.
2014．06
TIG 202E AC/DC
INVERTER AC/DC PULSED TIG WELDER
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.
OPERAT OR ’S MANUAL
II
CONTENT
§1 SAFETY ............................................................................................................................................. 1
§1.1
SIGNAL EXPLANATION ................................................................................................................... 1
§1.2
ARC WELDING DAMAGE ............................................................................................................... 1
§1.3
THE KNOWLEDGE OF ELECTRIC AND MAGNETIC FIELDS ............................................................... 5
§2 SUMMARY ........................................................................................................................................ 6
§
2.1 BRIEF INTRODUCTION ................................................................................................................... 6
§2.2
MODULE EXPLANATION ................................................................................................................ 8
§2.3
WORKING PRINCIPLE ..................................................................................................................... 8
§2.4
VOLT-AMPERE CHARACTERISTIC .................................................................................................. 9
§3 INSTALLA TION AND ADJUSTMENT ........................................................................................ 10
§3.1
PARAMETERS ............................................................................................................................... 10
3.2
DUTY CYCLE & OVER HEAT ........................................................................................................... 11
§3.3
MOVEMENT AND PLACEMENT ...................................................................................................... 11
§3.4
POWER SUPPLY INPUT CONNECTION ............................................................................................. 11
§3.5
POLARITY CONNECTION（MMA） ............................................................................................ 12
§3.6
ASSEMBLING THE EQUIPMENT (TIG) ........................................................................................... 13
§4 OPERATION ................................................................................................................................... 14
§4.1
LAYOUT FOR THE PANEL .............................................................................................................. 14
§4.2
CONTROL PANEL .......................................................................................................................... 15
§4.3.1
PEDAL SWITCH CONTROL ....................................................................................................... 19
§4.3.2
GUN SWITCH CONTROL CURRENT ........................................................................................... 19
§4.4
ARGON ARC WELDING OPERATION ............................................................................................. 20
§4.4.1
TIG WELDING
（
4T OPERATION） ...................................................................................... 20
§4.4.2
TIG WELDING (2T OPERATION) .............................................................................................. 21
§4.5
WELDING PARAMETERS ............................................................................................................... 23
§4.5.1
JOINT FORMS IN TIG/MMA ................................................................................................... 23
§4.5.2
THE EXPLANATI O N OF W ELDING QUALITY ............................................................................... 23
§4.5.3
TIG PARAMETERS MATCHING ................................................................................................. 23
§4.6
OPERATION ENVIRONMENT ......................................................................................................... 26
§4.7
OPERATION NOTICES ................................................................................................................... 27
§5 MAINTENANCE & TROUBLESHOOTING .............................................................................. 28
§5.1
MAINTENANCE ............................................................................................................................ 28
§5.2
TROUBLESHOOTING ..................................................................................................................... 29
§5.3
ELECTRICAL PRINCIPLE DRAWING ............................................................................................... 32
SAFETY
1
§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 We ldin g 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.
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 to the operation manual.
The electrode and work (or ground) circuits are electrically “h ot” 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
SAFETY
2
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.
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.
Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the
SAFETY
3
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.
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 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
SAFETY
4
an explosion even though they have been “cleaned”.
Vent hollow castings or containers before heating, cutting or welding. They may explode.
Spark s 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 d angerous.
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
5
§1.3 The knowledge of Electric and Magnetic Fields
Electric current flowing through any conductor causes localized Electric and Magnetic Fields
(EMF). The discuss 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 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 workpiece as close as possible to the area being welded.
The people with heart-pacemaker should be away from the welding area.
SUMMARY
6
§2 SUMMARY
§ 2.1 Brief Introduction
TIG200E AC/DC 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 TIG200E AC/DC on the front panel all 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, A C 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.
TIG200E AC/DC Characteristics：
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 w ith special means, even if arc-break occurs the HF will keep the arc
stable.
Pedal control the welding cur rent.
TIG/DC operation,If the tungesten electrode touches the workpiece 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 w ill be on and the output current will be cut off.
