H&S AUTOSHOT HST201 User manual

Part # HSW-6321
Processes
TIG (GTAW) Welding
STICK (SMAW) Welding
.
HST201 AC/DC PFC
PULSED INVERTER TIG WELDER
IMPORTANT: Read this Owner’s Manual Completely before attempting to use this
equipment. Save this manual and keep it handy for quick reference. Pay particular
attention to the safety instructions we have provided for your protection. Contact your
distributor if you do not fully understand this manual.
OPERATOR’S MANUAL

II
CONTENT
SECTION 1: SAFETY ................................................................................................................1
1.1 SIGNAL EXPLANATION..........................................................................................................1
1.2ARC WELDING DAMAGE.......................................................................................................1
1.3 EXPLANATION OF ELECTRIC AND MAGNETIC FIELDS ..............................................................4
SECTION 2: INTRODUCTION...................................................................................................5
2.1 TG2010AC/DC INFORMATION.........................................................................................5
2.2 MODULE EXPLANATION........................................................................................................7
2.3WORKING PRINCIPLE...........................................................................................................7
2.4 VOLT-AMPERE CHARACTERISTIC..........................................................................................8
SECTION 3: INSTALLATION AND ADJUSTMENT..................................................................9
3.1 PARAMETERS......................................................................................................................9
3.2 DUTY CYCLE &OVER HEAT ................................................................................................10
3.3 MOVEMENTAND PLACEMENT..............................................................................................10
3.4 POWER SUPPLY INPUT CONNECTION...................................................................................11
3.5 MACHINE OPERATIONAL LAYOUT.......................................................................................113
3.6ELECTRODE /TORCH CONNECTIONS....................................................................................14
3.7 FOOT PEDAL CONTROL.....................................................................................................115
SECTION 4: OPERATION .......................................................................................................96
4.1 CONTROL PANEL LAYOUT..................................................................................................126
4.2ARGON ARC WELDING OPERATION ...................................................................................138
4.2.1 TIG WELDING (4T OPERATION).................................................................................148
4.2.2 TIG WELDING (2T OPERATION)...................................................................................19
4.2. TIG WELDING (REPEAT))..............................................................................................20
4.3 SAFE OPERATION..............................................................................................................20
4.4WELDING PARAMETERS.....................................................................................................21
4.4.1 JOINT FORMS IN TIG/MMA..........................................................................................21
4.4.2 THE EXPLANATION OF WELDING QUALITY......................................................................21
4.4.3 TIG PARAMETERS MATCHING......................................................................................21
4.5 OPERATION ENVIRONMENT ................................................................................................24
4.6OPERATION NOTICES.........................................................................................................24
SECTION 5: MAINTENANCE & TROUBLESHOOTING ......................................................256
5.1 MAINTENANCE.................................................................................................................256
5.2 TROUBLESHOOTING...........................................................................................................26
5.3 ELECTRICAL PRINCIPLE DRAWING .......................................................................................30
5.4EXPLODED PARTS LISTING..................................................................................................31
5.5 EXPLODED TORCH PARTS LISTING.......................................................................................32

OPERATION
1
1 SAFETY
1.1 Signal and Hazard Explanation
The above signals mean Warning, Notice, and Running Parts
Safe operation is simple after taking several necessary protection measures. The protection
measures and hazard explanations are listed in the following pages.
The following pages are meant to prevent most injuries that might occur while welding. While
welding, please remind yourself and others of any danger that that you might be in.
Only trained professionals can install, operate, maintain and repair the welding equipment.
During the operation, only necessary people should be present in the work space.
After shutting off the main power, please remain to examine and maintain the equipment
according to section 5 because of the DC voltage stored in the electrolytic capacitors.
1.2 Arc Welding Damage
ELECTRIC SHOCK CAN KILL.
Never touch electrical parts.
Wear welding-duty safety clothing including hole-free gloves to insulate yourself.
Insulate yourself from other work and the ground by using dry insulation. Make certain the
insulation is large enough to cover your full area of physical contact with work and ground.
Machine should not be operated in wet areas and all cables and hoses should be dry.
Never turn “ON” the machine power before reinstalling covers, guards and cables.
Be sure to install the power cord correctly. Ground the work or metal to be welded with an
earth clamp and be certain that the machine is grounded according to the operation manual.
The electrode and earth circuits are electrically “hot” when the welder is on. Do not touch
these “hot” parts with your bare skin or wet clothing as electrocution may result.
Always be sure the work cable makes a good electrical connection with the metal being

