ARCCAPTAIN TIG200 User manual

Inverter Welding Machine
TIG200
User Manual
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Dear Valued Customer,
Thank you very much for being our valued customer. ARCCAPTAIN welder was built by
high quality components, every single unit machine was passed multiple industry leading
laboratory tests to provide a great welding experience and performance.
For your safety, please read and understand this manual carefully before using this
product. Your satisfaction is our priority! For any question or concerns, please do not
hesitate to contact ARCCAPTAIN for SUPPORT :
[email protected]
www.arccaptain.com
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CONTENTS
1. SAFETY GUIDANCE..............................................................................................1
1.1 Precautions for Operations and Installation.....................................................................1
1.2 Preparation before welding................................................................................................ 3
1.3 Precautions for discard....................................................................................................... 4
2. PRODUCT DESCRIPTION....................................................................................4
2.1 Function and Features........................................................................................................ 4
2.2 Technical Parameters.......................................................................................................... 5
2.3 Dimension and weight......................................................................................................... 5
2.4 Composition and Picture of the welding machine system............................................. 6
2.5 System characteristics........................................................................................................ 7
3. FUNCTION............................................................................................................... 8
3.1 Panel of TIG200................................................................................................................... 8
3.2 Panel functions of TIG200.................................................................................................. 8
4. INSTALLATION AND CONNECTION................................................................. 9
4.1 Installation requirements.....................................................................................................9
4.2 Electrical connection..........................................................................................................11
4.3 Installation and Commission............................................................................................ 11
4.4 Strap Installation................................................................................................................ 15
5. WELDING PARAMETERS TABLE................................................................... 16
6. MAINTENANCE.................................................................................................... 18
7. FAILURE DIAGNOSIS AND TROUBLESHOOTING.....................................21
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1. SAFETY GUIDANCE
1.1 Precautions for Operations and Installation
Beware of electric shock!
Install grounding devices according to application standard.
Do not touch live parts with naked skin, wet gloves or wet clothes.
Be sure you are insulated from ground and workpiece.
Cover the cover plate of the machine before power on to avoid an electric
shock.
Confirm the safety of your working position.
Beware of fire hazard!
To avoid fire hazard, please install the machine on non-combustible
materials;
To avoid fire hazard, please make sure there are no inflammables nearby.
Beware of explosion!
To avoid explosion, please do not install the machine in an explosive gas
environment.
Smoke-may be harmful to your health!
Keep your head away from the smoke to avoid inhalation of waste gas in
welding.
Keep the working environment well ventilated with exhaust or ventilation
equipment when welding.
Arc radiation-may hurt your eyes and burn your skin!
Use proper mask and wear protective clothing to protect your eyes and body.
Use proper mask or curtain to protect onlooker from being injured.
Magnetic field can make cardiac pacemaker a bit wonky.
People with cardiac pacemaker should consult the doctor before carrying out
welding.
Stay away from the power source to reduce the affect of magnetic filed.
Improper use and operation may result in a fire or an explosion.
Welding spark may result in a fire, so please make ensure there are no
inflammables near the welding position, and pay attention to fire safety.
Ensure there is fire extinguisher nearby, and make sure someone has been
trained to operate the fire extinguisher.
Do not weld closed container.
Do not use this machine for pipe thawing.
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Hot workpiece can cause severe scald.
Do not touch hot workpiece with bare hands.
Cool the welding torch for a while after continuously working.
Excessive noise can be harmful to hearing.
Wear ear covers or other hearing protectors when welding.
Give warning to nearby personnel that noise may be potentially hazardous to
hearing.
Moving parts may injure your body.
Please keep away from moving parts (such as fan).
All doors, panel, cover, baffle plate, and other protective device should be closed
and well located.
Asking for professional support while trouble strikes.
When trouble strikes in installation and operation, please resort to this
manual for according contents.
If you are still in lost, or you still cannot solve the problem, please contact the
dealer or the service center for professional support.
Moving the machine can be dangerous.
Please make sure the input power switch is turned off before moving the machine.
Do not stress the operation panel and cover plate while moving the machine so that to avoid falling
items hurting others.
Please fix the wheels tightly while moving the machine with a forklift.
To avoid possible fire hazard or other damages, please do not install and operate this machine if it’s
found damaged or lack of components.
Replacing machine components can be dangerous.
Only qualified personnel can replace the machine components. Make sure there are no foreign
bodies such as wire leads, screws, gaskets and metal bars falling into the machine when replacing
the components.
