AC/DC TIG-MASTER 200
DIGITAL AC/DC PULSE GTAW (TIG) MMA (STICK) WELDER
OPERATOR’S MANUAL
IMPORTANT: Welcome to use the arc welding machine. Read This Owner’s Manual carefully before
attempting to use this equipment. Used correctly, can prolong the service life of the arc welding machine.
WE APPRECIATE YOUR BUSINESS
Congratulations on your new SWS product. We are proud to have you as our customer and will strive to
provide you with the best service and reliability in the industry. This product is backed by our extensive 3
year warranty.
This Operating Manual has been designed to instruct you on the correct use and operation of your SWS
product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore please
take the time to read the entire manual, especially the Safety Precautions. They will help you to avoid
potential hazards that may exist when working with this product.
YOU ARE IN GOOD COMPANY
SWS is The Brand of Choice for Contractors and Fabricators Worldwide. SWS is a mainline supplier to major
welding industry sectors in the Asia Pacific and emerging global markets including; Manufacturing,
Construction, Mining, Automotive, Engineering, Rural and DIY. We distinguish ourselves from our
competition through market leading, dependable products. We pride ourselves on technical innovation,
competitive prices, excellent delivery, superior customer service and technical support, together with
excellence in sales and marketing expertise. Above all, we are committed to develop technologically
advanced products to achieve a safer working environment for industry operators.
SWS WELDING
WEBSITE: WWW.SWSWELDING.COM.AU
EMAIL: SUPPORT@SWSWELDING.COM.AU
TELEPHONE: (03) 5766 2331
NOTE:
Product Specifications and features are subject to change without notice. While every attempt has been
made to provide the most accurate and current information possible at the time of publication, this manual is
intended to be a general guide and not intended to be exhaustive in its content regarding safety, welding, or
the operation/maintenance of this unit. SWS does not guarantee the accuracy, completeness, authority or
authenticity of the information contained within this manual. The owner of this product assumes all liability for
its use and maintenance. SWS does not warrant this product or this document for fitness for any particular
purpose, for performance/accuracy or for suitability of application. Furthermore, SWS does not accept
liability for injury or damages, consequential or incidental, resulting from the use of this product or resulting
from the content found in this document or accept claims by a third party of such liability.
AC/DC TIG-MASTER 200
TABLE OF CONTENTS
Introduction
2
Specifications
3
Warranty Information
4
Duty Cycle Explained
5
Safety
6, 7, 8
Front Panel Features
9
Rear Panel Features
10
Setup Guide - TIG (GTAW)
11
Setup Guide - STICK (GTAW)
12
Digital Control Panel Operation & Features
Troubleshooting - TIG Welding (GTAW)
Routine Servicing
13, 14, 15, 16, 17, 18
19, 20, 21
22
INTRODUCTION
The SWS AC/DC Tig-Master with power factor correction is a high output, highly portable digital inverter
power supply. Standard features include Adjustable slope, gas and pulse functions. The TIG-MASTER power
supply with Infineon microprocessor and IGBT Module provides the ultimate in precision and portable TIG
and Stick welding for non-ferrous and ferrous metals.
Inverter Technology
Infineon microprocessor and Infineon IGBT Module
with digital control delivers increased reliability and
perfect welding characteristics.
Operator Friendly Digital Display
The large and easy to use LCD panel makes
selecting your process and setting up easy.
AC/DC TIG & Stick (MMA)
AC for aluminum and DC for non-ferrous alloys,
stainless, mild steel and chrome moly.
AC Frequency
Adjustable frequency of the Advanced AC square
wave when welding aluminium for optimised welding
performance.
AC Frequency
Wave Balance
Adjustable frequency of the Advanced AC square
Adjustable for optimised penetration or cleaning
wave when welding aluminium for optimised welding action when welding aluminium.
performance.
Advanced Pulse for both AC and DC
Focus the arc, increase the amperage, run faster
and shrink the heat affected zone – while
maintaining excellent penetration.
Store Parameters
Store up to 5 sets of welding parameters for easy
access later.
TIG Slope
Pre-flow & Post-flow
Initial Current / Upslope / Downslope & Last Current Shielding gas control enables independent gas
eliminates blow holes on arc starting and cracking at control before and after the weld.
the end of welds.
