INSTRUCTION MANUAL ELITE AC/DC 225
INSTRUCTION MANUAL ELITE AC/DC 225 SI8200AL DESCRIPTION The ELITE AC/DC 225 is the new generation of multi functional high quality welding machine, designed and developed independently by our company. The welder adopts a microcomputer system control, dual current loop PWM control, full-bridge high frequency inverter system. It has convenient operation, stable performance, small size and high duty cycle. The welder is mainly applied to the welding of aluminum, aluminum alloy, copper, titanium, and other non-ferrous metals and stainless steel, carbon steel and other metals, Characteristics ☆ High successful rate of arc start ☆ Stable arc without breaking arc ☆ Safety, efficiency ☆ One model, seven functions: ◆ TIG/DC ◆ TIG/PULSE ◆ TIG/AC ◆ TIG/AC /PULSE ◆ TIG/MIX ◆ TIG/SPOT ◆ MMA SAFETY Arc welding can be dangerous and can cause serious and even fatal injuries Protect yourself and others Ensure the following safety precautions are taken: Arc radiation Protect yourself with a hamlet fitted with filters Rain, steam, damp Use your welding unit in a clean/dry environment, on a flat surface. Electric shock Falls This device must only be used with an earthed power supply. Do no touch high voltage parts. Check that the power supply is suitable for this unit Ensure the unit is placed in a stable position to prevent the machine from falling onto prople/objects Burns Wear protective (fire-proof) clothing (cotton, overalls or jeans). Wear protective gloves and a fire-proof apron Ensure other people keep a safe distance from the work area and do not look directly at welding arc. protect others by installing fire-proof protection walls. Fire risks Remove all flammable products from the work area. Do not work in presence of flammable gases Fumes Do not inhale welding gases and fumes. Use the device in a well ventilated environment, with artificial extraction if welding indoors Additional Precautions Any welding operation undertaken in..... - rooms where there is an increased risk of electric shocks, - poorly ventilated rooms, - in the presence of flammable or explosive material, should always be approved by a "responsible expert”, and made in presence of people trained to intervene in case of emergency. Technical protection as described in the Technical Specification CEI/IEC 62081 must be implemented. Welding in raised positions is forbidden, except in case of safety platforms use. SPECIFICATION TIG /DC Rated input voltage Max input power factor Rated open voltage Load voltage 10.2~18 V Welding 5~200 current A Arc current A 5~200 Base / current % Crater current 5~200 Arc force / current Pulse / Frequency Hz Pulse ratio % / TIG TIG TIG/AC TIG TIG /PULSE /AC /PULSE /MIX /SPOT AC230V±15% (195V～265V) 50/60Hz MMA 8.1KW 10.5KW 70V 10.2~18 10.4~18 10.4~18 10.4~18 10.2~18 70V/12 V 20.2~28 5~200 10~200 10~200 10~200 5~200 5~200 5~200 10~90 10~200 / 10~200 10~90 10~200 / / / / / 5~200 / 10~200 / 10~200 / 10~200 / / / / 5~200 0.1~800 / 0.1~800 / / / 10~90 / 10~90 / / / AC Frequency Hz AC Balance % Slop up time S Slop down time S Pre Gas Time S Post Gas Time S Spot time S Duty Cycle at 25 OC / / 30～ 200 30～ 200 30～ 200 / / / / 10~50 10~50 10~50 / / 0～10 0～10 0～10 0～10 0～10 / / 0～10 0～10 0～10 0～10 0～10 / / 0～10 / 0～30 / / / / / / 0.01-5 / 60 60 50 50 50 60 60 Insulation class IP class Dimension mm F IP21S 443*200*238 FRONT PANEL LAYOUT The front panel includes 6 button switches ( welding model switch, welding function switch, arc start switch, 2T/4T switch, VRD switch, data loading and recall switch), 1 encoder switch, 33 LED indicator and 1digital display. Welding model switch: MMA DC TIG AC TIG SPOT Welding function switch DC ( Pulse) Pulse( output current will change periodically based on the setted Pulse frequency and base current ) MIX (AC square wave current will be inserted a DC current to stabilize arc) Arc start switch LIFT TIG: Contact start HF TIG: High frequency start without contact 2T/4T switch 2T: short welding 4T: long welding VRD switch ON/OFF Working ( Open voltage will be limited DC 12V safe voltage) Data loading and recall switch Loading( 20 of setting mode can be saved) Recall Encode switch(Setting) The switch can be turned and pushed. Turning for choosing program and