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MONOTIG 160
İP
DC INVERTER TIG
WELDING MACHINE
CONTENTS
SAFETY RULES .................................................................................................................................................2
1. TECHNICAL INFORMATION ..............
...........................................................................................................6
1.1 GENERAL EXPLANATIONS ....................................................................................................................6
1.3 DATA PLATE .............................................................................................................................................7
1.4 TECHNICAL SPECIFICATIONS ...............................................................................................................7
1.5 ACCESSORRIES .....................................................................................................................................8
2. INSTALLATION ...............................................................................................................................................9
2.1 UPON RECEIPT AND CLAIMS ................................................................................................................9
2.2 INSTALLATION AND WORKING RECOMMENDATIONS .......................................................................9
2.3 CONNECTIONS FOR TIG WELDING ......................................................................................................9
2.3.1 Mains Connection and Switching ON ..............................................................................................9
2.3.2 Gas Connections .............................................................................................................................9
2.3.3 Torch Cooling System (Optional) ...................................................................................................10
2.3.4 Preparing the Torch .......................................................................................................................10
2.3.5 Torch Connections .........................................................................................................................10
2.3.6 Earth Clamp Connections ..............................................................................................................10
2.3.7 Changing the Tungsten Electrode .................................................................................................10
2.4 CONNECTIONS FOR MMA WELDING ..................................................................................................11
3. OPERATION .................................................................................................................................................12
3.1 CONTROL PANEL ..................................................................................................................................12
3.2 TIG CYCLE .............................................................................................................................................13
3.3 MENU STRUCTURE ..............................................................................................................................13
3.3.1 TIG Welding Process .....................................................................................................................14
3.3.2 Usage of the TIG Welding Modes .................................................................................................14
3.3.3 MMA Welding Process ..................................................................................................................14
3.3.4 Error Message ...............................................................................................................................14
4. MAINTENANCE AND TROUBLESHOOTING ..............................................................................................15
4.1 PERIODIC MAINTENANCE .............................................................................................................15
4.2 NONPERIODIC MAINTENANCE .....................................................................................................15
4.3 TROUBLESHOOTING .....................................................................................................................15
APPENDIX 1: SPARE PARTS ..........................................................................................................................16
APPENDIX 2: ELECTRICAL DIAGRAM ...........................................................................................................17
MONOTIG 160ip 1
SAFETY RULES
OBEY ALL THE SAFETY RULES
STATED IN THE MANUAL!
IDENTIFYING SAFETY INFORMATION
These symbols are being used to identify potential risks.
When seen a safety symbol in the manual, it must be understood that there is an injury risk and following instructions must be read carefully to avoid potential risks.
While welding, keep the third persons and especially the children away from the work area.
UNDERSTANDING THE SAFETY WARNINGS
Read carefully the manual and the labels and the safety warnings on the machine.
Make sure that the warning labels positioned on your machine are in good order. Renew the damaged and the missing labels.
Learn to operate the machine and how to make the controls properly.
Operate your machine in convenient work areas. Improper modifications affect the safety of your machine negatively and shorten its lifetime.
ELECTRICAL SHOCK C AN BE FATAL
Installation procedure must comply with national electricity standards and other relevant regulations and ensure that installation is performed by qualified persons.
Wear dry insulating gloves free of damage and body protection.
Do not touch electrode with bare hand. Do not wear wet or damaged gloves and body protection.
Do not touch live electrical parts .
Never touch electrode while in contact with working surface, ground or another electrode which is connected to a different machine .
Protect yourself from electric shock by insulating yourself from work and ground.
Use non-flammable, dry insulating material if possible, or use dry rubber mats, dry wood or plywood, or other dry insulating material big enough to cover your full area of contact with the work or ground, and watch for fire.
Never connect more than one electrode to the electrode holder .
Turn off the machine, when not in use .
Disconnect input plug or swtich off the power before working on the machine.
Frequently inspect input power cord for damage or bare wiring - repair or replace cord immediately if damaged.
Be sure that the machine is properly ground ed.
