monotig 160ip son - · pdf filearc rays can burn eyes and skin ... for example, a welder with...

MONOTIG 160İP

DC INVERTER TIG

WELDING MACHINE

2.3.2 Gas Connections

2.3.3 Torch Cooling System (Optional)

2.3.4 Preparing the Torch

2.3.5 Torch Connections

2.3.7 Changing the Tungsten Electrode

3. OPERATION

3.1 CONTROL PANEL

3.2 TIG CYCLE

3.3 MENU STRUCTURE

3.3.1 TIG Welding Process

3.3.2 Usage of the TIG Welding Modes

3.3.3 MMA Welding Process

3.3.4 Error Message

SAFETY RULES

1. TECHNICAL INFORMATION

1.1 GENERAL EXPLANATIONS

1.2 COMPONENTS OF MONOTIG 160iP

1.3 DATA PLATE

1.4 TECHNICAL SPECIFICATIONS

1.5 ACCESSORRIES

2. INSTALLATION

2.1 UPON RECEIPT AND CLAIMS

2.2 INSTALLATION AND WORKING RECOMMENDATIONS

2.3 CONNECTIONS FOR TIG WELDING

Mains Connection and Switching ON

Earth Clamp Connections

2.4 CONNECTIONS FOR MMA WELDING

4. MAINTENANCE AND TROUBLESHOOTING

4.1 PERIODIC MAINTENANCE

4.2 NONPERIODIC MAINTENANCE

4.3 TROUBLESHOOTING

APPENDIX 1: SPARE PARTS

APPENDIX 2: ELECTRICAL DIAGRAM

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1MONOTIG 160ip

CONTENTS

2 MONOTIG 160ip

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 followinginstructions 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 andthe 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 machinenegatively and shorten its lifetime.

SAFETY RULES

ELECTRICAL SHOCK C FATALAN BE

Installation procedure must comply with national electricity standards and other relevant regulationsand ensure that installation is performed by qualified persons.

Wear dry insulating gloves and body protection.

Do not touch electrode with bare hand. Do not wear wet or damaged gloves andbody protection.

Do not touch live electrical parts

Never touch electrode while in contact with working surface, ground or anotherelectrode which is connected to a different machine

free of damage

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, drywood or plywood, or other dry insulating material big enough to cover your full areaof contact with the work or ground, and watch for fire.

Never connect more than electrode to the .one electrode holder

Turn off the machine, when not in use

Disconnect input plug or power before working on machine.

Frequently inspect input power cord for damage or bare wiring - repair or replacecord immediately if damaged.

Be sure ground

swtich off the the

that the machine is properly ed.

HOT PARTS CAN CAUSE SEVERE BURNS

Do not touch hot parts

Allow cooling time before servicing

hot parts, use appropriate tool, insulating gloves and fireproof clothes.

If needed to hold

OBEY ALL THE SAFETY RULES

STATED IN THE MANUAL!

3MONOTIG 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 andforbidden .

Irritation of the eyes, nose and throat are symptoms of inadequate ventilation. Takeimmediate 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 neededinstall a system that can remove the fume and vapor accumulated in the entire workarea, 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 suppliedrespirator 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-ventilatedarea. When not being used, turn off the main cylinder valve and watch out for gasleakage

Shielding gasses such as argon is denser than air and when being used in confinedplaces, can be inhaled is dangerous for health

Do not perform welding operations near chlorinated hydrocarbon vapors producedby degreasing or painting

it which .

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 adequateprotective clothing

To protect others by arc rays and hot metals, surround the working area with flameproof 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.

4 MONOTIG 160ip

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 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-proofcovers.

Do not weld on and cut closed tubes or pipes

Before welding on closed containers, open and clear them entirely. Weldingoperations on these parts must be performed with the utmost caution

Never weld containers or pipes containing or which have contained substancesthat 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 asfire extinguishers, water and sand easy reach

security valves, regulators and other valves on flammable, explosiveand compressed gas circuits in good condition

which are to .

Keep , used, .

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 unwindingwelding 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.

