GYS TITAN 400 DC Arc Welding Battery Chargers and Body Repair Instruction Manual

GYS TITAN 400 DC Arc Welding Battery Chargers and Body Repair

Specifications:

• Model: TITAN 400 DC
• Manufacturer: GYS
• Power Supply: 400 V
• Made in: France

Product Usage Instructions

Environment and Safety Precautions:
Before welding, ensure proper individual and environmental protection. Weld on a cart for convenience.

Fire and Explosion Risk:
Be cautious with gas cylinders to avoid fire hazards. Consider electromagnetic emissions.

Transport and Maintenance:
Handle the welding power source with care during transport. Follow maintenance advice provided in the manual.

User Interface (FIG-2):
Understand the functions, menus, and pictograms. Familiarize yourself with the various modes like TIG HF, TIG lift, MMA pulse setup, etc.

Accessories and Options:

• Chariot 10 m3 – Product code: 037328
• Cooling unit WCU1KW_C – Product code: 013537
• ABITIG liquid torches – 450 W – 8 m
• Manual RC-HA1 8 m – Product code: 045675
• Filter – Product code: 046580

Power On and Settings:
Ensure the power supply is connected correctly (400V) and follow instructions for setting up the welding parameters.

Welding Function Description:
Understand the different welding functions like MMA, TIG DC, post-gas, cold current, torch modes, purge gas, hot start, anti-sticking, etc.

FAQ:

• Q: What are the recommended safety precautions for using the TITAN 400 DC?
  A: Ensure proper individual and environmental protection before welding. Use on a stable surface or cart.

• Q: How should I handle gas cylinders to avoid fire hazards?
  A: Be cautious when handling gas cylinders and follow safety guidelines provided in the manual to prevent fire risks.

• Q: What are the key accessories available for the TITAN 400 DC?
  A: Accessories include a chariot, cooling unit, various torch options, manual welding handle, and filters.

TITAN 400 DC

WARNING – SAFETY RULES

GENERAL INSTRUCTIONS

Read and understand the following safety instructions before use.
Any modification or maintenance not specified in the instructions manual should not be undertaken.

The manufacturer is not liable for any injury or damage due to non-compliance with the instructions featured in this manual. In the event of problems or uncertainties, please consult a qualified person to handle the installation properly.

ENVIRONMENT

This equipment must only be used for welding operations in accordance with the limits indicated on the descriptive panel and/or in the user manual. Safety instructions must be followed. In case of improper or unsafe use, the manufacturer cannot be held liable. This equipment must be used and stored in a room free from dust, acid, flammable gas or any other corrosive agent. Operate the machine in an open, or well-ventilated area.

Operating temperature:

• Use between -10 and +40°C (+14 and +104°F).
• Storage between -20 and +55°C (-4 and 131°F).

Air humidity:

• Lower or equal to 50% at 40°C (104°F).
• Lower or equal to 90% at 20°C (68°F).

Altitude:

• Up to 1000 meters above sea level (3280 feet).

PROTECTION OF THE INDIVIDUALS

Arc welding can be dangerous and can cause serious and even fatal injuries. Welding exposes the user to dangerous heat, arc rays, electromagnetic fields, noise, gas fumes, and electrical shocks. People wearing pacemakers are advised to consult with their doctor before using this device. To protect oneself as well as the other, ensure the following safety precautions are taken:

****In order to protect you from burns and radiations, wear clothing without cuffs. These clothes must be insulated, dry, fireproof and in good condition, and cover the whole body.
Wear protective gloves which guarantee electrical and thermal insulation.
Use sufficient welding protective gear for the whole body: hood, gloves, jacket, trousers… (varies depending on the application/operation). Protect the eyes during cleaning operations. Do not operate whilst wearing contact lenses. It may be necessary to install fireproof welding curtains to protect the area against arc rays, weld spatters and sparks. Inform the people around the working area to never look at the arc nor the molten metal, and to wear protective clothes.
Ensure ear protection is worn by the operator if the work exceeds the authorised noise limit (the same applies to any person in the welding area).
Never remove the safety covers from the cooling unit when the machine is plugged in – The manufacturer is not responsible for any accident or injury that happens as a result of not following these safety precautions.
The pieces that have just been welded are hot and may cause burns when manipulated. During maintenance work on the torch or the electrode holder, you should make sure it’s cold enough and wait at least 10 minutes before any intervention. The cooling unit must be on when using a water cooled torch in order to ensure that the liquid does not cause any burns. ALWAYS ensure the working area is left as safe and secure as possible to prevent damage or accidents.

WELDING FUMES AND GAS

Fumes, gas and dust produced during welding are hazardous to health. It is mandatory to ensure adequate ventilation and/or extraction to keep fumes and gas away from the work area. Using an air fed welding helmet is recommended in case of insufficient ventilation in the workplace. Check that the air supply is effective by referring to the recommended safety regulations.

Precautions must be taken when welding in small areas, and the operator will need supervision from a safe distance. Welding certain pieces of metal containing lead, cadmium, zinc, mercury or beryllium can be extremely toxic.

The user will also need to degrease the workpiece before welding. Gas cylinders must be stored in an open or ventilated area. They must be stored vertically and held by a support or trolley to limit the risk of falling. Do not weld in areas where grease or paint are stored.

