Monotig 160ip User Manual.cdr - Magmaweld Welding and Cutting
Contents
1. a z 10 2 3 6 Earth Clamp GCornn ectlOris saa alsada muUis qb id resi 10 2 3 7 Changing the Tungsten 7 10 2 4 CONNECTIONS FOR 2 0 0 ARAR YARAYA ARR AYYY YY YARAYA Ra eee 11 3 OPERAT ON scsi EE 12 3 1 GONTROL PANEL iti ettet ut bte Ip uti etia 12 Corc daa IOS 13 3 9 MENU STR GLTIURE 2 2 ise Ward tentacle rd ep E iet d eo lam da 13 3 3 1 TIG Welding Process deutet ern o ed ee ARAM 14 3 3 2 Usage of the TIG Welding 14 3 9 3 MMA Welding 55 rid e ERREUR 14 3 3 4 Error cic ees agar a a deae m ae rna a BER 14 4 MAINTENANCEANDTROUBLESHOOTING 1 11 15 4 1 PERIODIC 15 4 2 NONPER IODIC MA NTENANCE suala ep iu 15 4 3 TROUBLESHOOTIN G a sala a ear rra ete e I 15 APPENDIX 1 SPARE PARTS iita dicet diia ininde oA nao eei Ee eater UR Pb 16 APPENDIX 2 ELECTRICAL DIAGRAM stis ote eee ide va bean e dnt asi ee 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 b2. 2 0 Figure 6 Changing the Tungsten Electrode Unscrevv the clamping cap 27 Remove the existing tungsten electrode 26 from the collet 28 and insertthe new electrode in nsertthe collet 28 into the torch Screw the clamping cap 27 tightly The ceramic gas nozzle 30 and the tungsten electrode 26 diameters should be selected according to the working current and the shape of the work piece Therefore the collet 28 the collet body 29 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 insert the electrode holder cable 20 and the earth clamp cable 18 plugs into their appropriate sockets 5 6 and tighten them by turning clock wise Connect the earth clamp tightly to the work piece 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 2 0 i 40 60 A 2 5 60 90 A 60 90 A 60 100 A 3 25 100 140 A 100 130 A 70 130 A 4 0 140 180 A 140 180 A 120 170 A MONOTIG 160ip Fig
3. Noise from certain industrial processes or equipments damage hearing Wearapproved 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 NR 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 Forthat reason keep extinguishing means such as fire extinguishers water and sand which are easy to reach Keep security valves regulators and other valves used on flammable explosive and co
4. 5096 Apc 160 Rated Welding Current MMA 25 Apc 150 Fuse A 32 Delayed Protection Class EN 60529 IP23S Cooling Method Air Dimensions LxVVxH mm 515x160x312 Weight kg 10 Standards and Approvals MONOTIG 160ip CE EN60974 1 EN60974 10 TECHNICAL INFORMATION 1 5 ACCESORRIES Electrode Holder and Cable 16mm 3m 1 K301000203 Earth Clamp and Cable 16mm 3m 1 K301100203 TIG Torch Plug CX79 1 Y512000029 Torch Abitig 200 200A 3596 DC 4m 1 5510031901 Torch Sintig 18W 4 320A 100 DC 4m 1 S510031211 Torch Sintig 18VV 4 320A 10096 DC 8m 1 S510031212 Gas Pressure Regulator Ar CO 1 S520001002 VVater Cooling Unit CS 200 1 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 E mail servis magma com tr Fax 90 236 226 27 28 Standard box contains Power Source Electrode Holder Cable n Earth Clamp Cable TIG Torch Plug Transportation Belt User Manual 2 2 INSTALLATION AND WORKING RECOMMENDATIONS DO NOT USE THE MACHINE WITH LONG MAINS CABLES AT CONSTRUCTION SITES Mains cables are under 220V 50 Hz and these cables are no
5. with the code K307000010 2 3 4 Preparing the Torch Connections TIG torch connection via CX79 TIG torch adaptor Thread the nut 16 of the torch through the plastic body 17 and screw to the torch plug 18 tightly Then place the torch plug 18 into the plastic body 17 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 20 to the elbow union 19 with the clamp tightly Install the connector pins 22 to the control cables 21 ofthe torch Figure 4 Mounting the Torch Plug and the Torch 2 3 5 Torch Connections Connectthe TIG torch plug that you ve prepared to the negative welding socket 5 tightly Screw the gas hose of the torch to the gas outlet 4 nsert the connector pins 17 to the torch control connections 7 n case of using water cooling unit connect the water hoses of the water cooled torch to the water cooling unit 10 2 3 6 Earth Clamp Connections Connect the earth cable plug 23 to the positive welding socket 6 tightly 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 Figure 5 TIG Welding Connections 2 3 7 Changing the Tungsten Electrode p 22 27 22 28
