LOKERMANN Grand Tig 200 User manual

USER MANUAL
INVERTER Based Welding Machines
IMPORTANT: Read this OPERATOR MANUAL together
with PRESCRIPTION AND COMPLIANCE MANUAL before
to use this equipment. In case of loss one of two parts
contact immediately your dealer.
Allow the operator to consult this manual.
GRAND TIG 200
AC DC PULSE PFC MV

1 INSTALLATION WARNING
2 OVERVIEW
2.1 Features
2.2 Technical Data
2.3 Brief Introduction
2.4 Duty cycle and Over-heat
2.5 Working Principle
2.6 Volt-Ampere Characteristic
3 INSTALLATION & OPERATION
3.1 Layout for the front and rear panel
3.2 Power supply input Connection
3.3 Installation & Operation for MMA Welding
3.3.1 Set up installation for MMA Welding
3.3.2 Operation for MMA Welding
3.4 Installation & Operation for TIG Welding
3.4.1 Set up installation for TIG Welding
3.4.2 Operation for TIG Welding
3.4.3 Remote current control
3.4.4 Tig Welding Techniques
3.4.5 Electrodes
3.4.6 TIG Welding trouble shooting
3.5 Remote control Configuration
3.5.1 Wireless remote control Configuration
3.5.2 Wire foot pedal Configuration
3.6 Operation environment
3.7 Operation Notices
4 MAINTENANCE & TROUBLESHOOTING
4.1 Maintenance
4.2 Troubleshooting
4.3 List of error code
4.4 Electrical schematic drawing
CONTENT

This machine is certified according to 60974 -10:2014
Arc Welding Equipment Part 10: Electromagnetic compatibility (EMC)
WARNING: This Class A equipment is intended for industrial use and it is
in residential locations where the elctric
al power is provided by the public low voltage supply
system. There may be potential difficulties in ensuring electromagnetic
locations, due to conducted as well as radiated
WARNING: This equipment does not comply with
IEC 61000
- 3 - 12. If it is connected to a public low
that the equipment may be connected.
Assessment of area
Before installing arc welding equipment the user shall make an assessment of potential
electromagnetic problems in the surrounding area:
a) other supply cables, control cables, signalling and telephone
adjacent to the arc welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, for example guarding of industrial equipment;
e) the health ofthe people around, for example the use of pacemakers;
f) equipment used for calibration or measurement;
g) the immunity of other equipment in the environment.
The user shall ensure that other
equipment being used in the environment is compatible.
This may require additional protection measures;
h) the time of day that welding or other activities are to be carried out.
The size of the surrounding area to be considered will depend on the
structure of the building and other activities that are
taking place. The surrounding area may extend beyond the boundaries of the premises.
requirement and the EUT belongs to Group 2 Class A.
not intended for use
compatibility in those
disturbances.
voltage system
it is the responsability of the installer or user of the equipment to ensure,
by consultation with the distribution network operator if necessary
cables, above, below and
Methods of reducing emissions
Public supply system
Arc welding equipment should be connected to the public supply system
according to this manual recommendations. If interference occurs, it may be
necessary to take additional precautions such as filtering of the public supply
system. Consideration should be given to shielding the supply cable of
permanently installed arc welding equipment, in metallic conduit or equivalent.
Shielding should be electrically continuous throughout its length. The shielding
should be connected to the welding power source so that good electrical
contact is maintained between the conduit and the welding power source
enclosure. Maintenance of the arc welding equipment. The arc welding
equipment should be routinely maintained according to this manual
recommendations. All access and service doors and covers should be closed and
properly fastened when the arc welding equipment is in operation. The arc
welding equipment should not be modified in any way, except for those changes
and adjustments covered in this manaul. In particular, the spark gaps of arc striking
and stabilising devices should be adjusted and maintained according to our
recommendations.
1
Installation
warning