MAINTENANCE MADE BY UNQUALIFIED PERSONS MAY CAUSE INJURIES

Electrical devices should not be repaired by unqualified persons. Improper repairs can cause seriousinjuries or even death during applications

The components of the gas circuit works under pressure. The service given by unqualified persons maycause explosions and operators can be injured seriously

5MONOTIG 160ip

SAFETY RULES

FALLING UNIT CAN CAUSE INJURY

Wrong positioned power source or other equipment may cause serious injury to persons or damageto 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 andseparately carry the small ones by handgrips and the big ones by lifting eyes or by using appropriatevehicles like forklifts

Install your machine on flat platforms having maximum 10 that it does not fall over. Install it on wellventilated, non-confined places away from the dust, also avoiding the risk of falling caused by cables andhoses. 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.

° slope

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 unit.

Do not filter airflow to unit without the approval of manufacturer

hrough the

ARC WELDING CAN CAUSE INTERFERENCE

Electromagnetic energy arising during welding and cutting operations can interfere with sensitive electronicequipment 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, suchas on the floor

To avoid possible EMC damages, locate welding operation as far as possible (100 meters) from anysensitive 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, usingshielded cables, using line filters, or shielding the work area

� Do not expose the welding machine to rain, protect from water drops and vapour.

PROTECTION

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.

1.2 COMPONENTS OF MONOTIG 160iP

Figure 1: Monotig 160ip

Line Cable Inlet

Earth Cable and Welding Cable Socket (-)

Power Switch

Gas Inlet

Gas Outlet

Earth Cable and Welding Cable Socket (+)

Adjustment Knob

Thermic / Error LED

Torch Control Connections

Control Panel

Multifunctional

Monotig 160ip is an inverter type portable, mono-phase Pulsed DC TIG/MMA welding machine designed forTIG welding of all kinds of thin metal sheets except aluminum & for MMAwelding of all kinds of stick electrodesup to 4 mm.Enhanced professional TIG controls such as, HF start, Touch-Lift, pre-gas, up-slope, pulse, down-slope, post-gas & 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 thismachine 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.

6 MONOTIG 160ip

TECHNICAL INFORMATION

1. TECHNICAL INFORMATION

1.1 GENERAL EXPLANATIONS

TIG Welding

Manual Metal Arc Welding

Direct Current

Descending Characteristics

Line Input-1 Phase Alternating Current

X :Duty Cycle*U :Open Circuit Voltage

U :Line Voltage and Frequency

U :Rated Welding Voltage

I :Input Current

I :Rated Welding Current

IP23S :Protection ClassS :Input Power

Single Phase Static Frequency ConverterTransformer Rectifier

*Duty Cycle

Temperature ( C)°

Time (min.)6 min. 6 min. 6 min.4 min. 4 min. 4 min.

Duty cycle defines the percentage of welding time out of a period of 10 minutes at a given current and ambienttemperature (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

VALUEUNITTECHNICAL SPECIFICATIONS

Line Voltage phase

Power Factor

Open Circuit Voltage

Welding Current Range

- MMA 25%

Protection Class (EN 60529)

Cooling Method

Dimensions (LxWxH)

Weight

Standards and Approvals

Input Power - TIG

Input Power - MMA

Input Current - TIG

Input Current - MMA

Rated Welding Current - TIG

Rated Welding Current

10 - 160

25 - Delayed

515x160x312

CE, EN60974-1, EN60974-10

7MONOTIG 160ip

Appropriate To Operate In DangerousWork Area

1.3 DATA PLATE

MONOTIG 160ip

22A 15.5A

5kVA 3.5kVA 3kVA

1.5 ACCESORRIES

STANDARD ACCESORRIES PIECE PRODUCT CODE

K301000203

Y512000029

K301100203

Electrode Holder and Cable (16mm² - 3m)

TIG Torch Plug - CX79

Earth Clamp and Cable (16mm² - 3m)

OPTIONAL ACCESORRIES PIECE PRODUCT CODE

S510031901

S510031212

K307000010

S510031211

S520001002

Torch Abitig 200 (200A 35% DC - 4m)

Torch Sintig 18W-4 (320A 100% DC - 8m)

Water Cooling Unit (CS 200)

Torch Sintig 18W-4 (320A 100% DC - 4m)

Gas Pressure Regulator (Ar-CO )2

8 MONOTIG 160ip

INSTALLATION

2.1 UPON RECEIPT AND CLAIMS

Be sure that you have received all the items thatyou have ordered. In case of any item is missing ordamaged, contact your supplier immediately.

