Top Gun 3200 AC/DC TIG User manual

1
OPERATION MANUAL
TOPGUN 3200 AC/DC TIG

TOPGUN 3200 AC/DC TIG USER MANUAL
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CONTENTS
SAFETY RULES, DESCRIPTION OF SYMBOLS 3
APPLICATION 6
DESCRIPTION OF THE MACHINE 6
TECHNICAL SPECIFICATIONS 7
EQUIPMENT 8
DESIGN CONNECTION 8
TIG / MMA WELDING BEFORE YOU WORK 8
WORKING CONDITIONS 8
DESCRIPTION OF THE CONTROL PANEL FUNCTIONS 10
MAINTENANCE 31
TROUBLE SHOOTING 34
ELETRICAL DIAGRAM 36

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1.
SAFETY RULES, DESCRIPTION OF SYMBOLS
It is absolutely necessary to read the following signs and safety rules to protect the health and
life of yourself and others.
Read the instructions before starting the device. Use only original equipment supplied
by the manufacturer.
Some components may explode. Always use a face shield and protective clothing with long
sleeves.
Use approved face shields and welding shields. Always use protective clothing designed for
welders. Metal splinters can damage your eyes. Always use safety glasses.
Electric shock can result in death. Do not touch electrical components when the device is
connected to power. Use dry and complete protective gloves and protective clothing.
Gases and vapors can be hazardous to health. Welding gases and fumes are emitted during
the welding process. Inhalation of these substances can be hazardous to health.
Eye protection with welding filters. Depending on the current used, use protective shields
with appropriate filters.
Moving parts of the device can cause injuries.
Continuous operation for too long can cause the device to overheat. Wait until the device
cools down. Follow the guidelines in the chapter "Thermal efficiency and protection”

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Damaged technical gas cylinders may explode. The cylinders contain high pressure
gas. Make sure that cylinders are handled and stored in accordance with health
and safety and fire protection requirements.
Welded parts may burn.
The protruding wire from the torch is sharp and can cause skin puncture.
Danger of fire and explosion. During welding work, a fire may result. The welding
station must be remote and protected against flammable and
explosive materials.
The magnetic field can disrupt the functioning of pacemakers. Consult a doctor
before starting work.
Do not weld at height without proper protection.
A device falling or falling over may cause injury.
Before starting work, specify the place where the device is to be used.
The device should be connected to the network so that it can be easily manipulated at all times.
The power cord should not be taut during operation.
Do not use the device on a surface that may cause it to tip over.
Only use the transport handle to move the device.
The device must not be used to defrost pipes.
Work on the device may only be carried out by qualified personnel staff with up-to-date training
and permits.
Incorrect use is prohibited.

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In situations not specified in the instructions, always follow the safety rules and regulations in force at
the place where the device is operated.
ATTENTION
The heating test was carried out at ambient temperature and the duty cycle (load factor) at 40C was
determined as a result of the simulation.
The device is intended for conducting professional welding works in industrial conditions by personnel
having valid qualification certificates in accordance with applicable standards.
!
!
WARNING: This Class A equipment is not intended for use in residential areas where electricity is
supplied through the public low voltage network system. There may be potential difficulties in
ensuring electromagnetic compatibility at these locations due to conducted and radiated
disturbances.
The device should be operated in accordance with the Regulation of the Minister of Economy of April
27, 2000. on health and safety at work during welding (Journal of Laws No. 40 item 470).
Keeping this user manual and following the guidelines outlined in it will allow for proper maintenance
of the device in the future. The following warnings are intended to ensure user safety and
environmentally friendly operation. Read the entire manual carefully before
installing and using the device.
After opening the packaging, check that the device has not been damaged during transport. If in doubt,
contact our service department.
The device should only be used by a trained employee or consumer.
When installing the appliance, you should entrust all electrical activities to a qualified
electrician.

