ASKAYNAK 201 TIG PFC User manual

33
2 years limited spare part warranty
(Clamps and cables excluded)
Welding method and
specications
TIG Welding
MMA Welding
1
Phase
2.5 - 4.0 mm220V - 1Ph
TIG Welding Machine
Arc Welding Machine
USER MANUAL
USER
MANUAL

34
“AT” UYGUNLUK BEYANI
“EU” DECLARATION OF CONFORMITY
Kaynak Tekniği Sanayi ve Ticaret A.Ş.
İmalatçı / Manufacturer
Teknik Hizmetler Müdürü - Technical Sevices Manager
Sertaç ÖZEN
Kocaeli, TURKEY
Kaynak Tekniği Sanayi ve Ticaret A.Ş.
TOSB Otomotiv Yan Sanayi İhtisas Organize Sanayi Bölgesi
2. Cadde, No: 5, Şekerpınar 41420 Çayırova, Kocaeli - TURKEY
CE sertifikası yılında eklenmiştir.
CE mark was first affixed in .
Ürün / Product
Marka - Model / Brand - Model
Yukarıda tanımlanan beyanın nesnesi, ilgili uyumlaştırılmış AB mevzuatı ile uyumludur.
The object of the declaration described above, is in conformity with the relevant union
harmonisation legislation.
Direktifler / Directives
Uyumlaştırılmış Standartlar / Harmonised Standards
Bu uygunluk beyanı yalnızca imalatçının sorumluluğu altında düzenlenir.
This declaration of conformity is issued under the sole responsability of the manufacturer.
2013
2013
TS EN 60974-1:2013, TS EN 60974-10:2014
TIG Kaynak Makinesi - (GTA) TIG Welding Machine
®
Askaynak Inverter 201-TIG PFC
03.10.2016
2014/35/EU, 2014/30/EU
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MANUAL

35
Contents
MANUFACTURER
Kaynak Tekniği Sanayi ve Ticaret A.Ş.
TOSB Otomotiv Yan Sanayi İhtisas Organize Sanayi Bölgesi
2. Cadde, No: 5, Şekerpınar 41420 Çayırova, KOCAELİ - TURKEY
Tel: [phone] Fax: [phone]
www.askaynak.com.tr
Manufactured in People’s Republic of China by
KAYNAK TEKNİĞİ SANAYİ ve TİCARET A.Ş.
Safety in Welding ................................................................ 36 - 41
General Characteristics ............................................................. 42
Installation and Operator Instructions........................................ 43
Preparations for Work ........................................................ 44 - 45
Maintenance and Troubleshooting .................................... 46 - 49
Electromagnetic Compliance ............................................. 50 - 52
Efcient Use in Terms of Energy Consumption ........................ 52
Unpacking .................................................................................. 52
Transportation and Storage Conditions ................................... 52
De-commissioning the Welding Machine ..................................52
Warning Label and Technical Specication Table .................... 53
Spare Parts ......................................................................... 54 - 55
Accessories Delivered with the Machine .................................. 54
Electrical Connection diagram................................................... 56
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36
Safety in Welding - 1
This machine has been designed for TIG welding and MMA welding works with coated
electrodes.
Can not be used for any other purpose.
This machine must absolutely be used by authorized personnel, who is trained welder.
Please make sure that all the operations, maintenance repair procedures are carried out by
authorized persons. Before operating the machine read and understand this user manual. Not
complying with the instructions given in the user manual may result in serious injuries, loss of
life and damages in the machine. Please read the cautions stated with below symbols. Kaynak
Teknigi Sanayi ve Ticaret A.S. is not responsible for damages caused by improper installation,
improper storage or abnormal operation.
WARNING: This symbol means that the instructions provided in the user manual
must absolutely be obeyed in order to prevent serious injuries, loss of life and
severe damage to the machine. Please protect yourself and those around you.
READ AND UNDERSTAND THE INSTRUCTIONS CAREFULLY: Read and
understand this manual before operating this equipment. Not complying with the
instructions given in the user manual may result in serious injuries, loss of life and
damages in the machine.
Welding works should not be performed in a careless, pre-occupied, tied or
sleepless state.
Arc welding is a safe application only when adequate measures against any
potential hazards are taken. If those measures are missed or ignored, it might result
in serious or probably fatal electrical shock, exposure to excessive amounts of
smoke and gases, arc radiation, re or explosion etc. hazards.
Note: For detailed information on safety in welding, please read the ANSI Z49.1
standard.
Protective Equipments:
The welding operators should wear clothing for protection against risk of burning.
Welding burns caused by the contact of the splashing sparks with the skin are one
of the most common risks encountered.
Skin burns is one of the most common risks encountered caused by welding sparks.
Woolen clothing should be preferred due to the resistance against re. Because the
synthetic clothing melts when exposed to heat, they must not be worn.
The protective clothing should be kept away from grease and oil. Such materials
may increase the ammability.
