Grand TIG 202 DC PULSE PFC Operator's Manual

Inverter dc pulse tig welder

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OPERATOR'S MANUAL

GRAND TIG 202 DC PULSE PFC

INVERTER DC PULSE TIG WELDER

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.

Table of Contents

Troubleshooting

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Page 1 OPERATOR’S MANUAL GRAND TIG 202 DC PULSE PFC INVERTER DC PULSE TIG WELDER 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 CONTENT §1 SAFETY..............................1 §2 SUMMARY..............................9 §2.1 Features..............................9 §2.2 Brief Introduction..........................10 §2.3 Parameters............................. 11 §2.4 Duty cycle & Over heat........................12 §2.5 Working Principle..........................12 §2.6 Volt-Ampere Characteristic....................... 13 §3 Installation & Operation......................... 14 §3.1 Layout for Front and Rear panel.....................14 §3.2 Layout for Control panel........................
Page 3: Safety
SAFETY §1 SAFETY Notice: The instructions are for reference only. The manufacturer reserves the right to explain the differences between the description and the product due to product changes and upgrades! The device is manufactured using state-of-the-art technology and according to recognised safety standards. If used incorrectly or misused, however, it can cause: ...
Page 4 SAFETY cause damage, please avoid the above situation. Excessive ambient temperature will cause the machine heat dissipation is not smooth, so that the internal components of the machine heat seriously. Usually the maximum operating temperature is 104°F (40°C). Low temperature may lead to performance degradation or damage of components inside the product, resulting in ice inside the water tank.
Page 5 SAFETY  Shafts  Wire spools and welding wire Many harmful phenomena, such as noise, bright light and harmful gas, will inevitably occur in the welding process. In order to avoid harmful By product phenomena causing harm to the human body, it is necessary to make corresponding preparations in advance.
Page 6 SAFETY Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.  Do not breathe the smoke and gas generated whilst welding or cutting, keep your head out of the fumes. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone.
Page 7 SAFETY Flying sparks from the welding arc, hot work piece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating or fire.  Welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
Page 8 SAFETY Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition. ...
Page 9 SAFETY Don’t sling cables or leads around either the body or parts of the body. The electrode (rod electrode, tungsten electrode, welding wire, etc) must  Never be immersed.  Never be touched when current is flowing. When the machine is connected to the power supply, there is electricity inside the machine.
Page 10 SAFETY Radiation Class A Device.  Only can be used in the industrial area.  If it is used in other area, it may cause connection and radiation problems of circuit. Radiation Class B device.  Satisfy the emissions criteria for residential and industrial areas. EMC Class This is also true for residential areas in which the energy is supplied from the public low-voltage mains.
Page 11: Summary
SUMMARY §2 SUMMARY §2.1 Features  New appearance and new panel design: More trendy and humanized.  LCD screen for accurate setting & feedback of welding output.  PFC Technology: Power factor more than 0.99.  Input voltage, works with single-phase: 110V/230V. ...
Page 12: Brief Introduction
SUMMARY §2.2 Brief Introduction TIG DC-series 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. Thus, it is characterized with portable, small size, light weight, low consumption and etc.
Page 13: Parameters
MMA——Manual Metal Arc welding PWM——Pulse-Width Modulation IGBT——Insulation Gate Bipolar Transistor TIG——Tungsten Insert Gas welding §2.3 Parameters Models GRAND TIG 202 DC PULSE PFC Parameters Power source 1-110±10% 1-230±10% Frequency (Hz) 50/60 Rated input current (A) 38.5...
Page 14: Duty Cycle & Over Heat
§2.4 Duty cycle & Over heat The letter “X” stands for Duty Cycle, Relation of welding current and duty cycle which is defined as the portion of the for GRAND TIG 202 DC PULSE PFC time a welding machine can weld continuously with...
Page 15: Volt-Ampere Characteristic
SUMMARY §2.6 Volt-Ampere Characteristic TIG DC-series 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: When I ≤600A, U =10+0.04I (V);...
Page 16: Installation & Operation
INSTALLATION & OPERATION §3 Installation & Operation §3.1 Layout for Front and Rear panel TIG torch remote connection socket. “-” Output terminal. TIG torch gas connector. “+” Output terminal. Power source switch: Switch to “ON”, the welder is turned on, while switch to “OFF”, the welder is turned off.
Page 17: Layout For Control Panel
INSTALLATION & OPERATION §3.2 Layout for Control panel §3.2.1 Control panel 1. Welding mode button: Press it to select MMA/ HF TIG/ Lift TIG welding mode. 2. Trigger mode selecting button: Press it to select 2T or 4T trigger mode. * 3.
