CARBONE PowerMaster205 User manual

PowerMaster205 DC INVERTER
AC/DC TIG/DC STICK/CUT
4IN1 MACHINE
(Suitable for 1x220V)
Operators’s Manual
Safety, Setup and General Use Guide
REV.2 0 00146-16
Issue Date: May. 10, 2016
Manual No.: 0-1536
EMPRESAS CARBONE S.A.
Calle 5ta. Rio Abajo, Panamá, Panamá
Telefonos: (507) 3916309 / 3916313
www.empresascarbone.com

Dear Customer,
Thank you for selecting the our machine. We appreciate you as a customer and hope that you
will enjoy years of use from your welder.
Please go directly to the our website to register your unit and receive your warranty information. Your
unit registration is important should any information such as product updates or re-calls be issued. It is also
important so that we may track your satisfaction with our products and services. If you are unable to register
by website, contact our directly through the sales department through the main customer service number in
your country. Your unit will be registered and warranty will be issued and in full effect. Keep all information
regarding your purchase. In the event of a problem you must contact technical support before your
welder can be a candidate for warranty service and returned.
Please review the current online warranty statement and information found on the website of the
our division located in or nearest to your country. Print it for your records and become familiar of its
terms and conditions.
We offers full technical support, in several different forms. We have online support available through
email, and a welding support forum designed for customers and noncustomer interaction. Technical advisors
are active on the forum daily. We also divide our support into two divisions: technical and welding
performance. Should you have an issue or question concerning your unit, please contact performance/
technical support available through the main company headquarters available in your country. For best
service call the appropriate support line and follow up with an email, particularly if off hours, or you cannot
reach a live person. In the event you do not reach a live person, particularly during heavy call volume times,
holidays, and off hours, leave a message and your call will normally be returned within 24 hours. Also for
quick answers to your basic questions, join the company owned forum available through the website.
Should you need to call or write, always know your model name, purchase date and welder manu-
facturing inspection date. This will assure the quick and accurate customer service. REMEMBER: Be as
specific and informed as possible. Technical and performance advisors rely upon you to carefully
describe the conditions and circumstances of your problem or question. Take notes of any issues
as best you can. You may be asked many questions by the advisors to clarify prob-lems or issues
that may seem very basic. However, diagnosis procedures MUST be followed to begin the warranty
process. Advisors can't assume anything, even with experienced users, and must cover all aspects
to properly diagnose the problem. Depending upon your issue, it is advisa-ble to have basic tools
handy such as screwdrivers, wrenches, pliers, and even an inexpensive test meter with volt/ohm
functions before you call.
Let us know how we may be of service to you should you have any questions.

We want you to take pride in operating our machine as much pride as we have taken in making this
product for you. Please read all information in this manual before operation
PLEASE EXAMINE CARTON AND EQUIPMENT FOR DAMAGE IMMEDIATELY
When this equipment is shipped, title passes to the purchaser upon receipt from the courier. Consequently
all claims for material damaged in shipment must be made by purchaser against the transportation company
used.
Please record your equipment identification below for future reference. This information can be
found on data plate at rear of machine.
：
Product
PowerMaster 205
Serial No. ___________________________________
Date of Purchase _____________________________
Where Purchased _____________________________
Whenever you request replacement parts or information on this equipment please always supply information
you have recorded above
This product is covered by 1 years parts and labour warranty, you are responsible for costs of shipping unit
to us, we will cover cost of returning item to you. External items, torch, earth lead etc are covered by 3
months warranty. Any faults/damage found caused by customer will be charged prorata.
Pay particular attention to the safety instructions we have provided you for your protection The level of
seriousness to be applied to each section is explained below
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury.
CAUTION
This statement appears where the information must be following to avoid a minor personal injury or damage
to this equipment.

We are dedicated to providing you with the best possible equipment and service to meet the demanding
jobs that you have. We want to go beyond delivering a satisfactory product to you. That is the reason we
offer technical support to assist you with your needs should an occasion occur. With proper use and care
your product should deliver years of trouble free service.
Safe operation and proper maintenance is your responsibility.
We have compiled this operator's manual, to instruct you in basic safety, operation and maintenance of
our product to give you the best possible experience. Much of welding and cutting is based upon
experience and com-mon sense. As thorough as this welding manual may be, it is no substitute for either.
Exercise extreme caution and care in all activities related to welding or cutting. Your safety, health and even
life depends upon it. While accidents are never planned, preventing an accident requires careful planning.
Please carefully read this manual before you operate machine.
This manual is not only for the use
of the machine, but to assist in obtaining the best performance out of your unit. Do not operate the unit
until you have read this manual and you are thoroughly familiar with the safe operation of the unit. If you feel
you need more information please contact our Support.
The warranty does not cover improper use, maintenance or consumables. Do not attempt to alter or
defeat any piece or part of your unit, particularly any safety device. Keep all shields and covers in
place during unit operation should an unlikely failure of internal components result in the possible presence
of sparks and explosions. If a failure occurs, discontinue further use until mal-functioning parts or
accessories have been repaired or replaced by qualified personnel.
Note on High Frequency electromagnetic disturbances:
Certain welding and cutting processes generate High Frequency (HF) waves. These
waves may disturb sensitive electronic equipment such as televisions, radios, computers, cell
phones, and related equipment. High Frequency may also interfere with fluorescent lights.
Consult with an electrician if disturb-ance is noted. Sometimes, improper wire routing or poor
shielding may be the cause.
HF can interfere with pacemakers.See EMF warnings in following safety sec-tion for
further information. Always consult your physician before entering an area known to have
welding or cutting equipment if you have a pacemaker.
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut fingers and hands and catch loose
clothing.
Do not put your hands near the engine fan. Do not attempt to override the governor or idler by
pushing on the throttle control rods while the engine is running.
SAFETY PRECAUTIONS