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2.
APPLICATION
TOPGUN 3200 AC/DC TIG devices are intended for manual welding with a non-fusible electrode in a gas shield -
GTAW (TIG AC / DC) and a coated electrode - SMAW (MMA). Industrial devices TOPGUN 3200 AC/DC TIG are
microprocessor welding sources based on IGBT technology, adapted for welding carbon, stainless, acid-resistant
steel, copper, brass, magnesium, titanium and all aluminum alloys.
3.
DESCRIPTION OF THE MACHINE
TOPGUN 3200 AC/DC TIG series of devices allows welding in the following modes:
TIG DC lift-arc - In the TIG (Tungsten Inert Gas) method, an electric hatch. strikes in inert gas (argon), between the
welded part and the non-fusible electrode made of pure tungsten or tungsten with additions. In the TIG lift-arc
mode, the arc strikes when the electrode makes contact with the part being welded.
TIG DC HF - to completely eliminate the possibility of weld contamination tungsten, it is recommended that the
electrode does not touch the work piece; for this purpose, contactless touch ignition is used when using high-
frequency charges generated by the built-in ionizer.
TIG DC PULSE Lift-arc - ignition of the arc occurs by contact of the electrode with the welded material, the pulse
function allows welding of heavy elements through periodic changes in current.
TIG DC PUL S HF - HF non-contact ignition by means of an ionizer in the TIG DC PULS mode.
TIG AC lift-arc - a function that allows aluminum welding through the use of alternating current, which means
aluminum welding, cathodic cleaning. By setting the AC BALANCE parameter, i.e. the balance of alternating current, it
is possible to adjust the ratio of its phase duration relative to each other.
TIG AC HF - analogous function enabling alternating current aluminum welding, ignition occurs contactless through
high-frequency current generated by the ionizer.
TIG AC PULS lift-arc - welding in this mode is a combination of the use of alternating current with pulse, which allows
welding of very thin aluminum parts. The tuk ignition occurs through the contact of the electrode with the workpiece.
TIG AC PULS HF - a function that allows welding of aluminum elements with a small thickness. Non-contact ignition
through the use of an ionizer.
MMA DC + - in the MMA method a coated electrode is used, consisting of a metal core covered with a lagging. An
electric tuk is produced between the end of the electrode and the welded material. Tuk striking occurs by touching
the electrode tip to the workpiece. MMA DC + means welding with positive polarity - more heat is released in the
material and less in the electrode.
MMA DC- - the difference between MMA DC + lies in the fact that the polarity in MMA DC mode is clear, so the
distribution of the heat is the opposite - more heat is emitted on the electrode, and less in the welded material.
MMA VRD DC + - available in MMA DC mode + VRD (Voltage Reduction Device - function module that reduces the
quiescent (no-load) voltage of the device's secondary circuit.Increases safety and reduces the risk of electric shock.
The function turns off and on welding power, when resistance between the terminals is measured during welding.
MMA VRD DC- - available in MMA DC mode - the VRD (Voltage Reduction Device) function works in
the same way as MMA VRD DC +, the difference is the negative polarity.

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4.
TECHNICAL SPECIFICATIONS
Parameter
TOPGUN 3200 AC/DC TIG
Output current range TIG DC [A]
10-320
Output current range TIG AC [A]
10-320
Efficiency [A]
30%
320
60%
226
100%
175
Waveform on AC mode
Square Wave
Sine Wave Triangular
Ramp Wave
Triangular growing
Triangular sloping
Trapezoidal wave
AC current frequency
range [Hz]
40-100
AC balance [%]
10-90
Pre-Flow / Post-Flow AC / DC mode [s]
0-10/0-10
initial/final current DC mode [A]
10-320
initial/final current AC mode [A]
20-320
Pulse base current DC
[A]
10-304
Pulse base current AC
[A]
20-304
Pulse current frequency
[Hz]
1-200
Pulse modulation [%]
5-95
arc ignition function
HF
Load voltage [V]
71
Welding current range
MMA [A]
30-250
Efficiency [A]
40%
320
60%
261
100%
202
Arc Force [%]
0-100
Power consumption [KVA]
TIG:9.2/MMA:9.5
Degree of protection
IP21S
power voltage .
3~415 V 50 Hz
Insulation class
F
Dimension [mm ]
810x510x800
Net weight [kg]
53.8