FIRE AND EXPLOSION RISKS

Protect the entire welding area. Flammable materials must be moved to a minimum safe distance of 11 meters. A fire extinguisher must be readily available near the welding operations.

• Be careful of weld spatter and sparks, even through cracks. If not careful then this could potentially lead to a fire or an explosion.
• Keep people, flammable materials/objects and containers that are under pressure at a safe distance.
• Welding in closed containers or pipes should be avoided and , if they are opened, they must be emptied of any flammable or explosive material (oil, fuel, gas …).  Grinding operations should not be carried out close to the power supply or any flammable materials.

GAS CYLINDERS

Gas leaking from the cylinders can lead to suffocation if present in high concentration around the work area (ventilation required). Transport must be done safely: cylinders closed and welding machine switched off. They must be stored vertically and held by a support to limit the risk of falling.

• Close the cylinder between two uses. Beware of temperature variations and sun exposure.
• The cylinder must not be in contact with a flame, electric arc, torch, earth clamp or all other sources of heat.
• Always keep gas cylinders away from electrical circuits, and therefore never weld a cylinder under pressure.
• Be careful when opening the valve on the gas bottle, it is necessary to remove the tip of the valve and make sure the gas meets your welding requirements.

ELECTRICAL SAFETY

The electrical mains used must have an earth terminal. Use the recommended fuse size. An electric shock could cause serious injuries or potentially even deadly accidents.

• Do not touch any live part of the machine (inside or outside) when it is plugged in (Torches, earth cable, cables, electrodes) because they are connected to the welding circuit.
• Before opening the device, it is imperative to disconnect it from the mains and wait 2 minutes, so that all the capacitors are discharged.
• Do not touch the torch or electrode holder and the earth clamp at the same time.
• Damaged cables and torches must be changed by a qualified and skilled professional. Make sure that the cable cross section is adequate with the usage (extensions  and welding cables). Always wear dry clothes which are in good condition in order to be isolated from the welding circuit. Wear insulating shoes, regardless of the workplace/environment in which you work in.

EMC CLASSIFICATION

This Class A machine is not intended to be used on a residential site where the electric current is supplied by the domestic low-voltage power grid. There may be potential difficulties in ensuring electromagnetic compatibility at these sites, due to conducted interferences as well as radiation.
This equipment does not comply with IEC 61000-3-12 and is intended to be connected to private low-voltage systems interfacing with the public power grid only at the medium- or high-voltage level. If it is connected to a public low-voltage power grid, the installer or user of the machine has to ensure, by checking with the network operator, that the device can be connected.

ELECTROMAGNETIC INTERFERENCES

The electric current flowing through any conductor causes electrical and magnetic fields (EMF). The welding current generates an EMF around the welding circuit and the welding equipment.

The EMF electromagnetic fields can interfere with certain medical implants, such as pacemakers. Protection measures must be taken for people having medical implants. For example, by restricting access to passers-by or conducting an individual risk evaluation for the welders.

All welders should take the following precautions in order to minimise exposure to the electromagnetic fields (EMF) generated by the welding circuit:

• position the welding cables together – if possible, attach them;
• keep your head and torso as far as possible from the welding circuit;
• never wrap the cables around your body;
• never position your body between the welding cables.s Hold both welding cables on the same side of your body;
• connect the earth clamp as close as possible to the area being welded;
• do not work too close to, do not lean and do not sit on the welding machine
• do not weld when you’re carrying the welding machine or its wire feeder.

People wearing pacemakers are advised to consult their doctor before using this device.
Exposure to electromagnetic fields while welding may have other health effects which are not yet identified.

RECOMMENDATIONS FOR WELDING AREA ASSESSMENT AND WELDING

Overview
The user is responsible for the installation and use of the arc welding equipment according to the manufacturer’s instructions. If electromagnetic disturbances are detected, the user is responsible for resolving the situation with the manufacturer’s technical assistance. In some cases, this corrective action may be as simple as earthing the welding circuit. In other cases, it may be necessary to construct an electromagnetic shield around the welding power source and around the entire piece by fitting input filters. In all cases, electromagnetic interferences must be reduced until they are no longer inconvenient.

Welding area assessment
Before installing the machine, the user must evaluate the possible electromagnetic problems that may arise in the area where the installation is planned. The following elements should be taken into account:

• the presence (above, below and next to the arc welding machine) of other power cables, remote cables and telephone cables;

• television transmitters and receivers;

• computers and other hardware;

• critical safety equipment such as industrial machine protections;

• the health and safety of the people in the area such as people with pacemakers or hearing aids;

• calibration and measuring equipment;

• the isolation of other pieces of equipment which are in the same area.
  The user has to ensure that the devices and pieces of equipment used in the same area are compatible with each other. This may require extra precautions;

• the time of day during the welding or other activities have to be performed.

The surface of the area to be considered around the device depends on the building’s structure and other activities that take place there. The area taken into consideration can be larger than the limits of the installations.

Welding area assessment
Besides the welding area assessment, the assessment of the arc welding systems installation itself can be used to identify and resolve cases of disturbances. The assessment of emissions must include in situ measurements as specified in Article 10 of CISPR 11. In situ measurements can also be used to confirm the effectiveness of mitigation measures.

