMAW (Stick/MMA) Welding

Electrode Diameter(mm)

Welding Current(A)

Electrode Diameter(mm)

Welding Current(A)

2.0

40-60

4.0

130-180

2.5

60-95

5.0

180-220

3.2

95-130

6.0

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

Insert the cable plug with electrode holder into the

“+” socket on the front panel of the welding

machine, and tighten it clockwise.

Insert the cable plug of the work return lead into
the “-” socket on the front panel of the welding
machine, and tighten it clockwise

 After connecting the welding leads as detailed you will need to switch the power switch on the

back panel to “ON”

 Select MMA by switching to the MMA welding mode. There is voltage output at both output

terminals.

 Set the amperage on the machine suitable for the electrode being used. Ensure you check that

you have the electrode polarity correct.

Please see below a guide to amperages required.

TitanMig Pulse 2700/3500/5000 Operators Manual
Issue. A 0516 42

3.2 MMAW (Stick/MMA) Welding

1) Use welding process buttons to select MMA welding method.

2) Turn left side to alter A to adjust welding current

3) Turn right side to set the arc force.

4) Start welding

All the parameters in steps 1.2.3 could be saved automatically when the machine is working and
remain the same even if the machine is killed halfway. The MMA welding has seven adjustable
parameters:
Current: The range (10A ~ rated current) is welding current, please choose the proper Knob A Knob
M MMA 35 current according to welding technology.
Arc force: 1 ~ 100, refers to the slop of current rise in the process of short circuit. It should be settled
based on electrode diameter, set current value and welding procedure requirements. The stronger arc
force, the faster droplets, the less sticking. However, too strong arc force would increase splashes. The
weaker arc force, the lower splashes, the better welding seam, but sometimes, people feel that the
arc is soft or cause sticking. So the arc force should be increased when use wide electrode rod (4mm)
with small current (120A). The arc force should be 10~50 in general.
Hot starting arc current (HotI) : 0 ~ 100%, 20 refers to Hot starting arc current = welding current + 20%
* welding current. The hot starting arc time (Hott) : 0 ~ 1.5 s, refers to the duration of Hot starting arc
time. In order to strike arc successfully, the welder would output a high current as striking current, the
duration of striking current is determined by the ignition time. The two parameters should be set
according to the welding situation, the higher striking current and the longer duration, the easier
ignition. But for sheet welding, the striking current and duration can not be too high and too long, so
as not to burn the workpiece. In general, the striking current should be 1.5 times of welding current,
and striking time is 0.02~0.05s.
External characteristics (Slop): In order to fit different kinds of electrodes, the MMA welding machine
own adjustable external characteristics curve. Adjust the SLOP to change external characteristics. CC:
constant-current characteristic. Arcing current is constant, independent of the welding voltage.
Adapted to acid electrode, basic electrode and groove weld.. 1-20 is decreasing characteristic of
adjustable slope, the lower the voltage, the greater the current. 20 represents the voltage drops each
1V, the current increases 20A. Adapted to the cellulose electrodes. CP: Constant power characteristics:
Output power (I × V) remains the same, especially for cellulose electrodes.
Arc-break adjustment: It is for snapping the arc easily when intermittent welding. It can be set as
30V、40V、50V、 60V,The greater the value, the more difficult to pull off the arc, the parameter should
be off when continuous welding.
Anti-sticking function (Felt) When it is on, it can prevent red and failure electrodes caused by
striking. The machine would stop till the striky electrode is away from workpiece. Then the machine
would continue to work.
VRD function (VRD) 36 There are ON and OFF available for VRD function. When it is ON, the main
circuit would not work under welder not welding. Only output less than 12V voltage. It can not only
avoid no-load voltage injury, but also save electrical energy, reduce noise and increase the life-span.

