AC/DC TIG/MMA DIGITAL WELDING SYSTEM
Operating Manual
WWW.SWSWELDING.COM.AU
ALUMTIG 200
�
THANK YOU FOR YOUR PURCHASE OF THE ALUMTIG™ 200 Digital TIG/MMA
WELDING SYSTEM.
At SWS, we take pride in the professional quality, innovation, and support we deliver to our customers and
the welding industry as a whole. The ALUMTIG™ 200 is the next step in our progression as the new standard
in welding and cutting products delivered fast marking the continuing evolution of SWS. This welding
machine is the latest development in inverter technology. It has been tested and approved by production
welders and the best fabricating professionals in the industry.
Providing better outcomes through innovation and new product creation have been staples of SWS since
its inception. It is the very principle by which we do business. Our goal has always been to provide an
outstanding product that not only stands out from the competition but also reflects the quality we strive
for in every aspect of our business philosophy. From our second to none customer service excellence to
technical support, we work hard at what we do so that you can too.
We know you will enjoy using this machine!
The ALUMTIG™ 200 is manufactured and compliant with AS60974.1:2006, IEC60974.10, CE
Guaranteeing you electrical safety and performance.
CAUTION!: The ALUMTIG™ 200 Operating Manual has been designed to instruct you on the proper use and
operation of your SWS product. Your satisfaction with this system and its safe operation is our primary
concern. It is important to take the time to read the entire manual, especially the safety sections. They will
help you to avoid potential hazards that may exist when working with this product.
™
Terms of Warranty
This SWS product has a limited warranty that covers manufacturing and material defects only. The warranty
commences on the day of purchase and does not cover any freight, packaging and insurance costs. Verbal
promises that do not comply with terms of warranty are not binding on SWS.
Limitations on Warranty
The following conditions are not covered under terms of warranty: loss or damage due to or resulting
from natural wear and tear, non‑compliance with operating and maintenance instructions, connection to
incorrect or faulty voltage supply (including voltage surges outside equipment specs), incorrect gas pressure
overloading, transport or storage damage or fire or damage due to natural causes (e.g. lightning or flood).
This warranty does not cover direct or indirect expenses, loss, damage of costs including, but not limited to,
daily allowances or accommodation and traveling costs.
Modification of the 15A primary input plug or fitting of a lower rated primary input plug will render the
warranty null and void.
NOTE: Under the terms of warranty, welding torches and their consumables are not covered. Direct or
indirect damage due to a defective product is not covered under the warranty. The warranty is void if
changes are made to the product without approval of the manufacturer, or if repairs are carried out using
non‑approved spare parts. The warranty is void if a non‑authorised agent carries out repairs.
Warranty Period
The warranty is valid for *5 years from the date of purchase provided the machine is used within the
published specification limits.
Warranty Repairs
A SWS approved service provider must be informed within the warranty period of any warranty defect. The
customer must provide proof of purchase and serial number of the equipment when making a warranty
claim using the form on our website https://www.swswelding.com.au/pages/warranty
NOTE: Store the product box and packaging materials for ease of return in the event of a claim.
*5‑Years warranty website registered users / 3‑years standard warranty
Where Purchased:
Purchase Date:
Power Supply Serial #:
WARRANTY INFORMATION
This product comes with a 3 year warranty, for an extra 2 years coverage
please go to our website and register your equipment. This also helps us
to assist you quickly in the event of a claim
https://www.swswelding.com.au/pages/product‑registration
SWS WELDING & CUTTING
WEBSITE: WWW.SWSWELDING.COM.AU
EMAIL: SUPPORT@SWSWELDING.COM.AU
TELEPHONE: (03) 5766 2331
ALUMTIG 200
TABLE OF CONTENTS
SECTION 1: INTRODUCTION
1.0 Welcome 1
1.1 Specifications 1
SECTION 2: SAFETY
2.0 Hazards 3
2.1 Precautions 4
SECTION 3: GTAW (TIG)
3.0 GTAW (TIG) Welding Process 5
3.1 Typical TIG Welding Setup 5
3.2 Advantages of the TIG Welding Process 5
3.3 Concentrated Arc 6
3.4 Slag Free 6
3.5 No Sparks and Spatter 6
3.6 No Smoke or Fumes 6
3.7 TIG Disadvantages 6
3.8 Process Overview 6
SECTION 4: RECEIPT OF EQUIPMENT
4.0 Unboxing 7
SECTION 5: INSTALLATION
5.0 Working Environment 8
5.1 Machine Installation GTAW (TIG) 8
5.2 Machine Installation MMA (Stick) 9
SECTION 6: OPERATION & FUNCTIONS
6.0 Digital Control & Functions AC/DC GTAW (TIG) 10‑13
6.1 Digital Control & Functions AUTO MMA (Stick) 14
6.2 Digital Control & Functions Pro MMA (Stick) 15
SECTION 7: SERVICE
7.0 General Maintenance 16
SECTION 8: TROUBLESHOOTING
8.0 Machine codes 17
8.1 Tungsten corrodes quickly 17
8.2 Contaminated tungsten electrode 17
8.3 Porosity and or poor weld appearance and color 18
8.4 Unstable arc during DC welding 18
8.5 Unstable arc during AC welding 18
8.6 HF present but no welding power 19
8.7 Arc wanders during DC welding 19
8.8 Arc wanders during AC welding 19
8.9 Arc diicult to start or will not start DC welding 20
8.10 Arc diicult to start or will not start DC welding 20
Manual Version 1.3 - June/2017
1
ALUMTIG 200
ALUMTIG 200
INTRODUCTION
1.0 Welcome
The SWS ALUMTIG™ 200 is one of the most advanced, feature‑packed and aordable digital AC/DC TIG/
MMA welding systems on the Australian market for welding of almost all ferrous and non‑ferrous metals.
