Stealth SWP 9010, SWP 9010H, 9011H Operator's Manual

Part No. 9010H

DIGI-TIG 180 DC PULSE PFC MV

OPERATOR’S

MANUAL

STEALTH DIGI-TIG 180 DC PULSE PFC MV

IMPORTANT

Read this Owner’s Manual completely before attempting to use this equipment.

Save this manual and keep it handy for quick reference. Pay particular attention
to the safety instructions provided for your protection. Contact your distributor if
you do not fully understand this manual.

CONTENTS

1. SAFETY 4

1.1 SIGNAL EXPLANATION 4

1.2 ARC WELDING DAMAGE 4

1.3 ELECTRIC AND MAGNETIC FIELDS 7

2. SUMMARY 8

2.1 BRIEF INTRODUCTION 8

2.2 MODULE EXPLANATION 9

2.3 WORKING PRINCIPLE 9

2.4 VOLT-AMPERE CHARACTERISTIC 9

3. INSTALLATION AND ADJUSTMENT 11

3.1 PARAMETERS 11

3.2 DUTY CYCLE AND OVER HEATING 12

3.3 MOVEMENT AND PLACEMENT 12

3.4 POWER SUPPLY INPUT CONNECTION 12

3.5 POLARITY CONNECTION (MMA) 13

3.6 ASSEMBLING THE EQUIPMENT (TIG) 13

4. OPERATION 14

4.1 MACHINE CONTROLS 14

4.2 CONTROL PANEL 15

4.3 ARGON ARC WELDING OPERATION 18

4.3.1 TIG WELDING (4T OPERATION) 18

4.3.2 TIG WELDING (2T OPERATION) 19

4.4 WELDING PARAMETERS 20

4.4.1 JOINT FORMS IN TIG/MMA 20

4.4.2 EXPLANATION OF WELDING QUALITY 20

4.4.3 PARAMETERS MATCHING 21

4.5 OPERATION ENVIRONMENT 23

4.6 OPERATION NOTICES 23

5. MAINTENANCE AND TROUBLESHOOTING 24

5.1 MAINTENANCE 24

5.2 TROUBLESHOOTING 25

5.3 MAIN ELECTRICAL DIAGRAM 27

STEALTH DIGI-TIG 180 DC PULSE PFC MV

STEALTH DIGI-TIG 180 DC PULSE PFC MV

1. SAFETY

1.1 Icons Explanation

• The above icons mean Warning! Notice! Running and thermal parts or receiving an
electric shock may harm you or others. The following precautions apply as a guide
to working safely.

1.2 Arc Welding Damage

• The following icons explanations are to prevent accidents to you or others during
the welding process.

• Only experienced personell can install, operate, maintain and repair the equipment.

• During the operation make sure those around you are properly protected.

• After turning off the machine power, please maintain and examine the equipment
according to 5 due to DC voltage existing in the electrolytic capacitors.

ELECTRIC SHOCK CAN KILL

• Never touch live electrical parts.

• Wear dry, hole-free gloves and clothes to insulate yourself.

• Insulate yourself from work and ground using dry insulation. Make certain the
insulation is large enough to cover your full area of physical contact with work and
ground.

• Take care when using the equipment in a confined space, on uneven surfaces and
in damp conditions.

• Shut down the incoming electrical supply prior to the equipment’s installation.

• Ensure the equipment is installed correctly and the work or metal is earthed
according to the operation manual.

• The electrode and work (or ground) circuits are ‘hot’ when the machine is on. Do not
touch these electrically ‘hot’ parts with your bare skin or wet clothing. Wear dry,
hole-free gloves to insulate hands.

• In semiautomatic or automatic wire welding, the electrode, electrode reel, welding
head, nozzle or semiautomatic welding gun are also electrically ‘hot’.

• Always ensure the work cable makes a good electrical connection and is as close as
possible to the metal being welded.

• Ensure the electrode holder, work clamp, welding cable and welding machine are
in good, safe operating condition. Replace any damaged insulation.

• Never dip the electrode in water for cooling.

• Never simultaneously touch electrically ‘hot’ parts of electrode holders connected to
two machines as voltage between the two can be the total of the open circuit voltage
of both welders.

• When working above floor level, use a safety belt to protect yourself from a fall
should you receive an electric shock.

SAFETY

§1 SAFETY

§1.1 Signal Explanation

SAFETY

§1 SAFETY

§1.1 Signal Explanation

 The above signals mean warning! Notice! Running parts and getting an electric shock or thermal parts

will take damage for your body or others. The corresponding notices are as follows. It is quite a safe

operation after taking several necessary protection measures.

§1.2 Arc Welding Damage

 The following signals and word explanations are to some damages for your body or others happening

on the welding operation. While seeing these, please remind of yourself or others to be dangerous.

 Only ones who are trained professionally can install, debug, operate, maintain and repair the

equipment.

 During the operation, non-concerned people should be lift, especially for children.

 After shut off the machine power, please maintain and examine the equipment according to §5

because of the DC voltage existing in the electrolytic capacitors.

ELECTRIC SHOCK CAN KILL.

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STEALTH DIGI-TIG 180 DC PULSE PFC MV

FUMES AND GASES CAN BE DANGEROUS

• Welding may produce fumes and gases hazardous to health. Avoid breathing these
fumes and gases.

• When welding, keep your head out of fumes. Use enough ventilation and/or exhaust
at the arc to keep fumes and gases away from the breathing zone. When welding
with electrodes which require special ventilation such as stainless or hard facing or
lead or cadmium plated steel and other metals or coatings which produce highly
toxic fumes, keep exposure as low as possible and below Threshold Limit Values
using local exhaust or mechanical ventilation. In confined spaces or in some
circumstances, outdoors, a respirator may be required. Additional precautions are
also required when welding on galvanized steel.