The shirt and pant sleeves should not be folded. Because the sparks of molten
metal may fall in to the folds. The pants should be kept over the work boots and not
inserted in. Otherwise the sparks of molten metal may fall in to the boots.
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Safety in Welding - 2
The other protective materials to be used in hazardous circumstances are as
follows:
• Fire resistant clothing,
• Leg Dusters,
• Aprons,
• Leather arm covers and shoulder cloaks,
• A cap worn under the welding mask.
Gloves made of re-resistant materials such as leather etc. must to be worn without
fail, in order to protect the hands against burns, cuts and scratches. Additionally,
the gloves made of re-resistant materials such as leather etc. have to be robust and
dry to ensure protection against electrical shock.
Noise:
Ear protection should be used for protecting the ears against sparks and molten
metal as well as loss of hearing caused by the noise of the arc welder. When the
noise level in the work environment reaches a disturbing level for the ears and
causes head ache, a hearing problem may be experienced. Ear protection must be
used immediately in such cases.
The loss of hearing may not be evident until a test is conducted, but treatment after
that point may also be too late.
Importance and Cleanliness of Working Environment:
The order and cleanliness of the work environment is equally important as
maintaining the welding machine.
The degree of hazard increases along with the number of the employees. Despite
reading the warning notes about the machine and taking the measures required,
someone tripping on a live cable in the work environment could still create the risk
of electric shock, contact with hot metals or falling down.
All the equipment, cables, hoses and gas cylinders must be kept away from the
oors, corridors and stairs etc. with heavy trafc. The environment must be kept
orderly and neat and the work environment must be cleaned after the welding works
are nished. This will improve the work efciency along with work safety. Moreover,
somebody in the work environment my accidentally step in to the welding bath;
therefore barriers should be placed around the area during the welding works.
GAS CYLINDER MAY EXPLODE: Only the gas cylinders specically manufactured
for welding purposes containing compressed gas should be used. Make sure that
correct regulators for the gas and cylinder pressure used are installed properly.
The cylinders must be kept in an upright position and attached somewhere with
the safety chain. Do not displace the cylinders without installing the safety caps.
Make sure that the electrodes, electrode handles, work clamps and all types of
parts carrying voltage do not come in touch with the cylinders. Store the cylinders
away from risky places, where heat and sparks are generated.
WELDED MATERIAL MAY BURN: Intense heat may be released while welding.
Contact with the hot surfaces and materials may cause serious burns. Gloves must
be used without fail while touching or carrying such materials.
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Safety in Welding - 3
ELECTRIC SHOCK CAN KILL: Electrical shock is the most serious risk that the
welding operator might face frequently. Contact with the live electrical materials
can lead to injuries, death, electrical shocks or sudden falls by reex. Do not touch
the electrode, grounding wire or work piece under voltage attached to the machine.
Insulate yourself against contact with the electrode, grounding wire or work piece.
Do not touch the plug’s metal pins after disconnection from the power. It contains
risk of electrical shock.
The electrical shock risk associated with the welding machine is divided in to two categories:
• Primary voltage shock (e.g. 230 - 460 V)
• Secondary voltage shock (e.g. 20 - 100 V DC)
The primary electrical shock is much more dangerous, since the voltage is higher
than the welding voltage. Primary electrical shock may happened by contact with
a live part in the machine while the body is grounded when there is power on
the machine. Please do not forget that the ON/OFF switch on the machine may
not cut off the electricity connected to the machine itself. In order to get a safe
disconnection from mains supply; switch off the fuse and disconnect the input
cables from the connection terminals.
Never remove the side covers of the machine and in case of a failure, have an
authorized technician check and repair the machine.
Ground the machine and work piece without fail.
Do not use un-insulated cables and electrode holders, replace them with new ones.
Never immerse the electrodes in water for cooling.
Do not touch the electrode cables connected to two separate welding machines;
the voltage carried may be equal to the sum of the open circuit voltage of both
machines.
Please use a safety harness without fail while working on high places to prevent
falling because of an electrical shock.
FUMES AND GASES MAY BE DANGEROUS: The welding works may cause the
emission of smoke and gas hazardous for human health. In order to protect the user
against this hazard, the smoke or gases have to be removed by providing adequate
ventilation.
Generally short-term effects such as burns in the face and skin, dizziness, nausea
and fewer etc. may be experienced during the welding operations depending on the
exposure length to the smoke and amount of smoke present. Longer exposure to
smoke may lead to the accumulation of iron in the lungs and may cause functional
disorders. Bronchitis and lung brosis are the most frequently seen effects.
Some electrodes may contain certain alloys that make special ventilation
compulsory. The labels on the products that require special ventilation should not
be ignored and the “Material Safety Data Sheet (MSDS)” must be read carefully.
Gas masks may have to be used while welding with such materials.
Keeping the head out of the smoke cloud is one of the easiest ways of protection
against hazardous gases and smoke.
Do not breathe the smoke and gases and use mechanical air circulation and
ventilation apparatus; and if the ventilation is till insufcient, gas masks should be
used.
