CARBONE Digi-Tig250ACDC, Operator'S Manual

Page 1: ... MACHINE Suitable for 1x110V or 1x220V Operators s Manual Safety Setup and General Use Guide REV 2 0 00139 16 Issue Date May 12 2016 Manual No 0 1529 EMPRESAS CARBONE S A Calle 5ta Rio Abajo Panamá Panamá Telefonos 507 3916309 3916313 www empresascarbone com ...

Page 2: ...performance Should you have an issue or question concerning your unit please contact performance technical support available through the main company headquarters available in your country For best service call the appropriate support line and follow up with an email particularly if off hours or you cannot reach a live person In the event you do not reach a live person particularly during heavy ca...

Page 3: ..._________ Where Purchased _____________________________ Whenever you request replacement parts or information on this equipment please always supply information you have recorded above This product is covered by 1 years parts and labour warranty you are responsible for costs of shipping unit to us we will cover cost of returning item to you External items torch earth lead etc are covered by 3 mont...

Page 4: ...re information please contact our Support The warranty does not cover improper use maintenance or consumables Do not attempt to alter or defeat any piece or part of your unit particularly any safety device Keep all shields and covers in place during unit operation should an unlikely failure of internal components result in the possible presence of sparks and explosions If a failure occurs disconti...

Page 5: ...otection is available exclude them from the work area Even brief expo sure to the rays from the welding arc can damage unprotected eyes Always wear hearing protection because welding and cutting can be extremely noisy E ar protection is necessary to prevent hearing loss Even prolonged low levels of noise has been known to create long term hearing damage Hearing protection also further protects aga...

Page 6: ...es nose or throat are signs that you need to increase ventilation Stop immediately and relocate work if necessary until adequate ventilation is ob tained Stop work completely and seek medical help if irritation and discomfort persists WARNING Do not weld on galvanized steel stainless steel beryllium titanium cop per cadmium lead or zinc without proper respiratory equipment and or ventilation WARNI...

Page 7: ... materials including rags and spare clothing away from area Keep all flammable fuels and liquids stored separately from work area Visually inspect work area when job is completed for the slightest traces of smoke or embers If welding or cutting outside make sure you are in a cleared off area free from dry tender and debris that might start a forest or grass fire Do not weld on tanks drums or barre...

Page 8: ...Welding Capability B 2 Limitations B 2 Control Panel B 3 Controls and Settings 2 Step and 4 Step Tig Sequence B 3 B 6 Operating steps B 7 Welding in Tig mode B 7 Welding Polarity B 7 DC Electrode Negative Polarity B 7 DC Electrode Positive Polarity B 7 D C Pulsed TIG B 7 A C Alternating Current B 8 A C Pulsed TIG Alternating Current Pulsed B 8 Steel Tig Welding B 8 Copper Tig Welding B 8 Tips For ...

Page 9: ...justing Range 5 150A 5 250A SP AC balance 10 90 AC Square Wave Frequency 30 250Hz AC TIG Rated Duty Cycle 35 Current Adjusting Range 3 150A 3 250A DC TIG Rated Duty Cycle 35 Peak Current 3 150A 3 250A Base peak Current ratio 5 95 Rated Duty Cycle 35 Pulse width 5 95 Standard PULSE TIG pulse Freq 0 1 500Hz DC 0 1 250Hz AC Current UP Down slope Time 0 10S Initial current weldingcurrent 5 150 crater ...

Page 10: ... 1 National Electric Code Use a Super Lag type fuse or circuit breaker with a delay in tripping action Models with NEMA 6 50P plug may be used with a 50 amp protected 6 50R receptacle or with a maximum 70 amp protected 6 50R receptacle if dedicated for the welder 120 140 160 180 200 220 240 260 100 90 80 70 60 50 40 30 20 10 0 OUTPUT AMPS OUTPUT AMPS DUTY CYCLE Using standard input cable for prote...

Page 11: ...oblems STACKING The machine cannot be stacked TRANSPORT UNLOADING Never underestimate the weight of the equipment Never make the cargo pass or leave it suspended over people or things Neither let the equipment or the single unit fall nor put it down with force Once it has been removed from the packing the power source can be used to move it in the hand or on the shoulder Never lift welder with gas...

Page 12: ... to an earth ground close to the work clamp using one of the following methods a A metal underground water pipe in direct contact with the earth for ten feet or more b A 3 4 19mm galvanized pipe or a 5 8 16mm solid galvanized iron steel or copper rod driven at least eight feet into the ground The ground should be securely made and the grounding cable should be as short as possible using cable of t...