• Do not weld in locations near chlorinated hydrocarbon vapours coming from
degreasing, cleaning or spraying operations. The heat and rays of the arc can react
with solvent vapours to form phosgene – a highly toxic gas – and other irritating
products.

• Shielding gases used for arc welding can displace air and cause injury or death.
Always use enough ventilation, especially in confined areas, to ensure breathing air
is safe.

• Read and understand the manufacturer’s instructions for this equipment and the
consumables to be used, including the material safety data sheet and follow your
employer’s safety practices.

ARC RAYS CAN BURN

• Use a shield with the correct filter and cover plates to protect your eyes from sparks
and the rays of the arc when welding or observing open arc welding.

• Use suitable clothing made from durable flame-resistant material to protect your
skin and that of your helpers from the arc rays.

• Protect nearby personnel with suitable, non-flammable screening and/or warn them
to avert their eyes from the arc rays or expose themselves to hot spatter or metal.

SELF-PROTECTION

• Keep all equipment safety guards, covers and devices in position and in good repair.
Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other
moving parts when starting, operating or repairing equipment.

• Do not put your hands near the engine fan. Do not attempt to override the governor
or idler by pushing on the throttle control rods while the engine is running.

DO NOT add fuel near an open flame welding arc or when the
engine is running. Stop the machine and allow it to cool before refuelling to prevent
spilled fuel from vapourising on contact with hot engine parts and igniting. Do not
spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until
fumes have been eliminated.

SAFETY

semiautomatic welding gun are also electrically “hot”.

 Always be sure the work cable makes a good electrical connection with the metal being welded. The

connection should be as close as possible to the area being welded.

Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe

operating condition. Replace damaged insulation.

 Never dip the electrode in water for cooling.

 Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders

because voltage between the two can be the total of the open circuit voltage of both welders.

 When working above floor level, use a safety belt to protect yourself from a fall should you get a

shock.

FUMES AND GASES CAN BE DANGEROUS.

SAFETY

arc when welding or observing open arc welding.

 Use suitable clothing made from durable flame-resistant material to protect your skin and that of your

helpers from the arc rays.

 Protect other nearby personnel with suitable, non-flammable screening and /or warn them not to

watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

connection should be as close as possible to the area being welded.

Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe

operating condition. Replace damaged insulation.

 Never dip the electrode in water for cooling.

 Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders

because voltage between the two can be the total of the open circuit voltage of both welders.

 When working above floor level, use a safety belt to protect yourself from a fall should you get a

shock.

FUMES AND GASES CAN BE DANGEROUS.

 Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.

When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When welding with electrodes which require special

ventilation such as stainless or hard facing or on lead or cadmium plated steel and other metals or

coatings which produce highly toxic fumes, keep exposure as low as possible and below Threshold

Limit Values using local exhaust or mechanical ventilation. In confined spaces or in some

circumstances, outdoors, a respirator may be required. Additional precautions are also required when

welding on galvanized steel.

 Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or

spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a

highly toxic gas, and other irritating products.

 Shielding gases used for arc welding can displace air and cause injury or death. Always use enough

ventilation, especially in confined areas, to insure breathing air is safe.

 Read and understand the manufacturer’s instructions for this equipment and the consumables to be

used, including the material safety data sheet and follow your employer’s safety practices.

ARC RAYS CAN BURN.

SAFETY

arc when welding or observing open arc welding.

 Use suitable clothing made from durable flame-resistant material to protect your skin and that of your

helpers from the arc rays.

 Protect other nearby personnel with suitable, non-flammable screening and /or warn them not to

watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

SELF-PROTECTION

 Keep all equipment safety guards, covers and devices in position and in good repair. Keep hands, hair,

clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or

repairing equipment.

 Do not put your hands near the engine fan. Do not attempt to override the governor or idler by

pushing on the throttle control rods while the engine is running.

DO NOT adds the fuel near an open flame welding arc or when the engine is

5

WELDING SPARKS can cause fire or explosion

• Remove fire hazards from the welding area. If this is not possible, cover them to
prevent the welding sparks from starting a fire. Remember that welding sparks and
hot materials from welding can easily go through small cracks and openings to
adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily
available.

• Where compressed gases are to be used at the job site, special precautions should
be taken to prevent a hazardous situation.

• When not welding, make certain no part of the electrode circuit is touching the work
or ground. Accidental contact can cause overheating and create a fire hazard.

• Do not heat, cut or weld tanks, drums or containers until the proper steps have been
taken to ensure that any flammable or toxic vapours have been eliminated from
within. They can cause an explosion even though they have been ‘cleaned’.

• Vent hollow castings or containers before heating, cutting or welding. They may
ignite.

• Sparks and spatter are thrown from the welding arc. Wear oil free protective
garments such as leather gloves, heavy shirt, cuff less trousers, high shoes and a
cap over your hair. Wear ear plugs when welding out of position or in a confined
space. Always wear safety glasses with side shields when in a welding area.

• Connect the work cable to the work as close to the welding area as practical. Keep
work cables connected to the building framework or other locations away from the
welding area.

Rotating parts may be dangerous

• Use only compressed gas cylinders containing the correct shielding gas for the
process used and properly operating regulators designed for the gas and pressure
used. All hoses, fittings, etc. should be suitable for the application and maintained
in good condition.

• Always keep cylinders in an upright position securely chained to an undercarriage or
fixed support.

• Cylinders should be located:
– Away from areas where they may be struck or subjected to physical damage.
– A safe distance from arc welding or cutting operations and any other source of
heat, sparks, or flame.

• 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.

• Valve protection caps should always be in place and hand tight except when the
cylinder is in use or connected for use.

SAFETY

an explosion even though they have been “cleaned”.

 Vent hollow castings or containers before heating, cutting or welding. They may explode.

 Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather

gloves, heavy shirt, cuff less trousers, high shoes and a cap over your hair. Wear ear plugs when

welding out of position or in confined places. Always wear safety glasses with side shields when in a

welding area.

 Connect the work cable to the work as close to the welding area as practical. Work cables connected

to the building framework or other locations away from the welding area increase the possibility of the

welding current passing through lifting chains, crane cables or other alternate circuits. This can create

fire hazards or overheat lifting chains or cables until they fail.

Rotating parts may be dangerous.

STEALTH DIGI-TIG 180 DC PULSE PFC MV

6

SAFETY

arc when welding or observing open arc welding.

 Use suitable clothing made from durable flame-resistant material to protect your skin and that of your

helpers from the arc rays.

 Protect other nearby personnel with suitable, non-flammable screening and /or warn them not to

watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

SELF-PROTECTION

 Keep all equipment safety guards, covers and devices in position and in good repair. Keep hands, hair,

clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or

repairing equipment.

 Do not put your hands near the engine fan. Do not attempt to override the governor or idler by

pushing on the throttle control rods while the engine is running.

DO NOT adds the fuel near an open flame welding arc or when the engine is

running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on

contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it

up and do not start engine until fumes have been eliminated.

STEALTH DIGI-TIG 180 DC PULSE PFC MV

1.3 Electric and Magnetic Fields

• Electric current flowing through any conductor causes localised Electric and
Magnetic Fields (EMF). The discussions of the effect of EMF is ongoing globally.
Up to now, there is no material evidence that EMF has any adverse effects on
health.
Minimise exposure to EMF as far as possible by applying the following procedures:
– Route the electrode and work cables together. Secure them with tape when
possible.
– All cables should be stored away from the operator.
– Never coil the power cable around your body.
– Make sure welding machine and power cable are far enough away from the
operator according to the working environment.
– Connect the work cable to the workpiece as close as possible to the area being
welded.
– Personnel fitted with a heart-pacemaker should keep their distance from the
welding area.

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STEALTH DIGI-TIG 180 DC PULSE PFC MV

2 SUMMARY

2.1 Brief Introduction

The TIG DC PULSE PFC MV welding machine features the latest Pulse Width
Modulation (PWM) technology and Insulated Gate Bipolar Transistor (IGBT) power
module, which can change work frequency to medium frequency so as to replace the
traditional large transformer with a medium frequency transformer – making it smaller,

portable light- weight and low consumption.
The front panel parameters can be adjusted continuously and steplessly, such as start
current, crater arc current, welding current, base current, duty ratio, upslope time,
downslope time, pre-gas, post-gas, pulse frequency, hot start, arc force and arc length
etc. When welding, it takes high frequency and high voltage for arc igniting to ensure
the success ratio of igniting arc.

TIG DC PULSE PFC MV Characteristics

• DC Pulsed TIG and MMA, adopt IGBT and advanced PWM technology

• High performance MCU, Digital control, Digital display

• Preset all parameters with hold process

• HF/Lift TIG, current down slope and up slope, gas post-flow, pulse frequency

• Intelligent protection: over-voltage, under-voltage, over-current, over-heat

1. For MMA, polarity connection can be chosen according to different electrodes
(please refer to 3.5).

2. For DC TIG, DCEP is used normally (workpiece connected to positive polarity, while
torch connected to negative polarity). This connection has many characters, such as
stable welding arc, low tungsten pole loss, more welding current, narrow and deep
weld.

3. DC Pulsed TIG has the following characteristics:
– Pulse heating. Metal in Molten pool has short time on high temperature status
and freezes quickly, which can reduce the possibility to produce hot crack of
the materials with thermal sensitivity
– Workpiece gets little heat. Arc energy is focused. Suitable for thin sheet and
super thin sheet welding.
– Exact control heat input and size of molten pool. Depth of penetration is even
and suitable for welding one side and forming two sides and all position pipe
welding.
– High frequency arc can make metal for microlite fabric, eliminate blowhole and
improve the mechanical performance of the joint. It is also suitable for high
welding speed for improved productivity.

TIG DC PULSE PFC MV-series welding machine is suitable for all position welding for
a variety of plates of stainless steel, carbon steel, alloyed steel, titanium, magnesium,
cuprum, etc, also applied to pipe installation, mould repair, petrochemical,
architectural decoration, car repair, bicycle, handicraft and DIY.

MMA Manual Metal Arc welding

PWM Pulse-Width Modulation

IGBT Insulated Gate Bipolar Transistor

TIG Tungsten Insert Gas welding

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STEALTH DIGI-TIG 180 DC PULSE PFC MV

2.2 Module Explanation

The module explanation of arc welding machine must accord with the National
Standard GB10249, explained as follows (using the TIG 180 DC PULSE PFC MV as an
example).

TIG 180 DC PULSE PFC MV

2.3 Working Principle

The working principle of TIG DC PULSE PFC MV-series welding machines is shown
as follows: Single phases work frequency AC 110/220V(50 Hz) is transformed into
DC(155/312V), then is converted to medium frequency AC (about 50/40KHZ) by
inverter device (IGBT). After reducing voltage by medium transformer (the main
transformer) and rectifying by medium frequency rectifier (fast recovery diode), output
is produced by inductance filtering. The circuit adopts current feedback control
technology to ensure current output stability. Meanwhile, the welding current
parameter can be adjusted continuously and steplessly to meet with the requirements
of welding craft.

SUMMARY

sides and all position welding for pipe. 4) High frequency arc can make metal for microlite fabric,

eliminate blowhole and improve the mechanical performance of the joint. 5) High frequency arc is

suitable for high welding speed to improve the productivity.

TIG DC PULSE PFC MV-series welding machine is suitable for all positions welding for various

plates made of stainless steel, carbon steel, alloyed steel, titanium, magnesium, cuprum, etc, which is

also applied to pipe installment, mould mend, petrochemical, architecture decoration, car repair, bicycle,

handicraft and common manufacture.