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5.EQUIPMENT
STANDARD PACKAGE
1. WP-18 WATER COOLING TORCH WITH CABLE X8 METERS
2. EARTH CLAMP WITH CABLE X5 METERS
3. 3 MTR QUICK CONNECT GAS HOSE WITH FITTINGS
4. TOPGUN TIG CONSUMABLE KIT
5. MANUAL
6.TIG / MMA WELDING BEFORE YOU WORK
Specify the location where the device is operated.
Check the voltage, number of phases and frequency of the supply current before switching on
mains devices.
Supply voltage parameters with technical data are given in this chapter and on the type plate
of the device.
Check the connection of the machine's earth wires and the power supply wire.
Ensure that the power can cover the input power demand of this device in the conditions of
its operation.
Fuse size and parameters power cord are provided in the technical data and on the rating
plate.
Remove any flammable materials from the welding area.
Do not use the device on a stable surface.
Use suitable protective clothing for welding: gloves, apron, work boots, mask or a helmet
with certification.
7.WORKING CONDITIONS
Working temperature: -10 ° C to 40 ° C
It is forbidden to work in conditions of high humidity.
Protect against flooding (in case of flooding, immediately turn off the device, power sources,
contact the service center). Avoid working in the environment of flammable, aggressive gases
and dust.
Ensure good dissipation. Avoid interference with the cooling system.
It is forbidden to cover the ventilation openings of the device.
Do not overload the device. Maintain the correct machine work cycle.
Do not allow the maximum permissible voltage fluctuations from the mains to be exceeded.
The duty cycle (efficiency) is always given in the technical data table and on the device rating plate.
It is determined according to the requirements specified in the EN 609741 standard. It is expressed as a

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percentage for a 10-minute work cycle. Determines the time enabling the device to work under
maximum / set load. When the duty cycle is exceeded, the device parameters drop temporarily or the
overload protection switches on.
The operator must wait a certain amount of time to cool down the device, depending on
degree of device overload and external conditions it may take a few to several minutes.
Efficiency 40%4 minutes of continuous operation of the device under maximum / set load. Efficiency
60%6 minutes of continuous operation of the device under maximum / set load. Efficiency 100%
uninterrupted operation of the device under maximum / set load.

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8.
DESCRIPTION OF THE CONTROL PANEL FUNCTIONS
1
2
3
4
5
6
1. LCD display
2. Left function key when welding parameters are selected. (additionally holding for 5 to save
settings. View all welding parameters).
.
3. Button to return to the previous menu. (additionally held for 5 seconds to return to factory
settings (RESET))
4. Adjustment knob,
Turn - Select and Adjust.
Press - Confirm and Switch to next.
Long press for 5 second in welding mode setting to turn on/off water cooling.
5. Button confirming selected settings and entering the next menu. (in addition, holding for 5
seconds to recall setting.
6. Function key "right" when selecting welding parameters.

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9.
DESCRIPTION OF THE SYSTEM
B.CHOICE OF WELDING METHOD
Use the botton 2 or 6 to choose welding method
press button 5
to confirm.

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C.TIG AUTO MODE
TIG AUTO MODE –synergic settings. The user selects the basic parameters such as the type of
material and the thickness of the material being welded. Other parameters of the device are
selected automatically using the database of uploaded programs.
Step 1 material selection
The user selects the welded material
from the list of alloys
Step 2 choice of the thickness of the
plate
Choose the welding plate thickness. The
device
will automatically change the voltage the
current.

