Parweld XTM 221Di User manual

OPERATOR MANUAL
ISSUE 2
XTM 221Di

2
Welcome
Thank you for choosing Parweld. This Owner's
Manual is designed to help you get the most
out of your Parweld products. Please take time
to read the Safety Precautions. They will help
you protect yourself against potential hazards
in the workplace. With proper maintenance
this equipment should provide years of reliable
service. All our systems conform to ISO9001:
2015 and are independently audited by NQA.
The product range carries the CE and UKCA
mark, and is constructed in accordance with
European directives and the product specific
standards where they apply.
Further Information
Parweld is the UK's leading supplier of MIG, TIG
and Plasma torches and consumables.
For more information about Parweld's complete
range visit: www.parweld.com
[e-mail] parweld_uk

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Contents
Page
1.0 Safety Precautions 4-5
2.0 Product Description 5
3.0 Technical Specications 6
4.0 Installation 6
4.1 Location 6
4.2 Input and Grounding Connection 7
5.0 Description of Controls 7
and Torch Connections
6.0 Operation 8-10
6.1 Use of Controls 8
6.2 Language of Operation 8
6.3 Process Selection 8
6.4 MIG Welding Preparing the Machine 9-10
7.0 Setting the Machine for Welding 10-20
7.1 MIG Torch Selection 10
7.2 MIG SYN - Synergic MIG Welding 10-11
7.3 MIG MAN - Manual MIG Welding 11
7.4 Remote Control MIG Torch 11
7.5 MIG Welding Procedure 12
7.6 MMA Welding 12
7.7 TIG Welding 12
7.7.1 TIG Torch Selection 12
7.7.2 TIG Torch Installation 13
7.7.3 TIG Welding Setup 13-15
7.7.4 TIG Welding Guide 15
7.7.5 DC TIG Welding (No Pulse) 15-16
7.7.6 AC TIG Welding (No Pulse) 16-17
7.7.7 TIG Welding (With Pulse) 17-18
7.8 Plasma Cutting 18-19
7.8.1 Setting Air Pressure 18
7.8.2 Preparing to Cut 18
7.8.3 Mesh Cutting 19
7.8.4 Normal Cutting 19
7.8.5 Gouging 19
7.8.6 Torch Operation Logic 19
7.9 Saving to Memory 20
7.10 Process Switch 20
8.0 Fault Finding 21-25
8.1 MIG Welding Problems 21-22
8.2 MMA Welding Problems 23
8.3 TIG Welding Problems 24
8.4 Plasma Cutting Problems 25
9.0 Control Torch Schematic 26-27
10.0 Accessories 28
10.1 Feed Rolls 28
10.2 MIG Torch Spares 28
10.3 Gas Equipment 28
11.0 EC Declaration of Conformity 29-30
11.1 RoHS Compliance Declaration 29
11.2 WEEE Statement 30
11.3 Statement of Warranty 30

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1.0 Safety Precautions
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or severe burns.
The electrode and work circuit is electrically live whenever the output
is on. The input power circuit and machine internal circuits are also
live when power is on. In semi automatic or automatic wire welding,
the wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
Do not touch live electrical parts.
Wear dry, sound insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
ground.
Additional safety precautions are required when any of the following
electrically hazardous conditions are present: in damp locations
or while wearing wet clothing; on metal structures such as floors,
gratings, or scaffolds; when in cramped positions such as sitting,
kneeling, or lying; or when there is a high risk of unavoidable
or accidental contact with the work piece or ground. For these
conditions, use the following equipment in order presented: 1) a semi
automatic DC constant voltage (wire) welder, 2) a DC manual (stick)
welder, And, do not work alone!
Disconnect input power before installing or servicing this equipment.
Lockout/tagout input power according to Safety Standards.
Properly install and ground this equipment according to national and
local standards.
Always verify the supply ground - check and ensure that input power
cable ground wire is properly connected to ground terminal in the
receptacle outlet.
When making input connections, attach proper grounding conductor
first - double-check connections.
Frequently inspect input power cable for damage or bare wiring -
replace cable immediately if damaged - bare wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, under sized, or poorly spliced cables.
Do not drape cables over your body.
If earth grounding of the work piece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground, or
another electrode from a different machine.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece or
worktable as near the weld as practical.
Insulate work clamp when not connected to a workpiece to prevent
contact with any metal object.
Welding produces fumes and gases. Breathing these fumes and
gases can be hazardous to your health.
FUMES AND GASES can be hazardous.
Do not breathe the fumes.
Ensure local extraction is effective or use a personal filtration
system. Welding fume can be carcinogenic.
Read and understand the Material Safety Data Sheets (MSDS's) and
the manufacturer s instructions for metals, consumables, coatings,
cleaners, and de-greasers.
Work in a confined space only while wearing an air-supplied
respirator. Always have a trained watch person nearby. Welding
fumes and gases can displace air and lower the oxygen level
causing injury or death. Be sure the breathing air is safe.
Do not weld / cut in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapours to
form highly toxic and irritating gases.
Do not weld on coated metals, such as galvanized, lead, or cadmium
plated steel, unless the coating is removed from the weld area, the
area is well ventilated, and while wearing an air-supplied respirator.
The coatings and any metals containing these elements can give off
toxic fumes if welded.
ARC RAYS can burn eyes and skin.
Arc rays from the welding / cutting process produce intense, visible
and invisible (ultraviolet and infrared) rays that can burn eyes and
skin. Sparks fly off from the weld.
Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes when welding, cutting or
watching.
Wear approved safety glasses with side shields under your helmet.
Use protective screens or barriers to protect others from flash, glare
and sparks; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant material
(leather, heavy cotton, or wool) and foot protection. Welding / cutting
on closed containers, such as tanks, drums, or pipes, can cause
them to blow up. Sparks can fly off from the welding arc. The flying
sparks, hot workpiece, and hot equipment can cause fires and
burns. Accidental contact of an electrode to metal objects can cause
sparks, explosion, overheating or fire. Check and be sure the area is
safe before doing any welding / cutting.

