Top Gun Welding GTAW 215E AC/DC Inverter Ac Dc Pulsed TIG Welder User Manual

Top Gun Welding GTAW 215E AC/DC Inverter Ac Dc Pulsed TIG Welder

Product Information

• Product Name: Inverter AC/DC Pulsed TIG Welder
• Model: GTAW 215E AC/DC
• Manufacturer: Unknown
• Date of Manual: 201406

Product Usage Instructions

Safety Precautions

• Read the entire owner’s manual before using the equipment.
• Keep the manual handy for quick reference.
• Pay attention to the safety instructions provided.
• Contact your distributor if you have any doubts or questions.

Electric Shock Prevention

• Never touch the electrical parts of the welder.
• Wear dry, hole-free gloves and clothes to insulate yourself.
• Insulate yourself from work and ground using dry insulation.
• Ensure the insulation is large enough to provide adequate protection.
• Maintain the electrode holder, work clamp, welding cable, and welding machine in good operating condition.
• Replace damaged insulation immediately.
• Avoid dipping the electrode in water for cooling.
• Never simultaneously touch electrically hot parts of electrode holders connected to two welders.
• When working above floor level, use a safety belt to protect against falls in case of a shock.

Fumes and Arc Rays Protection

• Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc.
• Wear suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.
• Protect other nearby personnel with suitable, non-flammable screening or warn them not to watch the arc or expose themselves to the arc rays or hot spatter.

Self-Protection

• Keep all equipment safety guards, covers, and devices in position and good repair.
• Avoid placing hands, hair, clothing, and tools near V-belts, gears, fans, and other moving parts when starting, operating, or repairing equipment.
• Avoid putting your hands near the engine fan.
• Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.
• Do not add fuel near an open flame welding arc or when the engine is running.
• Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing in contact with hot engine parts and igniting.
• Do not spill fuel when filling the tank. If fuel is spilled, wipe it up and do not start the engine until fumes have been eliminated.

Fire and Explosion Prevention

• Use only compressed gas cylinders containing the correct shielding gas for the process used.
• Ensure regulators are properly operating and designed for the gas and pressure used.
  • Maintain hoses, fittings, etc. in good condition and suitable for the application.
• Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.
• Follow proper cylinder storage guidelines.

Signal Explanation

SAFETY

• The above signals mean a warning! Notice! Running parts and getting an electric shock or thermal parts will cause damage to your body or others. The corresponding notices are as follows. It is quite a safe operation after taking several necessary protection measures.

Arc Welding Damage

• The following signals and word explanations are to some damages to your body or others happening during the welding operation. While seeing these, please remind yourself or others to be dangerous.
• Only ones who are trained professionally can install, debug, operate, maintain, and repair the happening
• During the operation, non-concerned people should be lifted, especially equipment
• After shutting off the machine power, please maintain and examine the equipment according to 5 because of the DC voltage existing in the electrolytic capacitors.

ELECTRIC SHOCK CAN KILL

• Never touch electrical parts
• Wear dry, hole-free gloves and clothes to insulate
• Insulate yourself from work and ground using dry Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
• Take care when using the equipment in small places, when it falls off, and in wet circumstances.
• Never close the machine power before installation and adjustment.
• Ensure to installation of the equipment correctly and ground the work or metal to be welded to a good electrical (earth) ground according to the operation manual.
• The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate your hands.
• In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle, or semiautomatic welding gun are also electrically “hot”.
• Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.
• Maintain the electrode holder, work clamp, welding cable, and welding machine in good, safe operating condition. Replace damaged insulation.
• Never dip the electrode in water for cooling
• Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because the voltage between the two can be the total of the open circuit voltage of both welders.
• When working above floor level, use a safety belt to protect yourself from a fall should you get a shock

FUMES AND GASES CAN BE DANGEROUS

• Welding may produce fumes and gases hazardous 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. When welding with electrodes that require special ventilation such as stainless or hard facing or on lead or cadmium plated steel and other metals or coatings that produce highly toxic fumes, keep exposure as low as possible and below Threshold Limit Values using local exhaust or mechanical ventilation. In confined spaces or some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.
• Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products.
• Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to ensure breathing air is safe.
• Read and understand the manufacturer’s instructions for this equipment and the consumables to be used, including the material safety data sheet, and follow your employer’s safety practices

ARC RAYS CAN BURN

• Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding.
• Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.
• Protect other nearby personnel with suitable, non-flammable screening and /or warn them not to watch the arc nor expose themselves to the arc rays or hot spatter or metal.