SAFETY
2
welded. The connection should be as close as possible to the area being welded.
Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe
operating condition. Replace any damaged insulation.
Never dip the electrode in water for cooling.
Never simultaneously touch electrically “hot” parts of electrode holders connected to two
welders because voltage between the two can be the total of the voltage of both welders.
When working above ground level in unenclosed areas, use a safety belt to protect yourself
per local codes.
FUMES AND GASES CAN BE DANGEROUS.
Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes
and gases. When welding, keep your head out of the fumes and have enough ventilation near
the arc to keep fumes and gases away from the breathing zone. When welding with electrodes
which require special ventilation such as stainless, hard facing, lead or cadmium plated steel
and other metals or coatings which produce highly toxic fumes, keep exposure as low as
possible and below Threshold Limit Values using local exhaust or mechanical ventilation. In
some instances, specifically when in small spaces, a respirator may be required. Additional
precautions are also required when welding on galvanized steel.
Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing,
cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating products.
Shielding gases used for arc welding can displace air and cause injury or death. Always use
enough ventilation, especially in confined areas, to insure breathing air is safe.
Read and understand the manufacturer’s instructions for this equipment and the
consumables, including the material safety data sheet and follow employer’s safety practices.
ARC RAYS CAN BURN AND BLIND.
Use suitable, flame-resistant clothing material to protect your skin from the arc rays.
Protect other nearby personnel with suitable, non-flammable screening and /or warn them not
to watch the arc nor expose themselves to the arc rays.

SAFETY
3
Be careful to avoid hot spatter or metal caused from the arc rays.
Use a shield with the proper filter and cover plates to protect your eyes from sparks and the
rays of the arc when welding or observing open arc welding.
WELDING SPARKS can cause fire or explosion.
Remove fire hazards from the welding area. If this is not possible, cover them with a
nonflammable material to prevent the welding sparks from starting a fire.
Have a fire extinguisher readily available.
Avoid welding near hydraulic lines as the fluid may be flammable.
Secure all gas cylinders and use only rated regulators and certified hoses.
When not welding, make certain no part of the electrode circuit is touching the work or ground
as accidental contact can cause overheating and create a fire hazard.
Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to
insure that such procedures will not cause flammable or toxic vapors from substances inside.
They can cause an explosion even though they have been “cleaned”.
Vent hollow castings or containers before heating, cutting or welding to prevent explosions.
Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such
as leather gloves, heavy shirt, cuff less trousers, high closed-toe shoes and a cap over your
hair. Wear ear plugs when welding out of normal position or in confined places. Always wear
safety glasses with correct DIN shading and side shields when in a welding area.

