zika I-TIG200DC User manual

ZIKA
OWNER'S MANUAL
I-TIG200DC

USER’S MANUAL 1 I-TIG200DC
Table of contents
1. Safety instruction and cautions
1.1 Safety in welding.....................................................................................................................................................2
2. Introduction instruction
2.1 How to use this manual ..........................................................................................................................................5
2.2 Confirmation of equipment......................................................................................................................................5
2.3 Acceptance of equipment.......................................................................................................................................5
2.4 Description of product.............................................................................................................................................6
2.5 Symbol table .........................................................................................................................................................7
2.6 External characteristic ...........................................................................................................................................8
2.7 Operating principle block diagram of circuit.............................................................................................................9
2.8 Means of transportation...........................................................................................................................................9
3. Equipment installation
3.1 Work environment .................................................................................................................................................10
3.2 Working place.........................................................................................................................................................10
3.3 Electrical input connection and requirement distribution.........................................................................................10
3.4 Input power source rate ..........................................................................................................................................11
3.5 Duty cycle...............................................................................................................................................................11
3.6 Specification...........................................................................................................................................................11
4. Technical parameters table.........................................................................................................................................12
5. Installation instruction.................................................................................................................................................13
6. Panel function instruction
6.1 Description of panel ..............................................................................................................................................15
6.2 Operation and control.............................................................................................................................................16
7. Maintenance and service
7.1 Caution and precautions.........................................................................................................................................18
7.2 Common problem in welding and settlement measures.........................................................................................19
7.3 Routine maintenance..............................................................................................................................................20
8. Troubleshooting
8.1 Maintenance tool ..................................................................................................................................................21
8.2 Troubleshooting......................................................................................................................................................22

USER’S MANUAL 2 I-TIG200DC
SAFETY INSTRUCTION AND CAUTION
Warning----- Protect other people and yourself from the potential personal injury. Children should keep
away from the working place. The heart pacemaker wearer should keep away from the working place
according to doctor’s orders.
Before installation, debugging or repair, please read this manual carefully.
Please keep this manual safely to avoid missing.
Failing to observe safety regulations and accident preventive measures, both arc welding equipment and welding process may
cause grievous personal injury even life safety or other equipment's damage and property loss.
Safety habits is formed in the past welding and cutting operation experience. These practical experience has to be acquired
through hard study and training and can be used in operating the equipment.
People who have never been trained in welding and cutting practice do not attempt to perform welding.
All installation, debugging and maintenance, ie maintenance service should be carried out by professional person.
1.1 Safety in Welding
Warning----- Touch the parts bearing electricity may cause fatal shock and severe burnt. Once starting
up, output terminal and working circuit always are electrified; when turn on the input power source, input
circuit and interior circuit are also electrified. Welding electrode and all of metal components that
contacting welding electrodes and electrode holder are electrified too. Therefore, the improper installation
and wrong grounding are dangerous.
1. Do not contact electrified parts.
2. Please wear dry glove and protective clothing and safety helmet.
3. Lay out the working space carefully to ensure you, workpiece and floor are insulated reliably.
4. In installation and maintenance of equipment, make sure the machine is powered off or shutdown. Please lockup the air
switch or remove the fuse to prevent power switch closing accidentally.
5. Carry out installation and grounding according to manufacturer's safety advice, national standard and local code and
regulation.
6. Please cut off the power when not use the equipment. When the equipment is not watched over or is repaired or scrap,
the power supply circuit should be disconnected.
7. Make sure to use electrode holder with excellent insulation, do not cool the electrode holder in water or place it on ground
and work piece. At the same time, do not touch the connection point of electrode holder of the two equipments, do not