SELF-PROTECTION

• Keep all equipment safety guards, covers, and devices in position and in good Keep hands, hair, clothing, and tools away from V-belts, gears, fans, and all other moving parts when starting, operating, or repairing equipment.
• Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

DO NOT

DO NOT add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing in contact with hot engine parts and igniting. Do not spill fuel when filling the tank. If fuel is spilled, wipe it up and do not start the engine until the fumes have been eliminated.

WELDING SPARKS can cause fire or explosion

• Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.
• Where compressed gases are to be used at the job site, special precautions should be taken to prevent hazardous situations.
• 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 ensure that such procedures will not cause flammable or toxic vapors from substances They can cause an explosion even though they have been “cleaned”.
• Vent hollow castings or containers before heating, cutting or They may explode.
• Sparks and spatter are thrown from the welding arc. Wear oil-free protective garments such as leather gloves, heavy shirts, cuffless trousers, high shoes, and a cap over your Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.
• Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables, or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

Rotating parts may be dangerous

• 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.
• Always keep cylinders in an upright position securely chained to an undercarriage or fixed
• Cylinders should be located:
  • Away from areas where they may be struck or subjected to physical
  • A safe distance from arc welding or cutting operations and any other source of heat, sparks, or  source
• Never allow the electrode, electrode holder, or any other electrically “hot” parts to touch a cylinder
• Keep your head and face away from the cylinder valve outlet when opening the cylinder
• Valve protection caps should always be in place and hand-tight except when the cylinder is in use or connected for use.

The knowledge of Electric and Magnetic Fields
Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). The discussion on the effect of EMF is ongoing all over the world. Up to now, no material evidence shows that EMF may have effects on health. However, the research on the damage of EMF is still ongoing. Before any conclusion, we should minimize exposure to EMF as few as possible.

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 the welding machine and power cable are as far away from the operator as possible according to the actual circumstance.
• Connect the work cable to the workpiece as close as possible to the area being welded.
• The people with heart pacemakers should be away from the welding area.

SUMMARY

Brief Introduction
GTAW 200P AC/DC 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 to replace the traditional hulking work frequency transformer with the cabinet medium frequency transformer. Thus, it is characterized as portable, small in size, lightweight, low consumption, etc.

The parameters of GTAW 200P AC/DC on the front panel all can be adjusted continuously and steplessly, such as start current, crater arc current, welding current, base current, duty ratio, upslope time, downslope time, pre- gas, post-gas, pulse frequency, AC frequency, balance, hot start, arc force, and arc length, etc. When welding, it takes high frequency and high voltage for arc igniting to ensure the success ratio of igniting arc.

GTAW 200P AC/DC Characteristics：

• MCU control system, responds immediately to any changes
• High frequency and high voltage for arc igniting to ensure the success ratio of igniting arc, the reverse polarity ignition ensures good ignition behavior in TIG-AC welding.
• Avoid AC arc-break with special means, even if arc-break occurs the HF will keep the arc stable
• Pedal control of the welding current
• TIG/DC operation, If the tungsten electrode touches the workpiece when welding, the current will drop to a short-circuit current to protect the tungsten.
• Intelligent protection: over-voltage, over-current, over-heat, When the problems listed before occur, the alarm lamp on the front panel will be on and the output current will be cut off. It can self-protect and prolong the user’s life.
• Double purposes: AC inverter TIG/MMA and DC inverter TIG/MMA, Excellent performance on Al-alloy、carbon steel、stainless steel、

According to choosing the front panel functions, the following six welding ways can be realized.