Featuring smart programming with auto and advanced modes make setting up easy for the beginner and
versatile for the pro. You can depend on the ALUMTIG™ 200 to weld all day at its rated capacity and to pack
more punch when you need it most.
Latest Inverter Technology
Embedded microprocessor with Infineon
components delivers ultimate durability and perfect
welding characteristics.
Revolutionary Digital Display
Large high visibility durable display allows easy
viewing from a distance and continually provides
you with necessary feedback for optimum welds.
Smart Programming
AUTO AC TIG, AUTO DC TIG and AUTO MMA
modes will have you welding in no time flat using
optimised settings with the beginner in mind. For
more proficient users, you have complete control
over welding parameters with the ability to store
settings for later.
AC Features
The advanced square wave with a wide balance and
frequency range gives you the versatility for any
Aluminium or Magnesium job.
Digital Pulse for AC and DC welding
When welding thin gauge materials and joints like
thin sheet metal and outside corners pulse allows
you to focus the arc increase travel speed and
minimise warpage.
Superior Duty Cycle
Make bigger longer welds with ease. The duty cycle
of 25% at 200 Amps and 100% at 25 Amps (40°C)
gets most if not all jobs done.
Highly Portable
Dependable IGBT inverter technology ensures a
highly portable and lightweight unit weighing only
11kg.
Meets the Highest Standards
Meets and exceeds the latest Australian, NZ and
International electrical and electromagnetic
compatibility standards. AS60974.1:2006,
IEC60974.10, CE
Manual Version 1.3 - June/2017
2
ALUMTIG 200
ALUMTIG 200
INTRODUCTION
1.1 Specications
Processes HF TIG AC/DC (GTAW‑AC/DC), LIFT TIG AC/DC (GTAW‑AC/DC), Pulsed TIG
(GTAW‑P), Stick AC/DC (MMA)
Current Type AC/DC
Weldable Metals Aluminium, Mild Steel, Stainless Steel, Specialty Metals
General Aluminium, Steel and Stainless Steel Fabrication, Stainless Steel
Tank and Pipe Fabrication, Boat Building / Shipyards, Motorcycle custom
Industries shops, Automotive customs shops, Automotive Components and Repairs,
Motorcycle Components and Repairs, Technical Schools, Aerospace,
Agriculture, Farming, Building and Construction, Home Repair
Workshops.
Input Voltage/Hz 1 Phase 230V +/‑ 15% (15 Amp Plug) 50/60 Hz
Minimum Generator 6.6kW (8.5kVA at 0.8 PF)
Duty Cycle 40°C AMB (TIG/MMA) 25% @ 200A, 100% @ 100A
Duty Cycle 25°C AMB (TIG/MMA) 40% @ 200A, 100% @ 140A
Welding Current Range (TIG/MMA) 10‑200 Amps
Arc Ignition (TIG) HF, Li TIG
AC Frequency (TIG) 10‑200Hz
AC Balance (TIG) 50‑98%
Adjustable Parameters (TIG) Pre‑Flow, Post‑Flow / Start‑Amps, End‑Amps / Upslope, Downslope
Pulse Peak Amps (TIG) 10‑200 Amps
Pulse Time On (TIG) 10‑90%
Pulse Frequency (TIG) 1‑500Hz
Pulse Base Amps (TIG) 20‑50%
Hot Start (MMA) 0‑60 Amps
Arc Force (MMA) 0‑99%
Dimensions L 435mm H 265mm W 180mm
Weight 11Kg
Warranty 5 Years registered (3 Years standard)
Manufactured to Standards AS60974.1:2006, IEC60974.10, CE
Manual Version 1.3 - June/2017
3
ALUMTIG 200
ALUMTIG 200
WARNING
Arc welding and plasma cutting can be dangerous to yourself and others. Take special care when
welding and cutting. Note your employer’s safety practices which should be based on manufacturers’
hazard data documents.
