Top Gun TIG 202E AC/DC Operator's Manual
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Top Gun TIG 202E AC/DC Operator's Manual

Inverter ac/dc pulsed tig welder
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OPERATOR'S MANUAL
INVERTER AC/DC PULSED TIG WELDER
TIG 202E AC/DC
2014．06
IMPORTANT: Read this Owner's Manual Completely before attempting to use this
equipment. Save this manual and keep it handy for quick reference. Pay particular
attention to the safety instructions we have provided for your protection. Contact your
.
distributor if you do not fully understand this manual.

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  • Page 1 OPERATOR’S MANUAL INVERTER AC/DC PULSED TIG WELDER TIG 202E AC/DC 2014．06 IMPORTANT: Read this Owner’s Manual Completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. Contact your...

  • Page 2: Table Of Contents

    CONTENT §1 SAFETY ............................. 1 §1.1 S ........................1 IGNAL XPLANATION §1.2 A ....................... 1 ELDING AMAGE §1.3 T ............... 5 HE KNOWLEDGE OF LECTRIC AND AGNETIC IELDS §2 SUMMARY ............................6 § 2.1 B ........................6 RIEF NTRODUCTION §2.2 M ........................

  • Page 3: Safety

    SAFETY §1 SAFETY §1.1 Signal Explanation  The above signals mean warning! Notice! Running parts and getting an electric shock or thermal parts will take damage for your body or others. The corresponding notices are as follows. It is quite a safe operation after taking several necessary protection measures.
  • Page 4 SAFETY semiautomatic welding gun are also electrically “hot”.  Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition.
  • Page 5 SAFETY arc when welding or observing open arc welding.  Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.  Protect other nearby personnel with suitable, non-flammable screening and /or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.
  • Page 6 SAFETY an explosion even though they have been “cleaned”.  Vent hollow castings or containers before heating, cutting or welding. They may explode.  Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuff less trousers, high shoes and a cap over your hair.

  • Page 7: The Knowledge Of Electric And Magnetic Fields

    SAFETY §1.3 The knowledge of Electric and Magnetic Fields Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). The discuss on the effect of EMF is ongoing all the world. Up to now, no material evidences show that EMF may have effects on health.

  • Page 8: Summary

    SUMMARY §2 SUMMARY § 2.1 Brief Introduction TIG200E AC/DC welding machine adopts the latest pulse width modulation (PWM) technology and insulated gate bipolar transistor (IGBT) power module, which can change work frequency to medium frequency so as to replace the traditional hulking work frequency transformer with the cabinet medium frequency transformer.
  • Page 9 SUMMARY  DC Pulse TIG  AC MMA  AC TIG  AC Pulse TIG 1.For DC MMA, polarity connection can be chosen according to different electrodes，please refer to §3.5； 2.For AC MMA, magnetic flow caused by invariable DC polarity can be avoided； 3.For DC TIG, DCEP is used normally (workpiece connected to positive polarity, while torch connected to negative polarity).

  • Page 10: Module Explanation

    SUMMARY IGBT——Insulation Gate Bipolar Transistor TIG——Tungsten Insert Gas welding §2.2 Module Explanation The module explanation of arc welding machine must accord with the correlative prescripts of National Standard GB10249. It is explained as the following (take TIG 200 AC/DC as an example). §2.3 Working Principle The working principle of TIG200E AC/DC welding machines is shown as the following figure.

  • Page 11: Volt-Ampere Characteristic

    SUMMARY §2.4 Volt-Ampere Characteristic TIG200E AC/DC welding machine has an excellent volt-ampere characteristic, whose graph is shown as the following figure. The relation between the conventional rated loading voltage U and the conventional welding current I is as follows: ≤600A，U ＞600A,U When I =10+0.04I...