• DC MMA
• DC TIG
• DC Pulse TIG
• AC MMA
• AC TIG
• AC Pulse TIG

1. For DC MMA, polarity connection can be chosen according to different electrodes， please refer to §3.5；
2. For AC MMA, magnetic flow caused by invariable DC polarity can be avoided；
3. For DC TIG, DCEP is used normally (workpiece connected to positive polarity, while torch connected to negative polarity). This connection has many characteristics, such as stable welding arc, low tungsten pole loss, more welding current, narrow and deep weld;
4. For AC TIG (rectangle wave), the arc is more stable than Sine AC TIG. At the same time, you can not only obtain the maximum penetration and the minimum tungsten pole loss but also obtain better clearance
5. DC Pulsed TIG has the following characteristics: 1) Pulse heating. Metal in the Molten pool has a short time on the high-temperature status and freezes quickly, which can reduce the possibility of producing hot cracks of the materials with thermal sensitivity. 2) The workpiece gets little heat. Arc energy is focused. It is suitable for thin sheet and super thin sheet welding. 3) Exactly control heat input and the size of the molten pool. The depth of penetration is even. Be suitable for welding by one side and forming by two sides and all position welding for pipe. 4) High-frequency arc can make metal for microlite fabric, eliminate blowholes, and improve the mechanical performance of the joint. 5) High-frequency arc is suitable for high welding speed to improve productivity.

TIG 200E AC/DC-series welding machine is suitable for all positions welding for various plates made of stainless steel, carbon steel, alloyed steel, titanium, aluminum, magnesium, cup rum, etc., which is also applied to pipe installment, mold mend, petrochemical, architecture decoration, car repair, bicycle, handicraft, and common manufacture.

• MMA: Manual Metal Arc welding;
• PWM: Pulse-Width Modulation;
• IGBT: Insulation Gate Bipolar Transistor
• TIG: Tungsten Insert Gas welding

Module Explanation
The module explanation of the arc welding machine must accord with the correlative prescripts of National Standard GB10249. It is explained as the following (take WSME-200 as an example).

Working Principle
The working principle of GTAW 200P AC/DC welding machines is shown in the following figure. Single-phase 220V work frequency AC is rectified into DC (about 312V), then is converted to medium frequency AC (about 20KHz) by inverter device (IGBT module), after reducing the voltage by a medium transformer (the main transformer) and rectifying by medium frequency rectifier (fast recovery diodes), then is outputted DC or AC by selecting IGBT module. The circuit adopts current feedback control technology to ensure current output is stable. Meanwhile, the welding current parameter can be adjusted continuously and steplessly to meet the requirements of welding craft

Volt-Ampere Characteristic
GTAW 200P AC/DC welding machine has an excellent volt-ampere characteristic, whose graph is shown in 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).

Installation and Adjustment

Parameters

Models

Parameters

| GTAW 200 AC/DC| GTAW 200P AC/DC
---|---|---
Input power  (V)| 1~220/230/240±10%| 1~220/230/240±10%
Free. （HZ）| 50/60HZ| 50/60HZ

Rated input current（A）

| 30.5（AC TIG）

28.3（DC TIG）

| 39.1（AC MMA）

40.7（DC MMA）

| 30.5（AC TIG）

28.3（DC TIG）

| 39.1（AC MMA）

40.7（DC MMA）

Rated input power （r KW）

| 6.1（AC TIG）

6.4（DC TIG）

| 8.6（AC MMA）

8.9（DC MMA）

| 6.1（AC TIG）

6.4（DC TIG）

| 8.6（AC MMA）

8.9（DC MMA）

Duty cycle（40℃， 10 minutes）

| AC TIG| MMA ＆DC TIG| AC TIG| MMA ＆DC TIG
35% 200A| 40% 170A| 35% 200A| 40% 170A
60% 155A| 60% 140A| 60% 155A| 60% 140A
100% 120A| 100% 110A| 100% 120A| 100% 110A
No load voltage (V)| 52| 52
Adjustment     range     of

welding current（A）

| ****

10～200（AC TIG）

| 10～170

( MMA ＆DC TIG)

| ****

10～200（AC TIG）

| 10～170

( MMA ＆DC TIG)

Downslope（S）| 0～10| 0～10
Post flow （S）| 0～10| 0～10
Pulse frequency（HZ）| /| 0.5~200
AC frequency（HZ）| 60| 60
Pulse width range（%）| /| 5~95
Clearance effect（%）| 15～50| 15～50
Efficiency（%）| ≥85| ≥85
Power factor| 0.6| 0.6
Cooling| AF| AF
Protection class| ****

IP23

| ****

IP23

Insulation class| H| H
Dimensions of Machine

（L×W×H）（mm）

| ****

480X150X310

| ****

480×150×310

Weight(Kg)| ****

7.0

| ****

7.0

Duty cycle and overheat
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 in the right figure.