RECOMMENDAED METHODS TO REDUCE ELECTROMAGNETIC EMISSIONS

• National power grid : the arc welding machine must be connected to the national power grid in accordance in accordance with the manufacturer’s recommendation. In case of interferences, it may be necessary to take additional precautions such as the filtering of the power supply network. Consideration should be given to shielding the power supply cable in a metal conduit or equivalent of permanently installed arc welding equipment. It is necessary to ensure the electrical continuity of the shielding along its entire length. The shielding should be connected to the welding current source to ensure a good electrical contact between the conduit and the casing of the welding current source.
• Maintenance of the arc welding equipment : The arc welding machine should be subject to a routine maintenance check according to the recommendations of the manufacturer. All accesses, service doors and covers should be closed and properly locked when the arc welding equipment is on. The arc welding equipment must not be modified in any way, except for the changes and settings outlined in the manufacturer’s instructions. The spark gap of the arc start and arc stabilization devices must be adjusted and maintained according to the manufacturer’s recommendations.
• Welding cables: Cables must be as short as possible, close to each other and close to the ground, if not on the ground.
• Equipotential bonding : consideration should be given to bonding all metal objects in the surrounding area. However, metal objects connected to the workpiece increase the risk of electric shock if the operator touches both these metal elements and the electrode. It is necessary to insulate the operator from such metal objects.
• Earthing of the welded part: When the part is not earthed – due to electrical safety reasons or because of its size and its location (which is the case with ship hulls or metallic building structures), the earthing of the part can, in some cases but not systematically, reduce emissions It is preferable to avoid the earthing of parts that could increase the risk of injury to the users or damage other electrical equipment. If necessary, it is appropriate that the earthing of the part is done directly, but in some countries rules may not allow such a direct connection, it is appropriate that the connection is made with a capacitor selected according to national regulations.
• Protection and shielding: The selective protection and shielding of other cables and devices in the area can reduce perturbation issues. The protection of the entire welding area can be considered for specific situations.

TRANSPORT AND TRANSIT OF THE WELDING MACHINE

The machine is equipped with two handles to facilitate transport, which requires two people. Be careful not to underestimate the weight of the machine.
Do not use the cables or torch to move the machine. The welding equipment must be moved in an upright position.

Do not place/carry the unit over people or objects. Never lift the machine while there is a gas cylinder on the support shelf. The transport rules applying to each item are different.

INSTALLATION

• Put the machine on the floor (maximum incline of 10°.)
• Provide an adequate area to ventilate the machine and access the controls.
• Do not use in an area with conductive metal dust.
• The machine must be placed in a sheltered area away from rain or direct sunlight.
• The equipment protection is rated IP23 meaning that : sensitive parts of the equipment are protected from objects with a diam >12.5 mm and, it is protected again rainfall with a 60° vertical incline.

The equipment can be used outside in accordance with the IP23 protection certification.
Power cables, extension leads and welding cables must be fully uncoiled to prevent overheating.

The manufacturer does not accept any liability in relation to damages caused to objects or harm caused to persons as the result of incorrect and/or dangerous use of the machine.

MAINTENANCE / RECOMMENDATIONS

• Maintenance should only be carried out by a qualified person. A yearly maintenance is recommended.
•  Ensure the machine is unplugged from the mains, and then wait 2 minutes before carrying out maintenance work. High Voltage and Currents inside the machine.
• Remove regularly the casing and any excess of dust. Take this opportunity to have the electrical connections checked by a qualified person, with an insulated tool.
• Regularly check the condition of the power supply cable. If the power cable is damaged, it must be replaced by the manufacturer, its after sales service or an equally qualified person to prevent danger.
• Ensure the vents of the device are not blocked to allow adequate air circulation.
• Do not use this equipment to thaw pipes, to charge batteries, or to start any engine.

INSTALLATION – PRODUCT OPERATION
Only qualified personnel authorised by the manufacturer should perform the installation of the welding equipment. During the installation, the operator must ensure that the machine is disconnected from the mains. Connecting generators in serial or in parallel is forbidden.

EQUIPMENT DESCRIPTION (FIG-1)

• The TITAN 400 DC provides Inverter welding current designed for electrode welding (MMA & TIG) in direct current (DC).
• The MMA process allows to weld all types of electrodes : rutile, basic, stainless and cellulosic.
• TIG welding requires gas shield protection of pure gas (Argon).

This material can be connected to a remote control (ref. 045675), a foot pedal (ref. 045682) or an automated system (CONNECT-5).

1. Keypad
2. Torch button connector
3. polarity plug
4. Torch gas connector
5. Wire feeder connector or MMI remote interface
6. Positive polarity plug
7. ON / OFF switch
8. Power supply cable
9. Remote controller connector
10. Gas bottle connector
11. USB connector for updates
12. Handles
13. Lifting eyes
14. Filter (option)

INTERFACE (MMI) (FIG-2)

1. Welding cycle (8 settings available)
2. Display
3. Gas purge
4. Welding processes
5. Trigger mode (button)
6. Sub-processes
7. Button to access JOB menu
8. Lock/unlock button
9. Special mode : E.TIG
10. Navigation and validation scrollwheel

ACCESSORIES AND OPTIONS

POWER SWITCH

• This equipment is supplied with a 3-phase 32A plug (3P+N+PE) of the type EN 60309-1 and needs to be powered by a 400V 3-phase EARTHED power supply (50 – 60 Hz). This machine must only be used with a three phase electricity supply system with four wires and one earthed neutral. The absorbed effective current (I1eff) is displayed on the machine, for optimal use. Check that the power supply and its protection (fuse and/or circuit breaker) are compatible with the current needed by the machine. In some countries, it may be necessary to change the plug to allow the use at maximum settings. The user has to make sure that the plug can be reached.
• The device turns into protection mode if the power supply tension is below or above the 15%. To indicate this default, the screen displays an error code.
• The start is done via an on / off switch (7) set to I, and the stop is done by switching it to O. Warning ! Never disconnect the power supply when the welding electrical distribution is in operation.
• Fan: in MMA mode, the fan works continuously. In TIG mode, the fan works only when welding, then stops after cooling.
• The arc priming and stabilisation device is designed for manual and mechanically guided operation.