  • Page 12: Installation And Adjustment

    INSTALLATION AND ADJUSTMENT §3 Installation and Adjustment §3.1 Parameters Models TIG 200E AC/DC TIG 200E AC/DC PULSE Parameters Input power (V) 1~220/230/240±10% 1~220/230/240±10% Fre.（HZ） 50/60HZ 50/60HZ 30.5（AC TIG） 39.1（AC MMA） 30.5（AC TIG） 39.1（AC MMA） Rated input current（A） 28.3（DC TIG） 40.7（DC MMA） 28.3（DC TIG）...

  • Page 13: Duty Cycle & Over Heat

    INSTALLATION AND ADJUSTMENT 3.2 Duty cycle & Over heat The letter “X” stands for duty cycle, which is defined as the proportion of the time that a machine can work continuously within a certain time (10 minutes). The rated duty cycle means the proportion of the time that a machine can work continuously within 10 minutes when it outputs the rated welding current.

  • Page 14: Polarity Connection（Mma

    INSTALLATION AND ADJUSTMENT When the power supply voltage is over the safe work voltage, there are over voltage and under voltage protection inside the welder, the alarm light will on, at the same time, the current output will be cut off. If the power supply voltage continually goes beyond the safe work voltage range, it will shorten the welder life-span.

  • Page 15: Assembling The Equipment (Tig)

    INSTALLATION AND ADJUSTMENT §3.6 Assembling the equipment (TIG)  Workpiece is connected to the positive electrode of welding machine, and welding torch is connected to the negative electrode, which is called DC POSITIVE CONNECTION; otherwise, that is called DC NEGATIVE CONNECTION. Generally, it is usually operated in DC POSITIVE CONNECTION in TIG welding mode.

  • Page 16: Operation

    INSTALLATION AND ADJUSTMENT §4 Operation §4.1 Layout for the panel Positive output: The welder’s positive polarity output. Negative output: The welder’s negative polarity output. Aero socket: Is connected to torch switch control wire.（It has 14 leads and lead 8 - lead 9 are connected to torch switch control wire）.

  • Page 17: Control Panel

    INSTALLATION AND ADJUSTMENT §4.2 Control panel TIG 200E AC/DC...
  • Page 18 INSTALLATION AND ADJUSTMENT TIG 200E AC/DC PULSE...
  • Page 19 INSTALLATION AND ADJUSTMENT Available parameters where 2T and 4T mode have been selected: Gas pre-flow time Unit Setting range 0.0—2.0 Starting current (only with 4T) Unit Setting range 10—170 (DC)；10—200(AC) Upslope time Unit Setting range 0.0—10 Welding current Unit 10—170 (TIG-DC)；10—200 (TIG-AC)； Base current Unit 10—170 (TIG-DC)；10—200 (TIG-AC)；...
  • Page 20 MAINTENANCE AND TROUBLESHOOTING Unit Setting range 0—10 Crater arc current (only with 4T) Unit Setting range 10-170 (DC)；10-200 (AC) Gas post-flow time Unit Setting range 0—10 Balance (only with TIG-AC) Balance adjustment is mainly used to set the adjustment of eliminating metal-oxide (such as Aluminium, Magnesium and its alloy) while AC output.

  • Page 21: Pedal Switch Control

    MAINTENANCE AND TROUBLESHOOTING §4.3.1 Pedal switch control ● When plug the fourteen-lead aero-socket of pedal switch in it. Welder will identify the pedal switch, the welding current knob on the front panel will can’t use，and only 2T can be selected. ●...

  • Page 22: Argon Arc Welding Operation

    MAINTENANCE AND TROUBLESHOOTING §4.4 Argon Arc Welding Operation §4.4.1 TIG welding （4T operation） The start current and crater current can be pre-set. This function can compensate the possible crater that appears at the beginning and end of the welding. Thus, 4T is suitable for the welding of medium thickness plates.

  • Page 23: Tig Welding (2T Operation)

    MAINTENANCE AND TROUBLESHOOTING 10S）;  t7：Electromagnetic valve is closed and stop argon flowing. Welding is finished. §4.4.2 TIG welding (2T operation) This function without the adjustment of start current and crater current is suitable for the Re-tack welding、transient welding、thin plate welding and so on. I（A）...
  • Page 24 MAINTENANCE AND TROUBLESHOOTING Short circuit protect function： ○ 1 TIG /DC/LIFT：If the tungesten electrode touches the workpiece when welding, the current will drop to 20A, which can reduce the tungsten spoilage farthestly，prolong the using life of the tungsten electrode，and prevent tungsten clipping. ○...