If the welder is over-heat, the IGBT over-heat protection unit inside it will output an instruction to cut output welding current and brighten the over-heat pilot lamp on the front panel. At this time, the machine should be relaxed for 15 minutes to cool the fan. When operating the machine again, the welding output current or the duty cycle should be reduced

Movement and placement

• Please take care of the welder when moving it, and do not make it sloped.
• It also can be moved by the handle on the top of the welder. Place the welder well when moving it to the right position. When the machine gets to the destination, it needs to be fixed up to avoid gliding.
• When using a forklift, its arm length must be long enough to reach the outside to ensure lifting safely.
• The movement may result in potential danger or substantive hazard, so please make sure that the machine is in a safe position before using it.

Power supply input connection

• GTAW 200P AC/DC: Welding machines’ power supply connects to 220V.

When the power supply voltage is over the safe work voltage, there are over voltage and under voltage protection inside the welder, the alarm light will be on, and at the same time, the current output will be cut off. If the power supply voltage continually goes beyond the safe work voltage range, it will shorten the welder’s life span. The below measures can be used:

• Change the power supply input net. Such as connecting the welder with the stable power supply voltage of the distributor
• Induce the machines using a power supply at the same time;
• Set the voltage stabilization device in front of the power cable input.

Polarity Connection MMA

• MMA (DC) : Choosing the connection of DCEN or DCEP according to the different electrodes.
  Please refer to the electrode manual.

• MMA (AC) : No requirements for polarity connection.

Assembling the equipment (TIG)

• The workpiece is connected to the positive electrode of the welding machine, and the welding torch is connected to the negative electrode, which is called a DC POSITIVE CONNECTION; otherwise, that is called a DC NEGATIVE CONNECTION. Generally, it is usually operated in DC POS ITIVE CONNECTION in TIG welding mode.
• The control cable of the torch switch consists of 2 wires, the pedal control of 3 wires, and the aero socket has 14 leads.
• Consumable parts for the TIG torch, such as tungsten electrode tip gas nozzle electrode shield(short/long), please enquire us by mail or phone according to the accessory codes.
• When GTAW 200P AC/DC welding machines are operated in the HF ignition method, the ignition spark can cause interferences in equipment near the welding machine. Be sure to take special safety prprecautions or shielding measures

Operation

Layout for the panel

• Positive output The welder’s positive polarity output.
• Negative output The welder’s negative polarity output.
• The Aero socket Is connected to the torch switch control wire. （It has 14 leads and leads 8 – lead 9 are connected to the torch switch control wire）.
• The shield gas connector Is connected to the gas input pipe of the torch.
• Power source switch Switch to “ON”, the welder is turned on, while the switch to “OFF”, the welder is turned off.
• Power source input To connect the power source.
• Shield gas input joint To connect one head of the gas hose while the other head is connected to the argon gas cylinder

Control panel

• SIM-GTAW 200P AC/DC
• GTAW 200P AC/DC

Pedal switch control

• When plugging the fourteen-lead aero-socket of the pedal switch in it. Welder will identify the pedal switch, the welding current knob on the front panel will can’t use， and only 2T can be selected.
• When using the adjustment knob of the max-welding current beside the pedal, can set the max-current you want.
• The eighth and ninth of the fourteen-lead aero-socket is a gun switch; The first and second of the fourteen-lead aero-socket are short circuit; The third、fourth and fifth of the fourteen-lead aero-socket are pedal adjustable resistance

Gun switch control current

Argon Arc Welding Operation

TIG welding 4T operation
The start current and crater current can be pre-set. T his function can compensate for the possible crater that appears at the beginning and end of the welding. Thus, 4T is suitable for the welding of medium-thickness plates.

Introduction

• 0: Press and hold the gun switch, The Electromagnetic gas valve is turned on. The shielding gas stars to flow;
• 0～t1: Pre-gas time (0.1~1S);
• t1～t2: Arc is ignited at t1 and then output the setting value of start current;
• t2 Loosen the gun switch, the output current slopes up from the start current;
• t2～t3: The output current rises to the setting value (Iw or Ib), the upslope time can be adjusted;
• t3～t4: Welding During this period, the gun switch is loosened;

Note: Select the pulsed output, the base current and welding current will be outputted alternately; otherwise, output the setting value of the welding current;

• t4: Press the torch switch again, the welding current will drop by the selected down-slope time.
• t4～t5: The output current slopes down to the crater The downslope time can be adjusted;
• t5～t6: The crater’s current time;
• t6: Loosen the gun switch, stop the arc, and keep on argon flowing;
• t6～t7: Post-gas time can be set by the post-gas time adjustment knob on the front pane（l 10S）0.1～
• t7: Electromagnetic valve is closed and stop argon Welding is finished.