2
HOT PARTS CAN CAUSE SEVERE BURNS
Do not touch hot parts .
Allow cooling time before servicing .
If needed to hold hot parts, use appropriate tool, insulating gloves and fireproof clothes.
MONOTIG 160ip
SAFETY RULES
BREATHING WELDING FUMES CAN BE HAZARDOUS TO YOUR HEALTH
Inhaling fumes and gases over a long period of time, generated during welding is dangerous and forbidden .
Irritation of the eyes, nose and throat are symptoms of inadequate ventilation. Take immediate steps to improve ventilation. Do not continue welding if symptoms persist .
Install a natural or forced air ventilation system in the work area .
Install an adequate ventilation system in the welding and cutting area, if needed install a system that can remove the fume and vapor accumulated in the entire work area, to prevent pollution use adequate filtration in discharge .
In the event of welding in small, confined places, or welding lead, beryllium, cadmium, zinc, zinc coated or painted materials; also wear a fresh air supplied respirator in addition to the above mentioned rules .
Always have a trained watchperson nearby, while working in small confined places.
Avoid working in such confined places if possible .
If gas cylinders are grouped in a different area, make sure that it is a well-ventilated area. When not being used, turn off the main cylinder valve and watch out for gas leakage .
Shielding gasses such as argon is denser than air and when being used in confined which is dangerous for health .
Do not perform welding operations near chlorinated hydrocarbon vapors produced by degreasing or painting .
ARC RAYS CAN BURN EYES AND SKIN
Use adequate welding helmet with correct shade of filter (4 or 13 considering EN 379) to protect your eyes and face .
Protect open parts of your body (arms, neck and ears) from arc rays by adequate protective clothing .
To protect others by arc rays and hot metals, surround the working area with flame proof curtains which are higher than eye level and put up warning boards.
SPARKS & FLYING METALS CAN INJURE EYES
Welding, wire brushing and grinding cause sparks and flying metal.
To prevent injuries wear appropriate safety glasses with side shields even under your welding helmet .
MOVING PARTS CAN CAUSE INJURY
Keep away from moving parts .
Keep all doors, panels, and guards closed and secured .
Wear shoes with metal protection over the fingers.
MONOTIG 160ip 3
SAFETY RULES
NOISE CAN DAMAGE HEARING
Noise from certain industrial processes or equipments can damage hearing.
Wear approved ear protection if noise level is high.
WORKING IN SMALL AND CONFINED PLACES CAN BE DANGEROUS
While welding and cutting in small, confined places, always have a trained watchperson nearby .
Avoid working in such confined places .
WELDING WIRE MAY CAUSE INJURY
Do not point the torch toward any part of a human body, other persons or any type of metal when unwinding welding wire .
While extracting the wire from the spool by hand, it may spring suddenly and injure you or a nearby person, protect especially your eyes and face.
WELDING CAN CAUSE FIRE OR EXPLOSION
Never weld near flammable material. It may cause fire or explosions.
Before starting to weld, move flammables away or protect them with flame-proof covers.
Do not weld on and cut closed tubes or pipes .
Before welding on closed containers, open and clear them entirely. Welding operations on these parts must be performed with the utmost caution .
Never weld containers or pipes containing or which have contained substances that could give rise to explosions .
Welding equipments warms up so never position them on flammable surfaces.
Welding sparks can cause fire. For that reason, keep extinguishing means, such as fire extinguishers, water and sand which are easy to reach .
Keep security valves, regulators and other valves , used and compressed gas circuits in good condition .
on flammable, explosive
4
MAINTENANCE MADE BY UNQUALIFIED PERSONS MAY CAUSE INJURIES
Electrical devices should not be repaired by unqualified persons. Improper repairs can cause serious injuries or even death during applications .
The components of the gas circuit works under pressure. The service given by unqualified persons may cause explosions and operators can be injured seriously .
MONOTIG 160ip
SAFETY RULES
FALLING UNIT CAN CAUSE INJURY
Wrong positioned power source or other equipment may cause serious injury to persons or damage to objects.
While repositioning the power source always carry by using the lifting eye. Never pull cable, hose or torch.