Page 13: ...s The Inverter machine is recommended for use on an individual branch circuit 1Also called inverse time or thermal magnetic circuit breakers These circuit breakers have a delay in tripping action that decreases as the magnitude of the current increases 220 230 240V INPUT The equipment is provided with a 230 115V cable 6 6ft 2m in length with a 230V 6 50P attachment plug The Inverter machine perfor...

Page 14: ...roper procedure on grounding the work clamp and work piece SHIELDING GAS CONNECTION Obtain the necessary inert shielding gas usually argon Connect the cylinder of gas with the pressure regulator and flow gage Install the gas hose between the regulator and gas inlet located on the rear of the welder CYLINDER could explode if damaged Keep cylinder upright and chained to a support Keep cylinder away ...

Page 15: ...nder electrically hazardous conditions such as welding in wet areas or on or in the workpiece FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust at the arc or both to remove fumes and gases from breathing zone and general area WELDING SPARKS can cause fire or explosion Keep flammable material away Do not weld on containers that have held combustibles RC RAYS ca...

Page 16: ... as many industry standard items such as TIG torches adapted for Twist Mate hoses PROCESS LIMITATIONS The Precision TIG machines are not recommended for arc gouging due to it s limited output capacity and are also not recommended for pipe thawing RECOMMENDED QUIPMENT INTERFACE See Installed Options in Accessories Section for more details The Precision TIG will be available as a basic Machine Only ...

Page 17: ...tput Ground clamp 17 argon out 18 argon arc control or remote control 19 Amp Adjustment slector remote control panel pedal finger torch 20 power switch 21 argon inlet 22 power supply 23 safety earthing column 24 fan 25 HF Lift TIG slector 26 110V or 220v receptacle CONTROL FUNCTIONALITY 1 Memory Function The unit has 9 programs which allow the operator to select parameters then save the settings t...

Page 18: ...re presettable The default start current is 15 amps and the default upslope time is 0 2 seconds 2 Release the Arc Start Switch to stop welding The machine will now decrease the output current at a controlled rate or down slope time until the Finish current also commonly referred to as Crater Current is reached and the output of the machine is turned OFF Both the Down slope Time and the Finish Curr...

Page 19: ...ontrol knob is used increase or decrease parameter values To increase adjustment speed push in on the knob while turning 15 output Electrode Connection Positive For quick disconnect system using Twist Mate cable plugs 16 output Electrode Connection Negative This quick connect Twist Mate receptacle provides electrical connection to the electrode holder and cable for Stick welding and connection for...

Page 20: ...oler be sure to unplug and discontinue use of cooler until the welder can be operated on the correct voltage needed to supply the cooler or severe damage to the cooler may result nameplate The data plate stamped on the metal structure complies with the EN 60974 1 EN50199 EN60974 10 international standards and contains the following information a Manufacturer s name and address b Trademark c Model ...

Page 21: ...n on with the output and remain on continuously until the remote control is released WELDING POLARITY DC Electrode Negative Polarity Direct Current Straight Polarity see FIGURE B 4 While Welding there is a continuous flow of electrons from the electrode to the workpiece This is the most used polarity ensuring limited wear of the electrode since the majority of the heat concentrates on the anode wo...

Page 22: ...e gas Considering the fluidity of molten copper the use of backup support may prove useful FILLER MATERIAL In order to avoid the oxidation of the molten material filler materials containing phosphorus silicon or other deoxidating materials are typically used The mechanical properties can also be improved through the use of silver TIPS FOR AC TIG WELDING AC Inverter TIG power sources offer two sign...

Page 23: ... 2 4 Up to MAX A Up to 160 A Up to MAX A 13 17 6 8 11 15 5 7 1 8 3 2 X Up to MAX A X 15 23 7 11 11 15 5 7 Tungsten electrodes are classified as follows by the American Welding Society AWS Pure EWP green 1 Thoria EWTh 1 yellow 2 Thoria EWTh 2 red 2 Ceria EWCE 2 orange 1 5 Lanthana EWLa 1 black 0 5 to 0 40 Zirconia EWZr brown TRI MIX of elements EWG gray Ceriated Tungsten is now widely accepted as a...

Page 24: ...laces a lot of heat on the tungsten In a balanced wave where both EP and EN are equal in time length 50 penetration is reduced and over cleaning results in wide etch lines running parallel to the side of the weld Not all welds conditions will be alike so more cleaning is required at times than others Similarly more penetration will be required at times than others Ordinarily about 30 35 electrode ...

Page 25: ...ll and service this equipment Turn the input power off at the fuse box disconnect or unplug supply lines and allow machine to sit for five minutes minimum to allow the power capacitors to discharge before working inside this equipment Do not touch electrically hot parts Connect up the shielding gas typically argon using an appropriate regulator Connect Adjustable foot control torch and work lead t...