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Safety in Welding - 4
THE WELDING ARC MAY CAUSE BURNS: During the welding operations,
appropriate masks, lters and protective lenses should be used for protecting the
eyes against the light emitted by the welding arc and the ying particles. The skin
should be protected using re-resistant clothing. The people in the vicinity should
be protected by panels made of reproof materials, they should not look at the
welding arc directly and must be warned against effects of the arc light.
Even short periods of exposure to the UV rays may cause eye burns called “welding
dazzle”. The person affected may not be aware of the “welding dazzle” for hours
after exposure, which can become extremely disturbing in the end and even cause
temporary loss of sight. Normally the eye dazzle is a temporary condition, but long
term exposure of the eyes to the UV rays may result in permanent damages in the
eyes. As protective measures besides not looking at the welding arc, a protective
welding mask with appropriate ltering lens should be used.
The following table may be used for selecting the proper lter against arc welding
with shielded electrodes.
From ANSI Z49.1-2005
WELDING SPLASHES MAY CAUSE FIRE OR EXPLOSION: Keep the ammable
materials away from the welding areas and maintain a re extinguisher at an easily
accessible place. The splashes and hot materials ejected by arc welding may y
around easily even from the narrowest opening. Do not perform any welding on
any barrel, container or material until making sure that the measures required for
removing the ammable and noxious gases from the environment are taken. Never
operate the machine in places, where ammable gases, vapors or uids may be
present.
Keep the possibility of re risk in mind as arc welding may produce very high
temperatures.
The welding arc temperature may reach 5000°C, but heat alone is not a reason for re
generally. The re risk is created by the sparks and molten metal particles splashing
around. Such metal splashes may reach ten meters of distance. Therefore, keep the
easily ammable materials away from the welding environment. Furthermore, make
sure that your work piece does not contact any material that might ame as it heats
up. The materials that might catch re when heated are divided in to three groups
as uids (gasoline, oil, paint, thinner, etc.), solids (wood, cardboard, paper etc.) and
gases (acetylene, hydrogen etc.)
Welding
Method
Electrode
Diameter
(mm)
Current Range
(Amper)
Protective
Filter
(lower limit)
Protective
Filter
(recommended)
Covered
Electrode
Arc
welding
< 2.4
2.5 - 4.0
4.0 - 6.4
> 6.4
< 60
60 - 160
160 - 250
250 – 550
7
8
10
11
-
10
12
14
Protective Filter Selection Table
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Safety in Welding - 5
Watch the welding environment. If there is any systems using gasoline or hydraulic
oil present and if the welding environment cannot be moved elsewhere, place a re-
resistant barrier in between. If you are welding at a high place or on a ladder, make
sure that no explosive or ammable materials are stored below. Moreover do not
forget the possibility of slag and sparks falling on the people around.
Special measures have to be taken while welding in a dusty environment. The dust
particles may catch re and cause a sudden re or explosion. If you have no idea
about the ammability or volatility of the ambient dust, do not start the welding or
cutting works before obtaining the approval of an expert or authorized person.
Before starting welding, check if the welding piece has a ammable coating that could
catch re when heated.
When you take a pause during the welding works, make sure that the electrode handle
does not touch the ground or work piece.
If you are carrying out welding works within ten meters from ammable materials,
keep an observer with you. The observer should watch where the sparks and splashes
are falling around and should have easy access to the re extinguishers if necessary.
Once the welding work is nished, check the welding area for any trace of smoke for
about half an hour with the observer.
The rst rule during a welding-related accident is not to panic just like any other
emergency situation. Depending on the magnitude of the re, activate the re alarm,
notify the re department, turn off the welding machine and leave the area as fast as
possible through the re exits.
ELECTRICAL EQUIPMENT: Before starting to work on the machine, cut the power
supply by means of the switch located in the fuse box. Make the electrical connections
in conformity with the rules currently in force.
GROUNDING: For your safety and trouble-free operation of the machine, it should be
connected to a power outlet with proper power supply and grounding cables.
ELECTRICAL EQUIPMENT: Check the condition of the electrical cables such as
supply and welding cables regularly. In case of any irregular condition, replace the
defective parts immediately. In order to prevent any arc ashing and re risks, do not
leave the electrode clamp (handle) on the welding table or any surface in contact with
the grounding clamp.
ELECTRIC and MAGNETIC FIELDS MAY BE HAZARDOUS TO THE HUMAN
HEALTH: The current passing through the conductors creates an electromagnetic
eld. The electromagnetic eld thus formed may have an effect on the pace-maker
etc. equipment. The welders, who use pace-makers, should consult with a physical
therapist before working with the machine. The electrical and magnetic elds could
also cause other unknown health—related problems.
MOVING PARTS MAY CRUSH YOUR HANDS: Do not place your hands on or near
the fan and the moving parts of the machine.
COMPLIANCE WITH CE NORMS: This machine has been manufactured in
compliance with the European Instructions.
SAFE OPERATION: This machine is suitable for carrying out welding works in the
places with high probability of electrical shock.
