OWNER`S MANUAL

TIG160S/180S/200S TIG180A/200A

INSTRUCTION MANUAL

PRODUCTS INTRODUCE

Tig160S/180S/200S are single process argon-arc welding.

Tig180A/200A are two processes of sticking and argon-arc welding (choose it by function
switch).
As sticking, outer characteristics of welding machine are continue current and arc drive
controlling .It is constant current characteristics when arc voltage is normal, it makes that welding
current will not be changed with arc length .Current will become higher and higher with arc voltage
down-slope, when arc voltage is too low, it makes that arc length will return into normal range (it is
arc driving). When arc voltage is too low to support arc, voltage will down slope immediately in
order to protect from splashing which is caused by short circuit.
Arc welding characteristic is continue current ,welding current will not change arc length ,so
current is very stabilizing .When electrode circuit is short ,current will declined to 0 automatically
in order to protect tungsten ad work piece .
 TIG160S/180S/200S/180A/200A MAIN TECHNICAL DATA
Model TIG160S TIG180S TIG200S TIG180A TIG200A
Item
Power AC220v±15% AC220v±15% AC220v±15% AC220v±15% Three phase
voltage(v) 50/60 50/60 50/60 50/60 AC220v±15%,
50/60
Input 3.2 KVA 3.9 KVA 4.5 KVA 3.9 KVA 3.9 KVA
current(A)
No-load 42 55 42 55 55
voltage(V)
Output current 10~160 10~180 10~200 10~180 10~200
adjustment
range (A)
Rate work 16.4 17 18 17 18
voltage(V)
Driving -- -- -- -- --
adjustment
range (A)
Duty cycle 60% 60% 60% 60% 60%
No-load loss 35 40 35 40 40
(W)
Pilot arc model HF HF HF HF HF
Efficiency 85% 85% 85% 85% 85%
Power factor 0.93 0.93 0.93 0.93 0.93
Insulation class B B B B B
Protection class IP21 IP21 IP21 IP21 IP21
Weight(kg) 8 9 9 8 9
Overall 371x155x287 371x152x287 371x155x287 371x152x290 371x155x287
Dimensions

INSTALLATION
When use longer cable ,please choose cable of bigger section in order to protect voltage from
stepping down .If torch cable is too long ,it maybe effect to function of arc-striking and other
function of system .So we suggest that user must use coordinated length which is recommended by
manufacturer .

Input Cable Connection

1. Every welding machine has disposed a once power cable, power cable must be connected to
corresponding voltage in compliance with input voltage. If single phase 220V DC power
cable is connected to 380V AC power cable by carelessness, it makes power is in over-
voltage protection position. Please turn power supply off first then connect to power cable
of 220V and open machine again.
 Input voltage of TIG160S/180A/200S/200A is single phase 220V.
2. Make sure that power cable is connected to power switch or connector firmly and prevent
from oxidizing. Check if the power voltage is inside waved range.
3. Cable connection methods:
From machine, there are 3 wires of line RED (L), BLUE (N), YELLOW/GREEN (G)
should be connected probably to BREAKERS, that Maximum Current is 25A, as:
1.) RED wire to L ;
2.) BLUE wire to N;
3.) YELLOW/GREEN wire to Ground.

Output Cable Connection

1. Argon-arc welding: TIG160S/180S/200S
1) Connect to gas source: Make sure that argon tube is connected to copper tip tightly. Supply gas
circuit must include gas cylinder, argon flow meter and gas tubes. Tubes must be tied firmly by
laryngeal hoop or something else in order that gas is leaked and air comes into.
2) Make sure that mantle has been grounded by cable whose section is min 6 square millimeters in
order to prevent static electricity and leaking .The cable is connected to the ground plug pin
behind machine.
3) Connect welding torch according to diagram .Electrify integration connector of welding torch
and air plug are installed to coordinated connectors then tighten firmly.
4) Mobile plug of return circuit cable is inserted in mobile socket of positive electrode then
tightened it clockwise rotation firmly, another terminal of grounding pincer clamps work piece.

2. Sticking and Argon-arc Welding Two Processes Machine

(TIG180A/200A)
When use argon-arc welding, please connect as aforementioned .When use sticking, pay attention as
following:
1) Every machine has a pair of mobile plugs, cable of welding handle is connected to black mobile
plug, another terminal of grounding pincer is connected to red mobile plug, and then they must
be tightened.
Make sure secondary cables (handle cable and grounding cable) are connected to mobile plug
reliably.
2) Insert the mobile plug in mobile socket, then tighten it .Or the plug and socket will be burned up
if current is too high or working time is too long.
Pay attention the electrode of connection cable, there are two methods of connection that are
positive connection and negative connection .Positive connection is that work piece is
connected to positive electricity and torch handle is connected to negative electrode, negative
connection is that work piece is connected to negative electricity and torch handle is connected
to positive electrode.

