ARCCAPTAIN TIG200P ACDC User manual

Inverter Welding Machine
TIG200P ACDC
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 :
[e-mail]
www.arccaptain.com
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Contents
1. Safety Precautions ...........................................................................................................................................1
1.1 Installation Precautions ............................................................................................................................ 1
1.2 Operation Precautions ..............................................................................................................................2
1.3 Scrap Disposal ..........................................................................................................................................3
2. Product Overview .............................................................................................................................................3
2.1 Product Model Description ....................................................................................................................... 3
2.2 Product Feature ........................................................................................................................................ 3
3. Technical Parameters ...................................................................................................................................... 4
3.1 Technical Parameters ............................................................................................................................... 5
3.2 External (Static) Characteristic Curve ......................................................................................................5
4. Function and Description ................................................................................................................................6
4.1 Panel Structure and Description .............................................................................................................. 6
4.2 TIG200PACDC Panel ............................................................................................................................... 6
4.3 Functional Description .............................................................................................................................. 9
5. Installation and connection .......................................................................................................................... 16
5.1 Connection of Power Cord ..................................................................................................................... 16
5.2 Connection of power distribution box .....................................................................................................17
5.3 Welder Installation .................................................................................................................................. 17
6. Function and Operation ................................................................................................................................ 19
6.1 TIG Introduction ...................................................................................................................................... 19
6.2 MMA Introduction ....................................................................................................................................23
6.3 MMA Welding ..........................................................................................................................................23
7. Precautions & Maintenance ..........................................................................................................................26
7.1 Precautions ............................................................................................................................................. 26
7.2 Maintenance ........................................................................................................................................... 28
8. Trouble shooting ............................................................................................................................................ 28
8.1 Common Malfunction Analysis and Solution ..........................................................................................28
8.2 TIG Problems and Elimination ................................................................................................................29
8.3 Welding Procedure Checklist (for reference only) ................................................................................. 30
8.4 SMAW Process Parameters ...................................................................................................................30
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1. Safety Precautions
1.1 Installation Precautions
Warning: It is important that operators of this machine protect yourselves and others
from harm or even death. For details, please refer to the operator's safety protection
guide that meets the manufacturer's accident prevention requirements.
Electric shock!
Install the grounding device according to the applicable standards.
Do not touch live parts when the skin is exposed, wearing wet gloves or
wearing wet clothes.
Make sure you are insulated from the ground and the weldment.
Do not use the machine with the covers removed.
Make sure your station is safe.
Fire!
Install the welder in a dry indoor environment, and ensure that the machine is
at least 30 cm away from walls or other objects.
Ensure that there is no flammable material near the welding station; otherwise,
there will be a fire hazard.
Ensure that there are fire extinguishing devices nearby and that a trained
person can skillfully use the fire extinguisher.
Explosion!
The welder can be installed in the environment with waste gas and dust
generated by general welding, but cannot be installed in the environment with
flammable gas or metal dust; otherwise, welding sparks may cause explosion.
Moving the welder may be dangerous
Please turn off the power of distribution box before moving the welder.
When moving the welder with lifting device, please ensure the lifting eye screws are tightened and the
welder cover is installed properly.
When the welder is damaged or missing parts, do not open or use it; otherwise, it may cause fire or
personal injury.
Changing parts can be dangerous
Only professional personnel can change the machine parts. When replacing parts, do not to drop foreign
objects such as conductor trace lines, screws, washers, metal rods, etc. into the inside of the machine.
When replacing the circuit board, ensure that the wiring is correct and the machine works normally;
otherwise, it may cause property damage.
Installation environment.
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Avoid installing the machine in an environment with dust or metal powder;
Avoid installing the machine in an environment with corrosive or explosive gas;
Ensure that the working environment is between -10°C and 40°C. If it is used in an environment higher
than +40℃, additional forced cooling measures or derating should be taken;
It should be used in an environment where the humidity is less than 90% and there are no condensation
water beads;
Please make sure that there is no wind on the welding side. Use a windshield if necessary; otherwise, it
will affect the welding quality.
Please consult and confirm with experienced personnel first for any special Installation requirements.
1.2 Operation Precautions
Only qualified personnel should operate this machine!
Always use the appropriate personal protective equipment.
The operator shall be a special operator with a valid "Metal Welding (Oxygen
Cutting) Operation" certificate.
