Snap-On TIG 150i User Manual

Page 1

032011

150 A TIG WELDING MACHINE

TIG150i

INTRODUC T I O N

The TIG150i is a 150A inverter-style AC/DC TIG welder that is used to weld both ferrous and non-ferrous metals. The inverter technology is a smaller and therefore lighter package size allows portability when needed or can also be placed onto a cart for traditional use around the shop. Welding capabilities range from extremely thin up to 1/4” on multiple passes. The welder features ease-of-use for quick start-up in addition to multiple features such as upslope, downslope, pulse and frequency adjustment or the most experienced welder. Applications include automotive repair, collision repair, motorsports, manufacturing, marine, aviation, agriculture and metal fabrication shops.

Page 2

Introduction............................................................................................................................... Front Cover

Table of Contents ...................................................................................................................................... 1

Safety Information ..................................................................................................................................2-3

Specifications ............................................................................................................................................ 4

Features .................................................................................................................................................... 5

Description of Equipment .......................................................................................................................6-9

Assembling the Unit/Start-up Guide ........................................................................................................ 10

TIG Welding – Introduction................................................................................................................. 11-12

- DC TIG Welding............................................................................................................................ 13

- AC TIG Welding....................................................................................................................... 14-15

- Optional Foot/Remote Amperage Control .................................................................................... 16

Stick Arc Welding .................................................................................................................................... 17

Troubleshooting/Maintenance ................................................................................................................. 18

Replacement Parts ............................................................................................................................. 19-20

- Parts List....................................................................................................................................... 19

- Standard and Optional Accessories ............................................................................................. 20

Wiring Diagram........................................................................................................................................ 21

Warranty/Service and Repair .................................................................................................................. 22

TABLE O F CONTENTS

Page 3

MUST READ INSTRUCTIONS BEFORE USE

Read, understand and follow all safety messages and instructions in this manual. Safety messages in this section ofthe manual contain a signal word with a three-part message and, in some instances, an icon.

The signal word indicates the level of the hazard in a situation.

DANGER

Indicates an Imminently hazardous Situation which, if not avoided, will result in death or serious injury to the operator or bystanders.

WARNING

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury to the operator or bystanders.

CAUTION

Indicates a potentially hazardous situation which, if not avoided, may result in moderate or minor injury to the operator or bystanders.

IMPORTANT

Indicates a situation which, if not avoided, may result in damage to the welding equipment.

Safety messages in this section contain three different type styles.

• Normal type states the hazard.

• Bold type states how to avoid the hazard.

• Italic type states the possible consequences of not avoiding the hazard.

An icon, when present, gives a graphical description of the potential hazard.

Arc Welding

DANGER

• Electric welding or plasma cutting cause ultra violet rays and weld spatter

Bystanders will be exposed to ultraviolet rays and weld spatter. Wear welding helmet with appropriate shade lens while using electric welders or plasma cutters. Do not allow bystanders while welding or cutting. Wear safety shield and protective clothing.

Ultraviolet rays will burn eyes; weld spatter can cause injury.

WARNING

• Welding produces heat, sparks, hazard of electric shock and/or hazardous vapors

Wear appropriate gloves, helmets or goggles and other protective clothing. Follow all instructions and safe practices while welding or cutting. Keep bystanders away from immediate area.

Byproducts of welding can cause burns or other bodily injury.

SAVE THESE INSTRUCTIONS

SAFETY INFORMATION

Page 4

Risk of Electrical Shock

WARNING

• Electrical shock can result when contacting live electrode or internal components

• Electrical shock can result from absence of grounding prong

Do not touch electrode or internal components without protection. Disconnect power before servicing. Do not remove the grounding prong in any electrical plug.

Electrical shock can cause injury

Risk of Explosion

WARNING

• Welding causes sparks that can cause explosion

Use caution and proper procedures when welding. Avoid sparks if gasoline vapor and other fuels are present.

Electrical shock, flames and explosion can cause serious injury

Electrical and Magnetic Fields

WARNING

• Welding may cause localized Electrical and Magnetic Fields around cables and power sources

• The magnetic fields created by high currents may affect the operation of medical equipment.

Route the electrode and work cables together. Do not place your body between the electrode/torch and work cables. Never coil the electrode/torch lead around your body.

Do not work next to welding/cutting power source.

Electrical shock and Magnetic fields can cause injury.

