Top Gun 3200 AC/DC TIG Operation Manual
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Top Gun 3200 AC/DC TIG Operation Manual

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OPERATION MANUAL
TOPGUN 3200 AC/DC TIG
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  • Page 1 OPERATION MANUAL TOPGUN 3200 AC/DC TIG...

  • Page 2: Table Of Contents

    TOPGUN 3200 AC/DC TIG USER MANUAL CONTENTS SAFETY RULES, DESCRIPTION OF SYMBOLS APPLICATION DESCRIPTION OF THE MACHINE TECHNICAL SPECIFICATIONS EQUIPMENT DESIGN CONNECTION TIG / MMA WELDING BEFORE YOU WORK WORKING CONDITIONS DESCRIPTION OF THE CONTROL PANEL FUNCTIONS MAINTENANCE TROUBLE SHOOTING...

  • Page 3: Safety Rules, Description Of Symbols

    TOPGUN 3200 AC/DC TIG USER MANUAL 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.
  • Page 4 TOPGUN 3200 AC/DC TIG USER MANUAL 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.
  • Page 5 TOPGUN 3200 AC/DC TIG USER MANUAL 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.

  • Page 6: Application

    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.

  • Page 7: Technical Specifications

    TOPGUN 3200 AC/DC TIG USER MANUAL 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] 100% Square Wave Sine Wave Triangular Ramp Wave Waveform on AC mode...

  • Page 8: Equipment

    TOPGUN 3200 AC/DC TIG USER MANUAL 5. EQUIPMENT STANDARD PACKAGE WP-18 WATER COOLING TORCH WITH CABLE X8 METERS EARTH CLAMP WITH CABLE X5 METERS 3 MTR QUICK CONNECT GAS HOSE WITH FITTINGS TOPGUN TIG CONSUMABLE KIT MANUAL 6. TIG / MMA WELDING BEFORE YOU WORK Specify the location where the device is operated.
  • Page 9 TOPGUN 3200 AC/DC TIG USER MANUAL 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.

