Tig200 DC Digital
Tig Welder
Operating Instructions
www.r-techwelding.co.uk
Email: sales@r-techwelding.co.uk
Tel: 01452 733933 Fax: 01452 733939
Important Notice: This document has been prepared by R-Tech Welding Ltd.
as general information and does not contain and is not to be taken as containing any specific
recommendation.The document has been prepared in good faith and is professional opinion only. Information in this
document has been derived from third parties, and though R-Tech Welding Ltd believes it to be reliable as at the time of printing,
R-Tech Welding makes no representation or warranty as to the accuracy, reliability or completeness of information in this
document and does not assume any responsibility for updating any information or correcting any error or omission which
may become apparent after the document has been issued.Neither R-Tech Welding nor any of its agents has independently
verified the accuracy of the information contained in this document.The information in this document is commercial in
confidence and is not to be reproduced.The recipient acknowledges and agrees that it must make its own independent
investigation and should consider seeking appropriate professional recommendation in reviewing and evaluating the
information.This document does not take into account the particular circumstances of the recipient and the recipient
should not rely on this document in making any decisions, including but not limited to business, safety or other operations
decisions. Except in so far as liability under any statute cannot be excluded, R-Tech Welding and its affiliates, directors, employees,
contractors and consultants do not accept any liability (whether arising in contract, tort or otherwise) for any error or
omission in this document or for any resulting loss or damage (whether direct,indirect, consequential or otherwise) suffered
by the recipient of this document or any other person relying on the information contained herein.The recipient agrees that
it shall not seek to sue or hold R-Tech Welding or their respective agents liable in any such respect for the provision of this
document or any other information.
1
Contents
1.0 Recommended Safety Precautions
1.1 Health Hazard Information 6
1.2 Personal Protection 6
1.3 Electric Shock 8
1.4 User Responsibility 8
2.0 Gas Tungsten Arc Welding (GTAW/TIG)
2.1 Introduction 9
2.2 Process 9
2.3 ProcessVariables 9
2.4 Shielding Gas Selection 11
2.5 Consumable Selection 12
2.6 Welding Techniques 13
2.7 Torch Movement DuringWelding 8
2.8 Joint Preparation 17
3.0 TIG Welding of Materials
3.1 Application Summary 21
3.2 C-Mn Steel 22
3.3 Alloyed Steel 23
3.4 Stainless Steel 24
3.5 Aluminium 25
3.6 Balanced Squarewave 25
3.7 Copper and Copper Alloys 26
4.0 Connection Your R-Tech
TIG200DC PFC
4.1 Power 28
4.2 Shielding Gas 28
4.3 TIG Torch Connection 28
4.4 MMA Operation 28
4.5 TIG Welding Operation 29
5.0 Technical Specifications 32
6.0 Warranty
6.1 Terms ofWarranty 33
6.2 Limitations on Warranty 33
6.3 Warranty Repairs 33
2
1.1 Health Hazard Information
The actual process of welding is one that can
cause a variety of hazards.All appropriate
safety equipment should be worn at all times,
i.e. headwear,respiratory, hand and body
protection. Electrical equipment should be
used in accordance with the manufactur ser
recommendations.
Eyes:
The process produces ultra violet rays that
can injure and cause permanent damage.
Fumes can cause irritation.
Skin:
Arc rays are dangerous to uncovered skin.
Inhalation:
Welding fumes and gases are dangerous to
the health of the operator and to those in
close proximity.The aggravation of pre-existing
respiratory or allergic conditions may occur in
some workers. Excessive exposure may cause
conditions such as nausea, dizziness, dryness
and irritation of eyes, nose and throat.
1.2 Personal Protection
Respiratory
Confined space welding should be carried out
with the aid of a fume respirator or air supplied
respirator as per AS/NZS 1715 and AS/NZS
1716 Standards.
You must always have enough ventilation in
confined spaces. Be alert to this at all times.
Keep your head out of the fumes rising from
the arc.
Fumes from the welding of some metals could
have an adverse effect on your health. ’tDon
breathe them in. If you are welding on material
such as stainless steel, nickel, nickel alloys
or galvanised steel, further precautions are
necessary.
Wear a respirator when natural or forced
ventilation is not good enough.
Eye protection
A welding helmet with the appropriate welding
filter lens for the operation must be worn at all
times in the work environment.The welding arc
and the reflecting arc flash gives out ultraviolet
and infrared rays. Protective welding screen and
goggles should be provided for others working
in the same area.
