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TEC.LA Ergus WIG 160 DCi User Manual

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INDUSTRIE LINE
WIG 160 DCi/CDI
WIG 201 DCi/CDI
USER MANUAL
MANU.115.M.TIG.00

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  • Page 1 INDUSTRIE LINE WIG 160 DCi/CDI WIG 201 DCi/CDI USER MANUAL MANU.115.M.TIG.00...
  • Page 2 TEC.LA S.r.l. thanks you for having chosen its welding machine, built with the principles of safety and reliability. The quality materials used in building the machines ensure total reliability and ease of maintenance. We recommend reading the manual before connecting the system to the mains.

  • Page 3: Table Of Contents

    Valued Customer, Hoping you will find our product to your satisfaction, we welcome you to our family, informing you that the ERGUS marked machines have been ISO 9000:2001 certified, thus guaranteeing greater product reliability and quality. TABLE OF CONTENTS GENERAL SAFETY INFORMATION ..................5 DESCRIPTION OF POWER SOURCE ..................
  • Page 4 7. Antisticking ..........................20 WHAT IF THE INVERTER DOESN’T WORK? ................. 20 AVAILABLE ACCESSORIES ....................21 1. Pulse unit (built-in the CDi versions) ..................21 2. Foot control ..........................21 3. Remote control ........................21 4. Other accessories ........................21 TECHNICAL DATA ........................

  • Page 5: General Safety Information

    GENERAL SAFETY INFORMATION Electric shock ELECTRIC SHOCK CAN KILL. Do not touch the parts under high voltage; Disconnect the power supply from mains before any intervention; Operator must be insulated from the weld piece and from the ground, using insulated gloves and clothing;...
  • Page 6 Noise The welding arc respects current legislation on noise levels (not exceeding 80 db); Protective ear plugs or muffs must be worn to avoid damage when working overhead or in small areas. Electromagnetic disturbance The power source respects legislation regarding electromagnetic disturbances and is suitable for work in industrial surroundings.

  • Page 7: Description Of Power Source

    DESCRIPTION OF POWER SOURCE The INDUSTRIE WIG 160 DCi/CDI and WIG 201 DCi/CDI power source are designed for coated electrodes welding and TIG welding with HF ignition. Their basic parts are: 1. Control electronics 2. Power electronics 3. HF generator. Reduced size and weight make these welders ideal for operators having frequent moving jobs.

  • Page 8: Front Panel Controls

    3. Front panel controls WIG 201 DCi 1. ON-OFF SWITCH 7. WELDING MODE SELECTOR - ELECTRODE , TIG 2- 2. OVERHEATING LED 4 step, with/without HF. 3. OUTPUT CURRENT KNOB 8. TIG TORCH CONNECTION SOCKET 4. POSITIVE CONNECTOR 9. GAS TIG TORCH QUICK CONNECTOR 5.
  • Page 9 1 on the back panel WIG 201 CDI 1. ON-OFF SWITCH (on the back panel) 2. FUNCTION SELECTOR 3. OUTPUT CURRENT KNOB 4. POSITIVE CONNECTOR 5. NEGATIVE CONNECTOR 6. REMOTE, FOOT CONTROL SOCKET 7. DISPLAY 8. TIG TORCH CONNECTION SOCKET 9.

  • Page 10: Installation And Use

    INSTALLATION AND USE Machine installation must be done by qualified personnel. All connections must be done in conformity with current specifications and with respect for industrial accident prevention regulations. Before connecting the power source to the mains, check that it is between 210 V and 250 V. Mains receptacle must be earthed.

  • Page 11: Installation Of Electrode Machine

    INSTALLATION OF ELECTRODE MACHINE All welding parameter controls are placed on the welding machine front panel. Plug the power cord into a 230V single phase mains socket, making sure that it is earthed. Ref. 4 Ref. 5 Connect positive (+) and negative (-) connectors to the electrode holder and the earth cable. Rutile electrodes need the electrode holder be connected to negative pole (-) while basic electrodes need the electrode holder connected to positive pole (+).

  • Page 12: Electrode Welding

    1. Electrode welding Arc welding with coated electrodes is a fusion procedure that uses an electric arc as a source of heat. This is formed between the extremities of a coated electrode and a base material. The heat developed by the arc melts the base material, the rod and part of the coating. The remaining part of it burns into smoke, creating an atmosphere that protects the welding bead from the oxidising action of the air.

  • Page 13: Electrode Welding Defects-Troubleshooting

    NB: Descending welding needs a quick movement, while ascending welding needs a slow movement which heats the material to be welded.  Overhead: the electrode works upwards, while the parts to weld are in a horizontal position. FOR OPTIMAL WELDING ON MATERIALS OF CONSISTENT THICKNESS, THE EDGES TO BE JOINED SHOULD BE PREPARED FOR WELDING BEFORE PROCEEDING.

  • Page 14: Installation Of Machine In Tig Hf

    INSTALLATION OF MACHINE IN TIG HF DC - DIRECT CURRENT Connect the mains power cable to a 230V single phase line, making sure that the socket is earthed. Place the gas bottle in a safe place and make sure that it is well secured. Connect the TIG torch gas hose to the pressure gauge following the manufacturer’s instructions which are included with the gauge.