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41
Safety in Welding - 6
EXTRA SAFETY MEASURES:
Applying the safety measures under certain circumstances may become difcult; nonetheless, the
rules set forth should be abided with. Keep your gloves dry and if that becomes impossible, keep a
spare pair with you.
Stand on a non-conducting material such as plywood, plastic mat etc. Insulate your body from the
welding piece.
If you have to carry out welding works with high possibility of electrical shock such as in a moist
environment, in wet clothing, grids or scaffolding on your knees or leaning out or, where contact with
the ground is prevented, prefer to use the machine types specied below:
• Semi-automatic xed DC voltage machines,
• DC manual arc welding machines,
• Reduced voltage controlled AC welding machines.
The condition of the electrode handle and cables is very important. The plastic or ber insulator
on the handle prevents contact with live parts. Always check the condition of the handle before
operating the welding machine. Replace the old and worn out handles and do not try to repair.
Conduct the same checks on the cables as well and since replacing the cable may be costly, repair
them with a high-resistance heat shrink etc. Check the insulation at all times before operating the
machine.
If you feel an electrical shock, remember that this is a warning. In such a case, before continuing with
the work, check your working habits and work environment in terms of electrical shock risks. In case
of any abnormal situation, do not continue with welding without taking the measures required. If you
cannot identify the source of the problem, have it checked by an authorized specialist.
PRECAUTIONS FOR THE OTHER PERSONS IN THE WORK AREA:
The cleanliness and order of the work area are very important for you and the other people in the
area both. Other welders or people walking around may step into your welding bath accidentally or
trip on the cables and fall inviting the risk of an electrical shock to you and the other people around.
Furthermore, the welding splashes may cause risk of burns to the other people in the vicinity.
Segregating the welding site with a re-proof barrier could reduce the above risks.
Warn other people in the work area about using work safety equipment. In particular if they have to
work in a welding site, warn them about wearing re-resistant work outts, work goggles, insulated
shoes and gloves etc. remove the people, who do not heed your warnings, from the work site.
If you are welding on a high place, use warning signs showing the risk of welding splashes falling
down on the people below.
Electromagnetic elds may be dangerous for the pace-makers.
Warn the people in the vicinity, regardless of welders or otherwise, regarding the above and post
warning signs. Tell such people that they should consult a doctor before entering the welding area.
The welding sites pose high risk of electrical shocks. Other people may face the risk of an electrical
shock by passing on a cable while working around. Do not use un-insulated welding cables and
pass the cables through insulated, plastic ducts where possible.
INFORMATION ABOUT THE RESIDUAL RISKS :
Askaynak Inverter 201-TIG PFC welding machine has been designed and manufactured in
conformity with the safety rules setout by the TS EN 60974-1 standard. All the measures required for
eliminating the safety risks involved have been taken and the measures to be taken by the users and
the rules to be observed have been indicated in the user manual. Eliminating the said risks is not
possible if due care is not exercised and the safety measures prescribed are not taken. Such risks
may start from slight injuries, but the risk of explosion may become fatal for multiple people as well.
Ensuring the safety of the welding area is the responsibility of the user and if the said measures are
not taken properly, the work must be stopped and the authorized persons must be notied
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42
General Characteristics
The ASKAYNAK Inverter 201-TIG PFC is an inverter type TIG-MMA welding machine manufactured
using the latest PFC (Power Factor Correction) technology. Starting from the 1980s, the welding
machines in the market have been sized down thanks to the inverter arc welding machines appearing
in the market while increasing the efciency. However, many semi-conductor devices (i.e. diodes,
transistors, IGBTs etc.) used in such machines chop the mains voltage for use, hence distorting the
wave-form of the mains supply that result in harmonic waves. The total current drawn by the machine
from the mains (RMS) includes all such harmonic components. With the PFC technology, active
PWM technique is used for ltering out the harmonic components drawn from the mains although
they are not used by the machine.
The Askaynak Inverter 201-TIG PFC welding machine draws maximum 33A of current from the
mains instead of 44A, thus increasing the energy efciency. With this property, the Askaynak
Inverter 201-TIG PFC reduces the amount of energy used, hence the operating costs, for the
consumers while reducing the pollution in the transmission and distribution lines, contributing to the
sustainable development through the reduction of power losses.
The Askaynak Inverter 201-TIG PFC is a shielded electrode and TIG welding machines operates in
the CC characteristic and features igniting with HF (high frequency), down slope, up slope, hot start
and short circuit protection properties:
Operating principle: The 220 VAC mains power is converted in to 380 VDC by the PFC. The half
bridge inverter structure converts the DC voltage ib to AC voltage again, which is reduced by a
transformer. The reduced voltage rectied again, ltered and sent to the output.