Always carry the gas cylinders separately .
Before carrying the welding and cutting equipment, disassemble all the connections between and separately carry the small ones by handgrips and the big ones by lifting eyes or by using appropriate vehicles like forklifts .
Install your machine on flat platforms having maximum 10 ° slope that it does not fall over. Install it on well ventilated, non-confined places away from the dust, also avoiding the risk of falling caused by cables and hoses. For gas cylinders not to fall over, attach it to the mobile machine or to the wall with a chain .
Ensure that operators easily reach the controls and connections on the machine.
OVERUSE CAN CAUSE OVERHEATING
Allow cooling period; follow rated duty cycle .
Reduce current or reduce duty cycle before starting to weld again .
Do not block airflow t hrough the unit.
Do not filter airflow to unit without the approval of manufacturer
.
ARC WELDING CAN CAUSE INTERFERENCE
Electromagnetic energy arising during welding and cutting operations can interfere with sensitive electronic equipment such as microprocessors, computers, and computer-driven equipment such as robots .
Be sure all equipment in the welding area is electromagnetically compatible .
To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor .
To avoid possible EMC damages, locate welding operation as far as possible (100 meters) from any sensitive electronic equipment .
Be sure this welding machine is installed and grounded according to this manual .
If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area .
PROTECTION
Do not expose the welding machine to rain, protect from water drops and vapour.
ENERGY EFFICIENCY
Choose appropriate welding method and welding machine for your work.
Choose appropriate welding current and welding voltage for the material and its thickness.
If you will have a long break after welding, turn off the machine after cooler fan cooled the machine.
MONOTIG 160ip 5
TECHNICAL INFORMATION
1. TECHNICAL INFORMATION
1.1 GENERAL EXPLANATIONS
Monotig 160ip is an inverter type portable, mono-phase Pulsed DC TIG/MMA welding machine designed for
TIG welding of all kinds of thin metal sheets except aluminum & for MMA welding of all kinds of stick electrodes up to 4 mm.
Enhanced professional TIG controls such as, HF start, Touch-Lift, pre-gas, up-slope, pulse, down-slope, postgas & crater filling are present.
Up to 10 complete jobs can be stored in the memory and run when it is necessary.
Current, time and program settings can easily be monitored by digital displays.
Monotig 160ip proved well that it can work between 160 to 240 V 50/60 Hz line voltages. Therefore this machine is quite immune to mains voltage fluctuations and perfectly welds with generator-sets.
Monotig160ip can also be used with long welding cables up to 25 mt.
The machine is fan cooled and thermally protected against over heating.
1.2 COMPONENTS OF MONOTIG 160iP
8
10
9
6
5
7
6
4
1
3
4
5
1
2
Line Cable Inlet
Power Switch
Gas Inlet
Gas Outlet
Earth Cable and Welding Cable Socket (-)
Figure 1: Monotig 160ip
8
9
10
6
7
Earth Cable and Welding Cable Socket (+)
Torch Control Connections
Control Panel
Multifunctional Adjustment Knob
Thermic / Error LED
3
2
MONOTIG 160ip
TECHNICAL INFORMATION
1.3 DATA PLATE
MONOTIG 160ip
30A / 11.2V ~ 160A / 16.4V
50
160A 145A 110A
16.4V
15.8V
14.4V
22A 15.3A
13.2A
5kVA
3.5kVA
3kVA
22A 15.5A
30A / 21.2V ~ 160A / 26.4V
Single Phase Static Frequency Converter
Transformer Rectifier
TIG Welding
Manual Metal Arc Welding
Direct Current
Descending Characteristics
Line Input-1 Phase Alternating Current
Appropriate To Operate In Dangerous
Work Area
X
U
0
U
1
I
U
2
1
I
2
IP23S
S
1
:Duty Cycle*
:Open Circuit Voltage
:Line Voltage and Frequency
:Rated Welding Voltage
:Input Current
:Rated Welding Current
:Protection Class
:Input Power
*Duty Cycle
1 2
6 min.
4 min.
6 min.
4 min.