TitanMig Pulse 2700/3500/5000 Operators Manual
Issue. A 0516 43

3.3 GTAW (TIG) Welding

Electrode

Diameter(mm)

Welding

Current(A)

Gas Nozzle

Diameter (mm)

Electrode

Diameter(mm)

Welding

Current(A)

Gas Nozzle

Diameter(mm)

1.0

15-80

8.0

2.4

150-250

9.5

1.6

70-150

9.5

3.2

250-400

11.0

Type

Mode

Colour

Thoriated 2%

DC welding of steel, stainless steel and copper

Red

Ceriated

DC welding of steel, stainless steel and copper

Grey

Lanthanated 1.5%

DC welding of steel, stainless steel and copper

Gold

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
the front panel of the machine and tighten clockwise.

Connect the gas hose to the regulator / flowmeter located
on the shield gas cylinder.

Open the valve on the TIG torch and “scratch” the electrode

on the work piece to start the arc

 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 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 to be used can be selected from the table below

Electrode type

TitanMig Pulse 2700/3500/5000 Operators Manual
Issue. A 0516 44

method

operation mode

TIG torch switch & Current Curve

2T

①Press the on/off button, arc strike and
upslope ②Loose the on/off button, down
slop and arc quench ③If press the on/off

button again before arc quenching, it will
continue up sloping to the settled parameter,
and turn to ②

4T

① Press the on/off button, arc strike and
upslope ②Re-press the on/off button, down

slop and arc quench

Special 2T

① Press the on/off button, arc strike and
upslope to initial current HotI ②Last Hott

time, then down slope to the set current

③Loose the on/off button, down slop to end
current EndI ④Last Endt time, then quench

arc

Special 4T

① Press the on/off button, arc strike and
upslope to initial current HotI ② Loose the

on/off button, down slop to set current

③Re-press the on/off button ,down slop to
end current EndI ④Loose the on/off button,

quench arc

3.3 GTAW (TIG) Welding

1) Use welding process button to select Lift-TIG or Pulse Lift-TIG welding method.

2) Turn left side to alter A to adjust welding current

3) Select the suitable operation mode by the welding process button.

4) Adjust the gas-flow rate of the cylinder after pressing the gas check button.

5) Start welding

All the parameters in steps 1.2.3 could be saved automatically when the machine is working and
remain the same even if the machine is killed halfway.
Current: 2～Rated Current The welding current of DC TIG and Spot TIG, the peak current of the Pulse
TIG, please adjust the suitable current according to the welding technology.
Operation Mode: TIG operation is the operation mode, which use the torch switch to control the
welding current during working of DC TIG and PULSE TIG. There are 5 ways for TIG welding, including
2T, 4T, S2T, S4T and Spot Welding, The TIG welding ways should be selected according to the technical
requirements and the operation habit of the operator.

TitanMig Pulse 2700/3500/5000 Operators Manual
Issue. A 0516 45

Spot
welding

① Press the on/off button, strike arc to set
value ②Last spot time, quench arc.

Table 4.1 the operation mode of TIG welding

Note: graphic means pressing on/off button of the TIG torch, means loosing the on/off

button of the TIG torch, means pressing the on/off button once (press, then loose)

Upslope time(SLPU): 0～15s The upslope time means the time, which the current from 0 to set current, it
should be set according to the technological requirements
Downslope time(SLPD):0～15s The downslope time means the time, which the current from the set
current to 0, it should be set according to the technological requirements
Arc strike mode(HF): the welder provide two arc strike modes including lift (HF) arc strike and contact arc
strike.

End current(EndI):0～200%, it means the percent of the set current, it is used for filling the crater.
Initial current(HotI):0～200%, it means the percent of the set current. The initial current is the current

after arc ignition; it should be set according to the technological requirements. The higher initial current,
the easier arc striking, but it is not suggest to use when welding the sheet metal. Otherwise, it will burn
out the workpiece easily. After ignition arc under some operation mode, the current should keep the
initial current, in order to heat up the workpiece or lighting.