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WELDING AND CUTTING can cause re or explosion.
Remove all flammables within 10m of the welding / cutting arc. If this
is not possible, tightly cover them with approved covers.
Do not weld or cut where flying sparks can strike flammable material.
Protect yourself and others from flying sparks and hot metal.
Be alert that welding / cutting sparks and hot materials from welding /
cutting can easily go through small cracks and openings to adjacent
areas.
Watch for fire, and keep a fire extinguisher nearby. Be aware that
welding or cutting on a ceiling, floor, bulkhead, or partition can cause
fire on the hidden side.
Do not weld or cut on closed containers such as tanks, drums,
or pipes, unless they are properly prepared according to local
regulations
Connect work cable to the work as close to the welding / cutting
area as practical to prevent current from travelling along possibly
unknown paths and causing electric shock, sparks, and fire hazards.
Cut off welding wire at contact tip when not in use.
Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap. Remove any
combustibles, such as a butane lighter or matches, from your person
before doing any welding / cutting.
FLYING METAL can injure eyes.
Welding, cutting, chipping, wire brushing, and grinding cause
sparks and flying metal. As welds cool they can throw off slag. Wear
approved safety glasses with side shields even under your welding
helmet.
BUILDUP OF GAS can injure or kill.
Shut off shielding gas supply when not in use. Always ventilate
confined spaces or use approved air-supplied respirator.
HOT PARTS can cause severe burns.
Do not touch hot parts with bare handed.
Allow cooling period before working on gun or torch.
To handle hot parts, use proper tools and/or wear heavy, insulated
welding gloves and clothing to prevent burns.
MAGNETIC FIELDS can a󰀨ect pacemakers.
Pacemaker wearers keep away.
Wearers should consult their doctor before going near arc welding,
cutting, gouging, or spot welding operations.
NOISE can damage hearing.
Noise from some processes or equipment can damage hearing.
Wear approved ear protection if noise level is high.
Shielding gas cylinders contain gas under high pressure.
CYLINDERS can explode if damaged.
Protect compressed gas cylinders from excessive heat, mechanical
shocks, physical damage, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping. Keep cylinders
away from any welding or other electrical circuits. Never drape a
welding torch over a gas cylinder. Never allow a welding electrode
to touch any cylinder. Never weld or cut on a pressurized cylinder
- explosion will result. Use only correct shielding gas cylinders,
regulators, hoses, and fittings designed for the specific application;
maintain them and associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Use the right equipment, correct procedures, and sufficient number
of persons to lift and move cylinders.
Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
WARNING
When using an open arc process, it is necessary to use correct
eye, head, and body protection.
2.0 Product Description
The XTM 221Di is a multi-mode welding machine using inverter
technology. A micro controller allows the machine to be quickly and
easily configured for MIG, TIG, MMA and Plasma operations. Within
each welding mode there are features and functions which improve
the welding performance and ease of use as detailed below.
All processes can be rapidly configured through the use of synergic
programs where the base settings are already programmed into
the machine and the user only needs to provide information on the
material type and thickness.
MIG welding controls:- Synergic or manual parameter setting
for Volts and Wire speed( Amps). Dynamic Arc starting program
eliminating the need for soft start function. Adjustable burn back to
vary the wire stick out after welding.
TIG welding controls:- Synergic or manual parameter setting for Pre
Gas, Upslope, Welding current, pulse parameters, AC frequency,
downslope and post gas time.
MMA Controls:- Synergic or manual setting of welding Power.
Automatic Hotstart which assists electrode striking by boosting the
start current.
Automatic Antisticking which drops the welding current when the
electrode is shorted during welding to prevent the electrode welding
itself to the job.
Arc Force increases the current when the arc gets too short, to
prevent the electrode sticking to the job; the level of arc force is user
adjustable. You may wish to increase arc force so you can dig the
electrode into the work piece for improved penetration; the level of
arc force selected will depend upon the type of electrode and joint
configuration.
PLASMA Controls:- Synergic parameter setting of Amps. The
recommended air pressure will be displayed on the screen but will
need to be manually set on the regulator. There are 3 plasma modes
available, mesh, standard and gouging.