SAFETY
4
Connect the work cable to the work as close to the welding area as practical. Work cables
connected to the building framework or other locations away from the welding area increase
the possibility of the welding current passing through lifting chains, crane cables or other
alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.
Gas cylinder safety precautions.
Use only compressed gas cylinders containing the correct shielding gas for the process used
and properly operating regulators designed for the gas and pressure used. All hoses, fittings,
etc. should be suitable for the application and maintained in good condition.
Always keep cylinders in an upright position securely chained to a fixed support.
Cylinders should be located:
-Away from areas where they may be struck or subjected to physical damage.
-A safe distance from arc welding or cutting operations and any source of heat, sparks or
flame.
Never allow the electrode or any other electrically “hot” parts to touch a cylinder.
Keep your head and face away from the cylinder valve outlet when opening the valve.
Valve protection caps should always be securely in place except when the cylinder is in use
or connected for use in secured location.
1.3 Explanation of Electric and Magnetic Fields
Electric current flowing through any conductor causes localized Electro Magnetic Fields
(EMF). The effects of EMF are an ongoing discussion around the world. Up to now, no material
evidence has shown that EMF may have effects on health; however, the research on potential
damage due to EMF is still ongoing. Before any conclusion, all should minimize exposure to
EMF as much as possible by routing cables together (in cable cover if possible), keeping
cables a safe distance from the operator, being sure never to coil around your arms or body,
connecting the LINE power & ground (GRD) correctly and clamping the work cable to the
work-piece as close as possible to the weld area.
Warning: People with heart-pacemaker should be away from the welding operating area.

SUMMARY
5
2 Introduction
2.1 HST201 AC/DC Information
The HST201AC/DC TIG welding machine adopts the latest pulse width modulation (PWM)
technology and insulated gate bipolar transistor (IGBT) power module, which can change work
frequency to medium frequency so as to replace the traditional hulking work frequency
transformer with the cabinet medium frequency transformer. Thus, it is known for being
portable, small in size, light weight, and having low consumption.
The parameters of HST201 on the front panel all can be adjusted with a single control
knob. The parameters include, start current, crater arc current, welding current, base current,
duty ratio, upslope time, downslope time, pre-gas, post-gas, pulse frequency, AC frequency,
balance, hot start, arc force and arc length etc. When welding, it takes high frequency and high
voltage for arc igniting to ensure the success ratio of ignition.
Characteristics：
MCU control system: Responds immediately to any changes.
High frequency & voltage ignition: Ensures the success ratio of igniting arc, the
reverse polarity ignition ensures good ignition behavior for TIG welding.
Break-arc Protection: Avoid arc-break by keeping torch in close proximity to
material; however, if arc-break occurs the HF will keep the arc stable.
Foot pedal control: Provides adjustable welding current for best quality welds.
Tungsten protection: If the tungsten electrode touches the work-piece when DC-TIG
welding, the current will drop automatically to protect tungsten rod.
Intelligent protection: In the event of over-voltage, over-current or over-heating, the
alarm lamp on the front panel will illuminate and the output current will be cut off.
Machine will auto reset when condition has cleared.
Double purpose AC/DC inverter: Excellent performance on Al-alloy、all carbon
steels、stainless steel & titanium.

SUMMARY
6
Machine Welding Functions
DC MMA (STICK electrode welding for ferrous metals)
DC TIG (TIG welding for ferrous metals)
DC Pulse TIG (TIG with pulsed power for welding ferrous metals)
AC MMA (STICK electrode welding for aluminum metals)
AC TIG (TIG welding for aluminum metals)
AC Pulse TIG (TIG with pulsed power for welding aluminum metals)
1. For DC MMA, polarity connection can be chosen according to different electrodes，
please refer to 3.5；
2. For AC MMA, magnetic flow caused by invariable DC polarity can be avoided；
3. For DC TIG, DCEP is normally used (work-piece connected to positive polarity, while
torch connected to negative polarity). This connection has many characters, such as stable
welding arc, low tungsten pole loss, more welding current, narrow and deep weld.
4. For AC TIG Square wave arc is more stable than Sine wave arc. Additionally, you can
not only obtain maximum penetration with the minimum tungsten pole loss, but also obtain
better cleaning effect.
5. For DC TIG Pulsed, see the following characters: 1) Pulse heating. Metal in Molten pool
has short time on high temperature status and freezes quickly, which can reduce the
possibility to produce hot crack of the materials with thermal sensitivity. 2) The work-piece
gets little heat. Arc energy is focused. Suitable for thin sheet and super thin sheet welding.
3) Exactly control heat input and the size of the molten pool. The depth of penetration is
even. Suitable for welding by one side and forming by two sides and all position welding for
pipe. 4) High frequency arc can make metal for microlite fabric, eliminate blowhole and
improve the mechanical performance of the joint. 5) High frequency arc is suitable for high
welding speed to improve the productivity.

