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Precision TIG375PACDC Operator's Manual

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TIG375PACDC(E20401)
MODEL:
E20401 SC-A0

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Summary of Contents for Precision TIG375PACDC

  • Page 1 TIG375PACDC(E20401) MODEL: E20401 SC-A0...
  • Page 3 Thanks for your purchase of this series of welder products! This series of products are safe, reliable, firm, durable, convenient to maintain, and capable of greatly raising the welding productivity. This user’s manual contains important information on use, maintenance and safety of the product.
  • Page 4 CONTENTS 1. SAFETY................................- 4 - 2. SYMBOL EXPLANATION...........................- 6 - 3. PRODUCT OVERVIEW..........................- 7 - 4. FUNCTION OVERVIEW..........................- 7 - 5. PERFORMANCE CHARACTERISTICS....................- 8 - 6. OUTPUT VOLT-AMPERE CHARACTERISTICS.................. - 10 - 7. ORDER INFORMATION...........................- 10 - 8. TECHNICAL PARAMETERS........................- 11 - 9.
  • Page 5 14.1 Pedal Remoter Operation......................- 34 - 15. MAINTENANCE............................- 34 - 16. TROUBLESHOOTING........................... - 35 - 16.1 Common Malfunction Analysis and Solution................- 35 - 16.2 Alarm and Solutions (Table 16-3)....................- 37 - 16.3 Spare Parts List for Maintenance....................- 38 - APPENDIX A: PACKING, TRANSPORTATION AND STORAGE............
  • Page 6 1. SAFETY Welding may result in injury to you and others, so please implement protection during welding. See more details in Safety Protection Guidebook for Operator which meets the requirements to manufactures on accident prevention. Operate this equipment by trained professional only! ...
  • Page 7 Hot workpiece can cause severe scald.  Do not touch hot workpiece with bare hands.  Cool the welding torch for a while after continuously working. Excessive noise does great harm to people’s hearing.  Wear ear covers or other hearing protectors when welding. ...
  • Page 8 2. SYMBOL EXPLANATION Cautions in operation Items need special instruction It’s forbidden to dispose electric waste together with other ordinary waste. Please take care of our environment. - 6 -...
  • Page 9 The integration of unique electric structure with air channel design in TIG375PACDC series can speed up the heat dissipation of the power device, so that to improve duty cycle. The unique air channel heat dissipation efficiency can...
  • Page 10  Excellent insulating property.  Three proofing design; fine antistatic and anticorrosion performance.  Optimized auto protection  TIG375PACDC is of optimized auto protection function. When there is large scale voltage - 8 -...
  • Page 11 fluctuation, welder will shut off automatically and display the failure information; welder will restart when network voltage is stable. Welder will shut off in case of over-current, over-heat, or other abnormities, and display the according failure information. Multi protections largely prolong welder’s lifespan.
  • Page 12 All other welding parameters are within the curve range. Please note the volt-ampere characteristics curves of various welding modes in below. Note: Lift arc is not a standard function but instead is depending on customer’s actual requirements. 7. ORDER INFORMATION Function Production Model Code TIG375PACDC E20401 - 10 -...
  • Page 13 8. TECHNICAL PARAMETERS Model TIG375PACDC Rated input power supply AC220V±15% AC440±15% Input frequency（Hz） 50/60 Rated input peak current（A） Rated Power capacity（KVA） Output current 10-200A 10-300A range（A） 5-275A 5-375A No load voltage(V) Pre-blow time（S） Initial current（A) 5-275A 5-375A AC output frequency（Hz）...
  • Page 14 9. ELECTRICAL SCHEMATIC DIAGRAM Fig 9.1 - 12 -...
  • Page 15 10. OPERATION DESCRIPTION 10.1 Machine appearance description Operation panel: function selection and parameters setting Argon gas connector Negative output terminal: to connect earth clamp or welding torch Positive output terminal: to connect holder clamp Torch switch aviation socket Handle 7. Mains input: input cable 8.
  • Page 16 10.2 Panel description ： Tig/MM Digital AC/DC Panel/Remote Pulse A Switch Meter Switch Switch Switch Peak Current Frequenc Post Pulse Backgroun Frequency Balanc 10.3 Welding Mode Description 10.3.1 MMA Fig 10.4Current and Voltage Change during MMA - 14 -...