2T/4T Operation (TIG)
2T/4T operation gives you greater control over your
welds reducing fatigue and allowing for precision
control.
Perfect MMA (Stick) Welding
Pro and Automatic settings for easy setup with hot
start, anti-stick and arc force regulation allows the
operator to achieve excellent Stick welding results.
Lift TIG / Scratch Start
Provides optimised TIG arc starting without the use
of high frequency.
Thermal Overload Protection
Alerts the operator if the duty cycle is exceeded or
airflow is blocked. Shuts down the power source to
protect the internal electrical components from
overheating.
Intelligent Heat Sensing Fan
Operates as needed to cool components and
reduce airborne contaminants pulled through the
power source.
Digital Meter Amperage
Amperage Preview with hold function for easy
setup.
Robust Case
Drop proof protection with eight individual impact
points.
Highly Portable
Compact size and light weight ensure a small
Workspace footprint and job site portability.
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AC/DC TIG-MASTER 200
SPECIFICATIONS
Processes
HF TIG AC/DC (GTAW-AC/DC), LIFT TIG AC/DC
(GTAW-AC/DC), Pulsed TIG (GTAW-P), Stick AC/
DC (MMA)
Current Type
AC/DC
Weldable Metals
Aluminium, Mild Steel, Stainless Steel, Specialty
Metals
Industries
General Aluminium, Steel and Stainless Steel
Fabrication, Stainless Steel Tank and Pipe
Fabrication, Boat Building / Shipyards, Motorcycle
custom shops, Automotive customs shops,
Automotive Components and Repairs, Motorcycle
Components and Repairs, Technical Schools,
Aerospace.
Input Voltage
1 Phase 230V +/- 15% (15 Amp Plug)
Input Hz
50/60 Hz
Minimum Generator
6.6kW (8.5kVA at 0.8 PF)
Duty Cycle (TIG)
25% @ 200A, 100% @ 100A
Duty Cycle (MMA)
25% @ 200A, 100% @ 100A
Welding Current Range (TIG)/(MMA)
5A - 200A
Dimensions
L 410mm H 180mm W 250mm
Weight
11Kg
Warranty
3 Years
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AC/DC TIG-MASTER 200
DUTY CYCLE EXPLAINED
Duty cycle is the amount of arc-on time (actual welding or cutting time) during a 10 minute period that the
machine can operate at its rated output without damaging internal components. For example, this machine is
designed for a 25% duty cycle at 200 amps. This means that it has been designed and built to provide the
rated amperage, 200 amps, for 2.5 minutes continuously out of every 10 minute period. During the other 7.5
minute period the unit will go into overload protection mode to cool. As a general rule, this machine rated at
25% duty cycle at 200 amps and 100% at 100 amps is more than ample for the majority of general purpose,
non-automatic welding or cutting applications.
Note: All duty cycles are calculated for a maximum ambient temperature of 40ºC as per AS1966. Duty
cycles must be reduced, i.e. reduce the arc-on time, when the ambient temperature exceeds 40ºC. At 25ºC
this machine is rated for 40% at 200 Amps.
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AC/DC TIG-MASTER 200
WARRANTY INFORMATION
Terms of Warranty
The SWS machine has a limited warranty that covers manufacturing and material defects only. The warranty
is affected on the day of purchase and does not cover any freight, packaging and insurance costs. Verbal
promises that do not comply with terms of warranty are not binding on warrantor.
Limitations on Warranty
The following conditions are not covered under terms of warranty: loss or damage due to or resulting from
natural wear and tear, non‑compliance with operating and maintenance instructions, connection to incorrect
or faulty voltage supply (including voltage surges outside equipment specs), incorrect gas pressure
overloading, transport or storage damage or fire or damage due to natural causes (e.g. lightning or flood).
This warranty does not cover direct or indirect expenses, loss, damage of costs including, but not limited to,
daily allowances or accommodation and travelling costs. Modification of the 15A primary input plug or fitment
of a lower rated primary input plug will render the warranty null and void.
NOTE
Under the terms of warranty, welding torches and their consumables are not covered. Direct or indirect
damage due to a defective product is not covered under the warranty. The warranty is void if changes are
made to the product without approval of the manufacturer, or if repairs are carried out using non-approved
spare parts. The warranty is void if a non authorised agent carries out repairs.