6 min.
4 min.
Time (min.)
Duty cycle defines the percentage of welding time out of a period of 10 minutes at a given current and ambient temperature (standard is 40°C). For example, a welder with 60% duty cycle must be rested (2) for 4 minutes, after 6 minutes of continuous welding (1).
1.4 TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
Line Voltage (1 phase )
Input Power - TIG ( 50% )
Input Power - MMA ( 25% )
Input Current - TIG ( 50% )
Input Current - MMA ( 25% )
Power Factor
Open Circuit Voltage
Welding Current Range
Rated Welding Current - TIG
Rated Welding Current
Fuse
(50% )
- MMA 25% )
Protection Class (EN 60529)
Cooling Method
Dimensions (LxWxH)
Weight
Standards and Approvals
MONOTIG 160ip
UNIT
V kVA kVA
A
A
V
DC
A
DC
A
DC
A
DC
A mm kg
VALUE
5
7,2
22
31,5
0,97
75
30 - 160
160
150
32 - Delayed
IP23S
Air
515x160x312
10
CE, EN60974-1, EN60974-10
7
TECHNICAL INFORMATION
1.5 ACCESORRIES
STANDARD ACCESORRIES
Electrode Holder and Cable
(16mm² - 3m)
Earth Clamp and Cable
(16mm² - 3m)
TIG Torch Plug - CX79
OPTIONAL ACCESORRIES
Torch Abitig 200
(200A 35% DC - 4m)
Torch Sintig 18W-4
(320A 100% DC - 4m)
Torch Sintig 18W-4
(320A 100% DC - 8m)
Gas Pressure Regulator
(Ar-CO )
Water Cooling Unit
(CS 200)
PIECE
1
1
1
PIECE
1
1
1
1
1
PRODUCT CODE
K301000203
K301101204
A377900022
PRODUCT CODE
S510031901
S510031211
S510031212
S520001002
K307000010
8 MONOTIG 160ip
INSTALLATION
2. INSTALLATION
2.1 UPON RECEIPT AND CLAIMS
Be sure that you have received all the items that you have ordered. In case of any item is missing or damaged, contact your supplier immediately.
In the event of damaged or missing delivery,
draw up a record, take a photo of the damage and report
it to the shipping agency and MAGMA
MEKATRONIK with the photocopy of shipping bill.
Standard box contains:
ú
Power Source
ú
Cable
ú
Earth Clamp Cable
ú
TIG Torch Plug
ú
Transportation Belt
ú
User Manual
E-mail: [email protected]
Fax: +90 236 226 27 28
2.2
INSTALLATION AND WORKING RECOMMENDATIONS
DO NOT USE THE MACHINE WITH LONG
MAINS CABLES AT CONSTRUCTION SITES!
Mains cable s are under 220V/50 Hz and these cables are not suitable to be used in harsh environments, they can easily wear and tear which may lead to electric leakage to the metals where welders may be working on. ELECTRIK SHOCK
CAN KILL or cause people to FALL DOWN from elevated working areas . I t is ALWAYS recommended to use long instead of MAINS CABLES er WELDING CABLES for safety reasons .
For a better performance, keep the machine at least 20 cm away from the surrounding objects.
Beware of excessive heat, dust and humidity around the machine. Try not to operate the machine under direct sunlight. Machines should be operated on
lower capacities
when ambient air temperature exceeds
40ºC
.
2.3 CONNECTIONS FOR TIG WELDING
Avoid welding at outdoors where it is windy and rainy, if this is a must, protect the welding area with curtains, mobile screens or tents.
U se suitable welding fume extraction systems.
Use breathing apparatus if there is a risk of inhaling in confined places.
Respect the duty cycles given at the data plate.
Exceeding the duty cycles frequently can damage the machine and this would void the warranty.
Do not use stronger fuses than those stated on the data plate .
Ensure that the earth clamp is tightly connected as close as possible to the welding location. Do not let welding current flow through any media other than welding cables; e.g. over the machine itself, gas tubes, chains, ball bearings, etc .
Secure the gas cylinder to a wall by a chain.