Disposal of Equipment

IMPORTANT

• Disposal of electrical equipment can be hazardous to the environment

Contact local regulations prior to disposal

Improper disposal can cause an environmental hazard

SAFETY INFORMATION cont’d

Page 5

By selecting TIG AC welding mode you may

weld aluminum, aluminum alloys, brass and magnesium, while selecting

TIG

DC allows you to weld steels,

stainless steel, iron and

copper

This welding machine is a direct and alternating

curr

ent

power source built using

INVERTER

technology, designed

weld covered electrodes

(not

including

cellulosic)

and for TIG

procedures, with contact starting and high frequency

EXPLANATION OF THE TECHNICAL

SPECIFI

CATIONS

LISTED ON THE MACHINE PLATE.

N°. Serial number, which must be indicated on any type of

request regarding the welding machine.

Single Phase

Downslope.

TIG/MMA Suitable for TIG/MMA welding. U0. Secondary open-circuit voltage (peak value) X. Duty cycle percentage. % of 10 minutes

during

which the welding machine may run at a

certain

current without overheating.

I2. Welding

curr

ent U2. Secondary voltage with current I2 U1. Rated supply

voltage

1~ 50/60Hz 50- or 60-Hz single-phase power

supply

I1 Max Max. absorbed current at the

corr

esponding

current I2 and voltage U2.

I1 eff This is the maximum value of the actual

curr

ent absorbed, considering the duty

cycle.

This value usually corresponds to the

capa

city of the fuse (delayed type) to be used as a protection for the

equipment.

IP23S Protection rating for the housing. Grade 3 as

the second digit means that this machine may be stored, but it is not suitable for use

out-

doors in the rain, unless it is protected.

Suitable for hazardous

envir

onments.

SPECIFICATIONS+

Power+Input+

Voltage(

208/230(Volts(AC(

Phase((

Single(Phase(

Frequency(

50/60(Hertz(

Current(

30(Amps(

Current(

15.8(Amps(

Power+Output+

Weld(Current(Ra nge(

5‐150(Amps(

Duty(Cycle(@(100A((

100%(

(Duty(Cy cle(@(110A((

60%(

(Duty(Cy cle(@(150A((

30%(

Arc(Voltage(

14.5(Vol ts(

Output+Control+

On/Off(Remote(

Standard(

Foot(Pedal(

Optiona l(

Finger(Control((

Optiona l(

Pulse+Frequency+

0.16(‐150Hz(

Backgro und+Amp+Setting+

0‐150(Amps(

AC+Waveshape+Balance+

Cleaning(

(1‐8(

Penetration(

(1‐8(

Frequency+

50(‐(150(Hz(

Pulse+Frequency+

0.16‐250(Hz(

Upslope +

0‐10(Seconds(

Downslope+

0‐10(Seconds(

Post+Gas+

0‐30(Seconds(

Gas+Req uirement+

100%(Argon(

Torch+Cable+Length+

25(Feet(

Ground+Cable+Length+

25(Feet(

Gas+Hose+Length+

10(Feet(

Unit+Dimensions+

((

Height(

17"(

Width(

8"(

Depth(

17"(

Base+Un it+Weight+

37(lbs(

Shipping+Weight +

57(lbs(

SPECIFICATIONS

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FEATU RE S

• 150 Amp AC/DC TIG Welder

• TIG weld most metals.

• MMA “Stick Welding” with optional cable

assembly.

• Inverter technology allows the welder to be lightweight (37lbs.) and still able to perform most welding applications.

• The adjustable amperage output of a minimum of 5 amps, along with pulse technology, allows welding of extremely thin materials.

• The maximum of 150 amps will weld most applications up to ¼” with multiple passes.

• Power Factor Correction “PFC” system only requires a 30 amp 220 volt circuit saving substantial electric cost. This also allows increased input voltage tolerance of +15% to 20%.

• High frequency start allows for easy arc starting and can be turned off for scratch start if needed.

• Scratch start feature if high frequency start is not desirable.

• Adjustable upslope and downslope feature helps to prevent burn through at the edge of the material.

• Adjustable post gas prevents air from getting to material before it cools.

• Pulsed arc for working even on thin sheets, where the heat transferred must be kept to a minimum.

• Tunnel design construction allowing an exceptional cooling efficiency, keeping those components that suffer in dusty environments, such as electronic circuits, out of the cooling flow.

• AC balance adjustment or penetration and tungsten consumption control.

• Adjustable AC Frequency 50 - 150Hz for precise heat output control.