Clothing
Suitable clothing must be worn to prevent
excessive exposure to UV radiation and
sparks.An adjustable helmet, flameproof loose
fitting cotton clothing buttoned to the neck,
protective leather gloves, spats, apron and steel
capped safety boots are highly recommended.
Recommended filter shades for
arc welding
Less than 150 amps Shade 10*
150 to 250 amps Shade 11*
250 to 300 amps Shade 12
300 to 350 amps Shade 13
Over 350 amps Shade 14
*Use one shade darker for aluminium
1.0 Recommended Safety Precautions
3
Cylinder Safety
Ten Points about Cylinder Safety
1 Read labels and Material Safety Data Sheet
(MSDS) before use.
2 Store upright and use in well ventilated,
secure areas away from pedestrian or vehicle
thoroughfare.
3 Guard cylinders against being knocked
violently or being allowed to fall.
4Wear safety shoes,glasses and gloves when
handling and connecting cylinders.
5 Always move cylinders securely with an
appropriate trolley.Take care not to turn the
valve on when moving a cylinder.
6 Keep in a cool, well ventilated area, away
from heat sources, sources of ignition and
combustible materials, especially flammable
gases.
7 Keep full and empty cylinders separate.
8 Keep ammonia-based leak detection
solutions, oil and grease away from cylinders
and valves.
9 Never use force when opening or closing
valves.
10 Don’t repaint or disguise markings and
damage. If damaged, return cylinders to
your local supplier.
Cylinder Valve Safety
When working with cylinders or operating
cylinder valves, ensure that you wear
appropriate protectiv ves, bootse clothing glo
and safety glasses.
When moving cylinders, ensure that the valve is
not accidentally opened in transit.
Before operating a cylinder valve:
Ensure that the system you are connecting the
cylinder into is suitable for the gas and
pressure involved.
Ensure that any accessories (such as hoses
attached to the cylinder valve, or the system
being connected to) are securely connected.
A hose, for example, can potentially flail
around dangerously if it is accidentally
pressurised when not restrained at both ends.
Stand to the side of the cylinder so that
neither you nor anyone else is in line with
the back of the cylinder valve.This is in case a
back-plus is loose or a bursting disc vents.The
correct stance is shown in the diagram above.
When operating the cylinder valve:
Open it by hand by turning the valve handwheel anti-clockwise. Use only reasonable force.
Ensure that no gas is leaking from the cylinder
valve connection or the system to which the
cylinder is connected. DO NOT use
ammonia-based leak detection fluid as this can
4
damage the valve.Approved leak detection
fluid can be obtained from a gas supplier
When finished with the cylinder, close the
cylinder valve by hand by turning the valve
hand-wheel in a clockwise direction. Use only
reasonable force.
1.3 Electrical Shock
Never touch live electrical parts.
Always repair or replace worn or
damaged parts.
Disconnect power source before
performing any maintenance or service.
Earth all work materials.
Never work in moist or damp areas.
Avoid electric shock by:
Wearing dry insulated boots
Wearing dry leather gloves
Never changing electrodes with bare
hands or wet gloves
Never cooling electrode holders in water
Working on a dry insulated floor where
possible
Never hold the electrode and holder
under your arm.
1.4 User Responsibility
Read the Operating Manual prior to
installation of this machine.
Unauthorised repairs to this equipment may
endanger the technician and operator and will
void yourWarranty. Only qualified personnel
approved by R-Tech Welding should perform
repairs.
Always disconnect mains power before
investigating equipment malfunctions.
Parts that are broken, damaged, missing or
worn should be replaced immediately.
Equipment should be cleaned periodically.
PLEASE NOTE that under no circumstances
should any equipment or parts be altered
or changed in any way from the standard
specification without written permission given
by R-Tech Welding.To do so, will void the
Equipment Warranty.
5
2.1 Introduction
The Tungsten Inert Gas, or TIG process, uses
the heat generated by an electric arc struck
between a non-consumable tungsten electrode
and the workpiece to fuse metal in the joint
area and produce a molten weld pool.The arc
area is shrouded in an inert or reducing gas
shield to protect the weld pool and the nonconsumable electrode.The process may be
operated autogenously, that is, without filler, or
filler may be added by feeding a consumable
wire or rod into the established weld pool.
2.2 Process
Direct or alternating current power sources
with constant current output characteristics
are normally employed to supply the welding
current. For DC operation the tungsten may
be connected to either output terminal, but
is most often connected to the negative pole.
The output characteristics of the power source
can have an effect on the quality of the welds
produced.
Shielding gas is directed into the arc area by the
welding torch and a gas lens within the torch
distributes the shielding gas evenly over the
weld area. In the torch the welding current is
transferred to the tungsten electrode from the
copper conductor.The arc is then initiated by
one of several methods between the tungsten
and the workpiece.