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3.0 Technical
Specications
The XTM 221Di, is a compact type machine with integrated wire feed
unit for use with single phase 110/230V supply with smart
input switching.
Process Feature XTM 221Di
Input Voltage 110V+/10% 230V+/-10%
Hz 50/60
Phases 1
KVA 3.7
Generator Size 7 KVA
No-load Voltage (V) 45V
Wire Drive 4 Roll
Fuse Rating (A) 32 16
IP Rating IP23S
Weight (Kg) 27.8
MIG DC Input Current (A) 35.5 26.2
DC Input e󰀨ective
Current (A) 19.4 14.4
DC Welding Current (A) 10~140 10~200
Welding Voltage (V) 14.5~21 14.5~24
TIG DC Input Current (A) 32.2 25.0
DC Input e󰀨ective
Current (A) 17.7 12.5
AC Input Current (A) 31.9 25.7
AC Input e󰀨ective
Current (A) 17.5 14.1
DC Welding Current (A) 10~140 10~200
AC Welding Current (A) 10~140 10~200
Welding Voltage (V) 10.4~15.6 10.4~18.8
MMA DC Input Current (A) 30.8 29.7
DC Input e󰀨ective
Current (A) 21.8 16.2
AC Input Current (A) 33.8 32.2
AC Input e󰀨ective
Current (A) 20.0 16.1
DC Welding Current (A) 10~110 10~200
AC Welding Current (A) 10~110 10~200
Welding Voltage (V) 20.4~24.4 20.4~28
Plasma DC Input Current (A) 49.1 29.2
Input e󰀨ective (A) 21.9 16.0
Load Voltage 140V 140V
No load Voltage 226V 226V
DC Output Current (A) 15-25 15-40
4.0 Installation
Read entire installation section before starting installation.
SAFETY PRECAUTIONS
• ELECTRIC SHOCK can kill.
• Only qualied personnel should perform this installation.
• Only personnel that have read and understood the Operating
Manual should install and operate this equipment.
• Machine must be grounded per any national, local or other
applicable electrical regulations.
• The MIG power switch is to be in the OFF position when
installing work cable and torch and when connecting other
equipment.
4.1 Location
Position the power source so that its cooling air inlets and outlets are
not obstructed.
A. 100mm (4in.) minimum
B. 100mm (4in.) minimum
B
A
Duty Cycle (DC)
110V input 230V input
MIG 30% 60% 100% 30% 60% 100%
140A 100A 75A 200A 140A 110A
TIG 30% 60% 100% 25% 60% 100%
140A 100A 75A 200A 130A 100A
MMA 50% 60% 100% 30% 60% 100%
110A 100A 80A 200A 140A 110A
Plasma 20% 30% 60% 100%
25A 40A 28A 22A
Duty Cycle (AC)
110V input 230V input
TIG 30% 60% 100% 30% 60% 100%
140A 100A 75A 200A 140A 110A
MMA 30% 60% 100% 25% 60% 100%
110A 80A 60A 200A 130A 100A