SUMMARY
7
HST201 welding machine is suitable for all positions welding for various plates made of
stainless steel, carbon steel, alloyed steel, titanium, aluminum, magnesium, cuprum, etc. It can
be used for pipe installment, mold mend, petrochemical, architecture design, car repair, bicycle
repair, common manufacturing and more.
2.2 Inverter module explanation
MMA——Manual Metal Arc welding (STICK welding)
PWM——Pulse-Width Modulation (Method of varying output power)
IGBT——Insulation Gate Bipolar Transistor (Fast acting, high power switching)
TIG——Tungsten Insert Gas welding
2.3 Working principle
The working principle HST201 welding machines is shown as the following figure.
Single-phase 110-220V work frequency AC is rectified into DC (about 312V), then is converted
to medium frequency AC (about 20KHz) by inverter device (IGBT module), after reducing
voltage by medium transformer (the main transformer) and rectifying by medium frequency
rectifier (fast recovery diodes), then is outputted DC or AC by selecting IGBT module. The
circuit adopts current feedback control technology to insure stable current output. Meanwhile,
the welding current parameter can be adjusted continuously and infinitely to meet with the
requirements of welding craft.
Rectif
ier Invert er
Trans
forme
r
Rectif
ier
Hall
devic
e
Current feedback
control
Single-phase, AC DC AC DC
220V，50Hz
AC Invert
er
AC or DC
Control signal
AC or DC

SUMMARY
8
2.4 Volt-Ampere Characteristic
The HST201 AC/DC welding machine has an excellent volt-ampere characteristic as
shown in the following figure. The relation between the conventional rated loading voltage U2
and the conventional welding current I2is as follows:
When I2≤600A，U2=10 + 0.04I2(V); When I2＞600A,U2=34(V).
67
34
10
0600 I2（A）
U2（V）
Working
point
Volt-ampere characteristic The relation between the
conventional loading
voltage and welding current

OPERATION
9
3 Installation and Adjustment
3.1 Parameters
Model
Parameters
HST201 AC/DC PULSE PFC
Input power
1~220±10%，50Hz
1~110±10%，50Hz
Rated input current
（A）
20/18（AC/DC
TIG）
30/27（AC/DC
MMA）
29/33（AC/DC
TIG）
34/39（AC/DC MMA）
Rated input power
（KW）
4.5/3.9（AC/DC
TIG）
7/5.7（AC/DC
MMA）
3.4/3.7（AC/DC
TIG）
3.8/4.3（AC/DC MMA）
Power factor
0.99
Max-no-load
voltage(V)
67
Start current
adjustment（A）
TIG
MMA
TIG
MMA
AC
DC
AC
DC
AC
DC
AC
DC
5～
welding
current
5～
weldin
g
current
——
——
5～
welding
current
5～
weldin
g
current
——
——
Welding current
adjustment （A）
10～200
5～200
10～
170
5～170
10～
200
5～
200
10～170
5～170
Down slope time
adjustment（S）
0～10
Pre-gas time（S）
0.1~2
Post-gas time
adjustment（S）
0～10
Clearance effect
（%）
20～50
Efficiency
Duty cycle（40℃,
10 minutes）
AC
DC
AC
DC
40% 200A
35% 200A
30% 130A
30% 160A
60% 165A
60% 155A
60% 95A
100% 130A
100% 120A
100% 70A
100% 125A
Protection class
IP23
Insulation class
H
Dimensions
（L×W×H）（ mm）
510×190×340
Weight(Kg)
14.5