These safety precautions are for protection of safety and health. Failure to follow these
guidelines may result in serious injury or death. Be careful to read and follow all cautions and
warnings. Protect yourself and others.
Welding and cutting processes produce high levels of ultraviolet (UV) radiation that can
cause severe skin burn and damage.There are other potential hazards involved with welding
such as severe burns and respiratory related illnesses. Therefore ob-serve the following to
minimize potential accidents and injury:
Use appropriate safety glasses with wrap around shields while in the work area, even
under welding helmets to protect your eyes from flying sparks and debris.When chip-ping
slag or grinding, goggles and face shields may be required.
When welding or cutting, always use an approved shielding device, with the correct
shade of filter installed. Always use a welding helmet in good condition. Discard any broken
or cracked filters or helmets. Using broken or cracked filters or helmets can cause severe eye
injury and burn. Filter shades of no less than shade 5 for cutting and no less than shade 9 for
welding are highly recommended. Shades greater than 9 may be required for high amperage
welds. Keep filter lenses clean and clear for maxi-mum visibility. It is also advisable to consult with your eye
doctor should you wear contacts for corrective vision before you wear them while welding.
Do not allow personnel to watch or observe the welding or cutting operation unless fully
protected by a filter screen, protective curtains or equivalent .protective equip-ment. If no
protection is available, exclude them from the work area. Even brief expo-sure to the rays from
the welding arc can damage unprotected eyes.
Always wear hearing protection because welding and cutting can be extremely noisy. E
ar protection is necessary to prevent hearing loss. Even prolonged low levels of noise has
been known to create long term hearing damage. Hearing protection also further protects
against hot sparks and debris from entering the ear canal and doing harm.
Always wear personal protective clothing. Flame proof clothing is required at all times.
Sparks and hot metal can lodge in pockets, hems and cuffs. Make sure loose clothing is tucked
in neatly. Leather aprons and jackets are recommended. Suitable welding jackets and coats
may be purchased made from fire proof material from welding supply stores. Discard any
burned or frayed clothing. Keep clothing away from oil, grease and flammable liquids.
Leather boots or steel toed leather boots with rubber bottoms are required for ade-quate
foot protection. Canvas, polyester and other man made materials often found in shoes will
either burn or melt. Rubber or other non conductive soles are necessary to help protect from
electrical shock.
Flame proof and insulated gauntlet gloves are required whether welding or cutting or
handling metal. Simple work gloves for the garden or chore work are not sufficient. Gauntlet
type welding gloves are available from your local welding supply companies. Never attempt to
weld with out gloves. Welding with out gloves can result in serious burns and electrical shock.
If your hand or body parts comes into contact with the arc of a plasma cutter or welder, instant
and serious burns will occur. Proper hand protection is required at all times when working
with welding or cutting machines!
SAFETY PRECAUTIONS

WARNING! Persons with pacemakers should not weld, cut or be in the welding area
until they consult with their physician. Some pacemakers are sensitive to EMF radiation and
could severely malfunction while welding or while being in the vicinity of someone welding.
Serious injury or death may occur!
Welding and plasma cutting processes generate electro-magnetic fields and
radiation. While the effects of EMF radiation are not known, it is suspected that there may be
some harm from long term exposure to electromagnetic fields. Therefore, certain pre-cautions
should be taken to minimize exposure:
* Lay welding leads and lines neatly away from the body.
* Never coil cables around the body.
* Secure cables with tape if necessary to keep from the body.
* Keep all cables and leads on the same side the body.
* Never stand between cables or leads.
* Keep as far away from the power source (welder) as possible while welding.
* Never stand between the ground clamp and the torch.
* Keep the ground clamp grounded as close to the weld or cut as possible.
Welding and cutting processes pose certain inhalation risks. Be sure to follow any
guidelines from your chosen consumable and electrode suppliers regarding possible need for
respiratory equipment while welding or cutting. Always weld with adequate ventilation. Never weld
in closed rooms or confined spaces. Fumes and gases re-leased while welding or cutting may be
poisonous. Take precautions at all times.
Any burning of the eyes, nose or throat are signs that you need to increase ventilation.
* Stop immediately and relocate work if necessary until adequate ventilation is ob-tained.
* Stop work completely and seek medical help if irritation and discomfort persists.
WARNING! Do not weld on galvanized steel, stainless steel, beryllium, titanium, cop-per,
cadmium, lead or zinc without proper respiratory equipment and or ventilation.
WARNING! This product when used for welding or cutting produces fumes and gas-es
which contains chemicals known to the State of California to cause birth defects and in some
§
cases cancer. (California Safety and Health Code 25249.5 et seq.)
WARNING! Do not weld or cut around Chlorinated solvents or degreasing areas. Release
of Phosgene gas can be deadly. Consider all chemicals to have potential deadly results if welded
on or near metal containing residual amounts of chemicals.
Keep all cylinders upright and chained to a wall or appropriate holding pen. Certain
regulations regarding high pressure cylinders can be obtained from OSHA or local regulatory
agency. Consult also with your welding supply company in your area for further recommendations.
The regulatory changes are frequent so keep informed.
All cylinders have a potential explosion hazard. When not in use, keep capped and closed.
Store chained so that overturn is not likely. Transporting cylinders incorrectly can lead to an
explosion. Do not attempt to adapt regulators to fit cylinders. Do not use faulty regulators. Do
not allow cylinders to come into contact with work piece or work. Do not weld or strike arcs on
cylinders. Keep cylinders away from direct heat, flame and sparks.
SAFETY PRECAUTIONS