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8. Wire Spool Holder
9. Wire Feed Unit
10.Air pressure regulator
(plasma)
1. Power Switch for Incoming Mains
2. QF Incoming Gas Connection MIG
3. QF Incoming Gas Connection TIG
4. QF Incoming Air Connection Plasma
5. MIG Torch Connector
6. Work Lead Connector
7. TIG Torch / Electrode Holder Socket
9
7
6
10
8
5
11
13
12
13
5.0 Description of Controls
and Torch Connections
14
15
4.2 Input and Grounding Connection
WARNING
Before starting the installation, check that your power supply
is adequate for the voltage, amperage, phase, and frequency
specied on the Machine nameplate.
The 110/230 volt 50 Hz machine is supplied with a 3m input cable
and without plug, ensure that you connect a plug that is suitably rated
for the power draw of the machine and the environmental location.
Have a qualified electrician connect the input plug.
3
4
11.Multifunction Control Knob
12.Amperage / Wire Speed Adjustment
13.Voltage / Downslope / Arc Force
Adjustment
14.Inductance / Post Gas Control
15.Digital Display
16. TIG Torch Gas Connector
17.TIG Torch Trigger Connector
18. Plasma torch connector
17 18
17 16

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6.0 Operation
6.1 Use of Controls
Multifunction Control Knob.
Rotate and Select
Rotate left or right to highlight an option on the screen.
Press to select
Press and hold to step back in menu tree
Short press at end of menu returns to start menu
6.2 Language of Operation
Short Press (1 sec) to return to start menu
6.3 Process Selection
TIG Synergic TIG Welding Setup
MMA Synergic MMA Welding Setup
MIG MAN Manual MIG Welding Setup
MIG SYN Synergic MIG Welding Allows Simple and
Rapid Setup.
Plasma Cutting setup

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Fig 1 Fig 2
6.4 MIG Welding Preparing the Machine
1. Open the Wire Drive Compartment Door by lifting the 2 finger
catches on the side panel.
2. Release the pressure on the idle roll by swinging the adjustable
pressure arms down towards the side of the machine. Lift the idle
roll assemblies and allow it to sit in an upright position.
3. Unscrew the knob retaining the lower grooved feed roll and slide
off the feed roll.
4. Ensure the wire size marked on the side of the feed roll matches
the wire size to be used.
5. Replace the drive in reverse of the above procedure ensuring the
wire size to be used is marked on the outward facing side of the
roller as it is refitted.
Note: Be sure that the torch liner and contact tip are also sized
to match the selected wire size.
Welding Wire Installation
1. Position the wire spool so that it will rotate in a direction when
feeding so as to be de-reeled from the bottom of the coil. If using
200 mm spool use the spacer to ensure the spool is aligned with
the feed box.
Note: There is a friction brake on the reel hub assembly to
prevent the wire spool over running when welding stops;
ensure this is slackened to the minimum setting. It can be
adjusted by means of the nut visible when the plastic hand nut
is removed.
2. Turn the Spool until the free end of the electrode is accessible.
While securely holding the electrode, cut off the bent end and
straighten the first six inches. (If the electrode is not properly
straightened, it may not feed properly through the wire drive
system). Manually feed the wire from the wire reel and through
the wire guide and then over the top of the wire feed roller
(ensure the pressure arm is in its raised position).
3. Continue to feed the wire through the outlet guide until 20mm of
wire is protruding from the front of the machine torch connector.
4. Reposition the adjustable pressure arms to their original position
to apply pressure. Adjust pressure as necessary.
Note: The pressure arms should be adjusted in order to give
the minimum amount of pressure on the wire to allow reliable
feeding.
MIG Torch Installation
Your Parweld MIG/MAG Welding Torch has been supplied ready to
weld. It has been supplied with the standard consumables denoted
in the product brochure.
To connect the torch to the power source:
1. Remove the contact tip.
2. Inch the wire from the exit of the wire guide on the feed unit
as Figure 1. Ensure that it does not short out on any machine
panels.
3. Carefully slide the electrode wire into the torch liner and slowly
locate the torch gun plug body into the feed unit central connector
and tighten the gun plug nut as Figure 2
Note: To aid the initial location of a new torch and to prevent
damage to the gas nipple O-Ring a very light application of
grease to the O-Ring is benecial.
4. Keeping the torch as straight as possible, use the power source
inch facility or torch trigger to feed the electrode wire 50mm from
the end of the torch.
5. Once the electrode wire has stopped, refit the contact tip and gas
nozzle.
6. Trim the electrode wire to within 5mm of the face of the nozzle;
this will facilitate jolt free arc initiation.
Note: Check that drive rolls, and torch parts are correct for
the wire size and type being used
7. The optimum idle roll pressure varies with type of wire, wire
diameter, surface conditions, lubrication and hardness. As a
general rule, hard wires may require greater pressure, and soft
or aluminium wire, may require less pressure than the factory
setting. The optimum idle roll setting can be determined as
detailed on the following page.
4
2
3