• Background amperage adjustable from 5 to 150 amps DC and 10 to 150 amps AC.

• Remote foot control can be set for momentary on or continuous on.

• Optional foot pedal or finger tip torch control allowing precise amperage adjustment between low amp and high amp setting.

• The TIG150i includes lightweight torch assembly, ground cable, flow style regulator, on/off control switch, installed gas hose, and consumable tungsten kit. The only additional start up purchases needed are the input plug and welding gas.

• Exceptional technical support of over 30 years

of experience by calling 800 ABC WELD.

Page 7

The LEDs

light alongside the

various

symbols to display your

choice:

F N M L Z Y J AA

AC AB

DESCRIP TION OF EQUIPMENT

Page 8

A - Procedure selector switch

(Left-hand “down arrow” Key

This push-button selects the welding procedure (MMA or TIG).When selected, one of the following LEDs

lights:

B C o r D

E Mode key. (Right-hand “down” arrow key.)

When selected, one of the following LEDs

lights:

F, G, H, L, M, N TIG mode there will always be two LEDs lit: one indicating HF or striking start m ode, t he oth e r con t in u ou s or pu l se m od e in 2 o r 4 st a ge .

F - LED. TIG welding with arc

started

without high

frequency.

To light the arc, press the torch trigger and touch the

tung

sten

electrode to the work piece, then lift it. This move

must

be quick and decisive (0.3 sec.). Use this process when high frequency is not permitted.

L – LED TIG welding with arc started with high

frequency.

To light the arc, press the torch trigger: a high

voltage

frequency pilot spark will light the arc.

G - LED. Continuous 2-stage TIG welding

(manual).

When the torch trigger is pressed, the current begins. When the

trig

ger is released, returns to zero. In this position, you

may connect the optional pedal control

acces

sory

(TIGINVFP).

H - LED. Continuous 4-stage TIG welding (automatic).

This program differs from the previous one in that the arc is both started and shut off by pressing and releasing the

tor

ch trigger

M - LED. Pulsed 2-stage TIG welding (manual).

When the torch trigger is pressed, the current begins. When the

trig

ger is released, returns to zero. In this position, you

may connect the optional pedal control

acces

sory

(TIGINVFP).

N - LED.

Pulsed

4-stage TIG welding

(Automatic)

This program differs from the previous one in that the arc is both started and shut off by pressing and releasing the

tor

ch trigger

The Pulsed welding feature varies the weld current from the main welding current (Peak Amperage – high heat) and the second level of welding or base current (Background Amperage – low heat) levels. The TIG150i has two (2) different weld settings for the pulse features 2-stage TIG welding (manual) M – LED or 4-stage TIG welding (automatic) N - LED.

The Pulse frequency is adjustable from .16 to 250 pulses per second by selecting the mode U and setting the value with the knob AA. The duration of total time “on” between “High heat” and “Low heat” are equal.

“LED T ” – Main welding current (Peak Amperage – high heat)

This value is usually set somewhat higher than it would be set for a non-pulsed weld.

“LED V ” – Second level of welding or base current (Background Amperage – low heat)

This of course would be set lower than Main welding current. This value cannot be higher than the Main welding current. Once the base current V is set (a percentage in respect to the main current is established), so this value will change automatically when increasing or decreasing the Main current T .

“LED U ” – Pulse frequency (Pulses per Second . 16 – 250 HZ) Is the number of times per second that the

welding current achieves main welding current (Peak Amperage – high heat).

Some of the advantages:

• Good Penetration with less heat input to material “burn through”.

• Less distortion.

• Good control of the pool when welding out of

position.

• Ease of welding thin materials.

• Ease of welding materials of dissimilar thickness.

• Helps weld training.

• Smaller bead profile.

• Smaller heat-affected zone.

DESCRIP TION OF EQUIPMENT c ont’d

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J - LED - THERMAL PROTECTION

Lights when the operator exceeds the duty cycle or per

cen

tage intermittence admissible for the machine, and

simulta

neously blocks the current

output.

NOTE: In this condition the fan continues cooling

the

power source.

Y - LED

This LED must always be lit to ensure safe

welding

conditions in AC

mode.

AA - KNOB

Adjusts the welding

curr

ent. (LED – T)

Also, in

combination with the push-button P,

you

may:

- adjust the second level of current LED V

-adjust the "slope up" L E D S

-adjust the "slope down" L E D W

- adjust the pulse frequency LED U

-adjust the post gas LED X

-adjust the current frequency in AC welding LED Q

-adjust the wave balance in AC welding LED R

- adjust the arc striking in relation to the diameter of the elec

trode used in TIG AC mode

LED

O .

