DISSTON WELDING PRODUCTS TIG/MMA-160/180/200/250D. Welding Machines
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1 DISSTON WELDING PRODUCTS TIG/MMA-160/180/200/250D Welding Machines
2 FOR SAFE OPERATION: Keep the work area clean. Cluttered work areas invite injuries (indoor and outdoor). Consider the work environment. Don t expose power equipment to rain or any other liquid. Don t use welding equipment in damp of wet locations. Keep your work area well lit. Don t use welding equipment in the presence of flammable liquids or gases. Guard against electric shock. Avoid body contact with grounded surfaces (e.g. Pipes, radiators and electrical appliances). Keep children and visitors away. Keep children and visitors away from the area of operation. Do not let children or visitors touch equipment or extension cables. Store idle machinery. When power equipment is not in use, keep them in a dry, high or locked up area away from children. Wear safety glasses. Always wear safety glasses or other suitable eye protection when using welding equipment. Secure Work. Use clamps or a vice whenever possible to secure your work piece Don t over reach. Keep proper footing and balance at all times. Dress properly. DO NOT wear loose clothing or jewellery; they can be caught in moving parts. Wear protective hair covering to cover long hair, using gloves and non-slip footwear is recommended when working outdoors. Take care of cables. Never carry welding equipment by the cable and never pull the cable to disconnect it from the socket. Keep cables away from heat, oil and sharp edges. Replace damaged cables.
3 Disconnect Tools. Disconnect welding equipment when not in use, before servicing, and when changing accessories on other tools such as blades, bits and cutters. Avoid unintentional operation. Don t carry plugged in welding equipment with a finger on the switch. Be sure that the switch is off when plugging in the machine. Outdoor use; extension cables. When electric power equipment is used outdoors, only use extension cables market as suitable for outdoor use. Stay Alert. Watch what you are doing. Use common sense. Do not operate welders when you are tired or under the influence of alcohol or drugs. Check damaged parts. Before using welding equipment, parts that are damaged should be carefully checked to determine that they will operate properly and perform their intended function. Any part that is damaged should be properly repaired or replaced by an authorized service agent. Do not operate power equipment if it cannot be turned OFF and ON by the switch. Repair of power equipment by experts. Power equipment is built in accordance with relevant safety authority requirements. The repair of power equipment must only be carried out by experts; non-expert repairs may cause considerable danger for the user and void warranty. WARNING LABELS
4 Model Power Supply Voltage SPECIFICATION TIG-160 WS-160 TIG-180 TIG-200 WS-180 WS-200 AC220V- 240V(Single phase) TIG-250 WS-250 Welding Current A A A A Rated Duty Cycle 60% Arc striking mode Scratching arc striking and high frequency arc striking Current Down-slop Time 0.5-1Sec(fixed) After Flow Time 3-5Sec(fixed) Protection Class of enclosure IP21S 1. MAIN USAGE AND THE RANGE OF USAGE (APPLICATIONS): Machine inverse argon arc welder is produced with international advanced technology using MOSFET. It has great performance and high efficiency that the traditional welder cannot be compared to. TIG-130/160/200 welder is triple functional machine used as DC TIG welder. All ferrous metal, copper and stainless steel material can be welded. The welding current is stable, the welding seam is clean and has low spatter and low noise during welding. It has two methods of arcing such as, contacting arc striking and high frequency arc striking. The welder has outstanding feature and minimum current usage. The welder is reliable, lightweight and easy to use. DUTY CYCLE The rated duty cycle refers to the amount of continuous welding you can do within a period of time: It is normally measured in cycle s blocks of 10 minutes: If the machine has a duty cycle of 60%: it can be used for a period of 6 minutes and must be allowed to cool for 4 minutes. Outside temperature is a factor in determining duty cycle when manufactured: example is 35% Duty Cycle at 35 C. 2. OPERATING CONDITION AND WORK SURROUNDING 1. Operating condition: Voltage of power source: single phase, AC 240V±10% Frequency: 50/60HZ Reliable grounding protection 2. Working surrounding (1) relative humidity: 90%(average monthly temperature 20 ) (2) ambient temperature:
5 (3) The welding site should have no harmful gas, chemicals and inflammable matter, explosive and corrosive medium. No big vibration and bump to the welder. (4) Avoiding rain water. Operating in rain is not allowed. 3. SET UP OF MACHINE (1) Before welding, the operator should read the operation instructions and uses the welder correctly according to the process specification. (2) Checking the welder appearance for deformation and damage. (3) For the safety of the equipment and the persons, the customer must correctly make grounding or protecting according to the power supply system: using 4mm lead to connect the protection grounding of the welder. Welding operation should be carried out in dry and good ventilating area. (1) The surrounding objects should be not less than 0.5m away from the welder. (2) Checking the welder output connector for tightness. (3) The welder cannot be moved or the cover cannot be opened during the power is on and welding operation is carried out. (4) The welder should be carried, used and managed by specialized person. (5) Confirming that the power source is signal phase and 220V±10%; Current of the distribution board: 5KVA. It cannot be connected with 380V power. FRONT PANEL 4. SKETCH OF THE PANEL FUNCTION BACK PANEL
6 5. METHOD OF THE OPERATION TIG 6.1 CLEARING BEFORE WELDING Tungsten argon arc welding is very sensitive to surface contamination of filed metal. Therefore before welding is carried out, grease, paint and coating on the surface, lubricant for machining and oxidized film should be removed. 6.2 DC argon arc welding (DC TIG) (1) Before welding please turn 4 to TIG (2) Connect the gas inlet pipe to gas inlet 11 of the welder. (3) Connect the welding torch to the output negative pole(-)8, the gas controlling socket 6and the gas connector 7. (4) Connect the work piece to Output Positive pole(+)9. (5) Connect input power for the welder, then turn on the power switch 12 and the pilot lamp 2 is lighted. (6) To test gas: connect the gas regulator to gas bottle, and then open the gas bottle switch. Press the torch switch, select suitable argon flow, release the torch switch and automatically shutting off the gas in about 3-5 seconds.