Warranty Period
The warranty is valid for 3 years from the date of purchase provided the machine is used within the
published specification limits.
Warranty Repairs
A SWS approved service provider must be informed within the warranty period of any warranty defect. The
customer must provide proof of purchase and serial number of the equipment when making a warranty claim
and emailed to support@swswelding.com.au Warranty repairs may only be carried out by SWS.
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AC/DC TIG-MASTER 200
SAFETY
SWS is dedicated to providing you with the best possible equipment and service to meet the demanding jobs
that you have. We want to go beyond delivering a satisfactory product to you. That is the reason we offer
technical support to assist you with your needs should an occasion occur. With proper use and care your
product should deliver years of trouble free service.
We have compiled this operator’s manual, to instruct you in basic safety, operation and maintenance of your
SWS product to give you the best possible experience. Much of welding and cutting is based upon
experience and common sense. As thorough as this welding manual may be, it is no substitute for either.
Exercise extreme caution and care in all activities related to welding or cutting. Your safety, health and even
life depends upon it. While accidents are never planned, preventing an accident requires careful planning.
Safe operation and proper maintenance is your responsibility.
The warranty does not cover improper use, maintenance or consumables. Do not attempt to alter or defeat
any piece or part of your unit, particularly any safety device. Keep all shields and covers in place during
unit operation should an unlikely failure of internal components result in the possible presence of sparks and
explosions. If a failure occurs, discontinue further use until malfunctioning parts or accessories have been
repaired or replaced by qualified personnel.
Note on High Frequency electromagnetic disturbances:
Certain welding and cutting processes generate High Frequency (HF) waves. These
waves may disturb sensitive electronic equipment such as televisions, radios, computers,
cell phones, and related equipment. High Frequency may also interfere with fluorescent
lights. Consult with a licensed electrician if disturbance is noted. Sometimes, improper
wire routing or poor shield-ing may be the cause.
HF can interfere with pacemakers. See EMF warnings in following safety section for
further information. Always consult your physician before entering an area known to have
welding or cutting equipment if you have a pacemaker.
These safety precautions are for protection of safety and health. Failure to follow these
guidelines may result in serious injury or death. Be careful to read and follow all cautions
and warnings. Protect yourself and others.
Welding and cutting processes produce high levels of ultraviolet (UV) radiation that can
cause se-vere skin burn and damage. There are other potential hazards involved with
welding such as severe burns and respiratory related illnesses. Therefore observe the
following to minimize potential acci-dents and injury:
Use appropriate safety glasses with wrap around shields while in the work area, even
under weld-ing helmets to protect your eyes from flying sparks and debris. When chipping
slag or grinding, gog-gles and face shields may be required.
When welding or cutting, always use an approved shielding device, with the correct
shade of filter installed. Always use a welding helmet in good condition. Discard any
broken or cracked filters or helmets. Using broken or cracked filters or helmets can cause
severe eye injury and burn. Filter shades of no less than shade 5 for cutting and no less
than shade 9 for welding are highly recommend-ed. Shades greater than 9 may be
required for high amperage welds. Keep filter lenses clean and clear for maximum
visibility. It is also advisable to consult with your eye doctor should you wear con-tacts for
corrective vision before you wear them while welding.
Do not allow personnel to watch or observe the welding or cutting operation unless fully
protected by a filter screen, protective curtains or equivalent protective equipment. If no
protection is availa-ble, exclude them from the work area. Even brief exposure to the rays
from the welding arc can damage unprotected eyes.
6
AC/DC TIG-MASTER 200
SAFETY
Always wear hearing protection because welding and cutting can be extremely noisy. Ear
protection is necessary to prevent hearing loss. Even prolonged low levels of noise has
been known to create long term hearing damage. Hearing protection also further protects
against hot sparks and debris from entering the ear canal and doing harm.
Always wear personal protective clothing. Flame proof clothing is required at all times.
Sparks and hot metal can lodge in pockets, hems and cuffs. Make sure loose clothing is
tucked in neatly. Leather aprons and jackets are recommended. Suitable welding jackets
and coats may be purchased made from fire proof material from welding supply stores.
Discard any burned or frayed clothing. Keep clothing away from oil, grease and
flammable liquids.