P –

SELECTOR (Right Arrow)

When this button is pressed, the LEDs light in suc

cession:

Q - LED

Current frequency in AC welding (50 - 150 Hz).

Current Frequency Control is enabled only in AC TIG. Use this control to set the AC frequency (cycles per second).

Current frequency controls bead width and directional control. As AC frequency decreases, weld bead/puddle gets wider. As AC frequency increases, weld bead/puddle becomes narrower and the arc becomes more focused. Travel speed can increase as frequency increases.

R - LED

Wave

balance in AC welding

(balance

= 0; Cleaning = from 1 to 8, flashing; Penetration = from 1 to 8, not flashing).

The Wave Balance R feature makes it possible to vary the half cycles of the square wave when working in TIG AC when welding aluminum alloys. The point where the two half-waves meet is zero. The TIG150i offers 3 positions, Balanced, Cleaning and Penetration. Penetration (electrode negative) – is when the Wave Balance R is set clockwise from the “0” position with non-flashing numbers between“1 - 8” on the display Z . This is set to produce the more time at electrode negative and the minimum time at electrode positive.

This adds the following benefits:

• Can use higher currents with smaller electrodes.

• Increased penetration at a given amperage and

travel speed.

• Use of smaller gas cup and reduced shielding gas flow rate.

• Reduced heat input with smaller heat effected zone and less distortion.

Balanced (zero) – is when the Wave Balance R is set to “0” position on the display Z . This position is set to produce equal amounts of time electrode negative (penetration) and electrode positive ). This will give you less current absorption, reduced electrode consumption and an ideal ratio between the width and depth of the welding bead.

Cleaning (electrode positive) – is when the Wave Balance

R is set counter-clockwise from the “0” position flashing

numbers between “1 - 8” on the display Z . This is set to produce more time at electrode positive and the minimum time at electrode negative. This adds the following benefits:

• Removes more surface oxides from the plate but reduces electrode life.

O – Led Displays the electrode diameter. The choice

electrode

diameter ranges from 1mm to 4mm (.040 –

5/32”). Use the knob

change the diameter. This

function is active only for AC

TIG

welding.

DESCRIP TION OF EQUIPMENT c ont’d

Page 10

S - LED

Slope up. This is the time in which the cur

rent, starting from the minimum,

reaches

the

set current value. (0-10 sec.)

Slope Up can be used to assist in preheating cold material prior to depositing filler material, or to ensure a soft start on higher amperage settings.

T - LED

Main welding current. (10-130A in MMA

and

150A in TIG)

V - LED

Second level of welding or base current. This curr

ent

is always a percentage of the main. Pulsed 2-stage or Pulsed 4-stage only - Use the Second level of welding or base current to set the low current pulse of the weld amperage, which cools the weld puddle and affects overall heat input. This current is always a percentage of main current.

U - LED

Pulse frequency (0.16-250 Hz) The peak and base times are equal. These pulses and the base current level -V- between them (called the Second level of welding ) alternately heat and cool the molten weld puddle. The combined effect gives better control of penetration, bead width, undercutting, and heat input

W - LED

Slope down. This is the time in which the

current reaches the minimum value and the arc. Slope Down should be used while welding materials that are crack sensitive, and/or to eliminate the crater at the end of the weld.

X - LED

Post gas. Adjusts the time gas flows after

welding ends. (0-30 sec.) Post Gas is required to cool the tungsten rod and weld puddle, and to prevent contamination of tungsten and weld. Increase post gas time if tungsten or welds have a dark appearance.

Note: only those LEDs that refer to the chosen

welding mode will light; i.e., in continuous TIG welding the LED U , representing the pulse frequency, will not

light.

Each LED indicates the parameter that may be adjusted

means of the knob

while the

LED

itself is lit.

Five

seconds

after the last variation, the LED involved will shut off;

the main welding current will be displayed, and the correspon

ding LED T

lights.

AE - 10-PIN CONNECTOR

The

following remote controls

are

connected to

this connector: a)

foot

contr

ol or on/off button.

b) torch with start

button.

c) torch with varia b le amperage devi c e .

General Notes

Make sure the

insula

tion of the cables, electrode clamps, sockets and plugs are intact, and that the size and length of the welding cables are compatible with the current used.