Welding cables
The welding cables should be kept as short as possible and should be positioned
close together, running at or close to the floor level.
Equipotential bonding
Bonding of all metallic objects in the surrounding area should be considered.
However, metallic objects bonded to the work piece will increase the risk that the
operator could receive an electric shock by touching these metallic objects and
the electrode at the same time. The operator should be insulated from all such
bonded metallic objects.
Earthing of the workpiece
Where the workpiece is not bonded to earth for electrical safety, nor connected to
earth because of its size and position, for example, ship’s hull or building steelwork,
a connection bonding the workpiece to earth may reduce emissions in some, but
not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users or damage to other electrical equipment. Where
necessary, the connection of the workpiece to earth should be made by a direct
connection to the workpiece, but in some countries where direct connection is not
permitted, the bonding should be achieved by suitable capacitance, selected
according to national regulations.
Screening and shielding
Selective screening and shielding of other cables and equipment in the surrounding
area may alleviate problems of interference. Screening of the entire welding area
may be considered for special applications.

-PFC Technology: Power factor more than 0.99.
Multiple advantages such as energy saving and wider input voltage.
Multivoltage: It can be supplied both with 110V and 230V.
-Lift TIG and HF Start Modes for
versatility when welding around
sensitive.
electronic equipment.
-Adjustable arc force, hot start & anti stick control for greater control and ease
of use in MMA welding.
-Electronic HF TIG arc ignition system
for contamination free and easy arc
starting with low EMF interference.
-2T/4T /Repeat trigger control.
-AC waveforms include square wave,
sine wave, triangular wave.
-AC balance control monitors the
oxide and helps better cleaning
uring aluminum welding.
-Digital display meter for accurate
setting & feedback of welding
output.
-Equipped with temperature,
voltage and current sensors for high
protection.
-Designed to work with diesel
generators and to avoid failures
due to its voltage spikes.
-Up/ Down Button Remote Control
torch.
-Wireless Remote Control (optional).
-Wire / Wireless Foot Pedal (optional).
-Possibility of connection with water cooler unit (optional) and to be mounted
on two wheels trolley.
2
Overview
2.1
Features

Models
Parameters
GRAND TIG 200 AC DC PULSE PFC MV
Input power
1~110/120/130±10%
，
50/60HZ
1~220/230/240±10%
，
50/60HZ
Rated input current
I1max
（
A
）
40（MMA）32（TIG）32 (MMA）21（TIG）
Rated input power
（
KW
）
4.3（MMA）3.9（TIG）7.2（MMA）6（TIG）
Duty cycle
（40℃，10
minutes）
MMA
TIG
MMA
TIG
30% 130A
35% 200A
60% 110A
60% 160A
60% 140A
60% 200A
100% 80A
100% 125A
100% 110A
100% 155A
Adjustment range of
welding current
（
A
）
5～130 5～160 5～200
Power factor
0.99
No-load voltage(V) 67
Adjustment range of
downslope time
（
S
）
0～10
Pre-gas time
（
S
）
0.1
～
2
Adjustment range of
post-gas time
（
S
）
0～10
Pulse Frequency
（
HZ
）
0.5～999
AC Frequency
（
HZ
）
50
～
250
Clearance effect
（
%
）
-5
～
+5
Pulse width range
（
%
）
5～95
Efficiency
（
%
） ≥
80%
Insulation class
IP23
Protection Class
H
Cooling
AF
Dimensions of Machine
（L×W×H） （mm） 630×240×425
Net Weight(Kg)
17
2.2
Technical
Data
Grand Tig 200 AC/DC Pulse PFC MV adopt the latest Pulse Width Modulation
(PWM) technology and the Insulated Gate Bipolar Transistor (IGBT) power modules.
It uses switching frequencies in the 20KHz-50KHz ranges so as to replace the
traditional line-frequency transformer type welding machines. Thus, machines are
characterized with portability, small size, lightweight, low energy consumption and
noise, etc. The parameters of the machine on the front panel all can be adjusted
continuously and steplessly, such as 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 igniting arc.
2.3
Brief
Introduction