It can self-protect and prolong the using life.
Double purposes : 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.
DC MMA
DC TIG
SUMMARY
7
DC Pulse TIG
AC MMA
AC TIG
AC Pulse TIG
1.For DC MMA, polarity connection can be chosen according to different electrodes，please refer
to §3.5；
2.For AC MMA, magnetic flow caused by invariable DC polarity can be avoided；
3.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;
4.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.
5.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 workpiece 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. T he 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.
TIG200E AC/DC -series welding machine is suitable for a ll positions welding for various plates
made of stainless steel, carbon steel, allo yed steel, tita nium, alu minium, 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;
SUMMARY
8
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 200 AC/DC as an example).
§2.3 W ork ing Princi ple
The working principle of TIG200E AC/DC welding machines is shown as the following figure.
Single-phase 220V work frequency AC is rectified into DC (about 312V), then is converted to medium
frequency AC (about 40KHz) 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
er
Trans
forme
r
Rectif
ier
Hall
devic
e
Current feedback
control
Single-phase, AC
DC
AC DC
220V，50Hz
AC
Invert
er
AC or DC
Control signal
AC or DC
SUMMARY
9
§2.4 Volt-Ampere Characteristic
TIG200E AC/DC welding machine has an excellent volt-ampere characteristic, whose graph is
shown as the following figure. The relation between the conventional rated loading voltage U
2
and the
conventional welding current I
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
INSTALLATION AND ADJUSTMENT
10
§3 Installation and Adjustment
§3.1 Param eters
Models
Parameters
TIG 200E AC/DC TIG 200E AC/DC PULSE
Input power (V) 1~220/230/240±10% 1~220/230/240±10%
Fre.（HZ） 50/60HZ 50/60HZ
Rated input current（A）
30.5（AC TIG）
28.3（DC TIG）
39.1（AC MMA）
40.7（DC MMA）
30.5（AC TIG）
28.3（DC TIG）
39.1（AC MMA）
40.7（DC MMA）
Rated input power（KW）
6.1（AC TIG）
6.4（DC TIG）
8.6（AC MMA）
8.9（DC MMA）
6.1（AC TIG）
6.4（DC TIG）
8.6（AC MMA）
8.9（DC MMA）
Duty cycle（40℃，
10 minutes）
AC TIG MMA ＆DC TIG AC TIG MMA ＆DC TIG
35% 200A 40% 170A 35% 200A 40% 170A
60% 155A 60% 140A 60% 155A 60% 140A
100% 120A 100% 11 0A 100% 120A 100% 110A
No load volta ge (V)
52 52
Adjustment range of
welding current（A）
10～200（AC TIG）
10～170
( MMA ＆DC TIG)
10～200（AC TIG）
10～170
( MMA ＆DC TIG)
Down slope（S） 0～10 0～10
Post flow （S） 0～10 0～10
Pulse frequency（HZ）
/ 0.5~200
AC frequency（HZ）
60 60
Pulse width range（%） / 5~95
Clearance effect（%） 15～50 15～50
Efficiency（%） ≥85 ≥85
Power factor 0.6 0.6
Cooling AF AF
Protection class
IP23 IP23
Insulation class H H
Dimensions of Machine
（L×W×H）
（mm）
410×146×278 410×146×278
Weight(Kg)
7.0 7.0
INSTALLATION AND ADJUSTMENT
11
3.2 Duty cycle & Over heat
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 right figure.
If the welder is over-heat, the IGBT over-heat
protection unit inside it will output an instruction to cut
output welding current, and brighten the over-heat pilot
lamp on the front panel. At this time, the machine
should be relaxed 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 for the welder when moving it, and do not make it sloped.
It also can be moved by the handle on the top of the welder. Place the welder well when
moving it to the right position. When the machine gets to the destination, it needs to be fixed up to
avoid gliding.
When using forklift, its arm length must be long enough to reach the outside so as to ensure
lifting safely.
The movement may result in the potential danger or substantive hazard, so please make sure
that the machine is on the safe position before using it.