2.3.1 Mains Connection and Switching ON 2.3.2 Gas Connections
Before plugging your machine to the electrical line, check the line voltage
[230 VAC].
“OFF” “0” and insert the plug into the socket.
SWITCH ON the machine via power switch (2).
Observe that the switch itself and the led displays sound of the cooler fan.
Secure the gas cylinder
(11)
to a wall by a chain. To operate safely and get best results, use approved regulators.
Open the gas cylinder valve
(13)
few times in order to blow out any possible dirt or particles.
Connect the gas regulator to the cylinder, make sure that the threading of the gas outlet of the cylinder and the nut of the regulator match.
13
12
15
11
14
Figure 3: Gas Cylinder - Regulator - Hose Connections
Figure 2: Gas and Mains Connections
MONOTIG 160ip 9
INSTALLATION
Connect one end of gas hose regulator
(12)
(14)
to the gas and connect the other end to the gas supply inlet
(3)
. Open the gas cylinder valve
(13)
.
Set the gas quantity with the pressure adjustment valve
(15)
.
Make sure that there are no gas leakages from any connection.
Diameter of
Electrode
(mm)
1.0
1.6
Diameter of
Nozzle
(mm)
6.3
9.5
Welding
Current
(A
DC
)
15 - 70
30 - 150
Gas Debit
(lt/dak)
6 - 8
6 - 8
2.3.3 Torch Cooling System (Optional)
CS200 water cooling unit is an optional accessory for cooling the water cooled torches in demanding applications and it can be ordered with the code
K307000010.
2.3.4 Preparing the Torch Connections
TIG torch connection via CX79 TIG torch adaptor :
Thread the nut body
(17)
(16)
of the torch through the plastic and screw to the torch plug
(18)
tightly.
Then place the torch plug
(17)
.
(18)
into the plastic body
Thread the L shape gas hose adapter
(19)
through the hole on plastic body and screw it to the socket
(18)
tightly.
Connect the gas hose with the clamp tightly.
(20)
Install the connector pins
(21)
of the torch.
to the elbow union
(22)
(19)
to the control cables
16 17 18
2.3.6 Earth Clamp Connections
Connect the earth cable plug welding socket tightly .
(23)
to the positive
To increase the quality of the welding, connect the earth clamp
(24)
tightly to the work-piece as close as possible to the welding area.
24
5
7
4
6
23
Figure 4: Mounting the Torch Plug and the Torch
2.3.5 Torch Connections
' the negative welding socket
(5)
tightly.
Screw the gas hose of the torch to the gas outlet
(4)
.
Insert the connector pins connections
(7)
.
(17)
to the torch control
In case of using water cooling unit, connect the water hoses of the water-cooled torch to the water cooling unit.
10
21
19
20
22
Figure 5: TIG Welding Connections
2.3.7 Changing the Tungsten Electrode
26
27
28
29
30
Figure 6: Changing the Tungsten Electrode
Unscrew the clamping cap
(27)
.
Remove the existing tungsten electrode the collet
(28)
(26)
and insert the new electrode in.
from
Insert the collet
(28)
into the torch.
Screw the clamping cap
(27)
tightly.
The ceramic gas nozzle electrode
(26)
(30)
and the tungsten diameters should be selected according to the working current and the shape of the work-piece. Therefore the collet body
(29)
(28)
, the collet must be matched with the diameter of the tungsten electrode
(26)
.
MONOTIG 160ip
INSTALLATION
2.4 CONNECTIONS FOR MMA WELDING
Switch ON the machine by following the steps
2.3.1
.
According to the polarity of the electrode to be used, i nsert the electrode holder cable the earth clamp cable
(18)
(20)
and plugs into their appropriate sockets turning clock-wise .
( 5-6 )
and tighten them by
Connect the earth clamp
(24)
tightly to the workpiece as close as possible to the welding area.
Adjust the desired current and the machine is ready to weld.
Below table is given as a reference for current adjustment of mild steel electrodes, please refer to the electrode manufacturer's recommendations.