TIG welding (2T operation)
This function without the adjustment of start current and crater current is suitable for Re-tack welding、transient welding、thin plate welding and so on.

Introduction:

• 0: Press the gun switch and hold it. The electromagnetic gas valve is turned on. The shielding gas starts to flow.
• 0～t1 : Pre-gas time (0.1~1s)
• t1～t2 : Arc is ignited and the output current rises to the setting welding current (Iw or Ib) from the min welding current.
• t2～t3: During the whole welding process, the gun switch is pressed and held without current.

Note : Select the pulsed output, the base current and welding current will be outputted alternately; otherwise, output the setting value of the welding current;

• t3: Release the gun switch, the welding current will drop by the selected down-slope time.
• t3～t4: The current drops to the minimum welding current from the setting current (Iw or Ib), and then the arc is turned off.
• t4～t5: Post-gas time, after the arc is turned off. You can adjust it (0.1~10s) by turning the knob on the front panel.
• t5: The electromagnetic gas valve is turned off, the shield gas stops flowing, and welding is

Short circuit protection function

1. TIG /DC/LIFT: If the tungsten electrode touches the workpiece when welding, the current will drop to 20A, which can reduce the tungsten spoilage farthest， prolong the using life of the tungsten electrode， and prevent tungsten clipping.

2. TIG /DC/HF: If the tungsten electrode touches the workpiece when welding, the current will drop to 0 within 1s, which can reduce the tungsten spoilage farthest， prolong the using life of the tungsten electrode， and prevent tungsten clipping.

3. MMA operation: If the electrode touches the workpiece over two seconds, the welding current will drop to 0 automatically to protect the electrode.
   Prevent arc-break function: TIG operation Avoid arc-break with special means, even if arc-break occurs the HF will keep the arc stable

4. TIG: If the TIG torch is pressed quickly, the welding current will drop a half, then if the TIG torch is pressed quickly again, the welding current will get back.

Notices:

• Check the condition of welding and connection units first, otherwise, there will be malfunctions such as ignition spark、gas leakage、out of control, and so on.
• Check whether there is enough Argon gas in the shield gas cylinder, You can test the electromagnetic gas valve through the switch on the front panel.
• Do not let the torch aim at your hand or else of your body. When you press the torch switch, the arc is ignited with a high-frequency, high-voltage spark, and the ignition spark can cause interferences in equipment.
• The flow rate is set according to the welding power used in the job. Turn the regulation screw to adjust the gas flow which is shown on the gas hose pressure meter or the gas bottle pressure
• The spark ignition works better if you keep the 3mm distance from the workpiece to the tungsten electrode during the ignition.

Note : When selecting AC output, the current and the waveform are as same as the above, but output polarity changes alternately

Welding Parameters

Joint forms in TIG/MMA

• Butt joint
• Lap joint
• Corner joint
• T joint

The explanation of welding quality

The relation of welding area color & protection effect of stainless steel

Welding area

color

| argent, golden| blue| red-grey| grey| black
---|---|---|---|---|---
Protect effect| best| better| good| bad| worst

The relation of welding area color & protection effect of Ti-alloy

Welding area

color

| bright argent| orange-yellow| blue-purple| caesious| white powder of

titanium oxide

---|---|---|---|---|---
Protect effect| best| better| good| bad| worst

TIG Parameters Matching

The corresponding relationship between gas nozzle diameter and electrode diameter

Notice: The above parameters originate from《Welding Dictionary》P142, Volume 1 of

Edition 2.