Make sure the connecting wires inside the machine are correctly connected after replacing the
PCBs, and then the machine can be run. Otherwise, there is a risk of damage to property.
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Other Precautions
1) Make sure the place to install the machine can bear the weight of welding machine.
2) Do not install the machine at places where water droplet splash may occur, such as near water
pipes.
3) Welding should be carried out in dry environment with humidity less than 90%.
4) Avoid welding in the open air unless sheltered from sunlight and rain. Keep it dry and do not place it
on wet ground or in puddles.
5) Do not carry out welding with the welding machine placed on a platform with a pitch greater than 10°.
This product is equipped with over current/over voltage/overheating protection circuit. When the mains
voltage, output current or inner temperature exceeds the set standard, the machine will stop
automatically. However, excessive use of machine may also damage the machine; therefore, please pay
attention to the following:
Good ventilation
A working welder will generate big current and has strict cooling requirements that cannot be met
with natural ventilation. Therefore the built-in fan is very important in enabling the machine to work
stable with effective cooling. Operator should make sure that the louvers be uncovered and
unblocked.
Over voltage is forbidden.
This machine is of automatic mains voltage compensation, which ensures that the welding current
varies within the given range. In case that the input mains voltage exceeds the tolerance value, it
would possibly damage the machine; therefore, operators should understand take relevant
precautions in advance.
Overload is forbidden.
Please observe the max load current at any moment (refer to the corresponding duty cycle). Make
sure that welding current not exceeding the maximum load current. Overload could obviously
shorten the machine's lifespan, or even damage the machine.
Suddenly the “E61” code may appear on the digital screen while the machine is of over-load status.
Under this circumstance, it is unnecessary to restart the machine. Keep the built-in fan working to
lower the temperature inside the machine. Welding can be continued after the inner temperature falls
into the standard range and the “E61” code is disappeared.
1.2 Preparation before welding
1) Safety devices
To avoid gas poisoning, suffocation, dust poisoning, please use air discharge equipment as
required and wear respiratory protection devices.
Please wear safety goggles or other protection devices which are of sufficient shading when
welding or guiding welding.
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To avoid eyes being hurt by spatters, please wear protective goggles.
Please wear welding specialized protective clothing, such as leather protective gloves, long-sleeved
clothes, welding spats, aprons, etc.
Please install protective barrier to protect standbys from hurting by arc light.
Please wear sound insulation devices when noise is too huge.
Please use ventilator for air exchanging; please take anti-wind measures so that to avoid poor
welding performances resulted from direct blowing to arc.
2) Cable connection check
Fix welder—place welders on dry, flat position which is of good ventilation.
Please make sure the correct and tight connection of grounding cable, power input cable, welding cable
and workpiece side cable.
3) Other items’ check
Please check the shielding gas, welding environment, welding torch and make sure they are all in good
condition.
1.3 Precautions for discard
Pay attention to the following when discarding welding machine:
Burning the electrolytic capacitors in the main circuit or on the PCBs may cause an explosion.
Burning the plastic parts such as the front panel may produce poisonous gas.
Dispose it as industrial waste.
2. PRODUCT DESCRIPTION
2.1 Function and Features
TIG welder is of constant current external characteristic. Welding current will not be changed per arc
length but being kept at a very stable level. It adopts PWM technology and high-power switching
element IGBT (discrete) to rectify AC110V/AC220V (50Hz/60Hz) voltage to DC310V, after inverting
it to 45KHz, there is a voltage step-down and rectification again, stable welder current is obtained by
output current feedback and adjustment.
Built-in MCU technology and IGBT inverter Welder, totally digital control, which ensures great and
stable welding performance.
TIG200 is TIG and MMA 2 in 1 Multi-Process welding machine.
MMA/Stick welding features: hot start, arc force and an-stick.
TIG welding features: 2T/4T Operation, current regulation, post-flow adjustable, down-slope.
Fan-On-Demand power source cooling system operates only when needed, reducing noise, energy
use and the amount of contaminants pulled through the machine.
Portable and Lightweight: 11.68lb, carry with handle or shoulder strap.
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Safety protection: over current/over voltage/overheating protection circuit.
Unique Design & LED Display Panel, read data more clear, concise distribution and convenient
operation. Warning indicator for normal working and abnormal working.
Remote control function available: support foot pedal & analog torch (purchase additional if need).