GRAND TIG 200 AC DC PULSE PFC MV
Characteristics：
-MCU control system, responds immediately to any changes.
-High frequency and high voltage for arc igniting to ensure the success ratio of
igniting arc, the reverse polarity ignition ensures good ignition behavior in
TIG-AC welding.
-Avoid AC arc-break with special means, even if arc-break occurs the HF will
keep the arc stable.
-Pedal control the welding current.
-TIG/DC operation, If the tungesten electrode touches the workpiece when
welding, the current will drop to short-circuit current to protect tungsten.
-Intelligent protection: over-voltage, over-current, over-heat, when the problems
listed before occurred, the alarm lamp on the front panel will be on and the
output current will be cut off. It can self-protect and prolong the using life.
-Double purposes: AC inverter TIG/MMA and DC inverter TIG/MMA.
- Excellent performance on Al-alloy, carbon steel, stainless stell, titanium.
According to choosing the front panel functions, the following six welding ways
can be realized.
-DC MMA
-DC TIG
-DC Pulse TIG
-AC MMA
-AC TIG
-AC Pulse TIG
1. For DC MMA, polarity connection can be chosen according to different
electrodes;
2. For AC MMA, magnetic flow caused by invariable DC polarity can be avoided；
3. For DC TIG, DCEP is used normally (workpiece 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 (rectangle wave), arc is more stable than Sine AC TIG. At the same
time, you can not only obtain the max penetration and the min tungsten pole
loss, but also obtain better clearance effect.
5. DC Pulsed TIG has the following characters: 1) Pulse heating. Metal in Molten
pool has short time on high temperature status and freezes quickly, which can r
educe the possibility to produce hot crack of the materials with thermal
sensitivity. 2) The workpiece gets little heat. Arc energy is focused. Be 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. Be 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 i
mprove the mechanical performance of the joint. 5) High frequency arc is suitable
for high welding speed to improve the productivity.

The letter “X” stands for Duty Cycle, which is defined as the portion of the time a
welding machine can weld continuously with it’s rated output current within a
certain time cycle (10 minutes).
The relation between the duty cycle “X” and the output welding current “I” is shown
as the right figure. If the welding machine is overheating, the IGBT over-heat
protection sensing will send a signal to the welding machine control unit to cut the
output welding current OFF and light the over-heat pilot lamp on the front panel.
In that case, the machine should not be welding for 10-15 minutes to cool down
with the fanrunning. When operating the machine again, the welding output
current or the duty cycle should be reduced.
2.4
Duty cycle
and
Over-heat
Relation of welding current and
duty
cycle for
GRAND TIG 200 AC DC
PFC MV
The working principle of TIG series of welding machines is shown as the following
figure. Single-phase 110V/220V work frequency AC is rectified into DC, then is
converted to medium frequency AC 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 current output stably. Meanwhile, the welding current parameter can be
adjusted continuously and steplessly 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
2.5
Working
Principle

Methods of reducing emissions
Public supply system
Arc welding equipment should be connected to the public supply system
according to this manual recommendations. If interference occurs, it may be
necessary to take additional precautions such as filtering of the public supply
system. Consideration should be given to shielding the supply cable of
permanently installed arc welding equipment, in metallic conduit or equivalent.
Shielding should be electrically continuous throughout its length. The shielding
should be connected to the welding power source so that good electrical
contact is maintained between the conduit and the welding power source
enclosure. Maintenance of the arc welding equipment. The arc welding
equipment should be routinely maintained according to this manual
recommendations. All access and service doors and covers should be closed and
properly fastened when the arc welding equipment is in operation. The arc
welding equipment should not be modified in any way, except for those changes
and adjustments covered in this manaul. In particular, the spark gaps of arc striking
and stabilising devices should be adjusted and maintained according to our
recommendations.
2.6
Volt-
Ampere
Characteristic
TIG series of welding machines has excellent volt-ampere characteristic. Referring to
the following graph. In TIG welding, the relation between the rated loading voltage U2
and welding current I2 is as follows:
When I2≤600A，U2＝10＋0.04 I2（V）； When I2＞600A，U2＝34（V）.
67
34
10
0 600 I
2
（A）
U
2
（V）
Working
point
Volt-ampere characteristic The relation between the
conventional loading
voltage and welding current
3
Installation
& Operation
3.1
Layout
for the front
and rear
panel
（1）“-” Output terminal.
（2）TIG torch gas connector.
（3）TIG torch remote connection
socket. *
（4）“+” Output terminal.
（5）Water cooler remote
connection socket.
（6）Inlet gas connector.
（7）Power switch
（8）Input power cable.