AB - Negative output terminal

Plug the TIG torch in here.

AC -Positive output terminal (+).

Plug the “ground” cable in here.

AD - 1/4 GAS OUTLET FITTING

DESCRIP TION OF EQUIPMENT cont’d

Page 11

INSTALLATION

Make sure that the supply voltage is 230 volt and a minimum of 30 amp service. When mounting a plug, make sure it has an adequate

capa

city, and that the "yellow/green

conductor" of the power

supply cable is connected to the ground or “earth” terminal. The blue and brown wires need to be connected to the “hot leg” terminals

WARNING

Only skilled personnel should install the machine. All connections must be carried out according to current regulations.

See complete listing of safety messages at the beginning of this manual.

TORCH HEAD ASSEMBLY

1. Select the size tungsten electrode to be used

– see table A

2. Make sure the Teflon heat shield is in place.

3. Locate the matching size Collet and Collet body.

4. Drop the Collet, slit-end down, into the Collet body.

5. Screw assembly into the torch head, heat shield side,

and tighten firmly.

6. Install a Gas cap, screw into place seating the cup

against the Teflon heat shield.

7. Insert tungsten electrode, prepped end first, thru the

torch head, Collet and center hole of the Collet body.

8. Allow tungsten electrode to extend past the cup ~ 3

times the electrode diameter.

9. Screw Backcap into torch head and tighten firmly.

Review the exploded view on the next page.

ASSEMBLIN G THE UNIT/START UP GUIDE

For detailed machine start up see

“SETTING UP YOUR NEW

TIG WELDING SYSTEM”.

Page 12

TIG WELDING – GENERAL

aluminum, aluminum alloys, brass and magnesium, while

stainless steel, iron and copper.

1. Connect the earth (work) cable connector to the positive pole (+) (AC) of the welding machine, and the clamp to the work piece as close as possible to the welding point, making sure there is good electrical contact.

2. Connect the power connector of the TIG torch to the negative pole (-) (AB) of the welding machine.

3. Connect the foot pedal or on/off switch control plug to the welding machine connector AE.

4. Connect the torch gas hose fitting to the gas outlet fitting AD on the machine, and the gas hose from the cylinder pressure regulator to the gas fitting AG on the rear panel.

AF – switch

Turns the machine on and off. 0 = Off l = On

AG - gas inlet fitting

DANGER

Do not touch

live

parts and output terminals while the

machi

power

ed.

Read complete listing of safety messages at the beginning of this manual.

1. The first time the machine is turned on, select the pr

ocess

and mode using the push-buttons A and E ,

and the

welding

parameters by means of the key P and

the knob AA .

2. The type and diameter of the electrode to be used must be

selected according to table A:

TABLE A

Inches/mm

(frequency 50/60

Hz)

Pos. Max Penetration

Pos. Balanced zero

Pos. Max Cleaning

Electrode Type

ungsten

Thorium

Red

ungsten

Pure Green

ungsten

0,8%

White

ungsten

Pure Gr

een

ungsten

0,8%

White

ungsten

Pure Gr

een

ungsten

0,8%

White

1/16in 1.6mm

70A – 150A

50A – 100A

70A – 150A

30A – 60A

50A – 80A

20A – 40A

30A – 60A

3/32in 2.4mm

150A – 250A

100A – 160A

140A – 235A

60A – 120A

80A – 140A

40A – 100A

60A – 120A

1/8in 3.2mm

200A – 350A

150A – 210A

225A – 325A

80A – 160A

100A – 180A

60A – 140A

80A – 160A

5/32in 4mm

300A – 400A

200A – 275A

300A – 400A

100A – 240A

150A – 280A

80A – 200A

150A – 250A

TIG WELDING - IN TR OD UC TION

By selecting

welding mode you may weld

selecting TIG DC allows you to weld steels,

the TIG AC

Page 13

TIG WELDING – INTR OD UC TION cont’d

3. The flow of inert gas must be set to a value of 20-25 CFH. If you are using gas-lens type accessories, the gas throughput may be reduced.

4. The diameter of the ceramic nozzle must be 4 to 6 times the diameter of the electrode

5. Use D.I.N. 10 protective glasses for up to 75A, and D.I.N. 11 from 75 A up.

Page 14

TIG Welding DC Basic Setup

• With High Frequency Start

• Using the On/Off Switch

Push the procedure selector switch (Left Hand Down Arrow). This push-button selects the welding procedure (MMA or TIG). When selected, one of the following LEDs lights:

B , C , or D

Push the button until the TIG DC LED lights .