Input
Power Factor : 0.99
Input Voltage
220 V ± % 10 / 1 Phase
Height
275 mm
Width
155 mm
Length
480 mm Weight
13.3 kg
Duty Cycle
(10 minutes period)
% 20
% 60
% 100
Frequency
50/60 Hertz (Hz)
Output Voltage
(Volt)
28.0 V (MMA) 18.0 V (TIG)
24.6 V (MMA) 14.6 V (TIG)
23.2 V (MMA) 13.2 V (TIG)
Power Consumption
7.0 kW (20% operation cycle)
Output Current
(Amper)
200 A (MMA / TIG)
115 A (MMA / TIG)
80 A (MMA / TIG)
Welding Current Range
10 - 200 A
Maximum Open Circuit Voltage
72 V (DC)
Output Range
Welding Current Output Rates
Supply Cable: 3 x 2.5 mm2
Operation Temperature between –10°C and +40°C
Physical Dimensions
Insulation Class : H
Pollution degree : 3
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43
Installation and Operator Instructions
Location and ambient conditions :
(Read this section well before installing and operating the machine)
In order to ensure a long and reliable service life of this machine, the simple preventive measures
indicated below should be observed:
1- Do not place or operate the machine on a surface with more than 15°’ of incline.
2- Machine has to be operated in a place with fresh air ow and any obstructions that could prevent
air ow should be eliminated. Do not cover the machine with paper or cloth while operating.
3- Dust and dirt may enter the machine. It must be minimized dust to enter the machine. Do not
operate the machine in very dusty places or in an environment with water, paint, oil particles or
corrosive gases.
4- This machine has a protection class of IP21S. Please keep the machine as dry as possible and
do not place or puddles of water.
5- The welding machine should be used in well lighted place and not used in the dark. Furthermore,
it is designed for indoor usage and is not suitable for use under direct sunlight and rain or snow.
The welding machine mustn’t be used for pipe thawing purposes.
6- Place the machine away from the radio-controlled devices. The normal operation of the machine
may affect the operation of the other machines of this type in the vicinity adversely, which may
lead to injuries or equipment failure. Please read the section “Electromagnetic Compliance” in
this manual.
7- Do not operate this machine in temperatures below -10°C and above +40° C with a relative
humidity of above 70 %.
8- Do not allow unauthorized people to open the work covers of the machine and carry out any
work inside, which might lead to mortal danger. Any contrary behavior shall be considered as
having accepted the possible consequences in advance.
9- This is a dropping characteristic welding machine designed for tig welding and welding with
the 2.50 and 4.00 mm diameter welding electrodes with rutile and basic coating used for light
welding operations.
10- Not recommended for use with generators without output regulation, which could cause
operating disorders and malfunctions.
Duty Cycle and Overheating :
The duty cycle of the machine is the percentage rate of welding capability of the machine at the
specied welding current to 10 continuous minutes without resulting in overheating or interrupting
the work.
The machine is protected against overheating by the basic protection provided. When this protection
trips, the warning lamp on the panel lights up. When the machine is cooled to the safe working
temperature, the warning lamp goes off and welding is resumed.
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44
Preparation for Work - 1
Mains Cable Connection / Controls and Operational Characteristics :
Check the mains voltage, phases and frequency before operating the machine. The mains voltage to
be used is declared in the section “Technical Characteristics” of this manual and on the name-plate
of the machine.
Make sure that the cables connecting the machine to the mains are properly grounded and power
supply is sufcient for the normal operation of the machine. The welding machine must only
connected to a 16 A slow-blow fuse protected line with the plug provided.
1- This machine has been designed to operate on 1 phase, 220 V (AC) and 50-60 Hz mains
voltage with insulation based on the line-neutral voltage values. It should be used only with
the single phase, 3 wire systems with earthed neutral.
2- The machine must not be connected to the mains and turned on without a proper protective
grounding approved by an authorized electrician. The electrical leaks may be fatal for the
human health.
3- Do not connect to a 3-phase mains system. Any damages caused to the machine by incorrect
connection to the mains are not covered by the warranty.
FRONT PANEL REAR PANEL
211
3
12
13
7
8
10
5
4
6
9
1
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45
Preparation for Work - 2
Front and Rear Panel components :
1- Overload/temperature Warning led : These leds light up when the machine cannot provide
output current sue to overheating. This situation is encountered when the ambient temperature
rises above 40°C and the duty cycle (operating efciency) of the machine is exceeded. Leave
the machine on and wait until it cools off. The machine will be ready for operation again when
the lamp goes off.
2- Power indication Led : Shows the On/Off state of the machine.
3- Welding Current Control Knob : Adjusts the output current of the machine (welding amp. cong).
4- TIG torch gas connection socket
5- Negative (–) Welding Cable Connection : Welding current negative (–) output connection.
6- LIFT TIG-HF TIG (High Frequency TIG) selector switch
7- 2/4 trigger TIG and Coated electrode selector switch
8- ARc force (Coated electrode) and down slope (TIG) adjustment button
9- TIG torch trigger connection socket
10- Positive (+) Welding Cable Connection : Welding current positive (+) output connection
11- On/Off switch : Controls the main power input to the machine.