ELECTRIC SHOCK - Can kill
‑ Connect and earth (ground) the welding or plasma cutting unit adhering to applicable standards.
‑ Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
‑ Insulate yourself from the natural ground and the workpiece.
‑ Ensure your working stance is safe.
FUMES AND GASES - Can be dangerous to health.
‑ Keep your head out of the fumes.
‑ Use ventilation, extraction at the welding or cutting arc, or both, to take fumes and gases away
from your breathing zone and the surrounding area.
ARC RAYS - Can injure eyes and burn skin.
‑ Protect your eyes and body. Use an approved welding/plasma cutting helmet and filter lens and
wear protective clothing.
‑ Protect bystanders with suitable screens or curtains.
FIRE HAZARD
‑ Sparks (spatter) can cause fires. Make sure therefore that there are no flammable materials
nearby.
NOISE - Excessive noise can damage hearing.
‑ Protect your ears. Use ear mus or other suitable hearing protection.
‑ Warn all bystanders of the risk.
MALFUNCTION - Call an for expert assistance in the event of a malfunction.
CAUTION
This product is only intended welding. Any other use may result in personal injury and
equipment damage.
CAUTION
Read and understand the instruction manual before installing or operating.
SAFETY
2.0 Hazards
Manual Version 1.3 - June/2017
4
ALUMTIG 200
ALUMTIG 200
SAFETY
2.1 Precautions
Users of SWS welding and plasma cutting products have the primary responsibility for ensuring that anyone
who works on or near this equipment adheres to all the relevant safety precautions. The following listed
recommendations must be observed along with the standard regulations that apply to the workplace.
All use must be carried out by trained personnel well versed with the safe operation of the equipment.
Incorrect operation of plasma cutting or welding equipment may lead to hazardous events which can result
in serious injury to the user and damage to the equipment. Safety precautions must meet the requirements
that apply to this type of welding or plasma cutting equipment.
1. Persons who use welding or plasma cutting equipment must be familiar with the following:
‑ Welding and plasma cutting machine operation
‑ Location of emergency stops
‑ The machines purpose
‑ Relevant safety precautions
‑ Arc welding and / or hand held plasma cutting
2. The user must make sure that:
‑ No unauthorized person in the vicinity of the working area of the equipment when it is used.
‑ No person is unprotected when the arc is started.
3. The workplace must:
‑ Be suitable for the purpose
‑ Be free from weather
4. Personal safety equipment:
‑ Always wear approved personal safety equipment, such as welding helmets, safety glasses, flame proof
clothing and safety gloves.
‑ Never wear loose fitting items, such as hooded jumpers, bracelets, rings, etc., which can become trapped
or cause serious injury burns.
5. General safety precautions:
‑ Ensure the return cable is connected securely.
‑ Work on high voltage equipment must only be carried out by a qualified electrician or electrical
technician.
‑ Approved fire extinguishing equipment must be clearly marked and in the vicinity.
‑ Lubrication and maintenance must not be carried out on the equipment during operation.
READ AND UNDERSTAND THE OPERATING MANUAL BEFORE
INSTALLING OR USING THIS EQUIPMENT - ALWAYS PROTECT
YOURSELF AND OTHERS!
Manual Version 1.3 - June/2017
5
ALUMTIG 200
ALUMTIG 200
GTAW (TIG)
3.0 GTAW (TIG) Welding Process
The heat needed for Gas Tungsten Arc Welding is produced by an electric arc maintained between a non‑
consumable tungsten electrode and the workpiece to be welded. The heat‑aected zone (HAZ) molten metal
and the tungsten electrode are all shielded from the atmosphere by a blanket of inert gas typically argon
ran through the TIG torch. An inert gas such as argon is inactive, or deficient in active chemical properties
making it non‑reactive so it does not take from or add anything to the metal. Inert gases like argon and
helium do not chemically react or mix with other types of gases. They have no smell and are transparent,
giving the welder maximum visibility of the arc. In some cases, small amounts of a reactive gas such as
hydrogen can be added to enable faster travel speeds.
The TIG welding process produces extreme temperatures of up to 19,426 C, and the TIG torch contributes
only heat to the workpiece through the tungsten electrode. If some filler metal is needed to perform the
weld, it may be added manually in the same way as it is in the oxyacetylene welding process. There are also
ways to feed the filler metal in automatically by specialist systems.
