Mweld POWER TIG DPIII User manual

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CATALOGUE
POWER TIG DPIII
WARNING:
Read carefully and understand all ASSEMBLY
AND OPERATION INSTRUCTIONS before
operating. Failure to follow the safety rules and
other basic safety precautions may result in
serious personal injury.
OWNER’S MANUAL
WELDING AND CUTTING TOTAL SOLUTION

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CATALOGUE
General Safety Rules
Welder Instruction
Safety Usage
Technical Specifications
Functions
CurrentAdjustment Instruction
Welder Installation
List of Spare Parts
Operations Methods
Common faults and solving methods
Explosive View and Spare Parts List
Main Circuit Principle Diagram
Complete Set List
Delivery & Storage

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GENERAL SAFETY RULES
WARNING: Read and understand all instructions. Failure to follow all instructions listed below may result in
serious injury.
CAUTION: Do not allow persons to operate or assemble this POWER TIG DPIII
until they have read this manual and have developed a thorough understanding of how the
POWER TIG DPIII works.
WARNING: The warnings, cautions, and instructions discussed in this instruction
manual cannot cover all possible conditions or situations that could occur. It must be understood
by the operator that common sense and caution are factors which cannot be built into this product, but
must be supplied by the operator.
IMPORTANT SAFETY CONSIDERATIONS
1.1 Your Welding Environment
-Keep the environment you will be welding in free from flammable materials.
-Always keep a fire extinguisher accessible to your welding environment.
-Always have a qualified person install and operate this equipment.
-Make sure the area is clean, dry and ventilated. Do not operate the welder in humid, wet or poorly
ventilated areas.
-Always have your welder maintained by a qualified technician in accordance with local, state and
national codes.
-Always be aware of your work environment. Be sure to keep other people, especially children, away
from you while welding.
-Keep harmful arc rays shielded from the view of others.
-Mount the welder on a secure bench
or cart that will keep the welder secure and prevent it from tipping over or falling.
1.2 Your Welder’s Condition
-Check ground cable, power cord and welding cable to be sure the insulation is not damaged. Always
replace or repair damaged components before using the welder.
-Check all components to ensure they are clean and in good operating condition before use.
1.3 Use of Your Welder
Do not operate the welder if the output cable, electrode, torch, wire or wire feed system is wet. Do not

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immerse them in water. These components and the welder must be completely dry before
attempting to use them.
-Follow the instructions in this manual.
-Keep welder in the off position when not in use.
-Connect ground lead as close to the area being welded as possible to ensure a good ground.
-Do not allow any body part to come in contact with the welding wire if you are in contact with the
material being welded, ground or electrode from another welder.
-Do not weld if you are in an awkward position. Always have a secure stance while welding to prevent
accidents. Wear a safety harness if working above ground.
-Do not drape cables over or around your body.
-Wear a full coverage helmet with appropriate shade (see ANSI Z87.1 safety standard) and safety
glasses while welding.
-Wear proper gloves and protective clothing to prevent your skin from being exposed to hot metals, UV
and IR rays.
-Do not overuse or overheat your welder. Allow proper cooling time between duty cycles.
-Keep hands and fingers away from moving parts and stay away from the drive rolls.
-Do not point torch at any body part of yourself or anyone else.
-Always use this welder in the rated duty cycle to prevent excessive heat and failure.
1.4 Specific Areas of Danger, Caution or Warning
Electrical Shock
Electric arc welders can produce a shock that can cause injury or death. Touching electrically live parts
can cause fatal shocks and severe burns. While welding, all metal components connected to the wire
are electrically hot. Poor ground connections are a hazard, so secure the ground lead before welding.
-Wear dry protective apparel: coat, shirt, gloves and insulated footwear.
-Insulate yourself from the work piece. Avoid contacting the work piece or ground.
- Do not attempt to repair or maintain the welder while the power is on.
-Inspect all cables and cords for any exposed wire and replace immediately if found.
-Use only recommended replacement cables and cords.
-Always attach ground clamp to the work piece or work table as close to the weld area as possible.
-Do not touch the welding wire and the ground or grounded work piece at the same time.
-Do not use a welder to thaw frozen pipes.
Fumes and Gases
-Fumes emitted from the welding process displace clean air and can result in injury or death.
-Do not breathe in fumes emitted by the welding process. Make sure your breathing air is clean and safe.
-Work only in a well-ventilated area or use a ventilation device to remove welding fumes from the
environment where you will be working.
-Do not weld on coated materials (galvanized, cadmium plated or containing zinc, mercury or barium).
They will emit harmful fumes that are dangerous to breathe. If necessary use a ventilator, respirator with
air supply or remove the coating from the material in the weld area.
-The fumes emitted from some metals when heated are extremely toxic. Refer to the material safety data
sheet for the manufacturer’s instructions.
-Do not weld near materials that will emit toxic fumes when heated. Vapors from cleaners, sprays and
degreasers can be highly toxic when heated.

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UV and IR Arc Rays
The welding arc produces ultraviolet (UV) and infrared (IR) rays that can cause injury to your
eyes and skin. Do not look at the welding arc without proper eye protection.
-Always use a helmet that covers your full face from the neck to top of head and to the back of each ear.
-Use a lens that meets ANSI standards and safety glasses. For welders under 160 Amps output, use a
shade 10 lens; for above 160 Amps, use a shade 12. Refer to the ANSI standard Z87.1 for more
information.
-Cover all bare skin areas exposed to the arc with protective clothing and shoes. Flame-retardant cloth
or leather shirts, coats, pants or coveralls are available for protection.
-Use screens or other barriers to protect other people from the arc rays emitted from your welding.
-Warn people in your welding area when you are going to strike an arc so they can protect themselves.
Fire Hazards
Do not weld on containers or pipes that contain or have had flammable, gaseous or liquid combustibles
in them. Welding creates sparks and heat that can ignite flammable and explosive materials.
-Do not operate any electric arc welder in areas where flammable or explosive materials are present.
-Remove all flammable materials within 35 feet of the welding arc. If removal is not possible, tightly cover
them with fireproof covers.
-Take precautions to ensure that flying sparks do not cause fires or explosions in hidden areas, cracks or
areas you cannot see.
-Keep a fire extinguisher close in the case of fire.
-Wear garments that are oil-free with no pockets or cuffs that will collect sparks.
-Do not have on your person any items that are combustible, such as lighters or matches.
-Keep work lead connected as close to the weld area as possible to prevent any unknown, unintended
paths of electrical current from causing electrical shock and fire hazards.
-To prevent any unintended arcs, cut wire back to ¼" stick out after welding.
Hot Materials
Welded materials are hot and can cause severe burns if handled improperly.
-Do not touch welded materials with bare hands.
-Do not touch TIG gun nozzle after welding until it has had time to cool down.
Sparks/Flying Debris
Welding creates hot sparks that can cause injury. Chipping slag off welds creates flying debris.
-Wear protective apparel at all times: ANSI-approved safety glasses or shield, welder’s hat and ear plugs
to keep sparks out of ears and hair.
Electromagnetic Field
-Electromagnetic fields can interfere with various electrical and electronic devices such as pacemakers.
-Consult your doctor before using any electric arc welder or cutting device

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-Keep people with pacemakers away from your welding area when welding.
-Do not wrap cable around your body while welding.
-Wrap TIG gun and ground cable together whenever possible.
-Keep TIG gun and ground cables on the same side of your body.
Shielding Gas Cylinders Can Explode
High pressure cylinders can explode if damaged, so treat them carefully.
-Never expose cylinders to high heat, sparks, open flames, mechanical shocks or arcs.
-Do not touch cylinder with TIG gun.
-Do not weld on the cylinder
-Always secure cylinder upright to a cart or stationary object.
-Keep cylinders away from welding or electrical circuits.
-Use the proper regulators, gas hose and fittings for the specific application.
-Do not look into the valve when opening it.
-Use protective cylinder cap whenever possible
1.5 Proper Care, Maintenance and Repair
-Always have power disconnected when working on internal components.
- Do not touch or handle PC board without being properly grounded with a wrist strap. Put PC board in
static proof bag to move or ship.
-Do not put hands or fingers near moving parts such as drive rolls of fan
POWERTIG SERIES USE AND CARE
Do not modify the POWER TIG DPIII in any way. Unauthorized modification may impair the function
and/or safety and could affect the life of the equipment. There are specific applications for which the
POWER TIG DPIII was designed.
Always check of damaged or worn out parts before using the POWER TIG DPIII . Broken parts will
affect the POWER TIG DPIII operation. Replace or repair damaged or worn parts immediately.
Store idle POWER TIG DPIII . When POWER TIG DPIII is not in use, store it in a secure place out of
the reach of children. Inspect it for good working condition prior to storage and before re-use.

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Welders Instructions
POWERTIG pulse inverter welder uses inert gases (Argon) as the protection medium for the arc, using high
frequency or high pulse to do the gas ionization and melt metals by the arc, made between the tungsten electrode
and work piece, to reach the welding purpose. It can give fast good compensation for power grids fluctuation, and
can control accurately for various welding process. Thus, it is smooth soft, little splash and easy appearance of
weld. In the welding of high strength steel and low carbon steel, stainless steel, alloy steel materials can easy get
good appearance of weld.
The characteristics of the argon arc welding machines is:
-The tungsten is not melting, arc is stable, easy to control welding quality during welding.
-It can do wire filling, also without wire filling, is suitable for welding sheet, also suitable for thick plate..
-The arc heat concentration, the work piece de-formation less than the mig machines and MMA machines.
-Suitable for all position welding.
-Especially suitable for welding sheet below 3 mm, also can get good welding quality for less than 1 mm thick
sheet.
-Soft arc, arc concentricity is good, fillet welding is easy, and reliable positioning welding.
POWERTIG series inverter dc pulse argon arc welding machine adopts the advanced inverter technology, using
international advanced IGBT as a converter, supplemented by special development control circuit, make the whole
machine has high reliability, fast dynamic response, stable arc characteristics. This series welding machine has: dc
pulse argon arc welding, dc MMA arc welding, and many other functions, can satisfy the requirement of all kinds
of welding process. Its widely used in pressure vessels, construction, shipbuilding, petrochemical industries.
This manual as content has errors, or welding machine function change, will change this manual at any time,
without prior notice.
Safety Operation
Operator’s self protection:
* Comply the work safety, sanitation rules, wear relevant work protection equipments to avoid the damage to eyes
and skins.
* In welding time, cover head by the welding face shield, watch the arc only through the observing windows on
the welding veil.
* Do not let any part of your body touch the two output poles (Electrode pole and work pole) of the welders at one
time, before you are under the insulated protection.
* Do not weld in water or high humidity places.
Operator’s notices
* POWERTIG pulse inverter TIG welder is electric equipment. Its spare parts are fragile. So do not change or
adjust with a rush otherwise the switch will be damaged.
* Before every welding work, check carefully whether the welder’s correction & earth wire are correct and
reliable.
* Inflammable or explosive materials are prohibited in the welding areas.
* To ensure the air flow in the welding areas, as the welding smoke is bad for the health.
* Isolate the arc light to protect others
* Irrelevant persons are not allowed to enter into the welding area. Forbid to adjust or move the welders in the
welding time.

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* Welders have strong electromagnetism and electric frequency disturbs. Do not let near the persons with heart
pacemaker or easily affected by electromagnetism and electric frequency.
* Do not press, pile or stress the welding wires by any apparatus. Do not bend the welding wires into very small
angle, otherwise it would hurt the inside wires to cause the hidden troubles.
* Do not touch any output joints with electric in the welding time.
* Forbid to use the welder for the pipe ice-out.
* Deliver the welder by forking machine or with base. Forbid to move by handles above the welders.
* Pay high attention on the rated duty cycle of welders to avoid the overload.
Safety protection in the welder’s installed and used places
* Protection on persons and welders under areas, where there are items dropped down.
* Dusts, Acid, Causticity airs or materials contents in the welding area air to be lower than the relevant standards
(except for these caused by the welding)
* Inflammable ,explosive or other dangerous materials are prohibited in the welding areas.
* The welders should be installed in these places, without direct sunshine, rain drench, lower humidity,
-10~+40℃.
* 50cm space to be ensured around the welders for the nice airness.
* Metal eyewinker not allowed into the welders.
* No strong shake allowed in the welding area.
* Protect the welder from the dumpage, when the welders put in the over 10° declining plane.
* Choose the installation area to avoid any disturbs to other electromagnetic equipments, when the welders used.
* Block the wind, when the air protection welding used.
Safety Check
Operator should check below procedures before every welding job:
*Make sure the welder’s earth protection is reliably connected.
* Make sure the welder’s input, output wires is fine, not exposed outside.
After the fixing of the welders, make safety check each six months by qualified persons.
* Make sure no spare parts not tightened inside the welder and clear the dusts.
* Check the spare parts on the welder panel to ensure the welder could work well.
* Check the welding wires whether aged for used
* Check the input wires whether damaged or not. If damaged, improve it.
* Check the power supply network to ensure its capacity could make the welder work normally. Ensure welder’s
input power source have security protection device.
Cut off the power supply before opening the case to check.
Please do not hesitate to contact us for technical assistance whenever you come across the problems you
can not work out or you may deem difficult to fix

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Technical Specifications
Environment Conditions
*Ambient air temperature range:
5~+40℃in welding,water cooling
-10~+40℃in welding, air cooling
-25~+55℃in delivery, storage
* Air relevant humidity: in 40℃,≤50%; in 20℃,≤90%
* Dusts, Acid, Causticity airs or materials contents in the welding area air lower than the relevant standards
(except for these caused by the welding), No strong shake allowed in the welding area.
* Altitude degree lower than 1000m
* Protect for the rain, when the welder to be used outdoor.
* Wind speed less than 1m/s
Power supply net requirements
* Power voltage wave shape should be the actual sine wave, frequency wave less than ±1% of its rated amount.
* Power voltage wave less than ±15% of its rated amount.
Main principles of the welders
POWERTIG series inverter dc pulse argon arc welding machine adopts the international advanced IGBT and fast
recovery diode as the main power device of power transformation and transmission, can accurately control the arc,
supplemented by gas pre-flow and gas post-flow, non-contact high-frequency arc, can guarantee the arc starting
and stable welding. Combine with various protection functions make welding machine quality is reliable.
Welding machine get 220 ~ 240V AC power through wave form switch SW1, rectify by BD1 single-phase
rectifier, the capacitor C1 ~ C4 filtering into direct current (dc), via the IGBT (Q1, Q2, Q3 and Q4) composed of
bridge type inverter ac inverter into 33 KHz AC POWER, then through intermediate frequency transformer T1
transformer, after fast recovery D1-3, D4-6 rectifier, offering the stable DC power. In the output at the same time,
via high pressure of coupling transformer T2 arc with high frequency pulse coupled to the output of the negative
side, for non-contact start arc conveniently.
Main structure of the welders
POWERTIG series inverter dc pulse argon arc welding machine used to move around freely enclosure structure:
the upper part on the front panel is equipped with digital displayer, current welding mode selection button, over
voltage indicator, overheat lights, parameter adjustment of the indicator knob; The lower part is equipped with "+"
quick socket output current, output current "-" quick socket, welding gun control cable interface, as well as the
welding torch gas interface; Rear panel is equipped with cooling fan, power input lead, and the power switch, and
argon gas input interface; At the bottom of the box body is equipped with four feet and the handle.

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Main technical specifications of the welder
No special advice on above parameter. The nameplate parameter on the welder is prior.
ITEM UNIT POWER TIG 200DPIII POWER TIG 180DPIII
ted Input Voltage V 220(220~240) 230(220~240) 220(220~240) 230(220~240)
Power Frequency Hz 50/60 50/60 50/60 50/60
Rated Input
Capacity
KVA 8.58 8.74 7.48 7.59
Rated Input Current A 39 38 34 33
Output No Load
Voltage
V62 66 62 66
Rated Working
Voltage
V18 18 17.2 17.2
Stick welding
current
A20-200 20-200 20-180 20-180
Welding Curre nt A 5～200 5～200 5～180 5～180
Base value current A 5～200 5～200 5～180 5～180
Current rise Time s 0～15 0～15 0～15 0～15
Current Drop Time s 0～25 0～25 0～25 0～25
Pulse Frequency Hz 0.5～200 0.5～200 0.5～200 0.5～200
Duty cycle % 15～85 15～85 15～85 15～85
Gas pre-flow time s 0～50
～50 ～50 ～5
Gas post flow Time s 0～60 0～60 0～60 0～60
Rated Duty Cycle % 20 20 20 20
Cooling Type Wind Cooling Wind Cooling Wind Cooling Wind Cooling
Effiency η≥85% ≥85% ≥85% ≥85%
Power Factor Cosφ0.73 0.73 0.73 0.73
Insulation Degree H H H H
Cover Protection
Degree
IP IP21S IP21S IP21S IP21S
Weight kg 9.3 9.3 9.3 9.3
Dimension L×W×H mm 440*175*340 440*175*340 440*175*340 440*175*340
Standards of the welders
The POWERTIG series Inverter TIG Welder according to the following standard EN60974-1 EN60974-10
High frequency arc pilot method instruction
This kind of arc pilot method is absolutely different with the traditional arc pilot method. It
does not need to connect Tungsten electrode with the work piece. It use high voltage & high
frequency pulse to make ionization on the air, transmitting the electricity by the air after
ionization, and form the arc.