§3.4 Power su pp ly i np ut connection
TIG 200E AC/DC welding machines’ power supply connects to 220V.
INSTALLATION AND ADJUSTMENT
12
When the power supply voltage is over the safe work voltage, there are over voltage and
under voltage protection inside the welder, the alarm light will on, at the sa me 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.
MMA (AC): No requirements for polarity connection.
INSTALLATION AND ADJUSTMENT
13
§3.6 Assembling the equipment (TIG)
Workpiece is connected to the positive electrode of welding machine, and welding torch is
connected to the negative electrode, which is called DC POSITIVE CONNECTION;
otherwise, that is called DC NEGATIVE CONNECTION. Generally, it is usually operated in
DC POSITIVE CO N NECTION in TIG welding mode.
The control cable of torch switch consists of 2 wires, pedal control of 3 wires and the aero
socket has 14 leads.
Consumable parts for TIG torch, such as tungsten electrode、tip、gas nozzle、electrode
shield(short/long) , please enquire us by mail or phone according to the accessory codes.
When TIG 200E AC/DC welding machines are operated in HF ignition method, the ignition
spark can cause interferences in equipment near the welding machine. Be sure to take
specially safety precautions or shielding measures.
INSTALLATION AND ADJUSTMENT
14
§4 Operation
§4.1 Layout for the panel
1 Positive output: The welder’s positive polarity output.
2 Negative output: The welder’s negative polarity output.
3 Aero socket: Is connected to torch switch control wire.（It has 14 leads and lead 8 - lead 9 are
connected to torch switch control wire）.
4 Shield gas connector: Is connected to the gas input pipe of torch.
5 Power source switch: Switch to “ON”, the welder is turned on, while switch to “OFF”, the welder
is turned off.
6 Power source input: To connect power source.
7 Shield gas input joint: To connect one head of the gas hose while the other head of which is
connected to argon gas cylinder.
INSTALLATION AND ADJUSTMENT
15
§4.2 Control panel
TIG 200E AC/DC
INSTALLATION AND ADJUSTMENT
16
TIG 200E AC/DC PULSE
INSTALLATION AND ADJUSTMENT
17
Available parameters where 2T and 4T mode have been selected:
Tpr Gas pre-flow time
Unit S
Setting range 0.0—2.0
Is Starting current (only with 4T)
Unit A
Setting range 10—170 (DC)；10—200(AC)
Tup Upslope time
Unit S
Setting range 0.0—10
Ip Welding current
Unit A
10—170 (TIG-DC)；10—200 (TIG-AC)；
Ib Base current
Unit A
10—170 (TIG-DC)；10—200 (TIG-AC)；
Dcy Ratio of pulse duration to base current duration
Unit %
Setting range 5—95
Fp Pulse frequency
Unit Hz
Setting range 0.5—200
Tdown Downslope time
MAINTENANCE AND TROUBLESHOOTING
18
Unit S
Setting range 0—10
Ic Crater arc current (only with 4T)
Unit A
Setting range 10-170 (DC)；10-200 (AC)
Tpo Gas post-flow time
Unit S
Setting range 0—10
Balance (only with TIG-AC)
Balance adjustment is mainly used to set the adjustment of eliminating metal-oxide (such as
Aluminium, Magnesium and its alloy) while AC output.
Unit
Setting range -5—+5
MAINTENANCE AND TROUBLESHOOTING
19
§4.3.1 Pedal switch control
● When plug the fourteen-lead aero-socket of pedal switch in it. Welder will identify the pedal
switch, the welding current knob on the front panel will can’t use，and only 2T can be selected.
● When use the adjustment knob of max-welding current beside the pedal ,can set the
max-current you want.
● The eighth and ninth of the fourteen-lead aero-socket is gun switch; The first and second of the
fourteen-lead aero-socket is short circuit; The third、fourth and fifth of the fourteen-lead aero-socket is
pedal adjustable resistance.