  • Page 17 Note: t0—Standby: No welding current; output voltage is the no-load voltage. t1—Arc ignition: Welding current is arc ignition current (I1). t3—Arc burning: Welding current is the preset current (I2). t4—Short-circuit transfer: Welding current is the short-circuit transfer current (I3). In SMAW mode, 4 parameters that can be adjusted directly and 1 parameter that can only be adjusted through programming are available for this machine.
  • Page 18 50～90 22～24 80～120 23～25 100～140 24～26 140～160 26～28 10.3.2 DC TIG welding Fig 10.5 DC TIG Current Change Waveform In DC TIG mode, 8 adjustable parameters are available for this machine. Describe them as below.  Current (I3): This parameter can be set according to users’ own technical requirements. ...
  • Page 19  Tungsten Electrodes Selection: see details in Table 4.2 Table 4-2 TIG Process Specification Reference Table Electrode Recommended Welding Current （mm） （A） 5～30 20～90 45～135 70～180 130～200 10.3.3 Pulsed TIG welding Fig 10.6 DC Pulse TIG Current Change Waveform In pulsed TIG mode, all DC TIG parameters except current (I3) and another 4 adjustable parameters are available for this machine.
  • Page 20 I0-Initial current, I1-Welding current, I2-Pilot arc current, tu-Upslope time, td-Downslope time tp-AC period, tc-Cathode current time Fig 10.7 AC Square Wave TIG Current Change Waveform In AC square wave TIG welding, the pre-flow time and post-flow time are the same with those in DC TIG welding, and others are described as below.
  • Page 21 tc-Cathode current time, tp-AC period Tp-Pulsed peak current time, T-Pulse period Fig 10.8 AC Pulse TIG Current Change Waveform AC pulsed TIG welding is almost the same as AC square wave TIG welding, and what makes them different is that in AC pulsed TIG welding, the welding current varies with the pulse and peak current and base current are generated because the welding current is controlled by a low frequency pulse.
  • Page 22 Mode Operation Torch trigger operation and current curve 1T/Spot welding mode: Push the torch trigger: arc is ignited and current rises to the preset value. When the spot welding time is up, current drops gradually, and arc stops. Note: Spot welding time is 1/10 of the upslope time. Standard 2T mode: Push the torch trigger: arc is ignited and current rises gradually.
  • Page 23 11. INSTALLATION & OPERATION Notice: Please install the machine strictly according to the following steps. Turn off the power supply before any electric connection operation. IP21 enclosure protection grade, and please do not operate it in rain. 11.1 Installation Please connect the primary power line to the according voltage class. Please make sure the power line is connected to the right voltage class.
  • Page 24 Fig 11.1 MMA Sketch Map 3) Please connect earth clamp t welder’s “+” and torch connect to welder’s “-“before TIG operation( as shown in Fig 11.2). No PC is permitted or else welding can not processed normally. Connect torch control cable to according connector and choose the proper welding mode per workpiece material and check if the Tungsten electrode is in match with panel’s Tungsten electrode parameters and current parameters.
  • Page 25 11.3 TIG Welding Torch Standard Torch model：WP-18 Max current：375A Rated current：350A Cooling type ： water Gas connector：M10×1.0 Rated duty circle：35% Welding torch accessory 1. Long handle cover 2. Tungsten needle 3. Tungsten electrode clamp 4. Torch head 5. Tungsten electrode clamp 6.
  • Page 26 12. CAUTION 12.1 Working Environment 1) Welding should be carried out in dry environment with humidity of 90% or less. 2) The working environment temperature should be between -10℃ and 40℃. 3) Avoid welding in the open air unless sheltered from sunlight and rain. Keep welder dry . 4) Avoid welding in dusty area or environment with corrosive chemical gas.
  • Page 27 13. BASIC KNOWLEDGE OF WELDING 13.1 Basic knowledge of MMA Manual metal arc welding (MMA) is an arc welding by manually operating electrode. MMA requires simple equipment and is a convenient, flexible and adaptive welding processing type.MMA is applied to various metal materials with thickness more than 2mm. It’s suitable for various material structures, particularly to workpiece with complex structure and shape, short weld joint or bending shape, as well as weld joints in various spatial locations.
  • Page 28 conveniently. c) Slag hammer (peen hammer): for the use of removing slag crust on the surface of weld joint. d) Wire brush: for the use of removing dirt and rust at the joints of the workpiece before welding, as well as cleaning the surface of weld joint and the spatter after welding.
  • Page 29 light striking to form short circuit, and then quickly lift the electrode 2~4mm away to ignite arc. If arc ignition fails, it is probably because there is coating at the end of the electrode, which affects the electric conduction. In this case, the operator can strongly knock the electrode to remove the insulation material until the metal surface of the core wire can be seen.