Do not carry out any maintenance with the power on the machine
Fumes and gases may be hazardous to your health!
Welding may produce hazardous fumes and gases. Do not breathe the
welding fume.
Keep your head out of the welding fume, and ensure the welding zone is
provided with ventilation or fume extraction system.
Arc rays may injure the eyes and burn the skin!
Use a suitable welding helmet and wear protective clothing to protect your
eyes and body.
Use adequate helmet or protective screens to protect others from injury.
Magnetic field affects cardiac pacemaker
Pacemaker users should consult a doctor before performing welding
operations.
Stay away from welding power source to reduce electromagnetic interference.
Improper use and operation may cause fire or explosion
Welding sparks may cause fire. Please confirm that there are no combustibles
near the welding station and pay attention to safety and fire prevention.
Ensure that there are fire extinguishers nearby and that a trained person can
skillfully use the fire extinguisher.
Do not weld closed containers.
It is forbidden to use the machine for pipeline thawing.
Hot weldments can cause severe burns
Do not touch any hot surfaces or parts bare handed.
Always allow the welding gun to cool down when using it continuously.
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Pulse / AC / DC
Rated welding current
Gas tungsten arc welding
Moving parts may cause personal injury
Keep away from moving parts (such as fans).
Protective devices such as doors, panels, covers and baffles shall be tightly
closed and in place.
Seek professional help when encountering problems
If you still do not fully understand or cannot solve the problem after reading
the instructions in this manual, you should contact the supplier service
center immediately for professional help.
1.3 Scrap Disposal
Please pay attention to the following when scraping the welder:
Igniting electrolytic capacitors on the main circuit or circuit board can cause an explosion;
The machine belongs to industrial waste.
2. Product Overview
2.1 Product Model Description
TIG 200PACDC
2.2 Product Feature
2.2.1 Machine Overview
TIG200PACDC is a fully digital 7 in 1 inverter AC/DC welder with complete functions, excellent performance
and advanced technology. It supports AC TIG (square wave/triangular wave), AC pulse TIG, DC TIG, DC pulse
TIG, SMAW (DC), argon arc spot welding (DC/AC), etc.
It can be widely used in precise welding of carbon Steel, Stainless Steel, Aluminum etc, good performance in
thin Aluminum plate.
The unique “Dash-Arc” technology patent improve arc striking speed from 200ms to 40ms, 99.99% arc striking
success rate.
Digital control system makes TIG200PACDC more reliability and stability, it could adjust more parameter to
promote good performance within one LED display, such as adjustable pre-flow\Initial current\ Up-slope\ Peak
current\ Down-slope\ Crater current \ Post-flow\ AC frequency\ AC balance\ Pulse frequency. LED display
show real-time dynamic output current, easily know the output state of welder.
Automatically Parameters storage: parameters saved even after the welder is turned off and on again.
New electrical structure and “Dust free” air passage can effectively prevent damage to power devices and
control circuits from dust drawn in by the fan, thus greatly improving the reliability of the machine. Support
remote control function, could match foot pedal/analog TIG torch.
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2.2.3 Performance Features
Advanced IGBT inverter technology
The inverter frequency is 43KHz, which significantly reduces the loss of copper and iron, improves the
efficiency of the whole machine, and saves energy.
The main power electronics use spike withstanding IGBT, smaller volume and high reliability.
Leading digital control method
Adopt the internationally-leading MCU intelligent digital control technology, welding functions,
performance and welding procedure requirements all have been greatly improved.
New software controlled, easy to upgrade and maintain.
Excellent welding ability in TIG&MMA
Achievable high-quality MMA welding: easier arc ignition, stable welding current, little spatter, and
well-formed weld, support acid/alkaline electrodes.
The unique “Dash-Arc” technology patent improve arc striking speed from 200ms to 40ms, 99.99% arc
striking success rate. Digital constant current regulation technology ensures low noise and high stable arc
quality in the full specification.
TIG weld supports three typical TIG operation methods: two-step, four-step and spot welding, providing a
good way for users to meet special process requirements.
AC TIG can be widely used in welding of various aluminum alloys, magnesium alloys and other
non-ferrous metals, and has various waveform options.
DC TIG welding can be used for welding of various stainless steels and carbon steels.