MMA——Manual Metal Arc welding

PWM——Pulse-Width Modulation

IGBT——Insulation Gate Bipolar Transistor

TIG——Tungsten Insert Gas welding

§2.2 Module Explanation

The module explanation of arc welding machine must accord with the correlative prescripts of

National Standard GB10249. It is explained as the following (take

TIG 180 DC PULSE PFC MV as an

example).

TIG 180 DC PULSE PFC MV

Multi voltage

Power factor correction

PULSE

DC welding machine

Max welding current 180A

TIG welding machine/MMA

Multi voltage

Power factor correction

PULSE

DC welding machine

Max welding current 180A

TIG welding machine/MMA

SUMMARY

control technology to insure current output stably. Meanwhile, the welding current parameter can be

adjusted continuously and steplessly to meet with the requirements of welding craft.

2.4 Volt-Ampere Characteristic

The TIG DC PULSE PFC MV welding machine has an excellent volt-ampere
characteristic, as shown as the following graph (see next page). The relation between
the conventional rated loading voltage U2 and the conventional welding current I2 is
as follows:

When I2≤600A, U2=10+0.04I2(V); When I2>600A,U2=34(V).

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STEALTH DIGI-TIG 180 DC PULSE PFC MV

SUMMARY

TIG DC PULSE PFC MV welding machine has an excellent volt-ampere characteristic, whose

2

2

is as follows:

When I

2

≤600A，U2=10+0.04I2(V); When I2＞600A,U2=34(V).

67

34

10

0 600

I

2

（A）

U

2

（V）

Working

point

Volt-ampere characteristic

The relation between the

conventional loading

voltage and welding current

10

DIGI-TIG 180 DC PULSE PFC MV

TIG

STEALTH DIGI-TIG 180 DC PULSE PFC MV

11

3 INSTALLATION AND ADJUSTMENT

3.1 Parameters

1~110/120/130

±10%

5-110

Power Supply Voltage (V)

±10%

5-180

50/60

IP23

H

AF

7.5

465 × 146 × 278

66

0-10

0-2/0-10

0.5-200

5-95

≥85

TIG

17.2

1.9

35%

110A

60%

85A

100%

65A

30%

110A

60%

80A

100%

65A

35%

180A

60%

140A

100%

110A

25%

180A

60%

120A

100%

100A

0.99

MMA

33

3.2

17

3.7

MMA

26.5

5.8

1~220/230/240

Frequency (Hz)

Rated Input Current (A)

Rated Input Power (Kw)

Power Factor

Welding Current Adjustment Range (A)

Maximum No Load Voltage (V)

Up-slope/Down-slope (S)

Pre/Post Flow (S)

Pulse Frequency (Hz)

Pulse Width Range (%)

Efficiency (%)

Duty Cycle (40ºC / 10 min)

Protection Class

Insulation Class

Cooling

Net Weight (Kg)

Dimensions (mm) L × W × H

STEALTH DIGI-TIG 180 DC PULSE PFC MV

3.2 Duty Cycle and Over-heating

The letter ‘X’ stands for duty cycle,
which is defined as the proportion
of the time that a machine can work
continuously within a certain time (10
minutes). The rated duty cycle means
the proportion of the time that a
machine can work continuously within
10 minutes when it outputs the rated
welding current.

The relation between the duty cycle ‘X’
and the output welding current ‘I’ is
shown as the figure on the right.

If the welder is over-heating, the IGBT over-heating protection unit inside will send a
message to cut output welding current and illuminate the pilot lamp on the front
panel.

At this point, the machine should be turned off for 15 minutes to cool the fan. When
operating the machine again, the welding output current or the duty cycle should be
reduced.

3.3 Movement and Placement

Please take care when moving it the machine and keep it level.
It also can be moved by the handle on the top. Place the machine securely when in
the right location. When moving using a forklift, ensure the arm lengths are long
enough to reach outside the machine to safely lift.
The movement may result in the potential danger or substantive hazard, so please
make sure that the machine is in a safe position before using it.

3.4 Power Supply Input Connection

TIG DC PULSE PFC MV welding machine’s power supply connects to 110/220V.
When the power supply voltage is over the safe working voltage, there are over-voltage
and under-voltage protection inside the welder. The alarm light will illuminate and, at
the same time, the current output will be cut off.
If the power supply voltage continually goes beyond the safe work voltage range, it will
shorten the machine’s life-span. The below measures can be used:

• Change the power supply input net (connect the welder with the stable power supply
voltage of distributor).

• Switch on the machines using power supply at the same time.

• Set the voltage stabilisation device in the front of power cable input.

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STEALTH DIGI-TIG 180 DC PULSE PFC MV

3.5 Polarity Connection (MMA)

MMA (DC): Choosing the connection of DCEN or DCEP according to the different
electrodes.
Please refer to the electrode manual.

3.6 Assembling the Equipment (TIG)

• The workpiece is connected to the positive electrode of the welding machine,
and the welding torch is connected to the negative electrode – DC POSITIVE
CONNECTION, otherwise – DC NEGATIVE CONNECTION.
Generally, it is operated in DC POSITIVE CONNECTION in TIG welding mode.

• Control of the torch switch cable consists of 2 wires, pedal control of 3 wires and
the aero socket of 14 leads.

• Consumable parts for TIG torch, such as tungsten electrode / tip / gas nozzle /
electrode shield (short/long) – contact your supplier quoting the part numbers.

• When TIG DC PULSE PFC MV-series welding machines are operated in HF Ignition
mode, the ignition spark can cause interferences in equipment near the welding
machine. Be sure to take appropriate safety precautions or shielding measures.

INSTALLATION AND ADJUSTMENT

under voltage protection inside the welder, the alarm light will on, at the same time, the current

output will be cut off.