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7.2 MIG SYN Synergic MIG Welding Allows
Simple and Rapid Setup.
Follow the screen prompts to complete the machine setup.
Example setting.
MIG Torch Installation (continued)
8. Press end of gun against a solid object that is electrically isolated
from the welder output and press the gun trigger for several
seconds.
9. If the wire "bird nests", jams or breaks at the drive roll, the idle
roll pressure is too great. Back the adjustment knob out 1/2 turn,
run new wire. If the only result was drive roll slippage, loosen
the Hand nut on the central connector and pull the torch forward
about 6" (15cm) away from the power source. There should be
a slight waviness in the exposed wire. If there is not waviness,
the pressure is too low. Tighten the adjustment knob 1/4 turn,
reinstall the torch cable and repeat the above steps.
10. When triggering, the electrode and drive mechanism are
electrically "LIVE" relative to work and ground and remain "LIVE"
several seconds after the gun trigger is released.
Burn back
Adjusted on screen from the Help Menu.
Soft start
The machine has a pre-set soft start system.
7.0 Setting the Machine
for Welding
7.1 MIG Torch Selection
Select the HELP menu from the main Process Selection screen and
follow the screen prompts as follows.

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Adjust by Pressing Torch Buttons on the Handle.
7.4 Remote Control MIG Torch
Allows remote adjustment of the Voltage and wire speed from the
torch handle when in the welding screen.
MIG SYN MIG MAN
Operating screen (MIG SYN)
7.3 MIG MAN Manual MIG welding setup
Follow the screen prompts to complete the machine setup.
Example setting.
In manual mode you can adjust the parameters using the
controls indicated.
Parameter Scroll
Adjust Inductance (short circuit current)
Adjust Inductance (short circuit current)
Adjust Voltage Value
Inductance
Voltage
Up
Wire Speed
Parameter Scroll
Down
Torch with
OLED Display
Up Parameter Scroll
Down
Parameter Scroll
Torch with
4 Button Control
Adjust Wire Speed Value
Trim Wire Speed Trim Voltage

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7.7 TIG Welding
Follow the screen prompts to complete the machine set up.
7.7.1 TIG Torch Selection
Select the HELP menu from the main Process Selection screen and
follow the screen prompts as follows.
Adjust Amperage Value Adjust Arcforce Value
7.6 MMA Welding
Follow the screen prompts to complete the machine setup.
Example setting.
7.5 MIG Welding Procedure
1. Position wire over joint. The end of the wire may be lightly
touching the work.
2. Lower welding helmet, operate torch trigger, and begin welding.
Hold the torch so the contact tip to work distance is about 3/8"
(10 mm).
3. To stop welding, release the torch trigger and then pull the torch
away from the work after the arc goes out.
4. When no more welding is to be done, close valve on gas cylinder
(if used), momentarily operate torch trigger to release gas
pressure and turn off the machine.

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Manual Set allows adjustment of all weld parameters.
Auto Set allows rapid setting of the machine based on material type
and thickness, with HF starting.
Auto Set Example
7.7.3 TIG Welding Set Up
Follow the screen prompts to complete the machine set up.
Manual Set Example
Adjust downslope and post flow to user preference using the
knobs on the right of the screen.
7.7.2 TIG Torch Installation
See page 7 for Torch Connections to the Machine.

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Welding Screens
DC Without Pulse.
DC With Pulse.
AC Without Pulse.
AC With Pulse.
To Select and adjust Pre-Gas, Slope Up, Welding
Current, Slope Down, or Post Gas do the following:
Rotate control knob to move red dot
Press to select (flashing)
Rotate control knob to adjust
TIG Welding Trigger Operation
-2T -4T
This toggles between 2 step and 4 step operation of the torch
trigger. In 2 step mode the trigger should be pressed and held down
until the end of the weld. In 4 step mode the trigger is pressed and
released to start and pressed and released to finish the weld. Not all
functions are available in 2T mode.
Release Press Release
Initial
Current
Final
Current Post Gas
Current
Adjustment
Pre Gas
Press
Press
Pre Gas Post Gas
Release
2T mode
Press control knob to deselect (stops flashing)