  • Page 30 6) Arc extinguishing Arc extinguishing is unavoidable during welding. Poor arc extinguishing may bring shallow weld crater and poor density and strength of weld metal by which cracks, air holes, slag inclusion and shortage the like are easy to be produced. Gradually pull the end of the electrode to the groove and raise the arc when extinguishing arc, in order to narrow the weld crater and reduce the metal and heat.
  • Page 31 Fig.13.7 Sketch map of TIG Since argon is a kind of inert gas and it does not react with metals, the alloying elements in the weld metal will not be burned out and the metal molten pool can be fully protected from oxidation. Besides, because argon is insoluble in liquid metal at high temperature, air holes can be avoided in weld bead.
  • Page 32 welding torch, the maximum welding current is 100A. And the welding current can reach up to 400~600A for large-type welding torch with water cooling. The torch body is pressed from nylon, so it is light, small-sized, insulated and heat-resistant. The torch nozzle plays an important part in the protective performance of argon. The common nozzle shapes are shown in Fig.
  • Page 33 Welding arc can be better protected and the consumption of shield gas can be reduced in flat position welding. As inert gas, argon does not react with metal chemically even under high temperature. Thus, the alloying elements will not be oxidized or burned out, and problems caused accordingly will be avoided.
  • Page 34 13.2.5 Welding process parameters The gas protective effect, welding stability and weld bead quality of GTAW has direct relationship with the welding process parameters. Therefore, select appropriate welding process parameters to ensure high quality weld joint. The welding process parameters for GTAW include type and polarity of current, diameter of tungsten electrode, welding current, argon gas flow, welding speed and process factors, etc.
  • Page 35 Generally, the nozzle diameter should be within 5~20mm, the distance between the nozzle and workpiece should not be greater than 15mm, the stick-out should be 3~4mm, and the filling wire diameter should be selected according to the thickness of workpiece. 13.2.6 General requirements for TIG 1) The control of gas: Pre-flow and post-flow are required in TIG.
  • Page 36 14. OPTIONAL ACCESS OPERATION DESCRIPTION 14.1 Pedal Remoter Operation Pedal remoter control internal structure is composed by inching switch and sliding potentiometer, as shown in below Fig 14.1. Fig 14.1 Pedal Remote Controller Pedal controlling function is mainly used while it’s under TIG mode. ●...
  • Page 37 The following operation requires professional knowledge on electric application and comprehensive safety knowledge. Operators should be licensed with related qualification certificates (still in validation) which can prove their skills and knowledge. Make sure the power supply is cut off before uncovering the welding machine.
  • Page 38 Difficult arc Low arc ignition current or Adjust (increase) the arc ignition current and ignition short ignition time. time. Over arc ignition or Ignition current is too big or Adjust (decrease) the arc ignition current and over-size ignition time is too long. time.
  • Page 39 Reverse connection Over burning welding torch and ground Exchange the two plugs’ position of tungsten cable electrode. Clearing intensity is too big Decrease the clearing intensity 1.make sure the argon cylinder valve is open and has enough pressure. If the internal pressure is lower than 0.5Mpa, please refill the gas.
  • Page 40 Error Welder Type Alarm Reason Solutions code reaction Do not power off; restart welding Overheat when the overheat indicator stop indicator Temporary lighting up. Over lights up Over-working E - 1 close and there of main circuit -heat main circuit is alarm sound Please...
  • Page 41 Table 16.1 Table 16-4 Material Material Name Material Material Name Code Code 10046896 Handle 10071559 Reactor 10047353 Plastic parts 10073949 Contactor 10084999 Cover 10072246 Capacitor 10004938 Switch 10066501 Inverter board 10056165 Display panel 10071836 10047339 Plastic parts 51000022 Valve 10084760 Front panel 10068600 Tank outlet...
  • Page 42 APPENDIX A: PACKING, TRANSPORTATION AND STORAGE A1. Packing Name Unit Quantity E20401 User’s manual Volume Product certificate Sheet Warranty card Sheet Desiccant Pack Ground clamp： Piece 500A-35mm2-KDP50A(3M) A2. Transportation Equipment should be handled with care in transportation to avoid severe impact. Equipment should be prevented from being affected with damp and caught in the rain in transportation.
  • Page 43 APPENDIX C: WIRING DIAGRAM OF COMPLETE MACHINE E20401 Wiring Diagram - 41 -...

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E20401