Friendly human-computer interface and beautiful structure design
Big size LED display provide a simple, intuitive and understandable human-computer interface. The layout
of the operation panel is convenient to operation.
TIG200PACDC’s front and back panels are made of high-strength engineering plastics, to ensure the
machine works efficiently under harsh conditions such as high impact and drop.
Enjoy excellent insulation performance.
Adopt moisture-proof, dust-proof, and anti-static design and have good corrosion resistance.
Perfect automatic protection function
The machine has a perfect protection function which provides a corresponding code prompt when
providing protection.
When the ambient temperature is too high or the machine is used overloaded, the overheat protection can
prevent the high temperature from damaging the welder.
Support remote control
The machine provides gun control and foot switch options for users to select as required.
3. Technical Parameters
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3.1 Technical Parameters
SN Project Name Unit Value
1 Power voltage VAC AC110V±15% AC220V±15%
2 Input frequency Hz 50
3 Rated input current A 33@TIG 35@MMA
4 Capacity of power supply KVA 6.0@TIG 7.5@MMA
5 Output current range (TIG) A 10~120 10~200
6 Output current range (MMA) A 10~110 10~160
7 Arc force range A 0~40
8 Hot start current range A 0~80
9 No-load voltage V 60
10 Rated working voltage V 18@TIG 26.4@MMA
11 AC output frequency Hz 20~250
12 AC balance % 20~60
13 Background level A 10~200
14 Pulse frequency Hz 0.5~200 (DC) 0.5~25(AC)
15 Pulse duty factor %5~95
16 Pre-flow time S 0~5
17 Post-flow time S 0~15
18 Rising time S 0~15
19 Fall time S 0~15
20 Remote control - Yes
21 Arc start mode - HF arc starter
22 Efficiency (%) % 80
23 Duty cycle (%) % TIG: 200@25% - MMA: 160@25%
24 Power factor - 0.70
25 Type of cooling - Air cooled
26 Working temperature range °C —10~+40
27 Storage temperature range °C —25~+55
28 Protection class - IP21S
29 Insulation class - B
3.2 External (Static) Characteristic Curve
MMA electrode welding
has drop characteristic, and outputs
the external (static) characteristic
curve as shown in the right figure:
Simple TIG has drop characteristic,
and outputs the external (static)
characteristic curve as shown in the right figure:
MMA: U2=20+0.04I2（≦44V
)
TIG: U2=10+0.04I2（≦34V
)
U
0
I(
U(V)
U
0
I(A)
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4.FUNCTION AND DESCRIPTION
4.1 Panel Structure and Description
Pic1:
1. Digital plastic display panel
2.Positive output fast socket
3.TIG outlet interface
4.Gun control aviation socket
5. Negative output fast socket
6. Encoder
Pic2:
1. Input power cord
2.Cooling fan
3. TIG inlet nozzle
4.Power switch
Pic 1 Pic 2
4.2 TIG200PACDC Panel
Pic 3 Plastic display panel
Function table of plastic display panel
1Protection
indicator
Overheat indicator, indicating that the temperature of internal
components is too high and the welder displays overheat
protection.
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Alarm indicator, indicating that the welder works abnormally.
2Data display
The table header shows the specific value of the parameters;
"A" is current unit indicator. The indicator will flash when there is
current;
"S" is time unit indicator. The indicator will be on when the time
is displayed.
"%" is percentage indicator. The indicator will be on when the
percentage is displayed.
"Hz" is frequency unit indicator. The indicator will be on when the
frequency is displayed;
3TIG
Parameters
Pre-flow time indicator.When the indicator is on, it indicates the
pre-flow protection time.
Initial current indicator. When the indicator is on, it indicates
the initial current.
Up-slope time indicator. When the indicator is on, it indicates
the time when the initial current reaches the peak current.
Peak current indicator. When the indicator is on, it indicates the
welding current.
Background level indicator. When the indicator is on, it
indicates the background level if there is pulse.
Down-slope time indicator. When the indicator is on, it indicates
the time when the peak current drops to the crater current.
Crater current indicator. When the indicator is on, it indicates
the current when stopping arc.
Post-flow time indicator. When the indicator is on, it indicates
the delayed air-off time.
AC frequency indicator. When the indicator is on, it indicates
the AC frequency.