2.3 Process Variables
DCEN
When direct-current electrode-negative
(straight polarity) is used:
Electrons strike the part being welded at a
high speed.
Intense heat on the base metal is produced.
The base metal melts very quickly.
Ions from the inert gas are directed towards
the negative electrode at a relatively slow rate.
Direct current with straight polarity does not
require post-weld cleaning to remove metal
oxides.
2.0 Gas Tungsten Arc Welding
(GTAW/TIG)
6
Use of DCEN
For a given diameter of tungsten electrode,
higher amperage can be used with straight
polarity. Straight polarity is used mainly for
welding:
Carbon steels
Stainless steels
Copper alloys
The increased amperage provides:
Deeper penetration
Increased welding speed
A narrower, deeper, weld bead.
DCEP
The DCEP (reverse polarity) are different from
the DCEN in following ways:
High heat is produced on the electrode rather
on the base metal.
The heat melts the tungsten electrode tip.
The base metal remains relatively cool
compared to sing straight polarity.
Relatively shallow penetration is obtained.
An electrode whose diameter is too large will
reduce visibility and increase arc instability.
Use of DCEP
Intense heat means a larger diameter of
electrode must be used with DCEP.
Maximum welding amperage should be
relatively low (approximately six times lower
than with DCEN).
Alternating Current with High-Frequency
Welding with alternating current
Welding with alternating current combines both
direct-current characteristics:
In the positive phase, cleaning action occurs in
the weld puddle.
During the negative phase, heat is
concentrated in the weld puddle.
The above causes increased penetration.
7
2.4 Shielding Gas Selection
8
2.5 Consumable Selection
a) Welding wire
The following table includes the recommended
welding consumable for the most commonly
welded materials.
9
2.6 Welding Techniques
2.7 Torch Movement During Welding
2.8 Positioning Torch Tungsten for Various Weld Joints
10
11
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13
2.9 Joint Preparation
14
15
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3.0 TIG Welding of Materials
3.1 Application Summary
18
3.2 C-Mn Steel
TIG welding may be used for welding carbon
steel but because deposition rates are low, it
is usually only used for welding sheet and thin
sections for high quality applications, small
components, and root passes of multipass butt
joints in plate and pipe.
Standard DC TIG equipment is normally
suitable and DCEN polarity is usually chosen to
provide good workpiece heating.
Only inert or reducing gases should be used
for TIG welding and pure argon is normally
recommended as the shielding gas for steel.
Filler rods are usually selected to match the
chemical composition and the mechanical
properties of the parent plate.The weldability of
the steel may impose restrictions on the choice
of filler rod.
Steels with carbon contents above about 0.3%
are hardenable, and fast cooling will produce a
hard HAZ and this is liable to result in
hydrogen cracking.This form of cracking can
be prevented by use of preheat and suitable
welding procedures.
19
3.3 Alloyed Steel
TIG welding may be used for welding alloy
steels but because deposition rates are low,
it is usually only used for welding sheet and
thin sections for high quality applications, small
components, and root passes of multipass butt
joints in plate and pipe.
Standard DC TIG equipment is normally
suitable and DCEN polarity is usually chosen
to provide good workpiece heating. Tungsten
electrodes with additions of thorium oxide,
cerium oxide, or lanthanum oxide are used for
welding steel and they give good arc stability.
Only inert or reducing gases should be used
for TIG welding and pure argon is normally
recommended as the shielding gas for welding
alloy steel.
Filler rods are usually selected to match the
chemical composition and the mechanical
properties of the parent plate.The weldability
of the steel may impose restrictions on the
choice of filler rod.
Alloy steels with high carbon equivalents are
hardenable, and fast cooling will produce a hard
HAZ and this is liable to result in hydrogen
cracking.This form of cracking can be prevented
by use of preheat and suitable welding
procedures.
20
3.4 Stainless Steel
Is a high quality process ideally suited for
welding of stainless steels, particularly thin sheet
up to about 5mm thick where weld integrity
and good surface finish are critical.The process
has a high degree of controllability resulting
in clean, smooth, high quality welds with good
penetration and strength with very low defect
rates.
Standard TIG equipment is suitable and stainless
steels are TIG welded using DCEN polarity.
A thoriated tungsten electrode is normally
used but health concerns have promoted use
of ceriated or lanthanated instead.The filler
rod used depends on the type of stainless being
welded but, in general, is matching for austenitic
grades, enriched in nickel for duplex grades,
and may be matching or an austenitic type for
ferritic and martensitic grades.