adjust data. Pushing for confirming and exit of program and data. Setting: Start setting: Push the setting switch to start the setting, the default setting LEDs are on Program choosing: Turn the setting switch to choose program for setting, the matched LED will be on. Adjust parameters: Push the setting again, the chosen LED shinning, then turn the setting for adjust the parameters. Parameter confirmation: .Push the setting again for confirmation set parameters, the LED keeps on. Exit of setting: Push the setting again, the chosen LED off, then quit the setting. Digital display Current Time Frequency Balance % TIG/DC operation Data setting: Choose the TIG /DC model, DC welding function, LIFT/HF , 2T/4T, adjust the pre gas time, arc current, slope up time, peak current, slop down time, crater current, slope down time. 1. Pre gas time setting: In order to ensure that the workpiece and the tungsten from contamination and burnout, set the pre gas time to let go argon air to push out the rest air in the torch. The pre-gas provides protection for the area where the welding pool will be formed. It also improved stability when the welding arc is created. 2. Arc current Setting: Usually set the current less than the max current. 3. Slop up time Setting: Time needed to go from minimum current welding current. 4. Max Current: It is the welding current. Set the current refer to the TIG welding table. 5. Slop down time Setting: Time needed to shift from welding current to minimum current. Avoid cracks and craters at the end of welding. 6. Crater current Setting: Usually set the current less than the max current. 7. Post gas time Setting: In order to ensure that the workpiece and the tungsten from contamination and burnout, set the pre gas time to let go argon air keep some time. It protects the weld poil and the electrode against oxidization whilst the metal is cooling after welding. TIG/DC WELDING TABLE WORKPIECE Flow rate （ ） (Argon L/mn) Φ Electrode （MM） Φ Rod (filler metal) MM CURRENT A 0.6 1.0,1.6 ~1.6 20~40 4 1.0 1.0,1.6 ~1.6 30~60 4 1.6 1.6,2.4 ~1.6 60~90 4 2.4 1.6,2.4 1.6~2.4 80~120 4 3.2 2.4,3.2 2.4~3.2 110~150 5 4.0 2.4,3.2 2.4~3.2 130~180 5 4.8 2.4,3.2,4.0 2.4~4.0 150~220 5 6.4 3.2,4.0,4.8 3.2~4.8 180~250 5 DEOXIDIZE 1.0 1.6 ~1.6 60~90 3~4 D COPPER 1.6 2.4 1.6~2.4 80~120 3~4 2.4 2.4,3.2 2.4~3.2 110~150 4 3.2 3.2,4.0 3.2~4.8 140~200 4~5 4.0 3.2,4.0,4.8 4.0~4.8 180~250 4~5 4.8 4.0,4.8 4.8~6.4 250~300 5~6 6.4 4.0,4.8,6.4 4.8~6.4 300~400 5~6 1.0 1.6 ~1.6 50~60 5~6 1.6 1.6,2.4 ~1.6 60~90 5~6 2.4 1.6,2.4 1.6~2.4 80~110 6~7 3.2 2.4,3.2 2.4~4.0 100~140 6~7 4.0 3.2,4.0 3.2~4.8 140~180 7~8 4.8 3.2,4.0,4.8 4.0~6.4 170~220 7~8 6.4 4.0,4.8 4.0~6.4 200~270 8~12 1.0 1.6 ~1.6 30~40 3~4 1.6 1.6,2.4 1.6~2.4 40~70 4~5 2.4 1.6,2.4 1.6~2.4 60~90 4~5 3.2 1.6,2.4 2.4~3.2 75~110 5~6 4.0 2.4,3.2 3.2~4.0 90~120 5~6 4.8 3.0,4.0 3.2~4.8 110~150 5~6 6.4 3.2,4.0 4.0~4.8 130~170 6~7 MATERIAL THICKNESS STAINLESS STEEL （DC+） （DC+） ALUMIUM （AC） Magnesi um（AC） （MM） （ ） To optimize the welding process, it is recommend to gind the electrode prior to welding as described in the diagram below TIG welding process 1 Shielding gas 2 Arc 3 TIG filler rod 4 Weld pool 5 Collect 6 Tunsten Electrode 7 Workpiece TIG welding techniques The suggested electrode and welding rod angles for welding a bead on plate. The same angles are used when marking a butt weld. The torch is held 60-75o from the metal surface. This is the same as holding the torch 15-30o from the vertical. Take special note that the rod is in the shielding gas during the welding process TIG/DC/PULSE Operation Data setting: Choose the TIG /DC model, Pulse welding function, LIFT/HF , 2T/4T, adjust the pre gas time, arc current, slope up time, peak current, base current, slop down time, crater current, slope down time, pulse frequency, pulse ratio.. 1. Base current setting: Usually set in a small value as long as not break the arc. 2. Pulse ratio setting: The ratio determines the hear input, the bigger ratio it is, the weld seam is wider and deeper and vice versa. Usually set the ration between 30%-70%. 