3.1 Typical TIG Welding Setup
3.2 Advantages of the TIG Welding Process
The biggest advantage of the TIG welding process is that it will weld more metals and metal alloys than any
other type of arc welding process. TIG is used to weld almost all steels including mild steel, stainless steel,
Chromoly, titanium, aluminium, magnesium, copper, brass, bronze, and you can even weld gold. You can
also join dissimilar metals to one another such as stainless to mild steel.
Manual Version 1.3 - June/2017
6
ALUMTIG 200
ALUMTIG 200
GTAW (TIG)
3.3 Concentrated Arc
The precise nature of the TIG welding arc allows a high level of control of heat input to the metal resulting in
a narrow HAZ (heat‑aected zone). This high concentration of heat is a significant advantage when welding
metals with very high heat conductivity such as aluminium and copper. A narrow HAZ is an advantage
because the base metal has undergone a change due to the very fast heating of the arc and rapid cooling
rate. The HAZ is where the welded joint is the weakest and is the area that is most likely to break under
destructive testing.
3.4 Slag Free
Unlike stick welding, there is no need for flux with TIG. Therefore, there is no slag to obscure vision of the
weld pool. The finished weld also does not have the layer of slag le.
3.5 No Sparks and Spatter
In the TIG welding process, there is no transfer of metal across the arc, so there is no molten globules of
spatter to deal with and no sparks produced if the metal being welded is free of contaminants. TIG is also
very quite compared to stick or MIG welding and the only time any real noise will be present is when using a
pulsed arc, or AC welding is being done.
3.6 No Smoke or Fumes
TIG welding on its own does not produce smoke or dangerous fumes. But if the base metal contains coatings
or elements like lead, zinc, nickel or copper that do produce fumes, these must be dealt with as in any
electric arc welding process. If the workpiece has oil present, paint, grease or other contaminants, harmful
smoke and fumes will always be made as the heat of the process burns them away. It is of the utmost
importance when TIG welding to clean and prepare your meals with diligence.
3.7 TIG Disadvantages
The major disadvantage of the TIG welding process is the slow and low filler metal deposition rate. Another
disadvantage is that the skills needed to accomplish a beautiful sound weld can be diicult to learn, and
requires a good deal of practice to become skilled. The higher amounts of ultraviolet rays from the arc also
causes the formation of ozone and nitrous oxides. Extra care should be taken to protect skin with the proper
PPE with the correct shade welding filter and helmet.
3.8 Process Overview
TIG is a very clean process, and it is a great choice from a welders point of view because of the reasons
above. For an excellent result, it is a must that the welder maintains sound welding conditions by always
properly cleaning the material, using cleaning and using clean filler metal, clean gloves, and ensuring to
keep oil, dirt and other contaminants away from the welding area. Cleanliness is one of the most important
factors with TIG, especially on aluminium and magnesium. These metals are more prone to contaminants
than ferrous metals the porosity in aluminium welds has been known to be caused by hydrogen this is
why it is the most necessary to completely remove hydrogen containing elements such as moisture and
hydrocarbons that reside in the form of oils and paint.
Manual Version 1.3 - June/2017
7
ALUMTIG 200
ALUMTIG 200
RECEIPT OF EQUIPMENT
4.0 Unboxing
When you receive the equipment, check it against the invoice to make sure it is complete and inspect the
equipment for possible damage due to shipping. If there is any damage, notify us immediately so that we
can file a claim. Please Include all equipment identification numbers as on parts or a full description of the
parts in error.
SWS WELDING & CUTTING
WEBSITE: WWW.SWSWELDING.COM.AU
EMAIL: SUPPORT@SWSWELDING.COM.AU
TELEPHONE: (03) 5766 2331
Manual Version 1.3 - June/2017
8
ALUMTIG 200
ALUMTIG 200
INSTALLATION
5.0 Working Environment
• The workspace in which this equipment is installed must be free of excessive grinding dust,
natural dust, flammable and corrosive chemicals, flammable gas or materials, etc. And at no
more than a maximum of 80% humidity.
• When using the equipment outdoors protect the machine from precipitation and direct sun
light. The working temperature environment should be kept within –15°C to +40°C.
• Keep this machine as least 250mm away from walls.
• Ensure the working environment is well ventilated with fan extraction when necessary.
5.1 Machine Installation GTAW (TIG)
1. Connect the ground clamp to the positive connection (+) and the Welding torch to the Negative
(‑) connection DCEN (Direct current electrode negative)
2. Connect the 7‑Pin plug into the 7‑Pin control connector taking care to align correctly.
3. Connect the gas line.
NOTE: In almost all TIG welding applications DCEN (Direct Current Electrode Negative) is used.