CONNECTION TO A GENERATOR

The machine can work with generators as long as the auxiliary power matches these requirements :

• The voltage must be AC, always set as specified, and the peak voltage below 700V,
• The frequency must be between 50 and 60 Hz.
• It is imperative to check these requirements as certain generators can create high voltage peaks that can damage these machines.

USE OF EXTENSION LEADS

• All extension cables must have an adequate size and section, relative to the machine’s voltage. Use an extension lead that complies with national safety regulations.

| Current input| Thickness of the extension lead (Length < 45m)
---|---|---
TITAN 400 DC| 400 V| 6 mm²

TITAN 400 DC

ELECTRODE WELDING (MMA)

CONNECTIONS AND RECOMMENDATIONS

• Connect the electrode holder and earth clamp to the corresponding sockets.
• Ensure that the welding polarities and intensities indicated on the electrode packaging are observed.
• Remove the electrode from the electrode holder when the machine is not in use.
• The machine has 3 features exclusive to Inverters:
• The Hot Start creates an overcurrent at the beginning of the welding.
• The Arc Force creates an overcurrent which prevents the electrode from sticking to the weld pool.
• The Anti-Sticking technology makes it easier to unstick the electrode from the metal.

MMA WELDING PROCESSES

MMA STANDARD
The MMA STD mode is recommended for most applications. It can weld any type of electrode : rutile, basic, cellulosic… and on any material: steel, stainless steel, cast iron.

Process MMA STD

The grey areas are not useful for this mode.

| HotStart| Arc Force
---|---|---
Adjustable values| 0 – 100%| -10 à +10

Recommendations:

• Low Hot start, for thin sheets, high Hot start for difficult-to-weld metals (dirty or oxidised).
• The Arc Force is set between -10 and +10. It needs to be combined with the choice of type of electrodes selected in the Advanced Menu (refer to Advanced Menu section).
• MMA PULSE
  The MMA Pulsed mode is recommended for vertical-up welding (PF). The pulse mode keeps the weld pool cold and eases the transfer of matter. Wit-hout the pulse mode, vertical-up welding requires a difficult «Christmas tree» shape triangular movement.
  With the MMA Pulsed mode, this movement is no longer required and a simple straight up movement is enough (depending on the thickness of the workpiece). If you wish to widen your weld pool, a simple lateral movement is enough (similar to normal welding). In this case the pulse current frequency can be adjusted on the display. This process allows greater control during vertical- up welding.

Process MMA PULSE
The grey areas are not useful for this mode.

| HotStart| Arc Force| __

Cold current/Back- groundcurrent)

| __Pulse frequency
---|---|---|---|---
Adjustable values| 0 – 100%| -10 à +10| +20 – +80%| 0.4 – 20 Hz

Recommendations:

• Low Hot start, for thin sheets, high Hot start for difficult-to-weld metals (dirty or oxidised).
• The Arc Force is set between -10 and +10. It needs to be combined with the choice of type of electrodes selected in the Advanced Menu (refer to Advanced Menu section).

MMA – ADVANCED MENU

It is possible to access the end of welding cycle settings.
Access to these advanced parameters is possible via the menu Using the scroll- wheel, the available advanced settings are :

TUNGSTEN ELECTRODE WELDING WITH INERT GAS (TIG MODE)

CONNECTIONS AND RECOMMENDATIONS

• The TIG DC welding requires gas shield protection of pure gas (Argon).
• Connect the earth clamp to the positive connector (+). Connect the power cable to the negative plug (–), as well as the torch and the gas connec-tions.
• Ensure that the torch is equipped and ready to weld, and that the consumables (Vice grip, ceramic gas nozzle, collet and collet body) are not damaged.

SELECT IGNITION MODE

• TIG HF : High Frequency start without contact
• TIG LIFT : Contact start (for environments sensitive to HF disturbances).

1. Place the torch in welding position above the metal with a gap of roughly 2-3 mm.

2. Press the torch trigger (the arc starts without contact using High Frequency impulsions).

3. The initial welding current circulates, the welding carries on according to the welding cycle.

4. Position the torch nozzle and the tip of the electrode on the piece of metal and press the trigger.

5. Position the torch to create a gap of roughly 2-3 mm between the tip of the electrode and the metal. The arc starts.

6. Put the position back into position to start the welding cycle.

Warning : Increasing the length of the torch or earth return cables beyond the maximum length specified by the manufacturer will increase the risk of electric shock.

WELDING PROCESSES TIG STD or PULSE

TIG STANDARD
This welding mode in direct current (DC) is designed for ferrous metal such as steel, stainless steel or even copper and its alloys.