  • Page 10: Description Of The Control Panel Functions

    TOPGUN 3200 AC/DC TIG USER MANUAL 8. DESCRIPTION OF THE CONTROL PANEL FUNCTIONS 1. LCD display 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...
  • Page 11 TOPGUN 3200 AC/DC TIG USER MANUAL 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.
  • Page 12 TOPGUN 3200 AC/DC TIG USER MANUAL 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.
  • Page 13 TOPGUN 3200 AC/DC TIG USER MANUAL 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.
  • Page 14 TOPGUN 3200 AC/DC TIG USER MANUAL PREPARATION OF VOLUME ELECTRODES Preparation of tungsten electrodes depending on the type of welding current...
  • Page 15 TOPGUN 3200 AC/DC TIG USER MANUAL Table 1. Choice of electrode diameter – steel welding Current range welding [A] The diameter of electrode [ mm] Material thickness [mm] Stainless steel 10-50 0.5-1.0 20-80 1.0-1.5 50-160 1.5-3.0 110-250 3.0-5.5 200-350 5.5-8.0 Table 2.
  • Page 16 TOPGUN 3200 AC/DC TIG USER MANUAL 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)
  • Page 17 TOPGUN 3200 AC/DC TIG USER MANUAL Control welding parameters panel/remoet control potentiometer in the welding gun or pedal 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...
  • Page 18 TOPGUN 3200 AC/DC TIG USER MANUAL 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.
  • Page 19 TOPGUN 3200 AC/DC TIG USER MANUAL 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.
  • Page 20 TOPGUN 3200 AC/DC TIG USER MANUAL Heat distribution and its impact on DC TIG welding process Polarity Positive (DC+) Negative (DC-) Penetration Deep and narrow Shallow and wide Efficiency heat BAD - high wear Very good electrode Heat 70% - material...
  • Page 21 TOPGUN 3200 AC/DC TIG USER MANUAL SETTING OF THE PULSING CURRENT PARAMETERS OF TIG 3200 AC / DC DEVICE Pulse or continuous current welding Select the pulse mode Select the pulse mode The parameter specifies the time proportion between welding with peak current in relation to the base current.
  • Page 22 TOPGUN 3200 AC/DC TIG USER MANUAL ALTERNATING CURRENT WELDING–TIG AC TIG AC (AC) welding is used to connect magnesium or aluminum components and their alloys. During AC welding, polarity changes between the poles positive and negative. A positive halfwave allows the oxide surface layer to penetrate, while a half-wave negative, which is accompanied by a decrease in the temperature of the electrode and heat flow to the workpiece, promotes deeper arch penetration.
  • Page 23 TOPGUN 3200 AC/DC TIG USER MANUAL Pulse or continuous current welding Synergy mode / manual mode In synergic mode the user regulates only basic welding parameters. The device constantly checks the correctnessettings, suggesting the user thickness material to be welded (see screen for current).
  • Page 24 TOPGUN 3200 AC/DC TIG USER MANUAL Pre-flow Attention ! The welding arc will catch fire any time after the set gas flow time before welding. For a 4m long handle max. suggested time: 2 seconds. Welding peak current Basic welding current...
  • Page 25 TOPGUN 3200 AC/DC TIG USER MANUAL AC frequency Number of voltage and current changes AC welding in one second. Post flow Attention! After the welding arc has expired, keep the torch in a position that allows the welding area to cool down with shielded gas.
  • Page 26 TOPGUN 3200 AC/DC TIG USER MANUAL Saving data in the device's memory Using saved programs AC Balances settings AC balance is the ratio of the positive current tbal + to the negative tbal-current in a single cycle Tbal alternating current waveform. The ability to adjust the balance allows you to control the temperature of the electrode and the workpiece, including the welder has an effect on the depth of penetration and the width of the weld.
  • Page 27 TOPGUN 3200 AC/DC TIG USER MANUAL Turning the adjustment dial to the left and setting the AC Balances below 50 will reduce the time tbal + duration and proportional extension of the t bal- duration Fig. Lyn. 5 TIG 3200 AC/DC Balance AC 25 %...
  • Page 28 TOPGUN 3200 AC/DC TIG USER MANUAL E. MMA MODE Arc welding with a coated electrode is also called the MMA (Manual Arc Welding) and this is the oldest and most universal method of arc welding. The MMA method uses a covered electrode, consisting of a metal core covered with lagging.
  • Page 29 TOPGUN 3200 AC/DC TIG USER MANUAL Connect the welding and mass leads to the appropriate output sockets on the welding machine, in accordance with the polarity recommended by the manufacturer of the electrodes you intend to weld. Welding current setting Spin the knob to adjust welding current.
  • Page 30 TOPGUN 3200 AC/DC TIG USER MANUAL The device has a VRD (Voltage Reduction Device), which for welding mode MMA with rutile and basic electrodes reduces no-load voltage, which significantly increases user security. VRD CAN ONLY BE TURN ON IN MMA MODE DUE TO...

  • Page 31: Maintenance

    TOPGUN 3200 AC/DC TIG USER MANUAL 10. MAINTENANCE Regular cleaning and maintenance of the device will reduce the risk of unwanted faults. Devices are factory-fitted with service seals that will break before the warranty period may expire. Regularly clean the inside of the device through the ventilation holes, clean and dry compressed air (compressed air in an aerosol for use in electronics, compressed air produced by the compressor - subjected to appropriate filtration *).
  • Page 32 TOPGUN 3200 AC/DC TIG USER MANUAL * Minimal degree of compressed air filtration - 5μm pre-filter, oil mist filter. BEFORE ANY MAINTENANCE, SWITCH OFF DEVICE, AND THEN DISCONNECT THE PLUG FROM THE POWER SOURCE! MAXIMUM PERMISSIBLE AIR PRESSURE USED FOR INTERIOR FAN THE DEVICES ARE 3 BAR.
  • Page 33 TOPGUN 3200 AC/DC TIG USER MANUAL ERROR CODES In special cases, the following messages may appear on the display indicating a problem with the operation of the device. Errors on the display will appear until the defect is removed. Error 001 Overload The device is operated in a step exceeding its rated efficience.

  • Page 34: Trouble Shooting

    TOPGUN 3200 AC/DC TIG USER MANUAL 11. Trouble shooting Table 5. trouble shooting PROBLEM POSSIBLE CAUSE SOLUTION DEVICE FUNCTIONING PROBLEMS Check if the device is connected The device is not connected to the is to the mains network supply, the device does not...
  • Page 35 TOPGUN 3200 AC/DC TIG USER MANUAL Incorrectly selected consumables TIG (TIG) Select the handle components Difficulties with torch for these same parameters - diameter. ignition of the arc (connector, collet, electrode)

  • Page 36: Eletrical Diagram

    TOPGUN 3200 AC/DC TIG USER MANUAL 12. ELECTRICAL DIAGRAM Lyn. 9 Electrical diagram...

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