Control Panel
（9）LH multifunction display*
（10）RH multifunction display *
（11）Power indicator
（12）Water cooling system error indicator *
（13）Alarm indicator *
（14）Water /air cooling selection button *
（15）Air cooling mode indicator
（16）Water cooling mode indicator
（17）2T trigger mode indicator *
（18）4T trigger mode indicator *
（19）MMA hot start setting Indicator *
（20）MMA welding current setting Indicator
（21）MMA arc force setting Indicator *
（22）2T/4Ttrigger mode selector button
（23）TIG parameter setting indicator *
（24）Parameter select/adjust Knob *
（25）Welding current mode selection button
（26）DC wave output indicator *
（27）AC triangle wave output indicator *
（28）AC sine wave output indicator *
（29）AC advanced square wave output indicator *
（30）MMA mode indicator
（31）Lift TIG mode indicator *
（32）Hf TIG mode indicator *
（33）Welding mode selection button
（34）JOB indicator *
*Denotes more detailed explanation of function to follow.

Further Controls Explained
LH Digital Multifunction Display (9)
Before welding this displays the setting selected or being adjusted using the control
knob (24). During welding it displays welding current. The parameter setting
displayed is indicated by the LEDs beside the display; Current (A), Saved Setting
(JOB), Time (S), Percentage (%) and Frequency (Hz). If left inactive for several s
econds, display will revert back to main welding current setting.
RH Digital Multifunction Display (10)
Before welding this displays secondary functions and error codes. During welding
it displays welding voltage.
Multifunction Smart Control Knob (24)
Press knob to navigate through the control panel parameters not controlled by
specific selector buttons. Parameter/setting selected will be indicated by the LED
on the control panel and the value shown on the LH display (9).
Adjust the parameter by turning the knob. Access the job/ program store/ recall
function by pressing and holding the knob.
Water Cooling System Error Indicator (12)
When using the integrated water cooler, the system is equipped with a pressure
sensor.If the coolant pressure is insufficient, this indicator will light and the welding
output will not be able to be active, in order to protect the torch and cooling system.
Alarm Indicator (13)
Lights when over voltage, over current, input phase loss or electrical
overheating (due to exceeding duty cycle) is detected and protection is activated.
When protection is activated, welding output will be disabled until the safety system
senses the overload has reduced sufficiently and indicator lamp goes out. May
also trigger if machine experiences an internal power circuit failure.
Water / Air Cooling Selection Button (14)
When using the integrated water cooling system with a water cooled torch, select
the ‘water’ option (16). This will activate the water cooler power and the water
cooling protection system. If using air cooled torch, select ‘Air’ option (15).
MMA settings
Hot start (19)
Hot start provides extra power when the weld starts to counteract the high
resistance of the electrode and workpiece as the arc is started. setting range (0-10).