TIG STD PROCESS
The grey areas are not useful for this mode.

• PULSE TIG
  This pulse welding mode create alternative high current pulses (I, welding pulse) and low current pulses (I_cold, pulses to cool the piece). This pulse mode allows to assemble pieces while while keeping the machine cooler. The I welding current is set to a 100A and % (I_cold) = 50%, thus a Cold current of = 50% x 100A = 50A. F(Hz) is set to 10Hz, the signal period will be 1/10Hz = 100ms.
  Every 100ms, a 100A pulse then a 50A pulse will succeed each other

TIG PULSE PROCESS
The grey areas are not useful for this mode.

Advice :
The choice of frequency:

• If welding with TIG electrodes, then F(Hz) synchronised to the gesture,
• If thin plate without TIG electrodes (< 8/10 mm), F(Hz) >> 10Hz
• If special metal requiring a welding pool sweep for degassing, then F(Hz) >> 100Hz

TIG WELDING PROCESSES

• Spotting- SPOT
  This mode is recommended to pre-assemble workpieces before welding.
  The adjustable spot weld duration enables control of the weld time for better spot welding results and a non-oxidised spot (accessible via the advanced menu).

TIG SPOT PROCESS
The grey areas are not useful for this mode.

• Spotting – TACK (TIG DC)
  This mode can also pre-assemble workpieces, but in two phases : first phase is DC pulse which concentrates the arc for enhanced penetration, fol-lowed by a DC standard phase which enlarges the arc and the weld pool for a good spot.
  The adjustable duration of each phase enables control of the weld time for better spot welding results and a non-oxidised spot (accessible via the advanced menu).

TIG TACK Process
The grey areas are not useful for this mode.

• The mode E-TIG (Fig 2 – 9)
  This mode ensures that the power is stable throughout the weld by measuring the variations in arc length in real time. This is important to ensure a consistent penetration and weld bead. In case the assembly requires the welding power to be controlled, the E.TIG mode can be used as it is designed to ensure that the welding power remains the same regardless of the position of the torch.

TIG – ADVANCED MENU

• It is possible to access the end of welding cycle settings.
• Access to these advanced parameters is possible via the menu  Using the scroll-wheel, the available advanced settings are.

I Start

|

Current threshold when starting the weld.

|

10% – 200%

|

X

|

X

| | | This current threshold is a phase before the current upslope.

t Start

|

Time threshold when starting the weld.

|

0s – 10s

|

X

|

X

| |
I Stop|

Current threshold when the weld stops.

|

10% – 100%

|

X

|

X

| | | This current threshold is a phase before the current upslope.
---|---|---|---|---|---|---|---
t Stop|

Time threshold when the weld stops.

|

0s – 10s

|

X

|

X

| |
Shape (wave shape)|

Pulse with wave shape.

| Square Sinus Triangle

Trapeze

| |

X

| | | The square wave shape is the traditional shape for PULSE welding but it is noisy in high frequency. Other shapes can be used to adapt the penetration and the noise level.
t Pulse|

Pulse current spot wel- ding duration.

|

Manual,

0.1s – 10s

| | | |

X

|

The spot welding times allow to define a spot that can be reused over time.

tContinuous

|

Spot welding duration in continuous current.

|

Manual,

0.1s – 10s

| | |

X

|

X

COMPATIBLE TORCHES

For the 1 button torch , the button is called «main button».
For the 2 buttons torch , the first button is called «main button» and the second button is called «secondary button».

2T MODE

• T1 – The main button is pressed, the welding cycle starts (PreGas,
• I_Start, UpSlope and welding).
• T2 – The main button is released, the welding cycle is stopped (DownS-lope, I_Stop, PostGas).

4T MODE

• For the double button torch and in 2T mode only, the secondary button works like the main button.
• T1 – The main button is pressed, the cycle starts at PreGas and stops in the I_Start phase.
• T2 – The main button is released, the cycle continues in UpSlope and in welding.
• T3 – The main button is pressed, the cycle switches to DownSlope and stops in I_Stop.
• T4 – The main button is released, the cycle ends with PostGas.
• Nb : for torches, double button and double button with potentiometer => command « up/welding current » and active potentiometer, com-mand «low » inactive.

4T MODE

• T1 – The main button is pressed, the cycle starts at PreGas and stops in the I_Start phase.
• T2 – The main button is released, the cycle continues in UpSlope and in welding.
• LOG : this mode is used during welding :

4T MODE log

• A brief press of the main button (<0.5s), the current switches from I welding current to I cold and vice versa.
• the secondary button is kept pressed, the welding current switches from I welding current to I cold
• the secondary button is kept released, the welding current switched

For this mode it may be convenient to use the dual button torch option or dual button with potentiometer. The «up» command keeps the same func-tion as the single button or trigger torch. The «down» button can, when pressed, switch to the cold current. The potentiometer of the torch, where available, can control of the welding current from 50% to 100% of the value displayed.