Diameter
2.0
2.5
3.25
4.0
Rutile
40-60 A
60-90 A
100-140 A
140-180 A
Basic
--
60-90 A
100-130 A
140-180 A
Cellulosic
--
60-100 A
70-130 A
120-170 A
24
5
20
18
Figure 5: MMA Welding Connections
6
MONOTIG 160ip 11
OPERATION
3. OPERATION
3.1 CONTROL PANEL
16
17
18
19
26
20
21
Frequency
22
23
24
25
2 4
10 11 12 14 15 6 7
8
1 3
5 9
Monotig 160ip
[1] Multifunctional Knob
is used for selecting and adjusting welding parameters. To select a parameter, press the button and observe that the corresponding
LED lights. Clockwise and counter clockwise turning of the knob, increases and decreases the value respectively. To store the value, press the button.
[2] Multifunctional Display
displays the value of the welding parameter which is selected by multifunctional knob. Plus it displays the welding current value during welding.
[3] Program Selection Button
desired program.
is for selecting the
[4] Program Display
selected program.
displays the number of the
[5] Welding Mode Selection Button
is for selecting
MMA, HF Start TIG, and Touch-Lift TIG modes.
When
MMA
mode is selected, its LED
[6]
lights.
When
Touch-Lift TIG
mode is selected, its LED
[7]
lights. In this mode, arc starts after touching the tungsten electrode to the work-piece and lifting the electrode.
When
HF Start TIG
mode is selected, its LED
[8]
lights. In this mode, arc starts via ignition through the gas without any torch touching to the work-piece.
[9] 2Stroke / 4Stroke / Spot Welding Selection
Button is
for selecting 2-Stroke, 2-Stroke, and Spot
Welding modes.
When
2-Stroke TIG
is selected, its LED
[10]
lights.
When
4-Stroke TIG
is selected, its LED
[11]
lights.
When
Spot Welding
is selected, its LED
[12]
lights.
Button [13]
TIG.
is for selecting Flat DC TIG / Pulse DC
12
13
LED [14]
LED [15]
lights when Flat DC TIG is selected and lights when Pulse DC TIG is selected.
When
Pulse DC TIG
is selected, its LED
[15]
lights.
[16] Pre-Gas Flow Time LED
is selected by pushing multifunctional knob. While LED is on, the desired value is adjusted by turning the multifunctional knob.
[17] Starting Current LED
is selected by pushing multifunctional knob. While LED is on, the desired value is adjusted by turning the multifunctional knob.
[18] Up-Slope Time LED
is selected by pushing multifunctional knob. While LED is on, the desired value is adjusted by turning the multifunctional knob.
[19] Main Current LED
is selected by pushing multifunctional knob. While LED is on, the desired value is adjusted by turning the multifunctional knob.
[20] Base Current LED
is selected by pushing multifunctional knob. While LED is on, the desired value is adjusted by turning the multifunctional knob.
[21] Pulse Frequency Adjustment LED
is selected by pushing multifunctional knob. While LED is on, the desired value is adjusted by turning the multifunctional knob.
[22] Spot Welding LED
lights while the torch trigger is pushed in spot welding mode.
[23] Down-Slope Time LED
is selected by pushing multifunctional knob. While LED is on, the desired value is adjusted by turning the multifunctional knob.
[24] Final Current LED
is selected by pushing multifunctional knob. While LED is on, the desired value is adjusted by turning the multifunctional knob.
MONOTIG 160ip
OPERATION
[25] Post Gas-Flow Time LED
is selected by pushing multifunctional knob. While LED is on, the desired value is adjusted by turning the multifunctional knob.
[26] Thermal Error LED
overheated.
lights when machine is
3.2 TIG CYCLE
i
**Spot Welding Time
*Pulse
Frequency
According to the modes, active and inactive functions are shown in the table below.