  • Page 25: Welding Parameters

    MAINTENANCE AND TROUBLESHOOTING §4.5 Welding Parameters §4.5.1 Joint forms in TIG/MMA lap joint coner joint T joint butt joint §4.5.2 The explanation of welding quality The relation of welding area color & protect effect of stainless steel Welding area argent , golden blue red-grey grey...
  • Page 26 MAINTENANCE AND TROUBLESHOOTING Gas nozzle and the shield gas flow rate DC positive connection Welding current Gas nozzle Gas flow Gas nozzle Gas flow range/A diameter/mm diameter/mm rate/L·min rate/L·min 10～100 4～9.5 4～5 8～9.5 6～8 101～150 4～9.5 4～7 9.5～11 7～10 151～200 6～13 6～8 11～13...
  • Page 27 MAINTENANCE AND TROUBLESHOOTING Corner 115～145 joint Butt joint 150～225 Corner 175～250 joint Notice: the above parameters originate from《Welding Dictionary》P150, Volume 1 of Edition 2. Parameters of piping back sealing welding for mild steel （DCEP） Argon Welding Piping Tungsten Welding Gas nozzle Welding flow rate rate...

  • Page 28: Operation Environment

    MAINTENANCE AND TROUBLESHOOTING 150～ － 2～3 8～12 8～12 180～ － 10～15 8～12 180～ － 3～4 10～15 10～12 240～ － 16～20 14～16 260～ 4～5 16～20 14～16 100～ 280～ V-groove butt 4～5 16～20 14～16 welding 150～ 300～ 4～5 5～6 18～22 16～20 180～ 340～...

  • Page 29: Operation Notices

    MAINTENANCE AND TROUBLESHOOTING §4.7 Operation Notices ● Read §1 carefully before attempting to use this equipment. ● Connect the ground wire with the machine directly, and refer to §3.5. ● In case closing the power switch, no-load voltage may be exported. Do not touch the output electrode with any part of your body.

  • Page 30: Maintenance & Troubleshooting

    MAINTENANCE AND TROUBLESHOOTING §5 Maintenance & Troubleshooting §5.1 Maintenance In order to guarantee that arc welding machine works high-efficiently and in safety, it must be maintained regularly. Let customers understand the maintenance methods and means of arc welding machine more , enable customers to carry on simple examination and safeguarding by oneself, try one's best to reduce the fault rate and repair times of arc welding machine, so as to lengthen service life of arc welding machine .Maintenance items in detail are in the following table.

  • Page 31: Troubleshooting

    MAINTENANCE AND TROUBLESHOOTING Using the dry compressed air to clear the inside of arc welding machine. Especially for clearing up the dusts on radiator, main voltage transformer, inductance, IGBT module, the Monthly fast recover diode and PCB, etc. examination Check up the bolt in arc welding machine, if it is loose, please screw down it. If it is skid, please replace.
  • Page 32 MAINTENANCE AND TROUBLESHOOTING  If there is any problem and has no the authorized professional maintenance personal, please contact local agent or the branch company! If there are some simple troubles of TIG200E AC/DC -series welding machine, you can consult the following overhauling chart: Troubles Reasons...
  • Page 33 MAINTENANCE AND TROUBLESHOOTING Troubles Reasons Solution Check the welding gun switch, control The malfunction of the welding gun switch. cable and aero socket. Gas cylinder is close or gas pressure is low Open or change the gas cylinder No gas flow (TIG) Something in the valve Remove it Electromagnetic valve is damaged...

  • Page 34: Electrical Principle Drawing

    MAINTENANCE AND TROUBLESHOOTING §5.3 Electrical principle drawing...
  • Page 35 MAINTENANCE AND TROUBLESHOOTING...

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