RECOMMENDED COMBINATIONS

TIG DC| |

Current (A)

| ****

Electrode (mm)

| ****

Shroud (mm)

| ****

Argon flow rate (L/min)

---|---|---|---|---|---
0.3 – 3 mm| 3 – 75| 1| 6.5| 6 – 7
2.4 – 6 mm| 60 – 150| 1.6| 8| 6 – 7
4 – 8 mm| 100 – 200| 2| 9.5| 7 – 8
6.8 – 10 mm| 170 – 250| 2.4| 11| 8 – 9
9 – 12 mm| 225 – 330| 3.2| 12.5| 9 – 10
–| 275 – 450| 4| 15| 10 – 13

ELECTRODE GRINDING
To optimise the welding process, it is recommended to grind the electrode prior to welding as described below:

SAVE AND LOAD WELDING SETTINGS

• JOB IN / JOB OUT

The current settings are automatically saved and loaded at start up.
On top of the current settings, it is also possible to save and load the «JOB» settings. There are 50 JOBS by welding process, the memorisation applies to:

• The main setting,
• The secondary setting (MMA, TIG),
• The sub-processes and button modes.

Save a setting « JOB IN » :

• Press the button job (Fig 2 – 7), select using the scrollwheel
• Validate by pushing the SCROLLWHEEL BUTTON
• The screen flashes to point out a memory slot (01 to 50),
• Use the scrollwheel to select the destination memory slot
• Validate by pushing the SCROLLWHEEL BUTTON
• The choice is now saved and exit.

Recall an existing setting « JOB OUT » :

• Press the button , job select using the scrollwheel 
• Validate by pushing the SCROLLWHEEL BUTTON
• The screen flashes to point out a memory slot (01 to 50),
• Use the scrollwheel to select the destination memory slot
• Validate by pushing the SCROLLWHEEL BUTTON
• The choice is now saved and exit.

QUICK LOAD « q.L. » :

The Quick Load is a mode to recall a JOB (50 max) when not welding and only available when using TIG. The JOB recalls are done by holding and releasing the torch buttons for a brief moment (<0.5s).
Access to this mode is done by pressing the menu , job then the sub-menu . Deactivated by default , the user activates this mode by entering the last JOB number of the list to recall (the list starts at the first JOB). At least 2 JOBS must be saved prior to that.

Ex : if the JOBS 2, 5, 7 and 10 have been created and that the user has entered number 7, then the JOBS recalled will be 2, 5 and 7.
On activation of this mode, the first JOB is recalled and displayed on the screen (on this example : JOB2).
The different JOBs are queued in for recall : when the last JOB is reached, (for example : JOB7), the next JOB recalled will be the first one (on the example : JOB2).

Welding is activated by pressing the button for longer than 0.5s.

What is displayed by MMI interface:

• The JOB is displayed permanently as well as the settings (TIG LIFT/HF, 2T/ 4T../ Pulse/ Spot…).
• The cycle is accessible and amendable (the JOB can be changed*),
• The menus are accessible and are amendable. Example :
• JOB 5, amendable, SAVE IN / JOB 5, the JOB is saved and amended in line with the new settings entered.
• JOB 5, amendable, SAVE IN / JOB inexistent, it will be taken into account in the current q.L if and only if this new JOB X is below the number of the JOB entered.
• The recall of the JOB is inactive when navigating in the welding cycle or one of the two menus,
• A JOB is amended by action on the interface (welding settings, JOB recall…), the welding is authorised using the new settings entered. If a JOB recall is done, then the first JOB of the list if recalled.

CHAIN « Chn » :
The chain is a recall mode for complex JOBs (50 max) and only available when using the TIG STD and PULSE processes (all the JOBs defined in 2T are forced in 4T) :

• Outside . On reaching the last item in the list, the selection goes back to the first item.
• Welding is activated by pressing the top button for 0.5s where in the standard mode, it is activated by simply pressing this button.
• During welding, briefly releasing the buttons (less than 0.5s) allow to recall a consecutive and defined JOB number, also called sequence and starting from the JOB previously recalled when not welding.

Access to this mode is done by pressing the menu JOB , then the sub-menu . Deactivated by default , the user activates this
mode by entering a number of JOBS part of its sequence. At least 2 JOBS must be saved prior to that. Spot welding jobs (SPOT, TACK), are no longer part of the list of saved JOBS (they are transparent).

Ex : if the JOBS 1 to 50 have been created and the user has entered the number 3 in the sub-menu « C H n » :

• On activation of the sub-mode and when not welding, briefly releasing the torch button allows to show the JOBS one by one from the 1st to the 50th (going back to the beginning when JOB 100 is reached). Here the user displays the JOBS and chooses the 10.
• Pressing the button for over 0.5s allows to start welding with JOB 10 (first of the sequence) and briefly releasing it loads JOB 11 and then JOB 12 (these 3 JOBS make the sequence).
• When the welding stops, the JOB 10 is loaded and displayed on the interface (this saves the user the task of having to show all the JOBS again).

The MMI interface has these features:

• The JOB is displayed permanently as well as the settings (TIG LIFT/HF, 4T, Pulse…).
• The cycle is accessible and amendable (the JOB can be changed*),
• The menus are accessible and are amendable. Ex :
• JOB 5, amendable, SAVE IN / JOB 5, the JOB is saved and amended in line with the new settings entered.
• JOB 5, amendable, SAVE IN / JOB inexistent, it will be taken into account in the current q.L if and only if this new JOB X is below the number of the JOB entered.
• When currently browsing the welding cycle or one of the two menus, the JOB recall function is disabled.
• During welding, when recalling a JOB of the sequence, the screen displays JOB X for 1s.