The gas nozzle and the shield gas flow rate

Welding current range/A

| DC positive connection| AC
---|---|---
Gas nozzle

diameter/mm

| Gas flow

rate/L·min-1

| Gas nozzle

diameter/mm

| Gas flow

rate/L·min-1

10～100| 4～9.5| 4～5| 8～9.5| 6～8
101～150| 4～9.5| 4～7| 9.5～11| 7～10
151～200| 6～13| 6～8| 11～13| 7～10
201～300| 8～13| 8～9| 13～16| 8～15

Notice : The above parameters originate from《Welding Dictionary》P149, Volume 1 of Edition 2.

tungsten electrode

diameter /mm

| sharpened of the

electrode diameter/mm

| angle of cone（°）| background current/A
---|---|---|---
1.0| 0.125| 12| 2～15
1.0| 0.25| 20| 5～30
1.6| 0.5| 25| 8～50
1.6| 0.8| 30| 10～70
2.4| 0.8| 35| 12～90
2.4| 1.1| 45| 15～150
3.2| 1.1| 60| 20～200

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
3.2| Butt joint| 1.6| 2.4| 7| 100～135| 30
3.2| Corner

joint

| 1.6| 2.4| 7| 115～145| 25
4.8| Butt joint| 2.4| 3.2| 8| 150～225| 25
4.8| Corner

joint

| 3.2| 3.2| 9| 175～250| 20

Notice : The above parameters originate from《Welding Dictionary》P150, Volume 1 of Edition 2.

Parameters of piping back sealing welding for mild steel DCEP

Piping diameter Φ/mm| Tungsten electrode diameter/mm|

Gas nozzle diameter/mm

| Welding wire diameter/mm|

Welding current/A

|

Arc voltage/V

| Argon flow rate

/

L·min-1

| Welding rate

/

cm·min-1

---|---|---|---|---|---|---|---
38| 2.0| 8| 2| 75～90| 11～13| 6～8| 4～5
42| 2.0| 8| 2| 75～95| 11～13| 6～8| 4～5
60| 2.0| 8| 2| 75～100| 11～13| 7～9| 4～5
76| 2.5| 8～10| 2.5| 80～105| 14～16| 8～10| 4～5
108| 2.5| 8～10| 2.5| 90～110| 14～16| 9～11| 5～6
133| 2.5| 8～10| 2.5| 90～115| 14～16| 10～12| 5～6
159| 2.5| 8～10| 2.5| 95～120| 14～16| 11～13| 5～6
219| 2.5| 8～10| 2.5| 100～

120

| 14～16| 12～14| 5～6
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.

Parameters of AC TIG (MMA) for Aluminum and its alloy

Sheet thickness

/mm

|

Welding wire diameter

/mm

|

Tungsten electrode diameter

/mm

|

Pre-heat Temper

-mature

/℃

|

Welding current

/A

| Argon flow rate

/ L·min-1

|

Gas nozzle diameter

/mm

|

Remark

---|---|---|---|---|---|---|---
1| 1.6| 2| －| 45～60| 7～9| 8| Flange welding

1.5

|

1.6～2.0

|

2

|

－

|

50～80

|

7～9

|

8

| Flange or butt welding by one

side

2| 2～2.5| 2～3| －| 90～120| 8～12| 8～12| Butt welding

3

|

2～3

|

3

|

－

| 150～

180

|

8～12

|

8～12

|

V-groove butt welding

4

|

3

|

4

|

－

| 180～

200

|

10～15

|

8～12

5

|

3～4

|

4

|

－

| 180～

240

|

10～15

|

10～12

6

|

4

|

5

|

－

| 240～

280

|

16～20

|

14～16

8

|

4～5

|

5

|

100

| 260～

320

|

16～20

|

14～16

10

|

4～5

|

5

| 100～

150

| 280～

340

|

16～20

|

14～16

12

|

4～5

|

5～6

| 150～

200

| 300～

360

|

18～22

|

16～20

14

|

5～6

|

5～6

| 180～

200

| 340～

380

|

20～24

|

16～20

16

|

5～6

|

6

| 200～

220

| 340～

380

|

20～24

|

16～20

18

|

5～6

|

6

| 200～

240

| 360～

400

|

25～30

|

16～20

20

|

5～6

|

6

| 200～

260

| 360～

400

|

25～30

|

20～22

16～20

|

5～6

|

6

| 200～

260

| 300～

380

|

25～30

|

16～20

|

X-groove butt welding

22～25

|

5～6

|

6～7

| 200～

260

| 360～

400

|

30～35

|

20～22

Notice : The above parameters originate from《Welding Dictionary》P538, Volume 2 of Edition 2.