In the event of damaged or missing delivery,

it to the shipping agency and MAGMAMEKATRONIK with the photocopy of shipping bill.

E-mail: servis@magma.com.tr

Fax: +90 236 226 27 28

drawup a record, take a photo of the damage andreport

Standard box contains:

Power Source

H Cable

Earth Clamp Cable

TIG Torch Plug

Transportation Belt

User Manual

Electrode older

2. INSTALLATION

2.2 INSTALLATION AND WORKING RECOMMENDATIONS

9MONOTIG 160ip

DO NOT USE THE MACHINE WITH LONGCABLES AT CONSTRUCTION SITES!

cable 220V/50 Hz and thesecables are not suitable to in harshenvironments, they can easily wear and tear whichmay lead to electric leakage to the metals wherewelders may be working on. ELECTRIK SHOCKCAN KILL or cause people to FALL DOWN from

. I ALWAYSuse long WELDING CABLES

for safety reasons

For a better performance, keep the machine atleast 20 cm away from the surrounding objects.Beware of excessive heat, dust and humidityaround the machine. Try not to operate themachine under direct sunlight. Machines shouldbe operated on when ambientair temperature exceeds .

MAINSMains s are under

be used

elevated working areas t isrecommended to erinstead of MAINS CABLES .

lower capacities40ºC

Avoid welding at outdoors where it is windy andrainy, if this is a must, protect the welding area withcurtains, mobile screens or tents.

se suitable welding fume extraction systems.Use breathing apparatus if there is a risk ofinhaling in confined places.Respect the duty cycles given at the data plate.Exceeding the duty cycles frequently can damagethe machine and this would void the warranty.

Do not use stronger fuses than those stated on thedata plate

Ensure that the earth clamp is tightly connected asclose as possible to the welding location. Do not letwelding current flow through any media other thanwelding cables; e.g. over the machine itself, gastubes, chains, ball bearings, etc

Secure the gas cylinder to a wall by a chain.

2.3 CONNECTIONS FOR TIG WELDING

2.3.2 Gas Connections

Switch the machine t the position ando “OFF” “0”

insert the plug into the socket.

SWITCH ON the machine via power switch (2).Observe that the switch itself and the led displaysin the front panel li s, also you should hear thesound of the cooler fan.

Before plugging your machine to theelectrical line, check the line voltage[230 VAC].

2.3.1 Mains Connection and Switching ON

Figure 2: Gas and Mains Connections

Figure 3: Gas Cylinder - Regulator - Hose Connections

� Secure the gas cylinder to a wall by a chain. Tooperate safely and get best results, use approvedregulators.

Open the gas cylinder valve few times in orderto blow out any possible dirt or particles.

Connect the gas regulator to the cylinder, makesure that the threading of the gas outlet of thecylinder and the nut of the regulator match.

INSTALLATION

10 MONOTIG 160ip

2.3.4 Preparing the Torch Connections

TIG torch connection via CX79 TIG torch adaptor :

Thread the nut of the torch through the plasticbody and screw to the torch plug tightly.Then place the torch plug into the plastic body

Thread the L shape gas hose adapter throughthe hole on plastic body and screw it to the socket

tightly.

Connect the gas hose to the elbow unionwith the clamp tightly.

Install the connector pins to the control cablesof the torch.

(16)(17) (18)

(18)(17)

(20) (19)

(22)(21)

2.3.3 Torch Cooling System (Optional)

� CS200 water cooling unit is an optional accessoryfor cooling the water cooled torches in demandingapplications and it can be ordered with the codeK307000010.

2.3.7 Changing the Tungsten Electrode

Figure 6: Changing the Tungsten Electrode

Unscrew the clamping cap .

Remove the existing tungsten electrode fromthe collet and insert the new electrode in.

Insert the collet into the torch.