WARNING! Electrical shock can kill. Make sure all electrical equipment is properly
grounded. Do not use frayed, cut or otherwise damaged cables and leads. Do not stand, lean
or rest on ground clamp. Do not stand in water or damp areas while weld-ing or cutting. Keep
work surface dry. Do not use welder or plasma cutter in the rain or in extremely humid
conditions. Use dry rubber soled shoes and dry gloves when welding or cutting to insulate
against electrical shock. Turn machine on or off only with gloved hand. Keep all parts of the
body insulated from work, and work tables. Keep away from direct contact with skin against
work. If tight or close quarters ne-cessitates standing or resting on work piece, insulate with
dry boards and rubber mats designed to insulate the body from direct contact.
All work cables, leads, and hoses pose trip hazards. Be aware of their location and
make sure all personnel in area are advised of their location. Taping or securing ca-bles with
appropriate restraints can help reduce trips and falls.
WARNING! Fire and explosions are real risks while welding or cutting. Always keep
fire extinguishers close by and additionally a water hose or bucket of sand. Periodi-cally check
work area for smoldering embers or smoke. It is a good idea to have someone help watch for
possible fires while you are welding. Sparks and hot metal may travel a long distance. They
may go into cracks in walls and floors and start a fire that would not be immediately visible.
Here are some things you can do to reduce the possibility of fire or explosion:
* Keep all combustible materials including rags and spare clothing away from area.
* Keep all flammable fuels and liquids stored separately from work area.
* Visually inspect work area when job is completed for the slightest traces of smoke or embers.
* If welding or cutting outside, make sure you are in a cleared off area, free from dry tender and
debris that might start a forest or grass fire.
* Do not weld on tanks, drums or barrels that are closed, pressurized or anything that held
flammable liquid or material.
Metal is hot after welding or cutting! Always use gloves and or tongs when handling hot
pieces of metal. Remember to place hot metal on fire-proof surfaces after han-dling. Serious
burns and injury can result if material is improperly handled.
WARNING! Faulty or poorly maintained equipment can cause injury or death. Prop-
er maintenance is your responsibility. Make sure all equipment is properly maintained and
serviced by qualified personnel. Do not abuse or misuse equipment.
Keep all covers in place. A faulty machine may shoot sparks or may have exploding parts.
Touching uncovered parts inside machine can cause discharge of high amounts of electricity.
Do not allow employees to operate poorly serviced equipment. Always check
condition of equipment thoroughly before start up. Disconnect unit from power source before
any service attempt is made and for long term storage or electrical storms.
Further information can be obtained from The American Welding Society (AWS) that
relates directly to safe welding and plasma cutting. Additionally, your local welding supply
company may have additional pamphlets available concerning their products. Do not operate
machinery until your are comfortable with proper operation and are able to assume inherent
risks of cutting or welding.
SAFETY PRECAUTIONS

TABLEOFCONTENTS
Page
SAFETY PRECAUTIONS................................................. .
Installation.....................................................Section A
Technical Specifications...............................................A-1
Output Amps %duty cycle ...............................................A-2
Select Suitable Location...............................................A-3
Stacking ..............................................................A-3
TRANSPORT - UNLOADING ............................................A-3
Tilting. ..............................................................A-3
Environmental Area ....................................................A-3
Machine Grounding and High Frequency Interference Protection .........A-4
Input Connections ...................................................A-4
Reconnect Procedure....................................................A-5
220/230/240V Input.....................................................A-5
Attachment Plug Installation, Engine Driven Generator..................A-5
Output Connections.....................................................A-6
Output and Gas Connection for Tig Welding..............................A-6
Work Cable Connection .................................................A-6
Output Connection for Stick Welding ...................................A-6
Quick Disconnect Plug .................................................A-6
Shielding Gas Connection...............................................A-6
Remote Control Connection..............................................A-6
Operation.......................................................Section B
Safety precautions.....................................................B-1
Product Description....................................................B-2
Welding Capability.....................................................B-2
Limitations ...........................................................B-2
Control Panel .....................................................B-3
Controls and Settings, 2 Step and 4 Step Tig Sequence .............B-3,B-6
Operating steps........................................................B-7
Welding in Tig mode....................................................B-7
Welding Polarity ......................................................B-7
DC Electrode Negative Polarity.........................................B-7
DC Electrode Positive Polarity ........................................B-7
D.C.-Pulsed TIG .......................................................B-7
A.C. (Alternating Current) ............................................B-8
A.C.-Pulsed TIG (Alternating Current Pulsed) ..........................B-8
Steel Tig Welding .....................................................B-8
Copper Tig Welding.....................................................B-8
Tips For AC TIG Welding ...............................................B-8
GTAW Process...........................................................B-9
Protective Gas ........................................................B-9
AC Tig Welding Quick Start Up ........................................B-10
DC Tig Welding Quick Start Up .........................................B-10
Remote Control operation ..............................................B-10
Welding in Stick mode .................................................B-16
Cutting in cut mode .................................................B-18
Maintenance .....................................................Section C
Safety Precautions ....................................................C-1
Routine and periodic Maintenance.......................................C-1
Troubleshooting .................................................Section D
How to Use Troubleshooting Guide ......................................D-1
Input Filter Capacitor Discharge Procedure ............................D-1
Troubleshooting Guide.........................................D-2 thru D-7
Wiring Diagram...................................................Section E
Main circuit wiring Diagram............................................E-1
Accessories......................................................Section F
Parts Lists(COMPONENT LISTS)..................................... Appendix