Leather boots or steel toed leather boots with rubber bottoms are required for adequate
foot protection. Canvas, polyester and other man made materials often found in shoes will
either burn or melt. Rubber or other non conductive soles are necessary to help protect
from electrical shock.
Flame proof and insulated gauntlet gloves are required whether welding or cutting or
handling met-al. Simple work gloves for the garden or chore work are not sufficient.
Gauntlet type welding gloves are available from your local welding supply companies.
Never attempt to weld with out gloves. Welding with out gloves can result in serious burns
and electrical shock. If your hand or body parts comes into contact with the arc of a
plasma cutter or welder, instant and serious burns will oc-cur. Proper hand protection is
required at all times when working with welding or cutting machines!
WARNING! Persons with pacemakers should not weld, cut or be in the welding area
until they consult with their physician. Some pacemakers are sensitive to EMF
radiation and could severely malfunction while welding or while being in the
vicinity of someone welding. Serious injury or death may occur!
Welding and plasma cutting processes generate electro-magnetic fields and radiation.
While the effects of EMF radiation are not known, it is suspected that there may be some
harm from long term exposure to electromagnetic fields. Therefore, certain pre-cautions
should be taken to minimise exposure:
•
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Lay welding leads and lines neatly away from the body.
Never coil cables around the body.
Secure cables with tape if necessary to keep from the body.
Keep all cables and leads on the same side the body.
Never stand between cables or leads.
Keep as far away from the power source (welder) as possible while welding.
Never stand between the ground clamp and the torch.
Keep the ground clamp grounded as close to the weld or cut as possible.
Welding and cutting processes pose certain inhalation risks. Be sure to follow any
guidelines from your chosen consumable and electrode suppliers regarding possible
need for respiratory equipment while welding or cutting. Always weld with adequate
ventilation. Never weld in closed rooms or confined spaces. Fumes and gases re-leased
while welding or cutting may be poisonous. Take precautions at all times.
Any burning of the eyes, nose or throat are signs that you need to increase ventilation.
• Stop immediately and relocate work if necessary until adequate ventilation is ob-tained.
• Stop work completely and seek medical help if irritation and discomfort persists.
7
AC/DC TIG-MASTER 200
SAFETY
Keep all cylinders upright and chained to a wall or appropriate holding pen. Certain
regulations regarding high pressure cylinders can be obtained from OSHA or local
regulatory agency. Consult also with your welding supply company in your area for further
recommendations. The regulatory changes are frequent so keep informed.
All cylinders have a potential explosion hazard. When not in use, keep capped and
closed. Store chained so that overturn is not likely. Transporting cylinders incorrectly can
lead to an explosion. Do not attempt to adapt regulators to fit cylinders. Do not use faulty
regulators. Do not allow cylinders to come into contact with work piece or work. Do not
weld or strike arcs on cylinders. Keep cylinders away from direct heat, flame and sparks.
WARNING! Electrical shock can kill. Make sure all electrical equipment is properly
grounded. Do not use frayed, cut or otherwise damaged cables and leads. Do not stand,
lean or rest on ground clamp. Do not stand in water or damp areas while welding or
cutting. Keep work surface dry. Do not use welder or plasma cutter in the rain or in
extremely humid conditions. Use dry rubber soled shoes and dry gloves when welding or
cutting to insulate against electrical shock. Turn machine on or off only with gloved hand.
Keep all parts of the body insulated from work, and work tables. Keep away from direct
contact with skin against work. If tight or close quarters necessitates standing or resting
on work piece, insulate with dry boards and rubber mats designed to insulate the body
from direct contact.
All work cables, leads, and hoses pose trip hazards. Be aware of their location and make
sure all personnel in area are advised of their location. Taping or securing cables with
appropriate restraints can help reduce trips and falls.
WARNING! Fire and explosions are real risks while welding or cutting. Always keep fire
extin-guishers close by and additionally a water hose or bucket of sand. Periodically
check work area for smoldering embers or smoke. It is a good idea to have someone help
watch for possible fires while you are welding. Sparks and hot metal may travel a long
distance. They may go into cracks in walls and floors and start a fire that would not be
immediately visible. Here are some things you can do to reduce the possibility of fire or
explosion:
• Keep all combustible materials including rags and spare clothing away from area.
• Keep all flammable fuels and liquids stored separately from work area.
• Visually inspect work area when job is completed for the slightest traces of smoke or
embers.