  • Page 15: Tig Welding

    1. TIG welding TIG welding is a fusion procedure that uses as a source of heat an electric arc created between an infusible tungsten electrode and the base material to be welded. For TIG welding an inert gas must be used (ARGON) which protects the welding bead.
  • Page 16 Electrode preparation for DC welding The electrode should be pointedaccording to the welding current. Angle @ Range of current [°] [ A ] 0-30 60-90 30-120 90-120 120-250 >250 TYPES OF ELECTRODES ELECTRODE COLOUR Cerium-Tungsten Grey Universal Thorium Tungsten Fe-Stailess steel-Copper Welding Position Place the tip at 3-4 mm (.12 - .16in) from the weld piece, press the torch trigger, the arc will automatically ignite;...
  • Page 17 TIG WELDING PARAMETERS Stainless STEEL Filling Sheet Welding current (A) Electrode Welding Number material metal Argon Type of seam speed Horizontal Vertical thickness lit./min. mm./min. passages position position 25 – 60 23 – 55 250 – 300 Head to head 250 –...

  • Page 18: Tig Welding Defects - Troubleshooting

    2.TIG welding defects – troubleshooting DEFECT POSSIBLE CAUSES REMEDIES 1. The electrode melts A. Electrode connected to the “+” pole. A. Connect the electrode to the “-“ pole. when the arc strikes. A. Electrode contaminated from contact A. Remake the electrode tip. 2.

  • Page 19: Using The Digital Panel

    USING THE DIGITAL PANEL 1. Setting welding parameters Set welding parameters using the “FUNCTION” (2) keys. For each function selected, the present value appears on the DISPLAY (7) and the LED of the corresponding icon turns on. Press “ENTER”: the measurement symbol flashes. Set the new value with the “+” and “-“ touch buttons. Press “ENTER”...

  • Page 20: Antisticking

    7. Antisticking If during STICK or STICK + ARC FORCE welding procedure the electrode sticks for a few seconds, “ANTISTICKING” will appear on the display and the output current drops to lmin, avoiding electrode overheating. WHAT IF THE INVERTER DOESN’T WORK? The welder doesn’t switch-on: check the mains connection and the switch position (1).

  • Page 21: Available Accessories

    AVAILABLE ACCESSORIES 1. Pulse unit (built-in the CDi versions) Using pulsed current allows greater control in certain operating situations. I MIN basic current (MIN/MAX adjustable) Low frequency adjustable from 0.6 to 6 Hz I MAX peak current (MIN/MAX adjustable) Medium frequency adjustable from 6 to 60 Hz High frequency adjustable from 60 to 600 Hz Base/peak percentage time (30/70%).

  • Page 22: Technical Data

    TECHNICAL DATA WIG 160 DCi/CDI WIG 201 DCi/CDI Mains voltage 230V + 10% 230V + 10% Frequency 50/60 HZ 50/60 HZ Power factor 0,85 0,85 Nominal current ProtectiveFuses 16A t-lag 16A t-lag Electrode Nominal Power 5,3 KW 5,3 KW TIG DC Nominal Power 3,3 KW 4,5 KW 20,2 –...

  • Page 23: Block Diagram

    BLOCK DIAGRAM WIG 160 DCi...
  • Page 24 WIG 160 CDI...
  • Page 25 WIG 201 DCi...
  • Page 26 WIG 201 CDI...

  • Page 27: Remote Control Connection Diagram

    REMOTE CONTROL CONNECTION DIAGRAM WIRING OF CONNECTORS...

  • Page 28: Spare Parts List

    SPARE PARTS LIST WIG 160 DCi TEC.LA Code Descrizione Description 1 DDF115.160.T-E.02.00 WIG 160 DCi WIG 160 DCi 2 Y.DD.COPE.115.06.00 COPERCHIO CON MANIGLIA COVER WITH HANDLE 3 Y.DD.MANO.438.02.00 MANOPOLA 15 COMPLETA KNOB 4 Y.DD.MANO.438.01.00 MANOPOLA 22 COMPLETA KNOB 5 MMCD00200...
  • Page 29 WIG 160 DCi...
  • Page 30 WIG 160 CDI TEC.LA Code Descrizione Description 1 DDD115.160.T-E.02.01 WIG 160 CDi WIG 160 CDi 2 Y.DD.COPE.115.07.00 COPERCHIO CON MANIGLIA COVER WITH HANDLE 3 Y.DD.MANO.115.01.00 MANOPOLA 15 COMPLETA KNOB 4 AVVO.002.002.00 AVVOLG. HF DC DOPPIA FERRITE DOUBLE CORE HF FERRITE WINDING...
  • Page 31 WIG 160 CDI...
  • Page 32 WIG 201 DCi TEC.LA Code Descrizione Description 1 DDF115.200.T-E.01.00 WIG 201 DCi WIG 201 DCi 2 Y.DD.COPE.115.06.00 COPERCHIO CON MANIGLIA COVER WITH HANDLE 3 Y.DD.MANO.438.02.00 MANOPOLA 15 COMPLETA KNOB 4 Y.DD.MANO.438.01.00 MANOPOLA 22 COMPLETA KNOB 5 MMCD00300 DINSE 50 CONNECTOR DINSE 50 6 PFON.002.002.00...
  • Page 33 WIG 201 DCi...
  • Page 34 WIG 201 CDi TEC.LA Code Descrizione Description 1 DDD115.200.T-E.01.01 WIG 201 CDi WIG 201 CDi 2 Y.DD.COPE.115.06.00 COPERCHIO CON MANIGLIA COVER WITH HANDLE 3 Y.DD.MANO.115.01.00 MANOPOLA 15 COMPLETA KNOB 4 AVVO.002.002.00 AVVOLG. HF DC DOPPIA FERRITE DOUBLE CORE HF FERRITE WINDING...
  • Page 35 WIG 201 CDI...
  • Page 36 TEC.LA. S.r.l. Via Castel Morrone 15/C - 16161 Genova – ITALIA Phone +39 0107 450 222 – 0107 411 034 Fax +39 0107 406 917 e-mail info@teclaitalia.com...

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