If the power supply voltage continually goes beyond the safe work voltage range, it will

shorten the welder life-span. The below measures can be used:

 Change the power supply input net. Such as, connect the welder with the stable power supply

voltage of distributor;

 Induce the machines using power supply in the same time;

 Set the voltage stabilization device in the front of power cable input.

§3.5 Polarity Connection（MMA）

MMA (DC): Choosing the connection of DCEN or DCEP according to the different electrodes.

Please refer to the electrode manual..

DC NEGATIVE CONNECTION DC POSITIVE CONNECTION

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STEALTH DIGI-TIG 180 DC PULSE PFC MV

4 OPERATION

4.1 Machine Controls

MAINTENANCE AND TROUBLESHOOTING

§4 Operation

1 Positive output: Welder’s positive polarity output

2 Negative output: Welder’s negative polarity output.

3 Aero socket: Connected to torch switch control wire (has 14 leads with 8-9
connected to torch switch control wire).

4 Shield gas connector: Connected to torch gas input pipe.

5 Power source switch: Switch to ‘ON’ – welder is turned on. Switch to ‘OFF’ –
welder is turned off.

6 Power source input: Connects power source.

7 Shield gas input joint: Connects one head of the gas hose while the other is
connected to argon gas cylinder.

14

4.2 Control Panel

MAINTENANCE AND TROUBLESHOOTING

§4.2 Control panel

§4.2 Control panel

Overview

The key feature of the control panel is the logical way in which the controls are arranged. All the

main parameters needed for day-to-day working can easily be

-selected with the keys.

-altered with the adjusting dial.

-shown on the display during welding.

The illustration below shows an overview of the main settings needed for day-to-day working,

using the TIG DC PULSE PFC MV control panel as an example. You will find a detailed description

of these settings in the following section.

(1)TIG mode selecting key

2-step mode 4-step mode

Overview

The key feature of the Control Panel is the logical way in which the controls are
arranged. All the main parameters needed for day-to-day operation can easily be:

– Selected with the keys

– Altered with the adjusting dial

– Shown on the display during welding

The illustration below shows an overview of the main settings needed for day-to-day
working, using the TIG DC PULSE PFC MV control panel as an example. You will find a
detailed description of these settings in the following section.

(1) TIG mode selecting key

(2) Parameter select and adjust
Push the encoder to select, the parameter indicator lights up. The selected

parameter can then be adjusted.

STEALTH DIGI-TIG 180 DC PULSE PFC MV

15

STEALTH DIGI-TIG 180 DC PULSE PFC MV

Available parameters where 2T and 4T mode have been selected:

Tpr Gas pre-flow time

Unit S

Setting range 0-2

Factory setting

Is Starting current (only with 4T)

Unit A

Setting range 5-100%of main current Iw

Factory setting

Tup Upslope time

Unit S

Setting range 0-10

Factory setting

Iw Welding current

Unit A

TIG 180 DC PULSE PFC MV 5-110 (110V) 5-180(220V)

TIG 200 DC PULSE PFC MV 5-130 (110V) 5-220(220V)

Ib Base current

Unit A

TIG 180 DC PULSE PFC MV 5-110 (110V) 5-180(220V)

TIG 200 DC PULSE PFC MV 5-130 (110V) 5-220(220V)

Important! Only selectable when ‘pulse key’ has been pressed

Dcy Ratio of pulse duration to base current duration

Unit %

Setting range 5-95

Factory setting

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STEALTH DIGI-TIG 180 DC PULSE PFC MV

Important! Only selectable when ‘pulse key’ has been pressed

Fp Pulse frequency
Unit Hz
Setting range 0.5-200
Factory setting
Important! Only selectable when ‘pulse key’ has been pressed

Tdown Downslope time
Unit S
Setting range 0-10
Factory setting

Ic Crater arc current (only with 4T)
Unit S
Setting range 5-100% of main current Iw
Factory setting

Tpo Gas post-flow time
Unit S
Setting range 0-10
Factory setting

(3) Rod electrode (MMA) welding parameter

(4) Power/Alarm indicator

(5) Welding current and other parameter displays

Before starting welding indicate the open-circuit voltage by pushing the
encoder for 3 seconds and the display shows the pre-set value of Tpr, Is, Tup,
Iw, Dcy, Iw, Fp, Ib, Tdown, Ic, Tpo. After the start of welding, display shows
the present actual value of the welding current.

MAINTENANCE AND TROUBLESHOOTING

Important! Only selectable when “pulse key” has been pressed.

Fp Pulse frequency

Unit Hz
Setting range 0.5—200

Factory setting

Important! Only selectable when “pulse key” has been pressed.

Tdown Downslope time

Unit S
Setting range 0—10

Factory setting

Ic Crater arc current (only with 4T)

Unit S
Setting range 5—100% of main current Iw ；

Factory setting

Tpo Gas post-flow time

Unit S
Setting range 0—10

Factory setting

(3) Rod electrode(MMA) welding parameter

Parameter Setting range

Arc force 0-10

Hot start 0-10

(4) Power/Alarm indicator

Light up if the welder overheat.

MAINTENANCE AND TROUBLESHOOTING

Important! Only selectable when “pulse key” has been pressed.

Fp Pulse frequency

Unit Hz
Setting range 0.5—200

Factory setting

Important! Only selectable when “pulse key” has been pressed.

Tdown Downslope time

Unit S
Setting range 0—10

Factory setting

Ic Crater arc current (only with 4T)

Unit S
Setting range 5—100% of main current Iw ；

Factory setting

Tpo Gas post-flow time

Unit S
Setting range 0—10

Factory setting

(3) Rod electrode(MMA) welding parameter

Parameter Setting range

Arc force 0-10

Hot start 0-10

Parameter Setting range

Arc force 0-10

Hot start 0-10

Lights up if the machine overheats

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STEALTH DIGI-TIG 180 DC PULSE PFC MV

4.3 Argon Arc Welding Operation

4.3.1 TIG welding (4T operation)

The start current and crater current can be pre-set. This function can
compensate the possible crater that appears at the beginning and end of
welding. Thus, 4T is suitable for the welding of medium thickness plates.