AC balance indicator. When the indicator is on, it indicates the
ratio of tungsten anode time to AC cycle.
Pre-flow time
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Duty-cycle indicator. When the indicator is on, it indicates the
ratio of peak current time to pulse period.
Pulse frequency indicator. When the indicator is on, it indicates
the pulse frequency.
Spot welding time indicator. When the indicator is on, it
indicates the spot welding time.
4Encoder
Parameter setting function.
1. Rotate encoder to select the parameter to be set.
2. After pressing the encoder, the selected parameter indicator
flashes, and rotate encoder to set the parameter.
3. After setting, press the encoder to exit settings.
5Function
Selection
1. Press the welding mode button to switch the welding mode.
2. MMA indicator. When the indicator is on, it indicates that the
machine is in MMA mode.
3. DC TIG indicator. When the indicator is on, it indicates that
the machine is in DC TIG mode.
DC output is suitable for welding carbon steel, copper and
stainless steel.
4. AC TIG indicator. When the indicator is on, it indicates that
the machine is in AC TIG mode.
AC output is suitable for welding aluminum, magnesium and
their alloys.
1. Press the operation mode key to switch the operation mode.
Spot welding indicator. When the indicator is on, it indicates that
the machine is in spot welding mode.
In spot welding mode, press the torch trigger will reach the
preset current state after the pre-flow time. Spot welding will turn
off the output after the set running time.
2. Four-step indicator. When the indicator is on, it indicates that
the machine is in four-step mode.
In four-step mode, press the torch trigger, the machine will stop
at the initial current phase after the pre-flow time; release the
torch trigger, the machine will reach the peak current phase after
the up-slope time from initial current to peak current; press the
torch trigger again, the machine will stop at the final current
phase after the down-slope time from peak current to crater
current; and then release the torch trigger, the machine will start
gas supply after the crater current extinguishes.
3. Two-step indicator. When the indicator is on, it indicates that
Spot welding time
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the machine is in two-step mode.
In two-step mode, press the torch trigger, the machine will reach
the peak current after the pre-flow time and up-slope time from
initial current to preset current; release the torch trigger, the
machine will start gas supply after the preset current drops to
crater current and then extinguishes.
1. Press pulse key to switch between pulse and no pulse.Pulse
indicator. When the indicator is on, it indicates the pulse state.
2.Generally, the low-frequency pulse frequency is 0.5-10Hz. The
interactive effect of heating and cooling can reduce deformation
by reducing the average current. Low-frequency pulse current,
coupled with proper welding speed, can form fish-scale welds.
Besides, it is convenient to use wire filling device under
low-frequency pulse to optimize the weld formation. Pulse can
oscillate the molten pool and improve the microstructure of weld.
High-frequency pulse can enhance the concentration and
stiffness of the arc. Stable arc can increase the depth of molten
pool and improve welding speed.
3. No-pulse indicator. When the indicator is on, it indicates there
is no pulse.
1. Press the waveform selection key to switch the output
waveform in AC mode.
2. Triangular wave indicator. When the indicator is on, it
indicates that triangular wave is selected.
The triangular wave reduces the heat input, so the weld can
form rapidly, reducing the welding deformation. It is suitable for
thin-plate welding.
3. Square wave indicator. When the indicator is on, it indicates
that the machine selects square wave.
Standard AC square wave can quickly switch the polarity,
enjoying high arc stability, good dynamic characteristics, and
strong ability to clean aluminum oxide film. It is suitable for a
wide range of aluminum and aluminum alloy welding.
1. Press the MMA parameter key to switch the function
selection.
2. Hot start indicator. When the indicator is on, it indicates that
hot start current of MMA is selected.
3. Arc-force current indicator. When the indicator is on, it
indicates that the arc-force current of MMA is selected.
4. Welding current indicator. When the indicator is on, it
indicates that the welding current of MMA is selected.
4.3 Functional Description
Warning! Select the welding function according to requirements. The welding
mode and parameters should be selected according to the technical
requirements of the weldment. If the welding mode or parameters are not
appropriate, there will be unstable arc, big spatter, sticking electrode, etc.
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4.3.1 TIG200PACDC Function Table
Rotate the encoder to select different welding parameters according to actual requirements. Regardless in
no-load or welding mode, the parameter selection and adjustment can be carried out without affecting the
welding. The mode is switched by rolling mode. "●" indicates that the parameter is optional, and "×" means that
the parameter is not optional.