2.2 Technical Parameters
2.3 Dimension and weight
Model TIG200
Dimension(L*W*H) 424*135*243mm/16.69*5.3*9.56in
Weight 5.3kg/11.68lb
Items TIG200
Rated Input Power Single Phase AC220V/AC110V ±15% 50Hz/60Hz
Rated Input Capacity（kVA）7.8
Rated Input Current（A）TIG:28 MMA:35
Rated Output
Current/Voltage （A/V）
TIG:200A/18V
MMA:170A/26.8V
@220V
TIG:140A/15.6V
MMA:120A/24.8V
@110V
Rated Duty Circle 40%
No-load voltage (V) DC 62
Output Current Range（A）
TIG:10-200
MMA:10-170
@220V
TIG:10-140
MMA:10-120
@110V
Post-flow Time（s）0--10
Down slope(s) 0--10
Arc Ignition Type HF
Enclosure Protection Class IP21S
Insulation Grade H
Power Factor 0.73
Efficiency (%) 80
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Pic 1 Welder Appearance and Dimension（Unit：mm/in）
2.4 Composition and Picture of the welding machine system
1) Welding system composition
Pic 2 Welding System Composition
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2) Ordering and Packing List
Name Specification Quantity (pcs)
TIG welder TIG200 1
TIG torch & accessories WP-17 (13ft/4m) 1
Electrode Holder 200A-16mm2（9ft/ 3m）DKJ 35-50 1
Earth clamp 300A-16mm2（9ft/ 3m）DKJ 35-50 1
Operator’s manual Operator’s manual of TIG200 1
Gas hose Gas hose with gas connector 1
Conversion adapter American adapter plug 1
Strap 0.1*4.3ft (30mm*1500mm), Black 1
Tungsten electrode φ1/16”, 6”（1.6mm, 150mm) 1
2.5 System characteristics
Duty Circle
Rated duty circle means: Taking 10 min as a time cycle, the ratio of rated output time is taking in that
time cycle, as shown in Pic 3.
Static External Characteristics
TIG series welders’ power output is of dropping characteristics (constant current characteristics), as
shown in Pic 4. Picture is only for reference.
Pic 3 Duty Circle Sketch Map Pic 4 Output characteristic curves
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3. FUNCTION
3.1 Panel of TIG200
Pic 5 Front panel of TIG200 Pic 6 Back panel of TIG200
3.2 Panel functions of TIG200
Part name Function
1.It displays parameters value which is set currently;
2.It displays setting value of Down Slope;
3.It displays setting value of Post Gas;
4.It displays “E61” code while the machine is of over-load status;
5.It displays “E10” code while the machine is over current.
~110V The input voltage is AC110V when it is blinking.
~220V The input voltage is AC110V when it is blinking.
Panel The welder can only be used by panel control when it is blinking.
Remote The welder can only be used by remote control when it is blinking.
MMA MMA Welding mode.
TIG 2T 2T Welding mode.
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TIG 4T 4T Welding mode.
DownSlope This indicates the time taken from the peak current to the arc striking current.
PostGas This indicates the shielding gas post-flow time.
Current This indicates the value of output current.
A Unit of current.
s Unit of time.
Welding mode
button For MMA/2T/4T welding mode conversion.
Preference button For Down slope/Post Gas/Current conversion.
Control mode
button For Panel/Remote conversion.
Power wire For power supply input.
Power switch To control the ON/OFF of the input power of the machine.
Fan For heat dissipation through forced air cooling.
Gas nut Used to connect external gas.
4. INSTALLATION AND CONNECTION
4.1 Installation requirements
Environment requirements
Please pay attention to the following when choosing installation site:
Please avoid environment which contains too much dusts or metal powder.
Avoid installation in area which is with corrosive or explosive gases.
Ambient temperature should be within－10℃～＋40℃;Please reinforce radiation or lessen
power machine operation when temperature is over 40℃.
Installation should be carried out in dry environment with humidity less than 90%.
Avoid welding in the open air with strong wind; please install windscreen if necessary, or else
welding performances may be affected.
Please consult and confirm in advance if there is any special installation requirement.
If the Welding power is paced on tilt plane, pay attention to avoid it topple over.
The Welding power is forbidden to use thaw pipe.
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Installation space requirements
Distance between welder and wall should be more than 20cm（7.87”）; distance between two abreast
welders should be more than 30cm
（11.82”）
. You may refer to the below suggested reserved installation
space to confirm the installation position.