Screw the clamping cap tightly.

(26)(28)

(30)(26)

(28)(29)

The ceramic gas nozzle and the tungstenelectrode diameters should be selectedaccording to the working current and the shape ofthe work-piece. Therefore the collet , the colletbody must be matched with the diameter ofthe tungsten electrode .

2.3.5 Torch Connections

Connect the TIG torch plug that you ve prepared to

the negative welding socket tightly.

Screw the gas hose of the torch to the gas outlet.

Insert the connector pins to the torch controlconnections .

In case of using water cooling unit, connect thewater hoses of the water-cooled torch to the watercooling unit.

(17)(7)

1716 18

Figure 4: Mounting the Torch Plug and the Torch

Figure 5: TIG Welding Connections

Gas Debit(lt/dak)

Diameter ofElectrode

Diameter ofNozzle(mm)

WeldingCurrent

(A )DC

15 - 70

30 - 150

Connect one end of gas hose to the gasregulator and connect the other end to the gassupply inlet . Open the gas cylinder valve .

Set the gas quantity with the pressure adjustmentvalve .

Make sure that there are no gas leakages from anyconnection.

(14)(12)

(3) (13)

Connect.

the earth cable plug to the positivewelding socket tightly

(23)6( )

To increase the quality of the welding, connect theearth clamp tightly to the work-piece as closeas possible to the welding area.

2.3.6 Earth Clamp Connections

2.4 CONNECTIONS FOR MMA WELDING

According to the polarity of the electrode to beused, i the electrode holder cable andthe earth clamp cable plugs into theirappropriate sockets them

clock-wise

Below table is given as a reference for currentadjustment of mild steel electrodes, please refer tothe electrode manufacturer's recommendations.

and tighten byturning .

(20)(18)

5-6( )

Connect the earth clamp tightly to the work-pieceas close as possible to the welding area.

Adjust the desired current and the machine is readyto weld.

Switch ON the machine by following the steps.2.3.1

Figure 5: MMA Welding Connections

INSTALLATION

11MONOTIG 160ip

Diameter Rutile Basic Cellulosic

40-60 A

60-90 A 60-90 A 60-100 A

100-140 A 100-130 A 70-130 A

140-180 A 140-180 A 120-170 A

OPERATION

3. OPERATION

3.1 CONTROL PANEL

[1] Multi functional Knob

[2] Multi functional Display

[3] Program Selection Button

[4] Program Display

[5] Welding Mode Selection Button

MMA [6]

Touch-Lift TIG [7]

HF Start TIG [8]

[9] Stroke Stroke Spot Welding SelectionButton

2-Stroke TIG [10]

4-Stroke TIG [11]

Spot Welding [12]

Button [13]

is used for selecting andadjusting welding parameters. To select a parameter,press the button and observe that the correspondingLED lights. Clockwise and counter clockwise turningof the knob, increases and decreases the valuerespectively. To store the value, press the button.

displays the value ofthe welding parameter which is selected by multifunctional knob. Plus it displays the welding currentvalue during welding.

is to select thedesired program.

displays the number of theselected program.

is to selectMMA, HF Start TIG, and Touch-Lift TIG modes.

When mode is selected, its LED lights.

When mode is selected, its LEDlights. In this mode, arc starts after touching thetungsten electrode to the work-piece and lifting theelectrode.

When mode is selected, its LEDlights. In this mode, arc starts via ignition through thegas without any torch touching to the work-piece.

is to select 2-Stroke, 2-Stroke, and SpotWelding modes.

When is selected, its LED lights.

is to select Flat DC TIG / Pulse DC TIG.

2- / 4- /

Frequency

Spot Time

Monotig 160i

10 11 12

LED [14]LED [15]

Pulse DC TIG [15]

[16] Pre-Gas Flow Time LED

[17] Starting Current LED

[18] Up-Slope Time LED

[19] Main Current LED

[20] Base Current LED

[21] Pulse Frequency Adjustment LED

[22] Spot Time LED

[23] Down-Slope Time LED

[24] Final Current LED

lights when Flat DC TIG is selected andlights when Pulse DC TIG is selected.