A-1 INSTALLATION A-1
TECHNICAL SPECIFICATIONS -
max. rated Output Amps @% Duty Cycle (Based on a 10 minute cycle) (Example; 160A@35% for DC Stick
and 200A@60% for AC/DC Balance TIG)
MODEL PowerMaster 205
Voltage 1~AC220/230/ 240V 50/60Hz
INPUT Fuse rating 35A
No-load Voltage 70V
current Adjusting Range 5~200A
AC balance 10%~90 %
AC Square Wave Frequency 20~250Hz
Start Amps 20-200A
End Amps 20-200A
AC
TIG
Rated Duty Cycle 60%
AMP Adjusting Range 5~200A
Rated Duty Cycle 60%
Current Up-slope Time 0~10S
Current Down-slope Time 0~25S
pulse(Base/AMP) Current Ratio 5%-95%
Pluse Time On 0.1~0.9
Pluse Frequency 0.5~25(25~250)Hz
Start Amps 5-200A
End Amps 5-200A
Pre Flow 0-10s
Post Flow Time 0~25s
DC
TIG
Arc starting Mode high frequency arc striking
No-load Voltage 70V
current Adjusting Range 5~160A
Rated Output Current 160A
DC
MMA
Rated Duty Cycle 35%
current Adjusting Range 20~50A
CUT
Rated Duty Cycle 60%
Efficiency ≥83%
Mass 27kg
Protection Class of enclosure IP21S
Outline Dimensions mm3470x235x435

A-2 INSTALLATION A-2
Chart gives max. rated Output Amps @% Duty Cycle (Based on a 10 minute cycle) (Example; 160A@35%
for DC Stick and 200A@60% for AC/DC Balance TIG)
TIG
STICK(MMA)
(1)
Wiring and protection based on the IEC60974.1 National Electric Code: Use a Super Lag type fuse or circuit
breaker with a delay in tripping action. Models with NEMA 6-50P plug may be used with a 50 amp protected
6-50R receptacle, or with a maximum 70 amp protected 6-50R receptacle if dedicated for the welder.
80 100 120 140 160 180 200 220
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0
OUTPUT AMPS
OUTPUT AMPS %DUTY CYCLE
Using standard input cable for protected input supply

A-3 INSTALLATION A-3
SAFETY PRECAUTIONS
Read entire installation section before starting installation.
ELECTRIC SHOCK can kill.
·Only qualified personnel should
perform this installation.
·Turn the input power OFF at the
disconnect switch or fuse box
before working on this equipment.
·Do not touch electrically hot parts.
·Always connect the MACHINE to a power
supply grounded per the National Electrical
Code and any local codes.
SELECT SUITABLE LOCATION
Place the welder where clean cooling air can freely
circulate in and out through the rear louvers. Dirt,
dust or any foreign material that can be drawn into
the welder should be kept at a minimum. Failure to
observe these precautions can result in excessive
operating temperatures and nuisance shut-downs.
GRINDING
Do not direct grinding particles towards the welder.
An abundance of conductive material can cause
maintenance problems.
STACKING
The machine cannot be stacked.
TRANSPORT - UNLOADING
Never underestimate the weight of the
equipment.
Never make the cargo pass or leave it
suspended over people or things.
Neither let the equipment or the single unit fall,
nor put it down with force.
Once it has been removed from the packing, the
power source can be used to move it in the
hand or on the shoulder.
Never lift welder with gas cylinder attached.
Never lift welder above personnel.
TILTING
Each machine must be placed on a secure, level
surface, either directly or on a recommended
undercarriage. The machine may topple over if this
procedure is not followed. 10o
ENVIRONMENTAL RATING
The welding machine power source carries an
IP21s environmental rating. It may be used in
normal industrial and commercial environments.
Avoid using it in environments which have falling
water such as rain.
Read and follow "Electric Shock Warnings" in the
Safety section if welding must be performed under
electrically hazardous conditions such as welding in
wet areas or on or in the workpiece.
FALLING
EQUIPMENT
cause injury
PLASMA ARC
can injure
Keep your body away from nozzle and
plasma arc
Operate the pilot arc with cation. The
pilot arc is capable of burning the
operator,others even piercing safety
clothing