Pulsed TIG long welding (4T)

Introduction

• 0 Press and hold the gun switch – Electromagnetic gas valve is turned on.

The shielding gas starts to flow

• 0~t1 Pre flow time – adjustment range of pre flow time: 0~2S

• t1 Striking success – adjustment range of start current: 5~100% of main current

• t2 Loosen the gun switch – the output current slopes up from start current.
If the output pulse function is turned on, the output current is pulsed

• t2~t3 Output current slopes up to the setting current value – adjustment range of
up slope time 0~10S

• t3~t4 Welding process – during this period the gun switch is loosened
Note: If the output pulse function is turned on, the output current is pulsed.

If the output pulse function is turned off, the output current is the welding
current (Iw)

• t4 Repress the gun switch – the output current slopes down to crater current.
If the output pulse function is turned on, the slope down current is pulsed

• t4~t5 Down slope time – adjustment range of down slope time: 0~10S

• t5~t6 Crater current holds time – adjustment range of crater current: 5~100% of
main current

• t6 Loosen the gun switch – stop arc and keep the argon flowing

• t6~t7 Post flow time – adjustment range of post flow time: 0~10S

• t7 Electromagnetic valve is closed and stop argon flowing – welding is complete

MAINTENANCE AND TROUBLESHOOTING

t（s）

0

I（A）

Loosen the welding

gun switch

Press and hold the welding

gun switch

t1 t5

Striking success

Stop arc

t3 t4

Base current setting value

t2

Welding current (peak

current) setting value

5A

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STEALTH DIGI-TIG 180 DC PULSE PFC MV

4.3.2 TIG welding (2T operation)

Pulsed TIG short welding (2T)

MAINTENANCE AND TROUBLESHOOTING

t（s）

0

I（A）

Loosen the welding

gun switch

Press and hold the welding

gun switch

t1 t5

Striking success

Stop arc

t3 t4

Base current setting value

t2

Welding current (peak

current) setting value

5A

Introduction

• 0 Press and hold the gun switch – electromagnetic gas valve is turned on.

The shielding gas starts to flow

• 0~t1 Pre flow time – adjustment range of pre flow time: 0~2S

• t1~t2 Striking success – the output current slopes up to the setting current from
minimum current (5A). If the output pulse function is turned on, the slope
up current is pulsed

• t2~t3 During the whole welding process, the gun switch is pressed and held
without releasing
Note: If the output pulse function is turned on, the output current is pulsed.

If the output pulse function is turned off, the output current is DC

• t3 Loosen the gun switch – the output current slopes down. If the output pulse
function is turned on, the slope down current is pulsed

• t3~t4 The output current slopes down to minimum current (5A) – stop arc.
Adjustment range of down slope time: 0~10S

• t4~t5 Post flow time – adjustment range of post flow time: 0~10S

• t5 Electromagnetic valve is closed – argon stops flowing and welding is complete

Short circuit protection function

1 TIG /LIFT If the tungesten electrode touches the workpiece when welding, the
current will drop to 5A which can greatly reduce the tungsten spoilage,
prolong the life of the tungsten electrode and prevent tungsten clipping

2 TIG /HF If the tungesten electrode touches the workpiece when welding, the
current will drop to 0 within 1S which can greatly reduce the tungsten
spoilage, prolong the life of the tungsten electrode and prevent tungsten
clipping

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STEALTH DIGI-TIG 180 DC PULSE PFC MV

3 TMMA operation

If the electrode touches the workpiece over 2S, the welding current will drop auto-

matically to 0 to protect the electrode

Prevent arc-break function
TIG operation – Avoid arc-break. If arc-break occurs the HF will keep the arc stable

Notes

• First check the condition of welding and connection units for any malfunction,
such as ignition spark / gas leakage / out of control etc

• Check whether there is enough Argon gas in the shield gas cylinder. The electro­ magnetic gas valve can be tested via the switch on the front panel

• Do not point the torch at hand or body. When the torch switch is pressed, the arc is
ignited with a high-frequency, high-voltage spark. The ignition spark can cause
interference in equipment.

• The flow rate is set according to the welding power used. Turn the regulation screw
to adjust the gas flow shown on the gas hose pressure meter or the gas bottle
pressure meter.

• The spark ignition is most efficient if you keep a 3mm distance from the workpiece
to the tungsten electrode during the ignition

4.4 Welding Parameters

4.4.1 Joint forms in TIG/MMA

INSTALLATION AND ADJUSTMENT

§4.4 Welding Parameters

§4.4.1 Joint forms in TIG/MMA

a butt joint

b lap joint c coner joint d T joint

a) butt joint b) lap joint c) corner joint d) T joint

4.4.2 Explanation of welding quality

INSTALLATION AND ADJUSTMENT

§4.4 Welding Parameters

§4.4.1 Joint forms in TIG/MMA

§4.4.2 The explanation of welding quality

The relation of welding area color & protect effect of stainless steel

Welding area

color

argent , golden blue red-grey grey black

Protect effect best better good bad worst

a butt joint

b lap joint c coner joint d T joint

INSTALLATION AND ADJUSTMENT

§4.4 Welding Parameters

§4.4.1 Joint forms in TIG/MMA

§4.4.2 The explanation of welding quality

The relation of welding area color & protect effect of stainless steel

Welding area

color

argent , golden

blue

red-grey

grey

black

Protect effect

best

better

good

bad

worst

The relation of welding area color & protect effect of Ti-alloy

Welding area

color

bright argent orange-yellow blue-purple

caesious

white powder

of

titanium oxid

Protect effect best better good bad worst

a butt joint

b lap joint c coner joint d T joint

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STEALTH DIGI-TIG 180 DC PULSE PFC MV