USER’S MANUAL 3 I-TIG200DC
touch other people, electrode holder connection point and current-carrying electrode.
8. Do not use the cable which is used, broken, with small nominal section and unfirm terminal.
9. Do not let the welding cable enwind human body.
10.Grounding the work piece reliably.
11.When connecting ground wire, do not touch electrode.
12.In maintenance, must use perfect maintenance equipment.
13.The AC arc welding machine without voltage-reducing device (VDR)can not be used when welding is performed in narrow,
small and humid space. We recommend using direct current arc welder to ensure personal safety.
14.Please fasten your safety belt when working high above the ground or on unflat ground.
Warning----- Arc light may injure your eyes and skin, the noise may do harm to your hearing. Welding
process may generate high-heat and strong ultraviolet radiation which have potential to cause eye injury
and skin burnt, and some working process may generate.
Heavy noise which harms your hearing.
1. In welding and cutting course, please wear qualified helmet which can filter the radiation to protect your eyes and face.
2. Please wear a pair of standard goggles(see table:1 - 1) .
3. Protect other people with folding screen or fencing not affecting by arc light and splash and warn: do not look at electric
arc!
4. Please wear heat-proof and fireproof clothing and protective shoes.
5. Please wear qualified earplug or earcap in place where has great noise intensity.
Warning-----Fume may do harm to health. The smog and gas generated in welding process may do
harm to your health after inhalation.
1. Keep head out of fume and never inhale it.
2. Indoors, it is required to install ventilating device or exhaust fan to expel the fume and gas.
3. Please use air filtering respirator when the ventilation is poor.
4. Read material's security manual (MSDSS) and manufacturer's specification for metal material, consumption material,
bedding and clothing and cleaning methods.
5. When welding in narrow and small space, please always ensure ventilation is excellent or wear air filtering respirator. The air
filtering respirator can filter the harmful gas which may cause health hazard and even personal death to ensure the air you
inhaled is safe. .
6. Please do not perform welding in the location where the grease removal, washing or spray working are carried out. The
welding process may generate arc light and heat which can activize extremely toxic substance and irritative gas.

USER’S MANUAL 4 I-TIG200DC
7. The welding machine can not be used to weld galvanized, aluminized and cadmium plated steel plate, unless the coating
metal in welding area has been removed. The welding location should be well-ventilated. If it is necessary, please wear air
filtering respirator. Metal surface coating and any metal may generate toxic gas.
Warning----- Welding is easy to cause fire and explosion. Welding may generate spark, splash, jumping
fire and hot metal splash; heated work piece and heating equipment may cause fire and skin burnt.
Accident short circuit, open circuit or contacting metal may cause overheat of wire cable or generate
sparkle which may cause fire.
1. Ensure you and other not be injured by splash, spark and hot metal.
2. Do not weld in the place where the spark can reach the combustible substance.
3. Move the combustible substance 35FT(10.7m) away from electric arc. If condition is limited, please use the proper
sheathing to cover them closely.
4. Please watch out to prevent the spark and hot metal in welding course reach the neighbor area through narrow gap
and opening.
5. Place fire extinguisher and closely watch out .You must be aware of that: when welding on ceiling, floor, partition
plate or folding screen, the fire may occur on the back of them where it is not easy to be found.
6. Do not weld on the closed tanks such as tank, groove or cylinder barrel etc.
7. Due to long-distance power transmission in welding location, the connecting cable of workpiece and welding cable
may have broken insulation layer somewhere which may cause electric shock and fire.
8. Do not let welder to thaw out the frozen pipe.
Cutting and welding arc light protection selection
Weldingand cutting
Electrode size
Filter glass
Oxy-acetylene
welding and
cutting
light
Less than 25mm
3 to4
medium
25mm－150mm
4 to5
dark
Over 150mm
5 to6
Gas
shielded
welding
light
Less than 3mm
4 to5
medium
3mm－12mm
5 to6
dark
Over 12mm
6 to8
Manual electrode welding
Less than 4mm
10
4mm－6.4mm,
12
Over 6.4mm
14

