ionTig 200 Pulse PFC ionTig 200 Pulse PFC INVERTER - DC PULSED TIG WELDER OPERATION MANUAL 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. Copyright © Mundaka Welding & Gases, Inc.
ionTig 200 Pulse PFC CONTENT 1. SAFETY ............................................................................................................................................ 3 1.1 Signal Explanation............................................................................................................................ 3 1.2 The Knowledge of Electric and Magnetic Fields ............................................................................ 6 2. Overview .......................................
ionTig 200 Pulse PFC 1. SAFETY 1.1 Signal Explanation Welding may damage your body or others, so please take protection measure in operation. Only ones who are trained professionally can install, debug, operate, maintain and repair the equipment. Do not maintain and repair the machine when the machine is connected with power. THE ROTATING PARTS MAY BE DANGEROUS Keep all equipment safety guards, covers and devices in position and in good repair.
ionTig 200 Pulse PFC FUMES AND GASES CAN BE DANGEROUS Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone.
ionTig 200 Pulse PFC ELECTRIC SHOCK CAN KILL. Never touch electrical parts. Wear dry, hole-free gloves and clothes to insulate yourself. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground. Take carefully when using the equipment in small place, falling-off and wet circumstance. Never close the machine power before installation and adjustment.
ionTig 200 Pulse PFC Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situation. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside.
ionTig 200 Pulse PFC conclusion, we should minimize exposure to EMF as few as possible. In order to minimize EMF, we should use the following procedures: Route the electrode and work cables together – Secure them with tape when possible. All cables should be put away and far from the operator. Never coil the power cable around your body. Make sure welding machine and power cable to be far away from the operator as far as possible according to the actual circumstance.
ionTig 200 Pulse PFC ionTig 200 Pulse PFC Characteristics: DC Pulsed TIG and MMA, adopt IGBT and advanced PWM technology High performance MCU, Digital control, Digital display Preset all parameters with hold process HF/Lift TIG, current down slope and up slope, gas post-flow, Pulse Frequency Intelligent protection: over-voltage, under-voltage, over-current, over-heat 1. For MMA, polarity connection can be chosen according to different electrodes，please refer to §3.5； 2.
ionTig 200 Pulse PFC MMA——Manual Metal Arc welding PWM——Pulse-Width Modulation IGBT——Insulation Gate Bipolar Transistor TIG——Tungsten Insert Gas welding 2.2 Working Principle The working principle of TP- series welding machines is shown as the following figure.
ionTig 200 Pulse PFC 2.3 Volt-Ampere Characteristic ionTig 200 Pulse PFC welding machine has an excellent volt-ampere characteristic, whose graph is shown as the following figure. The relation between the conventional rated loading voltage U2 and the conventional welding current I2 is as follows: When I2≤600A，U2=10+0.04I2(V); When I2¬＞600A,U2=34(V). Copyright © Mundaka Welding & Gases, Inc.
ionTig 200 Pulse PFC 3. Installation and Adjustment 3.1 Parameters Models TIG 200 DC PULSE PFC Parameters Input power Single phase,110V,50/60Hz Single phase,220V, 50/60Hz TIG MMA TIG MMA Rated input current（A） 24.5 33 20 32 Rated input power（KW） 2.7 3.6 4.4 7 Power factor Welding current range（A） Max no-load voltage(V) 0.99 0.99 5～120 5～200 24 66 24 ≥85％ Efficiency 66 ≥85％ Duty cycle （ 40 ℃ ， 10 90% 120A 60% 120A 50% 200A 35% 200A minutes） ，see §3.
ionTig 200 Pulse PFC 3.2 Duty cycle and 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. The relation between the duty cycle “X” and the output welding current “I” is shown as the right figure.
ionTig 200 Pulse PFC the right position. When the machine gets to the destination, it needs to be fixed up to avoid gliding. When using forklift, its arm length must be long enough to reach the outside so as to ensure lifting safely. The movement may result in the potential danger or substantive hazard, so please make sure that the machine is on the safe position before using it. 3.4 Power supply input connection ionTig 200 Pulse PFC welding machines’ power supply connects to 220V.
ionTig 200 Pulse PFC 3.6 Assembling the equipment (TIG) Work piece 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. The control cable of torch switch consists of 2 wires, pedal control of 3 wires and the aero socket has 14 leads.
ionTig 200 Pulse PFC (1) Positive output: The welder’s positive polarity output. (2) Negative output: The welder’s negative polarity output. (3) 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）. (4) Shield gas connector: Is connected to the gas input pipe of torch. (5) Power source switch: Switch to “ON”, the welder is turned on, while switch to “OFF”, the welder is turned off.
ionTig 200 Pulse PFC -shown on the display during welding. The illustration below shows an overview of the main settings needed for day-to-day working, using the TIG 200 DC PULSE control panel as an example. You will find a detailed description of these settings in the following section.