Welding mode Torch trigger mode MMA current Hot start current Arc-force current
MMA None ● ● ●
Welding
mode
Torch
trigger
mode
Pre-flo
w
time
Initial
current
Up-sl
ope
time
Peak
current
Backgro
und
level
Down-
slope
time
Crater
curren
t
Post-fl
ow
time
Spot
welding
time
AC
freque
ncy
AC
balance
Pulse
frequency
Pulse
duty
factor
DC TIG Two-ste
p● ● ● ● × ● ● ● × × × × ×
Four-st
ep ● ● ● ● × ● ● ● × × × × ×
Spot
welding ● × × ● × × × ● ● × × × ×
DC
pulse
TIG
Two-ste
p● ● ● ● ● ● ● ● × × × ● ●
Four-st
ep ● ● ● ● ● ● ● ● × × × ● ●
Spot
welding × × × × × × × × × × × × ×
AC TIG Two-ste
p● ● ● ● × ● ● ● × ● ● × ×
Four-st
ep ● ● ● ● × ● ● ● × ● ● × ×
Spot
welding ● × × ● × × × ● ● × × × ×
AC TIG
pulse
Two-ste
p● ● ● ● ● ● ● ● × ● ● ● ●
Four-st
ep ● ● ● ● ● ● ● ● × ● ● ● ●
Spot
welding × × × × × × × × × × × × ×
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4.3.2 MMA Function
Pic 4 Welding process of manual electrode
1. Ih(hot start current) = IΔh(arc ignition current)+ Ia(welding current); the hot start time is fixed at th, which is
conducive to arc starting, and reduce the sticking tendency of welding electrode and weldment during arc
ignition.
The magnitude of hot start current is generally determined based on the type, specification, and welding
current of welding electrode. For welding rods with sound arc start performance and small diameter, generally
select small hot start current; large welding current also has little requirement for hot start current.
The hot start time is correlated with the arc starting current. The greater the hot starting current is, the shorter
the arc start time will be.
2. If(plus arc-force current) = IΔf (arc-force current)+Ia(welding current); the arc-force current shall be
determined according to electrode diameter, set current and process requirements. High arc force settings
lead to a faster metal transfer and non-sticking electrode but with some spatter. Lower arc force settings
provide a smooth arc with lower spatter and a good weld seam formation, but sometimes the arc is soft or the
welding rod can stick. In particular, heavy welding electrodes shall be welded at low currents with increased
arc force. Generally, the arc force is 2070A when welding.
3. After the short-circuit time exceeds Tp, it will enter the anti-sticking electrode current, which is small current
until the electrode is separated from the weldment.
4. U0is open circuit voltage and Uw is working voltage. When MMA is not working, the welder outputs the open
circuit voltage is U0.
4.3.3 TIG Function
1) DC TIG
Pic 5 Current change waveform of DC TIG
t0-Pre-flow time
I1-Initial current t1-Initial current period
I2-Current corresponding to the up-slope time t2-Up-slope time
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I3-Peak current t3-Peak current period
I4-Current corresponding to down-slope time t4-Down-slope time
I5-Crater current t5-Crater current period
t6-Post-flow time
●Initial current (I1): The initial current is the current after the gun torch trigger is pressed to ignite the arc,
which should be determined according to the process requirements. Large initial current is easy to ignite
the arc, but it should not be too large when welding the thin plate; otherwise, it is easy to burn through the
weldment. After the arc is ignited in some operations, the current stays at the initial current and does not
go upslope to achieve the purpose of preheating the workpiece or lighting.
●Up-slope time (t2): The up-slope time refers to the time when the current slowly rises from the initial
current to the peak current, which can be determined according to the use and process requirements.
●Peak current (I3): The parameter is set by the user according to the process requirements.
●Down-slope time (t4): Down-slope time refers to the time when the current drops from the peak current to
the crater current, which can be determined according to the use and process requirements.
●Crater current (I5): In some operating modes, the arc is not extinguished after down-slope of current and
maintains in a state of continuous arc. The operating current in this state is called the crater current, which
can avoid weld defect or large crater caused by immediate cutting off the output. The current shall be
determined according to the process requirements.
●Pre-flow time (t0): It refers to the time from pressing the torch trigger to send argon gas to arc ignition.
