Migatronic Commander User manual

INTRODUCTION
MIGATRONIC welding equipment has a good reputation - and we know how important it is to live up to the
standards we have set ourselves.
The welding machine you have purchased is the result of years of MIGATRONIC's experience in the field of
welding machine manufacture. This experience, combined with correct operation and maintenance of your
machine, provides a guarantee of excellent performance in the years ahead.
Thank you for buying a MIGATRONIC machine.
INSTRUCTION MANUAL
COMMANDER
Version G 50173110
EC DECLARATION OF CONFORMITY
MIGATRONIC A/S
Aggersundvej 33
9690 Fjerritslev
Denmark
hereby declare that our machine as stated below
Type: COMMANDER
as of: week 48 1995, step 4
conforms to directives 73/23/EEC and 89/336/EEC.
European Standards: EN60974-1
EN50199
Issued in Fjerritslev on 27th November 1995.
Peter Roed
Managing director
Valid from 0024

CONTENTS
Warning / Electromagnetic emissions .................. 4
General description.............................................. 5
Initial operation..................................................... 5
Instructions
BOX 1 .................................................................. 6
BOX 2, (TIG) ...................................................... 13
BOX 3, (MMA).................................................... 16
Secondary errors during
TIG welding........................................................ 19
Fixed functions................................................... 19
Technical data.................................................... 20
Fault identification .............................................. 22
Maintenance ...................................................... 22
Circuit diagrams
Spare parts list

4
Electromagnetic emissions
and the radiation of electromagnetic disturbances
This welding equipment for industrial and professional use is in
conformity with the European Standard EN50199. The purpose of
this standard is to prevent the occurrence of situations where the
equipment is disturbed or is itself the source of disturbance in other
electrical equipment or appliances. The arc radiates disturbances,
and therefore, a trouble-free performance without disturbances or
disruption, requires that certain measures are taken when installing
and using the welding equipment. The user must ensure that the
operation of the machine does not occasion disturbances of the
above mentioned nature.
The following shall be taken into account in the surrounding area:
1. Supply and signalling cables in the welding area which are
connected to other electrical equipment.
2. Radio or television transmitters and receivers.
3. Computers and any electrical control equipment.
4. Critical safety equipment e.g. electrically or electronically
controlled guards or protective systems.
5. Users of pacemakers and hearing aids etc.
6. Equipment used for calibration and measurement
7. The time of day that welding and other activities are to be
carried out.
8. The structure and use of buildings.
If the welding equipment is used in a domestic establishment it may
be necessary to take special and additional precautions in order to
prevent problems of emission (e.g. information of temporary
welding work).
Methods of reducing electromagnetic emissions:
1. Avoid using equipment which is able to be disturbed.
2. Use short welding cables.
3. Place the positive and the negative cables close together.
4. Place the welding cables at or close to floor level.
5. Remove signalling cables in the welding area from the supply
cables.
6. Protect signalling cables in the welding area, e.g. with selective
screening.
7. Use separately-insulated mains supply cables for sensitive
electronic equipment.
8. Screening of the entire welding installation may be considered
under special circumstances and for special applications.
WARNING
Arc welding and cutting can be dangerous to the user, people working nearby, and the surroundings if
the equipment is handled or used incorrectly. Therefore, the equipment must only be used under the strict
observance of all relevant safety instructions. In particular, your attention is drawn to the following:
Electricity
- The welding equipment must be installed according to safety regulations and by a properly trained and qualified
person.
- Avoid all contact with live components in the welding circuit and with electrodes and wires if you have bare
hands. Always use dry welding gloves without holes.
- Make sure that you are properly and safely earthed (e.g use shoes with rubber sole).
- Use a safe and stable working position (e.g. avoid any risk of accidents by falling).
- Make sure that the welding equipment is correctly maintained. In the case of damaged cables or insulation work
must be stopped immediately in order to carry out repairs.
- Repairs and maintenance of the equipment must be carried out by a properly trained and qualified person.
Light and heat emissions
- Protect the eyes as even a short-term exposure can cause lasting damage to the eyes. Use a welding helmet
with suitable radiation protection glass.
- Protect the body against the light from the arc as the skin can be damaged by welding radiation. Use protective
clothes, covering all parts of the body.
- The place of work should be screened, if possible, and other persons in the area warned against the light from
the arc.
Welding smoke and gases
- The breathing in of the smoke and gases emitted during welding is damaging to health. Make sure that any
exhaust systems are working properly and that there is sufficient ventilation.
Fire hazard
- Radiation and sparks from the arc represent a fire hazard. As a consequence, combustible materials must be
removed from the place of welding.
- Working clothing should also be secure against sparks from the arc (e.g. use a fire-resistant material and watch
out for folds and open pockets).
Noise
- The arc generates surface noise according to welding task. In some cases, use of hearing aids is
necessary.
Use of the machine for other purposes than it is designed for (e.g. to unfreeze water pipes) is strongly
deprecrated. If occasion should arise this will be carried out without responsibility on our part.
Read this instruction manual carefully
before the equipment is installed and in operation