SET-UP, OPERATION & TROUBLSHOOTING
10
3.2 CSA/UL Duty Cycle
The letter “X” stands for duty cycle, which is defined
as the proportion of the time that a machine can work
continuously within a defined time (10 minutes) at the
rated welding current. CSA/UL is 10 minutes @ 105°F.
The relation between the duty cycle “X” and the
output welding current “I” is shown as the right figure.
If the welder over-heats due to operation beyond duty-cycle, the IGBT over-heat
protection will output an instruction to cut output welding current, and brighten the over-heat
pilot lamp on the front panel. If this condition occurs, welding should stop for 10 minutes while
the machine cooling fan reduces internal heat. When operating the machine again, the
welding output current or the duty cycle should be reduced so as not to repeat over-heating
condition.
3.3 Movement and placement
Place the welder on a firm surface in horizontal position with all four feet in contact.
Locate machine in dry, clean environment with open-air space for cooling.
Place gas cylinder in upright position and secure in place for safe operation.
Make sure that all cables and torches are in a safe position before using welder.
Ensure all electrical and grounding connections are secure per local codes.
Safety shields and curtains should be used to protect other personnel in shop.
35%

SET-UP, OPERATION & TROUBLSHOOTING
11
3.4 Power supply input connection
The HST201 AC/DC PULSE PFC welding machine features electronic switching power
supply allowing it to be connected to any 115-240VAC, 1-Phase LINE power outlet.
208-240VAC LINE CONNECTION: Machine is provided with NEMA6-50P LINE Service
cord to be plugged into any 6-50R outlet with 208-240VAC, single-phase power and 50-amp
circuit breaker.
110-120VAC LINE CONNECTION: Machine is provided with NEMA 6-50R to NEMA
5-15P “Jumper” Service cord. This allows machine to be plugged into any 5-15R standard
outlet with 110-120VAC, single-phase power and 20-amp circuit breaker.
In the event NEMA6-50R or 5-15R outlets, with rated LINE circuit breaker
amperage are not available, they should be installed by a licensed electrician in
accordance to all national & local codes.
In the event LINE power supply is over voltage (>245) or under voltage (<195),
protection circuit inside the machine will illuminate alarm light and current will be cut off.
If the power supply voltage continually goes beyond the safe work voltage range, it will
shorten the life of the machine. If this occurs, the below measures should be taken:
Change the LINE power supply. Such as, connect the welder to a dedicated circuit.
Shut off other machines using LINE power supply at the same time as welding.
WARNING: Any modification or removal of factory installed service power cords
will VOID MACHINE WARRANTY!

SET-UP, OPERATION & TROUBLSHOOTING
12
3.5 Machine operational layout
1 Positive output: Socket with positive polarity output.
2 Negative output:Socket with negative polarity output.
3 Control output: Socket to torch or foot pedal control wire.（Lead 8 - lead 9 are trigger)
4 Shield gas output: Brass male fitting to connect gas input hose of torch.
5 Power switch: Controls input power ON/OFF to the welding machine
6 Power source input: Power cord service cable with input power plug
7 Shield gas input: Brass male fitting to connect gas hose from shield gas cylinder.

SET-UP, OPERATION & TROUBLSHOOTING
13
3.6 Electrode / Torch polarity connections（MMA）
DC POSITIVE CONNECTION (DCEP): Work-piece is connected to the positive (+)
socket of welding machine, and welding torch is connected to the negative (-) socket.
Most common TIG and MMA (Stick) welding connection: Torch to negative (-)
DC NEGATIVE CONNECTION (DCEN): Work-piece is connected to the negative (-)
socket of welding machine, and welding torch is connected to the positive (+) socket.
CONTROLCABLE SOCKET: Torch or foot pedal control plug with12 pins.
GAS LINE CONNECT: Gas hose from welding torch connects for automatic operation.
TIG TORCH CONSUMABLES: Refer to TIG torch parts breakdown
WARNING: Use of HF ignition can cause interferences in equipment near the
welding machine. Be sure to take safety precautions or shielding measures.