Generally, it should be greater than 0.5s to ensure that the argon gas has been sent to the welding gun at
normal flow when discharging arc initiation, especially when the gas pipe is long, the pre-flow time should
be increased.
●Post-flow time (t6): It refers to time from cutting off welding current to turning off gas valve in welder. Too
long time will cause waste of argon gas, but too short time will cause oxidation of weld. The time shall be
longer for AC TIG and special material welding.
2) DC Pulse TIG
Pic 6 Current change waveform of DC Pulse TIG
I1-Initial current t0-Pre-flow time
I2-Current corresponding to the up-slope time t1-Initial current period tb-Pulse base time
I3-Set pulse current t2-Up-slope time tp-Pulse peak time
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I4-Current corresponding to down-slope time t3-Peak current running period T-Pulse period
I5-Crater current t4-Down-slope time
IP-Pulse peak current t5-Crater current period
Ib-Pulse background level t6-Post-flow time
Pulse TIG includes all parameters of DC TIG, except that the parameters are set differently. The same
parameters will not be repeated here. In addition, there are 4 adjustable parameters, which are explained
separately in conjunction with the figure:
●Peak current (Ip): It is adjusted according to the process requirements.
●Background level (Ib): It is adjusted according to the process requirements.
●Pulse frequency (1/T): T=tp+tb, adjusted according to the process requirements.
●Duty cycle (100%*tp/T): Duty cycle is the percentage of peak current duration in the pulse cycle, which is
adjusted according to the process requirements.
3) AC TIG
Pic 7 Current change waveform of AC TIG
I1-Initial current t2-Up-slope time
I3-Set AC peak current t4-Down-slope time
I5-Crater current tc-Clearing current time
T-AC period
AC TIG supports square wave, triangular wave and sine wave, but the output waveforms are different.
Except for the same pre-flow time and post-flow time for AC TIG and DC TIG, other parameters are explained
separately in conjunction with the figure:
● Initial current (I1), peak current (I3) and crater current (I5): The set values of these three parameters are
approximately equal to the effective values of the actual welding current, which can be adjusted according to
the process requirements.
● AC frequency (1/T): It can be adjusted according to the process requirements.
● Ac balance (100%*tc/T): Generally, the current of positive tungsten electrode in AC welding is called the
cleaning current. Its main function is to break the dense oxide layer of the workpiece, and the AC balance
represents the proportion of the cleaning current. The parameter is generally 10-40%. When the value is small,
the arc is concentrated, the fusion depth is large, and the fusion width is small, vice versa.
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4) AC Pulse TIG
Pic 8 Current change waveform of AC pulse TIG
tc-Clearing current time Tc-AC period
tp-Pulse peak time Tp-Pulse period
t2-Up-slope time t4-Down-slope time
Ip-Peak current Ib-Background level
●AC frequency (1/Tc): It is adjusted according to the process requirement.
●Pulse frequency (1/Tp): It is adjusted according to the process requirement.
●Duty cycle (100%*tp/Tp): It is adjusted according to the process requirement.
●AC balance (100%*tc/Tc): It is adjusted according to the process requirement.
●AC pulse TIG supports square wave, triangular wave and sine wave, but the output waveforms are
different. AC pulse TIG is basically same as the AC square wave TIG, but its welding current is controlled
by a low-frequency pulse. Therefore, the welding current changes with pulse value to form peak and
background current, and the set peak and background current are the peak value (average value) and
background value (average value) of low-frequency pulse.
●In AC pulse mode, the pulse frequency range is affected by AC frequency and frequency division factor.
The minimum frequency division factor is 10, and the maximum value is 2 times the AC frequency.
Therefore, the pulse frequency range is 0.5Hz to AC frequency/10Hz, and the user can choose any
frequency in the range. When the AC frequency changes, the AC frequency/actual frequency of the
current pulse is equal to the frequency division factor and updated. When the frequency division factor is
determined, the current AC frequency/frequency division factor is equal to the actual frequency of the
current pulse and saved, so the pulse frequency does not change. After setting the AC frequency and
pulse frequency, the frequency division factor is determined, which is equal to AC frequency/pulse
frequency. For example: When AC frequency is set to 100Hz, the pulse frequency range is 0.5-10Hz. If the
AC frequency is set to 100Hz and the pulse frequency is set to 5Hz for the first time, the current frequency
division factor is 100/5=20. When the AC frequency is changed to 70Hz, the frequency division factor is
70/5=14, that is, the frequency division factor is variable, but the pulse frequency is constant. In other
words, the AC frequency affects the pulse frequency range. But when the pulse frequency is
determined, it will no longer be affected by the AC frequency.