***Base
Current
Gas
Pre-Flow
Start
Current
Current
Up-slope
Current
Down-slope
Final
Current
Gas
Post-Flow
* Only in TIG with PULSE
** Only in Spot mode
*** In all TIG modes except 2-Stroke DC TIG
3.3 MENU STRUCTURE
PARAMETER
RANGE
Pre-Gas Flow Time
Start Current
Up-slope Time
Main Current
Base Current
Frequency
Down-slope Time
Final Current
Post-Gas Flow Time
0.1 - 10 sec
30 - 160 A
0.1 - 10 sec
30 - 160 A
30 - 160 A
0.1 - 2000 Hz
0.1 - 10 sec
30 - 160 A
0 - 23 sec
FACTORY
SETTING
40 A
15 Hz
1 sec
30 A
2 sec
1 sec
30 A
1 sec
80 A
LED
MMA
Welding
20
21
23
24
25
16
17
18
19
P
2-Stroke
TIG
4-Stroke
TIG
Spot
TIG
DC Pulse DC Pulse DC Pulse
P P P P
P P P P
P P P P
P P P P
P P P
P P
P P P P
P P P P
P P P P
P P
P
P
MONOTIG 160ip 13
3.3.1
TIG Welding Process
Beware of electric shock!
In HF Start TIG mode, a high ignition voltage is present at the torch. Never touch the tungsten electrode or parts conducting welding current when the device is switched on.
10 Jobs (programs) including complete parameter settings can be stored and run for repeated jobs.
i
In the first use, all parameters of all programs are in factory settings which are shown in the table.
Push the program selection button
[3]
for selecting a previously adjusted program or changing its parameters.
Push the welding mode selection button selecting Touch-Lift TIG or HF start TIG.
[5]
for
Push the 2Stroke
Selection Button
[9]
mode for the work.
/ 4Stroke / Spot Welding for selecting the appropriate
Push the Flat DC TIG / Pulse DC TIG selection button
[13]
for selecting Flat DC TIG or Pulse DC
TIG.
Push the multifunctional knob
[1]
for selecting the desired welding parameter and adjust the parameter by turning the multifunctional knob
[1]
.
Latest adjusted parameter values will be saved automatically. There is no need to do anything else for saving the settings.
To recall a memorized parameter or to readjust any parameter, just push the program selection button
[3]
.
3.3.2
Usage of the TIG Welding Modes
2-Stroke TIG Welding
Push the torch trigger and do not release your finger. Current starts with start current after pre gas-flow period and increases according to the upslope time adjustment and reaches to value of the main current.
Welding goes on with the main current as long as the torch trigger is kept pushed. After releasing the trigger, current decreases according to downslope time adjustment and reaches to final current, after post gas-flow period the operation ends.
4-Stroke TIG Welding
When torch trigger is pushed, following the pregas flow, initial current starts and when the trigger is released the current ramp leads to the welding current. If DC Pulse Mode is selected, according to the adjusted frequency, welding current oscillates
14
OPERATION
between this reached welding current and the base current. If the trigger will be pushed and released more than 1 second, current decreases according to down-ramp adjustment, reaches to the final current, after post gas, welding ends.
Base current is generally used for repairing and cooling during welding and crater filling at the finishing of the welding beads. Either during DC or during Pulsed DC welding if the trigger is pushed and released less than 1 second , DC base current will be on. If the trigger will be pushed less than 1 second, welder will go back to the existing welding mode and parameters, but if the trigger will be pushed and released more than 1 second, welding will be finished by following the down-ramp, final current and post-gas.
Spot TIG Welding
When the torch trigger is pushed, main current starts immediately and goes on as long as the torch trigger is kept pushed.
Welding goes on during spot welding time. After spot welding time is over, current stops immediately.
For using welding modes (2-stroke, 4-stroke, Spot
Welding) in Flat DC mode, select Flat DC mode by button
[13]
, its LED
[14]
will be on. In this mode, only main current
[19]
is used and it is simply adjusted by the multifunctional knob
[1]
.
For using welding modes (2-stroke, 4-stroke, Spot
Welding) in Pulse DC mode, select Pulse DC mode by button
[13]
case, main current
, its LED
[19]
[15]
will be on. In this
, base current
[20]
and the
Pulse frequency
[21]
should be adjusted by the multifunction knob
[1]
. Welding current changes between main current and base current in the adjusted Pulse frequency.