OPERATION
TIG160S/200S Control Panel Description
1. Argon-arc Welding
1) Make sure the power switch is on “on” position, and the indicator will be lit.
2) Open the valve of argon cylinder, adjust the volume of flow meter and make it is adequate
to welding.
3) Inter axial-flow fan begins to work ,press the control knob of torch ,the electromagnetic
valve will start ,user can hear sound of HF arc-striking ,at the same time torch tip will flow
out argon .
4) Knob of arc-striking push is use to adjust welding function ,specially in low current
arrange ,that is cooperated with knob of welding current adjustment ,they may adjust
current of arc-striking and be out of control of knob of welding current adjustment .So
machine can grain powerful energy and push current can achieve effect that may imitate
DC welder revolving .
5) It is 2-4 mm from welding tungsten electrode to work piece ,press control knob of
torch ,burn and strike arc , sound of HF arc-striking will be diminished .The welding
machine can be operated now .

2. Sticking Description
1) Open the power switch of front control panel, fan starts to working.
2) Make sure the function switch is on “down” position.
3) Set the welding current is adequate to thickness of work piece.
4) Adjust welding characteristic by drive knob (TIG250/400).

NOTE: Do not touch any cable and connector when the machine is working, it will damage to
health of people and machine.

Stainless steel sheet tungsten sticking data (for reference only)

Thickness Connection Tungsten Wire Current Welding Argon Welding
(mm) model electrode diameter type current flow speed
diameter(mm) (mm) (A) (L/min) (cm/min)
1.0 Connect 2 1.6 DC 7~28 3~4 12~47
1.2 directly 2 1.6 positive 15 3~4 25
1.5 2 1.6 connect 5~19 3~4 8~32

Titanium and titaniferous-alloy tungsten sticking data (for reference only)

Thickness Slope Number Tungsten Wire Welding Air flow Tip inter-
(mm) model of electrode diameter current (L/min) diameter
welding diameter
layer
0.5 I shape 1 1.5 1.0 30~50 8~10 6~8 14~16 10
1.0 1 1.0 1.0~2.0 40~60 8~10 6~8 14~16 10
1.5 1 2.0 1.0~2.0 60~80 10~12 8~10 14~16 10~12
2.0 1 2.0~3.0 1.0~2.0 80~110 12~14 10~12 16~20 12~14
2.5 1 2.0~3.0 2.0 110~120 12~14 10~12 16~20 12~14
3.0 Y shape 1~2 3.0 2.0~3.0 120~140 12~14 10~12 16~20 12~14
4.0 2 3.0~4.0 2.0~3.0 130~150 1212~ 12~14 20~25 18~20
5.0 2~3 4.0 3.0 130~150 14~14 12~14 20~25 18~20
6.0 2~3 4.0 3.0~4.0 140~180 12~14 12~14 25~28 18~20
7.0 2~3 4.0 3.0~4.0 140~180 12~14 12~14 25~28 20~22
8.0 2~4 4.0 3.0~4.0 140~180 12~14 12~14 25~28 20~22

10 Double 4~6 4.0 3.0~4.0 160~200 14~16 12~14 25~28 20~22

20 Y shape 12 4.0 4.0 200~240 12~14 10~12 20 18
22 12 4.0 4.0~5.0 230~250 15~18 18~20 18~20 20
25 15~16 4.0 3.0~4.0 200~220 16~18 20~26 26~30 22
30 17~18 4.0 3.0~4.0 200~220 16~18 20~26 26~30 22

Aluminium and aluminium alloy tungsten electrode sticking data (for reference only )
Thickness Slope Number of Tungsten Wire Preheat Welding Argon Tip inter-
(mm) model welding electrode diameter temperature current flow diameter
layer(positive diameter (℃) (L/min) (mm)
/reversal) (mm)
1.5 I 1/0 2 1.6~2.0 -- 50~80 7~9 8
2 shape 1/0 2~3 2~2.5 -- 50~80 8~12 8~12
3 Y model 1/0 3 2~3 -- 15~180 8~12 8
4 1~2/1 4 3 -- 180~200 10~15 8~12
5 1~2/1 4 3~4 -- 180~240 10~15 8~12
8 2/1 5 4~5 100 260~320 16~20 10~12
10 3~4/1~2 5 4~5 100~150 280~340 16~20 14~16
12 3~4/1~2 5~6 4~5 150~200 300~360 18~22 14~16
16 4~5/1~2 6 5~6 200~220 340~380 20~24 16~20
20 4~5/1~2 6 5~6 200~260 360~400 25~30 20~22
16~20 Double 2~3/2~3 6 5~6 200~260 300~380 25~30 16~20
22~25 Y shape 2~3/2~3 6~7 5~6 200~260 360~400 30~35 20~22