7 (7) Regulating current knob 5, selecting suitable welding current according to thickness of the work piece to be welded. (8) Notice: during welding, switch of the torch must be pressed and cannot be released. Otherwise the arc will be broken. (9) Releasing the switch of the torch, welding current will reduce gradually (time is fixed) and arc extinguishes. The welding torch cannot be removed as soon as the arc extinguishing. Let the protection gas cooling down for the welding seam not to be oxidized. (10) When the welding operation gas is finished, turn off argon bottle regulator and switch off the power to the welder. Don t unplug the unit when the switch 12 is still on. 7.1 Current carrying capacity of tungsten electrodes (A) Dia. Of Tungsten Electrodes (mm) Pure Tungsten DC Positive Connecting Thorium Tungsten Cerium Tungsten DC Negative Connecting Pure Tungsten Relation between end form of tungsten electrode and arc stability Form Variety Current Application Cerium or thorium tungsten electrode DC positive Narrow gap welding and sheet welding Electrical Arc stable Tungsten cerium or thorium electrode DC positive Dia. 1mm tungsten electrode continuous welding good
8 7.3 TIG specification for stainless steel Power Polarity Thickness Of Sheet (mm) Curling Butt Connection Welding Current(A) Argon Flow (l/min) Butt Connection And Filling Welding Wire Welding Current Argon Flow(l/min) Dia. Of Welding Wire (mm) DC Positive Connection SYSTEMATIC BLOCK DIAGRAM 8. TROUBLSHOOTING FAQ. Troubles Causes Problem Solution Power lamp is not lit Fan not rotating 1. No electricity at input 2. Switch of welder power fails 1. Fan power line is off 2. Enclosure blocks the fan due to deformation 3. The fan fails 1. Checking incoming line 2. Replace the switch 1. Reconnect the line 2. Reform the enclosure 3. Replace
9 Warning lamp lights No output of welder Output current decreased Current cannot be regulated High frequency arc cannot be generated Arc of argon arc welding is broken or tungsten electrode is burnt 1. Overheat protection 2. Short invertal of welder switching on and off 3. Welder fails 1. Input voltage is low 2. Input line is too thin 1. Connecting line of the potentiometer is off 2. Potentiometer for current regulation fails 1. Switch or incoming line of the torch fails 2. Interval of high frequency discharging is too big 3. Distance of the torch and work piece is too far 1. Argon flow is not regulated well 2. Tungsten electrode fails 3. Value of current does not match with dia. Of tungsten electrode 1. Welding after cools 2. Extending on-off time 3. Maintenance in manufacturer or service centre 1. AC voltage stabilizer(over 5KVA) 2. Power line is thickened 1. Reconnecting the line 2. Replace potentiometer 1. Replace torch switch or control incoming line 2. Regulating discharging invertal to mm 3. Putting torch tungsten electrode close too 1. Regulate argon flow correctly 2. Replace or sharpen 3. Select tungsten electrode dia. and current correctly PACKING LIST: Amp TIG Welder 1 WP17 TIG Torch 3 Meter 1 Electrode Holder with 2 Meter Cable 1 Earth Clamp with 1.5 Meter Cable 1 Face Shield 1 Wire Brush with Chipping Hammer 1 Shoulder Strap
10 WARRANTY Subject to the warranty conditions below, this DISSTON product called ( the product ) is warranted by Androware (there in after called the company ) to be free from defects in material or workmanship for a period of 12 months from the date of original purchase covering both parts and labour. The repair or replacement of any part shall be the opinion of the Company or its authorised service agent. Should service become necessary during the warranty period, the owner should contact the Authorised DISSTON Retailer from whom the Product was purchased. In order to obtain warranty service, the owner must present the sales docket and Warranty Certificate to confirm the date of purchase. This product is sold by the dealer give any additional warranty or guarantee on the Company s behalf except as herein contained or herein referred to. WARRANTY CONDITIONS This warranty only applies provided that the Product has been used in accordance with the manufacture s recommendations under normal use and reason- able care (in the opinion of the Company) and such warranty does not cover damage, malfunction or failure resulting from misuse, neglect, abuse or used for a purpose for which it was not-designed or is not suited and no repairs, alterations of modifications have been attempted by other than an Authorised Service Agent. This guarantee will not apply if the tool is damaged by accident or if repairs arise from normal wear and tear. CONTACT DETAILS HEAD OFFICE SOUTH AFRICA ANDROWARE PTY LTD 14 Steenbok Street, Koedoespoort, Pretoria, South Africa 0186 Telephone: Fax: trevor@androware.co.za / dwayne@gndroware.co.za
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