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Step Current, 4T mode
Release Press Release
Initial
Current Final
Current Post Gas
Pre Gas
Press
Tap
Button
7.7.4 TIG Welding Guide
Torch starting in Lift TIG mode
Ensure the gas supply is switched on to the machine. Briefly contact
the tip of the tungsten electrode down onto the work piece with the
torch at around 700 from vertical. Depress the trigger to start the gas
flow and switch on the power, lift the torch up from the work piece to
draw out an arc. To prevent melting of the end of the tungsten the
machine will increase the output current when it detects the rise in
arc voltage as the tungsten is lifted from the work piece. At the end
of the weld release the torch trigger and the power will slope down
and switch off.
At the end of the weld release the trigger and allow the power and
gas to switch off before moving the torch from the weld.
Torch starting in HF mode
Ensure the gas supply is switched on to the machine. Hold the torch
with the tip of the tungsten approx 2-3 mm from the job. Depress the
trigger to start the gas flow and switch on the power. At the end of
the weld release the torch trigger and the power will slope down and
switch off.
TIG welding guide ranges
Electrode diameter AC current
(amps)
DC current
(amps)
0.040 (1.0mm) 15-30 20-60
1/16 (1.6mm) 60-120 75-150
3/32 (2.4mm) 100-180 150-250
Tungsten electrode types
Type Application Colour
Thoriated 2% DC welding of mild
steel,
Stainless steel and
Copper
Red
Type Application Colour
Ceriated 2% DC welding of mild
steel, Stainless
steel, Copper
AC welding
of aluminium,
magnesium and
their alloys
Grey
Zirconiated AC welding
of aluminium,
magnesium and
their alloys
White
Guide for selecting filler wire diameter
Filler wire diameter Current range
1/16 (1.6 mm) 20 - 90
3/32 (2.4 mm) 65 - 115
1/8 (3.2 mm) 100 - 165
3/16 (4.8 mm) 200-350
The filler wire diameter specified is a guide only, other diameter
wires may be used according to the welding application.
Shielding gas selection
Alloy Shielding gas
Aluminium & alloys Pure Argon
Carbon steel Pure Argon
Stainless steel Pure Argon
Nickel alloy Pure Argon
Copper Pure Argon
Titanium Pure Argon
7.7.5 DC TIG welding (No Pulse)
Note:- shorting or dipping the electrode into the weld pool
for more than 1 second will cause the machine to reduce the
welding power to zero in order to protect the tungsten and
minimise contamination.
1) Connect the torch to the TIG torch socket and the gas hose to the
gas outlet.
2) Connect the trigger control plug on the torch to the trigger socket.
3) Connect the Earth lead to the Earth socket.
4) Set the process mode to 2T or 4T if you prefer a latching trigger
action. (Note in 4T position you must press and release to start the
process and press and release again to stop the process).

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5) Select DC output.
6) Select HF start
7) Select No Pulse.
8) Rotate the control knob to move the illuminated LED to the gas
pre-flow position (A).
9) Press the control knob to select the parameter. The red LED will
now flash. Adjust the value by rotating the control knob. This can
be adjusted from 0.1 to 0.3 seconds. The value is displayed on the
digital display (B) Press the control knob again to accept the setting.
10) Rotate the control knob to move the LED to the initial current (C)
This can be adjusted from 5 to 100% of the main welding current.
The value is displayed on the digital display (B). 50% is a good initial
setting. Note this function only operates in 4T switch mode.
11) Rotate the control knob to move the LED to the slope up time (D)
This can be adjusted from 0 to 10s. The value is displayed on the
digital display (B). 2s is a good initial setting.
12) Rotate the control knob to move the LED to the main welding
current (E) This can be adjusted from 5 to 200A. The value is
displayed on the digital (B). Refer to the TIG welding guide for a
recommended welding current.
13) Rotate the control knob to move the LED to the slope down time
(F) This can be adjusted from 0 to 10s. The value is displayed on the
digital display (B). 2s is a good initial setting.
14) Rotate the control knob to move the LED to the final current (G)
This can be adjusted from 5 to 100% of the main welding current.
The value is displayed on the digital display (B). 10% is a good initial
setting. Note this function only operates in 4T switch mode
15) Rotate the control knob to move the LED to the Post Gas time
(H). This can be adjusted from 0.1 to 10s. The value is displayed on
the digital display (B). 3s is a good initial setting.
You are now ready to weld. These settings are a guide and you
should adjust to suit the job you are welding. If you are unfamiliar
with the machine try to adjust only one parameter at a time so you
become familiar with its effect.
7.7.6 AC TIG welding (No Pulse)
Note:- shorting or dipping the electrode into the weld pool
for more than 1 second will cause the machine to reduce the
welding power to zero in order to protect the tungsten and
minimise contamination.
1) Connect the torch to the TIG torch socket and the gas hose to the
gas outlet.
2) Connect the trigger control plug on the torch to the trigger socket.
3) Connect the Earth lead to the Earth socket.
4) Set the process mode to 2T or 4T if you prefer a latching trigger
action. (Note in 4T position you must press and release to start the
process and press and release again to stop the process).
5) Select AC output.