Page 18 INSTALLATION & OPERATION automatically removed. Setting range: 0~10 (arc force). 9. Function B button.* 10. Parameters select/adjust knob.* Denotes more detailed explanation of function to follow. Further Controls Explained Trigger mode selecting button (2) 2T Mode The trigger is pulled and held on to activate the welding circuit, when the trigger is released, the welding circuit stops.
Page 19 INSTALLATION & OPERATION (5) t3: Release the gun switch, the welding current will drop in accordance with the selected down-slope time. (6) t3～t4: The current drops to the minimum welding current from the setting current (I or I ), and then arc is turned off. (7) t4～t5: Post-gas time, after the arc is turned off.
Page 20 INSTALLATION & OPERATION (5) t2～t3: The output current rises to the setting value (I or I ), the upslope time can be adjusted; (6) t3～t4: Welding process. During this period, the gun switch is loosen; Note: Select the pulsed output, the base current and welding current will be outputted alternately;...
Page 21: Mma Display Introduction
INSTALLATION & OPERATION §3.2.2 MMA display introduction 1. Welding mode button: Press it to enter MMA welding mode. 2. Hot Start button: Press it to select Hot start. 3. Arc Force button: Press it to select Arc force. 4. Parameter adjust knob: Rotate it to adjust welding current and value of Hot start and Arc force.
Page 22: Hf/Lift Tig Display Introduction
INSTALLATION & OPERATION §3.2.3 HF/LIFT TIG display introduction 1. Welding mode button: Press it to enter HF TIG or Lift TIG welding mode. 2. Trigger mode button: Press it to select 2T or 4T trigger mode. 3. Welding function button: Press it to select No Pulse/ Pulse/ Spot welding function. (Here is no Spot function in Lift TIG welding mode.) 4.
Page 23: Tig Pulse Display Introduction
INSTALLATION & OPERATION §3.2.4 TIG PULSE display introduction 1. Peak current: 3~200A. 2. Base current: 3~200A, but less than Peak current. 3. Pulse frequency: 0.5~999Hz. 4. Pulse width: 5~95%. §3.2.5 TIG Spot display introduction 1. Current display: 3~200A. 2. T display: 0.2~1.0s.
Page 24: Job Program Introduction
INSTALLATION & OPERATION §3.2.6 JOB Program introduction 1. Welding mode display: Here are selected welding states. 2. Parameters display: Here are all selected parameters values. 3. JOB number: A total 1~10 JOB numbers can store or call the selected parameters by JOB button.
Page 25: Installation & Operation For Mma Welding
INSTALLATION & OPERATION §3.3 Installation & Operation for MMA welding §3.3.1 Set up installation for MMA Welding Connection of Output Cables Two sockets are available on this welding machine. For MMA welding the electrode holder is shown be connected to the positive socket, while the earth lead (work piece) is connected to the negative socket, this is known as DCEP.
Page 26: Operation For Mma Welding
INSTALLATION & OPERATION welding power cable connected to the appropriate position, not to pick the wrong voltage; (5) With the corresponding input power supply terminal or socket good contact and prevent oxidation; (6) With a multi meter measure the input voltage is within the fluctuation range; (7) The power ground is well grounded.
Page 27: Mma Welding
INSTALLATION & OPERATION §3.3.3 MMA Welding One of the most common types of arc welding is manual metal arc welding (MMA) or stick welding. An electric current is used to strike an arc between the base material and a consumable electrode rod or ‘stick’. The electrode rod is made of a material that is compatible with the base material being welded and is covered with a flux that gives off gaseous vapours that serve as a shielding gas and providing a layer of slag, both of which protect the weld area from atmospheric contamination.
Page 28: Mma Welding Fundamentals
INSTALLATION & OPERATION core wire melts and is deposited into the welding pool. The covering on a shielded metal arc welding electrode is called Flux. The flux on the electrode performs many different functions. These include: ● producing a protective gas around the weld area ●...
Page 29 INSTALLATION & OPERATION  Welding Current (Amperage) Electrode Size Current Range ø mm (Amps) 2.5 mm 60~95 3.2 mm 100~130 4.0 mm 130~165 5.0 mm 165~260 Correct current selection for a particular job is an important factor in arc welding. With the current set too low, difficulty is experienced in striking and maintaining astable arc.
Page 30: Installation & Operation For Tig Welding
INSTALLATION & OPERATION  Travel Speed The electrode should be moved along in the direction of the joint being welded at a speed that will give the size of run required. At the same time, the electrode is fed downwards to keep the correct arc length at all times. Excessive travel speeds lead to poor fusion, lack of penetration etc, while too slow a rate of travel will frequently lead to arc instability, slag inclusions and poor mechanical properties.
Page 31: Dc Tig Welding
INSTALLATION & OPERATION tighten it. (2) Plug the welding torch into the negative socket on the front panel, and tighten it. (3) Connect the gas line of TIG Gun to outlet gas connector on the front of the machine. (4) Connect the control cable of torch switch to 12 pin socket on the front of the machine.
Page 32: Tig Welding Fusion Technique