Operation Environment

• Height above sea level is below 1000m
• Operation temperature range:-100C～+400
• The relative humidity is below 90 % (200C).
• Preferably site the machine some angles above the floor level, the maximum angle does not exceed 150.
• Protect the machine against heavy rain or in hot circumstances against direct
• The content of dust, acid, and corrosive gas in the surrounding air or substance can not exceed normal
• Take care that there is sufficient ventilation during There is at least 30cm free distance between the machine and the wall.

Operation Notices

• Read 1 carefully before attempting to use this equipment.
• Connect the ground wire with the machine directly, and refer to 3.5.
• In case of closing the power switch, the no-load voltage may not touch the output electrode with any part of your body.
• Before the operation, no concerned people should be Do not watch the arc with unprotected eyes.
• Ensure good ventilation of the machine to improve duty
• Turn off the engine when the operation finished to economize energy
• When the power switch shuts off protectively Don’t restart it until the problem is resolved. Otherwise, the range of problems will be extended.

Maintenance & Troubleshooting

Maintenance
To guarantee that an arc welding machine works highly efficiently and safely, it must be maintained regularly. Let customers understand the maintenance methods and means of arc welding machines more, enable customers to carry on simple examination and safeguarding by themselves, and try one’s best to reduce the fault rate and repair times of arc welding machines, to lengthen the service life of arc welding machines. Maintenance items in detail are in the following table.

Warning : For safety while maintaining the machine, please shut off the supply power and wait for 5 minutes, until the capacity voltage already dropped to the safe voltage of 36V!

Daily examination

| Observe whether the panel knob and switch in the front and at the back of the arc welding machine are flexible and put correctly in place. If the knob has not been put correctly in place, please correct it; If you can’t correct or fix the knob, please replace it immediately;

If the switch is not flexible or it can’t be put correctly in place, please replace it immediately; Please get in touch with the maintenance service department if there are no accessories.

After turning the power, watch/listen to whether the arc welding machine is shaking, whistle-calling, or having a peculiar smell. If there is one of the above problems, find out the reason to get rid of it; if you can’t find out the reason, Please contact the local area agent or the branch company.

Observe whether the display value of the 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 whether the min/max value on the LED accords with the set value. If there is any difference and it has affected the normal welding craft, please adjust it.

Check up that Whether fan is damaged and is normal to rotate or control. If the fan is damaged, please change immediately. If the fan does not rotate after the arc welding machine is overheated, observe whether there is something blocked in the blade, If it is blocked, please get rid of it; If the fan does not rotate after getting rid of the above problems, you can poke the blade by the rotation direction of fan. If the fan rotates normally, the start capacity should be replaced; If not, change the fan.

Observe whether the fast connector is loose or overheated. if the arc welding machine has the above problems, it should be fastened or changed.

Observe Whether the current output cable is damaged. If it is damaged, it should be wrapped up, insulated, or changed.

Monthly examination

| Using the dry compressed air to clean the inside of the arc welding machine. Especially for clearing up the dust on the radiator, main voltage transformer, inductance, IGBT module, the fast recovery diode, and PCB, etc.

Check up the bolt in the arc welding machine, if it is loose, please screw down it. If it is a skid, please replace it. If it is rusty, please erase the rust on the bolt to ensure it works well.

Quarter-yearly examination| Whether the actual current accords with the displaying value. If they do not accord, they should be regulated. The actual current value can be measured by the adjusted plier-type ampere meter.

Yearly examination

| Measure the insulating impedance among the main circuit, PCB, and case, If it is below 1MΩ, insulation is thought to be damaged and needs to change, and needs to change or strengthened insulation.

Troubleshooting

• Before arc welding machines are dispatched from the factory, they have already been debugged accurately. So forbid anyone who is not authorized by us to make any changes to the equipment!
• The maintenance course must be operated carefully. If any wire becomes flexible or is misplaced, it may be a potential danger to the user!
• Only professional maintenance personnel who are authorized by us can overhaul the machine!
• Guarantee to shut off the arc welding machine’s power before turning on the outline of the equipment!
• If there is any problem and there are no authorized professional maintenance personnel, please contact the local agent or the branch company!