Department Front Left Side Right Side Back
Reserved Space ≥20cm/7.87”≥20cm/7.87”≥20cm/7.87”≥20cm/7.87”
4.2 Electrical connection
Precautions:
All connection should be carried out by qualified professional electric operators.
All connection should be carried out when distribution box is switched off and safety is 100%
confirmed.
Cable section area of the distribution box should withstand welder’s max output.
Don’t touch with bare hands.
Don’t place heavy items on cables.
Water pipe, building metal may not be fully grounded; please don’t use them as safe earth
connection.
Every welder’s yellow/green cable should be reliably grounded.
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4.3 Installation and Commission
4.3.1 Welder operation description for TIG function
A. Connection
1. Please connect TIG torch correctly according
to Pic 7. Connect the gas & electric connector of
the TIG torch to the corresponding connector on
the machine panel, and tighten it clockwise.
2. Connect the aviation plug on the TIG torch to
the corresponding socket on the machine
panel. (See Pic 7.)
3. Connection of TIG torch’s components.
①Torch trigger
②Short/Long Back cap
③Gasket
④Collet Body
⑤Collet
⑥Ceramic nozzle
Pic 7 Installation of TIG torch
Pic 8: Connection of TIG torch
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B. Operation for TIG function
1) power switch
Turn on the power switch on the back panel and fan starts rotating; panel display is normal and power
supply indicator is light on; welder is successfully started.
2) TIG available:
Connect well the argon cylinder and turn on cylinder valve; adjust the flow meter to the according value;
Connect welding torch and earth clamp;
Pull the torch trigger and solenoid valve starts working; there will be argon out, also HF discharging at
the same time.
Please set welding current according to workpiece thickness.
Keep the distance between torch tungsten and workpiece at 2-4mm/0.08-0.16in; pull the torch trigger
and welder’s HF discharging noise will disappear as long as arc is successfully ignited; welding can be
4. Insert the quick plug on the earth cable into
the “+” quick socket on the machine panel, and
tighten it clockwise. Clamp the workpiece with
the earth clamp at the other end of the earth
cable. (See Pic 9.)
Pic 9 Installation of Earth cable
5. Gas connection: connect argon tube with
welder back panel’s brass mouthpiece tightly.
Air supply passage should include argon
decompressed flowmeter, gas hose; please use
a hose clamp or other fixing items to crew the
hose connection part so that to avoid poor
welding spot protection which is caused by gas
leakage or air admission. (Pic 10)
Pic 10 Gas connection
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started;
3) Current regulation
Operators can choose according to welding current per workpiece thickness.(current range:10-200A)
4) Post-flow time
Post-flow time is the time between arc ending and post-flow. Post-time can be adjusted between
1-10seconds.
5) down slope time：to adjust the output current down slope time.
6) 2T/4T :select 4T 【The up- and down-slopes are switched off】.
Pic 11 4T welding logic
Step 1
• Press torch trigger 1, there is gas pre-flow time（150ms).
• HF ignition pulses from the electrode to the workpiece, the arc ignites.
• Welding current flows and immediately the ignition. HF is switched off.
Step 2
• Release torch trigger 1.
• The welding current increases with the set up-slope time( built-in 0 second) to the main current AMP.
Switching from main current AMP to secondary current AMP%:
Press torch trigger 2 or Tap torch trigger 1 *
Step 3
• Press torch trigger 1.
• The main current drops with the set down-slope time to the end-crater current Iend (minimum current).
Step 4
• Release torch trigger 1, the arc extinguishes.
• The set gas post-flow time begins.
Immediate termination of the welding process in the downslope by releasing torch trigger 1.
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7) pulse frequency adjust：to adjust the output current pulse frequency.
8) remote control
Adjustable welding current depending on the TIG torch of potentiometer/or foot pedal. (not included in
basic package)
4.3.2 Welder operation description for MMA function
Connecting the electrode holder and workpiece lead
• Insert cable plug of the electrode holder into either the "+" or "-" welding current connection socket and
lock by turning to the right.
• Insert cable plug of the workpiece lead into either the "+" or "-" welding current connection socket and
lock by turning to the right.
Polarity depends on the instructions from the electrode manufacturer given on the electrode packaging.
1. Connection socket for " " welding current
Electrode holder or workpiece lead connection
2. Connection socket, “ ” welding current
Workpiece lead or electrode holder connection
Pic12 Lower part of front panel
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4.4 Strap Installation
Step 1: Separate the velcro.(See Pic 13)
Pic 13
Step 2: Pull out one side through the strap hole
on the front panel with hook side of the velcro
up.(See Pic 14)
Pic 14
Step 3: Pull out it to well stick hook side of the
velcro to loop side and across the nylon buckle.