• If welding or cutting outside, make sure you are in a cleared off area, free from dry
tender and debris that might start a forest or grass fire.
• Do not weld on tanks, drums or barrels that are closed, pressurized or anything that
held flamma-ble liquid or material.
Metal is hot after welding or cutting! Always use gloves and or tongs when handling hot
pieces of metal. Remember to place hot metal on fire-proof surfaces after handling.
Serious burns and injury can result if material is improperly handled.
WARNING! Faulty or poorly maintained equipment can cause injury or death. Proper
mainte-nance is your responsibility. Make sure all equipment is properly maintained and
serviced by qualified personnel. Do not abuse or misuse equipment.
Keep all covers in place. A faulty machine may shoot sparks or may have exploding parts.
Touching uncovered parts inside machine can cause discharge of high amounts of
electricity. Do not allow em-ployees to operate poorly serviced equipment. Always check
condition of equipment thoroughly before start up. Disconnect unit from power source
before any service attempt is made and for long term storage or electrical storms.
8
AC/DC TIG-MASTER 200
FRONT PANEL FEATURES
1. Display
The main control features digital adjustment. It
offers features that include Pulse, Advanced AC
pulse, Stick welding feature, VRD Stick welding
feature, Stick Hot Start, Arc force control, Lift start
Tig, HF start TIG, 2T/4T/Pedal/Amptrol Control, and
storing of parameters.
2. Selection Knob
The push and turn selection knob selects and
adjusts welding parameters quickly and easily.
3. Negative Connector DINSE 10-25mm²
This is a standard 25 series connector.
4. Positive Connector DINSE 10-25mm²
This is a standard 25 series connector.
5. Gas Outlet M10
Connects the gas to the TIG torch.
6. 7-Pin Control for Pedal/Torch Switch
Connect the foot pedal or torch switch to this socket
to control the welder. Only one control connector
can be plugged in at one time. While using the foot
pedal tie the loose connector back or leave it
hanging
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AC/DC TIG-MASTER 200
REAR PANEL FEATURES
1. Power Switch
Machine Power ON/OFF
2. Power Cable
AS/NZS 3112 Power Plug and Cable (15 Amp)
3. Argon Gas Inlet
Secure gas line with the supplied or other suitable
clamp.
10
AC/DC TIG-MASTER 200
SETUP GUIDE TIG
1.
2.
3.
Connect the ground clamp to the positive connection (DCEN) and the Welding torch to the positive
connection.
Connect the 7-Pin plug into the 7-Pin control connector making sure to line up the locator slots correctly.
Connect the gas line ensuring to not over tighten.
NOTE: In most welding application DCEN (Direct Current Electrode Negative) is used.
NOTE: This arc welding machine is operating with high frequency arc start or LIFT arc starting, when
operating nearby to high frequency sensitive equipment, please use LIFT TIG.
11
AC/DC TIG-MASTER 200
SETUP GUIDE STICK
1.
Connect the ground clamp to the negative connection (DCEP) and the torch to the positive connection.
NOTE: In most welding applications DCEP (Direct Current Electrode Positive) is used. In some cases when
welding very thin material using DCEN may be an advantage.
12
AC/DC TIG-MASTER 200
DIGITAL CONTROL PANEL OPERATION AND FEATURES AC/DC TIG
FUNCTION
PARAMETERS
PURPOSE
0.1-9.9 Seconds
Pre-Flow sets the gas flow time before the arc starts after
the trigger or pedal is pressed. Used to purge the torch and
flood the weld area with shielding gas so the arc start is
stable and weld is free from porosity. Use enough time so
that first “blast” of argon is settled. (about .3-.5 seconds)
Pre-flow delays the arc start by the amount of time set.
2. Start Amps
10-200 Amps
Serves as the 2T/4T beginning arc start amp value while
using the torch switch, pedal or amptrol. Allows the arc to
be started at a different value than the selected maximum
or minimum welding amps while using the torch switch.
Typically used to start the weld puddle more quickly/slowly.
3. Upslope
0-9.9 Seconds
Upslope ramps amps “up” from the start amp value to the
welding amp value while starting the weld puddle.
4. Welding Amps
10-200 Amps
Welding amps define the top limit of amps at which the
machine has been programmed to operate. Used with the
foot pedal and amp control, this is the maximum limiting
value at the upper limit of the range of travel. With the torch
switch this is the destination, or maximum current reached
after up slope has occurred.