6. 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 grounded HOT PARTS CAN CAUSE SEVERE BURNS 2 Donottouch hot parts Allow cooling time before servicing e fneeded to hold hot parts use appropriate tool insulating gloves and fireproof clothes 2 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 rritation of the eyes nose and throat are symptoms inadequate ventilation Take immediate steps to improve ventilation Do not continue welding if symptoms persist Install a natural orforced 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 t
7. 9109 91029 Vveosa T3NVd TOYLNO9 1713 91023 17 MONOTIG 160ip FACTORY e Organize Sanayi B lgesi 5 Kisim 5503 Sokak No 1 MAN SA 90 236 226 27 00 90 236 226 27 28 OWM 06 21 2011 Made in Turkey MAGMA MEKATRON K MAK NE SANAY VE T CARET A www magmaweld com
8. CE 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 7 terminals torch electrode holder Clean and tighten the weld p Check isolation of the eff 67 earth clamp and their cables ONCE IN EVERY 6 MONTHS Open the covers of the machine and clean with dry air 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 m generally give better results 4 3 TROUBLESHOOTING f 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 Protectio
9. ION 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 amp for MMA welding of all kinds of stick electrodes 4 mm Enhanced professional TIG controls such as HF start Touch Lift pre gas up slope pulse down slope post gas amp crater filling are present Upto 10 complete jobs can be stored in the memory and run when itis 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 Monotig 160ip 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 Figure 1 Monotig 160ip 1 Line Cable Inlet 6 Earth Cable and Welding Cable Socket 2 Power Switch 7 Torch Control Connections 3 Gas Inlet 8 Control Panel 4 Gas Outlet 9 Multifunctional Adjustment Knob 5 Earth Cable and Welding Cable Socket 10 Thermic Error LED 6 MONOTIG 160ip TECHNICAL INFORMATION 1 3 DATA PLATE SHAH Single Phase Static Frequency Converter Tran
10. 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 In the first use all parameters of all programs are in factory settings which are shownin the table Pushthe program selection button 3 for selecting a previously adjusted program or changing its parameters Push the welding mode selection button 5 for selecting Touch Lift TIG or HF start TIG Push the 2 Stroke 4 Stroke Spot Welding Selection Button 9 to select the appropriate mode for the work Push the Flat DC TIG Pulse DC TIG selection button 13 for selecting Flat DC TIG or Pulse DC TIG Push the multi functional 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 up slope time ad
11. USER MANUAL magmaweld MONOTIG 160iP DC INVERTER T G WELDING MACHINE MAGMA MEKATRON K MAK NE SANAY VE T CARET A www magma com tr CONTENTS 2 TZIECHNICALE INFORMATION aa alaka daira ceeds 6 1 1 GENERAL EXPLANATIONS iie arasa darda ii tege ro ERR a a E diren 6 1 2 COMPONENTS OF MONONIG 160iB 2 E ra Gaza 6 1 3 DATA PLATE ernannt bn Las en at M 7 1 4 TECHNICAL SPECIFICATIONS ili 7 1 5 ACGESSORRIES andi arananlara siraya ana ences pb adeo s d cage a ir 8 25INSTAPEEATION salimen Mana dae e at ete 9 2 4 UPON REGEIPTAND GLEAIMS Es rete eth ea i edente dilan in 9 2 2 INSTALLATION AND WORKING RECOMMENDATIONS sse 9 2 3 CONNECTIONS FOR 1 9 2 3 1 Mains Connection and Switching EE T 9 2 3 2 Gas 3 t ed d erat e DU CREE er 9 2 3 3 Torch Cooling System Optional ded nt t Eee d bd nc ile did edens 10 2 3 4 Pr eparing the TOFchi ais ete ap en REEL RI cet ae 10 2 3 5 Torch Connections i sa an lala oat i alel a ana da
12. adjusted by turning the multi functional knob 24 Final Current LED is selected by pushing multi functional knob While LED is on the desired value is adjusted by turning the multi functional knob MONOTIG 160ip OPERATION pushing multi functional knob While LED is on the functions are shownin the table below 25 Post Gas Flow Time LED is selected by According to the modes active and inactive desired value is adjusted by turning the multi functional knob 26 Thermal Error LED lights when machine is overheated 3 2 TIG CYCLE Spot Welding Time Current Gas Post Flow Current Final Down slope Current Current Pre Flow Current Up slope Only in TIG with PULSE Only in Spot mode In all TIG modes except 2 Stroke DC TIG 3 3 MENU STRUCTURE PARAMETER FACTORY Welding TIG TIG TIG 16 muzdur fue nc pane oe fuso Pre Gas Flow Time 0 1 10 sec 1 sec vi vi Start Current 10 160A 20A 17 0 1 10 sec 1 sec 18 Main Current 10 160A 130A 19 Base Current 10 160A 80A 20 Vo v v v v Frequency 0 1 2000 Hz 15Hz 21 Spot Time 0 1 10 sec 5 sec 22 Down slope Time 0 1 10 sec 1 sec 23 Final Current 10 160A 40A 24 Vo v v v v Post Gas Flow Time 1 23 sec 2 sec 25 MONOTIG 160ip 13 OPERATION 3 3 1 TIG Welding