Then push the Mode Key E (Right Hand Down Arrow). When selected, one of the following LEDs lights: F,G,H,L,M,N. Continue to push the button until the L LED lights along with the G LED.

L - LED. TIG welding with arc started with

high frequency.

G LED. Continuous 2-stage TIG welding

(manual).

P - SELECTOR (Right Arrow) When this button is pushed, the following LEDs light in succession:

S - LED

Slope up. This is the time in which the current, starting from the minimum, reaches the set current value. (0-10 sec.)

AA – Knob

Adjusts the slope up time while watching the Z display.

Z – Display

Displays the settings selected. Set the slope up to “0” seconds.

Push the P – Selector (Right Arrow) until the T –

LED main welding current display lights.

(10-130A in MMA and 5-150A in TIG)

Turn the AA knob while watching the Z display.

Z DISPLAY Adjust the display to the required main welding amperage. Rule of Thumb: “1 amp per .001 of plate thickness. (.125 =

~125 amps)

** May require multiple passes.

Push the P – Selector (Right Arrow) until the W –

LED main welding current display lights.

W - LED

Slope down. This is the time in which the current reaches the minimum and the arc shuts off. (0-10 seconds).

Turn the AA -Knob watching the Z - Display.

Set the slope down to “0” seconds.

Push the P – Selector (Right Arrow) until the X –

LED post gas display lights.

Post Gas Adjusts the time gas flows after the welding

ends. ( 0-30 seconds)

Turn the AA - Knob watching the Z - Display.

Set the post gas to “10” seconds.

Basic TIG DC Setup is Complete.

DC TIG WELDING

Page 15

TIG AC Welding Mode Basic Setup

• With High Frequency Start

• Using On/Off Button

Push the procedure selector switch (Left Hand Down Arrow). This push-button selects the welding procedure (MMA of TIG). When selected, one of the following LEDs lights:

B , C , or D

Then push the Mode Key E

(Right Hand Down Arrow). When selected, one of the following LEDs lights: F,G,H,L,M,N. Continue to push the button until the L LED lights along with the G LED.

L - LED. TIG welding with arc started with

high frequency.

G LED. Continuous 2-stage TIG welding

(manual).

Push the P – Selector (Right Arrow) until the Q –

LED current frequency display lights.

adjusted from 50 – 150 Hz. Turn the AA - Knob watching the Z - Display.

Set the current frequency to “60” Hz.

Push the P – Selector (Right Arrow) until the R – LED

wave balance display lights.

R - LED

settings, balance = 0; Cleaning from 1-8, Penetration from 1-8.

Turn the AA - Knob watching the Z - Display.

Set the wave balance to the “0” position.

Push the P – Selector (Right Arrow) until the O –

LED electrode diameter display lights.

Displays the electrode diameter. The choice of

electrode diameter ranges from 1mm to 4mm.

Turn the AA - Knob watching the Z - Display.

Set the electrode diameter to the size recommended in Table “A”. EX.(3/32” = 2.4 mm).

Push the P – Selector (Right Arrow) until the S

– LED slope up display lights.

S - LED

Slope up. This is the time in which the current, starting from the minimum, reaches the set current value. (0-10 sec.)

AC TIG WELDING

Push the button until the TIG D LED lights .

Current frequency in AC welding mode. Can be

Wave balance in AC welding. There are three possible

Page 16

Turn the AA -Knob watching the Z - Display.

Set the slope up to “0” seconds.

Push the P – Selector (Right Arrow) until the T –

LED main welding current display lights.

(10-130A in MMA and 5-150A in TIG)

Turn the AA knob while watching the Z display.

Z DISPLAY Adjust the display to the required main welding amperage. Rule of Thumb: “1 amp per .001 of plate thickness.

(.125 = ~125 amps)

Use the following as a guide for

setting up the amperage:

** May require multiple passes.

Push the P – Selector (Right Arrow) until the W –

LED slope down display lights.

W - LED

Slope down. This is the time in which the current reaches the minimum and the arc shuts off. (0-10 seconds).

Turn the AA - Knob watching the Z - Display.

Set the slope down to “0” seconds.

Push the P – Selector (Right Arrow) until the X –

LED post gas display lights.

Post Gas Adjusts the time gas flows after the welding

ends. ( 0-30 seconds)

Turn the AA - Knob watching the Z - Display.

Set the post gas to “10” seconds.