INSTALLATION & OPERATION DC TIG welding is a process in which an arc is struck between a TUNGSTEN electrode and the metal work piece. The weld area is shielded by an inert gas flow to prevent contamination of the tungsten, molten pool and weld area. When the TIG arc is struck the inert gas is ionized and superheated changing its molecular structure which converts it into a plasma stream.
Page 33 INSTALLATION & OPERATION combining thin materials can be accomplished without filler metal like edge, corner, and butt joints. This is known as Fusion welding where the edges of the metal pieces are melted together using only the heat and arc force generated by the TIG arc. Once the arc is started the torch tungsten is held in place until a weld pool is created, a circular movement of the tungsten will assist is creating a weld pool of the desired size.
Page 34: Tungsten Electrodes
INSTALLATION & OPERATION §3.4.4 Tungsten Electrodes Tungsten is a rare metallic element used for manufacturing TIG welding electrodes. The TIG process relies on tungsten’s hardness and high-temperature resistance to carry the welding current to the arc. Tungsten has the highest melting point of any metal, 3,410 degrees Celsius.
Page 35 INSTALLATION & OPERATION the Material Safety Data Sheet (MSDS) for its use. E3 (Color Code: Purple) E3 tungsten electrodes (AWS classification EWG) contain a minimum of 98% percent tungsten and up to 1.5 percent Lanthanum and small percentages of Zirconium and Yttrium they are called E3 Tungsten.
Page 36: Tungsten Preparation
INSTALLATION & OPERATION excellent re-ignition characteristics. Lanthanated tungsten also share the conductivity characteristics of 2 percent thoriated tungsten. Lanthanated tungsten electrodes are ideal if you want to opti-mise your welding capabilities. They work well on AC or DC electrode negative with a pointed end, or they can be balled for use with AC sine wave power sources.
Page 37 INSTALLATION & OPERATION Tungsten electrodes are manufactured with the molecular structure of the grain running lengthwise and thus grinding crosswise is “grinding against the grain.” If electrodes are ground crosswise, the electrons have to jump across the grinding marks and the arc can start before the tip and wander.
Page 38: Operation Environment
INSTALLATION & OPERATION • Last Longer • Have better weld penetration • Have a narrower arc shape • Can handle more amperage without eroding. Sharper electrodes with smaller included angle provide: • Offer less arc weld • Have a wider arc •...
Page 39: Operation Notices
INSTALLATION & OPERATION §3.6 Operation Notices  Read §1 carefully before attempting to use this equipment.  Connect the ground wire with the machine.  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 40: Maintenance & Troubleshooting
MAINTENANCE & TROUBLESHOOTING §4 Maintenance & Troubleshooting §4.1 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 welding machine,...
Page 41: Troubleshooting
MAINTENANCE & TROUBLESHOOTING Observe that whether the fast connector is loose or overheated. If the arc welding machine has the above problems, it should be fastened or changed. Observe that whether the current output cable is damaged. If it is damaged, it should be wrapped up, insulated or changed.
Page 42 MAINTENANCE & TROUBLESHOOTING Troubles Reasons Solution displayed doesn’t the control board. accord with the set Adjust potentiometer in the The min value is not accordant value. current meter. no-load voltage The machine is damaged Check the main circuit output (MMA) The welding cable is not connected Connect the welding cable to with the two output of the welder.
Page 43: Mma Welding - Trouble Shooting
MAINTENANCE & TROUBLESHOOTING §4.3 MMA Welding - Trouble Shooting The following chart addresses some of the common problems of MMA welding. In all cases of equipment malfunction, the manufacturer’s recommendations should be strictly adhered to and followed. Trouble Possible Reason Suggested Remedy Check earth lead is connected.
Page 44: Dc Tig Welding - Trouble Shooting
MAINTENANCE & TROUBLESHOOTING Reduce the amperage or use a Excessive heat input smaller electrode Use the correct welding technique or Distortion − Poor welding technique seek assistance for the correct movement of base technique metal during Check the joint design and fit up, welding Poor joint preparation and or make sure the material is not too...
Page 45 MAINTENANCE & TROUBLESHOOTING Gas is connected, valve ON, check hoses, gas valve and torch are not Wrong gas/ poor gas flow/ gas restricted. Set the gas flow between leak 20~40 CFH (6~12 l/min). Check hoses and fittings for leaks Porosity - poor weld Remove moisture and materials like appearance and Contaminated base metal...
Page 46 MAINTENANCE & TROUBLESHOOTING Incorrect machine set up Check machine set up is correct Check the gas is connected and cylinder valve open, check hoses, gas No gas, incorrect gas flow valve and torch are not restricted. Set the gas flow between 20~40 CFH flow Arc difficult to start or will not start DC rate...
Page 47: List Of Error Code
MAINTENANCE & TROUBLESHOOTING §4.5 List of error code Error Type Error code Description Over-heating (1st thermal relay) Over-heating (2nd thermal relay) Thermal relay Over-heating (3rd thermal relay) Over-heating (4th thermal relay) Over-heating (Program in default) Phase loss No water No gas Welding machine Under voltage Over voltage...