5
GENERAL DESCRIPTION
The COMMANDER is a three-phase welding machine
based on inverter technology.
Block diagram COMMANDER DC
Block diagram COMMANDER AC/DC
There are several versions of the machine: MMA, TIG
DC and TIG AC/DC.
All versions are designed for welding with coated
electrodes and are equipped with Hot-start, Arc Power
and Antifreeze. In addition, all versions can be fitted
with all types of remote controls included in
MIGATRONIC's standard range of accessories.
The TIG COMMANDER machine is also designed for
TIG welding and features functions such as:
- variable slope-down
- fixed gas pre-flow time
- variable gas post-flow time
- option of 2-times or 4-times operation
- LIFTIG
- HF-TIG
- current control from the TIG torch handle
- remote control facility
- AC balance
- AC welding frequency
- Digital display
In LIFTIG ignition the TIG arc is ignited after making
contact between the workpiece and the tungsten
electrode, after which the trigger is activated and the
arc is established by lifting the electrode from the
workpiece.
In HF-TIG ignition the TIG arc is ignited without
contact. A high-frequency (HF) impulse initiates the
arc when the trigger is activated.
INITIAL OPERATION
Mains connection
After the mains cable has been connected, the
machine is ready for use. Please note that connection
must be made by an authorised electrician.
As standard, machines are supplied for connection to
a 3x400 V supply. However, machines with an auto-
transformer unit can be connected to other voltages.
Connection is made by moving the wires on the top of
the auto-transformer. All three phases have to be
connected similarly and in accordance with the wiring
diagram on the top of the auto-transformer unit and/or
the circuit diagram on page 30. Only machines up to
400 A output can be supplied with an auto-
transformer, and a 230V connection can only be used
on machines of up to 320 A output.
Warning: When making input voltage connection it
is essential that the machine is dis-
connected from the mains supply, as this
work can be extremely dangerous
because of the high voltages across the
connection terminals.
Fuse and mains voltage - see the type plate and
technical data.
Configuration:
MIGATRONIC disclaims all responsibility for damaged
cables and other damages related to welding with
under sized welding torch and welding cables
measured by welding specifications e.g. in relation to
permissible load.
Connection of welding cables
Connect the welding cables to the front of the
machine. Please note that the plug must be turned 45
degrees after inserting the cable into the socket -
otherwise the plug can be damaged due to excessive
contact resistance.
Cooling liquid
Before the machine is switched on, the water-cooling
module must be filled up with MIGATRONIC coolant.
(This applies only to water-cooled machines).