Shielding gas is conventionally pure argon, but
other gases are available to provide specific
properties and these include argon-hydrogen,
argon-helium mixtures, argon-helium-hydrogen,
and argon-nitrogen mixtures.
When welding pipes an inert gas purge is
required inside the pipe to prevent oxidation
on the underside of the weld. Gas purging may
also be used to protect the root side of butt
welds in plate or sheet materials too.
21
3.5 Aluminium
Is a high quality process widely used for welding
aluminium, particularly in section size up to
about 6mm.The process may be operated with
or without filler.
TIG welding of aluminium can be carried out
using any of the three standard operating
modes, alternating current (AC), direct current
electrode negative (DCEN) and direct current
electrode positive (DCEP).
AC is the most frequently used since with
AC cleaning of the oxide film occurs on the
electrode positive cycle and heating occurs on
the electrode negative cycle.With aluminium
the surface oxide film must be removed to
allow full fusion to take place and ACTIG
does this efficiently, allowing high quality joints
to be made. High purity argon and argonhelium
shielding gas mixtures can be used.
The AC output may be conventional sine wave
or square wave and many electronic power
sources allow the AC waveform to be adjusted,
and also provide facilities for pre- and post- gas
flow and current slope-in and slope-out.
3.6 Balanced Squarewave
The balance on squarewave machines can be
adjusted to achieve the desired results. Greater
amounts of EN create a deeper, narrower
weldbead and better joint penetration.This
helps when welding thick material and promote
faster welding speeds. Greater amounts of EP
removes more oxides from the surface but also
have a shallower penetration.
22
3.7 Copper and Copper Alloys
Cleanliness is important when welding copper,
and all dirt, grease, and other contaminants
must be removed before welding. Copper
alloys containing aluminium will form a surface
oxide film and this must also be removed
before welding. Preheat will be required for
unalloyed copper but some copper alloys can
be TIG welded without preheat except on thick
sections.
Standard DC TIG welding equipment is
suitable for most copper and copper alloys, but
aluminium bronze is normally TIG welded using
AC current to break down the tenacious oxide
film on the surface.
Pure argon, helium, or argon-helium mixtures
are standard shielding gases for DCTIG welding
copper and copper alloys.Alushield Heavy is
ideal for TIG welding copper and some copper
alloys, particularly in thicker sections. Pure
argon is the shielding gas used for AC TIG
welding.
TIG consumables are solid filler rods based
on pure copper and several copper alloy
compositions, including aluminium bronzes,
silicon bronzes, and cupro-nickels. It is normal
to try to use a filler material with a similar
composition to that of the parent material but
this is not always possible, and sometimes not
desirable.
Porosity is the main welding problem
encountered when TIG welding unalloyed
copper and some copper alloys are prone to
solidification cracking and porosity. Certain
alloys are difficult to weld (brass will lose zinc if
welding is attempted), and those containing lead
are virtually unweldable.
23
4.1 Power
The machine is designed to operate on a 240
+/- 15% input single phase AC outlet.
Ensure that there is adequate ventilation
around the machine when it is connected to
the mains power supply.
4.2 Shielding Gas
When working the machine in the TIG mode
of welding the process requires a shielding gas.
The shielding gas can be supplied via a pressure
regulator to the machine from either a fixed
installation or single cylinder of gas.
If a cylinder of gas is used, please ensure that
the cylinder is securely fastened (refer to the
section on cylinder handling and safety), before
starting any welding operation.
Refer to the application section for the
selection of the correct shielding gas.
4.3 TIG Torch Connection
The R-Tech TIG200DC PFC
machine is rated at 200A, 35% duty cycle.
The matching TIG torch for this machine is the
Wp26 torch.
1 The WP26 TIG torch is fitted to
the machine by means of the dinse back end.
For DC (-) TIG operation fit the torch back end
to the negative dinse connection (similarly for
DC (+) fit the torch
backend to the positive dinse connection).
2 The gas hose is fitted to the gas fitting (GAS)
located on the front bottom panel of the
machine.
4.4 MMA Operation
The R-Tech TIG200DC PFC can
be used as a MMA welding machine by fitting a
electrode holder and a work return lead to the
respective dinse connectors (dependant on the
type of electrodes being used. Please consult
the packaging supplied by the manufacturer for
the correct polarities).
4.0 Connecting your R-Tech TIG200DC PFC
welding machine
24
/TIG ARC 200MP/TIG ARC 200MP
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5
6
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10
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4.5.1 For Direct current (DC)
TIG Welding
Select the correct size and type of non
consumable tungsten and shielding gas for the
application. (See selection chart at the end of
the application section)
For (DC -) (most commonly used polarity
connect the TIG torch to the negative Dinse
plug connector and the work return lead to the
positive dinse plug connector.