Arc Force (21)
An MMA welding power source is designed to produce constant output current
(CC). This means with different types of electrode and arc length; the welding
voltage varies to keep the current constant. This can cause instability in some
welding conditions as MMA welding electrodes will have a minimum voltage they
can operate with and still have a stable arc. Arc Force control boosts the welding
power if its senses the welding voltage is getting too low. The higher the arc force
adjustment, the higher the minimum voltage that the power source will allow. This
effect will also cause the welding current to increase. 0 is Arc Force off, 10 is
maximum Arc Force. This is practically useful for electrode types that have a higher
operating voltage requirement or joint types that require a short arc length such as
out of position welds.
TIG settings
TIG 2T/4T Trigger Control
2T Mode (17)
The trigger is pulled and held on to activate the welding circuit, when the trigger is
released, the welding circuit stops.
4T Mode (18)
This is known as ’latching’ mode. The trigger is pulled once and released to activate
the welding circuit, pulled and released again to stops the welding circuit. This
function is useful to longer welds as the trigger is not required to be held on
continuously. TIG series of welding machines also has more current control options
that can be used in 4T mode.
TIG Parameter Setting (23)

Pre gas flow setting indicator (1)
Pre-flow controls the period shielding gas will flow for when the torch is triggered
before the arc starts. This purges the work area of atmospheric gas which could
contaminate the weld before the weld starts. Unit(S) and setting range (0.1-2S).
Start current setting indicator (2)
Available in 4T trigger mode, sets a welding current 10-100% of the main welding
current activated when the trigger is held on to ‘latch’ the trigger before the main
weld current is started. Once the trigger is released, the current will go through the
upslope (3) period if it is set, to the main welding current (4).
Up slope setting indicator (3)
When the trigger is activated, the welding current will increase gradually over the
time selected up to the set main welding current (4). Unit(S) and setting range (0-10.0S).
TIG welding current setting indicator (4)
Sets the main welding current . Unit(A) and setting range (5-200A).
Base current setting indicator (5)
Only available when pulse mode (12) is selected. Sets the current of the low/ base
pulse. Unit(A) and setting range (5-200A).
Down slope setting indicator (6)
When the trigger is released, the welding current will reduce gradually over the time
selected down to 0. This allows the operator to complete the weld without leaving
a ‘crater’ at the end of the weld pool. Unit(S) and setting range (0-10.0S).
End current setting indicator (7)
Available in 4T trigger mode only, sets a welding current 10-100% of the main welding
current activated when the trigger is held on to ‘unlatch’ the trigger before the weld
is finished. If downslope (6) is set, the current will go through the downslope period
before going to the end current set. When the trigger is released, the arc will stop.
Post gas flow setting indicator (8)
Controls the period of time the shielding gas continues to flow for after the arc is
stopped. This protects the weld area and torch tungsten from contamination while it
is still hot enough to react with atmospheric gases, after the weld is finished. Unit(S)
and setting range (0-10.0S).
Pulse width setting indicator (9)
Only available when pulse mode (12) is selected. Sets the time proportion as a
percentage between the peak current and base current when using pulse mode.
Neutral setting is 50%, the time period of the peak current and base current pulse is
equal. Higher pulse duty setting will give greater heat input, while lower pulse duty
will have the opposite effect. Unit(%) and setting range (5-95%).
Pulse frequency setting indicator (10)
Only available when pulse mode (12) is selected. Sets the rate that the welding
output alternates between the peak and base current settings. Unit(Hz) and setting
range (0.5-999Hz).