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6) Select HF start.
7) Select No Pulse.
8) Rotate the control knob to move the illuminated LED to the gas
pre-flow position (A).
9) Press the control knob to select the parameter. The red LED will
now flash. Adjust the value by rotating the control knob. This can
be adjusted from 0.1 to 0.3 seconds. The value is displayed on the
digital display (B) Press the control knob again to accept the setting.
10) Rotate the control knob to move the LED to the initial current (C)
This can be adjusted from 5 to 100% of the main welding current.
The value is displayed on the digital display (B). 50% is a good initial
setting. Note this function only operates in 4T switch mode.
11) Rotate the control knob to move the LED to the slope up time (D)
This can be adjusted from 0 to 10s. The value is displayed on the
digital display (B). 2s is a good initial setting.
12) Rotate the control knob to move the LED to the main welding
current (E) This can be adjusted from 5 to 200A. The value is
displayed on the digital (B). Refer to the TIG welding guide for a
recommended welding current.
13) Rotate the control knob to move the LED to the slope down time
(F) This can be adjusted from 0 to 10s. The value is displayed on the
digital display (B). 2s is a good initial setting.
14) Rotate the control knob to move the LED to the final current (G)
This can be adjusted from 5 to 100% of the main welding current.
The value is displayed on the digital display (B). 10% is a good initial
setting. Note this function only operates in 4T switch mode.
15) Rotate the control knob to move the LED to the Post Gas time
(H). This can be adjusted from 0.1 to 10s. The value is displayed on
the digital display (B). 3s is a good initial setting.
16) Rotate the control knob to move the LED to the AC frequency (I)
This can be adjusted from 25 to 200Hz dependant on the welding
amperage. The value is displayed on the digital display (B). 60hz
is a good initial setting. Increaseing the frequency has the effect of
stiffening and focussing the arc making it good for welding close to
threads or for crater filling.
Note the maximum frequency available depends upon the welding
amperage selected.
<50A 50 to 250Hz
50-100A 50-200Hz
100-150A Max 150Hz
150-200A Max 100Hz
17) Rotate the control knob to move the LED to the AC balance (J)
This can be adjusted from 15 to 50% . The value is displayed on
the digital display (B). 15% is a good initial setting. Increasing the
percentage has the effect of increasing the time the arc spends in
the electrode positive state which gives a greater cleaning effect on
the material but will reduce weld speed. For good clean material you
should be able to keep the cleaning percentage set at 15 to 20%
You are now ready to weld. The above settings are a guide and you
should adjust to suit the job you are welding. If you are unfamiliar
with the machine try to adjust only one parameter at a time so you
become familiar with its effect.
7.7.7 TIG welding (With Pulse)
It is possible to use the pulse function with both AC and DC TIG
welding. Power Pulsing can give significant advantages on thinner
material to control heat and penetration.
1) Follow the setup as previously described for AC or DC TIG
welding. At the Pulse Selection menu select Pulse.
3) Press the control knob to move the LED to the Peak current
(K) This can be adjusted from 5 to 200A (10-200A for AC welding)
dependant on the welding amperage. The value is displayed on the
digital display (B). Peak current is the maximum amperage that will
be output.