Adjustment knob of max
welding current
§4.3.2 Gun switch control current
Connected to the 12-lead
aero socket on the front
panel
Adjustment knob of welding
current
Gun switch
A
djust current button, when
it’
s pushed up, the current
increase, when it’
s pushed
down, the current decrease.
MAINTENANCE AND TROUBLESHOOTING
20
§4.4 Argon Arc W elding Operation
§4.4.1 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 the welding. Thus, 4T is suitable for the
welding of medium thickness plates.
Introduction ：
0：Press and hold the gun switch, Electromagnetic gas valve is turned on. The shielding gas stars
to flow;
0～t1：Pre-gas time (0~2S);
t1～t2：Arc is ignited at t1 and then output the setting value of start current;
t2：Loosen the gun switch, the output current slopes up from the start current;
t2～t3：The output current rises to the setting value (Iw or Ib), the upslope time can be adjusted;
t3～t4：Welding process. During this period, the gun switch is loosen;
Note: Select the pulsed output, the base current and welding current will be outputted alternately;
otherwise, output the setting value of welding current;
t4：Press the torch switch again, the welding current will drop in accordance with the selected
down-slope time.
t4～t5：The output current slopes down to the crater current. The downslope time can be
adjusted;
t5～t6：The crater current time;
t6： Loosen the gun switch, stop arc and keep on argon flowing;
t6～t7：Post-gas time can be set by the post-gas time adjustment knob on the front panel（0～
MAINTENANCE AND TROUBLESHOOTING
21
10S）;
t7：Electromagnetic valve is closed and stop argon flowing. Welding is finished.
§4.4.2 TIG welding (2T operation)
This function with out the adjustment of start current and crater current is suitable for the
Re-tack welding
、
transient welding、thin plate welding and so on.
t（s）
0
I（A）
Loosen the
welding gun
switch
Press and hold the welding
gun switch
t1 t4 t5
Arc is
ignited
Arc is
turned off
t2 t3
Welding current Is
The setting base
current Ib
Introduction：
0: Press the gun switch and hold it. Electromagnetic gas valve is turned on. The shielding gas
stars to flow.
0～t1: Pre-gas time (0~2s)
t1～t2: Arc is ignited and the output current rises to the setting welding current (Iw or Ib) from
the min welding current.
t2～t3: During the whole welding process, the gun switch is pressed and held without releasing.
Note: Select the pulsed output, the base current and welding current will be outputted alternately;
otherwise, output the setting value of welding current;
t3: Release the gun switch, the welding current will drop in accordance with the selected
down-slope time.
t3～t4: The current drops to the minimum welding current from the setting current ( Iw or Ib),
and then arc is turned off.
t4～t5: Post-gas time, after the arc is turned off. You can adjust it (0~10s) through turnning the
knob on the front panel.
t5: electromagnetic gas valve turned off, the shield gas stops to flow, and welding is finished.
MAINTENANCE AND TROUBLESHOOTING
22
Short circuit protect function：
○1 TIG /DC/LIFT：If the tungesten electrode touches the workpiece when welding, the current will
drop to 20A, which can reduce the tungsten spoilage farthestly，prolong the using life of the tungsten
electrode，and prevent tungsten clipping.
○2 TIG /DC/HF：If the tungesten electrode touches the workpiece when welding, the current will drop
to 0 within 1s, which can reduce the tungsten spoilage farthestly，prolong the using life of the
tungsten electrode，and prevent tungsten clipping.
○3MMA operation： if the electrode touches workpiece over two seconds, the welding current will
drop to the 0 automatically to protect the electrode.
Prevent arc-break function：TIG operation， Avoid arc-break with special means, even if arc-break
occurs the HF will keep the arc stable
④TIG：If the TIG torch is pressed quickly, the welding current will drop a half, then if the TIG torch
is pressed quickly again, the welding current will get back.
Notices:
Check the condition of welding and connection units firstly, otherwise there will be malfunction
such as ignition spark、gas leakage、out of control and so on.
Check that whether there is enough Argon gas in the shield gas cylinder, you can test the
electromagnetic gas valve through the switch on the front panel.