Pulse mode ‘off’ indicator (11)
Pulse mode ‘On’ indicator (12)
Clean Width Area/ AC Balance Adjustment (13)
Only available in AC welding mode (27,28,29). Adjusts the balance as a percentage
between the forward and reverse current cycles when welding in AC output mode.
The reverse part of the AC cycle gives the ‘cleaning’ effect on the weld material,
while the forward cycle melts the weld material. Neutral setting is 0. Increased
reverse cycle bias will give greater cleaning effect, less weld penetration and more
heat in the torch tungsten, which gives the disadvantage of reducing the output
current that can be used for a given tungsten size, to prevent the tungsten
overheating. Increased forward cycle bias will give the opposite effect, less
cleaning effect, greater weld penetration and less heat in the tungsten.
For maximum effectiveness, ideally the clean width/ AC balance should be set with
as much forward cycle bias as possible, while still maintaining a sufficient level of
oxidisation removal for a contamination free weld pool. Cleaner non-ferrous
metal is before welding, the more effective it is to weld. This effect can also be used
to reduce heat in the tungsten, allowing use of a pointed tungsten tip shape for a
more defined arc. setting range (-5-+5).
AC Frequency Adjustment (14)
Only available in AC welding mode (27,28,29). Increasing AC frequency will focus
the shape of the arc, resulting in a tighter, more controlled arc causing increased
penetration and less heated affected area for the same current setting. Slower f
requency will result in a wider, softer arc shape. Unit(Hz) and setting range
(50-250Hz).
AC/DC Output Modes
DC (Direct Current) Welding Output (26)
Suitable for TIG welding ferrous (iron based) metals such as mild steel and stainless
steel, copper and titanium. TIG welding reactive metals such as Aluminium,
Magnesium and Zinc requires AC (alternating current) output. When reactive
metals are exposed to air they form an oxide layer that insulates the base metal
and prevents welding current flowing, it also contaminates the weld pool. Reverse
current flow is required to break through/ clean off this oxide layer so that welding
can take place, while the current flow during the positive cycle does the majority of
the heating of the weld pool area.
AC Triangle Wave Welding Output (27)
Reduced heat input for same current setting. Especially useful for welding thin metal.
AC Sine Wave Welding Output (28)
Traditional AC TIG welding wave form. Quieter, ‘soft’ arc characteristic.
AC Square Wave (28)
Focused arc for maximum penetration, fast travel speed with best directional control.
TIG Arc Starting Modes.

TIG HF/ Lift Ignition Modes (31,32)
For TIG welding process, contact of the torch tungsten to the workpiece will cause
contamination of the tungsten and the workpiece that will adversely affect the weld
quality, especially when the tungsten is electrically energised.
HF Ignition (High Frequency) sends a pulse of high energy electricity through the
torch system that is capable of ‘jumping’ between the tungsten and the workpiece,
ensuring arc starting without any contact between the tungsten and workpiece.
The disadvantage of HF ignition is that the high ener-
gy electrical pulse creates significant electrical and radio signal interference, which
limits its use around sensitive electronic equipment such as computers.
Lift TIG Ignition is a compromise that minimises tungsten contamination while
eliminating the electrical interference of HF start systems. Lift arc starting works by
lightly resting the tungsten on the work piece, activating the torch trigger signal and
then lifting the tungsten off. The control circuit will sense when the tungsten is
removed from the work piece and send a low powered pulse of electricity through
the tungsten that will cause the TIG arc to initiate. Because the tungsten is not ‘live’
when it is in contact with the work, contamination is minimised.
Program/Job Memory (34)
The welding machine has 9 memory/ job spaces that parameters can be saved to
for easy recall. To access a saved program, press and hold in the control knob (24)
and the program number 1-9 will show on the display, the ‘JOB’ indicator will be lit.
Adjust to the program number required by rotating the control knob. Once the
program is accessed, it will automatically load. To return to normal parameter
settings, press the control knob again (which will also load the selected program)
To save parameters set as a program, press and hold the control knob for a few
seconds and the display will blink. The settings are now saved in the last program
space that was selected. If setting parameters to save as a program, ensure that
you start with a program number that the data is OK to overwrite, as the previous
settings saved to that memory space will be lost.
Pulse welding
Pulse welding mode switches the welding output between a high and low current
output in a cyclical manner. When used correctly this function has substantial
benefits in the TIG welding process including greater weld penetration for less work
heat input and greater control of the weld pool.
The basic theory for setting the base current using pulse mode is that the base
current should be sufficient to maintain the existing molten weld pool, while the
peak current is sufficient to melt new metal in order to move/ expand the molten
weld pool. Increased pulse frequency will have the effect of making the arc more
tightly focused which is useful for fine stainless work and similar.
Pulsing can also be used to help move the weld pool, this technique is useful for
welding out of position or with materials that have higher viscosity weld pool. Higher
pulse duty setting will give greater heat input, while lower pulse duty will have the
opposite effect.