A JOB is changed by action on the interface without saving, the welding is authorised without taking into account the modifications on the JOB recalled.

COMMAND BUTTON(S) CONNECTOR

Torch double button + potentiometer

|

Torch double button

|

Torch with trigger

| Common/Earth| 2
Button 1| 4
| Button 2| 3
| Common/Potentio- meter earth| 2
10 V| 1
Cursor| 5

REMOTE CONTROL

Connection :

1. Plug the remote control into the connection at the back of the machine.
2. The interface will detect automatically the remote control and open a selection menu :

A command is shown but not active.
Remote control with potentiometer selection.
Remote control with potentiometer selection

Pressing the scroll wheel validates the choice of type of remote controller and allows to go back to stand-by mode.
Connection

• The TIG 300 DC is equipped with a female socket for a remote control.
• The specific 7 pin male plug (option ref.045699) enables connection to the different types of manual remote control or foot pedal. For the cabling layout, please see the diagram below.

CONNECT-5

|

|

distance manuelle

| 10 V| A
Curseur| B
Commun/Masse| C
| Switch / Interrupteur| D
| AUTO-DETECT| E
ARC ON| F
REG I| G

Operating :

• Manual remote control (option ref. 045675).
  The remote control enables the variation of current from 50% to 100% of the set intensity In this configuration, all modes and functions of the machine are accessible and can be set.

• Foot pedal (option ref. 045682) :
  The pedal control enables variation of the current from the minimum current to 100% of the set intensity.
  In TIG, the welding machine only operates in 2T mode. The upslope and downslope are not automatically managed by the current source, and are controlled by the user with the foot pedal.

• CONNECT 5 – automaton mode :
  This mode enables to pilot the machine from a console or from an automaton using the 5 pre-saved programs.
  For the foot pedal, the «Switch (D)» enables to start or stop welding according to the chosen cycle. The voltage value for the «slider (B)» matches a program or the actual status.

The voltage must be between 0 and 10.0V by step of 1.6V matching program reminder :

• Current context : 0 – 1.6 V
• Program 1 : 1.7 – 3.3 V
• Program 2 : 3.4 – 5.0 V
• Program 3 : 5.1 – 6.6 V
• Program 4 : 6.7 – 8.3 V
• Program 5 : 8.4 – 10.0 V

An additional potentiometer enables to change the current (+/- 15%) either whilst welding or not.
The information ARC ON (arc presence) enables the automaton to synchronise itself (Pull Up 100k entry, automaton side).
Put the pin AUTO_DETECT to the earth enables to start the product without going through the selection window where you can select the type of remote control used.

• The 5 loaded settings correspond to the first 5 saved programs (P1 to P5).
• The signals’ I/O (input/output) are protected at 6.1V.
• Additional explanations are available on our website (https://goo.gl/i146Ma).

COOLING FAN

To minimise sound and dust aspiration, the station integrates a controlled fan system. The fan’s rotation speed depends on the temperature and the machine’s settings.

ACCESS TO SETUP MENU

Advanced MENU : MMA STD or PLS

MMA STD + MMA PLS Advanced MENU : TIG DC, PLS, SPOT and TACK

TIG DC + PLS TIG PLS only TIG SPOT TIG TACK

COOLING UNIT

The cooling unit is automatically detected by the machine. In the menu the cooling unit can be disabled in TIG mode.

Make sure that the cooling unit is turned off before disconnecting the inlet and outlet hoses for torch liquid. The coolant is harmful and irritates the eyes, the mucous membranes and the skin. Hot liquid may cause burns.

LOCK MODE

The LOCK feature will disable the knobs and keypad to prevent accidental changes in the settings. Pressing and holding the button  seconds (Fig 2 – 8) activates and displays  , the machine is then locked.
The buttons are not active, use the scrollwheel to adjust the current value previously set by a percentage related to the tolerance setting

To unlock the commands, press the button for 3 seconds, the display shows , then goes back to current display.

CALIBRATION

This mode is dedicated to the calibration of the welding accessories such as the torch, earth clamp and earth cable.
The calibration is designed to compensate variables such as the length of the accessories in order to adjust the measurement of the voltage and improves the calculation of the energy.

Use the menu to access the calibration.
The first step  requires short-circuiting the accessories. It is recommended in TIG to create the short-circuit between the torch nozzle support and the earth clamp or directly on the metal being welded on. Once the short-circuit is created, validate using the scroll-wheel.

The second step starts, a bar of progress is shown on the MMI display of the machine. Press the button on the torch to start the  circulation of the current for the calibration.

If the operation is successful, the machine leaves the mode directly and display the resistance value of the accessories shortly. This value is now taken into account when displaying the voltage and calculating the energy.

Otherwise, the machine leaves the menu directly with a long display of  . If the operation fails, the circuit was not done correctly and the calibration must be redone.

DISPLAY CURRENT/VOLTAGE DURING WELDING

• During welding, the machine measures and displays the welding current and voltage.
• After the weld, the average current and voltage values or the energy and duration of the welding bead are displayed until the interface (buttons or scrollwheel) are touched or if the weld resumes.
• Access to current / voltage or energy / duration configuration is available through the menu   

ENERGY MODE

This mode is designed for welding with energy control framed by a DMOS and allows, as well as displaying weld bead energy information, to set :

• The thermal coefficien in line with the standard used : 1 for standard ASME and 0.6 (TIG) or 0.8 (MMA) for the European standard. The energy displayed is calculated taking this coefficient into account.
• The length   (OFF – mm) : if a length is stored, then the energy is not shown in joule but in joule / mm (the unit displayed of the weld bead «J» flashes).