Electrode
Diameter (mm)
1.6
2.0
2.4
Recommended
TIG Welding Current (A)
15 - 130
45 - 180
70 - 240
3.3.3
MMA Welding Process
Push the welding mode selection button the MMA LED
[6]
lights.
[5]
until
In this mode, only the main current LED
[19]
lights and welding current can be adjusted by the main knob. All other functions are inactive.
3.3.4
Error Message
When the machine overheats, an error message
[Err]
appears on multi functional digital display
[2]
and the LED
[26]
flashes.
In this case, wait for the machine to cool down and the error message to disappear, then you can start welding safely again.
MONOTIG 160ip
MAINTENANCE AND TROUBLESHOOTING
4.
MAINTENANCE AND TROUBLESHOOTING
Strictly follow the instructions in safety rules while servicing the machine.
Before removing any screw on the machine for maintenance, power supply must be disconnected from the electric lines and enough time (10 seconds) should be allowed for capacitor discharging.
4.1 PERIODIC MAINTENANCE
ONCE IN EVERY 3 MONTHS
Clean the labels on the machine, replace the worn out labels.
Repair or replace the worn out welding cables.
Clean and tighten the weld terminals.
ONCE IN EVERY 6 MONTHS
Open the covers of the machine and clean with dry air.
Check isolation of the torch, electrode holder, earth clamp cables.
and their
OR
NOTE: The above recommended maintenence periods are indicative, these may vary according to the work shop conditions.
4.2 NONPERIODIC MAINTENANCE
Contact tip and nozzle on the torch have to be cleaned regularly and changed if required. Contact tips must be in good condition, longer tips generally give better results.
4.3 TROUBLESHOOTING
If the Thermal Protection LED
(10)
lights up while cooling fan is working and the machine doesn't weld; machine maybe overheated and stopped for auto protection due to overheat. Hot weather or working in high current values for long time may cause this. Let the machine on for a while in order to cool down itself with the cooling fan. After it cools enough, Thermal Protection LED weld.
(10)
fades away and the machine can
When the lamp of power switch
(2)
is lighting, cooling fan is working but the machine does not weld; turn off the machine for 1 minute then turn it on again and try to weld. If it still doesn't weld, authorized technical service.
contact to your
MONOTIG 160ip 15
APPENDIX 1
SPARE PARTS
14 4
5
12
3
13
17
15
16
17
18
12
13
14
15
10
11
8
9
6
7
4
5
NO
1
2
3
16 11 7
DESIGNATION
Electronic Card - E201B-FLT
Electronic Card - E201B-01
Electronic Card - E201B-02 TIG
Grouped Electronic Cards - E201B-3/4/5 TIG
Electronic Card - E502A-1
Electronic Card - E502A-2
Electronic Card - E502A-3
Rotary Encoder
Fan
Cooler As888
Hall Effect Sensor 300A
Potent Button
HF Filter (Choke)
Handle - Monotig
Quick Coupling - Blue
Welding Socket
Born Socket - Black
Gas Ventile
ON/OFF Switch
Control Panel
6 3 2 1
IN ELECTRICAL DIAGRAM MATERIAL CODE
E201B-FLT
E201B-01
E201B-02
E201B-03
K405000101
K405000102
K405000111
K405000113
E502A-1
E502A-2
E502A-3
M1
Hall Effect
HF Coil
Torch Control Connections
Valve
Control Panel
K405000108
K405000109
K405000110
A229500001
A250200006
K000000902
A830900004
A229500001
A490900001
K103009002
A245700002
A377900104
A378290002
A253200003
A310100008
K109900024
9
10
18
16 MONOTIG 160ip
APPENDIX 2
ELECTRICAL DIAGRAM
MONOTIG 160ip 17
NOTES
FACTORY
Organize Sanayi Bölgesi 5.K
ısım Yalçın Özaras Caddesi No:1 45030 MANİSA
+90 236 226 27 00
+90 236 226 27 28
OWM 06.28.2012
Made in Turkey
www.magmaweld.com
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