SET-UP, OPERATION & TROUBLSHOOTING
14
3.7 Foot pedal switch control
● Once the foot pedal cable is inserted into control-socket on front panel of welder, it will
identify the pedal switch. Only 2T/4T modes should be selected when foot pedal operation is
desired.
● Adjustment knobs on machine will remain functional
● Pins #7 & #8 on control-socket are trigger contacts. Pins #1 & #2 are contact closure
(trigger) and pins #3, #4, & #5 are for adjustable resistance to control output power.
3.8 Control knob functions
TOGGLE TO SELECT various machine processes and functions (X & Y axis)
TURN TO SET operational levels (Clockwise +& Counter-Clockwise -)
PUSH TO SAVE settings to various stored JOB programs.
Connected to control
socket on the front
panel
Foot pedal adjustment
of welding curren

OPERATION
15
4 Operation
4.1 Control panel layout
The key feature of the control panel is the logical way in which the controls are arranged. All the
main parameters needed for operation are easily selected and adjusted to welding application.
Once parameters for a particular welding JOB have been set, push to save in memory to recall.
The illustration below shows an overview of the HTG201 control panel as an example. You will
find a detailed description of these settings in the following section.
(1) MMA (Stick), TIG with HF ignition or TIG with LIFT-ARC ignition process selection
(2) AC / DC output current and wave form selection

SET-UP, OPERATION & TROUBLSHOOTING
16
(3) Trigger mode selection (TIG only)
(4) TIG parameter settings
(5) AC parameter settings
(6) MMA stick electrode parameter settings

SET-UP, OPERATION & TROUBLSHOOTING
17
4.2 Argon Arc Welding Operation
4.2.1 TIG welding（4T operation）
The START and END current and can be pre-set to compensate for crater that
appears at the beginning and end of the welding making 4T ideal for aluminum and
medium thickness plates.
Process：
0：Press down and hold the pedal switch, gas valve is opened.
0～t1：Pre-gas flows at preset time (0.1~1S);
t1～t2：Arc is ignited at t1 and output is at preset value of start current;
t2：Release pedal switch, the output current slopes up from the start current;
t2～t3：The output current rises to the setting value (Iw or Ib), per upslope time set;
t3～t4：Welding process. During this period, the pedal switch is UP;
Note: Select the pulsed output, the base current and welding current will be outputted
alternately; otherwise, output the setting value of welding current;
t4：Press the pedal switch DOWN and the welding current will drop per the selected
down-slope time to end current setting;
t4～t5：The output current slopes down to the end crater current setting
t5～t6：The crater current time (controlled by pedal);
t6：Release pedal switch to stop arc but keep shield gas flowing;
t6～t7：Post-gas time（0.1～10S）until valve closes;
t7：Gas valve is closed and welding process is finished.

OPERATION
18
4.2.2 TIG welding (2T operation)
This function, without the adjustment of start current and crater current, is ideal for
tack welding、transient welding and thin plate welding.
t（s）
0
I（A）
Loosen the
welding gun
switch
Press and hold the welding
gun switch
t1 t4 t5
Arc is
ignited Arc is turned off
t2 t3
Welding current Is
The setting base
current Ib
Process：
0: Press the gun switch and hold it. Electromagnetic gas valve is turned on. The
shielding gas stars to flow.
0～t1: Pre-gas time (0.1~1s)
t1～t2: Arc is ignited and the output current rises to the setting welding current (Iw or Ib)
from the min welding current.
t2～t3: During the whole welding process, the gun switch is pressed and held without
releasing.
Note: Select the pulsed output, the base current and welding current will be outputted
alternately; otherwise, output the setting value of welding current;
t3: Release the gun switch, the welding current will drop in accordance with the
selected down-slope time.
t3～t4: The current drops to the minimum welding current from the setting current (Iw or
Ib), and then arc is turned off.
t4～t5: Post-gas time, after the arc is turned off. You can adjust it (0.1~10s) through
turning the knob on the front panel.
t5: electromagnetic gas valve turned off, the shield gas stops to flow, and welding is
finished.