Sherman digitec DIGITIG 200DC MULTIPRO User manual

V1.0 19.09.14

USER MANUAL

WELDING INVERTER RECTIFIER

DIGITIG 200DC MULTIPRO

WARNING!

Read the instructions before installing and starting the device

1. GENERAL REMARKS

Commissioning and operation of the device may only be carried out after thoroughly reading this Operator's Manual.

Due to the constant technical development of the device, some of its functions may be modified and their operation may differ in detail from the

descriptions in the manual. This is not a device error, but the result of progress and continuous modification work on the device.

Damage to the device caused by improper operation will void the warranty. Any modifications to the charger are prohibited and will void the warranty.

2. SAFETY

Employees operating the device should have the necessary qualifications authorizing them to perform welding work:

• should have the rights of an electric welder in the field of welding with coated electrodes and gas shields,

• know the principles of health and safety at work for power equipment such as welding equipment and auxiliary equipment powered by electricity,

•know the health and safety rules for handling cylinders and compressed gas (argon) installations,

• know the content of this manual and use the device for its intended purpose.

WARNING

Welding may endanger the safety of the operator and other persons in the vicinity. Therefore, special precautions should be taken when

welding. Before starting welding, read the health and safety regulations at the workplace. During MMA and TIG electric welding, the following

risks exist:

•ELECTRIC SHOCK

•NEGATIVE IMPACT OF THE ARC ON EYES AND SKIN

•VAPOR AND GAS POISONING

•BURNS

•EXPLOSION AND FIRE HAZARDS

•NOISE

Prevention of electric shock:

• connect the device to technically efficient electrical installation with adequate protection and zeroing efficiency (additional protection against

electric shock); other devices at the welder's workplace should be checked and correctly connected to the network,

• install power cables with the device switched off,

• do not touch simultaneously the non-insulated parts of the electrode holder, electrode and workpiece, including the device housing,

• do not use clamps and current leads with damaged insulation,

• in conditions of special risk of electric shock (work in environments with high humidity and closed tanks) work with an assistant supporting the work

of the welder and watching over safety, use clothing and gloves with good insulating properties,

• if you notice any irregularities, please contact competent persons to remove them,

• Operation of the device with covers removed is forbidden.

Prevention of negative effects of the electric arc on human eyes and skin:

• Wear protective clothing (gloves, apron, leather shoes),

• Use shields or protective helmets with a properly selected filter,

• Use protective curtains made of non-combustible materials and choose the right colors for the walls that absorb harmful radiation.

Prevention of poisoning by vapors and gases emitted during welding from electrode coating and metal evaporation:

• Use ventilation equipment and extractors installed in positions with limited air exchange,

• Blow out with fresh air when working in a confined space (tanks),

• Use masks and respirators.

Burn prevention:

• Use appropriate protective clothing and footwear to protect against burns from arc radiation and spatters,

• Avoid staining clothing with grease and oil that can ignite it.

Explosion and fire prevention:

• It is forbidden to operate the device and weld in rooms where there is a risk of explosion or fire,

• The welding station should be equipped with fire-fighting equipment,

• The welding station should be at a safe distance from flammable materials.

Prevention of negative effects of noise:

• Use ear plugs or other noise protection measures,

• Warn of the danger of people nearby.

WARNING!

Do not use the power source for thawing frozen pipes.

Before starting the device:

• Check the condition of electrical and mechanical connections. Holders and cables with damaged insulation must not be used. Inadequate

insulation of the grips and current leads can cause electric shock,

• Ensure proper working conditions, i.e. ensure proper temperature, humidity and ventilation at the workplace. Protect against atmospheric

precipitation outside enclosed rooms,

• Place the charger in a place that allows easy operation. Persons operating the welder should:

• have the authorization to electric welding with coated electrodes and the TIG method,

• know and comply with health and safety regulations applicable to welding works,

• use appropriate, specialized protective equipment: gloves, apron, rubber boots, shield or welding helmet with a properly selected filter,

• know the content of these operating instructions and use the welder for its intended purpose. All repairs to the device may only be

carried out after disconnecting the plug from the power socket.

When the device is connected to the network, it is forbidden to touch any part of the welding current circuit with bare hands or wet clothing.

It is forbidden to remove the outer covers when the device is connected to the network. Any modifications of the rectifier on your own are

prohibited and may constitute a deterioration of safety conditions.

All maintenance and repair works may only be carried out by authorized persons, observing the safety conditions in force for electrical equipment. It is

forbidden to operate the welder in rooms at risk of explosion or fire! The welding station should be equipped with fire extinguishing equipment. After

finishing work, disconnect the power cord from the device.

The threats and general health and safety rules presented above do not cover the welder's safety issues, as they do not take into account the specificity

of the workplace. An important addition to these are workplace health and safety instructions as well as training and instructions given by supervisors.

3. GENERAL DESCRIPTION

DIGITIG 200DC MULTIPRO is used for manual welding with direct current of structural steels with coated electrodes (MMA method) as well as

quality steels and non-ferrous metals with an inert gas shielding electrode (TIG method). In the design and construction of the device, the latest

achievements in the field of PWM technology (pulse width modulation) and IGBT modules (bipolar transistors with insulated gate) have been used,

thanks to which the welder is characterized by small dimensions and low weight.