USER’S MANUAL 5 I-TIG200DC
9. Remove the electrode from the welding holder when not welded.
INTRODUCTION INSTRUCTION
2.1 How to Use This Manual
Please carefully read instruction for safety in operation and chapter about warning to ensure reliable installation and
operation. Pay most careful attention to the content under the title of warning, caution and remark etc. These special
annotations are easy to understand.
Warning
Warning means: matters that have the potential to cause personal injury.
Caution mean: matters that have potential to damage the equipment.
Remark means: matters that provide helpful operating instruction.
2.2 Confirmation of Equipment
Please check and confirm whether the model of received equipment is correct, the accessories and parts accompanying
the equipment, the specification, guarantee repair card, certificate of conformity and packing list are complete, the serial
number or ex-factory No. is one-to-one correspondent and correct. After confirmation, record the result in relative forms
for reference.
2.3 Acceptance of Equipment
Please confirm the received equipment is complete and in good condition. In the event that something has been
damaged, please notify the post personnel your just claim as well as provide the recorded detailed information about the
equipment damage and transport error as the evidence in support of your rights and interests. The equipment should be
stored in a proper and safe place with reasonable care after acceptance.

USER’S MANUAL 6 I-TIG200DC
2.4 Description of Product
Our welding machine is equipped with advanced rectifier designed based on advanced inverter technology. The inverter
arc welding equipment is based on the appearance of inverter power source theory and parts. Inverter arc-welding
source converts 50/60Hz industrial frequency to high frequency (more than 100KHz) through high power parts: MOSFET
field effect tube, transfer electrical energy through high-frequency transformer and magnetic coupling mode and reduce
the voltage and then rectify. And output powerful direct current required by welding technology through pulse-width
modulation technology (PWM). High frequency of inverter switch makes the weight and volume of main transformer
considerable small. The conversion efficiency of transformer has also improved remarkably by 30%.The appearance of
inverter welding machine is praised as a revolution in welding machine industry.
Our inverter argon arc welding machine has the following characteristics: easy arc ignition, concentrated electric arc, air-
feed in advance, air-shut delay, automatic welding current attenuation, time continuously-adjustable device, pulse
selection, adjustable pulse frequency, adjustable peak current, adjustable valley current, auto-control arc starting and arc
stop, stable welding etc, which make both welding seam and internal quality reach optimal effect and suitable for the
welding which has special requirements for welding seam.
Our inverter argon arc welding machine can be used to weld stainless steel, alloy steel, carbon steel, copper and other
non-ferrous metal. In general, the power source conversion efficiency of welding machine may exceed 85%.
Welcome friends from all walks of life use our products and offer your valuable advice, we will commit ourselves to make
our product and service more perfect.

USER’S MANUAL 7 I-TIG200DC
2.5 Symbol Table
The following symbols are of universal identifier of welding, only part of them may be used in our equipment.
A
Ampere (current)
V
Volt(electricpressure)
Hertz (frequency)
sec
Second (time)
%
Percentage
DC(Direct Current)
~
AC (Alternating Current)
TIG torch
Remote control
-
Welding output (negative)
+
Welding output (positive)

USER’S MANUAL 8 I-TIG200DC
2.6 External Characteristic Description
TIG series welding power source has the gradual closing characteristic with decent output. The curve indicates the
maximum output voltage and minimum welding current of welding source. You can adjust the welding current within the
minimum welding current and maximum welding current through current regulation turn button.
Figure 2-1: external characteristic curve of TIG series welding power source
Current output
Voltage output
Maximum welding current
Sub-maximum welding current
Medium welding current
Sub-medium welding current
Minimum welding current

USER’S MANUAL 9 I-TIG200DC
2.7 Operating Principle Block Diagram of Circuit
2.8 Means of Transportation
Warning----crash down may cause equipment damage or personal injury.
Refer to transporting and placing methods marked on the external packing of equipment. Handle the equipment with trolley
or similar handling equipment which has adequate carrying capacity. When handle the equipment with fork truck, please fix it
firmly to prevent it from slipping.
Input
voltage
switch
Primary
rectify
filtering
inverter
switch
assembly
high-frequ
ency
transforme
r
temper
ature
sensor
secondary
rectifying
output
DC reactor
current
sensor
high-frequency
control circuit
secondary
inverter
switch
assembly
arc
ignition
device
PWM
control
waveform
generator
Cooling
fan
Auxiliary
Power
Supply
control
circuit
PWM control
Grid
input
OUT –
OUT +