For (DC+) applications connect the TIG torch
to the positive Dinse plug connector and the
work return lead to the negative dinse plug
connector. In this mode most of the heat is
generated within the non-consumable tungsten
and the heat input into the plate is reduced
resulting in lower penetration depths. (Larger
tungstens are normally selected for this
application.
Ensure that the process selector switch (3) is
switched to TIG.
Select 4T/2T on the trigger selector switch (5).
For 2T operation:
Depress the contactor switch on the torch and
hold this down for the entire weld.
Selecting the 2T function will disable the Start
current (9) and the process will immediately
rise to the selected welding current.
For 4T operation:
Depress the contactor switch on the torch
and release it when welding starts. Depress the
contactor switch again at the end of the weld.
Selecting the 4T function will enable the start
current (9) and the downslope cycle (12).
Both start current and downslope cycle time
must be manually selected.
Using a remote control device (such as a foot
control, or remote pendant).
When using a remote device ensure that the
device is properly fitted by connecting it to
the remote control outlet connector (21).The
remote operating control switch (7) must be
set in the on position.
4.5.2 For DC Pulse TIG Welding
SDC welding of thin material can be enhanced
by using the pulse mode.
When using the pulse mode for DC
applications the current will be varied between
the welding current and the set background
current.Additionally the pulse width and
pulse frequency can be adjusted. By adjusting
the pulse frequency and width the optimum
heat input for a particular application can be
obtained.
27
As a general rule, increasing the frequency at a
given set of welding and background current the
heat input into the plate will increase.
28
Model No. TIG 200DC PFC
Part No. TIG200DC PFC
Power voltage (V) 1ph AC 230V +/15%
Frequency (HZ) 50/60
Fuse rating 16
Output Current (A) Stick 10-150
TIG 5-200
No-load voltage (V) 62
Duty Cycle (%) @ 200A 35
Power Factor 0.95
Protection Grading 1P23
Weight (kg) 10
Dimensions (mm) 430 x 160 x 310
Warranty 3 Years
5.0 Technical Specifications
29
6.1 Terms of Warranty
R-Tech Welding provides aWarranty for the
TIG200DC PFC sold by it
against defects in manufacture and materials.
Valid for 12 months from date of purchase.
Only R-Tech Welding
must carry out Warranty repairs.
Freight, packaging and insurance costs are to
be paid for by the claimant.
No additional express Warranty is given unless in
writing signed by an authorised manager of
R-Tech Welding
This Warranty is in addition to any other legal
rights you may have.
Welding leads (which include the electrode
holder and the work clamp) are not covered
in these Warranty terms.
6.2 Limitations on Warranty
The following conditions are not covered:
non compliance with operating and
maintenance instructions such as connection
to incorrect faulty voltage supply including
voltage surges outside equipment specs, and
incorrect overloading
natural wear and tear, and accidental damage
transport or storage damage.
The Warranty is void if:
changes are made to the product without the
approval of the manufacturer
repairs are carried out using non-approved
spare parts
a non-authorised agent carries out repairs.
6.3 Warranty Repairs
R-Tech or their Authorised Service Agent
must be informed of the Warranty defects,
and the product returned within theWarranty
Period.
Before anyWarranty work is undertaken, the
customer must provide proof of purchase and
serial number of the equipment in order to
validate the Warranty.
The parts replaced under the terms of the
Warranty remain the property of R-Tech Welding
6.0 Warranty Information
30
Repair or replace defective cables immediately.
Never watch the arc except through
lenses of the correct shade.
In confined spaces, adequate ventilation
and constant observation are essential.
Leads and cables should be kept clear
of passageways.
Keep fire extinguishing equipment at a handy
location in the shop.
Keep primary terminals and live parts
effectively covered.
Never strike an electrode on any gas cylinder.
Never use oxygen for venting containers.
7.0 Recommended Safety Guidelines
Diagram and safety explanation
Electrical safety alert
Welding electrode causing
electric shock
Fumes and gases coming from
welding process
Welding arc rays
Read instruction manual
Become trained
Diagram and safety explanation
Wear dry, insulated gloves
Insulate yourself from
work and ground
Disconnect input power before
working on equipment
Keep head out of fumes
Use forced ventilation or local
exhaust to remove fumes
Use welding helmet with
correct shade of filter
Some safety precautions R-Tech Welding recommends are as follows:
31
Notes
33
Notes
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