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4) Rotate the control knob to move the LED to the Peak duration
(L) This can be adjusted from 5 to 100% Peak duration is the
percentage of time the peak current is on relative to the background
current. 30% is a good starting point.
5) Rotate the control knob to move the LED to the Background
current (N) This can be adjusted from 5 to 200A (10-200A for
AC welding). The value is displayed on the digital display (B).
Background current is the minimum amperage that will be output.
It cannot be higher than the peak current and generally will be set
withing 50 to 70% Amps of the peak current.
6) Rotate the control knob to move the LED to the Pulse Frequency
(M) This can be adjusted from 0.5 to 200Hz. The value is displayed
on the digital display (B). Pulse Frequency is the number of pulses
per second generally a range of 50 to 150 hz will be used with
100Hz being a good base setting.
30-40Hz will help agitate the weld puddle and allow you to weld at a
lower amperage than without pulse.
50-150Hz really stiffen the arc and let you pinpoint the arc more than
without pulse.
0.5-10Hz reduce heat input the most.
The selected amperage and the consistency of travel speed can
negate some of the effects of Power pulsing.
7.8 Plasma Cutting
1) Push the torch connector into the socket on the machine taking
care to line up the pins.
2) Tighten the hand nut on the torch to secure the torch.
CAUTION: Before switching on the machine ensure all spares
are tted correctly to the torch and in good condition. Failure to
do so can result in the destruction of the torch head.
7.8.1 Setting Air pressure
Connect the air line to the rear of the machine and Switch on
the machine. The air supply should be capable of supplying
compressed air at a pressure of 5Bar and a ow rate of 155lpm free
air delivery.
7.8.2 Preparing to Cut
Switch on the machine and return to the home menu, then select the
Plasma Cut option.
Select the type of cutting operation, Mesh, Normal cutting or
Gouging.
Select the material type to be Cut or Gouged
Select the material thickness using the main control knob to
increase or reduce the thickness and press to select.
You are now ready to operate. On the following example screen, the
air pressure quoted is the suggested air pressure for the parameters
selected. Adjust the regulator inside the machine to match this.

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7.8.3 Mesh cutting
With the torch in starting position press and hold the trigger. After an
initial gas purge, the main arc will come on. Once on, the main arc
remains on as long as the trigger switch is held down. As you move
across the mesh the machine will automatically switch between
cutting mode and pilot arc mode when in a gap before swtching
back to cutting mode when the arc contacts the material again. To
shut o󰀨 the torch simply release the trigger switch. When the switch
is released a 15 second post-ow will occur. If the torch switch is
closed during the post-ow, the cutting arc will restart after switching
o󰀨 the air. Refer to the ow chart below for the operating sequence.
7.8.4 Normal cutting
With the torch in starting position press and hold the trigger. After an
initial gas purge, the main arc will come on. Once on, the main arc
remains on as long as the trigger switch is held down, unless the
torch is withdrawn from the work or torch motion is too slow. If the
cutting arc is interrupted, the cutting process must be restarted. To
shut o󰀨 the torch simply release the trigger switch. When the switch
is released a 15 second post-ow will occur. If the torch switch is
closed during the post-ow, the cutting arc will restart after switching
o󰀨 the air. Refer to the ow chart below for the operating sequence.
7.8.5 Gouging
Hold the torch so that the nozzle is 1-2mm from the workpiece
before starting the torch. Angle the torch 40 Deg. to the workpiece
with a small gap between the torch tip and the workpiece. Maintain
an approximate 40 Deg. angle to the workpiece as you move
along the gouge in the direction of the uncut material. Keep a
small distance between the torch tip and the molten metal to avoid
reducing consumable life or damaging the torch.
Changing the torch angle changes the dimensions of the gouge.
A steeper angle (closer to 90 Deg) and slower forward movement
gives a deeper gouge, while a lower angle (less than 40 Deg) and
faster movement gives a shallower gouge.
7.8.6 Torch Operation logic
Press Torch
Trigger Air flows for
15 seconds
Air flow
switches on Release
trigger
Pilot arc
strikes
Pilot arc
runs for 5
seconds
Cutting
starts
Release
trigger
Cutting
stops air
flows for 15
seconds
Cutting
stops
Press
trigger
Air flow
goes off
Air flow
switches on
Switch on
power
source
Air purges
for
10 seconds
Machine self
tests for
5 seconds
Machine
ready to run

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7.9 Saving to Memory
In any welding screen press the memory button.
From here you can see the last weld setting used (O) or select one
of the memory locations (P) to save the job to.
Memory button
After selecting a memory location, the following screen loads and
gives the option to save to memory.
Memory button
To recall from memory location, from main menu, press the memory
button.
Select job to recall by rotating the control knob to the required
memory location and pressing the knob to select.
7.10 Process Switch
The XTM221Di allows instant swapping between the MIG, TIG
and Plasma processes which is ideal for pipe applications or multi
process workshops.
Connect the MIG, TIG and Plasma torches as previously described.
Ensure all gas types are connected to the rear of the machine.
Set the machine from the main menu for the MIG,TIG and Plasma
as required.
Switching the process. Press the torch trigger briefly to select the
process.