A-4 INSTALLATION A-4
MACHINE GROUNDING AND HIGH
FREQUENCY INTERFERENCE
PROTECTION
This welder must be grounded! See your local and
national electrical codes for proper grounding
methods.
The high frequency generator, being similar to a
radio transmitter, may cause radio, TV and
electronic equipment interference problems. These
problems may be the result of radiated interference.
Proper grounding methods can reduce or eliminate
radiated interference.
Radiated interference can develop in the following
four ways:
1 Direct interference radiated from the welder.
2 Direct interference radiated from the welding
leads.
3 Direct interference radiated from feedback into the
power lines.
4 Interference from re-radiation of "pickup" by
ungrounded metallic objects.
Keeping these contributing factors in mind, installing
equipment per the following instructions should
minimize problems.
1 Keep the welder power supply lines as short as
possible and enclose as much of them as possible
in rigid metallic conduit or equivalent shielding for a
distance of 50 feet (15.2m). There should be good
electrical contact between this conduit and the
welder case ground. Both ends of the conduit
should be connected to a driven ground and the
entire length should be continuous.
2 Keep the work and electrode leads as short as
possible and as close together as possible. Lengths
should not exceed 25 ft (7.6m). Tape the leads
together when practical.
3 Be sure the torch and work cable rubber
coverings are free of cuts and cracks that allow high
frequency leakage.
4 Keep the torch in good repair and all connections
tight to reduce high frequency leakage.
5 The work piece must be connected to an earth
ground close to the work clamp, using one of the
following methods:
a) A metal underground water pipe in direct contact
with the earth for ten feet or more.
b) A 3/4" (19mm) galvanized pipe or a 5/8"
(16mm)solid galvanized iron, steel or copper rod
driven at least eight feet into the ground.
The ground should be securely made and the
grounding cable should be as short as possible
using cable of the same size as the work cable, or
larger. Grounding to the building frame electrical
conduit or along pipe system can result in
reradiation, effectively making these members
radiating antennas.
6 Keep cover and all screws securely in place.
7 Electrical conductors within 50 ft (15.2m) of the
welder should be enclosed in grounded rigid
metallic conduit or equivalent shielding, wherever
possible. Flexible metallic conduit is generally not
suitable.
8 When the welder is enclosed in a metal building,
the metal building should be connected to several
good earth driven electrical grounds (as in 5 (b)
above) around the periphery of the building.
Failure to observe these recommended installation
procedures can cause radio or TV and electronic
equipment interference problems and result in
unsatisfactory welding performance resulting from
lost high frequency power.
INPUT CONNECTIONS
Be sure the voltage, phase, and frequency of the
input power is as specified on the rating plate,
located on the rear of the machine.
Have a qualified electrician provide input power
supply to the receptacle or cord in accordance with
all local and national electrical codes. Use a single
phase line or one phase of a two or three phase
line.
Choose an input and grounding wire size according
to local or national codes. Refer to the Technical
Specifications page at the beginning of this section.
Fuse the input circuit with the recommended super
lag fuses or delay type circuit breakers.

A-5 INSTALLATION A-5
Using fuses or circuit breakers smaller than
recommended may result in "nuisance" shut-off
from welder inrush currents even if not welding at
high currents.
1Also called "inverse time" or "thermal/magnetic" circuit
breakers; circuit breakers which have a delay in tripping action
that decreases as the magnitude of the current increases.
INPUT RECONNECT PROCEDURE
On multiple input voltage welders, be sure the
machine is connected per the following instructions
for the voltage being supplied to the welder.
Failure to follow these instructions can cause
immediate failure of components within the welder
and void machine's warranty.
Multiple voltage models are shipped connected for
the highest voltage. To change this connection refer
to the following instructions.
ELECTRIC SHOCK can kill.
Turn the input power OFF at the
disconnect switch or fuse box
before working on this equipment.
. Have a qualified electrician
install and service this
equipment.
. Turn the input power OFF and unplug the
machine from the receptacle
before working on this equipment.
. Allow machine to sit for 5 minutes minimum to
allow the power capacitors to discharge before
working inside this equipment.
. Do not touch electrically hot parts.
. Machine must be plugged into a receptacle
that is grounded according to the National
Electrical Code and local codes.
. Do not remove or defeat the purpose of the
power cord ground pin.
RECONNECT PROCEDURE
The Inverter machine auto reconnects to either
115V or 230V supply.
Fuse the input circuit with time delay fuses or delay
type1 circuit breakers. Using fuses or circuit
breakers smaller than recommended may result in
“nuisance”shut-offs from welder inrush currents
even if not welding at high currents.
The Inverter machine is recommended for use on
an individual branch circuit.
1Also called“inverse time”or“thermal/magnetic”
circuit breakers.
These circuit breakers have a delay in tripping
action that decreases as the magnitude of the
current increases.
220/230/240V INPUT
The equipment is provided with a 230 cable,
6.6ft.(2m) in length with a 230V 6-50P attachment
plug.
ATTACHMENT PLUG INSTALLATION
Connect the white (neutral) wire under terminal
clamp with silver screw, and black (hot) wire under
terminal clamp with brass screw. Connect green
wire under terminal clamp with green screw.
. Failure to wire as instructed may cause
personal injury or damage to equipment.
To be installed or checked by an
electrician or qualified person only.
In all cases, the green or green/yellow grounding
wire must be connected to the grounding pin of the
plug, usually identified by a green screw.
Attachment plugs must comply with the Standard
for Attachment Plugs and Receptacles,.
The product is considered acceptable for use only
when an attachment plug as specified is properly
attached to the supply cord.
For use on engine drives, keep in mind the above
input draw restrictions and the following precaution.