Initial time (Hott): it means the last time of the initial current, it is only valid in the S2T.
End time (Endt): it means the duration of the end current, it is only valid in the S2T.
Spot time: 0.1～2s Spot welding time is the time of the SPOT TIG; it should be confirmed according to the

technological requirements.

Base current: it is the base current of the PULSE TIG, the peak current is the set current
Duty ratio: it is the ratio of the peak time and cycle in the Pulse TIG.
Frequency: it is the frequency of the pulse TIG. These three parameters are for the PULSE TIG only, see the

diagram below:

In the figure the I1 is initial current, IB is base current, IP is peak current(set current), I2 is end current. T1
is upslope time, T2 is downslope time. TP is the duration of the peak current, TB is the duration of the
base current, TP+TB is the pulse cycle, the pulse frequency is the c reciprocal of the cycle: 1/(TP+TB), the
duty ratio is the percentage of the duration of peak current in the pulse cycle: 100*TP/(TP+TB), changing
the pulse frequency and duty ratio could adjust the TP and TB value.

TitanMig Pulse 2700/3500/5000 Operators Manual
Issue. A 0516 46

Current curve of PULSE TIG

3.4 Software Upgrade

It is the most important advantage that the software can be upgraded for digital welding machines. And
the welding performance can be improved, add and change the function by upgrading software. It is very
easy to operate. The steps are as following:

1） Insert the USB of UT-850 to computer, another side to the welding machine.
2） Turn on the computer and welding machine.
3） Run the rjsj4. exe in the computer as following(a~k)

A. Double click “rjsj4”

TitanMig Pulse 2700/3500/5000 Operators Manual
Issue. A 0516 47

B. Choose “English”

C. Click “Connect”

D. Double click “jm132”

TitanMig Pulse 2700/3500/5000 Operators Manual
Issue. A 0516 48

TitanMig Pulse 2700/3500/5000 Operators Manual
Issue. A 0516 49

E. Copy and paste the “Serial Number” into “Form1”

F. Click the button “Start”

TitanMig Pulse 2700/3500/5000 Operators Manual
Issue. A 0516 50

G. When you can see “”OK!”, close the small window

H. Click the “Upgrade”

I. Choose the document

TitanMig Pulse 2700/3500/5000 Operators Manual
Issue. A 0516 51

J. Now data has being transmitted.

K. k, Complete

TitanMig Pulse 2700/3500/5000 Operators Manual
Issue. A 0516 52

If there’s something wrong with connecting to the welding machine, the reasons may be following:

1. Disconnection or short circuit of the cable, two 485 cables are in reverse order, please check
the cables carefully.

2. Something wrong with the USB-RS485 converter, suggest the UT-850 or change new qualified
one.

3. Driver of USB-RS485 is set wrong, need re-install. If fail to upgrade because of power failure
during the process, please restart welding machine, It will check the correctness of software
automatically after each restart, if the software isn’t correct, it cannot work normally but waiting
to upgrade, in this case re-upgrade the software will be OK.

TitanMig Pulse 2700/3500/5000 Operators Manual
Issue. A 0516 53

3.5 Add function

TMP series welding machines have preset the welding processes according to user’s requirements
before delivery, if users need to add other welding processes, please replace the softdog or enter
passwords.

Notes: Only the same capacity and type softdog can be used, users cannot change the capacity
of welding machine, otherwise the welding machine may be damages permanently.

Replace softdog: Take off the case of welding machine, find the “CFM” on the PCB1, pull out the
plug with two pins on “CFM” (it’s the softdog),replace a new one.

Enter password: Enter into the menu of start the machine, enter 4 passwords in corresponding
options, save the passwords and then exit. When you restart the welder, new processes have
been added. Details as following steps(a~e).

A. Long press and turn on the switch.

B. Press , Select “More”

C. Turn on the left. You will find Pas 1, Pas 2,Pas 3, Pas4. displayed on LED

D. Turn on the right to make the numbers the same as the codes

E. Press again. The screen would show “Finished”. Turn off the switch.

Note: The softdog and password need to buy from sellers. Please contact the vendor.