3. Pulse frequency setting: The higher frequency it is, the weld seam denser and vice versa. TIG/DC/PULSE welding Table1 GAP MM MATERIAL MILD STEEL JOINT SHAPE PULSE CONDITION PEAK BASE PULSE PULSE FEED SPEED SPEED CM/MIN CM/MIN CURREN （） CURRE FREQU T A NT A ENCY 0 200 50 2.5 50 60 60 1.2 150 20 1.5 45 30 60 1.6 130 20 1 50 15 40 （） RATIO% WELDING （HZ） 0 150 50 3 50 80 40 STAINLES 1.2 150 20 1 35 17 40 S STEEL 1.6 130 20 0.8 30 10 40 2.0 130 20 0.8 30 83 0 0 280 50 3 50 80 1.2 280 50 2 50 50 1.6 280 50 1.5 40 25 0 200 100 1 30 25 COPPER TITANIUM 75 75 0 ）； ELECTRODE ： Thoriated tungsten electrode (3.2MM)； FILL METAL：Φ1.2MM； LENGTH OF ARC：2MM SHILDING GAS: ARGON (10L/MIN TIG/DC/PULSE welding Table2 GAP MARTE RIAL MM JOINT SHAPE PULSE CONDITION MAXC BASE PULSE WELDING FEED PULSE SPEED SPEED RATIO% CM/MIN CM/MIN URR CURREN ENT （） FREQUE T A NCY HZ 1 250 50 0.8 20 10 60 1 170 60 2.5 50 50 60 1 120 50 2 50 20 30 1 160 50 1.5 45 8.5 60 （A） （ ） STEEL+ MILD STEEL STAINL ESS STEE+ MILD STEEL MILD STEEL STAINL ESS STEEL ）； ELECTRODE ： Thoriated tungsten electrode (2.4MM)； FILL METAL：Φ1.2MM； LENGTH OF ARC：2-3MM SHILDING GAS: ARGON (10L/MIN TIG/AC Operation Data setting: Choose the TIG /AC model, , LIFT/HF , 2T/4T, adjust the pre gas time, arc current, slope up time, peak current, slop down time, crater current, slope down time, AC frequency, AC balance. 1. AC frequency setting: The higher frequency it is , the arc concreted more intensive, weld seam smoother, but the sound of arc relatively shrill. Usually suggest the low AC frequency. 2. AC Balance (EP ratio) setting: It is the percentage of AC negative wave against AC period. The higher it is, the weld seam smoother, but the penetration more shallow, tungsten worn easier. Usually suggest the low EP ratio TIG/AC/Pulse Operation Data setting: Choose the TIG /AC model, Pulse welding function, LIFT/HF , 2T/4T, adjust the pre gas time, arc current, slope up time, peak current, base current, slop down time, crater current, slope down time, Pulse frequency , Pulse Ratio , AC frequency, AC balance. TIG/DC/PULSE welding Table2 THIC MATE Filler metal PULSE CONDITION KNE PEAK BASE PULSE PULES DIAMET FEED SS CURRE CURRE FREQUENCY RATIO % ER MM SPEED MM NT A NT A HZ JOINT SHAPE RIAL CM/MIN 75 1.0 70 25 1 50 1.6 1.5 80 40 1 50 1.6 1.5 90 25 1 50 1.6 1.5 85 25 1 50 1.2 3.2 170 25 1 50 1.2 3.0 170 25 1 50 1.6 6.0 220 25 1 50 1.6 95 75 ALUM 95 290 IUM 170 250 250 FIRST L 180 25 1 50 1.6 180 25 1 50 1.6 250 6.0 220 25 1 50 1.6 270 3.0 120 25 1 50 1.6 60 6.0 SECOND TIG/MIX Operation MIX TIG: AC welding 0.3s+DC welding 0.2s. Data setting: Choose the TIG /AC mode, MIX welding function, LIFT/HF , 2T/4T, adjust the pre gas time, arc current, slope up time, peak current,, slop down time, crater current, slope down time, AC frequency, AC balance. Welding can refer to the TIG DC instruction. TIG/SPOT Operation Data setting: Choose the SPOT mode, adjust the pre gas time, slope up time(spot time), peak current,, slop down time. In this mode, the machine can works in HF and 2T only. MMA Operation Data setting: Choose the MMA mode, adjust slope up time( Arc force), peak current. Welding current setting table- Flat welding MM ELECTRODE Ilmenite electrode Titania calcium electrode 2.6 3.2 4.0 4.5 5.0 50~85 80~130 120~180 145~200 170~250 50~100 90~130 140~180 160~210 190~150 low hydrogen electrode 55~85 100~140 140~190 190~250 Welding current setting table- Vertical welding MM ELECTRODE Ilmenite electrode Titania calcium electrode low hydrogen electrode 2.6 3.2 4.0 4.5 5.0 40~70 60~110 100~150 120~180 130~200 50~90 80~130 110~170 125~190 140~210 50~80 90~130 120~180 160~210 TROUBLE SHOOTING Symptom Causes The device does not Thermal protection is on deliver any current and the yellow LED in on No arc exists Torch switch is useless Power switch is broken The cable to switch is disconnected The cable to workpiece is disconnected The cable of torch is broken Starting arc is not Connecting tie-in is loose good or jarless Argon gas is not pure The tungsten electrode is no good fixed or its quality is no good Surface of welding Dunghill or grease exists on the surface of workpiece line is no good Argon gas is not pure Flux of argon gas is not enough Dunghill exists on the surface of tungsten electrode Tungsten electrode Current is too great or tungsten electrode is too thin wastes hard Argon gas is not pure Polarity error
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