A-6 INSTALLATION A-6
ENGINE DRIVEN GENERATOR
The Inverter machine can be operated on engine
driven generators as long as the 220/230/240 volt
auxiliary meets the following conditions:
. The AC waveform peak voltage is below 400 volts.
. The AC waveform frequency is between 45 and
65Hz.
The following Lincoln engine drives meet these
conditions when run in the high idle mode:
●Ranger 250,305 ●. Commander 300, 400, & 500
Some engine drives do not meet these conditions
(e.g. Miller Bobcats, etc). Operation of the Inverter
machine is not recommended on engine drives not
conforming to these conditions. Such drives may
deliver unacceptably high voltage levels to the
Inverter machine power source.
CONNECTIONS FOR TIG (GTAW) WELDING
TIG TORCH CONNECTION
Refer to Included Equipment in the Operation
Section of this manual for TIG welding
equipment which is included with the machine
The TIG Torch Twist-Mate and work cable
Twist-Mate Connectors are supplied with the welder.
To connect the cables, turn the Power Switch
“OFF”. Connect the torch cable Twist-Mate plug
into the DC(-)
Electrode Receptacle on the front of the welder and
turn it clockwise until snug,(Do not Over tighten).
This is a quick connect terminal
To avoid receiving a high frequency shock, keep
the TIG torch and cables in good condition.
WORK CABLE CONNECTION
Next, connect the work cable to the “+”output
terminal in the same way.
To minimize high frequency interference, refer to
Machine Grounding and High Frequency
Interference Protection section of this manual for
the proper procedure on grounding the work clamp
and work piece.
SHIELDING GAS CONNECTION
Obtain the necessary inert shielding gas (usually
argon). Connect the cylinder of gas with the
pressure regulator and flow gage. Install the gas
hose between the regulator and gas inlet (located
on the rear of the welder).
CYLINDER could explode if
damaged.
Keep cylinder upright and
chained to a support.
Keep cylinder away from areas where it could
be damaged.
Never allow the torch to touch the cylinder.
Keep cylinder away from live electrical circuits.
Maximum inlet pressure 150 psi.
A cylinder is loaded by leaning it slightly sideways
and rocking it up on the platform, being careful not
to allow the Under-Storage Cart to roll. Secure the
cylinder in place with the provided chain. Unload by
following these steps in reverse.
ADJUSTABLE FOOT CONTROL CONNECTION
A Adjustable foot control receptacle is provided on
the case front of the welder for connecting a remote
control to the machine.
CONNECTIONS FOR STICK (SMAW) WELDING
A. NEGATIVE CONNECTION B . POSITIVE CONNECTION
STICK ELECTRODE CABLE AND WORK CABLE
CONNECTION
Refer to Field Installed Options in Accessories
Section of this manual for STICK welding
equipment which is available for use with the
inverter machine. An electrode holder with
Twist-Mate cable and Twist-Mate connector are
available separately for use with the inverter
machine.. Turn the Power Switch "OFF". Connect
the Twist-Mate quick connect plug into the
Electrode and turn it clockwise until it is tight. The
work cable and work clamp are factory connected.
welde
r
electrode
holde
r
workpiece workpiece
welde
r
electrode
holde
r
workpiec
GAS
Cylinder
torch
0
4
12
1
3
1
7
1
5
1
6
1
4
1
8
19
20
21
2
6
01
0
3
0
5
0
6
0
7
0
8
09 10
11
3
4

B-1 OPERATION B-1
Read and understand this entire section
before operating the machine.
SAFETY PRECAUTIONS
ELECTRIC SHOCK can kill.
· Do not touch electrically
live parts or electrode with
skin or wet clothing.
· Insulate yourself from
work and ground.
· Always wear dry insulating gloves.
Read and follow "Electric Shock Warnings" in the
Safety section if welding must be performed under
electrically hazardous conditions such as welding in
wet areas or on or in the workpiece.
FUMES AND GASES can be dangerous.
· Keep your head out of
fumes.
· Use ventilation or exhaust
at the arc, or both, to
remove fumes and gases
from breathing zone and general area.
WELDING SPARKS can cause fire or
explosion
· Keep flammable material
away.
· Do not weld on containers
that have held combustibles.
RC RAYS can burn.
Wear eye, ear and body
protection.
Only qualified personnel
should operate this equipment. Observe
additional Safety Guidelines detailed in
the beginning of this manual.

B-2 OPERATION B-2
PRODUCT DESCRIPTION
The Precision TIG is a member of our field
acclaimed Precision TIG family of industrial arc
welding power sources. Premium features include:
1 Precise constant current output.
2 Full range square wave AC/DC TIG (GTAW)
welding.
3 Enhanced version of the patented Micro-Start
Technology for its lower Minimum(5 amps at DC)
to higher Maximum output control range.
4 Built-in high frequency stabilization for DC TIG
starting and continuous AC TIG welding.
5 DC Stick (SMAW capability.)
The Precision TIG patented convenient built-in
storage provisions for welding components and
cable management.
The Precision ADC also provides advanced
features such as:
●Digital Meter
●Timers for fixed Preflow and variable Postflow
shielding gas.
●Tool-less Twist-Mate electrode cable
connection.
RECOMMENDED PROCESSES AND
EQUIPMENT
RECOMMENDED PROCESSES
The Precision TIG is recommended for the TIG
(GTAW) and Stick (SMAW) welding processes
within its output capacity range of 5 amps DC , or 5
amps AC, to MAX amps AC/DC. It is compatible
with most Magnum TIG accessories, as well as
many industry standard items, such as TIG torches
(adapted for Twist-Mate), hoses.
PROCESS LIMITATIONS
The Precision TIG machines are not recommended
for arc gouging due to it's limited output capacity,
and are also not recommended for pipe thawing.
RECOMMENDED QUIPMENT/INTERFACE
(See Installed Options in Accessories Section for
more details)
The Precision TIG will be available as a basic
Machine (Only) and in Factory Basic module will
also be available as with Domestic,.
(SEE PACKING LIST,PLEASE)
EQUIPMENT LIMITATIONS
The Precision TIG machines are protected from
over loads beyond the output ratings and duty
cycles, per the Specifications in the Installation
Section, with Thermostat protection of the output
power coils and rectifiers.
If a Precision Tig is powered from an engine
generator which doesn't have sufficient capacity,
the AC Balance control and the Output control will
not provide full range of control.
WELDING CAPABILITY(Duty Cycle)
The PRECISION TIG is rated at 200 amps, 18
volts, at 60% duty cycle on a ten minute basis. It is
capable of higher duty cycles at lower output
currents. See rated output graph, on specification
sheet located in the Installation Section. If the duty
cycle is exceeded, a thermal protector will shut off
the output until the machine cools.