TitanMig Pulse 2700/3500/5000 Operators Manual
Issue. A 0516 54

4.0 Trouble Shooting

Possible Reason

Suggested Solution

The Welding current is unstable

The pressure arm on the wire feeder is not

properly adjusted

Adjust it to get proper pressure.

The drive roll does not match the wire size being

used.

Make sure they match with each other.

The contact tip of the welding torch is badly

worn.

Replace it.

The wire-feeding tube of the welding torch is

badly worn.

Replace it

The welding wire is of poor quality

Replace it with welding wire of good quality

Excessive Spatter

Wire feed speed set too high

Select lower wire speed

Voltage to high

Select a lower voltage setting

Wrong polarity Set

Select the correct polarity for the wire being used

Stick out too long

Bring the torch closer to the work piece

Contaminated base metal

Remove any paint , grease, oil & dirt

Contaminated MIG Wire

Use clear dry rust free wire only.

Gas Flow too high or too low

Check gas is connected. Set gas flow between 10-15 l/min. Protect Weld Zone

from wind & drafts

Porosity

Wrong Gas

Check that correct gas is being used

Gas Flow too high or too low

Check gas is connected. Set gas flow between 10-15 l/min.

Protect Weld Zone from wind & drafts

Moisture on the base metal

Remove all moisture from base metal

Contaminated base metal

Remove any paint , grease, oil & dirt

Contaminated MIG Wire

Use clear dry rust free wire only.

Gas nozzle worn or out of shape

Replace it

Missing or damaged gas diffuser

Replace it

Mig Torch O-ring missing or worn

Replace it

Wire stubbing

Holding the torch too far away

Bring torch closer to work piece. Stick out should be 5-10mm

Welding Voltage too Low

Increase Voltage

Wire Speed Too High

Decrease the wire speed

4.1 Mig Welding Trouble Shooting

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

TitanMig Pulse 2700/3500/5000 Operators Manual

Issue. A 0516 55

4.1 Mig Welding Trouble Shooting (Continued)

Lack of Penetration

Poor joint preparation

Material too thick. Joint preparation needs to allow access to bottom of groove

Contaminated base metal

Remove any paint , grease, oil & dirt

Lack of Fusion

Contaminated base metal

Remove any paint , grease, oil & dirt

Not enough Heat input

Increase voltage range / adjust wire speed

No wire Speed

Wrong Mode selected

Check that the selector switch is set to MIG position

Inconsistent Wire Feed

Adjusting wrong dial

Adjust Wire Speed & Voltage for Mig. Amp dial is used for MMA & TIG

Wrong Polarity

Select the correct polarity for the wire being used

Incorrect Wire Speed

Adjust Speed setting

Voltage Setting Incorrect

Adjust Volt setting

Torch too long

Replace with shorter gun

Contact tip worn / wrong size

Replace with correct type

Liner worn or clogged

Replace with new liner

Wrong size liner

Replace with correct type

Blocked inlet or outlet guide

Clean or Replace

Incorrect drive roller

Fit correct type for wire being used

Worn drive roller

Replace with new

Drive roll pressure to high

Reduce Drive roll pressure

Too much tension on wire spool hub

Reduce the spool hub tension brake

There is output current when pushing the torch trigger to feed gas, but the wire feeder does not work.

The control cable of the wire feeder is broken

Get it repaired or replaced

The wire feeder is clogged.

Unclog it.

The wire feeder fails.

Repair it.

The control PCB or wire-feeder power PCB inside

the machine fails

Replace it.