Stainless steel impulse tungsten electrode argon-arc welding data

Thickness Current (A) Sustained time (s) Impulse Welding speed
(mm) Impuls cardinal volume impulse Cardinal frequency (cm/min)
e volume (Hz)
0.3 20~22 5~8 0.06~0. 0.06 8 50~60
0.5 55~60 10 08 0.06 7 55~60
0.8 85 10 0.08 0.08 5 80~100

ISSUES MIGHT BE RAN INTO WHILE WELDING

Fittings, gas, environment factor, supply power maybe has something to do with welding. User must
try to improve welding environment.
A. Black welding spot
Welding spot is not prevented from oxidizing .User may check as following:
1. Make sure the valve of argon cylinder is opened and its pressure is enough .argon cylinder must
be filled up to enough pressure again if pressure of cylinder is be low 0.5Mpa.
2. Check if the flow meter is opened and has enough flow .User can choose different flow
according to welding current in order to save gas .But too small flow maybe cause black
welding spot because preventive gas is too short to cover welding spot .We suggest that flow of
argon must be kept min 5L/min.
3. Check if torch is in block.
4. If gas circuit is not air-tight or gas is not pure can lower welding quality.
5. If air is flowing powerfully in welding environment, that can lower welding quality.
6. Empty rate is set too low.

B. Arc-striking is difficult and easy to pause.

1. Make sure quality of tungsten electrode is high.
2. Grind end of the tungsten electrode to taper .If tungsten electrode is not grinded, that will be
difficult to strike arc and cause unstable arc.

C. Current is not stabilizing when machine is been operating.

It has something with factors as following:
1. Electric wire net voltage has been changed.
2. There is harmful interference from electric wire net or other equipment.

NOTES OR PREVENTIVE MEASURES

1. Environment
1) The machine can perform in environments where conditions are dry with a
dampness lever of max 90%.
2) Ambient temperature is between –10 and 40 degrees centigrade.
3) Do not place the machine in positions where the air flow through the cooling air
slots is obstructed or limited.
4) Avoid to welding in sun shine or drippings.
5) Do not use the machine in environment where condition is polluted with
conductive dusts on the air or corrosiveness gas on the air.

2. Safety norms
Winner Wilding’s machines have installed protection circuit of over voltage and current and
heat .When voltage and output current and temperature of machine is exceed the rate
standard ,welding machine will stop working automatically .Because that will be damage to welding
machine ,user must pay attention as following :
1) The working area is adequately ventilated!
Winner Welding produces powerful machines, when it is being operated, it
generated by high currents, natural wind will not satisfy machine cooled demands. So
there are two axial-flow fans in inter-machine to cool down machine.
 Make sure two ends of fan and front shutter are not in block or covered ,it is 0.3
meter from welding machine to objects of environment .User should make sure the
working area is adequately ventilated ,it is very important to machine.
2) Do not over-load!
Keep welding current is not exceed max duty cycle current.
Over-load current will damage and burn up machine.
3) No over-voltage!
Power voltage can be found in diagram of main technical data .Automatic
compensation circuit of voltage will assure that welding current keep in allowable
arrangement .If power voltage is exceed allowable arrangement limited ,it is damage
to components of machine.
4) There is a grounding screw behind welding machine ,there is
grounding marker on it .Mantle must be grounded reliably with
cable which section is over 6 square millimeter in order to prevent
from static electricity and leaking .
5) If welding time is exceeded duty cycle limited, welding machine
will stop working for protection .Because machine is overheated,
temperature control switch is on “on” position.

MAINTENANCE
1. Remove dust by dry and clean compressed air regularly, if welding machine is operating in
environment where is polluted with smokes and pollution air, the machine need remove dust
everyday.
2. Pressure of compressed air must be inside the reasonable arrangement in order to prevent
damaging to small components of inter-machine.
3. Check inter circuit of welding machine regularly and make sure the cable circuit is connected
correctly and connectors are connected tightly (specially insert connector and components). If
scale and loose are found, please give a good polish to them, then connect them again tightly.
4. Avoid water and steam enter into inter-machine, if them enter into machine, please dry inter-
machine then check insulation of machine (include between connectors and mantle, between
connectors and connectors)
5. If welding machine will not be operated long time, it must be put into packing box and store in
dry environment.

