Sua ionTig 200 AC/DC Operation Manual

ionTig 200 AC/DC

INVERTER - AC/DC PULSED TIG WELDER

OPERATION MANUAL

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 we have provided for your protection. Contact your distributor if you do not fully understand this manual.

ionTig 200 AC/DC

CONTENT

1. SAFETY .................................................................................................................................................... 3

1.1 Signal Explanation....................................................................................................................................... 3

1.2 The Knowledge of Electric and Magnetic Fields........................................................................................... 6

2. Overview...................................................................................................................................................7

2.1 Brief Introduction ........................................................................................................................................ 7

2.3 Volt-Ampere Characteristic........................................................................................................................ 10

3. Installation and Adjustment..................................................................................................................... 11

3.1 Parameters................................................................................................................................................ 11

3.2 Duty cycle and Over-heat........................................................................................................................... 12

3.3 Movement and Placement.......................................................................................................................... 12

3.4 Power supply input connection .................................................................................................................13

3.5 Polarity Connection (MMA)........................................................................................................................ 13

3.6 Assembling the equipment (TIG)................................................................................................................ 13

4. Operation................................................................................................................................................ 14

4.1 Layout for the panel................................................................................................................................... 14

4.2 Control panel.............................................................................................................................................15

4.3 Remote control.......................................................................................................................................... 20

4.3.1 Pedal switch control ...............................................................................................................................20

4.3.2 Remote box control................................................................................................................................. 21

4.3.3 Gun switch control current .....................................................................................................................22

4.4 Argon Arc Welding Operation.................................................................................................................... 22

4.4.1 TIG welding （4T operation） ............................................................................................................... 22

4.4.2 TIG welding (2T operation)......................................................................................................................24

4.5 Welding Parameters................................................................................................................................... 26

4.5.1 Joint forms in TIG/MMA......................................................................................................................... 26

4.5.2 The explanation of welding quality.......................................................................................................... 26

4.5.3 TIG Parameters Matching........................................................................................................................ 27

4.6 Operation Environment.............................................................................................................................. 30

4.7 Operation Notices...................................................................................................................................... 31

5. Maintenance & Troubleshooting..............................................................................................................31

5.1 Maintenance.............................................................................................................................................. 31

5.2 Troubleshooting........................................................................................................................................ 33

5.3 Electrical principle drawing:...................................................................................................................... 36

ionTig 200 AC/DC

1. SAFETY

1.1 Signal Explanation

 Welding may damage your body or others, so please take protection

measure in operation.

 Only ones who are trained professionally can install, debug, operate,

maintain and repair the equipment.

 Do not maintain and repair the machine when the machine is

connected with power.

THE ROTATING PARTS MAY BE DANGEROUS  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.

 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:

o Away from areas where they may be struck or subjected to

physical damage.

o 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.

ionTig 200 AC/DC

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.

 Shielded 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.  Use a shield with the proper 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 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.

ionTig 200 AC/DC

ELECTRIC SHOCK CAN KILL.

 Never touch 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 carefully when using the equipment in small place, falling-off and

wet circumstance.

 Never close the machine power before installation and adjustment.  Ensure to install the equipment correctly and ground the work or metal

to be welded to a good electrical (earth) ground according the operation manual.

 The electrode and work (or ground) circuits are electrically “hot” when

the welder is on. Do not touch these “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 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 the floor level, use a safety belt to protect yourself

from a fall should you get a shock.

FIRE AND 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.

ionTig 200 AC/DC

1.2 The Knowledge of Electric and Magnetic Fields

Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). The discussion on the effect of EMF is ongoing all the world. Up to now, no material evidences show that EMF may have effects on health. However, the research on damage of EMF is still ongoing. Before any

 Where compressed gases are to be used at the job site, special

precautions should be used to prevent 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 insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause 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.

 Hot parts can lead to burn.  Do not touch the hot parts.  Please use the torch after cooling or use the welding blow lamp.

ionTig 200 AC/DC

conclusion, we should minimize exposure to EMF as few as possible. In order to minimize EMF, we should use the following procedures:

 Route the electrode and work cables together – Secure them with tape when possible.  All cables should be put away and far from the operator.  Never coil the power cable around your body.  Make sure welding machine and power cable to be far away from the operator as far as possible

according to the actual circumstance.

 Connect the work cable to the work piece as close as possible to the area being welded.  The people with heart-pacemaker should be away from the welding area.