5. Pulse Base Amps
10-200 Amps
Governs the lower(base or background current) amp value
during the pulse cycle.
1. Pre-Flow
13
AC/DC TIG-MASTER 200
6. Downslope
0-9.9 Seconds
Down Slope will ramp amps “down” from the welding amp
value to the end amp value to give time to fill the crater left
at the end of the weld bead. Can also be used in the 4T
mode to help with heat control by briefly tapping the switch
to cool off the weld before tapping it again to restart the up
slope sequence before the arc reaches the end amp stage.
7. End Amps
10-200 Amps
Sets the final or minimum current before the arc is
terminated. Used for filling craters at the ends of the weld
and crack prevention.
8. Post-Flow
0.1-9.9 Seconds
Controls the amount of time in seconds that the argon flows
after the arc has terminated. Provides proper shielding
during cooling to prevent rapid oxidation of the weld which
results in porosity. Use 1-2 seconds post flow time for every
10 amps.
9. Display Pre-Flow/
Start Amps
N/A
This displays the parameter.
10. Display Post-Flow,
End Amps
N/A
This displays the parameter.
11. Pulse Time On
(Balance) %
10-90%
Defines the duty cycle (balance) of the pulse, by dividing or
skewing the amount of time the pulse stays in the lower or
upper stage of the pulse. The pulse consists of two stages:
Welding amps (upper /Peak) and Pulse amps (lower/
background current). This is represented by a % of total
time the pulse spends in the pulse amp stage of the cycle
during one full pulse. The feature can be used to increase
or decrease pulse amp time relative to the welding amp
time of the cycle to help manage heat input.
12. Pulse Frequency
Hertz (Pulses per
second )
1-500 Hz
Represented by Hertz (Hz), the pulse frequency defines the
actual number of times each second the pulse makes one
complete cycle between welding amps (peak/high amp
value) and pulse amps (background/low amp value). This is
also commonly referred to as Pulses Per Second (PPS).
Low pulse frequencies are ideal for timing the point where
filler metal is added. This helps improve appearance and
uniformity. Higher pulse frequencies are useful for welding
seams and edges of thin material. Also it is useful for
overall heat input control for thicker metals. Higher pulse
frequencies are highly useful for automated welding
processes. WARNING: WELDING AT HIGH PULSE
FREQUENCIES INCREASES THE DECIBEL /NOISE
LEVEL OF THE ARC. HEARING PROTECTION IS
HIGHLY RECOMMENDED!
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AC/DC TIG-MASTER 200
13. 2T/4T Selection
N/A
To operate with the torch switch, select 2T or 4T (2T
Double ended arrow 4T separate arrows). For 2T
operation, simply press and hold the switch. The panel
program will cycle automatically. When the switch is
released, the arc will downslope and terminate with post
gas flow. When in 4T mode, the switch is pressed, and held
to start the pre-flow and the start amps part of the cycle.
When released, upslope be-gins and continues until the
amps are raised to the preset welding amps. When
pressed and held again, downslope starts and ramps down
to the end amp stage (crater current). When released, the
arc terminates, and post flow begins. If desired, before the
downslope finishes, the switch may be tapped again to
start the up slope again.
14. HF or Lift TIG
Selection
N/A
The Process selector offers the choice of Lift Tig (for DC
only) which requires contact with the metal to initiate the
arc and High Frequency Start which allows non contact
starting of the arc (for AC and DC). (HF is selected when
symbol is not striked out) When in HF mode, the unit relies
upon a gapless solid state HF module to start the arc,
which is a more reliable and trouble free design than
traditional point gap HF design. The lift start function on the
TIG-MASTER models provides a cold electrode for safety,
and prevents accidental starts. This requires that the pedal
or torch switch must be used to energise the arc. HF refers
to the start type only. The inverter design of the welder
eliminates the need for a constant HF overlay in AC.
15. Welding Current
N/A
This displays the Amps in real time while welding and will
hold for 5 seconds after weld is complete.
16. AC or DC Selection
N/A
The unit features AC/DC operation. This machine uses
advanced square wave for AC that has excellent wet in,
and arc controllability.
17. AC Balance
15
50-98%
Defines the percent of Electrode Positive (EP) used during
AC welding to provide cleaning action. This divides the time
that the AC cycle spends in Electrode Positive or Electrode
Negative during one full AC cycle. It controls the amount of
cleaning and penetration via a ratio to achieve the best
balance while welding on AC. Too much cleaning action will
result in tungsten balling or splitting. Too little cleaning can
result in dirty, sooty welds and even a dull weld
appearance. Simply put, as the percent increases, greater
cleaning will occur, but less penetration will be achieved.
For old aluminium that has some corrosion, adjust the ac
balance to where you use more (EP). For brand new clean
aluminium, set the ac balance to where you have around
70-80% (EP).
AC/DC TIG-MASTER 200
18. AC Frequency
19. Main Menu
16
10-99 Hz
N/A
Governs the number of times per second that the current
alternates in AC mode. To achieve greater arc focus
(constriction) and increase puddle agitation while welding in
AC mode, increase AC frequency. This allows pinpoint use
on thin materials, and helps penetration on thicker
materials. Ideal adjustment range is usually between
90-99Hertz. For comparison most transformer welders in
the US operate on 60 Hz. Greater arc control and stability
can be achieved through the higher frequency range
offered by this welder. Lower Frequencies will widen and
soften the arc and reduce the level of control. WARNING:
INCREASING THE AC FREQUENCY ALSO INCREASES
THE DECIBEL/NOISE LEVEL OF THE AC WELDING
ARC. HEARING PROTECTION SHOULD BE WORN!
This takes you back to select parameter menu.
AC/DC TIG-MASTER 200
DIGITAL CONTROL PANEL OPERATION AND FEATURES MMA PRO
FUNCTION
1. Hot Start
PARAMETERS
0-60 Amps
2. Hot Start Value
N/A
3. Welding Amps
10-200 Amps
4. Welding Amps Value
5. Arc Force
N/A
0-99%
PURPOSE
Sets the length of time that the Hot Start is active while
starting the arc. Used to reduce sticking of the electrode
during the arc strike phase.
This displays the value.
Welding amps define the top limit of amps at which the
machine has been programmed to operate.
This displays the parameter.
Controls the arc response when an arc is held short and
voltage begins to drop. Arc force automatically
compensates by modifying the volt/amp curve to maintain
the energy needed to weld. Represented as a percent of
available arc force amperage.
6. Arc Force Display
N/A
This displays the value.
7. Actual Welding Amps
N/A
This displays the actual welding amps in real time.
9. AC or DC Selection
N/A
The unit features AC/DC operation. This machine uses
advanced square wave for AC that has excellent wet in,
and arc controllability.
9. Main Menu
N/A
This takes you back to select process menu.
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AC/DC TIG-MASTER 200
DIGITAL CONTROL PANEL OPERATION AND FEATURES MMA AUTO
FUNCTION
1. Electrode Diamater
Selection
PARAMETERS
2-5mm
PURPOSE
Use this setting to select the approbate electrode size.
2. Welding Current Fine
Tuning
+20%—20%
3. Welding Amps Value
N/A
This displays the parameter.
4. AC or DC Selection
N/A
The unit features AC/DC operation. This SWS machine
uses advanced square wave for AC that has excellent wet
in, and arc controllability.
5. Main Menu
N/A
This takes you back to select process menu.
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Fine tuning of the welding amps for optimum
performance.