4.4.3 Parameters Matching

INSTALLATION AND ADJUSTMENT

§4.4 Welding Parameters

§4.4.1 Joint forms in TIG/MMA

§4.4.2 The explanation of welding quality

The relation of welding area color & protect effect of stainless steel

Welding area

color

argent , golden

blue

red-grey

grey

black

Protect effect

best

better

good

bad

worst

The relation of welding area color & protect effect of Ti-alloy

Welding area

color

bright argent

orange-yellow

blue-purple

caesious

white powder of

titanium oxid

Protect effect

best

better

good

bad

worst

§4.4.3 TIG Parameters Matching

The corresponding relationship between gas nozzle diameter and electrode diameter

Gas nozzle diameter/mm Electrode diameter/mm

6.4 0.5

8 1.0

9.5 1.6 or 2.4

11.1 3.2

Notice: the above parameters originate from《Welding Dictionary》P142, Volume 1 of

Edition 2.

a butt joint

b lap joint c coner joint d T joint

MAINTENANCE AND TROUBLESHOOTING

Welding current

range/A

DC positive connection

Gas nozzle diameter/mm Gas flow rate/L·min-1

10～100 4～9.5 4～5

101～150 4～9.5 4～7

151～200 6～13 6～8

201～300 8～13 8～9

tungsten electrode

diameter /mm

sharpened of the

electrode diameter/mm

angle of cone（°） background current/A

1.0 0.125 12 2～15

1.0 0.25 20 5～30

1.6 0.5 25 8～50

1.6 0.8 30 10～70

2.4 0.8 35 12～90

2.4 1.1 45 15～150

3.2 1.1 60 20～200

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STEALTH DIGI-TIG 180 DC PULSE PFC MV

MAINTENANCE AND TROUBLESHOOTING

Welding current

range/A

DC positive connection

Gas nozzle diameter/mm

Gas flow rate/L·min-1

10～100

4～9.5

4～5

101～150

4～9.5

4～7

151～200

6～13

6～8

201～300

8～13

8～9

tungsten electrode

diameter /mm

sharpened of the

electrode diameter/mm

angle of cone（°）

background current/A

1.0

0.125

12

2～15

1.0

0.25

20

5～30

1.6

0.5

25

8～50

1.6

0.8

30

10～70

2.4

0.8

35

12～90

2.4

1.1

45

15～150

3.2

1.1

60

20～200

TIG of stainless steel (single run welding)

Workpiece

thickness

/mm

Joint form

tungsten

electrode

diameter/mm

welding wire

diameter/mm

Argon gas

flow rate/

L·min-1

welding

current

(DCEP)

Welding

speed/

cm·min-1

0.8 Butt joint 1.0 1.6 5 20～50 66

1.0 Butt joint 1.6 1.6 5 50～80 56

1.5 Butt joint 1.6 1.6 7 65～105 30

1.5

Corner

joint

1.6 1.6 7 75～125 25

2.4 Butt joint 1.6 2.4 7 85～125 30

2.4

Corner

joint

1.6 2.4 7 95～135 25

3.2 Butt joint 1.6 2.4 7 100～135 30

3.2

Corner

joint

1.6 2.4 7 115～145 25

4.8 Butt joint 2.4 3.2 8 150～225 25

4.8

Corner

joint

3.2 3.2 9 175～250 20

Notice: the above parameters originate from《Welding Dictionary》P150, Volume 1 of Edition 2.

MAINTENANCE AND TROUBLESHOOTING

Parameters of piping back sealing welding for mild steel（DCEP）

Piping

diameter

Φ/mm

Tungsten

electrode

diameter/mm

Gas nozzle

diameter/mm

Welding

wire

diameter/mm

Welding

current/A

Arc

voltage/V

Argon

flow rate

/

L·min

-1

Welding

rate

/

cm·min

-1

38 2.0 8 2 75～90 11～13 6～8 4～5

42 2.0 8 2 75～95 11～13 6～8 4～5

60 2.0 8 2 75～100 11～13 7～9 4～5

76 2.5 8～10 2.5 80～105 14～16 8～10 4～5

108 2.5 8～10 2.5 90～110 14～16 9～11 5～6

133 2.5 8～10 2.5 90～115 14～16 10～12 5～6

159 2.5 8～10 2.5 95～120 14～16 11～13 5～6

219 2.5 8～10 2.5

100～

120

14～16 12～14 5～6

273 2.5 8～10 2.5

110～

125

14～16 12～14 5～6

325 2.5 8～10 2.5

120～

140

14～16 12～14 5～6

Notice: the above parameters originate from《Welding Dictionary》P167, Volume 1 of Edition 2.

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STEALTH DIGI-TIG 180 DC PULSE PFC MV

4.5 Operation Environment

• Height above sea level below 1000m

• Operation temperature range: –100ºC~+400C

• Relative humidity below 90% (20ºC)

• Preferably site the machine above floor level with the maximum angle not exceeding

15º.

• Protect the machine against heavy rain, hot environments and direct sunshine

• The content of dust, acid, corrosive gas in the surrounding air or substance should

not exceed normal standards

• Take care that there is sufficient ventilation during welding and there is at least
30cm free distance between the machine and wall

4.6 Operation Notices

• Read all notes carefully before attempting to use this equipment

• Connect the ground wire with the machine directly, and refer to 3.5

• If the power switch is accidentally closed, no-load voltage may be exported. Do not

touch the output electrode with any part of your body

• Before operation ensure no other presonnnel is present without proper eye
protection

• Ensure good ventilation of the machine to improve duty ratio.

• Turn off the engine when the operation finished to economize energy source.