NOTE: This machine uses high frequency arc start or LIFT arc starting, when operating nearby to high
frequency sensitive equipment, it is recommended to use LIFT TIG.
Manual Version 1.3 - June/2017
9
ALUMTIG 200
ALUMTIG 200
INSTALLATION
5.2 Machine Installation MMA (Stick)
1. Connect the ground clamp to the negative connection (DCEP) and the torch to the positive
connection.
NOTE: In most welding applications DCEP (Direct Current Electrode Positive) is used. In some cases when
welding very thin material using DCEN may be an advantage.
Manual Version 1.3 - June/2017
10
ALUMTIG 200
ALUMTIG 200
FUNCTION PARAMETERS PURPOSE
1. Pre‑Flow 1‑10 Seconds
(N/A AUTO MODES)
This parameter operates in 2T and 4T HF TIG mode only and is
used to provide gas to the weld zone prior to striking the arc,
once the torch trigger switch has been pressed. This control
is used to dramatically reduce weld porosity at the start of a
weld.
2. Start Amps 10‑200 Amps
(N/A AUTO MODES)
(N/A FOOT CONTROL)
This parameter is used to set the start current for TIG. In 4T
mode the Initial Current remains on until the torch trigger
switch is released aer it has been depressed. In 2T mode this
is the Initial Current for the Up Slope current ramp.
3. Upslope 0‑10 Seconds
(N/A AUTO MODES)
This parameter is used to set the time for the weld current to
ramp up from INITIAL current to BASE current. (N/A AUTO MODES)
(N/A FOOT PEDAL)
4. Welding Amps 10‑200 Amps
(N/A AUTO MODES)
This parameter sets the welding current. In PULSE TIG mode,
this parameter sets the PEAK current. (N/A AUTO MODES)
5. Pulse Base Amps 10‑200 Amps
(N/A AUTO MODES)
This parameter sets the welding current. In PULSE TIG mode,
this parameter sets the BASE current. (N/A AUTO MODES)
6. Downslope 0‑10 Seconds
(N/A AUTO MODES)
Down Slope will ramp amps “down” from the welding amp
value to the end amp value to give time to fill the crater le
at the end of the weld bead. Can also be used in the 4T mode
to help with heat control by briefly tapping the switch to cool
o the weld before tapping it again to restart the up slope
sequence before the arc reaches the end amp stage.
7. End Amps 10‑200 Amps
(N/A AUTO MODES)
Sets the final or minimum current before the arc is
terminated. Used for filling craters at the ends of the weld and
crack prevention.
OPERATION & FUNCTIONS
6.0 Digital Control & Functions AC/DC TIG
Manual Version 1.3 - June/2017
11
ALUMTIG 200
ALUMTIG 200
FUNCTION PARAMETERS PURPOSE
8. Post‑Flow 1‑10 Seconds
(N/A AUTO MODES)
Controls the amount of time in seconds that the argon flows
aer the arc has terminated. Provides proper shielding
during cooling to prevent rapid oxidation of the weld which
results in porosity the weld pool.
9. Pulse Peak Amps 10‑200 Amps
(N/A AUTO MODES)
This displays the parameter.
10. Pulse Base Amps 10‑200 Amps
(N/A AUTO MODES)
This displays the parameter.
11. Pulse Time On
(Balance) %
10‑90%
(N/A AUTO MODES)
Defines the duty cycle (balance) of the pulse, by dividing or
skewing the amount of time the pulse stays in the lower or
upper stage of the pulse. The pulse consists of two stages:
Welding amps (upper /Peak) and Pulse amps (lower/
background current). This is represented by a % of total
time the pulse spends in the pulse amp stage of the cycle
during one full pulse. The feature can be used to increase or
decrease pulse amp time relative to the welding amp time of
the cycle to help manage heat input.
12. Pulse Frequency
Hertz (Pulses per
second )
1‑500Hz
(N/A AUTO MODES)
Represented by Hertz (Hz), the pulse frequency defines
the actual number of times each second the pulse makes
one complete cycle between welding amps (peak/high
amp value) and pulse amps (background/low amp value).
This is also commonly referred to as Pulses Per Second
(PPS). Low pulse frequencies are ideal for timing the
point where filler metal is added. This helps improve
appearance and uniformity. Higher pulse frequencies are
useful for welding seams and edges of thin material. Also
it is useful for overall heat input control for thicker metals.
Higher pulse frequencies are highly useful for automated
welding processes. WARNING: WELDING AT HIGH PULSE
FREQUENCIES INCREASES THE DECIBEL /NOISE LEVEL OF
THE ARC. HEARING PROTECTION IS HIGHLY RECOMMENDED!