AC/DC TIG-MASTER 200
Troubleshooting
Excessive electrode consumption
Cause
Solution
Inadequate gas
Increase gas flow
Inadequate post gas flow
Increase post flow time to 1 sec per 10 amps
Improper size electrode for current required
Use larger electrode
Operating of reverse polarity
User larger electrode or change polarity
Electrode contamination
Remove contaminated portion, then prepare again
Excessive heating inside torch Replace collet
Try wedge collet or reverse collet
Electrode oxidising during cooling
Increase gas flow post time to 1 sec per 10 amps
Shielding gas incorrect
Change to Argon (no oxygen or CO2)
Erratic Arc
Cause
Solution
Incorrect voltage (arc too long)
Maintain short arc length
Current too low for electrode size
Use smaller electrode or increase current
Electrode contaminated
Remove contaminated portion, then prepare again
Joint too narrow
Open joint groove
Contaminated shield gas
Dark stains on the electrode or
weld bead indicate contamination
The most common cause is moisture or aspirated
air in gas stream
Use welding grade gas only Find the source of the
contamination and eliminate it promptly
Base metal is oxidised, dirty or oily
Use appropriate chemical cleaners, wire brush, or
abrasives prior to welding
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AC/DC TIG-MASTER 200
Inclusion of tungsten or oxides in weld
Cause
Solution
Excessive current for tungsten size used
Reduce the current or use larger electrode
Accidental contact of electrode with puddle
Maintain proper arc length
Accidental contact of electrode to filler rod
Maintain a distance between electrode and filler
metal
Using excessive electrode extension
Reduce the electrode extension to recommended
limits
Inadequate shielding or excessive drafts
Increase gas flow, shield arc from wind, or change
to gas saver or gas lens
Wrong gas
Do not use ArO2 or ArCO2 GMAW (MIG) gases for
TIG welding
Heavy surface oxides not being removed Use ACHF Adjust balance control for maximum cleaning, or
wire brush and clean the weld joint prior to welding
Porosity in Weld Deposit
Cause
Solution
Entrapped impurities, hydrogen, air, nitrogen, water
vapour
Do not weld on wet material
Defective gas hose or loose connection
Check hoses and connections for leaks
Filler material is damp (particularly aluminium)
Dry filler metal in oven prior to welding
Filler material is oily or dusty
Replace filler metal
Alloy impurities in the base metal such as sulphur,
phosphorous, lead and zinc
Change to a different alloy composition which is
weldable. These impurities can cause a tendency to
crack when hot
Excessive travel speed with rapid freezing of weld
trapping gases before they escape
Lower the travel speed
Contaminated shield gas
Replace the shielding gas
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AC/DC TIG-MASTER 200
Cracking in Welds
Cause
Solution
Hot cracking in heavy sections or welding on metals
prone to hot cracking
Increase weld bead cross-section size. Change
weld bead contour for e.g. concave to flat or
convex, check fit-up gap, reduce welding speed
Post weld cold cracking due to excessive joint
restraint, rapid cooling or hydrogen embrittlement
Preheat prior to welding. Use pure or noncontaminated gas. Increase the bead size. Prevent
craters or notches. Change the weld joint design
Centreline cracks in single pass weld Increase bead
size.
Decrease root opening. Use preheat. Prevent
craters
Under-bead cracking from brittle microstructure
Eliminate sources of hydrogen, joint restraint, and
use preheat
Inadequate shielding
Cause
Solution
Gas flow blockage or leak in hoses or torch
Locate and eliminate the blockage or leak
Excessive travel speed exposes molten weld to
atmospheric contamination
Use slower travel speed or carefully increase the
flow rate to a safe level below creating
excessive turbulence. Use a trailing shield cup
Wind or drafts
Set up screens around the weld area
Excessive electrode stick-out Reduce electrode
stick-out.
Use a larger size cup, or switch to gas saver or gas
lens
Excessive turbulence in gas stream
Change to gas safer parts or gas lens parts
Short parts Life
Cause
Solution
Cup shattering or cracking in use
Change cup size or type. Change tungsten position
Short collet life ordinary style is split and twists or
jams.
Change to wedge style
Short torch head life
Do not operate beyond rated capacity. Do not bend
torch heads
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AC/DC TIG-MASTER 200
ROUNTINE MAINTENANCE
WARNING!
Only authorised electricians should carry out repairs and internal servicing. Modification of the 15A primary
input plug or fitment of a lower rated primary input plug will render the warranty null and void. The working
environment or amount of use the machine receives should be taken into consideration when planning
maintenance frequency of your SWS welder. Preventative maintenance will ensure trouble-free welding and
increase the life of the machine and its consumables.
Power Source
• Check electrical connections of unit at least twice a year.
• Clean oxidised connections and tighten.
• Inner parts of machine should be cleaned with a vacuum cleaner and soft brush.
• Do not use any pressure-washing devices.
• Do not use compressed air as pressure may pack dirt even more tightly into components.
SWS WELDING
WEBSITE: WWW.SWSWELDING.COM.AU
EMAIL: SUPPORT@SWSWELDING.COM.AU
TELEPHONE: (03) 5766 2331
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AC/DC TIG-MASTER 200