TitanMig Pulse 2700/3500/5000 Operators Manual

Issue. A 0516 56

4.2 MMAW (Stick) Welding Trouble Shooting

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

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

TitanMig Pulse 2700/3500/5000 Operators Manual

Issue. A 0516 57

4.3 GTAW (TIG) Welding Trouble Shooting

Possible Reason

Suggested Solution

Tungsten burning Quickly

Incorrect Gas or No Gas

Check Pure Argon is in use

Insufficient Gas Flow

Check gas flow. Set to 10-15 l/min

Back Cap not fitted correctly

Check Back cap is fitted correctly and o ring in tact

Torch connected to (+) connection

Refit torch to (-) connection

Wrong Tungsten

Check Colour of tungsten & change to correct type

Tungsten oxidizing after weld

Post gas insufficient. Gas flow suggested 10-15 S after end of weld cycle

Contaminated Tungsten

Touching Tungsten into Weld Pool

Keep tungsten raised to 2-5mm of work peice

Touching Filler wire to Tungsten

Feed filler into the leading edge of the weld pool

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, oil & dirt

Contaminated Tungsten

Cut & re-grind Tungsten

Arc length too long

Keep torch raised to 2-5mm of work peice

Wandering Arc

Incorrect Gas or No Gas

Check Pure Argon is in use

Wrong Tungsten

Check Colour of tungsten & change to correct type

Poorly prepared Tungsten

Ensure Tungsten is ground lengthways

Contaminated base metal

Remove any paint , grease, oil & dirt

Contaminated TIG Wire

Use clear dry rust free wire only.

Difficulty Starting Arc

Incorrect Gas or No Gas

Check Pure Argon is in use

Contaminated Tungsten

Cut & re-grind Tungsten

Wrong Tungsten

Check Colour of tungsten & change to correct type

Loose connection

Check connections

Earth Clamp not connected

Connect earth clamp to the work piece

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

TitanMig Pulse 2700/3500/5000 Operators Manual

Issue. A 0516 58

4.4 Electrical Trouble Shooting

Possible Reason

Suggested Solution

There is output current when pushing the torch trigger to feed gas, but the wire feeder does not work.

The control cable of the wire feeder is broken

Get it repaired or replaced

The wire feeder is clogged.

Unclog it.

The wire feeder fails.

Repair it.

The control PCB or wire-feeder power PCB inside

the machine fails

Replace it.

When the torch trigger is pushed, there is gas output and the wire feeder works, but there is no output

current, and the protection LED is off.

The earth cable is not well connected with the

work piece

Reconnect it.

The wire feeder cable is not well connected.

Reconnect it.

The wire feeder or welding torch fails

Repair the wire feeder or welding torch

No response when pushing the torch trigger and the protection LED is off

The welding torch is not well connected with the

wire feeder.

Reconnect it

The control cable of the wire feeder is not well

connected with the welding power supply

Reconnect it

The torch trigger fails.

Repair or replace the welding torch.

The fan does not work or it works abnormally

The mains power supply or the mains supply

cable is not connected

Reconnect the mains supply cable

Phase failure

Solve the phase failure problem.

The mains voltage is too low

Welding can be carried out after the mains voltage recovers

There is no no-load voltage

The mains voltage is too low.

Welding can be carried out after the mains voltage recovers.

Phase failure

Solve the phase failure problem.

The no-load voltage is “0”, and the overheating LED is on.

Overheating protection

It will recover automatically after the welding machine is cooled.

Other malfunction

Contact the service center of your distributor

In the event of equipment malfunction, contact an authorized service agent

The following operation requires sufficient professional knowledge on electric aspects and comprehensive

safety knowledge. Make sure the input cable of the machine is disconnected from the electricity supply and

wait for 5 minutes before removing the machine covers Before taking your unit for servicing, check the list

below.

TitanMig Pulse 2700/3500/5000 Operators Manual
Issue. A 0516 59

5.0 Maintenance

The utilization level of the power source and its working environment should be taken into consideration
in planning the frequency of maintenance of the machine. Appropriate use and preventive maintenance
guarantee the trouble-free use of the equipment. This allows you to avoid interruptions in use and
increases the productivity of the machine.