12- Gas hose connection socket
13- Input cable : This machine is provided with a plugged input cord. Connect it to the mains.
TIG (GTAW) Welding :
The following actions need to be done before starting the welding procedures:
1- The TIG welding is generally carried out using the DC (–) pole. Connect the torch cable to the (–)
output of the machine (5) and the grounding clamp to the (+) output (10). Turn the connecter 1/4
turn clockwise after inserting in the plug with the guide pin on top. Attach the TIG torch gas hose
to the TIG torch gas hose socket (4). Make the connection between the gas cylinder regulator and
the gas hose connection socket (12). Connect the TIG torch trigger connector to the TIG torch
trigger plug (9) on the front panel of the machine.
2- Connect the work clamp to a clean place on the work piece free of paint or rust with the jaws in
complete contact.
3- Insert the mains cable to a suitable outlet.
4- Perform the following checks before starting the welding procedure:
a- Make sure that the welding machine is grounded securely.
b- Make sure that all contact surfaces, especially the contact between the clamp at the end of the
chassis cable and the work piece, are well secured.
c- Check that the welding cables are attached correctly.
d- The particles and sparks splashing around while Welding may cause a re. Therefore, make
sure that no ammable materials are present in the welding area.
5- Turn on the On/Off switch (11).
6- Select the desired welding mode and trigger mode (6&7). The welding machine can operate in
the 2 trigger and 4 trigger TIG modes. In the TIG welding mode, Lift-TIG and High Frequency TIG
operations are available. In the Lift-TIG mode, a low-current short circuit is made by touching the
TIG torch to the work piece, then the TIG arc is formed while lifting the torch. In the HF mode, the
welding machine is ready for high frequency welding, hence the arc forms without touching the
TIG torch to the work piece.
8- Start welding observing the welding rules
Note: This welding machine may also be used for welding works with 2.5 and 4.0 mm diameter
welding electrodes with rutile and basic coating.
Current range for rutile and basic electrodes:
Ø 2.5 mm : 70 - 100 A Ø 3.2 mm : 100 - 140 A Ø 4.0 mm : 140 - 200 A
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Maintenance and Troubleshooting - 1
The periodic maintenance procedures have to be carried out regularly to ensure the efcient and
safe operation of the welding machine. The user needs to understand the maintenance procedures,
two know the welding machine well, to be able to carry out the safety practices alone and take care
to prolong the service life of the machine by minimizing the error rates. Detailed information about
periodic maintenance has been given in the table below.
Warning : The welding machine must absolutely be disconnected from the mains supply during
the maintenance works. The maintenance works must be carried out by authorized specialists.
DAILY MAINTENANCE
Make sure that the welding current adjustment knob of the front panel of the machine
and the On/Off switch on the rear panel are in place and good working order. If current
adjustment knob is not installed properly or if the on/off switch is loose and not working
freely, contact to an authorized service shop.
After turning on, check the machine for vibrations, whistling sounds and smoke etc. In case
of any problem, try to nd the source; if the problem is stemming from the environment,
eliminate it and if the problem is stemming from the machine, do not intervene and contact
to an authorized service after disconnecting from the mains.
Check the proper operation of the thermal protection of the machine. To check this:
Load the machine at 200 A at %20 duty cycle. If the thermal protection does not activate
within approximately 4-5 minutes at this current value, something must be wrong with the
thermal protection. Contact the service in such a case. Otherwise, overheating may lead
to a risk of re.
Check the short circuit protection. To check this: Touch the electrode to the work piece
and measure the current passing through the welding cable with clampmeter. The current
should drop to 5 A in a short time. If not contact your service.
Make sure that the welding current is according to the setting value. In case of difference,
re-adjust as this may affect the normal welding operation.
Make sure that the cooling fan is not faulty and rotates normally. If the fan does not cut in
when the machine gets really hot, check if the fan impeller is stuck. If the fan is defective,
contact your service.
Check is the welding connections are loose and overheating. Incase of overheating or
looseness, tighten them or contact to your service.
Check the current cable for damages. If damaged, wrap the damaged section with an
appropriate insulator or replace the cable.
MONTHLY MAINTENANCE
Clean the dust accumulated in the machine in time using a dry air compressor. Be careful
about the pressure value of the air against damaging the smaller components.
Check the screws on the machine. Re-tighten any loose screws. Re-install any missing
screws and replace any rusty screws.
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Maintenance and Troubleshooting - 2
QUARTERLY MAINTENANCE
Check the current delivered by the machine is equal to the value adjusted with the
potentiometer. Measure the actual current value with a clamp-type ammeter.
YEARLY MAINTENANCE
Contact to authorized service for yearly maintenance. Grounding continuity and insulations
test must be applied during yearly maintenance. Check if this tests has been done from the
yearly maintenance report.
1- The welding machine is checked against any defects before leaving the factory. Therefore, do not
allow unauthorized persons to tamper with the machine.
2- The repair works must be carried out only by the “Authorized
Technical Services” allowed by Kaynak Tekniği Sanayi and Ticaret A.Ş.