13. e 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 cylinderto a wall by a chain 2 3 2 Gas Connections 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 ofthe regulator match Figure 3 Gas Cylinder Regulator Hose Connections INSTALLATION Connect one end of gas hose 14 to the gas regulator 12 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 thatthere are no gas leakages from any connection Diameter of Diameter of Welding 2 Electrode Nozzle Current mm mm Apc 15 70 6 8 1 6 9 5 30 150 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
14. e 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 Learntooperate 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 EN ELECTRICAL SHOCK CAN BE FATAL h Installation procedure must comply with national electricity standards and other relevant regulations andensure 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 nottouch 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
15. justment 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 down slope 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 pre gas 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 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
16. le Reduce current or reduce duty cycle before starting to weld again Do not block airflow through the unit Donotfilter airflow to unit without the approval of manufacturer ARC WELDING CAN CAUSE INTERFERENCE 11 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 Besureall equipmentin the welding area is electromagnetically compatible Toreduce possible interference keep weld cables as short as possible close together and down low such asonthe 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 RD Donotexpose 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 e Ifyou will have along break after welding turn off the machine after cooler fan cooled the machine MONOTIG 160ip 5 TECHNICAL INFORMATION 1 TECHNICAL INFORMAT
17. mpressed gas circuits in good condition 5 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 4 MONOTIG 160ip SAFETY RULES FALLING UNIT CAN CAUSE INJURY A 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 notto fall over attach itto the mobile machine orto the wall with a chain Ensurethatoperators easily reach the controls and connections on the machine inu OVERUSE CAN CAUSE OVERHEATING E Allow cooling period follow rated duty cyc
18. n LED 10 fades away and the machine can weld 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 contact to your authorized technical service MONOTIG 160ip 15 APPENDIX 1 SPARE PARTS DESIGNATION IN ELECTRICAL DIAGRAM MATERIAL CODE 1 Electronic Card E201B FLT E201B FLT K405000101 2 Electronic Card E201B 01 E201B 01 K405000102 3 Electronic Card E201B 02 E201B 02 K405000103 4 Grouped Electronic Cards E201B 3 4 5 E201B 03 K405000107 5 Electronic Card E502A 1 E502A 1 K405000108 6 Electronic Card E502A 2 E502A 2 K405000109 7 Electronic Card E502A 3 E502A 3 K405000110 8 Rotary Encoder A460501001 9 Fan M1 A250200006 10 Cooler As888 K000000902 11 Hall Effect Sensor 300A Hall Effect A830900004 12 Potent Button A229500001 13 HF Filter Choke HF Coil A490900001 14 Handle Monotig K103009002 15 Quick Coupling Blue A245700002 16 VVelding Socket A377900104 17 Born Socket Black Torch Control Connections A378290002 18 Gas Ventile Valve A253200003 ON OFF Switch A310100008 Control Panel Control Panel K109900024 16 MONOTIG 160ip APPENDIX 2 ELECTRICAL DIAGRAM gt gt swop 1 uoi oL 0 91023 22 20
19. o 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 places it can be inhaled 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 amp FLYING METALS CAN INJURE EYES Welding wire brushing and grinding cause sparks and flying metal Topreventinjuries wear appropriate safety glasses with side shields even under your welding helmet MOVING PARTS CAN CAUSE INJURY Keepaway from moving parts Keepall doors panels and guards closed and secured e Wear shoes with metal protection over the fingers MONOTIG 160ip SAFETY RULES NOISE CAN DAMAGE HEARING 0