Do not let the torch aim at your hand or else of your body. When you press the torch switch, the
arc is ignited with a high-frequency, high-voltage spark, and the ignition spark can cause
interferences in equipment.
The flow rate is set according to the welding power used in the job. Turn the regulation screw to
adjust the gas flow which is shown on the gas hose pressure meter or the gas bottle pressure
meter.
● The spark ignition works better if you keep the 3mm distance from the workpiece to the tungsten
electrode during the ignition.
Note: When select AC output, the current and the wave form are as same as the above, but
output polarity changes alternately.
MAINTENANCE AND TROUBLESHOOTING
23
§4.5 Welding Parameters
§4.5.1 Joint forms in TIG/MMA
§4.5.2 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
§4.5.3 TIG Parameters Matching
The corresponding rel ationship 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》P14
2, Volume 1 of
Edition 2.
a butt joint
b lap joint c coner joint d T joint
MAINTENANCE AND TROUBLESHOOTING
24
Gas nozzle and the shield gas flow rate
Welding current
range/A
DC positive connection AC
Gas nozzle
diameter/mm
Gas flow
rate/L·min
-1
Gas nozzle
diameter/mm
Gas flow
rate/L·min-1
10～100 4～9.5 4～5 8～9.5 6～8
101～150 4～9.5 4～7 9.5～11 7～10
151～200 6～13 6～8 11～13 7～10
201～300 8～13 8～9 13～16 8～15
Notice: the above parameters originate from《Welding Dictionary》P149, Volume 1 of Edition 2.
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
MAINTENANCE AND TROUBLESHOOTING
25
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.
Parameters of AC TIG (MMA) for Aluminum and its alloy
Sheet
thickness
/mm
Welding
wire
diameter
/mm
Tungsten
electrode
diameter
/mm
Pre-heat
Temper
-ature
/℃
Welding
current
/A
Argon
flow
rate
/
L·min-1
Gas
nozzle
diameter
/mm
Remark
1 1.6 2 － 45～60 7～9 8 Flange welding
1.5 1.6～2.0 2 － 50～80 7～9 8
Flange or butt
welding by one
side
2 2～2.5 2～3 － 90～120 8～12 8～12 Butt welding
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.
MAINTENANCE AND TROUBLESHOOTING
26
3 2～3 3 －
150～
180
8～12 8～12
V-groove butt
welding
4 3 4 －
180～
200
10～15 8～12
5 3～4 4 －
180～
240
10～15 10～12
6 4 5 －
240～
280
16～20 14～16
8 4～5 5 100
260～
320
16～20 14～16
10 4～5 5
100～
150
280～
340
16～20 14～16
12 4～5 5～6
150～
200
300～
360
18～22 16～20
14 5～6 5～6
180～
200
340～
380
20～24 16～20
16 5～6 6
200～
220
340～
380
20～24 16～20
18 5～6 6
200～
240
360～
400
25～30 16～20
20 5～6 6
200～
260
360～
400
25～30 20～22
16～20 5～6 6
200～
260
300～
380
25～30 16～20
X-groove butt
welding
22～25 5～6 6～7
200～
260
360～
400
30～35 20～22
Notice: the above parameters originate from《Welding Dictionary》P538, Volume 2 of Edition 2.
§4.6 Operation Environment
● Height above sea level is below 1000m.
● Operation temperature range:-10
0
C～+400C.
● Relative humidity is below 90 % (20
0
C).
● Preferably site the machine some angles above the floor level, the maximum angle does not exceed
15
0
.
● Protect the machine against heavy rain or in hot circumstance against direct sunshine.
● T he content of dust, acid, corrosive gas in the surrounding air or substance can not exceed normal
standard.
● Tak e care that there is sufficient ventilation during welding. There is at least 30cm free distance
between the machine and wall.
MAINTENANCE AND TROUBLESHOOTING
27
§4.7 Operation Notices
● Read §1 carefully before attempting to use this equipment.