B-3 OPERATION B-3
CONTROLS AND SETTINGS
All operator controls and adjustments are located on the case front of the TIG machine. Refer to Figure B.1
and the corresponding explanations.
FIGURE B.1 CONTROL PANEL
1. FRONT PANEL 2. BACK PANEL
1.indication of welding current
2.power switch 3.pulse current
regulator 4.AMP regulator
5.PulseTtimeOn
6.pulse Freq. regulator
7.indicating light of power
8. indicating light of over heat
9. current up-slope time regulator
10.current down-slope time
regulator 11.post flow time
regulator 12.MMA/TIG/CUT
switch 13.AC balance14.output"+"
15.AC square wave Frequency
16. arc force 17.argon out
18.torch control (or remote
control) 19. AC/DC TIG switch
20. output"-" 21.argon inlet
22.power supply 23.nameplate
24.fan 25.safety earthing column
26. 2 steps/ 4 steps switch
27. 220v receptacle
28,PreFlow29.Start Amps
30.End Amps 31.Pulse On/Off.
32.warning indicating light
34.Pilotarc
CONTROL FUNCTIONALITY
1 DIGITAL METER - A 3 digit LED meter is
used to display the preset output current level
before welding, and actual output level while
welding: A lit display indicates input power is turned
on. (See Item 2.)
2.POWER SWITCH - Input line switch turns
input power ON or OFF, as indicated by the on or
off status of the front panel digital display (See Item
1).
3. Pulse current regulator
Regulating the knob, It can be selected
between 5A TO 200A.
4. welding current regulator
Regulating the knob, It can be selected
between 5A TO 200A. For Remote TIG this knob
sets the Max.Amp level, with the Remote
Adjustable foot control (if used).
5.pulse width regulator
Regulating the knob, It can be selected
between 0.1 TO 0.9.
6.pulse Freq. regulator
Regulating the knob, It can be selected
between 0.5Hz TO 250Hz.

B-4 OPERATION B-4
7.indicating light of power
Turn power on, it will illuminate indicating.
8. indicating light of over heat
-If the welder overheats due to blocked air flow,
high ambient air temperature, or exceeded duty
cycle, an internal thermostat will open disabling the
welding output and this yellow light will illuminate.
The cooling fans will continue to run to cool the unit
during this time. The light will go out when the unit
cools and the thermostat resets. Once the light
goes out, the machine will again become available
to weld.
9.current up-slope time regulator
Regulating the knob, It can be selected
between 0s TO 10s
10.current down-slope time regulator
Regulating the knob, It can be selected
between 0s TO 25s.
11.post flow time regulator
Sets the TIG mode shielding gas post flow time
over the range of about 0 to 25 seconds after the
arc is shut off.
12. MMA/TIG/CUT switch (MODE SWITCH)
This button is used to select one of three processes: HF
start TIG, Plasma Cutting (Cut) or stick mode. The TIG
mode features HF start for a touchless arc initiation. The
cut mode is used to select for the plasma cutting mode.
The stick mode is used for stick welding only. Note: Cut
and Stick modes only allow DC operation.
13. SP %（AC Balance）
The AC Balance Control permits adjustment of the
AC TIG wave balance adjustment from Max.
Penetration (70% negative wave) at full CW rotation
setting, to Max. Cleaning (70% positive wave) at
CCW rotation,.
This setting position feature automatically provides
the proper amount of cleaning and penetration for
normal AC TIG welding.
14. output"+" （Electrode Connection (Positive)）
For quick disconnect system using Twist-Mate
cable plugs
15. AC square wave Frequency
Regulating the knob, It can be selected
between 20 TO 250Hz.
16.arc force
Regulating arc force
17. argon out
connected gas pipe of torch
18. REMOTE RECEPTACLE *note (OR argon arc
control)
Provides for connection of remote control and/or
arc start switch in TIG Mode: Plugging a remote
current control (Adjustable foot control) into this
receptacle automatically switches the output control
from the panel Max Output Control (See Item 3) to
the remote control.
The connected remote control will then control
the output current between the Min. range of the
machine and the setting of the panel Max Output
Control.
19. AC/DC TIG SWITCH
Select the mode of output
Do not switch the switch while
welding or damage may result to
the machine.
20.output"-"（Electrode Connection (Negative) ）
This quick connect Twist-Mate receptacle provides
electrical connection to the electrode holder and
cable for Stick welding and connection for the TIG
torch when TIG welding.
21.argon inlet
connected gas pipe of flow meter
22.power supply
connected main supply
23.nameplate
The data plate stamped on the metal structure
complies with the EN 60974-1,
EN50199(EN60974-10) international standards and
contains the following information:
*note：