20. s LED 12 lights Button 13 is to select Flat DC TIG Pulse DC TIG 12 magmaweld LED 14 lights when Flat DC TIG is selected and LED 15 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 multi functional knob While LED is on the desired value is adjusted by turning the multi functional knob 17 Starting Current LED is selected by pushing multi functional knob While LED is on the desired value is adjusted by turning the multi functional knob 18 Up Slope Time LED is selected by pushing multi functional knob While LED is on the desired value is adjusted by turning the multi functional knob 19 Main Current LED is selected by pushing multi functional knob While LED is on the desired value is adjusted by turning the multi functional knob 20 Base Current LED is selected by pushing multi functional knob While LED is on the desired value is adjusted by turning the multi functional knob 21 Pulse Frequency Adjustment LED is selected by pushing multi functional knob While LED is on the desired value is adjusted by turning the multi functional knob 22 Spot Time LED is selected by pushing multi functional knob While LED is on the desired value is adjusted by turning the multi functional knob 23 Down Slope Time LED is selected by pushing multi functional knob While LED is on the desired value is
21. sformer Rectifier 160ip SeriNo 00 BHD P 10A 10 4V 160A 16 4V A 50 60 100 160A 145A 144 224 153A TIG Welding Manual Metal Arc Welding Direct Current Descending Characteristics Line Input 1 Phase Alternating Current 10A 20 4V 160A 26 4V Appropriate To Operate In Dangerous 25 60 100 Work Area b 1504 97A 2 26V 239V h 315A 15A x Uoz75V 91 7 2 3 5kVA 3 1kVA U U U Cycle Open Circuit Voltage 31 5 here 15 7A i Line Voltage and Frequency Rated Welding Voltage 1 Current po U1 230V Rated Welding Current 1 50 60Hz IP23S Protection Class Le o 6 ON Duty Cycle Temperature 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 UNIT VALUE Line Voltage 1 phase V 230 Input Power TIG 5096 kVA 5 Input Power MMA 25926 kVA 7 2 Input Current TIG 5096 A 22 nput Current MMA 2596 A 31 5 Povver Factor 0 97 Open Circuit Voltage 75 Welding Current Range Apc 10 160 Rated Welding Current TIG
22. t 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 It is ALWAYS recommended to use longer WELDING CABLES instead of MAINS 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 40 C 2 3 CONNECTIONS FOR TIG WELDING 2 3 1 Mains Connection and Switching ON Before plugging your machine to the electrical line check the line voltage 230 VAC amp Switch the machine to the position OFF 0 and insertthe plug into the socket SWITCH ON the machine via power switch 2 Observe that the switch itself and the led displays in the front panel lits also you should hear the sound ofthe cooler fan Figure 2 Gas and Mains Connections MONOTIG 160ip 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 Use 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 th
23. torch trigger is kept pushed Welding goes on during spot welding time After spot welding time is over current stops immediately Flat DC Pulse DC Forusing 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 multi function knob 1 Forusing welding modes 2 stroke 4 stroke Spot Welding in Pulse DC mode select Pulse DC mode by button 13 its LED 15 will be on In this case main current 19 base current 20 and the Pulse frequency 21 should be adjusted by the multi function knob 1 Welding current changes between main current and base current in the adjusted Pulse frequency Electrode Recommended Diameter mm TIG Welding Current A 1 6 15 130 2 0 45 180 2 4 70 240 3 3 3 MMA Welding Process Push the welding mode selection button 5 until the MMA LED 6 lights 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 andthe 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 MAINTENAN
24. ure 5 MMA Welding Connections OPERATION 3 OPERATION 3 1 CONTROL PANEL Frequency 22 Monotig 160i 1 Multi functional 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 Multi functional Display displays the value of the welding parameter which is selected by multi functional knob Plus it displays the welding current value during welding 3 Program Selection Button is to select the desired program 4 Program Display displays the number of the selected program 5 Welding Mode Selection Button is to select MMA HF Start TIG and Touch Lift TIG modes When 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 2 Stroke 4 Stroke Spot Welding Selection Button is to select 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 it
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