Page 26: ...rator may have to turn the cur rent control up and depress the Ampcontrol approximately 1 4 of the way down Depressing the Ampcontrol to its minimum position may not start the arc Also if the current control is set too low the arc may not start In most cases a large or cold tungsten will not readily establish an arc at low currents This is normal In Direct Current mode the PRECISION TIG will start...

Page 27: ...B 13 OPERATION B 13 ...

Page 28: ...B 14 OPERATION B 14 ...

Page 29: ...B 15 OPERATION B 15 ...

Page 30: ... the power switch is turned on 5 Turn the power switch to ON 6 Adjust the Current Control to the desired amps 7 Strike an arc and weld NOTE When the MMA TIG switch is set to MMA the output is always on when the power switch is on A remote control has no effect on the welding current and the gas flow and high frequency TIG arc starter are disabled RECOMMENDED ELECTRODE AMPERAGE RANGES SMAW Process ...

Page 31: ...and automatic amp response needed to maintain the arc when voltage falls below the threshold 6011 Cellulose electrodes may require more arc force control than other rods but each brand and size will weld a little differently The arc force control setting will vary from person to person as well with different rod angles positions and arc lengths all factoring into the arc force control performance ...

Page 32: ...equire no maintenance 7 SPARK GAP ADJUSTMENT The spark gap 020 5mm is set at the factory to a gap of 0 015 inches 0 4mm See Figure D 1 This setting is adequate for most applications Where less high frequency is desired the setting can be reduced to 0 015 inches 0 4mm Use extreme caution when working with circuit of the high frequency The high voltages developed can be lethal Turn the input power o...

Page 33: ...S This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause gen...

Page 34: ...d duty cycle Allow the unit to run until the fan cools the unit and the yellow light goes out Machine does not respond no gas flow no high frequency and no open circuit voltage when arc start switch or Ampcontrol is activated fan is working 1 Machine MUST be in the TIG Mode 2 The Ampcontrol may be defective Check for continuity between pins D and E on cable connector when Ampcontrol is depressed W...

Page 35: ...significantly when AC Balance control knob is set near or at max penetration or when Output control is set near or at full output 1 Input power to machine doesn t have sufficient capacity Try changing Input power to a sufficient supply refer to Installation section 2 Machine is powered from an engine generator or an engine welder If welding at high currents are needed try powering machine from ele...

Page 36: ...g 2 Tungsten not sharp when welding in DC mode 3 Gas shielding may be insufficient Increase gas flow reduce tungsten stick out beyond gas cup 4 Check for contaminated gas or leaks in the gas line torch or connections 5 If a helium blend is used as a shielding gas then reduce the percentage of helium Arc Pulsates when AC TIG welding 1 Micro Switch mounted on Polarity Switch is not opening in AC mod...

Page 37: ...ck Spark Gap operation and setting 0 5mm High frequency spark is present at tungsten electrode but operator is unable to establish a welding arc Machine has normal open circuit voltage refer to Technical Specifications in the Installation Chapter 1 The tungsten electrode may be contaminated Replace or sharpen 2 The current control may be set too low 3 The tungsten electrode may be too large for th...

Page 38: ...t your local welder gas distributor When AC TIG welding the arc is erratic and there is a loss of cleaning of the work piece 1 Tungsten electrode may be too small for process Use a larger diameter tungsten or a pure tungsten 2 If a helium blend is used as a shielding gas then reduce the percentage of helium If all recommended possible areas of misadjustment have been checked and the problem persis...

Page 39: ...ler diameter electrode 2 Arc too short Excessive spatter 1 Long arc 2 High current Craters 1 Fast movement of the electrode away from piece Inclusions 1 Poor cleanliness or distribution of the Welding passes 2 Improper movement of the electrode Insufficient penetration 1 High progression speed 2 Welding current too low 3 Narrow chamfering Porosity 1 Humidity in electrode 2 Long arc If all recommen...

Page 40: ... transformer pass the power by insulation and voltage reducing with high efficiency Output the second rectifier and the second filter Output the required welding current and voltage NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual If the diagram is illegible write to the Service Department for a replacement Give the equipment code number ...

Page 41: ...justable foot control 1 Adjustable finger control torch 1 optional accessory Operation instructions 1 Certificate of quality 1 No Certificate of quality Name of product AC DC TIG WELDING Type of product Digi Tig250ACDC Packing No Test results of this welder fulfils_____________ _________technical requirements and its release from the works is granted Inspector_________ Date___________ ...

Page 42: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrode...

Page 43: ...gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não opere co...