The ARC FORCE function is available when MMA welding. During TIG welding, it is possible to regulate the rise and fall of current, pre-flow and

outflow of gas, and pulse parameters. The device has a memory for 10 sets of parameter settings for the TIG HF and MMA methods.

4. TECHNICAL PARAMETERS

4.1 Welder

Supply voltage AC 230V ± 10% 50Hz

Power consumption MMA: 5.7 kVA, TIG: 4.1 kVA

Rated welding current / duty cycle MMA: 180 A / 60% TIG 200 A / 60%

Rated voltage in no-load condition 67 V.

Maximum current consumption MMA: 26.6 A, TIG 19.6 A

Network Security 25 A.

Weight (without accessories) 7.5 kg

dimensions 395 x 160 x 310 mm

Level of security IP23

4.1.1 Parameter adjustment ranges

ARC FORCE 0 - 100 A.

Gas pre-flow 0.1 - 15 p

Gas outflow 0.1 - 15 p

Current build-up 0 - 15 p

Current drop 0 - 15 p

Starting current 5 - 200 A.

Welding current MMA: 20-180 A TIG: 5-200 A

Base current 10 - 90% welding current

Crater current 5 - 200 A.

4.2 TIG torch

Handle type T-26

Maximum current carrying capacity 200 A.

Gas flow 10-20 l / min

Ignition of the arc Contactless (HF)

Length 4 m

Work cycle

The work cycle is based on a 10-minute period. A 60% duty cycle means that a 4-minute break is required after 6 minutes of operation. A 100% duty

cycle means that the device can work continuously without interruptions.

Warning! Heating tests were carried out at ambient air temperature. The duty cycle at 40ºC was determined by simulation.

Level of security

IP determines to what extent the device is resistant to the penetration of solid and water pollutants. IP23 means that the device is designed to

work indoors and is not suitable for use in the rain.

5. CONSTRUCTION AND OPERATION

The basis for the construction of the welding machine's electricity conversion system are electronic systems made in IGBT technology enabling

operation in the frequency range above 200 kHz. The principle of operation consists in rectifying the voltage of a single-phase power supply to direct

voltage, converting the received direct voltage into a high-frequency rectangular waveform, transforming the voltage into the range required by the

welding process and re-straightening the obtained voltage to direct voltage. The welder is equipped with a supply voltage compensation system, which

enables their operation with voltage fluctuations in the supply network up to 10%.

6. CONNECTION TO THE MAINS NETWORK

1. The device should be used only in single-phase, three-wire power supply system with earthed zero point.

2. DIGITIG 200DC MULTIPRO inverter rectifiers are designed to work with 230V 50Hz mains protected with 25 A fuses with time delay. The

power supply should be stable, without voltage drops.

3. The device is equipped with a power cord and plug. Before connecting the power supply, make sure that the power switch (6) is in the

OFF position.

7. PREPARING THE APPLIANCE FOR WORK

If the device is stored or transported in low temperatures, the device should be brought to the right temperature before starting work

!!!

7.1 MMA method

The ends of the welding cables should be connected to the sockets (1) and (4) on the front panel so that the correct pole for the electrode is on the

electrode holder. The polarity of the welding cable connection depends on the type of electrode used and is indicated on the electrode packaging. The

ground hose clamp must be securely attached to the workpiece. Connect the device's plug to a 230V 50Hz power socket.

7.2 TIG method

The clamp's current clamp should be connected to the socket with negative polarity (1), the control plug of the clamp should be firmly screwed to the

socket (2), and the gas connection to the quick connector socket (3). The gas pipe from the regulator should be connected and secured to the gas

connector (9) located on the back of the housing. Connect the positive pole of the source (4) with the workpiece using a cable with a clamp. Connect the

device's plug to a 230V 50Hz power socket.

8. FUNCTION DESCRIPTION OF SWITCHES AND KNOBS

8.1 Front and rear panel

1. Negative polarization socket

2. Control socket

3. Shielding gas connection

4. Positive polarization socket

5. Grounding clamp

6. Main switch

7. Power cord

8. Fan

9. Shielding gas connection

8.2 Control panel

A - Pulse on / off button

Only active when TIG welding. Mode selection is signaled by the lighting of the symbol

- pulse welding, - pulseless welding.

B - Welding method selection button

The button is used to select the welding method. The choice of method is signaled by the lighting of the symbol:

MMA - covered electrode (MMA) welding, LI FT - gas shielded tungsten electrode welding MMA - covered electrode (MMA) welding, LI FT - gas shielded tungsten electrode welding

protective devices with arc ignition by rubbing (TIG Lift), H. F - welding with tungsten electrode in shielding gases with pilot arc (TIG HF). protective devices with arc ignition by rubbing (TIG Lift), H. F - welding with tungsten electrode in shielding gases with pilot arc (TIG HF). protective devices with arc ignition by rubbing (TIG Lift), H. F - welding with tungsten electrode in shielding gases with pilot arc (TIG HF). protective devices with arc ignition by rubbing (TIG Lift), H. F - welding with tungsten electrode in shielding gases with pilot arc (TIG HF). protective devices with arc ignition by rubbing (TIG Lift), H. F - welding with tungsten electrode in shielding gases with pilot arc (TIG HF).