When is selected, its LED lights.

is selected by pushingmulti functional knob. While LED is on, the desiredvalue is adjusted by turning the multi functional knob.

is selected by pushing multifunctional knob. While LED is on, the desired value isadjusted by turning the multi functional knob.

is selectedby pushing multi functional knob. While LED is on,the desired value is adjusted by turning the multifunctional knob.

is selected by pushingmulti functional knob. While LED is on, the desiredvalue is adjusted by turning the multi functional knob.

12 MONOTIG 160ip

[25] Post Gas-Flow Time LED

[26] Thermal Error LED

is selected bypushing multi functional knob. While LED is on, thedesired value is adjusted by turning the multifunctional knob.

lights when machine isoverheated.

According to the modes, active and inactivefunctions are shown in the table below.

PARAMETERRANGE FACTORY

SETTINGLED

2-StrokeTIG

MMAWelding

4-StrokeTIG

SpotTIG

0.1 - 10 sec

10 - 160 A

0.1 - 10 sec

10 - 160 A

0.1 - 2000 Hz

0.1 - 10 sec

10 - 160 A

1 - 23 sec

Pre-Gas Flow Time

Start Current

Up-slope Time

Main Current

Base Current

Frequency

Spot Time

Down-slope Time

Final Current

Post-Gas Flow Time

DC DC DCPulse Pulse Pulse

P P P P P P P

P P P P P P

3.3 MENU STRUCTURE

3.2 TIG CYCLE

* Only in TIG with PULSE** Only in Spot mode*** In all TIG modes except 2-Stroke DC TIG

OPERATION

GasPre-Flow

StartCurrent

CurrentUp-slope

CurrentDown-slope

FinalCurrent

GasPost-Flow

*PulseFrequency

***BaseCurrent

**Spot Welding Time

13MONOTIG 160ip

3.3.3 MMA Welding Process

Push the welding mode selection button untilthe MMA LED lights.

In this mode, only the main current LED lightsand welding current can be adjusted by the mainknob.All other functions are inactive.

[5][6]

3.3.1 TIG Welding Process

Push the program selection button for selectinga previously adjusted program or changing itsparameters.

Push the welding mode selection button forselecting Touch-Lift TIG or HF start TIG.

Push the Stroke Stroke Spot WeldingSelection Button to select the appropriatemode for the work.

Push the Flat DC TIG / Pulse DC TIG selectionbutton for selecting Flat DC TIG or Pulse DCTIG.

Push the multi functional knob for selecting thedesired welding parameter and adjust theparameter by turning the multifunctional knob .

Latest adjusted parameter values will be savedautomatically. There is no need to do anything elsefor saving the settings.

To recall a memorized parameter or to readjustany parameter, just push the program selectionbutton .

2- / 4- /

Beware of electric shock!

In HF Start TIG mode, a high ignitionvoltage is present at the torch. Nevertouch the tungsten electrode or parts

conducting welding current when the device isswitched on.

� 10 Jobs (programs) including complete parametersettings can be stored and run for repeated jobs.

In the first use, all parameters of allprograms are in factory settings which areshown in the table.

between this reached welding current and thebase current. If the trigger will be pushed andreleased more than 1 second, current decreasesaccording to down-ramp adjustment, reaches tothe final current, after post gas, welding ends.

Base current is generally used for repairing andcooling during welding and crater filling at thefinishing of the welding beads. Either during DC orduring Pulsed DC welding if the trigger is pushedand released less than 1 second , DC base currentwill be on. If the trigger will be pushed less than 1second, welder will go back to the existing weldingmode and parameters, but if the trigger will bepushed and released more than 1 second, weldingwill be finished by following the down-ramp, finalcurrent and post-gas.

Spot TIG Welding

When the torch trigger is pushed, main currentstarts immediately and goes on as long as thetorch trigger is kept pushed.

Welding goes on during spot welding time. Afterspot welding time is over, current stopsimmediately.

Flat DC Pulse DC

[13] [14][19]

[13] [15][19] [20]

[21][1]

For using welding modes (2-stroke, 4-stroke, SpotWelding) in Flat DC mode, select Flat DC mode bybutton , its LED will be on. In this mode,only main current is used and it is simplyadjusted by the multi function knob .