5.1 Cables

Check the condition of welding and mains cables daily. Do not use damaged cables. Also make sure that all
extension cables used in the mains connection are in proper condition and compliant with regulations.

NOTE! The mains cables may be repaired and installed only by electrical contractors and installers

authorized to perform such operations.

5.2 Power source

Before cleaning the interior of the machine, you need to remove the case by unscrewing the mounting
screws at the top and sides of the machine.

NOTE! To prevent damage, wait approximately two 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-washing device.

2. Check the electrical connections of the machine. Clean any oxidized connections, and tighten the
loosened ones.

•Check for the right tension before you start repairing the connections.

NOTE! Remember that the machine may be repaired only by an electrical contractor or installer

authorized to perform such operations.

5.3 Regular maintenance

Authorized service agents perform regular maintenance by agreement. Tasks included in regular
maintenance:

 Cleaning Equipment
 Inspection and maintenance of the welding gun.
 Checking of connectors, switches, and control knobs.
 Checking electrical connections.
 Checking the mains cable and plug
 Replacement of damaged or worn parts.
 Calibration testing, with adjustment of the functions and operational values of the machine, if

necessary

TitanMig Pulse 2700/3500/5000 Operators Manual
Issue. A 0516 60

6.0 Electrical Diagram

TitanMig Pulse 2700/3500/5000 Operators Manual
Issue. A 0516 61

7.0 Warranty Terms & Conditions

Weldtronic International P/L: ABN 99 149 754 263

Weldtronic International P/L (Weldtronic) warrants to the original retail purchaser that the
products supplied by us and purchased by you from an authorized We ldtronic distributor are free
of material and faulty workmanship defects except for those products listed under Warranty
Exclusions.

All warranty periods are from date of purchase from the retailer/distributor of the product.
Unless otherwise stated the warranty period includes parts and labour.

If a defect in material or workmanship becomes evident during the warranty period, Weldtronic
will, at its opinion, either:

 Repair the Product (or pay for the costs of repair of the product); or
 Replace the Product if repair is not possible.

In the unlikely event of such a defect, the customer should return the product to the original
place of purchase, with a proof of purchase, or contact Weldtronic on 03 9702 9366 to locate a
authorized service agent.
Any handling and transportation costs (and other expenses) incurred in claiming under this
warranty are not covered by this warranty and will not be borne by Weldtronic.
Weldtronic will return the replacement or repaired product, if 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 or otherwise dealt with by any

person in a manner other than as intended in respect of the relevant product; and

 The product not having been used or applied in a manner that is contrary to customary

usage or application for the relevant product or contrary to any stated instructions or

specification of Weldtronic International.
Our products come with a guarantee that cannot be excluded under the Australian Consumer Law.
You are entitled to a replacement or refund for a major failure and for compensation for any
other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or
replaced if the goods fail to be of an acceptable quality and the failure does not amount to a
major failure. The benefits given by this warranty are in addition to the other rights and remedies
which may be available to the customer under any law in relation to goods and services to
which this relates.

These terms and conditions supersede and exclude all former and other representations and
arrangements relating to any warranties on these products

TitanMig Pulse 2700/3500/5000 Operators Manual

Issue. A 0516 62

Warranty Periods

We offer the following Warranty Periods from date of purchase;

Equipment Power Sources

TitanTIG, TitanMIG, TitanARC Inverter Series (Power Source) 2 Years (Clause 2)
TronicTig, TronicMIG, TronicPlas Inverter Series (Power Source) 2 Years (Clause 2)

EuroMIG Transformer MIG Series (Power Source) 3 Years (Clause 1&2)
TronicCool Water Coolers 1 Year (Clause 2)
Electrode Ovens 1 Year (Clause 2)
Straight Line & Pipe Cutters (Power source only) 1 Year (Clause 2)
Positioners & Rotators (power source only) 1 Year (Clause 2)

Gas apparatus

TronicFlame Gas & Welding Kits 3 Months (Clause 2&4)
TronicFlame Regulators 1 Year