Manual Version 1.3 - June/2017
12
ALUMTIG 200
ALUMTIG 200
FUNCTION PARAMETERS PURPOSE
13. 2T/4T Selection N/A To operate with the torch switch, select 2T or 4T (2T Double
ended arrow 4T separate arrows). For 2T operation, simply press
and hold the switch. The panel program will cycle automatically.
When the switch is released, the arc will downslope and
terminate with post gas flow. When in 4T mode, the switch is
pressed, and held to start the pre‑flow and the start amps part
of the cycle. When released, upslope be‑gins and continues until
the amps are raised to the preset welding amps. When pressed
and held again, downslope starts and ramps down to the end
amp stage (crater current). When released, the arc terminates,
and post flow begins. If desired, before the downslope finishes,
the switch may be tapped again to start the up slope again.
14. HF or Li TIG
Selection
N/A The Process selector oers the choice of Li Tig (for DC only)
which requires contact with the metal to initiate the arc and
High Frequency Start which allows non contact starting of the
arc (for AC and DC). (HF is selected when symbol is not striked
out) The li start function on the ALUMTIG 200 provides a cold
electrode for safety, and prevents accidental starts. This requires
that the pedal or torch switch must be used to energise the arc.
HF refers to the start type only. The inverter design of the welder
eliminates the need for a constant HF overlay in AC.
15. Welding Current N/A This displays the Amps in real time while welding and will hold
aer weld is complete.
16. AC or DC Selection N/A The unit features AC/DC operation. This machine uses advanced
square wave for AC that has excellent wet in, and arc stability.
Manual Version 1.3 - June/2017
13
ALUMTIG 200
ALUMTIG 200
FUNCTION PURPOSE
17. AC Balance 50‑98% Defines the percent of Electrode Positive (EP) used during AC welding to
provide cleaning action. This divides the time that the AC cycle spends
in Electrode Positive or Electrode Negative during one full AC cycle. It
controls the amount of cleaning and penetration via a ratio to achieve
the best balance while welding on AC. Too much cleaning action will
result in tungsten balling or splitting. Too little cleaning can result in
dirty, sooty welds and even a dull weld appearance. Simply put, as the
percent increases, greater cleaning will occur, but less penetration will
be achieved. For old aluminium that has some corrosion, adjust the ac
balance to where you use more (EP).
18. AC Frequency 10‑200 Hz Governs the number of times per second that the current alternates in
AC mode. To achieve greater arc focus (constriction) and increase puddle
agitation while welding in AC mode, increase AC frequency. This allows
pinpoint use on thin materials, and helps penetration on thicker materials.
Ideal adjustment range is usually between 80‑120Hertz. For comparison
most transformer welders operate on 60 Hz. Greater arc control and
stability can be achieved through the higher frequency range oered by
this welder. Lower Frequencies will widen and soen the arc and reduce
the level of control. WARNING: INCREASING THE AC FREQUENCY ALSO
INCREASES THE DECIBEL/NOISE LEVEL OF THE AC WELDING ARC. HEARING
PROTECTION SHOULD BE WORN!
19. Main Menu N/A This takes you back to main menu.
Manual Version 1.3 - June/2017
14
ALUMTIG 200
ALUMTIG 200
6.1 Digital Control & Functions Pro MMA (Stick)
FUNCTION PARAMETERS PURPOSE
1. Hot Start 0‑60 Amps Sets the length of time that the Hot Start is active
while starting the arc. Used to reduce sticking of the
electrode during the arc strike phase.
2. Hot Start Value N/A This displays the value.
3. Welding Amps 10‑200 Amps Welding amps define the top limit of amps at which the
machine has been programmed to operate.
4. Welding Amps Value N/A This displays the parameter.
5. Arc Force 0‑99% Controls the arc response when an arc is held short
and voltage begins to drop. Arc force automatically
compensates by modifying the volt/amp curve to
maintain the energy needed to weld. Represented as a
percent of available arc force amperage.
6. Arc Force Display N/A This displays the value.
7. Actual Welding Amps N/A Real time display of welding Amps will hold for 5
seconds when weld is complete for reference.
9. AC or DC Selection N/A
9. Main Menu N/A This takes you back to main menu.
Manual Version 1.3 - June/2017
15
ALUMTIG 200
ALUMTIG 200
6.2 Digital Control & Functions AUTO MMA (Stick)
FUNCTION PARAMETERS PURPOSE
1. Electrode Diameter
Selection
2.0‑5mm Machine automatically set amps relevant to the diameter
of electrode being used.
2. Amps Fine Tuning ‑20‑20% Fine tunes the amps for the metal being welded.
3. Welding Amps 10‑200 Amps Real time display of welding Amps will hold for 5 seconds
when weld is complete for reference.