6
Use of the machine
During welding a heating of various components of
the machine takes place and during breaks these
components will cool down again. When using current
settings above a set value, the machines need
periods when they can cool down.
The length of these periods depends on the current
setting and the machine should not be switched off in
the meantime.
If the periods for cooling down during use of the
machine are not sufficiently long, the overheating
protection will automatically stop the welding process
and the yellow light will come on.
The yellow light switches off when the machine has
cooled down sufficiently, and the machine is ready for
welding. Max. load can be seen in the Technical data.
Definition:
60% max. load by welding means that a cooling
period of 4 minutes is required after welding for 6
minutes at a current setting of the value of 60%
variable intermittent duty; 10 minutes between start of
each welding period must be calculated.
INITIAL INSTRUCTIONS
BOX 1
General instructions for use
All "parameters" are set by the use of only one control
knob. These parameters include current, slope-up
time, etc.
This control knob is positioned below a digital display
which shows the value of the parameter being set.
The unit of measurement of the parameter is shown
at the right hand side of the digital display.
In order to display or adjust the parameters of a
particular function, the keypad in the section
concerned with that function is pressed repeatedly
until the indicator light below or next to the relevant
symbol is indicated by a bright light. Adjustment of
setting is then made with the control knob.
Welding current is set by pressing keypad marked
and then using the control knob.
Welding parameters e.g. pulse frequency can be
adjusted during the welding process.
Briefly: Keypads select the functions, the control knob
sets the parameters.
Function selection
As above, selection of a function, e.g. HF-TIG or
LIFTIG, is by means of the keypad in the relevant
section.
The function selected is indicated by a bright light
below or next to the relevant symbol.
CHANGE OF FUNCTION SETTING IS NOT
POSSIBLE DURING THE WELDING PROCESS.
Storage of parameters
The machine memorises all settings when the mains
input voltage is switched off, thus ensuring that the
same machine settings are available when the
machine is switched on again.
The exact adjustments in the two welding processes
(MMA electrode and TIG) are stored as well so that
shifting from one welding process to another does not
require a new current setting

7
FUNCTION SELECTION AND
PARAMETER SETTING
This chapter describes the operation of the machine
in detail and includes references to the three different
control panels illustrated at the end of the chapter.
A
Overheating
The overheating indicator is illuminated if
welding is interrupted due to overheating of the ma-
chine. The indicator remains illuminated 3 seconds
after the overheating error is removed.
Mains error
The mains error indicator is illuminated if the
mains voltage is too high or low. The indicator
remains illuminated 3 seconds after the mains error is
corrected/removed.
On pressing this keypad the control knob can be
used to set the welding current.
Welding voltage
The welding voltage indicator is illuminated for
reasons of safety and in order to show if there is
voltage on the electrode or the TIG torch.
Units of measurement of the parameter
shown in the digital display.
Setting of welding jobs
This function enables storage of often-used
machine settings and shift from one complete setting
to another. By pressing the keypad the display shows
a "P" and a number: "1", "2" etc. Each number is a
setting of all parameters and functions of the
machine. It is therefore possible to have one setting
for each welding job for which the machine is used.
The control knob is used for shifting between these
settings. During shifting it is possible to see both pro-
cess and the other on/off-functions in each setting.
Change of setting is not possible during the welding
process. The setting selected is effected by releasing
the keypad.
B
Welding process
Electrode TIG
This display is used to select the welding process to
be used, e.g. MMA electrode or TIG.
HGACD
EFBI
J

8
C
The triggermethod
Two Four Spot
times times
This display is used to decide if the start/stop method
of the TIG welding process is to be two-times, four-
times (latching), or spot.
It is not possible to change to another method of
trigger control during the welding process.
D
AMP Setting function
The AMP keypad is used to select the method by
which the required welding current shall be
established. This welding current is then shown in the
digital display.
The three options are as follows:
D1
Internal
The control knob positioned below the digital
display is used to set the current.
D2
External:
Current setting to be by means of a MIGA-
TRONIC remote control unit. The remote
control unit is connected to a plug positioned on
the rear of the machine (not standard equipment).
D3
Torch:
Torch adjustment
Current setting to be by means of the current control
knob located in the handle of a MIGATRONIC dialog
torch, if a dialog torch is used.
With regard to torch handle current control, it should
be noted the maximum current is set with the control
knob on the front panel. The torch control is used to
reduce the current from the maximum set current. The
adjustment of the machine must not be at the maxi-
mum setting by low current. (From software version
2.20 it is only possible to adjust 100 Amp lower than
maximum current).
E
HF Ignition of TIG welding
LIFTIG It is possible to choose between two
different methods of ignition for TIG wel-
ding: High-frequency (HF) and Liftig ignition.
F
ON OFF
Pilot arc
Used only in the TIG welding process, a pilot arc is a
weak arc which illuminates the workpiece, and there-
by makes it easier to find the starting point of the
actual welding process. The pilot arc function is 5% of
the chosen welding current, but 5 A is set as a
minimum.
The pilot arc can be ignited by briefly activating the
torch switch (less than 0.3 seconds). If activation is
longer, the machine switches automatically to ordinary
welding.
Switch from pilot arc to ordinary welding by keeping
the torch switch activated when two-times TIG
welding, or by long activation (> 0.3 seconds) when
four-times TIG or spot welding.
The welding process then continues in normal
fashion, with current slope-up and current slope-
down. However, after slope-down the machine does
not switch directly to post-flow but to pilot arc again.
This is true whether or not welding is initiated by the
pilot arc.
It is now possible to continue with a new welding
process by a lengthy activation of the torch switch
(>0.3 seconds), or to go to standby automatically by
a brief activation (<0.3 seconds).
The machine will also go to standby automatically if
the arc has been extinguished for more than 2
seconds.
To summarise, the pilot arc is switched on and off by
brief activation of the torch switch, and actual welding
is started and stopped by longer activation.