TROUBLESHOOTING

This device integrates a default management system. In the event of a default, error messages may be displayed.

WARRANTY

The warranty covers faulty workmanship for 2 years from the date of purchase (parts and labour).

The warranty does not cover:

• Transit damage.
• Normal wear of parts (eg. : cables, clamps, etc..).
• Damages due to misuse (power supply error, dropping of equipment, disassembling).
• Environment related failures (pollution, rust, dust).

In case of failure, return the unit to your distributor together with:

• The proof of purchase (receipt etc …)
• A description of the fault reported

SPARE PARTS

| TITAN 400 DC
---|---
1|  Keypad| 51962
2| Black button 28 mm| 73020
3| Screen protection| 56196
4|  Female / Conector Texas OF 95.24 HF Hembra / Texas OF

| 51502
5|  Torch connection cable| 91847
6| Acople gas BSP20| 55090

7

|  Wire feeder connector or MMI remote interface|

96000ST

8|  External protection grill| 56094
9| HF transformer| 63716
10|  Power transformer| 64667
11|  connection cable| 71483

 CIRCUIT DIAGRAM

TECHNICAL SPECIFICATIONS

 Primary

 Power supply voltage| 400V +/- 15%
 Mains frequency| 50 / 60 Hz
 Number of phases| 3
 Fuse| 32 A
Maximum effective supply current I1eff| 29 A
 Maximum supply current I1max| 37 A
 Mains cable section| 4 x 4.0 mm²
 Maximum active power consumed| 16 690 W
 Idle consumption| 37.0 W
Efficiency at I2max| 87 %
Power factor at I2max (λ)| 0.75
EMC class| A
Secondary| MMA| TIG
 No load voltage| 85 V
 Manual striking system’s maximum voltage (EN60974-3)|

9 kV

 Type of welding current| DC
Welding modes| MMA, TIG
Minimum welding current| 5 A| 3 A
 Normal current output (I2)| 5 – 400 A| 3 – 400 A
 Conventional voltage output (U2)| 20.2 V – 36 V| 10.12 V – 26 V
Norme EN60974-1.

Duty cycle at 40°C (10 min)
Standard EN60974-1. Einschaltdauer @ 40°C (10 min) EN60974-1 -Norm.

Ciclo de trabajo a 40°C (10 min)*

Norma EN60974-1

| ПВ% при 40°C (10 мин)* Норма EN60974-1.

Inschakelduur bij 40°C (10 min)*

Norm EN60974-1.

Ciclo di lavoro a 40°C (10 min)*

Norma EN60974-1.

Cykl pracy w 40°C (10 min)*

Norma EN60974-1.

| Imax| 60 %
60%| 400 A

100%

|

360 A

Functionning temperature| -10°C  +40°C
 Storage temperature| -20°C  +55°C
Protection level| IP23
 Minimum coil insulation class| B
Abmessung (LxBxH) / Dimensiones (Lxlxh)| 76 x 30 x 53 cm
Weight| 40 kg

• The duty cycles are measured according to standard IEC 60974-1 à 40°C and on a 10 min cycle.
• While under intensive use (> to duty cycle) the thermal protection can turn on, in that case, the arc swictes off and the indicator switches on.
• Keep the machine’s power supply on to enable cooling until thermal protection cancellation.
• The machine has a specification with a “dropping current output”.

SYMBOLS

****|

• Warning ! Read the instructions manual before use.

---|---

|

• Inverter technology welding current source delivering direct current.

****|

•  MMA welding (Manual Metal Arc)

****|

•  TIG welding (Tungsten Inert Gaz)

| Suitable for welding in an environment with an increased risk of electric shock.
|

• Direct welding current

U0| Off load voltage
Up| Allocated peak voltage

X(40°C)

|

• Duty cycle according to standard IEC 60974-1 (10 minutes – 40°C).

I 2|  I2: Corresponding conventional welding current
A|  Amperes
U 2|  U2: Conventional voltage in corresponding loads.
V| Volt
Hz| Hertz

|

• Three-phase power supply 50 or 60Hz

U 1|

• Rated power supply voltage

I1max

|

• Maximum rated power supply current (effective value)

• Device(s) compliant with European directives

IEC 60974-IEC 60974 -10Class A|

• This welding machine is compliant with standard IEC 60974-1/-3/-10 of class A.

**** IEC 60974-3|

• This welding current source is compliant with standard IEC 60974-3.

|

• This hardware is subject to waste collection according to the European directives 2002/96/UE. Do not throw away in a household bin!

****|

• This product should be recycled appropriately

|

• EAEC Conformity marking (Eurasian Economic Community)

| | |
**| The declaration Cم (CMIM) of conformity is available on our website (see cover page).

**|

• Equipment in compliance with British requirements.

****|

•  Temperature information (thermal protection)

****|

• Gas input

****|

• Gas output

****|

• Remote control

• 1, rue de la Croix des LandesCS 54159

• 53941 SAINT-BERTHEVIN Cedex France

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