4. AC or DC Selection N/A Selects AC or DC modes
5. Main Menu N/A This takes you back to main menu.
Manual Version 1.3 - June/2017
16
ALUMTIG 200
ALUMTIG 200
SERVICE
7.0 General Maintenance
3 Months
6 Months
Carefully clean exterior of power source with a dry brush.
Unplug the power source remove cover and visually check and carefully clean the interior without touching
any internal electrical components, wires or PCB boards and by taking special care not to damage any
components. Using a vacuum with plastic nozzle is highly recommended.
Warning!
There is extremely dangerous voltage, and power levels present inside this
product. Do not attempt to open or repair unless you are a qualified electrical
tradespersons and you are qualified in training in power measurements and
troubleshooting techniques. If major complex sub-assemblies are faulty, then the
Cutting Power Source must be returned to an accredited service provider.
Manual Version 1.3 - June/2017
17
ALUMTIG 200
ALUMTIG 200
TROUBLESHOOTING
8.0 Machine Codes
CODE DISPLAYED CODE INFORMATION
ERROR! Over Temperature Machine has reached its duty cycle limit. DO NOT
turn o and let it complete cooling cycle until display
return to normal.
ERROR! Over Current Over current has been supplied to the machine turn
o and locate the correct input power. This may have
damaged the machine if display persists.
8.1 GTAW (TIG)
8.2 Tungsten corrodes quickly
8.3 Contaminated Tungsten Electrode
POSSIBLE REASON SUGGESTED SOLUTION
Incorrect Gas Check that 100% Argon is being used.
No gas Check the gas cylinder contains gas and is
connected.
Inadequate gas flow Check the gas is connected, check hoses, gas
valve and torch are not restricted. Set the gas flow
between 15–25 CFH (7–12 LMN) flow rate.
Back cap not fitted correctly Make sure the torch back cap is fitted so that the
o‑ring is inside the torch body.
Torch connected to DC + Connect the torch to the DC – output terminal.
Incorrect tungsten being used Check and change the tungsten type if necessary.
Tungsten being oxidized aer weld is finished Keep shielding gas flowing 10–15 seconds aer
arc stoppage. 1 second for each 10 amps of weld
current.
Tungsten melting back into the nozzle on AC
welding
Check that correct type of tungsten is being used.
Check the balance control is not set too high —
reduce to a lower setting.
POSSIBLE REASON SUGGESTED SOLUTION
Touching tungsten into the weld pool Keep tungsten from contacting weld puddle. Raise
the torch so that the tungsten is o of the work
piece 1/8”–1/4” (3.2– 6.35mm).
Touching the filler wire to the tungsten Keep the filler wire from touching the tungsten
during welding, feed the filler wire into the leading
edge of the weld pool in front of the tungsten.
Tungsten melting into the weld pool Check that correct type of tungsten is being used.
Too much current for the tungsten size so reduce
the amps or change to a larger tungsten.
Manual Version 1.3 - June/2017
18
ALUMTIG 200
ALUMTIG 200
8.4 Porosity and or poor weld appearance and color
8.5 Unstable arc during DC welding
8.6 Unstable arc during AC welding
POSSIBLE REASON SUGGESTED SOLUTION
Incorrect Gas Check that 100% Argon is being used.
Inadequate gas flow / gas leaks Check the gas is connected, check hoses, gas
valve and torch are not restricted. Set the gas flow
between 7–14 LMN (15–25 CFH) flow rate. Check
hoses and fittings for holes, leaks, etc.
Moisture on the base metal Remove all moisture from base metal before
welding.
Contaminated base metal Remove materials like paint, grease, oil, and dirt,
including mill scale from base metal.
Contaminated filler wire Remove all grease, oil, or moisture from filler metal.
Incorrect filler wire Check the filler wire and change if necessary.
POSSIBLE REASON SUGGESTED SOLUTION
Torch connected to DC + Connect the torch to the DC – output terminal.
Contaminated base metal Check the gas is connected, check hoses, gas
valve and torch are not restricted. Set the gas flow
between 15–25 CFH (7–12 LMN) flow rate. Check
hoses and fittings for holes, leaks, etc.
Tungsten is contaminated Remove 3/8” (10mm) of contaminated tungsten and
re‑grind the tungsten.
Arc length too long Lower torch so that the tungsten is o of the work
piece 1/8”–1/4” (3.2– 6.35mm).
POSSIBLE REASON SUGGESTED SOLUTION
Incorrect gas or inadequate gas flow Check that pure Argon is being used. Check the gas
is connected, check hoses, gas valve and torch are
not restricted. Set the gas flow between 15–25 CFH
(7–12 LMN) flow rate flow rate.
Incorrect tungsten being used Check and change the tungsten type if necessary.