For using welding modes (2-stroke, 4-stroke, SpotWelding) in Pulse DC mode, select Pulse DCmode by button , its LED will be on. In thiscase, main current , base current and thePulse frequency should be adjusted by themulti function knob . Welding current changesbetween main current and base current in theadjusted Pulse frequency.

3.3.2 Usage of the TIG Welding Modes

3.3.4 Error Message

When the machine overheats, an error messageappears on multi functional digital display

and the LED flashes.

In this case, wait for the machine to cool down andthe error message to disappear, then you can startwelding safely again.

[Err] [2][26]

2-Stroke TIG Welding

4-Stroke TIG Welding

Push the torch trigger and do not release yourfinger. Current starts with start current after pregas-flow period and increases according to the up-slope time adjustment and reaches to value of themain current.

Welding goes on with the main current as long asthe torch trigger is kept pushed. After releasing thetrigger, current decreases according to down-slope time adjustment and reaches to final current,after post gas-flow period the operation ends.

When torch trigger is pushed, following the pre-gas flow, initial current starts and when the triggeris released the current ramp leads to the weldingcurrent. If DC Pulse Mode is selected, according tothe adjusted frequency, welding current oscillates

OPERATION

14 MONOTIG 160ip

ElectrodeDiameter (mm)

RecommendedTIG Welding Current (A)

15 - 130

45 - 180

70 - 240

4.2 NONPERIODIC MAINTENANCE

Contact tip and nozzle on the torch have to be cleaned regularly andchanged if required. Contact tips must be in good condition, longer tipsgenerally give better results.

NOTE: The above recommended maintenence periods are indicative, these may vary according to thework shop conditions.

4.3 TROUBLESHOOTING

If the Thermal Protection LED 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 inhigh current values for long time may cause this. Let the machine on for a while in order to cool down itselfwith the cooling fan. After it cools enough, Thermal Protection LED fades away and the machine canweld.

When the lamp of power switch is lighting, cooling fan is working but the machine does not weld; turn offthe machine for 1 minute then turn it on again and try to weld. If it still doesn't weld,

(2)contact to your

authorized technical service.

4.1 PERIODIC MAINTENANCE

Clean the labels on themachine, replace the wornout labels.

Repair or replace the wornout welding cables.

Clean and tighten the weldterminals.

Check isolation of thetorch, electrode holder,

and theircables.earth clamp

ONCE IN EVERY 3 MONTHS

ONCE IN EVERY 6 MONTHS

Open the covers of themachine and clean withdry air.

Strictly follow the instructions in safety rules while servicing the machine.Before removing any screw on the machine for maintenance, powersupply must be disconnected from the electric lines and enough time (10seconds) should be allowed for capacitor discharging.

15MONOTIG 160ip

MAINTENANCE AND TROUBLESHOOTING

4. MAINTENANCE AND TROUBLESHOOTING

16 MONOTIG 160ip

Electronic Card - E201B-FLT

Electronic Card - E201B-01

Electronic Card - E201B-02

Grouped Electronic Cards - E201B-3/4/5

Electronic Card - E502A-1

Rotary Encoder

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

E201B-FLT

E201B-01

E201B-02

E201B-03

E502A-1

E502A-2

E502A-3

Hall Effect

HF Coil

Torch Control Connections

Control Panel

K405000101

K405000102

K405000107

A250200006

A310100008

K109900024

K405000103

K405000108

K405000109

K405000110

K000000902

A830900004

A229500001

A490900001

K103009002

A460501001

A245700002

A377900104

A378290002

A253200003

16 11 7

DESIGNATION IN ELECTRICAL DIAGRAM MATERIAL CODE

APPENDIX 1SPARE PARTS

17MONOTIG 160ip

APPENDIX 2ELECTRICAL DIAGRAM

Connectiom

+90 236 226 27 00

+90 236 226 27 28

Made in Turkey

FACTORY

Organize Sanayi Bölgesi 5.Kısım 5503. Sokak No:1 MANİSA

www.magmaweld.com

OWM 05.04.2011

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