3- Watch out for the air pressure while cleaning in order to protect the smaller components. Never direct
water in to the machine for cleaning.
4- The welding machine should not be cleaned with volatile and synthetic cleaners. Use a moist and
soapy piece of cloth for cleaning the exterior.
5- The maintenance works must be carried out with care. Kinking or wrong connection of a cable may be
very dangerous for the user.
6- Ingress of water or steam should not be allowed in to the welding machine. If the machine might be
affected by humidity, the interior must be dried and the insulation re-checked.
7- The welding machine should be protected against tossing around while lifting and protected against
impacts.
8- If the welding machine is to be stored for a long time, place it in the original box and store in a dry place.
Replace the switch. Contact to the service
if necessary.
Contact to the service.
On/off switch defective.
Input lter and/or power
board defective.
Replace as necessaryMains input cable defective.
PROBLEM POSSIBLE REASON SOLUTION
The Machine does not work,
No Output, Fan does not
work.
Check the voltage of the phases entering
the machine. Reconnect the phases.
No mains power.
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Maintenance and Troubleshooting - 3
PROBLEM POSSIBLE REASON SOLUTION
Arc not stable,
welding cannot be done
properly
Improper voltage value.
Not seated on a sound and
at surface.
Problem in the cooling fan.
Machine defective
Not connected to the
machine outputs.
Connections loose or not
good.
Welding cable damaged.
Work piece dirty, oily or
excessively dusty.
Work cable not connected
or loose.
Machine vibrates.
Strange sounds and smell
from the machine
No voltage output at no load
No welding current output.
Welding arc starts with
difculty or the electrode
sticks to the work piece.
Change the poles correctly and tighten
the connections.
Is the mains voltage 220 V?
Extension cable of improper length
and size used.
Check and correct as necessary.
Place the machine on a strong and at
surface.
Check the cooling fan.
Contact to the service if necessary.
Contact to the service.
Connect properly.
Check the connections.
Replace the welding cable.
Check the work piece surface clean as
necessary.
Check the work cable, re-connect
if not connected.
Pole connections wrong
or weak.
Machine defective.
Cylinder closed or empty.
Valve clogged.
Valve defective.
No gas Flow:
(TIG welding)
HF mode cannot be closed.
(TIG welding) Contact to the service.
Open or replace the cylinder.
Vanayı temizle.
Clean the valve.
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Maintenance and Troubleshooting - 4
PROBLEM POSSIBLE REASON SOLUTION
Arc blow.
Warning led lights on.
Air ventilation is too strong.
Overheating due to high
welding current or
longperiod of work.
Over current protection
tripping due to an
abnormal current in
the main circuit.
Problem in the welding
electrode.
Magnetic eld effect.
Use a protective barrier against air
ventilation.
Reduce the welding current or
reduce the work periods with pauses
Contact to the service.
Check the welding electrode.
Use a shorter arc distance.
If the welding electrode has an eccentric
problem, replace the electrode.
Change the welding direction in
the opposite of arc blow.
Change the position of the work clamp
or place grounding cables on both
sides of the work piece
Welding current cannot
be adjusted properly.
Not enough penetration. Welding current setting
too low.
Input lter board defective.
Fuse blows when the main
switch of the machine is
turned on
Contact to the service.
Increase the welding current setting.
Contact to the service.
The current control
potentiometer on the
front panel is defective or
not working.
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Electromagnetic Compliance - 1
Designed according to the TS EN 60974-1
The EMU class of the machine according to TS EN 55011 is Group 2, class A.
Pls. see TS EN 60974-10 for detailed information.
• Do not switch on-off machine during welding. This may cause uctuations in the mains
voltage and shorten the service life of the machine.
• Wait for approximately 5-10 seconds after turning on the power unit to stabilize the machine,
then start welding.
• This Class A equipment is not intended for use in residential locations where the electrical
power is provided by the public low-voltage supply system. There can be potential difculties
in ensuring electromagnetic compatibility in those locations, due to conducted as well as
radiated radio-frequency disturbances.
The welding machine is designed according to the relevant norms and rules. However, it may still
cause problems for the telecommunication equipment (telephone, radio, television etc.) and safety
devices susceptible to the electromagnetic elds as it generates electromagnetic waves. In order
to reduce the effects of the electromagnetic waves (interference) generated by the machine, please
read the following carefully.
The Welding machine is designed for operating in industrial areas. If it is used in residential areas,
certain measures have to be taken in order to eliminate the possible effects of the electromagnetic
waves.
Installation and use
General : The user is responsible for installing and using the arc welding equipment according to
the manufacturer’s instructions. If electromagnetic disturbances are detected, then it shall be the
responsibility of the user of the arc welding equipment to resolve the situation with the technical
assistance of the manufacturer. In some cases this remedial action may be as simple as earthing the
welding circuit (see note). In other cases, it could involve constructing an electromagnetic screen
enclosing the welding power source and the work complete with associated input lters. In all cases
electromagnetic disturbances shall be reduced to the point where they are no longer troublesome.