• If the power switch shuts off accidentally, do not restart until the problem is

resolved

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STEALTH DIGI-TIG 180 DC PULSE PFC MV

5 MAINTENANCE AND TROUBLESHOOTING

5.1 Maintenance

In order to guarantee that an arc welding machine works efficiently and safely, it must

be maintained regularly. Read and understand the maintenance methods and regularly
carry out safety checks. Make any repairs as required in order to extend the service life
of the welding machine. Maintenance items are detailed in the following tables.

• Warning: Safely maintain the machine by shutting off the power supply and waiting
for 5 minutes until the capacity voltage drops to a safe voltage of 36V.

DATE MAINTENANCE CHECKS

Daily Observe whether panel knob and switch in the front and at the back of arc
examination welding machine are flexible and placed correctly. If the knob has not been
correctly installed, please correct. If this is not possible, replace immediately,

If the switch is not flexible or it cannot be correctly installed, please replace
immediately. Contact your distributor if there are no parts to hand.

After switching on power, watch and listen to check the arc welding machine is
not shaking, whistling or giving out an unusual odour. If so, investigate and
eliminate. If any problem persists please contact your distributor.

Observe the LED is working correctly. If the number is not displayed, replace the
LED. If it still does not work, maintain or replace the display PCB.

Observe whether the min/max value on LED accords with the set value. If there
is any difference and it has affected the normal welding process, adjust
accordingly.

Check fan for damage and correct rotation. If damaged, change immediately.
If the fan does not rotate after the arc welding machine is overheated, check
the blade is not obstructed. If the fan still does not rotate after eliminating the
above, push the blade in the direction the fan rotates. If the fan rotates
normally, the start capacity should be replaced. If not, change the fan.

Check whether the fast connector is loose or overheated. If so, it should be
fastened or changed.

Check the current output cable is not damaged. If so, it should be securely
insulated or replaced.

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STEALTH DIGI-TIG 180 DC PULSE PFC MV

DATE MAINTENANCE CHECKS

Monthly Use dry compressed air to clear the inside of arc welding machine. Pay
examination particular attention to clear any dust on radiator, main voltage transformer,
inductance, IGBT module, the fast recover diode and PCB, etc.

Check the arc welding machine bolt. If loose, tighten. Replace if worn. Scrape
off any rust to ensure it works efficiently.

Quarterly Check the actual current accords with the displaying value. If not, they should
examination be reconfigured. The actual current value can be measured by the adjusted
plier-type ampere meter.

Annual Measure the insulating impedance among the main circuit, PCB and case.
examination If it is below 1MΩ, insulation may be damaged and should be repaired or
replaced.

5.2 Troubleshooting

• Before arc welding machines are dispatched from the factory, they have already been
carefully checked. Do not allow anyone unauthorised to make any alterations to the
equipment.

• Maintenance work must be carefully undertaken. If any wire becomes loose or
misplaced, it may be a potential danger to the user.

• Only authorised professional maintenance personnel should overhaul the machine.

• If a problem persists and no authorised professional maintenance personnel is

available, contact your supplier.

If there are minor problems with the TIG DC PULSE PFC MV-series welding machine,
consult the following chart:

S/N PROBLEM REASON SOLUTION

There is something in the fan Clear out
Turn on the power source,
1 and the power lamp is on Fan start capacitor damaged Change capacitor
but fan doesn’t work
Fan motor damaged Change fan

2 Number on the display is not

Display LED is broken Change LED

clear

Max value is not in Adjust potentiometer Imax
The max and min value accordance (refer to 3.1) on the control
3 displayed doesn’t accord
with set value Min value is not in Adjust potentiometer Imin
accordance (refer to 3.1) the current meter.

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STEALTH DIGI-TIG 180 DC PULSE PFC MV

S/N PROBLEM REASON SOLUTION

4 No no-load voltage output

Machine is damaged Check Pr4 main circuit

(MMA)

Welding cable is not connected Connect welding cable to
with two output of the machine machine output

Welding cable is damaged Repair or change

Earth cable connection unstable Check earth cable

Welding cable is too long Use appropriate welding cable

5 Oil or dust on the workpiece Check and remove

Distance between tungsten and

Reduce distance (about 3mm)

workpiece is too long

HF igniting board does not work Repair or change Pr8

Distance between discharger

Adjust distance (about 0.7mm)

is too short

Welding gun switch malfunction

Check switch, control cable

and aero socket

Gas cylinder is closed or gas

Open or change gas cylinder

pressure is low

6 No gas flow (TIG) Blockage in the valve Remove

Electromagnetic valve damaged Change

Front panel gas-test is on Turn off

Blockage in the valve Remove

7 Gas continually flows Electromagnetic valve damaged Change

Front panel gas-test adjustment
knob is damaged

Repair or change potentiometer

Welding current cannot be

Welding current potentiometer

8

adjusted

on the front panel connection Repair or change potentiometer

is damaged

Minimum value displayed is not
accordant with actual value

Adjust potentiometer Imax on

Welding current displayed is (refer to 3.1)

the power board

9

not accordant with actual value

Maximum value displayed is not
accordant with actual value

Adjust potentiometer Imax on

(refer to 3.1)

the power board

10 Penetration of molten pool is Welding current adjusted too Increase welding current
insufficient low

Too much

Front panel alarm lamp is on

Over heat welding current

Reduce welding current output

11 Protection

Working time Reduce duty cycle (work
too long

intermittently)

Spark on the
HF igniting
board

Arc cannot be
ignited

No spark on
the HF igniting
board

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STEALTH DIGI-TIG 180 DC PULSE PFC MV

5.3 Main Electrical Diagram

MAINTENANCE AND TROUBLESHOOTING

110/220V AC

27

Specialised Welding Products Ltd

Unit 1, Farringdon Industrial Centre, Farringdon, Nr Alton, Hampshire GU34 3DD, UK
tel: [phone] • fax: [phone] • email: [e-mail]