Basic TIG AC Setup is Complete

AC TIG WELDING cont’d

Page 17

How to Setup the Optional Variable Amperage Foot Pedal or Remote Finger Amp Control (RAD).

• Using High Frequency Start

• TIG AC Mode

The Foot Pedal allows the welder to remotely control the amperage from 5 amps minimum to 150 amps maximum shown on the LED Z display.

Install the Foot Pedal or RAD control plug in the AE

receptacle.

Push the procedure selector switch (Left Hand Down Arrow). This push-button selects the welding procedure (MMA or TIG). When selected, one of the following LEDs lights:

B , C , or D

Then push the Mode Key E

(Right Hand Down Arrow). When selected, one of the following LEDs lights: F,G,H,L,M,N. Continue to push the button until the L LED lights along with the G LED.

L - LED. TIG welding with arc started with

high frequency.

---NOT AVAILABLE IN THE MMA MODE

G LED. Continuous 2-stage TIG welding

(manual).

Push the P – Selector (Right Arrow) until the T –

LED main welding current display lights.

(10-130A in MMA and 5-150A in TIG)

Activate the foot pedal or RAD to the maximum (pedal or slider fully depressed) position. While holding down the pedal to maximum,

turn the AA knob while watching the Z display.

Z DISPLAY Adjust the amperage to the approximate current that is required using the basic rule of thumb “one amp per thousandths of material thickness. Ex. 1/8” inch = .125 thousands so set the amps to ~125.

Push down on the pedal or slide the RAD.

 The gas should purge.  High frequency should activate.  Amperage on the display Z should range from

5 to 125 amps.

NOW BEGIN TO WELD.

OPTIO NA L FOOT PEDAL/

REMOTE AM PE RAGE CONTROL

Push the button until the TIG AC LED lights .

Page 18

MMA WELDING (MANUAL METAL ARC OR STICK WELDING)

DC (10-130 Amps)

- Make sure that the switch

is in position 0, or “off” position then

connect

the welding cables, observing the polarity

required by

the

manufacturer of the electrodes you will be using; also

con

nect the clamp of the ground cable to the work

piece, as close to the weld as possible, making sure that there is

good

electrical

contact.

WARNING Do

NOT

touch the electrode clamp simultaneously with

the

earth

clamp.

Read complete listing of safety messages at the beginning of this manual.

1. Turn the machine on to “l” using the switch

2. Select the MMA procedure by pressing the button A LED B

lit.

3. Adjust the current based on the diameter of the

electrode,

the welding position and the type of joint to be made.

- Always remember to shut off the machine and remove the electrode from the clamp after welding.

STICK ARC WELDING

Page 19

DESCRIPTION OF PROTECTIVE DEVICES

Thermal protection

This machine is protected by a temperature probe,

which prevents the machine from operating if the allowable tempe

ratures are exceeded. Under these conditions the fan

keeps running and the LED J

lights. The duty cycle of the welder has been exceeded if the welder overheats. Duty cycle of a welding power source is the percentage of a ten minute period that the welder can operate without causing harm to the welder. Ex. A 60% duty cycle means that the welder can operate for 6 minutes and should cool for 4 minutes.

Block Protections This welding machine is equipped with various safety

devi

ces that stop the machine before it can suffer damage. In the event of a malfunction, the letter E may appear

the

display Z , followed by a flashing

number:

52 = Start button pressed during

startup. 53 = Start button pressed during thermostat reset. In both cases, release the start

button.

The machine stop is signaled by the flashing LED J

When this occurs, it signals:

1) During the start-up p h a s e , the power status of

the

machine.

2) After the start-up phase, incorrect supply

voltage.

3) With the machine running, that the voltage has fallen below 118V.

4) With the machine running, that the supply voltage is above 280V.

5) During welding, that the voltage exceeds 300V.

switch, wait 5 seconds, and switch it on again. If the problem

has

been corrected, the welding machine will begin

opera

ting

again.

NOTE: If the

supply

voltage is below 170V at start-up, no LED

will light and the fan is

powered. If the message E2 appears on the display, the machine requires technical service. 800-ABC-WELD

TIG WELDER MAINTENANCE

Any maintenance operation must be carried out by qualified personnel.

GENERAL TIG WELDER MAINTENANCE

In the case of maintenance inside the machine, make sure that the switch AF is in position "O" and that the power cord is disconnected from the mains. It is also necessary to periodically clean the interior of the machine from the accumulated metal dust, using compressed air.