Water Cooling
The welding machine is supplied standard with water cooled TIG torch. The correct
coolant to use is a mixture of Mono Propylene Glycol and water in a 1:3 ratio (25%
propylene glycol). Pure water may be used as a coolant liquid, though it is not
recommended for the long term reliability of the water cooling system as it does not
have the lubrication properties of glycol and does not provide protection against
freezing. Ready to use coolant fluid can be purchased from authorised dealers.
Do not operate a water cooled torch without the cooling system operating!
3.2
Power
supply input
Connection
The TIG series of welding machines is designed to operate on a110V /220V AC
power supply. When the power supply voltage is over the safe work voltage, there
are over voltage and under voltage protection inside the welder, the alarm light will
on, at the same time, the current output will be cut off.
If the power supply voltage continually goes beyond the safe work voltage range,
it will shorten the welder life-span. The below measures can be used:
- Change the power supply input net. Such as, connect the welder with the stable
power supply voltage of distributor;
- Induce the machines using power supply in the same time;
- Set the voltage stabilization device in the front of power cable input.
Connection of Output Cables
Two sockets are available on this welding machine. For MMA welding the electrode
holder is shown be connected to the positive socket, while the earth lead
(work piece) is connected to the negative socket, this is known as DCEP. However
various electrodes require a different polarity for optimum results and careful
attention should be paid to the polarity, refer to the electrode manufacturers
information for the correct polarity.
DCEP: Electrode connected to “+”output socket.
DCEN: Electrode connected to“-” output socket.
MMA (DC): Choosing the connection of DCEN or DCEP according to the different
electrodes. Please refer to the electrode manual.
MMA (AC): No requirements for polarity connection.
3.3
Installation
& Operation
for MMA
Welding
3.3.1 Set up
installation
for MMA
Welding

Water Cooling
The welding machine is supplied standard with water cooled TIG torch. The correct
coolant to use is a mixture of Mono Propylene Glycol and water in a 1:3 ratio (25%
propylene glycol). Pure water may be used as a coolant liquid, though it is not
recommended for the long term reliability of the water cooling system as it does not
have the lubrication properties of glycol and does not provide protection against
freezing. Ready to use coolant fluid can be purchased from authorised dealers.
Do not operate a water cooled torch without the cooling system operating!
(1) Connect the earth lead to “-”, tighten clockwise;
(2) Connect the earth clamp to the work piece. Contact with the work piece must
be firm contact with clean, bare metal, with no corrosion, paint or scale at the
contact point;
(3) Connect the electrode lead to “+”, tighten clockwise;
(4) Each machine is equipped with a power cable should be based on the input
voltage welding power cable connected to the appropriate position, not to
pick the wrong voltage;
(5) With the corresponding input power supply terminal or socket good contact
and prevent oxidation;
(6) With a multi meter measure the input voltage is within the fluctuation range;
(7) The power ground is well grounded.

3.3.2
Operation
for MMA
Welding
3.4
Installation &
Operation
for TIG
Welding
3.4.1
Set up
installation
for TIG
Welding
(1) According to the above method to install is correct, turn the power switch, so
that the power switch is “ON” position, then the power indicator light, the fan
comes on, the device work properly.
(2) Set to ‘MMA’ welding mode.
(3) Set the welding parameters as required using the parameters control knob
(following the instructions in the previous section).
(4) Place the electrode into the electrode holder and clamp tight.
(5) Strike the electrode against the work piece to create and arc and hold the
electrode steady to maintain the arc.
(6) Commence welding. If necessary, readjust the Welding parameters control
knob to obtain the welding condition required.
(7) After completion of welding the Power Source should be left turned ON for 2 to
3 minutes. This allows the fan to run and cool the internal components.
(8) Switch the ON/OFF Switch (located on the rear panel) to the OFF position.
NOTE:
- Note the polarity of wiring, the general DC welding wire in two ways. Selected
according to the technical requirements of welding the appropriate connection,
if you choose incorrectly will result in arc instability and spatter large adhesion and
other phenomena, such cases can be quickly reversed to joints.
- If the work piece distance from the welding machine, the second line(electrode
holder and ground) is longer, so choose the appropriate conductor cross-sectional
area should be larger to reduce cable voltage drop.

(1) According to the above method to install is correct, turn the power switch to
the “ON” position, the power LED light should illuminate, the fan comes on, the
device work properly.
(2) Set the welding mode to ‘Lift TIG’ or ‘HF TIG’.
(3) If a water cooled torch and water cooler is used, check the water cooler has
sufficient coolant level and all connections are firmly secured. Set the water/air
setting button (14) to ‘water (16)’. The water cooler should now start operating.
If using an air cooled torch, set the button (14) to ‘air’ setting (15).
(4) Set the welding parameters as required using the parameters control knob
(following the instructions in the previous section).
(5) The tungsten must be ground to a blunt point in order to achieve optimum
welding results.
3.4.2
Operation
for TIG
Welding
S
witch the ON/OFF Switch (located on the rear panel) to OFF.
(1) Connect the earht lead to “+”, tighten clockwise. Connect the earth clamp to
the work piece. Contact with the work piece must be firm contact with clean
bare metal, with no corrosion, paint or scale at the contact point.
(2) Connect the TIG torch cable to “-”, tighten clockwise.
(3) Connect TIG torch gas connection to the TIG gas outlet and TIG torch remote
plug to remote socket, ensuring all connections are tight.
(4) If using a water cooled torch, connect the water cooling lines from the TIG
torch to the front of the water cooler, ensuring the red and blue return and
supply lines match the connectors.
(5) If using a water cooled torch, connect the water cooler interface cable from
the rear of the power source to the rear of the water cooler.
(6) Connect the gas regulator to the gas cylinder and connect the gas line to the
gas regulator.
(7) Connect the gas line to the machine inlet gas connector via the quick push
lok connector located on the rear panel.
Check for Leaks!
(8) Open gas cylinder valve and adjust regulator, flow should be between
5-10 l/min depending on application. Re-check regulator flow pressure with
torch valve open as static gas flow setting may drop once gas is flowing.
(9) Each machine is equipped with a power cable should be based on the input
voltage welding power cable connected to the appropiate position, not to
pick the wrong voltage.
NOTE:
Secure the gas cylinder in an upright position by chaining them to a stationary
support to prevent falling or tipping.

(6) Install the tungsten with approximately 3mm to 7mm sticking out from the gas
cup, ensuring you have correct sized collet.
(7) Tighten the back cap.
(8) Commence welding. If necessary, readjust the parameters control knob to
obtain the welding condition re-quired.
(9) After completion of welding the Power Source should be left turned ON for
2 to 3 minutes. This allows the fan to run and cool the internal components.
(10) Switch the ON/OFF Switch (located on the rear panel) to the OFF.
3.4.3
Remote current
control TIG series of welding machines can accept remote current control from a
potentiometer/ analogue signal or a digital up/down button signal. Potentiometer
remote control will change the current from the 5A minimum to the maximum set
using the machine current control. Using an up/ down button remote signal, the
current may be increased or decreased in 1A increments, or ‘scrolls’ up to 30A at a
time if the button is held down. This is very useful for precision work.
Potentiometer
Up/dow
n
12 Pin Remote Plug Connection
Socket
Pin
Function
Potentiometer
Up/down
1
Not connected
Not connected
2
Not connected
Not connected
3
10k ohm (maximum) connection to 10k ohm
remote control potentiometer
Not connected
4
Wiper arm connection to 10k ohm remote
control potentiometer
Not connected
5
Zero ohm (minimum) connection to 10k ohm
remote control potentiometer
Not connected
6
Not connected
The button of "UP" input
7
Not connected
The button of "DOWN" input
8
Trigger Switch Input
Trigger Switch Input
9
Trigger Switch Input
Trigger Switch Input
10
Be shorted with 11
Not connected
11
Be shorted with 10
The button of "UP"& "DOWN" input
12
Not connected
Not connected