5) Welding Mode Description of TIG Welding Gun
TIG operation mode has a special convention, which specifies the mode or method of controlling the
welding current change by different operations of torch trigger during TIG (DC, pulse, AC TIG, mixed TIG)
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welding. The introduction of TIG operation strengthens the application of torch trigger remote control function,
so users can obtain a practical welder remote control without increasing investment.
TIG mode should be determined according to the process requirements and users' operation habit. The
symbols in the diagram are described as follows:
Mode
No. Agreed Operation Torch trigger operation and typical DC TIG current curve
1
Spot welding mode:
1. Press the torch trigger to start the arc to the set
value
2. The arc extinguishes after the spot welding finishes
the set running time
2
"Two-step" mode:
1. Press the torch trigger to start the arc slowly to the
set peak value
2. Release the torch trigger to slowly drop to the
quenching of arc
3. If the gun switch is pressed again before quenching
of arc, it will slowly rise to the peak value
3
"Four-step" mode:
1. Press the torch trigger to start the arc to the initial
value
2. Release the torch trigger to slowly rise to the peak
value
3. Press the torch trigger to slowly drop to the
stopping arc
4. Release the torch trigger to extinguish the arc
Operation legend of commonly used torch trigger
Press the torch trigger Release the torch trigger
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6) TIG Welding Gun Description
Long handle
ca
p
Tungsten
needle
Connecting
needle
Gun head
Insulating cap
of
g
un head
Tungsten clamp
Ceramic nozzle
Standard welding gun
parameters
Gun type: gas-electric
integrated
Maximum current: 200A
Rated current: 200A
Type of cooling: Air cooled
Gas connector: M16.5
5.INSTALLATION AND CONNECTION
Warning! Electric shock may cause death! After power failure, there is still a high
voltage on the equipment, do not touch the live parts on the equipment.
Warning! The power supply connection of the machine must be operated by
experienced and qualified electricians.
Warning! Do not ground the live wire (blue, brown, black) of the power cord, and do
not connect the earth lead (yellow-green) to the live wire.
Warning! Incorrect input voltage may damage the equipment.
5.1 Connection of Power Cord
1) This machine is equipped with a power voltage compensation system. Therefore, it can be used in the
range of rated voltage ±15%.
2) Connect the power source to the suitable power distribution box according to the voltage grade of welder.
Meanwhile, ensure that the supply voltage deviation is within the allowable range.
3) When extension cord is required, it is recommended to use cables with larger cross-sectional area to
Pic 9 Accessories
Assemble the welding gun
according to the figure
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reduce the voltage drop. An excessively long cable may affect arc starting performance and normal operation
of system. Therefore, please use the recommended cable length.
4) YZ 3X2.5mm² 300/500V power cord is recommended for TIG200PACDC.
Ensure that the switch of the power distribution box is turned off when connecting the input power cord.
Connect the input power cord of the welder to the output of the power distribution box reliably.
5.2 Connection of power distribution box
Wiring diagram of
single-phase power
distribution box
1. Single-phase AC power input: 110V/220V;
2. Power switch of power distribution box;
3. Earth terminal strip;
4. Welder power cable or socket adapter cable: 200A machine shall use
cable of 3*2.5mm2 or above;
5. Yellow-green earth lead (connect to the ground);
6. Fuse: 200A machine shall use fuse of no less than 60A.
Please connect the cables according to the way shown or other correct ways
with the main power switch being turned off.
Note: Do not operate with electricity.
The wiring of the machine can only be carried out by professional
electricians.
Please distinguish the input voltage 380V and 220V for single-phase
machine.
Do not connect two welders to the same distribution box.
If the enclosure is grounded, line 5 is not grounded.
5.3 Welder Installation
Warning! All connections shall be made with the power supply being turned off. The
correct steps are: first, ground the welder reliably and ensure correct wiring without
missing correction; and then connect the input power cable.
1)MMA Installation
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