THECK FAULT
1. Maintenance or repairs performed by technical assistance centers not authorized by Winner
Welding will immediately render null and void the manufacturer warranty.
2. If user want to operate machine as following, the operator must be a personnel in a specific field
of electrify and safety.
TIG160S/180S/200S/180A/200A
Faults Resolvable Methods
1.Power indicator is 1. Power switch is out of work.
not lit ,fan does not 2. Check if electrify wire net (which is connected to input cable) is in
work and no welding work. .
output 3. Check if input cable is out of circuit.
2.Power indicator is lit, 1. Maybe connect wrong to 330v power because machine is in protection
fan does not work or circuit, connect to 220v power and operate machine again.
revolve several circles, 2. 220v power is not stable,(input cable is too slender)or input cable is
no welding output connected to electrify wire net cause machine is in protection
circuit .Add the section of cable and tighten input connector
firmly .Close machine 2-3 minutes then open it again.
3. Cable is loosed from switch to power panel, tighten them again.
4. Open and close power switch constantly in short time cause machine is
in protection circuit Close machine 2-3 minutes then open it again .
5. Main circuit 24v relay of power panel is not close or has
damaged .Check 24v power source and relay .If relay has damaged
replace it with same model.
3. Fan is working , 1. Positive and negative electrodes of VH-07 insert component voltage
Indicator is not lit and should be about DC308v from power panel to MOS board.
sound of HF arc- (1) If circuit is broken and silicon bridge is poor contact.
striking can not be (2) If some of four high electrolytic (about 470UF/450V) of power
heard, wiping welding panel capacitor is leaking.
can not strike arc. 2. There is a green indicator in auxiliary power of MOS board, if it is not
on, auxiliary power is out of work .Check fault spot and connect with seller.
3. Check if connectors are poor contact.
4. Check control circuit and find out reasons or connect with seller.
5. Check if control cable of torch is broken.
4. Abnormal indicator 1. Check if torch cable is broken.
is not on, sound of HF 2. Check if grounding cable is broken or not connected to welding piece.
arc-striking can be 3. Output terminal of positive electrode or torch electrify is loosed from
heard, but there is no inter-machine.
welding output.
5. Abnormal indicator 1. Primary cable of arc-striking transformer is not connected to power
is not lit, sound of HF panel firmly, tighten it again.
arc-striking can not be 2. Arc-striking tip is oxidized or too far, give a good polish to it or change
heard, wiping welding it is about 1 mm between arc-striking tips.
can strike arc. 3. Switch (sticking/argon-arc welding) is damaged, replace it.
4. Some of HF arc-striking circuit components are damage, find out and
replace it.
6. Abnormal indicator 1. Maybe it is overheated protection, please close machine first, and then
is lit but there is no open the machine again after abnormal indicator is out.
welding output. 2. Maybe it is overheated protection, wait for 2-3 minutes (argon-arc
welding does not has overheated protection function.)
3. Maybe inverter circuit is in fault, please pull up the supply power plug
of main transformer which is on MOS board (VH-07 insert which is
near the fan) then open the machine again.
 (1) If abnormal indicator is still lit ,close machine and pull up supply
power plug of HF arc-striking power source (which is near the
VN-07 insert of fan ),then open machine :
a. If abnormal indicator is still lit, some of fillister of MOS
board is damaged, find out and replace it with same model.
b. If abnormal indicator is not lit, rise transformer of HF arc-
striking circuit is damaged, replace it.
(2) If abnormal indicator is not lit ,
a. Maybe transformer of middle board is damage, measure
inductance volume and Q volume of main transformer by
inductance bridge (L=0.9-1.6mH Q>35) .If volume is too
low, please replace it.
b. Maybe secondary rectifier tube of transformer is damaged,
find out faults and replace rectifier tube with same model.
4. Maybe feedback circuit is broken.
7. Output current is not 1. 1K potentiometer is damage, replace it.
stabilizing or out of 2. All kinds of connectors are poor contact, specially inserts etc., please
potentiometer control check it.
and sometime is high,
sometime is low.
8. Sticking spatter is 1. Electrode is connected wrong, exchange grounding cable and handle
much and caustic cable.
electrode of is difficult.