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D.TIG mode
GENERAL OPERATION
In the TIG method (Tungsten Inert Gas), the electric arc ignites in an inert gas (argon) shield, between the
welding element and the non-fusible electrode, made of pure tungsten or tungsten with additives.
The TIG method is especially recommended for aesthetic and high-quality bonding of metals, no labor-
intensive mechanical processing after welding. however, this requires proper preparation and
cleaning of the edges of both welded elements. The mechanical properties of the additive material
should be similar to the properties of the welded parts. The role of shielding gas is always played by pure
argon, supplied in quantities depending on the welding current set.
Lynx. 1 TIG welding process, diagram
Negative polarity is used for most TIG welding operations. The welding gun is connected to the
negative pole, while the earth gun to the positive pole. In this way, the electrode consumption is
reduced, the amount of heat accumulated in the welded material increases.

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PREPARATION OF VOLUME ELECTRODES
Preparation of tungsten electrodes depending on the type of welding current

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Table 1.Choice of electrode diameter –steel welding
Current range welding [A]
The diameter of electrode [mm]
Material thickness [mm]
Stainless steel
10-50
0.5
0.5-1.0
20-80
1.0
1.0-1.5
50-160
1.6
1.5-3.0
110-250
2.4
3.0-5.5
200-350
3.2
5.5-8.0
Table 2.Choice of electrode diameter –aluminum welding
Current range welding [A]
diameter of the electrode [mm]
Material thickness [mm]
Aluminum welding
20-75
1.0
0.5-1.0
25-110
1.6
1.0-2.0
60-160
2.4
2.0-3.0
110-225
3.2
3.0-5.0
160-310
4.0
5.0-8.0
240-370
4.8
8.0-10.0
Table 3.Choice of electrode diameter –CuZn alloy welding
Current range welding [A]
The diameter of electrode [mm]
Material thickness [mm]
Cu Alloy
10-20
1.6
≤2.0
15-25
2.0
17-30
2.5
20-35
3.2
35-50
4.0
50-70
5.0
65-100
6.3

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TIG DC WELDING
AC / DC welding current selection -select
DC mode
Select operation mode on the right side
-select 2T/4T
Pulse or continuous current welding
description of pulse welding parameters is
on page19)
Synergic mode / manual mode
In synergic mode, the user only need to
adjusts the basic welding parameters. The
device constantly checks the correctness of
settings. Automactically suggest the plate
thickness on the left.

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Control of welding parameter
s
panel/remoet control
potentiometer in the welding gun or
pedal
r
.
Start current - 4 clock mode
Take-off current should be 70 to 90% values
of the basic welding current.
It is used to avoid remelting and melting in the
initial welding phase.
Up slope
Time at which the start current
reaches the value of the main welding
current.
Pre-flow-time before ignition of the arc
The welding arc will fire any time afte
the set gas flow time before welding.
For a 4m long handle max. suggested
time: 2 seconds

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Peak current
Basic welding current.
.
Down slope
Time at which the peak welding current
will pass to the final current (crater
filling).
Crater current
The final current should be 70 to 90%
values of the basic welding current..It
is used for the correct purpose end of
weld in its final phase (crater filling).
Very important when welding alloys
aluminum .
Post Flow
Attention !
After the arc has expired, it should be keep
the torch in the allowing position to cool the
welded area with gas.

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Welding parameters - summary chart
The screen shows all parameters welding
selected by the user.
Saving data in the device's memory
Using saved programs
TIG DC (direct current) welding is used for welding all types of steel, alloys copper and some
non-ferrous metal alloys. A distinction is made between DC negative and DC + positive
polarity welding on a TIG welding torch. Most welding work is carried out using DC negative
polarity (used for welding e.g. carbon steel, alloy steel, titanium, nickel, etc.)
The use of DC + positive polarity is recommended for welding zinc, copper and its alloys
(bronzes, brass). However, it should be remembered that the use of positive polarity causes
high wear fusible electrode.

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Table 4.Heat distribution and its impact on DC TIG welding process
Polarity
Negative (DC-)
Positive (DC+)
Penetration
Deep and narrow
Shallow and wide
Efficiency
heat
electrode
Very good
BAD -high wear
Heat
distribution
70% - material
30% - material
30% - electrode
70% - electrode
WELDING PULSE WELDING –TIG PULSE
Lynx 3 TIG welding process -PULSE