If there are some simple troubles with the WSME-series welding machine, you can consult the following overhauling chart:

1

|

Turn on the power source, and the fan works, but the power pilot lamp is not on.

|

Is the power light damaged or connection is not good

|

Check and repair Pr7

The transformer of power is broken| Repair or change the transformer
Control PCB failures| Repair or change the control Pr4

2

|

Turn on the power source, and the power lamp is on, but the fan doesn’t work

| There is something in the fan| Clear out
The start capacitor of the fan damaged| Change capacitor
The fan motor damaged| Change fan

3

| Turn on the power source, the

The power lamp is not on, and the fan doesn’t work

| No power supply input| Check whether there is a power supply
The fuse inside the machine damaged| Change it (3A)

4

| The number on the display is not

intact.

|

The LED in the display is broken

|

Change the LED

5

|

The max and min value displayed doesn’t accord with the set value.

| The max value is not accordant (refer to

§3.1)

| Adjust the potentiometer Imin on the power

board.

The min value is not accordant (refer to §3.1)

| Adjust potentiometer Imaxin the current

meter.

6

| No     no-load     voltage     output

(MMA)

|

The machine is damaged

|

Check the main circuit and the Pr4.

7

|

Arc can not be ignited (TIG)

|

There is a spark on the HF igniting board.

| The welding cable is not connected to the

two outputs of the welder.

| Connect  the  welding  cable  to  the

welder’s output.

The welding cable was damaged.| Repair or change it.
The earth cable connected unstably.| Check the earth cable.
The welding cable is too long.| Use an appropriate welding cable.
There is oil or dust on the workpiece.| Check and remove it.
The distance between a tungsten electrode and

the workpiece is too long.

|

Reduce the distance (about 3mm).

There is no spark on the HF igniting board.

|

The HF igniting board does not work.

|

Repair or change Pr8

The distance between the discharger is too

short.

|

Adjust this distance (about 0.7mm).

The malfunction of the welding gun switch.

| Check the welding gun switch, control

cable and aero socket.

8

|

No gas flow (TIG)

|

The gas cylinder is closed or the gas pressure is low

|

Open or change the gas cylinder

Something in the valve| Remove it
The electromagnetic valve is damaged| Change it

9

|

Gas always flows

| The gas test on the front panel is on| The gas test on the front panel is off
Something in the valve| Remove it
The electromagnetic valve is damaged| Change it
The adjustment knob of pre-gas time on the

the front panel is damaged

|

Repair or change it

10

|

The welding current can not be adjusted

| The welding current potentiometer on the front panel  connection  is  not good  or

damaged

|

Repair or change the potentiometer

11

|

No AC output while selecting “AC”

| The power PCB is in trouble.| Repair or change it.
The AC drive PCB is damaged.| Change it.
The AC IGBT module is damaged.| Change it.

12

|

The welding current displayed isn’t accordant with the actual value.

| The minimum value displayed isn’t accordant with

the actual value. (Please refer to §3.1)

| Adjust the potentiometer Imin on the power

board.

The max value displayed isn’t accordant with

the actual value. (Please refer to §3.1)

| Adjust the potentiometer Imax on the power

board.

13

| The penetration of molten pool

is not enough.

| The welding current is adjusted too low| Increase the welding current
The arc is too long in the welding process| Use 2T operation

14

|

The alarm lamp on the front panel is on

|

Overheat protection

| Two much welding

current

|

Reduce the welding current output

Working  time  too

long

| Reduce      the      duty      cycle      (work

intermittently)

protection

| Power             supply

fluctuates

|

Using a stable power supply

Low-voltage protection

| Power             supply

fluctuates

|

Using a stable power supply

Too many machines

using a power supply at the same time

|

Reduce the machines using power supply at the same time

Over-current

protection

| Unusual current in

the main circuit

| Check and repair the main circuit and

drive Pr6

Electrical principle drawing

Documents / Resources

| Top Gun Welding GTAW 215E AC/DC Inverter Ac Dc Pulsed TIG Welder [pdf] User Manual
GTAW 215E AC DC Inverter Ac Dc Pulsed TIG Welder, GTAW 215E AC DC, Inverter Ac Dc Pulsed TIG Welder, Dc Pulsed TIG Welder, Pulsed TIG Welder, TIG Welder, Welder
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