● Connect the ground wire with the machine directly, and refer to §3.5.
● In case closing the power switch, no-load voltage may be exported. Do not touch the output
electrode with any part of your body.
● Before operation, no concerned people should be left. Do not watch the arc in unprotected eyes.
● Ensure good ventilation of the machine to improve duty ratio.
● Turn off the engine when the operation finished to economize energy source.
● When power switch shuts off protectively because of failure. Don’t restart it until problem is
resolved. Otherwise, the range of problem will be extended.
MAINTENANCE AND TROUBLESHOOTING
28
§5 Maintenance & Troubleshooting
§5.1 Maintenance
In order to guarantee that arc welding machine works high-efficiently and in safety, it must be
maintained regularly. Let customers understand the maintenance methods and means of arc welding
machine more , enable customers to carry on simple examination and safeguarding by oneself, try
one's best to reduce the fault rate and repair times of arc welding machine, so as to lengthen service
life of arc welding machine .Maintenance items in detail are in the following table.
● Warning: For safety while maintaining the machine, please shut off the supply power and wait
for 5 minutes, until capacity voltage already drop to safe voltage 36V!
date Maintenance item
Daily
examination
Observe that whether panel knob and switch in the front and at the back of arc welding
machine are flexible and put correctly in place. If the knob has not been put correctly in
place, please correct; If you can't correct or fix the knob , please replace immediately;
If the switch is not flexible or it can't be put correctly in place, please replace
immediately; Please get in touch with maintenance service department if there are no
accessories.
After turn-on power, watch/list
en to that whether the arc welding machine has shaking,
whistle calling or peculiar smell.
If there is one of the above problems, find out the reason
to get rid of; if you can't find out the reason, Please contact local this area agent or the
branch company.
Observe that whether the display value of LED is intact. If the display number is not
intact, please replace the damaged LED. If it still doesn’t work, please maintain or replace
the display PCB.
Observe that whether the min/max value on LED accords with the set value. If there is
any difference and it has affected the normal welding craft, please adjust it.
Check up that Whether fan is damaged and is normal to rotate or control. If the fan is
damaged, please change immediately. If the fan does not rotate after the arc welding
machine is overheated , observe that whether there is something blocked in the blade, if it is
blocked, please get rid of ; If the fan does not rotate after getting rid of the above problems,
you can poke the blade by the rotation direction of fan. If the fan rotates normally, the start
capacity should be replaced ; If not, change the fan.
Observe that whether the fast connector is loose or overheated.
if the arc welding
machine has the above problems, it should be fastened or changed.
Observe that Whether the current output cable is damaged. If it is damaged, it should be
wrapped up, insulated or changed.
MAINTENANCE AND TROUBLESHOOTING
29
Monthly
examination
Using the dry compressed air to clear the inside of arc welding machine. Especially for
clearing up the dusts on radiator, main voltage transformer, inductance, IGBT module, the
fast recover diode and PCB, etc.
Check up the bolt in arc welding machine, if it is loose, please screw down it. If it is skid,
please replace. If it is rusty, please erase rust on bolt to ensure it works well.
Quarter-
yearly
examination
Whether the actual current accords with the displaying value. If they does not accord,
they should be regulated. The actual current value can be measured by the adjusted
plier-type ampere meter.
Yearly
examination
Measure the insulating impedance among the main circuit, PCB and case, if it below
1MΩ, insulation is thought to be damaged and need to change , and
need to change or
strengthen insulation.
§5.2 Troublesh ootin g
Before arc welding machines are dispatched from the factory, they have already been debugged
accurately. So forbid anyone who is not authorized by us to do any change to the equipment!
Maintenance course must be operated carefully. If any wire becomes flexible or is misplaced, it
maybe potential danger to user!
Only professional maintenance personal who is authorized by us could overhaul the machine!
Guarantee to shut off the arc welding machine’s power before turn on the outline of the
equipment!
MAINTENANCE AND TROUBLESHOOTING
30
If there is any problem and has no the authorized professional maintenance personal, please
contact local agent or the branch company!