9
G
The parameters that can be adjusted are illustrated in
the figure below:
Pre-flow
Pre-flow is the period of time for which
gas flows after the torch switch is pressed
and before the HF arc is established, or until the torch
is lifted away from the workpiece in the LIFTIG
process. Variable 0-10 secs.
Start Amp
Immediately after the arc has been
established, the machine regulates the welding cur-
rent to the value stated in the Start Amp parameter.
Start Amp is set as a percentage of the required
welding current and is variable between 0-100% of
the welding current with a minimum value of 5 amps.
Slope-up
Once the arc has been established, the wel-
ding process enters a slope-up stage during
which the welding current is increased in linear
fashion from the value stated in the Start Amp para-
meter to the required welding current. The duration of
this slope-up time is variable 0-10 secs.
Slope-down
When welding has stopped by activating the
trigger, the machine enters a slope-down
stage. During this stage current is reduced from
welding current to Stop Amp over a period of time
called the slope-down time and variable 0-10 secs.
Stop Amp
The slope-down stage is completed when
the current level has fallen to the value
stated in the Stop Amp parameter. Stop Amp is stated
as a percentage of the required welding current and
is variable between 0-100% of the welding current
with a minimum value of 5 Amps.
Post flow
Post-flow is the period of time for which gas
flows after the arc is extinguished and is
variable 3-20 secs.
Reduced current
When four-times welding a reduced current
is activated by pressing the trigger briefly. This
reduced current is set to a percentage value of the
welding current and is variable between 0-100% of
the welding current.
H
Pulse welding
This panel controls the setting of the conditions for
pulse welding. The panel is divided into two sections:
the upper section being used for the selection of the
pulse welding function and the lower section for the
setting of parameters.
It is not possible to introduce or discontinue the use of
the pulse welding function during the actual welding
process.
Pulse:
Pulse welding function is operational.
No pulse:
Pulse welding function is not in operation and
it is not possible to set pulse-welding para-
meters.
Pulse parameters
If the pulse welding function is in use then it is
possible to select and change the pulse parameters
during the welding process. The importance of the
pulse parameters can be seen from the illustration
below.

10
Pulse time
The pulse time reflects the time the machine is
welding with the pulse current. The pulse current in
the pulse frequency is the set welding current. Time
is given in seconds.
Pause time
The pause time reflects the time the machine
is welding with base (background) current. Time is
given in seconds.
Base amp
Base (background) current is set as a percentage
value between 1 and 100% of the current level set on
the display (that is, pulse current), though it cannot be
less than 5 Amps.
Note 1: If the pulse function is used during AC-welding the
pulse times can be reduced in proportion to the
AC frequency as the pulse frequency must be 5
times higher than the AC frequency. If the pulse
times are to short the indicator for AC frequency
will flash on and off for 5 seconds.
I
Arc power Used on the MMA welding process only,
the arc power function is used to
stabilise the arc.
I1
Arc power
This can be achieved by increasing welding current by
a percentage value when metal droplets are short-
circuited.
The additional current ceases when the short circuit
is no longer present.
The arc power value is a percentage value, and can
be set between 0 and 150% of the welding current
setting.
E.g. if the welding current is set to 40 A and Arc
power to 100% the additional current is 40 A equals
80 A when doing Arc power. If the Arc power is set to
150% the additional current is 60 A equals 100 A
when doing Arc power.
I2
Hot start
Hot start Hot start is a function that helps to
establish the arc during MMA welding.
This can be achieved by increasing welding current
(when the electrode is applied to the workpiece) by a
certain percentage value in relation to the set value.
This increased start amp is maintained for half a
second, after which it decreases exponentially over a
period of one second to the set value of welding
current.
The hot start value reflects the percentage value by
which initial current is increased, and can be set
between 0% and 100%.
I3
Spot time
Spot time Spot time is the time for the production of
a spot-weld and can only be used with
the TIG process. Variable from 0-50.0
secs, the time includes any slope-up and
slope-down times and can be set only
after spot trigger mode has been
selected on the TRIG keypad.

11
J
AC-welding
This panel is divided into two sections, with the
function current type at the top, and the setting of
conditions for special AC-functions at the bottom.
Current type
It is possible to select either AC (alternating current)
or DC (direct current). In the TIG-welding process, AC
is used for the welding of aluminium and its alloys,
while DC is used for the welding of other materials.
When TIG welding aluminium or its alloys the positive
part of the AC-wave removes the oxide film covering
the surface of the workpiece, and the negative part of
the wave melts the material.
AC frequency
The AC frequency can be adjusted from 1 to
300 Hz for TIG welding and from 1 to 100 Hz
for MMA-welding. A low frequency during TIG welding
increases the tendency for the formation of a large
ball at the end of the tungsten electrode. This
tendency will be reduced by increasing the frequency.
Note 2: The AC frequency and welding current cannot be
adjusted to maximum simultaneously during TIG
welding - see illustration below. When the limit is
reached by adjusting the AC-frequency, the A-
lamp will illuminate in "units for parameter" and the
machine will reduce the AC frequency
automatically.
Note 3: If the frequency limit is exceeded by adjustment of
the welding current the AC frequency will be
reduced automatically (the indicator for AC
frequency flashes on and off for 5 sec.).
Note 4: If the pulse function is used during AC-welding the
AC frequency can be reduced in proportion to the
pulse times as the pulse frequency must be 5
times higher than the AC frequency. If the AC
frequency is to low the indicators for pulse times
will flash on and off for 5 seconds.
Note 5: Pulse adjustment error: If the pulse function is
used during AC-welding an automatic adjustment
of the pulse setting may occur. The indicators for
pulse times will then flash on and off for 5 se-
conds. The pulse times change automatically so
the pulse time and base time will be 0.03 seconds.
Electrode preheating (TIG)
On ignition of the AC TIG pilot arc the
tungsten electrode is preheated by a direct
current with positive polarity. Preheating of an
electrode is necessary before starting the AC welding
process. The length of the preheat period depends on
both the diameter of the electrode and the angle of
the point of the electrode, as well as the size of the
ball at the end of the electrode. Adjustment is possible
from -9 to +9, with -9 being the minimum and +9
being the maximum preheat periods. If the period is
too short the pilot arc will extinguish shortly after
ignition. The size of the ball at the end of the
electrode will increase if the pre-heat period is too
long.
AC-t-balance, based on time (TIG)
Adjustment of the refinement function during
the AC TIG welding of aluminium and its alloys. The
function is a balance based on time between the
positive and negative halfperiod.
Adjustment is possible between 1 and 100 per cent as
the statement in per cent is based on the negative
part of the period time. Adjustment continues until a
suitable refinement zone is established around the
molten pool. When MMA welding the balance can be
locked at 50 per cent which means that further
regulation is impossible.
AC-I-balance, based on current intensity
(TIG)
The purpose of the function is also adjustment
of the refinement zone during AC TIG welding.

12
However, this balance is based on the current
intensity of the positive period proportional to the
current intensity of the negative period. A reduction of
the positive refinement current may have the effect
that dwell time of the tungsten electrode improves.
TIG-DC
It is also possible to weld in DC TIG with unalloyed
tungsten electrodes (green marking). Current is set to
AC and both AC-t-balance and AC-I-balance are set
at 100 per cent. The machine will then establish the
pilot arc by using the preheating function. After
finishing the preheating period the welding current will
be returned to negative polarity.
100% 150% 50%

13
INITIAL INSTRUCTIONS
BOX 2, TIG
General
1. Main switch
This control switches the machine on and off.
2. Welding cable plug +
(MMA + TIG)
3. Digital display
The control panel is fitted with a display which
shows the welding current. At stand by the set
welding current is shown. When welding the
average welding current is shown.
Please note that during 'START UP' and when
error messages, for instance overheat, are
displayed the digital readings may be displayed
incorrectly.
4a. Welding cable plug -
(MMA + TIG)
4b. Torch cooling
Quick release for supply of cooling water for
cooling of the welding torch.
4c. Return water
Quick release for return of hot water to the
water-cooling unit.
4d. Cooling Error
Occurs if there is insufficient flow in the hose or
if the water module lacks water.
5. Mains error
Cause: Excessive or insufficient mains
voltage.
Symptoms: The welding stops. This error is
indicated by the red light emitting
diode and the words "Mains error".
Action: Adjust mains voltage.
6. Overheating error
Cause: Overheating of an inverter module
due to incorrect use, or fault in
inverter module.
Symptoms: The welding process stops and
post-flow is activated. This error is
indicated by the yellow light
emitting diode and the words
"Overheating error". This LED
switches off after 7 - 10 min. if the
error is not corrected. When
pressing the trigger, the LED
switches on again.

14
Action: If the error has not been caused by
incorrect use, call in service staff.
7. INT/Torch control/EXT/Footswitch
This switch enables selection between inter-
nal/external or torch control of the welding
current.
When in internal position, the current is set on
the machine. When in external position, the
current is set through a remote control.
Slope-up, pulse welding, welding with reduced
current and slope-down are also possible
through remote control.
When set at torch control, the maximum current
will be determined by the machine's current
setting. This means that torch control can be
adjusted from the minimum current (5 A) to the
level selected when setting the machine's
current level.
Foot switch setting is used on when MIGA-
TRONIC FDF footswitch, part no. 78815009 is in
use.
When using the MIGATRONIC FDF footswitch,
part No. 78815010, the selector switch on the
electronic box must be set to EXT (external
control), and it should be noted that when used
in the maximum current setting, the maximum
current output obtainable will be between 210-
280 Amps.
8. Trigger mode
During TIG welding this switch determines the
function of the trigger on the TIG torch:
2-times:
Start welding by pressing the trigger on the
torch. Welding continues until the trigger is
released again, after which adjustable slope-
down is activated.
When activating the trigger once more, the
machine returns to ordinary welding. Otherwise
slope-down will continue for the set period, after
which post-flow will start.
4-times:
Welding starts the first time the trigger is
activated, and it is not necessary to keep the
trigger depressed. Adjustable slope-down is
activated the next time the trigger is activated. If
the trigger is released before slope-down time
has elapsed, welding stops.
The HF generator is activated in position HF.
This switch also enables selection between TIG
and MMA welding. When switching from MMA to
TIG welding, activate post-flow in order to fill the
hose with gas.
9. Welding current
Use this knob to control welding current from
min. 5 A to maximum welding current, as shown
in the digital display (pos. 3).
10. Slope-down
TIG-function
When welding is stopped by activating the
trigger, the machine starts a process of current
reduction.
During this process the current is reduced from
the set welding current to the minimum current (5
A). Slope-down time can be set between 0 and
10 seconds.
11. Hot-start
MMA-function
Hot-start is a function which can be used to help
establish the arc when starting to weld. This can
be achieved by increasing the initial current by a
certain percentage in relation to the value set
when the electrode is applied to the workpiece.
This increased initial current is reduced ex-
ponentially in relation to the welding current set
within approx. 0.5 seconds. The hot-start value
is the percentage value by which the initial
current is increased, and can be set between 0
% and 100 %.
12. Post-flow
TIG-function
Gas post-flow time
The gas post-flow time is the time that elapses
between switching off the arc and cutting off the
gas supply. Gas post-flow time can be set
between 0 and 30 seconds.
The following functions only apply to AC/DC
machines
13. AC/DC-switch
Use this knob to switch between AC welding and
DC welding.
14. Balance knob
With this knob the relation between cleaning and
penetration when TIG welding aluminium can be
adjusted. This is done by adjusting the positive
and negative halfwaves. The setting area is 0-
100%, thus allowing the possibility of reversed
polarity.
15. Frequency knob
When AC welding the alternating current (AC) is
infinitely variable from 10-500 Hz.

15
16. AC-safety
A green LED indicates that the AC safety circuit
is activated. The AC safety circuit ensures that
there is no AC voltage on the torch when the
machine is on no-load voltage.
17. Preheating of TIG-electrodes
Before the AC cycle is initiated, the following
adjustment should be made to set the positive
ignition period. Traditionally, thin TIG electrodes
require a low positive cycle and thick electrodes
require a high positive cycle.
If ignition problems are experienced:
If the electrode burns away rapidly or if a bulb is
formed on the tip of the electrode during ignition,
the preheating should be decreased. If there are
problems with arc ignition, the preheating period
should be increased.
The following values are recommended:
Electrode size Preheating
< 1.0 mm 0%
1.6 mm 20%
2.4 mm 40%
3.2 mm 60%
> 4.0 mm 80%
18. AC test
This trigger is used for testing of the AC safety
circuit.
When the machine is set for MMA welding with
AC, the LED (AC safety) lights continuously
when the machine is on no-load voltage. If the
trigger is activated, the LED will go out and
remain so as long as the trigger is activated.
Should this not be the case, an authorised
service technician should be called.
19. Gas connection
20. Plug for torch button, interactive control and
coding of air/water-cooling.

16
INITIAL INSTRUCTIONS
BOX 3, MMA
General
1. Main switch
This control switches the machine on and off.
2. Welding cable plug
3. Digital display
The control panel is fitted with a display which
shows the welding current. At stand-by the set
welding current is shown. When welding the
average welding current is shown. Please note
that during 'START UP' and when error
messages, for instance overheat, are displayed
the digital readings may be displayed incorrectly.
4. Mains error
Cause: Excessive or insufficient mains
voltage.
Symptoms: The welding process stops. This
error is indicated by the red light
emitting diode and the words
"Mains error".
Action: Adjust mains voltage.
5. Overheating error
Cause: Overheating of an inverter module
due to incorrect use, or fault in the
inverter module.
Symptoms: The welding process stops. This
error is indicated by the yellow light
emitting diode and the words
"Overheating error". This LED
switches off after 7 - 10 min. if the
error is not corrected. When pres-
sing the trigger, the LED switches
on again.
Action: If the error has not been caused by
incorrect use, call in service staff.
6. INT/EXT control
This switch enables selection between inter-
nal/external control of the welding current. When
in internal position, the current is set on the
machine.
When in external position, the current is set
through a remote control. Slope-up, pulse wel-
ding, welding with reduced current and slope-
down are also possible through remote control.

17
7. Hot-start
MMA-function
Hot-start is a function which can be used to help
establish the arc when starting to weld. This can
be achieved by increasing the initial current by a
certain percentage in relation to the set value,
when the electrode is applied to the workpiece.
This increased initial current is reduced
exponentially in relation to the set welding
current within approx. 0.5 seconds. The hot-start
value is the percentage value by which the initial
current is increased, and can be set between 0
% and 100 %.
8. Welding current
Use this knob to control welding current from
min. 5 A to maximum welding current, as shown
in the digital display (pos. 3).

18
INITIAL OPERATION
TIG COMMANDER DC & AC/DC
19. Multiple plug, 8-pole
For connection of remote control.
20. Multiple plug, 6-pole
For connection of footswitch control.
21. Gas hose
22. Mains cable

19
INITIAL OPERATION
Secondary errors during TIG welding
Safety disconnection
Cause: During 4-times trigger operation, welders
sometimes start a welding sequence and
then put the torch down by accident. In
such circumstances the machine will
retain voltage in the torch, and HF and the
gas valve will remain active, which is
dangerous for the welder concerned.
Reaction: If the arc is not initiated within 2 seconds,
the welding cycle stops.
Torch lift
Cause: During welding the welder may lift the TIG
torch away from the workpiece by acci-
dent, which results in the extinction of the
torch arc.
Reaction: The machine is initiated for 2 seconds,
after which the welding cycle stops.
Fixed functions
Antifreeze
MMA function
During electrode welding, electrodes sometimes stick
to the workpiece. The machine registers the fact that
the electrode has stuck onto the workpiece, and will
reduce the welding current to 5 A. This leads to the
hardening of the pool crater, and the electrode can
then be broken off. Welding can then be resumed in
normal fashion.
Arc power
MMA function
The arc power function is used to stabilise the arc
during electrode welding. This can be achieved by in-
creasing the welding current during short-circuits. This
function is only available when using coated elec-
trodes.
Pre-flow
TIG function – Gas pre-flow time
The gas pre-flow time is the time that elapses
between the activation of the torch trigger (which
establishes a gas supply) and the establishment of
the welding current.

20
TECHNICAL DATA
Power source: TIG 240 AC/DC TIG 320 DC TIG 320 AC/DC TIG 400 DC
Mains voltage / Fuse
Mains voltage / Fuse
(changeable)
Consumption, max.
Efficiency
Current range DC
Current range AC
Duty cycle 100%
Duty cycle 60%
Duty cycle 35%
Open circuit voltage DC
1 Sphere of application
2 Protection class
Standard
3x400 V / 16 A
11,7 KVA
0.85
5 - 240 A
5 - 240 A
165 A
180 A
240 A
85 V
S
IP 21
EN60974-1
EN50199
3x400 V / 25 A
3x230 V / 50 A
3x400 V / 25 A
3x440 V / 20 A
3x500 V / 20 A
17,0 KVA
0.85
5 - 320 A
-
310 A
320 A
-
85 V
S
IP 21
EN60974-1
EN50199
3x400 V / 25 A
3x230 V / 50 A
3x400 V / 25 A
3x440 V / 20 A
3x500 V / 20 A
17,7 KVA
0.85
5 - 320 A
5 - 320 A
300 A
320 A
-
85 V
S
IP 21
EN60974-1
EN50199
3x400 V / 25 A
-
3x400 V / 25 A
3x440 V / 20 A
3x500 V / 20 A
22,5 KVA
0.85
5 - 400 A
-
310 A
355 A
400 A
85 V
S
IP 21
EN60974-1
EN50199
Control:
Anti-stick
Pilot arc
Arc power
Hot-start
Pulse time
Pause time
Base current
Gas pre-flow
Gas post-flow
Slope up
Slope down
Reduced current
AC-t-balance, based on time (TIG)
AC-I-balance,
based on current intensity (TIG)
AC frequency (TIG)
AC frequency (MMA)
Starting current
Stop current
Spot welding time
Box 1
5 A
4 %, min. 5 A
0 - 150 %
0 - 100 %
0,01 - 10 secs
0,01 - 10 secs
1 - 99 %, min. 5 A
0 - 10 secs
3 - 20 secs
0 - 10 secs
0 - 10 secs
0 - 100 %, min 5 A
1 - 100 %
1 - 100%, min 5 A
1 - 300 Hz
1 - 100 Hz
0 - 100 %, min. 5 A
0 - 100 %, min. 5 A
0.1 - 50 secs
Box 2
5 A
4 %, min. 5 A
fixed
0 - 100 %
-
-
-
0.2 sec. (fixed)
0 - 30 secs
-
0 - 10 secs
-
0 - 100 %
-
10 - 500 Hz
-
-
-
-
Dimensions and weight:
Dimensions
Weight
Weight, changeable
700x550x1050
122 kg
700x550x1050
131 kg
161 kg
700x550x1050
149 kg
179 kg
700x550x1050
131 kg
161 kg
1
S
The machine meets the standards which are demanded of machines working in areas where there is an increased risk of electric shock
2 Indicates that the machine cannot be used outside in the rain