Repeat it on the other side.(See Pic 15)
Pic 15
Step 4: Adjust the length by pulling the nylon
buckle (as shown in the picture).(See Pic 16)
Pic 16
Step 5: Proper state after installation:
1. Strap does not twist;
2. Buckle side of shoulder pad is up, while its
flat side faces the machine (as shown in the
picture);
3. Straps are well locked.(See Pic 17)
Pic 17
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5. WELDING PARAMETERS TABLE
Parameters for TIG electrode
Electrode diameter Amperage range
on DCEN Straight
polarity
Amperage range on
DCEP Straight polarity Amperage range on AC
mm inch
1.040" 15-80 / 20-60
1.6 1/16 70-150 10-20 60-120
2.4 3/32" 150-250 15-30 100-180
3.2 1/8" 250-400 15-40 160-250
4 5/32" 400-500 40-55 200-320
Parameters for TIG welding on stainless steel sheet (for reference only)
Electrode diameter mm
(inch)
Plate thickness mm
(inch) Welding current(A) Gas flow(L/min)
1~2mm
(0.040”-5/64”)
1~3mm
(0.040”- 0.12”)
50 5
50~80 6
2~4mm
(5/64”-5/32 “)
3~6mm
(0.12”-0.24”)
80~120 7
121~160 8
161~200 9
201~300 10
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Parameters for TIG welding on titanium and its alloy (for reference only)
Plate
thickness
mm (inch)
Weldin
g
layers
Electrode
diameter mm
(inch)
Wire
diameter mm
(inch)
Welding
current(
A)
Gas flow (L/min)
Nozzle
diameter
mm (inch)
Square
groove
Single V
groove
with root
face
Double V
groove
with root
face
0.5(0.020") 1 1.5(0.059") 1 (0.040") 30~50 8~10 6~8 14~16 10(0.393")
1 (0.040") 1 2(0.079") 1.0~2.0
(0.040"-0.079") 40~60 8~10 6~8 14~16 10(0.393")
1.5(0.060") 1 2(0.079") 1.0~2.0
(0.040"-0.079") 60~80 10~12 8`10 14~16 10~12 (0.393"-0.472)
2(0.079") 1 2.0~3.0
(0.079"-0.118")
1.0~2.0
(0.040"-0.079") 80~110 12~14 10~12 16~20 12~14 (0.472"-0.551")
2.5(0.098") 1 2.0~3.0
(0.079"-0.118") 2 (0.079") 110~120 12~14 10~12 16~20 12~14 (0.472"-0.551")
3(0.118") 1~2 3(0.12") 2.0~3.0
(0.079"-0.118") 120~140 12~14 10~12 16~20 14~18 (0.551"-0.708")
4(0.157") 2 3.0~4.0
(0.12~5/32")
2.0~3.0
(0.079"-0.118") 130~150 14~16 12~14 20~25 18~20 (0.708"-0.787")
5(0.197") 2~3 4.0(5/32”) 3(0.118") 130~150 14~16 12~14 20~25 18~20
(0.708"-0.787")
6(0.236") 2~3 4.0(5/32”) 3.0~4.0
(0.118"-5/32”) 140~180 14~16 12~14 25~28 18~20 (0.708"-0.787")
7(0.257") 2~3 4.0(5/32”) 3.0~4.0
(0.118"-5/32”) 140~180 14~16 12~14 25~28 20~22 (0.787"-0.866")
8(0.315") 3~4 4.0(5/32”) 3.0~4.0
(0.118"-5/32”) 140~180 14~16 12~14 25~28 20~22 (0.787"-0.866")
10(0.394") 4~6 4.0(5/32”) 3.0~4.0
(0.118"-5/32”) 160~200 14~16 12~14 25~28 20~22 (0.787"-0.866")
20(0.787") 12 4.0(5/32”) 4(5/32”) 200~240 12~14 10~12 20 18(0.708")
22(0.866") 12 4.0(5/32”) 4.0~5.0
(5/32”-0.197") 230~250 15~18 18~20 18~20 20(0.787")
25(0.984") 15~16 4.0(5/32”) 3.0~4.0
(0.118"-5/32”) 200~220 16~18 20~26 26~30 22(0.866")
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