If there are some simple troubles of TIG200E AC/DC -series welding machine, yo u can consult the
following overhauling chart:
S/N
Troubles Reasons Solution
1
Turn on the power source, and
fan works, but the power pilot
lamp is not on.
The power light damaged or connection is
not good
Check and repair Pr7
The transformer of power is broken Repair or change the transformer
Control PCB failures Repair or change the control Pr4
2
Turn on the power source, and
the
power lamp is on, but fan
doesn’t work
There is something in th e fan Clear out
The start capacitor of fan damaged Change capacitor
The fan motor damaged Change fan
3
Turn on the power source, the
power lamp is not on, and fan
doesn’t work
No power supply input Check whether there is power supply
The fuse inside the machine damaged Change it (3A)
4
The number on the display is not
intact.
The LED in the display is broken Change the LED
5
The max and min value
displayed doesn’
t accord with
the set value.
The max value is not accordant (refer to
§3.1)
Adjust potentiometer Imin on the power
board.
The min value is not accordant (refer to §3.1)
Adjust potentiometer Imaxin the current
meter.
6
No no-
load voltage output
(MMA)
The machine is damaged Check the main circuit and the Pr4.
7
Arc can not be
ignited (TIG)
There is spark
on the HF
igniting board.
The welding cable is not connected with the
two output of the welder.
Connect the welding cable to the
welder’s output.
The welding cable damaged. Repair or change it.
The earth cable connect ed unstably. Ch eck t he earth cable.
The welding cable is too long. Use an appropriate welding cable.
There is oil or dust on the workpiece. Check and remove it.
The distance between tungsten electrode and
workpiece is too long.
Reduce the distance (ab out 3mm).
There is not
spark on the
HF igniting
board.
The HF igniting board does not work. Repair or change Pr8
The distance between the discharger is too
short.
Adjust this distanc e (abo ut 0.7mm).
MAINTENANCE AND TROUBLESHOOTING
31
S/N
Troubles Reasons Solution
The malfunction of the welding gun switch.
C
heck the welding gun switch, control
cable and aero socket.
8 No gas flow (TIG)
Gas cylinder is close or gas pressure is low Open or change the gas cylinder
Something in the valve Remove i t
Electromagnetic valve is d amaged Change it
9
Gas always flows
The gas-test on the front panel is on The gas-test on the front panel is off
Something in the valve Remove i t
Electromagnetic valve is d amaged Change it
The adjustment knob of pre-
gas time on the
front panel is damaged
Repair or change it
10
The welding current can not be
adjusted
The welding current potentiometer on the
front panel connection is not good or
damaged
Repair or change the potentiometer
11
No AC output while selecting
“AC”
The power PCB is in trouble. Repair or change it.
The AC drive PCB damaged. Change it.
The AC IGBT module damaged. Change it.
12
The welding current displayed
isn’t
accordant with the actual
value.
The min value displayed isn’t accordant with
the actual value. (Pl ease refer to §3.1)
Adjust potentiometer Imin on the power
board.
The max value displayed isn’t accor dan t with
the actual value. (Pl ease refer to §3.1)
A
djust potentiometer Imax on the power
board.
13
The penetration of molten pool
is not enough.
The welding current is adjusted too low Increase the welding current
The arc is too long in the welding process Use 2T operati on
14
The alarm lamp on the front
panel is on
Over heat protection
Two much welding
current
Reduce the welding current output
Working time too
long
Reduce the duty cycle (work
intermittently)
Over-voltage
protection
Power supply
fluctuates
Using the stable power supply
Low-voltage
protection
Power supply
fluctuates
Using the stable power supply
Too many machines
using power supply
in the same time
Reduce the machines using power
supply in the same time
Over-current
protection
Unusual current in
the main circuit
Check and repair the main circuit and
drive Pr6
MAINTENANCE AND TROUBLESHOOTING
32
§5.3 Electrical principle drawing
MAINTENANCE AND TROUBLESHOOTING
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