Automatic Welding Helmets

Clearwelding® CWH720S Series Automatic Helmet 1 Year (Clause 4)
Clearwelding® CWH800S / 815S / 820S Series Automatic Helmet 2 Years (Clause 4)

Welding Accessories

MIG , TIG & Plasma Torches 3 Months
Earth & Work Leads 3 Months
Gas Hose & Interconnecting Cables 3 Months

(Clause 1) 3 Year warranty on transformer, inductor, & Rectifier. 2 Year Warranty on PCB and all other
components.
(Clause 2) This only covers manufacture defaults on all accessories for the first three months after date of
purchase (e.g. MIG/TIG/Plasma Torches, Earth Leads, Gas hose, etc.).
(Clause 3) Gas Hose & Flashback arrestors are subject to and covered by the manufacturer’s individual
warranty.

(Clause 4) 1 & 2 Year warranty on ADF Lens. 3 Month warranty on Helmet shell, harness & fittings.

Warranty, Ret urns & Exc h ange s
(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 daily eight (8) hour
shift.

(2)The warranty shall not cover defect or damage which may be caused or partly caused by or arise through:
(a)Failure on the part of the buyer to properly maintain any goods.
(b)Failure on the part of the buyer to follow any instructions or guidelines provided by Weldtronic.
(c)Any use of any goods otherwise than for any application specified on a quote or order form.
(d)The continued use of any goods after any defect becomes apparent or would have become apparent to

a reasonably prudent operator or user.
(e)Fair wear and tear of goods or any part thereof including but not limited to items listed in warranty
exclusions.

(f)Misuse, neglect, accident, vandalism or damage in transit or natural disaster.
(3)The warranty shall cease and Weldtronic International P/L shall thereafter in no circumstances be liable under the

terms of the warranty if the workmanship is repaired, altered or overhauled without Weldtronic International
consent.
(4)In respect of all claims Weldtronic International P/L shall not be liable to compensate the buyer for any delay
in either replacing or remedying the workmanship or in properly assessing the buyers claim.

TitanMig Pulse 2700/3500/5000 Operators Manual

Issue. A 0516 63

(5)For goods not manufactured by Weldtronic International P/L, the warranty shall be the current warranty

provided by the manufacturer of the goods. Weldtronic International shall not be bound by nor be responsible for
any term, condition, representation or warranty other than which is given by the manufacturer of the goods.
(6)We understand that sometimes you may need to return a product you have purchased from Weldtronic
International p/l authorized dealer, to assist you , we have set out below the Weldtronic International P/L
Returns Policy that you should know.

Our Returns Policy includes the rights you have under the Australian Consumer Law and other relevant laws.
Your rights under the Australian Consumer Law;
Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a
replacement or refund for a major failure and for compensation for any reasonably foreseeable loss or damage. You are
also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not
amount to a major failure.
You shall inspect the goods on delivery and shall within seven (7) days of delivery notify Weldtronic
International P/L of any alleged defect, shortage in quantity, damage or failure to comply with the
description or quote.
You shall also afford Weldtronic International P/L the opportunity to inspect the goods within a reasonable
time following delivery if you believe the goods are defective an any way.
If you fail to comply with these provisions the goods shall be presumed to be free from any defect or damage. For defective
goods, which Weldtronic International P/L has agreed in writing that you are entitled to reject, Weldtronic International P/L
liability is limited to either (at Weldtronic discretion) replacing the goods or repairing the goods except where you have
acquired goods as a consumer within 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 price of the goods, or repair of the goods, or replacement of the goods.