2. Overview

2.1 Brief Introduction

ionTig 200 AC/DC arc welding machine adopts 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 hulking work frequency transformer with the cabinet medium frequency transformer. Thus, it is characterized with portable, small size, light weight, low consumption and etc. The parameters of ionTig 200 AC/DC on the front panel all can be adjusted continuously and sleeplessly, such as start current, crater arc current, welding current, base current, duty ratio, upslope time, downslope time, pre-gas, post-gas, pulse frequency, AC frequency, balance, 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. WSME Characteristics:

ionTig 200 AC/DC

 MCU control system, responds immediately to any changes.  High frequency and high voltage for arc igniting to ensure the success ratio of igniting arc, the

reverse polarity ignition ensures good ignition behavior in TIG-AC welding.

 Avoid AC arc-break with special means, even if arc-break occurs the HF will keep the arc stable.  Pedal control the welding current.  TIG/DC operation, if the tungsten electrode touches the work piece when welding, the current will

drop to short-circuit current to protect tungsten.

 Intelligent protection: over-voltage, over-current, over-heat, when the problems listed before

occurred, the alarm lamp on the front panel will be on and the output current will be cut off. It can self-protect and prolong the using life.

 Double purpose: AC inverter TIG/MMA and DC inverter TIG/MMA, Excellent performance on

Al-alloy、carbon steel、stainless steel、titanium.

According to choosing the front panel functions, the following six welding ways can be realized:

I. DC – MMA

II. DC – TIG

III. DC - Pulse TIG

IV. AC – MMA

V. AC – TIG

VI. AC - Pulse TIG

I. For DC MMA, polarity connection can be chosen according to different electrodes，please refer to

3.5

II. For DC TIG, DCEP is used normally (work piece 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.

ionTig 200 AC/DC

III. DC Pulsed TIG has the following characters: 1) 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. 2) The work piece gets little heat. Arc energy is focused. Be suitable for thin sheet and super thin sheet welding. 3) Exactly control heat input and the size of the molten pool. The depth of penetration is even. Be suitable for welding by one side and forming by two 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.

IV. For AC MMA, magnetic flow caused by invariable DC polarity can be avoided.

V. For AC TIG (rectangle wave), arc is more stable than Sine AC TIG. At the same time, you can not

only obtain the max penetration and the min tungsten pole loss, but also obtain better clearance effect.

ionTig 200 AC/DC welding machine is suitable for all positions welding for various plates made of stainless steel, carbon steel, alloyed steel, titanium, aluminum, magnesium, cuprum, etc., which is also applied to pipe installment, mold 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 Working Principle

The working principle of ionTig 200 AC/DC welding machines is shown as the following figure.

ionTig 200 AC/DC

Single-phase 220V work frequency AC is rectified into DC (about 312V), then is converted to medium frequency AC (about 20KHz) by inverter device (IGBT module), after reducing voltage by medium transformer (the main transformer) and rectifying by medium frequency rectifier (fast recovery diodes), then is outputted DC or AC by selecting IGBT module. The circuit adopts current feedback 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.

Rectif

ier

Invert

Trans forme

Rectif

ier

Hall

devic

Current feedback

control

Single-phase, AC

AC DC

220V，50Hz

Invert

AC or DC

Control signal

AC or DC

2.3 Volt-Ampere Characteristic

ionTig 200 AC/DCwelding machine has an excellent volt-ampere characteristic, whose graph is shown as the following figure. 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).

0 600

I2（A）

U2（V）

Working

point

Volt-ampere characteristic

The relation between the

conventional loading

voltage and welding current

ionTig 200 AC/DC

3. Installation and Adjustment

3.1 Parameters

Models

Parameters

ionTig 200 AC/DC

Input power

1~220±10%，50Hz

Rated input current（A）

35.4（TIG）

39.5（MMA）

Rated input power（KW）

5.2（TIG）

6.4（MMA）

Power factor

0.68

Max no-load voltage(V)

Adjustment range of start current（A）

TIG

MMA

D C

LIFT

5～

weldi

curre

—

10～

welding

current

30～

welding

current

Adjustment range of welding current（A）

10～

200

30～

2005～200

10～

170

5～170

Adjustment range of Crater arc current（A）

10～

200

30～

2005～200

10～

170

5～170

Adjustment range of

downslope time（S）

0～10

Pre-gas time（S）

0.1~1

Adjustment range of post-gas time（S）

0.1～10

Clearance effect（%）

15～50

Efficiency Duty cycle （ 40℃ ， 10 minutes）

25% 200A

60% 90A

60% 110A

100% 70A

100% 80A

Protection class

IP23S

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Sua ionTig 200 AC/DC Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual