Hyundai TIG-160 User manual

DC INVERTER TIG WELDER
TIG-
160/200
User Manual
For Your Safety
Read and understand this manual
before use. Keep this manual for future
reference.
EN

We are still constantly improving this welder, therefore, some parts of this welder may be changed in order to
achieve the better quality, but the main functions and operations will not be alternated and changed.
Your understanding would be greatly appreciated.
TIG-160/200

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Safety ............................................................................................................................................................
General Description .....................................................................................................................................
Main Parameters ..........................................................................................................................................
Operation Control and Description .............................................................................................................
Installation Debugging and Operation ........................................................................................................
Caution .........................................................................................................................................................
Maintenance .................................................................................................................................................
Troubleshooting ............................................................................................................................................
Exploded Drawing ........................................................................................................................................
2
4
4
5
6
7
8
9
11
Table of Contents

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Welding is dangerous, and may cause damage to you and others, so take good protection when welding. For
details, please refer to the operator safety guidelines in conformity with the accident prevention requirements
of the manufacturer.
Professional training is needed before operating the machine.
● Use labor protection welding supplies authorized by national security supervision department.
● The operator must be qualified personnel with a valid “metal welding (OFC) operations” operation certificate.
● Cut off power before maintenance or repair.
Electric shock—may lead to serious injury or even death.
● Install earth device according to the application criteria.
● Never touch the live parts when skin bore or wearing wet gloves/clothes.
● Make sure that you are insulated from the ground and work piece.
● Make sure that your working position is safe.
Smoke& gas—may be harmful to health.
● Keep the head away from smoke and gas to avoid inhalation of exhaust gas from welding.
● Keep the working environment in good ventilation with exhaust or ventilation equipment when welding.
Arc radiation—may damage eyes or burn skin.
● Wear suitable welding masks and protective clothing to protect your eyes and body.
● Use suitable masks or screens to protect spectators from harm.
Improper operation may cause fire or explosion.
●
Welding sparks may result in a fire, so please make sure no combustible materials nearby and pay attention
to fire hazard.
● Have a fire extinguisher nearby, and have a trained person to use it.
● Airtight container welding is forbidden
●
Must not use the machines for other purposes except welding, such as pipe thawing, battery charging,
heating.
1. Safety

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Hot work piece may cause severe scalding.
● Do not contact hot work piece with bare hands.
● Cooling is needed during continuous use of the welding torch.
Magnetic fields affect cardiac pacemaker.
● Pacemaker users should be away from the welding spot before medical consultation.
Moving parts may lead to personal injury.
● Keep yourself away from moving parts such as fan.
● All doors, panels, covers and other protective devices should be closed during operation.
Please seek professional help when encountering machine failure.
● Consult the relevant contents of this manual if you encounter any difficulties in installation and operation.
●
Contact the service center of your supplier to seek professional help if you still cannot fully understand after
reading the manual or still cannot solve the problem according to the manual.
Safe use of the welding torch.
●
Parts of the machine, such as the end of the filler wire and welding torch become burning hot during use.
The wire is also sharp and moves quickly, so be careful when threading it to place.
● Never carry the machine on your shoulder during welding, but place it on an even surface. Also, do not store
the machine by hanging it from the shoulder strap. The shoulder strap is for carrying only.
● Do not keep the machine near or on hot objects, as the plastic cover may melt.
● Do not move the shielding gas bottle when the control valve is in place. Fix the gas bottle securely in an
upright position to a separate wall rack or bottle cart.
● Always close the gas bottle after use.

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3. Main Parameters
The welding machine has the most advanced inverter technology adopting rectifier.
The development of inverter gas-shielded welding equipment profits from the development of the inverter
power supply theory and components. Inverter gas-shielded welding power source utilizes high-power
component MOSFET to transfer 50/60Hz frequency up to 100KHz, then reduce the voltage and commutate,
and output high-power voltage via PWM technology. Because of great reduction of main transformer’s weight
and volume; the efficiency increases by 30%. Its transfer efficiency is above 85%. The appearance of inverter
welding equipment is considered to be a revolution for welding industry.
Welding power source can offer stronger, more concentrated and more stable arc. When stick and work
piece get short, its response will be quicker. It means that it is easier to design welding machine with different
dynamic characteristics, and it can even be adjusted specially to make arc softer and also harder.
TIG welding machine is easy for arc initiation and has the functions of arc initiation current, arc stop current,
welding current, basic value current , current ascending time, current descending time, gas delay time, con-
tinuous adjustment What’s more, pulse frequency and pulse duty can also be adjusted independently It has
the characteristics of automatic control of arc initiation, arc stop and stable arc, which make the best result
for shape and inner quality of the welding surface.
The machine can be for multi-use, and can weld stainless steel, carbon steel, copper and other color metal,
and also can use for traditional electric welding.
2. General Description
Model TIG-160 TIG-200
Rated Input Voltage (V) 1P AC 230V, 50Hz
Rated Input Current (A) 15 20
Output Current (A) TIG
10~160
MMA
10-140
TIG
10~200
MMA
10~160
Rated Output Voltage (V) 16.4 25.6 18 26.4
No-load Voltage (V) 56 56
Rated Duty Cycle (%) 60 60
Efficiency (%) 85 85
Protection Class IP21S IP21S
Insulation Class F F
Arc Starting HF HF
No-load Loss (W) 35 35

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The panel picture below is for reference only. If any difference with the real machine, please follow with the
real machine.
TIG Welding Description
1) Turn on the power switch at the back panel, digital current meter is normal, fan begins to wheel.
2) Open the valve of argon cylinder, adjust the volume of flow meter and make it is adequate to welding.
3) Press switch of torch, electromagnetic valve is started. Sound of HF arc striking can be heard, at the same
time argon is flowing from torch burner.
Notes
When welding is first operated, user must press
switch of torch for several seconds and begin to
weld until all of air is be drained out. When welding
is over, argon will still flow out in several seconds in
order to protect welding spot before cooling down.
So torch must be kept onto welding place for some
time before arc has been extinguished.
4) Set suitable welding current and make sure
welding current is adequate to thickness of work
piece and process demand.
5) It is 2-4 mm from welding tungsten electrode to
work piece, press control knob of torch, burn
and strike arc, sound of HF arc-striking will be
diminished. The welding machine can be operated
now.
Stick Welding Description
1) Open power switch of front panel, fan is beginning to work.
2) Make sure function switch of front panel is “down” position that is sticking. Impulse changeover switch and
knob of current down-slope time will not work. 3. Make sure welding current is adequate to thickness of
work piece.
Warning
During welding, it is forbidden to pull off any plug or cable in use, or it will lead to life-threatening danger and
severe damage to the machine.
4. Operation Control and Description
Indicator light
Power switch
Output termind -
Output terminal
Output termind +
Stick/TIG shift
Welding current
adjustment
Gas-electricity
output terminal
Air plug

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The machine is equipped with power voltage compensation equipment. When power voltage moves between ±
15% of rated voltage, it still can work normally.
When using long cable, in order to prevent voltage from going down, bigger section cable is suggested. If cable
is too long, it may affect the performance of the power system. So we suggest you to use configured length.
1) Make sure intake of the machine not blocked or
covered, lest cooling system could not work.
2) Make good connection of shielded gas source. Gas
supply passage includes cylinder, argon decompress
flow meter and pipe. Connecting part of pipe should
use hoop or other things to fasten, lest argon leaks
out and air gets in.
3) Use inducting cable whose section is not less than 6
mm2 to connect the housing to the ground. The way
is from the ground-connecting screw at the back to
the earth device.
4) Correctly connect the arc torch or holder according
to the picture. When using MMA welding: Make
sure the cable, holder and fastening plug have been
connected with the ground. Put the fastening plug into the fastening socket at the “-” polarity and fasten it
clockwise. When using pulse arc welding: Put the gas-electricity plug of the welding gun to the joint at the
front panel, and fasten clockwise. Put the air switch on the gun to the relevant joint at the front panel, and
fasten the screw.
5) Put the fastening plug of the cable to fastening socket of “+” polarity at the front panel, fasten it clockwise,
and the earth clamp at the other terminal clamps the work piece.
6) According to input voltage grade, connect power cable with power supply box of relevant voltage grade.
Make sure no mistake and make sure the voltage difference among permission range. After the above job,
installment is finished and welding is available.
Warning
Before connecting operation, please make sure all the power is turned off. The right order is
to connect the welding and ground cable to the machine first, and make sure they are firmly connected and
then put the power plug to the power source.
5. Installation Debugging and Operation

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6. Caution
Environment
1) The machine can perform in environment in dry condition with a dampness level of max 90%.
2) Ambient temperature is between 10 to 40oC.
3) Avoid welding in sunshine or rain.
4) Do not use the machine in environment where condition is polluted with conductive dust on the air or
corrosiveness gas on the air
5) Avoid gas welding in the environment of strong airflow.
Safety norms
The welding machine is equipped with protection circuit of over voltage, current and heat. When voltage and
output current and temperature of machine are exceeding the rate standard, welding machine will stop work-
ing automatically. Because it will be damage to welding machine, user must pay attention as follows.3
1) The working area is adequately ventilated!
The welding machine is powerful machine, when it is being operated, it generated high currents, and natu-
ral wind will not make machine cool enough. So there is a fan in machine to cool down machine. Make sure
the intake is not in block or covered, it is 0.3 meter from welding machine to objects of environment. User
should make sure the working area is adequately ventilated. It is important for the performance and the
durability of the machine.
2) Do not overload!
The operator should remember to watch the max duty current (Response to the selected duty cycle).
Keep welding current from exceeding max duty cycle current. Over-load current will damage and burn up
machine.
3) No over voltage!
Power voltage can be found in table of main technical data. Automatic compensation circuit of voltage will
assure that welding current remain in allowable range. If power voltage exceeds limited range, it is damage
to components of machine. The operator should understand the situation and take preventive measures.
4) There is a grounding screw behind welding machine and there is grounding marker on it. Mantle must
be grounded reliable with cable which section is over 6 square millimeter in order to prevent from static
electricity and leaking.
(5) If welding time exceeds limited duty cycle, welding machine will stop working for protection. Because
machine is overheated, temperature control switch is on “ON” position and the indicator light is red. In this
situation, you don’t have to pull the plug in order to let the fan cool the machine. When the indicator light is
off, and the temperature goes down to the standard range, it can weld again. should be fully prepared for
protection.

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Caution : Before Maintenance and checking, power must be turned off, and before opening the housing,
make sure the power plug is pulled off.
1) Remove dust by dry and clean compressed air regularly, if welding machine is operating in environment
where is polluted with smoke and contaminated air, the machine needs to be cleaned everyday
2) Pressure of compressed air must be in reasonable range in order to prevent damage to small components
of machine.
3) Check internal circuit of welding machine regularly and the cable as well. Circuit is connected correctly and
connectors are connected tightly (especially insert and connect components). If scale and loose are found,
please give a good polish to them, then connect them again tightly.
4) Avoid water and steam enter into inter-machine. If they enter into machine, please dry the inside of machine
then check insulation of machine.
5) If welding machine has not operated long time, it must be put into packing box and stored in dry environment.
Correct Disposal of this product
This marking indicates that this product should not be disposed with other household wastes throughout the
EU. To prevent possible harm to the environment or human health from uncontrolled waste disposal, recycle
it responsibly to promote the sustainable reuse of material resources. To return your used device, please use
the return and collection systems or contact the retailer where the product was purchased. They can take this
7. Maintenance
Caution : Creep age-protecting switch. The machine is mainly used in industrial site. It will produce
radio wave, so the worker should be fully prepared for protection. should be added when using the
machine
Warning : BEFORE CHECKING : Blind experiment and careless repair may lead to more problem of the
machine that will make formal check and repair more difficult. When the machine is electrified,
the naked parts contain life-threatening voltage. Any direct and indirect touch will cause electric
shock, and severe electric shock will lead to death.
Caution : The machine is mainly used in industrial site. It will produce radio wave, so the worker should
be fully prepared for protection.

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Fittings, welding materials, environment factor, supply powers maybe have something to do with
welding. User must try to improve welding environment.
A. Black welding spot
Welding spot is not protected from oxidizing. User may check as following:
1. Make sure the valve or argon cylinder open and its pressure is enough. Argon cylinder must be filled up to
enough pressure again if pressure of cylinder is below 0.5Mpa.
2. Check if the flow meter opens and has enough flow. User can choose different flow according to welding
current in order to save gas. But too small flow maybe cause black welding spot because preventive gas is
too short to cover welding spot. We suggest that flow of argon must be kept min 5 L/min.
3. Check if torch is in block.
4. If gas circuit is not air-tight or gas is not pure, it can lower welding quality.
5. If air is flowing powerfully in welding environment, that can lower welding quality.
B. Arc-striking is difficult and easy to pause
1. Make sure quality of tungsten electrode is high.
2. Grind end of the tungsten electrode to taper. If tungsten electrode is not grinded, that will be difficult to
strike arc and cause unstable arc.
C. Output current not to rated value
When power voltage departs from the rated value, it will make the output current not matched with rated
value; when voltage is lower than rated value, the max output may be lower than rated value.
D. Current is not stable when machine operates
It has some factors as following:
1. Electric wire net voltage has been changed.
2. There is harmful interference from electric wire net or other equipment.
E. When use MMA welding, too much spatter
1. Maybe current is too big and stick’s diameter is too small;
2. Output terminal polarity connection is wrong, it should apply the opposite polarity at the normal technics,
which means that the stick should be connected with the negative polarity of power source and work piece
should be connected with the positive polarity. So please change the polarity.
8. Troubleshooting

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Malfunction Cause and Solution
Power indicator is not lit, fan does
not work and no welding output.
1. Power switch is out of work.
2. Check if electrify wire net (which is connected to input cable) is in work.
3. Check if input cable is out of circuit.
Power indicator is lit; fan does not
work or revolve several circles, no
welding output.
1. Maybe the machine is wrongly connected to 380V power and it causes machine to be in protection circuit.
Connect to 220V power and operate machine again.
2. 220V power is not stable,(input cable is too slender)or input cable is connected to electrify wire net because
machine is in protection circuit. Add the section of cable and tighten input connector firmly. Close machine for
2-3 minutes then open it again.
3. Cable loosens from switch to power panel. Tighten them again.
4. Open and close power switch constantly in short time because machine is in protection circuit Close machine
2-3 minutes then open it again.
Main circuit 24V relay of power panel is not close or has been damaged. Check 24V power source and relay. If
relay has been damaged, replace it with same model.
Fan is working, indicator is not lit
and sound of HF arc-striking
cannot be heard, wiping welding
cannot strike arc.
1. Positive and negative electrodes of VH-07 insert component voltage should be about DC308V from power panel
to MOS board.
(1) If circuit is broken and silicon bridge is poorly contacted.
(2) If some of four high electrolytic (about 470UF/450V) of power panel capacitor is leaking.
2. There is a green indicator in auxiliary power of MOS board, if it is not on, auxiliary power is out of work .Check
fault spot and connect with seller.
3. Check if connectors are poorly contacted.
4. Check control circuit and find out reasons or connect with seller.
5. Check if control cable of torch is broken.
Abnormal indicator is not on,
sound of HF arc-striking can be
heard, but there is no welding
output.
1. Check if torch cable is broken.
2. Check if grounding cable is broken or not connected to welding piece.
3. Output terminal of positive electrode or torch electrify loosens from inter-machine.
Abnormal indicator is not lit, sound
of HF arc-striking cannot be heard,
wiping welding can strike arc.
1. Primary cable of arc-striking transformer is not connected to power panel firmly, tighten it again.
2. Arc-striking tip is oxidized or too far, give a good polish to it or change it as about 1 mm between arc-striking
tips.
3. Switch (sticking/argon-arc welding) is damaged, replace it.
4. Some of HF arc-striking circuit components are damaged. Find out and replace it.
Abnormal indicator is lit but there
is no welding output.
1. Maybe it is overheat protection, please close machine first, and then open the machine again after abnormal
indicator is out.
2. Maybe it is overheat protection, wait for 2-3 minutes (argon-arc welding does not has overheat protection
function).
3. Maybe inverter circuit is in fault, please pull up the supply power plug of main transformer which is on MOS
board (VH-07 insert which is near the fan) then open the machine again.
(1) If abnormal indicator is still lit, close machine and pull up supply power plug of HF arc-striking power
source (which is near the VN-07 insert of fan ), then open machine :
a. If abnormal indicator is still lit, some of fieldistor of MOS board is damaged, find out and replace it with
same model.
b. If abnormal indicator is not lit, rise transformer of HF arc-striking circuit is damaged, replace it.
(2) If abnormal indicator is not lit ,
a. Maybe transformer of middle board is damage, measure inductance volume and Q volume of main
transformer by inductance bridge (L=0.9-1.6mH Q>35) .If volume is too low, please replace it.
b. Maybe secondary rectifier tube of transformer is damaged, find out faults and replace rectifier tube
with same model.
4. Maybe feedback circuit is broken.
Output current is not stabilizing or
out of potentiometer control and
sometime is high, sometime is low.
1. 1K potentiometer is damage, replace it.
2. All kinds of connectors are poor contact, specially inserts etc., please check it.
Sticking spatter is much and
caustic electrode of is difficult. Electrode is connected wrong, exchange grounding cable and handle cable.
Common Malfunction Analysis and Solution:

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9. Exploded Drawing
1. Silicone rubber
2. LED
3. Power switch
4. Switch
5. Fan net
6. Fan net
7. Electromagnetically operated valve
8. Foot
9. Black handle
10. Knob
11. Self-locking cable buckle
12. Fast connector
TIG-160/200
13. Bottom
14. Cover
15. Front panel
16. Side shield plate
17. Radiator left
18. Radiator right
19. Cross beam
20. Gas interface
21. Insulation board on top PCB
22. Insulation board on bottom PCB
23. Brass connector
24. Vertical beam
25. Vertical beam
26. Middle PCB
27. PCB
28. Top PCB
29. Bottom PCB
30. Top shield plate
31. Bottom shield plate
32. Silicon bridge 11 25A
33. Silicon bridge 14 25A
34. Coil
35. Current potentiometer
36. Socket

DC Inverter TIG Welder HYUNDAI
EC
Declaration of
Conformity
HYUNDAI Corporation
25, Yulgok-ro 2-gil, Jongno-gu, Seoul 03143 Korea
Declare that the product detailed below :
DC INVERTER TIG WELDER
MODEL : TIG-160/200
Satisfies the requirements of the Council Directives :
EC-Low voltage directive 2014/35/EU
EC Directive of Electromagnetic Compatibility 2014/30/EU
RoHS Directive 2011/65/EU
and conform with the norms :
EN 60974-1 : 2012
EN 60974-10 : 2014
IEC 62321 : 2008
2016
We :
Date : 2016.11.01
General Manager
Inseok Jeong
Project Manager
Donghoon Park

HYUNDAI Corporation
25, Yulgok-ro 2-gil, Jongno-gu,
Seoul 03143, Korea,
Post Code : 03143
82 2 390 1114
www.hyundaicorp.com
Copyright 2016 HYUNDAI Corporation All rights reserved.
Made in P.R.C
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