(7)Returns will only be accepted provided that;
(a)You have complied with the provisions outlined above, and…
(b)Where the goods are unable to be repaired, the goods are returned at your cost within thirty (30) days of

the delivery date, and…
(c)Weldtronic International P/L will not be liable for goods which have not been stored or used within the
proper manner, and…
(d)The goods are returned in the condition in which they were delivered and with all packaging material, brochures and
instruction material in as new condition as is reasonably possible in the circumstances. Failure to comply to this point
may mean that a re-stocking fee is charged to compensate Weldtronic for any lost materials and labour.
(8)Weldtronic International P/L accepts no responsibility for products lost, damaged or mislaid whilst in
transit.
(9)Weldtronic International P/L (at their sole discretion) accepts the return of goods for credit but this may
incur a handling fee of up to twenty percent (20%) of the value of the returned goods plus any freight costs.
(10)Where the failure does not amount to a major failure, Weldtronic International P/L is entitled to choose
between providing you with a repair, replacement or other suitable remedy.
(11)Your rights under the Australian Consumer Law are not limited by a defined time. However, the Australian
Consumer Law does recognize the relevant time period can vary from product to product, depending on factors such
as the nature if the product and price. Weldtronic International P/L adopts the same approach. As you can appreciate,
the type of remedy we can offer you may also vary depending on how long it takes you to return the product to use.

TitanMig Pulse 2700/3500/5000 Operators Manual

Issue. A 0516 64

Making a Claim
(12)If you wish to make a claim under this warranty you should;
(a)Return the product to the point of purchase either in person or on a prepaid courier; or
(b)Contact us by telephone on 03 9702 9366 or mail to PO 2096 Rowville VIC 3178
(c)When returned, the product must be accompanied with the original invoice including the purchase price and

disclosing the purchase date.

(d)All costs of installation, cartage, freight, travelling expenses, hiring tools and insurance are paid by the Customer.
(e)To the extent permitted by law, our total liability for loss or damage of every kind related to the

product in any way whatsoever is limited to the amount paid to the retailer by you for the product or
value of the product.

Warranty Exclusions
(13)This warranty covers material and faulty workmanship defects only. This warranty does not cover

damage caused by

(a)Normal wear and tear due to usage
(b)Misuse or abusive use of the instructions supplied with the product
(c)Failure to clean or improper cleaning of the product
(d)Failure to maintain the equipment such as regular services etc.
(e)Incorrect voltage or non-authorized electrical connections
(f)Improper installation
(g)Use if non-authorized/non-standard parts
(h)Abnormal product performance caused by any ancillary equipment interference or other external factors.
(i)Failure or breakage caused by overload, dropping or abusive treatment or use by the customer
(j)Repair, 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) Welding Torches & Consumables such as;

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 assembly, gas block, trigger spring, cable support,

neck insulator, lock nut, arc leas, welding cable, electrode holders & earth clamps, tungsten Electrodes, Collect, Back Cap,

Collet body, Torch head, gaskets, gas lens & O-rings.

Plasma (b)Cutting Torches & Consumables such as;

Cutting tips, Air diffuser, Swirl ring, Electrode, retaining cap, nozzle spring, spaces, air & power cables,

O-rings, guides, torch bodies, air filter

(c)Straight Line & Pipe Cutting consumables such as; Hoses, fittings, track, cutting nozzles, torch
(15)This warranty does not cover for products purchased:
(a)From a non-authorized Weldtronic dealer (such as purchases from unauthorized retailers and purchases over the

internet from unauthorized local/international sites such as EBay)

(b)At an auction
(c)From a private seller
(d)Unless it is a manufacturing fault, this warranty does not apply for products sold to hire

companies.
These conditions may only be varied with the written approval of the directors of Weldtronic
International P/L.

REMEMBER TO RETAIN YOUR ORIGINAL INVOICE FOR PROOF OF PURCHASE.

TitanMig Pulse 2700/3500/5000 Operators Manual
Issue. A 0516 65

TitanMig Pulse 2700/3500/5000 Operators Manual
Issue. A 0516 66

TitanMig Pulse 2700/3500/5000 Operators Manual
Issue. A 0516 67

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: [phone]

Fax. [phone]

Email. [email protected]

Web. www.weldtronic.com.au