PRECAUTIONS AFTER REPAIRS.

After making repairs, take care to organize the wiring so that there is secure insulation between the primary and secondary sides of the machine. Do not allow the wires to come into contact with moving parts or those that heat up during operation. Reassemble all clamps as they were on the original machine, to prevent a connection from occurring between the primary and secondary circuits should a wire accidentally break or be disconnected. Also mount the screws with geared washers as on the original machine.

TROUBLE SH OO TING/MAINTENANCE

To restore operation, check the voltage.

Then

shut off the AC

Page 20

REPLACEME NT PARTS – PARTS LIST

WHEN ORDERING SPARE PARTS PLEASE STATE THE MODEL NUMBER AND

SERIAL NUMBER AND PART NUMBER NEEDED.

Page 21

REPLACEME NT PARTS

– S TA ND ARD AND OPTIONAL AC CESSORIES

52 45

Page 22

WIRIN G DIAGRAM

Page 23

Snap-on Tools Company Limited Two (2) Year Warranty

Snap-on Tools Company (the “Seller") warrants only to original purchasers who use the Equipment in their business that under normal use, care and service, the Equipment (except as otherwise provided herein) shall be free from defects in material and workmanship for two years from the date of original invoice. Seller does not provide any warranty for accessories used with the Equipment that are not manufactured by Seller. Seller limits torch assembly to a period of 30 days.

SELLER'S OBLIGATIONS UNDER THIS WARRANTY ARE LIMITED SOLELY TO THE REPAIR OR, AT SELLER'S OPTION, REPLACEMENT OF EQUIPMENT OR PARTS WHICH TO SELLER'S SATISFACTION ARE DETERMINED TO BE DEFECTIVE AND WHICH ARE NECESSARY, IN SELLER'S JUDGMENT, TO RETURN THIS EQUIPMENT TO GOOD OPERATING CONDITION. NO OTHER WARRANTIES, EXPRESS OR IMPLIED OR STATUTORY, INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, SHALL APPLY AND ALL SUCH WARRANTIES ARE HEREBY EXPRESSLY DISCLAIMED.

SELLER SHALL NOT BE LIABLE FOR ANY INCIDENTAL, SPECIAL OR CONSEQUENTIAL COSTS OR DAMAGES INCURRED BY PURCHASERS OR OTHERS (including, without limitations, lost profits, revenues, and anticipated sales, business opportunities or goodwill, or interruption of business and any other injury or damage).

This warranty does not cover (and separate charges for parts, labor and related expenses shall apply to) any damage to, malfunctioning, inoperability or improper operation of the Equipment caused by, resulting from or attributable to (A) abuse, misuse or tampering; (B) alteration, modification or adjustment of the Equipment by other than Seller's authorized representatives; (e) installation, repair or maintenance (other than specified operator maintenance) of the Equipment or related equipment, attachments, peripherals or optional features by other than Seller's authorized representatives; (D) improper or negligent use, application, operation, care, cleaning, storage or handling; (E) fire, water, wind, lightning or other natural causes; (F) adverse environmental conditions, including, without limitation, excessive heat, moisture, corrosive elements, dust or other air contaminants, radio frequency interference, electric power failure, power line voltages beyond those specified for the Equipment. unusual physical, electrical or electromagnetic stress and/or any other condition outside of Seller's environmental specifications; (G) use of the Equipment in combination or connection with other equipment, attachments, supplies or consumables not manufactured or supplied by Seller; or (H) failure to comply with any applicable federal, state or local regulation, requirement or specification governing welders and related supplies or consumables.

Repairs or replacements qualifying under this Warranty will be performed on regular business days during Seller's normal working hours within a reasonable time following purchaser's request. All requests for Warranty service must be made during the stated Warranty period. Proof of purchase date is required to make a Warranty request. This Warranty is nontransferable.

Snap-on Tools Company

Kenosha, Wisconsin 53141-1410

Technical Support Line 800-ABC-WELD

Customer Service and Technical Support 800-ABC-WELD

Monday – Friday 7:00 a.m. – 3:00 p.m. EST

Made in Italy Snap-on and Wrench “S” are trademarks of Snap-on Incorporated. ©Snap-on Incorporated 2011. All Rights Reserved. Printed in United States Snap-on, 2801 80th St., Kenosha, WI 53143 www.snapon.com

WARRANTY/ SE RVICE AND REPAIR

Snap-On TIG 150i User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual