OTC DTX-2200 AC/DC User manual

DTX-2200 AC/DC
DTX-3000 AC/DC
User Manual

Contents
2
DTX-2200-3000 AC/DC
1 Contents
1Contents ........................................................................................................................................................... 2
2Foreword .......................................................................................................................................................... 4
3Regulations for the prevention of accidents...................................................................................................... 6
3.1Connection of the power source............................................................................................................. 6
3.2Operator protection ................................................................................................................................ 7
3.3Prevention of fire and slag ..................................................................................................................... 7
3.4Risk of poisoning.................................................................................................................................... 8
3.5Installation of the power source.............................................................................................................. 8
3.6Transport of the power source ............................................................................................................... 9
3.7Safety measures .................................................................................................................................... 9
4Description ..................................................................................................................................................... 11
5Features ......................................................................................................................................................... 11
6Technical Data ............................................................................................................................................... 13
7Usage Limits (IEC 60974-1) ........................................................................................................................... 14
8Open the packing ........................................................................................................................................... 14
9 Serial number ................................................................................................................................................ 14
10 How to lift up the machine ...................................................................................................................... 15
11 Installation ............................................................................................................................................... 15
12 Prepare the machine for welding .......................................................................................................... 16
12.1Connection to the electrical supply....................................................................................................... 16
13Outer view of the DTX-202 TIG ................................................................................................................ 17
14Operation.................................................................................................................................................. 18
14.1TIG-welding.......................................................................................................................................... 18
14.1.1Part to be welded............................................................................................................................. 20
14.1.2Welding Parameters ........................................................................................................................ 20
14.2Electrode welding (MMA) ..................................................................................................................... 21
14.2.1Part to be welded............................................................................................................................. 21
14.2.2Welding Parameters ........................................................................................................................ 22
14.3Control panel MTA22 / MTA30............................................................................................................. 23
14.3.1Panel surface................................................................................................................................... 23
14.3.2  Displaying the Software version installed .................................................................................. 29
14.3.3 Electrode welding (MMA) .............................................................................................................. 30
14.3.4  TIG “AC” welding ............................................................................................................................ 31
14.3.5 TIG „DC“ -welding ........................................................................................................................... 37
14.3.6 TIG “AC and LIFT DC” welding with the SPOT WELDING function ON...................................... 38
14.3.7 TIG HF DC welding with TACK function active and single ColdTack point ................................. 39
14.3.8 TIG HF DC welding with TACK function active and multi ColdTack point ................................... 40
14.3.9 TIG-welding – Welding parameters............................................................................................... 42
14.3.10 Editing the maximum and minimum limits for welding parameters........................................... 54
14.3.11  Creating and memorising automatic welding points ............................................................ 55
14.3.12PROGRAMMED and/or MANUAL welding.................................................................................. 56
14.3.13 Calling up saved programs ....................................................................................................... 57
14.3.14 Viewing the p arameters set ...................................................................................................... 58
14.3.15  Activating the VRD-device ......................................................................................................... 58
14.3.16 Auxiliary functions .................................................................................................................... 59
14.3.17Factory default............................................................................................................................. 59
14.3.18 Error and protection conditions ................................................................................................. 60
15Optional .................................................................................................................................................... 62
15.1MANUAL REMOTE CONTROL ........................................................................................................... 62
15.2 FOOT SWITCH .................................................................................................................................... 62

Contents
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DTX-2200-3000 AC/DC
15.3AIR AND/OR WATER-COOLED TORCH UP/DOWN .......................................................................... 62
15.4Interfacing accessories (optional)......................................................................................................... 63
16Maintenance............................................................................................................................................. 64
16.1Daily ..................................................................................................................................................... 64
16.2Weekly ................................................................................................................................................. 64
16.3All six months ....................................................................................................................................... 64
17TROUBLESHOOTING ............................................................................................................................. 65
17.1 DIGITAL INTERFACE PCB REPLACEMENT ................................................................................ 65
17.2  Adjustment of electronic circuit board ............................................................................................. 65
17.3 MEANING OF GRAPHIC SYMBOLS ON THE MACHINE ............................................................. 66
18WIRING DIAGRAM .................................................................................................................................. 67
18.1Key to the electrical diagram................................................................................................................ 67
18.2Colour key............................................................................................................................................ 68
19Spare parts list ......................................................................................................................................... 73
19.1Ordering spare parts ............................................................................................................................ 79

Foreword
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DTX-2200-3000 AC/DC
2 Foreword
Thank you for choosing our product. Your new welding equipment from OTC DAIHEN EUROPE GmbH offers you
the highest quality and latest technology.
To exploit the full capabilities of this device and to enjoy it for many years, please read these instructions carefully
before connecting and commissioning the device. It’s very important to operate your device as instructed.
The reliability and functionality of the device can only be guaranteed if you follow the general safety and accident
prevention Instructions in this manual. We assume no liability for damages caused by improper use or incorrect
operation.
Important
Please ensure that all persons who operate with the device have red and understood the operating instructions in
this manual. If you don’t have sufficient knowledge and experience concerning the operation and the safe use of
this machine, please contact our staff.
If you have any questions about the installation, the connection or the use of this device you can always contact
the manufacturer (customer service department).
Please keep this manual at a safe place in case of need to be
able to access it at any time!
Warning
The arc welding equipments from the company OTC DAIHEN EUROPE GmbH correspond to the "EN 50199
standard" for electromagnetic compatibility. The operators are required to operate according to manufacturer's
instructions when installing and handling the device.
In case of electromagnetic interference, the operators have to contact the manufacturer and search a solution.

Foreword
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DTX-2200-3000 AC/DC
Electric and Magnetic Fields
During the operations of the welding machine an electromagnetic field (EMF) can be created and may
caused health problems.
The operator is responsible for the proper installation and use of the device according to the manufacturer’s
instructions. In case of electromagnetic interference, it’s in the responsibility of the user to remove these
(technical support can be requested).
Before the installation and commissioning of the equipment, the user has to consider potential
electromagnetic interference in its environment.
The following should be considered:
Other supply, control, signal and telephone cables over, under and in the adjacent area of the
welding machine.
Radio, television sets and receivers.
Computer and other control devices.
Security and surveillance equipment.
The health status of all attendant persons, especially people with heart pacemakers, hearing aids,
etc.
Instruments and equipment used for the calibration.
The protection of the other devices in the vicinity of the welding unit. These must be compatible.
Additional precautions may be necessary.
The time of day in which the welding or other work will be performed.
Recommendation to reduce the electromagnetic interference
Installation of a filter on the supply.
Use of cables with protective wrapping.
Proper maintenance of the system.
The housing must be closed during the operation.
The weld cables as short as possible.
Grounding of the work piece.

Regulations for the prevention of accidents
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DTX-2200-3000 AC/DC
3 Regulations for the prevention of accidents
The use of welding equipment and welding itself are always associated with a certain safety risk. Therefore each
set up and operation of the device assumes that the instruction manual is understood and complied. The properly
used welding machine grants a high degree of operational security but can, in case of improper handling, lead to
property and personal damage.
Be sure that you observe the following safety rules:
3.1 Connection of the power source
The installation and maintenance of the system must be carried out in accordance with the general
safety and accident prevention regulations of the legislature.
The state of the power cord and plug must be checked and any damage eliminated. The
electrical equipment must be tested at regular intervals. Use cables of sufficient diameter.
The ground cable must be fastened as close as possible to the work area of the work piece be. Is it
connected directly to the building design or too far away from the work area, this can lead to energy
loss or discharging.
The system may not be used in damp areas and in no case encounter water or other liquids.
Direct contact with hands or with wet clothing to components that might be under tension is to be
avoided. Make sure that your gloves and protective clothing are dry.
When working in damp rooms or on metal surfaces, use protective gloves and work shoes with
rubber soles.
The system has to be cut off at each interruption, even at sudden loss of power. Accidental ground
contact can lead to overheating of the system and cause a fire. The system must therefore never
be turned on without supervision.

Regulations for the prevention of accidents
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DTX-2200-3000 AC/DC
3.2 Operator protection
All people must be protected during the welding process, with appropriate measures against UV
radiation, noise, heat and gas pollutants emitted during welding. Never expose yourself to the influences
of arc and the hot metal slag without a protective mask and appropriate protection. Welding work without
consideration of these standards could cause serious health problems.
Always wear protective clothing: gloves (fire resistant), shirts with long sleeves, long pants
without cuffs and high closed shoes. Protective clothing protects the skin from the arc and
the hot metal.
Wearing a cap or a helmet is required!
Protect your eyes with safety glasses and adequate protection level (at least NR10 or
more). The same goes for the ears, face and skin. All people must be informed of the
dangers.
In the workroom, all people have to wear earmuffs!
When you manually remove the hot metal slag wearing safety glasses with side flaps is required.
Present persons have to keep their distance!
The entire welding area must be secured with a fireproof bulkhead, in order to protect present
persons from the created radiation, slag and sparks.
3.3 Prevention of fire and slag
The glowing slag and the resulting spark can ignite a fire at any time. Explosions or the outbreak of fire
can be prevented if you meet the following requirements:
Remove all flammable objects in the vicinity of the welding machine or cover them with refractory
materials.
These flammable objects include the following: wood, saw dust, clothing, paints and solvents, gasoline,
fuel oil, natural gas, acetylene, propane, etc.
Even after emptying the collection vessels and pipes is caution while welding very important.
A fire extinguisher, sand or water must always be present in the workplace in order to be able to react quickly in
case of fire.
Never weld at adjoining tanks or piping. Do not weld in open containers or pipes that may contain flammable
substances.

Regulations for the prevention of accidents
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DTX-2200-3000 AC/DC
3.4 Risk of poisoning
Gases and fumes that are harmful when inhaled for a longer time can be released while
welding.
Because of this, the following safety guidelines have to be observed:
Ensure that you have adequate ventilation for the work area.
During the processing of materials such as, beryllium, potassium, zinc, or galvanized and painted
pieces, you must set up forced ventilation.
The operator has to protect his airway with appropriate equipment.
Wherever a sufficient air supply is ensured, you must use respirators and additional air supply.
In small rooms (in boilers, in the ditch, etc.), the welders have to be backed up by another person.
Provided that all requirements are met to prevent accidents.
Weld never near degreasing and painting, because there may be released bleach-water, which
transform under the influence of heat into phosgene, a highly toxic gas.
The signs of inadequate ventilation or a possible poisoning are charms in the eyes, nose and
throat. In this case, you have to interrupt the welding work and ventilate the work area. If you feel
uncomfortable anyway stop the welding work.
3.5 Installation of the power source
When setting up the welding machine the following requirements have to be obeyed:
All switch ports and devices must be accessible.
Thus, the source can be adequately ventilated, never set up the device in a narrow space. Avoid
dirty and dusty areas, so the device can absorb no foreign body.
The unit including all cables should not impede the ability to work and the passage to other rooms.
The unit must be secured against falling down.
Setting up objects higher, increases the risk that it may fall off during the work.

Regulations for the prevention of accidents
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DTX-2200-3000 AC/DC
3.6 Transport of the power source
The unit is generally suitable for transport.
The following requirements must be made to ensure an ease transport:
The device may only be lifted and transported with the provided handle.
Before lifting or transportation all connectors and cables have to be removed.
Never pull this device on the cables or plug.
3.7 Safety measures
Before using the machine, the following rules have to be observed:
Ensure the appropriate working conditions for the welder. At the work area no inflammable
substances may be presented. Reconciliation of dust and other substances that prevent the
isolation of the device must be removed.
Back up the welder properly when working outdoors.
If you notice any overheating or smoke, fire, find strange sounds and unusual vibrations, you have
to switch off the machine immediately and disconnect it from power. In such cases the device has
to be inspected by an expert.
In the event of a power outage, or when you realize power on the housing of the device, switch off
the machine immediately and disconnect it from power. The same applies in the case of
mechanical damage.
Too high humidity in the work area can reduce the insulation class and cause a short circuit.
During welding some parts of the machine exceeds 100 °C. Therefore these parts are protected
with a thermostat. Whenever you will notice any overheating, you have to turn off the power
immediately.
Use environment:
The device is not suitable for bathrooms, showers, swimming pools or similar areas. If it’s
necessary to work in these environments, you have to ensure that water can’t damage the
machine. The welding equipment isn’t suitable for use in rain or snow!
The welding equipment can’t be used in areas, where it is exposed to shock or vibration. Areas that
should be avoided necessarily are for example, road-, rail- and cable handling equipment, aircraft,
water crafts, cranes and parts of machine tools.

Regulations for the prevention of accidents
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DTX-2200-3000 AC/DC
Dust and cooling system:
The device has to be positioned in a way that sufficient air can flow through the cooling fins and the
cooling channels. The unit adjusts the cooling system automatically! Please pay attention, that no
metal dust can be sucked.
Stability:
The unit can be installed on up to 15° tilted planes. If the plane is tilted steeply, the welding
equipment can overturn!