ionTig 200 Pulse PFC Is Starting current (only with 4T) Unit A Setting range 5—100%of main current Iw Factory setting Tup Upslope time Unit S Setting range 0.0—2.0 Factory setting Iw Welding current Unit A TIG 200 DC PULSE TIG 200 DC PULSE PFC TIG 180 DC PULSE PFC 5—200； 5—200； 5—180； Ib Base current Unit A TIG 200 DC PULSE 5—200； TIG 200 DC PULSE PFC 5—200； TIG 180 DC PULSE PFC 5—180； Important! Only selectable when “pulse key” has been pressed.
ionTig 200 Pulse PFC Unit Setting range Factory setting S 0—10 Ic Crater arc current (only with 4T) Unit S Setting range 5—100% of main current Iw ； Factory setting Tpo Gas post-flow time Unit S Setting range 0.0—10.0 Factory setting (3) Rod electrode (MMA) welding parameter Parameter Arc force Hot start (4) Power/Alarm indicator Setting range 0-10 0-10 Light up if the welder overheat.
ionTig 200 Pulse PFC NOTE: Only the Iw of TIG or the welding current of MMA can be adjust when welding. 4.3 Argon Arc Welding Operation 4.3.1 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.
ionTig 200 Pulse PFC t4： Repress down the gun switch, the output current slopes down to crater current; if the output pulse function is turned on, the slope down current is pulsed; t4～t5： Down slope time, adjustment rang of down slope time: 0~10.0S; t5～t6： Crater current holds time; adjustment range of crater current: 5~180A (200A); t6： Loosen the gun switch, stop arc, and keep on argon flowing; t6～t7： Post flow time, adjustment range of post flow time: 0.0～10.
ionTig 200 Pulse PFC t4～t5： Post flow time, adjustment range of post flow time: 0.0～10.0S; t5： Electromagnetic valve is closed and stop argon flowing. Welding is finished. Short circuit protect function： (1) TIG /LIFT：If the tungsten electrode touches the workpiece when welding, the current will drop to 5A, which can reduce the tungsten spoilage，prolong the using life of the tungsten electrode and prevent tungsten clipping.
ionTig 200 Pulse PFC electrode during the ignition. 4.4 Welding Parameters 4.4.1 Joint forms in TIG/MMA a butt joint b lap joint c coner joint d T joint 4.4.
ionTig 200 Pulse PFC 4.4.3 TIG Parameters Matching The corresponding relationship between gas nozzle diameter and electrode diameter Gas nozzle diameter/mm Electrode diameter/mm 6.4 0.5 8 1.0 9.5 1.6 or 2.4 11.1 3.2 Notice: the above parameters originate from《Welding Dictionary》P142, Volume 1 of Edition 2.
ionTig 200 Pulse PFC TIG of stainless steel (single run welding) Workpiece thickness /mm Joint form tungsten electrode diameter/mm welding wire diameter/mm Argon gas flow rate/ L·min-1 welding current (DCEP) Welding speed/ cm·min-1 0.8 Butt joint 1.0 1.6 5 20～50 66 1.0 Butt joint 1.6 1.6 5 50～80 56 1.5 Butt joint 1.6 1.6 7 65～105 30 1.5 Corner joint 1.6 1.6 7 75～125 25 2.4 Butt joint 1.6 2.4 7 85～125 30 2.4 Corner joint 1.6 2.4 7 95～135 25 3.
ionTig 200 Pulse PFC 273 2.5 8～10 2.5 110～ 125 14～16 12～14 5～6 325 2.5 8～10 2.5 120～ 140 14～16 12～14 5～6 Notice: the above parameters originate from《Welding Dictionary》P167, Volume 1 of Edition 2. 4.5 Operation Environment ● Height above sea level is below 1000m. ● Operation temperature range:-100C～+400C. ● Relative humidity is below 90 % (200C). ● Preferably site the machine some angles above the floor level, the maximum angle does not exceed 150.
ionTig 200 Pulse PFC ● Turn off the engine when the operation finished to economize energy source. ● When power switch shuts off protectively because of failure. Don’t restart it until problem is resolved. Otherwise, the range of problem will be extended. 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.
ionTig 200 Pulse PFC Observe that whether the display value of LED is intact. If the display number is not intact, please replace the damaged LED. If it still doesn’t work, please maintain or replace the display PCB. Observe that whether the min/max value on LED accords with the set value. If there is any difference and it has affected the normal welding craft, please adjust it. Checkup that Whether fan is damaged and is normal to rotate or control. If the fan is damaged, please change immediately.
ionTig 200 Pulse PFC Maintenance course must be operated carefully.
ionTig 200 Pulse PFC S/N Troubles Reasons The HF igniting board does not work. There is not spark on the The distance between the discharger HF igniting is too short. board. The malfunction of the welding gun switch.
ionTig 200 Pulse PFC 5.3 Electrical principle drawing Copyright © Mundaka Welding & Gases, Inc.