NOTE : The practice for earthing the welding circuit is dependent on local safety regulations.
Changing the earthing arrangements to improve EMC can affect the risk of injury or equipment
damage. Further guidance is given in IEC 60974-9.
Assessment of area : Before installing arc welding equipment the user shall make an assessment
of potential electromagnetic problems in the surrounding area. The following shall be taken into
account:
a) other supply cables, control cables, signalling and telephone cables, above, below and adjacent
to the arc welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, for example guarding of industrial equipment;
e) the health of the people around, for example the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement;
g) the immunity of other equipment in the environment. The user shall ensure that other equipment
being used in the environment is compatible. This may require additional protection measures;
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Electromagnetic Compliance - 2
h) the time of day that welding or other activities are to be carried out.
The size of the surrounding area to be considered will depend on the structure of the building and
other activities that are taking place. The surrounding area may extend beyond the boundaries of
the premises.
Assessment of welding installation
In addition to the assessment of the area, the assessment of arc welding installations may be
used to evaluate and resolve cases of interference. An emission assessment should includ in situ
measurements as specied in Clause 10 of CISPR 11:2009. In situ measurements may also be used
to conrm the efciency of mitigation measures.
Mitigation measures
Public supply system : Arc welding equipment should be connected to the public supply system
according to the manufacturer’s recommendations. If interference occurs, it may be necessary to
take additional precautions such as ltering of the public supply system. Consideration should be
given to shielding the supply cable of permanently installed arc welding equipment, in metallic
conduit or equivalent. Shielding should be electrically continuous throughout its length. The
shielding should be connected to the welding power source so that good electrical contact is
maintained between the conduit and the welding power source enclosure.
Maintenance of the arc welding equipment : The arc welding equipment should be routinely
maintained according to the manufacturer’s recommendations. All access and service doors and
covers should be closed and properly fastened when the arc welding equipment is in operation. The
arc welding equipment should not be modied in any way, except for those changes and adjustments
covered in the manufacturer’s instructions. In particular, the spark gaps of arc striking and stabilising
devices should be adjusted and maintained according to the manufacturer’s recommendations.
Welding cables : The welding cables should be kept as short as possible and should be positioned
close together, running at or close to the oor level.
Equipotential bonding : Bonding of all metallic objects in the surrounding area should be
considered. However, metallic objects bonded to the work piece will increase the risk that the
operator could receive an electric shock by touching these metallic objects and the electrode at the
same time. The operator should be insulated from all such bonded metallic objects.
Earthing of the workpiece : Where the workpiece is not bonded to earth for electrical safety, nor
connected to earth because of its size and position, for example, ship’s hull or building steelwork,
a connection bonding the workpiece to earth may reduce emissions in some, but not all instances.
Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users
or damage to other electrical equipment. Where necessary, the connection of the workpiece to
earth should be made by a direct connection to the workpiece, but in some countries where direct
connection is not permitted, the bonding should be achieved by suitable capacitance, selected
according to national regulations.
Screening and shielding : Selective screening and shielding of other cables and equipment in the
surrounding area may alleviate problems of interference. Screening of the entire welding area may
be considered for special applications.
Not to be used in residential locations where the electrical power is provided by
the public low-voltage supply system.
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Transportation and Storage Conditions
De-commissioning the Welding Machine
Unpacking
When no welding work is done, place the machine in to its box to protect against dust and other
the adverse ambient effects, especially if it is to be transported long distance. Make sure that the
welding machine does not sustain hard impacts and do not drop the machine.
Lift and carry the machine from the handle. Do not lift or carry the machine while in operation. Do
not toss around the machine while lifting, carrying or operating and protect against impacts. The
insulation range of the machines under impact may be reduced.
If the machine is to be idle or stored for a long time before re-use, clean the machine and place it in
its original box and store in a dry and dust-free place.
When the service life of the machine expires and does not execute its functions
anymore, do not dispose of as household waste and throw in the thrash. Decommission
the welding machine in compliance with the local regulations.
ASKAYNAK Inverter 201-TIG PFC welding machine is sold in a cardboard box. Do not buy the
machines that are not in the original packaging. To remove the machine from the box, open the top
cover of the box and pull out the machine from the protective bag.
Do not discard the box and bag, keep them for repacking or storing the machine
1- The welding machine has been designed and manufactured to consumpt low power when
turned on.
2- In order to prevent excessive energy consumption while welding, current values suited to the
electrode diameter should be used and using unnecessarily high currents should be avoided.
Efcient Use in Terms of Energy Consumption
• The product is subject to conditional connection. The largest allowable system impedance
is Zmax = 0.22+ j 0.14 (Ref : TS EN 61000-3-11)
• If the machine is used in an area with high electromagnetic elds, the welding/cutoff current
adjusted may exceed ±10%.
• This equipment is compliant with IEC / EN 61000-3-12.
Electromagnetic Compliance - 3
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