B-5 OPERATION B-5
* (a) Manufacturer's name and address
* (b) Trademark
* (c) Model
* (No) Serial number
* ( ) The welding power
source comprises a frequency converter followed by
an transformer and rectifier that transforms input
voltage into direct current.
* (EN 60974-1/EN 50199) Standards applied.
*( )Directcurrent.
* (x) Utilisation factor expressed as a percentage of
useful work over a cycle of 10 minutes at an
ambient temperature of 40oC.
* (I2) Rated weld current.
* (U2) Conventional load voltage.
* (Uo) Rated no-load voltage.
*( )TIGwelding.
*( )MMAwelding.
* ( )) 1input phases.
* (IP21S) Casing protection degree in compliance
with the EN 60529 Standard:
IP2XX Casing protected against access to
dangerous components with fingers and against the
introduction of foreign matters with diameter 12.5
mm.
IPX3X Casing protected against rain failing at
60~on the vertical line.
IPXXC Casing protected against contact of a test
gauge φ2.5 mm length 100 mm with live
dangerous parts,
* (U1) Rated power supply voltage.
* (50/60 Hz) Power supply rated frequency.
* (llmax) Maximum supply current.
(I1 eff) Effective supply current.* ( S ) Generator
suitable for installation in places where major risks
of electric shocks are preset
* (CE) In compliance with the European regulations
in force.
24.fan
when power switch on, the cooling fan runs
25.safety earthing column
The earthing must be made according to the
national regulations. Make sure that the supply
mains and the earthing are sufficient and adequate
26. 2 steps/ 4 steps switch
Tig Trigger Sequences -
For the TIG machine AC/DC, TIG welding can be
done in either the 2-step or 4-step mode which is
selected with the Trigger Mode Push Button.
2-Step Sequence
With the Trigger Mode switch in the 2-step position,
the following welding sequence will occur. This
sequence is shown in (2-step diagram 1)
2 STEP DIAGRAM 1
1. Press and hold the Arc Start Switch to start the
sequence.
The machine will open the gas valve to start the
flow of the shielding gas. After a 0.5 second preflow
time, to purge air from the torch hose, the output of
the machine is turned ON. At this time the arc is
started.
After the arc is started the output current will be
increased from the start current to the welding
current. Both the start current and increase, or
upslope time are presettable. The default start
current is 15 amps and the default upslope time is
0.2 seconds.
2. Release the Arc Start Switch to stop welding.
The machine will now decrease the output current
at a controlled rate, or down slope time, until the
Finish current, (also commonly referred to as Crater
Current) is reached and the output of the machine is
turned OFF. Both the Down slope Time and the
Finish Current are can be preset.
After the arc is turned OFF, the gas valve will
remain open to continue the flow of the shielding
gas to the hot electrode and work piece. The
duration of this postflow shielding gas is adjusted by
the Postflow Parameter.
Possible variations of this standard sequence is
shown in (2 step diagram 2). It is possible to press
and hold the TIG torch trigger a second time during
downslope to restart. After the trigger is pressed the
output current will increase to the welding current.
This operation is shown in (2 step diagram 2).
2 STEP DIAGRAM 2
~
1
~f1
f2 ~
TORCH
BUTTON
OUTPUT
CURRENT
GAS
PRE
-
FLOW
GAS ON
POST-FLOW
TORCH
BUTTON
OUTPUT
CURRENT
GAS
PRE
-
FLOW
GAS ON
POST-FLOW

B-6 OPERATION B-6
4-Step Sequence
With the 4-step Selected, the following welding
sequence will occur.
1. Press and hold the Arc Start Switch to start the
sequence.
The machine will open the gas valve to start the
flow of the shielding gas. After a 0.5 second preflow
time, to purge air from the torch hose, the output of
the machine is turned ON. At this time the arc is
started.
After the arc is started the output current will be at
the Start current. This condition can be maintained
as long or as short as necessary.
If the Start current is not necessary, do not hold the
TIG torch trigger as described at the beginning of
this step. Instead, quickly press and release the
trigger. In this condition, the machine will
automatically pass from Step 1 to Step 2 when the
arc is started.
2. Release the TIG torch trigger to start the main
part of the weld.
The output current will be increased from the start
current to the welding current. Both the start current
and increase, or upslope time are presettable. The
default start current is 15 amps and the default
upslope time is 0.2 seconds.
3. Press and hold the TIG torch trigger when the
main part of the weld is complete.
The machine will now decrease the output current
at a controlled rate, or down slope time, until the
Finish current is reached. Both the Down slope
Time and the Finish Current are presettable. This
Finish current can be maintained as long or as short
as necessary.
4. Release the TIG torch trigger.
The output current of the machine will turn OFF and
the gas valve will remain open to continue the flow
of the shielding gas. The duration of this postflow
time is adjusted by the Postflow parameter. This
operation is shown in (4 step diagram 1).
4 STEP DIAGRAM 1
Possible variations of this standard sequence are
shown below. By releasing and re-pressing the TIG
torch trigger during the downslope step, the output
will immediately drop to and hold at the Finish
Current. Releasing the trigger will turn off the output
and begin postflow. This operation shown in
(4 step diagram 2)
27. 110V/220v receptacle
This connection supplies power to the water
cooler. This is a 110/220 VAC outlet. Do not use
this connection to power any other device. 4 amp
max.
28. PreFlow
Sets the TIG mode shielding gas pre flow time over
the range of about 0 to 10 seconds before the arc
will shut on.
29. Start Amps &30. End Amps
Serves as the 2T/4T beginning and final amp
value while using the torch switch. Allows the arc to
be started and ended at a different amp value than
normal welding while using the torch switch.
31. Pulse On/Off.
Press the touch-pad button to select the desired
pulse mode.
32. warning indicating light
output current is too high or the machine fails.
34.Pilotarc Connector
Loosen the black thumb screw to connect the pilot
arc wire to the plasma cutting torch. The
thumbscrew is only used with the plasma torch.
TORCH
BUTTON
OUTPUT
CURRENT
GAS
PRE
-
FLOW
GAS ON
POST
-
FLOW