Tungsten is contaminated Remove 3/8” (10mm) of contaminated tungsten and
re‑grind the tungsten.
Excessive rectification in the base metal Adjust balance control. Increase travel speed. Add
filler wire during welding.
7.2 GTAW (TIG)
Manual Version 1.3 - June/2017
19
ALUMTIG 200
ALUMTIG 200
8.7 HF present but no welding power
8.8 Arc wanders during DC welding
8.9 Arc wanders during AC welding
POSSIBLE REASON SUGGESTED SOLUTION
Incomplete welding circuit Confirm that the ground clamp is connected. Check
all cable connections. Check that the power cable is
not separated.
No gas Check that correct type of tungsten is being used.
Too much current for the tungsten size so reduce
the amps or change to a larger tungsten.
Incorrect filler wire Check the filler wire and change if necessary.
POSSIBLE REASON SUGGESTED SOLUTION
Poor gas flow Check and set the gas flow between 15–25 CFH
(7–12 LMN) flow rate.
Incorrect arc length Lower torch so that the tungsten is o of the work
piece 1/8”–1/4” (3.2– 6.35mm).
Tungsten incorrect or in poor condition Check that correct type of tungsten is being used.
Remove 3/8” (10mm) from the weld end of the
tungsten and re‑sharpen the tungsten.
Poorly prepared tungsten Grind marks should run lengthwise with tungsten,
not circular. Use proper grinding method and wheel.
Contaminated base metal Remove contaminating materials like paint, grease,
oil, and dirt, including mill scale from base metal.
Contaminated filler wire Remove all grease, oil, or moisture from filler metal.
Incorrect filler wire Check the filler wire and change if necessary.
POSSIBLE REASON SUGGESTED SOLUTION
Inadequate gas flow Set the gas flow between 15–25 CFH (7–12 LMN)
flow rate.
Incorrect arc length Set the torch so that the tungsten is o of the work
piece 1/8”–1/4” (3.2– 6.35mm).
Tungsten is contaminated Check and change the size and or the tungsten if
required.
Incorrect tungsten size and or tungsten being used Grind marks should run lengthwise with tungsten,
not circular. Use proper grinding method and wheel.
Excessive rectification in the base metal Increase balance control. Increase travel speed. Add
filler wire during welding.
Contaminated base metal Remove all grease, oil, or moisture from filler metal.
Incorrect filler wire Remove contaminating materials like paint, grease,
oil, and dirt, including mill scale from base metal.
7.2 GTAW (TIG)
Manual Version 1.3 - June/2017
20
ALUMTIG 200
ALUMTIG 200
8.10 Arc dicult to start or will not start DC welding
8.11 Arc dicult to start or will not start DC welding
POSSIBLE REASON SUGGESTED SOLUTION
Incorrect machine set up Check machine set up is correct.
No gas, incorrect gas flow Check the gas is connected and cylinder valve open,
check hoses, gas valve and torch are not restricted.
Set the gas flow between 15–25 CFH (7–12 LMN)
flow rate.
Tungsten is contaminated Remove 3/8” (10mm) of contaminated tungsten and
re‑grind the tungsten.
Incorrect tungsten size and or tungsten being used Check and change the size and or the tungsten if
required.
Loose connection Check all connectors and tighten.
Ground clamp not connected to work Connect the ground clamp directly to the work
piece wherever possible.
Loss of high frequency Check torch and cables for cracked insulation or
bad connections.
POSSIBLE REASON SUGGESTED SOLUTION
Incorrect machine set up Check machine set up is correct.
No gas, incorrect gas flow Check the gas is connected and cylinder valve open,
check hoses, gas valve and torch are not restricted.
Set the gas flow between 15–25 CFH (7–12 LMN)
flow rate.
Incorrect tungsten size and or tungsten being used Check and change the size and or the tungsten if
required.
Tungsten is contaminated Remove 3/8” (10mm) of contaminated tungsten and
re grind the tungsten. Use a pointed tungsten with
AC squarewave inverter machines. The point will
round o aer welding.
Loose connection Check all connectors and tighten.
Ground clamp not connected to work Connect the Ground clamp directly to the work
piece wherever possible.
Loss of high frequency Check torch and cables for cracked insulation or
bad connections.
7. GTAW (TIG)
Manual Version 1.3 - June/2017
21
ALUMTIG 200
ALUMTIG 200
This page is intentionally blank
™
SWS WELDING & CUTTING
WEBSITE: WWW.SWSWELDING.COM.AU
EMAIL: SUPPORT@SWSWELDING.COM.AU
TELEPHONE: (03) 5766 2331
FOR MORE PROFESSIONAL PRODUCTS DELIVERED FAST CHECK OUT...
WWW.SWSWELDING.COM.AU
Loading...