C - Control knob

The adjustment knob is used to change the welding parameters.

Briefly pressing the knob causes the transition between the parameters being set. The currently adjustable parameter is marked by the lighting of the

corresponding diode, and the current parameter value appears on the parameter display (I). Turning the knob to the left decreases it, and turning it to

the right increases the parameter value. Pressing the knob again will save the parameter value and go to the next parameter.

D - Settings memory

The device has the memory of the last setting, i.e. after turning it off and on again, the last set parameters are restored. It is also possible to

save a total of 20 sets of settings for TIG HF and MMA welding methods.

To call up a previously stored set of settings, press the button until displayed

the corresponding set number on the memory display (H).

If after calling the set of settings we change any of the parameters, the device will exit the memory mode - a dash will appear on the memory display (H)

and the diode will turn off USER The changed parameters will be automatically cached after 30 seconds. After the device is turned off and restarted, they and the diode will turn off USER The changed parameters will be automatically cached after 30 seconds. After the device is turned off and restarted, they and the diode will turn off USER The changed parameters will be automatically cached after 30 seconds. After the device is turned off and restarted, they

will be restored and a dash will appear on the memory display.

To save the current settings, press the button and hold for 2 seconds. Will light up

diode USER, and the number on the memory display (H) will flash. Turn the knob to changediode USER, and the number on the memory display (H) will flash. Turn the knob to changediode USER, and the number on the memory display (H) will flash. Turn the knob to change

kit number. Pressing the button again within 10 seconds will remember the current one within 10 seconds will remember the current one

settings under the currently set number. If the button is not pressed again for 10 seconds, the device will return to the main menu.

If the device is turned off while the parameter set is loaded in memory, when it is switched on again, the last used set will be automatically loaded

and its number will appear on the display. If no parameter set is loaded into the memory and the device is turned off, after switching on again the last

used parameters will be restored and a dash will appear on the display (H).

E - Source selection mode button (two-stroke / four-stroke)

Only active when TIG welding. Mode selection is signaled by lighting up

2T symbol for the double-touch mode or the corresponding LED 4T for four-stroke mode. In double-touch mode, pressing the switch on the handle of 2T symbol for the double-touch mode or the corresponding LED 4T for four-stroke mode. In double-touch mode, pressing the switch on the handle of 2T symbol for the double-touch mode or the corresponding LED 4T for four-stroke mode. In double-touch mode, pressing the switch on the handle of

the handle will turn on the ionizer and ignite the arc. Welding is carried out with the switch pressed. Releasing the switch will end welding. In the

four-stroke mode, pressing the switch in the handle of the handle will turn on the ionizer and ignite the arc then release the switch and weld with the

switch released. Pressing the switch again will end welding.

F - Parameter set memory display

USER

The display indicates the number of the parameter set that has been loaded or under which the current set will be saved.

G - welding parameter display

OC REMOTE

ASH%

The display indicates the parameters during setting and during welding. The lighting of the corresponding LED on the side of the display

indicates the unit of the parameter.

The display also has additional indicator lights:

REMOTE LED indicating that the device is in remote control mode. The LED will light up

automatically after connecting the remote control plug to the socket (4)

OC The LED indicates incorrect welding current parameters or a device failure. On

the display also shows the error code "E00"

OT Overheat protection - the power source is equipped with a thermal,

automatic circuit breaker. If the welding machine temperature is too high, the protection disconnects the welding current, the OT diode lights up and

the error code "E00" appears on the display. After the temperature drops, the circuit breaker will reset automatically.

The display can also show other error codes: E01 Incorrect mains parameters E02

Internal controller error

E03 Incorrect mains parameters and internal controller error

9. PARAMETER SETTINGS

9.1 MMA method

Cur rent Ar c For ce

After selecting the MMA method, it is possible to adjust the welding current and the ARC FORCE function. During welding current adjustment

the LED is on Cur r ent and the ARC FORCE function can be adjusted after the diode lights up Arc Force.the LED is on Cur r ent and the ARC FORCE function can be adjusted after the diode lights up Arc Force.the LED is on Cur r ent and the ARC FORCE function can be adjusted after the diode lights up Arc Force.the LED is on Cur r ent and the ARC FORCE function can be adjusted after the diode lights up Arc Force.

ARC FORCE function

The ARC FORCE function allows you to adjust the dynamics of the welding arc. The shortening of the arc length is accompanied by an increase in the

welding current, which stabilizes the arc. Decreasing the value gives a soft arc and a smaller penetration depth, while increasing the value causes

deeper penetration and the possibility of short arc welding. When the ARC FORCE function is set to a high value, it is possible to weld while maintaining

the minimum arc length and high electrode melting speed. Adjustment range: 0 - 100A

9.2 TIG method

Use the welding method selection button (B) to select TIG HF or TIG Lift welding. Switch pulse on or off (A). Set the welding parameters:

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