AC DC 206i

AC DC 256T
TIG INVERTER
WELDING MACHINE
CAUTION BEFORE INSTALLING OR OPERATING THIS MACHINE
ENSURE ALL INSTRUCTIONS AND WARNINGS HAVE BEEN READ AND
UNDERSTOOD.

INSTRUCTION MANUAL

Description The TIG 206i/256T is designed for light medium fabrication and maintenance for
professional ac-dc tig welding applications. The machine gives excellent performance on ac and dc and
is capable of producing the highest quality tig welds on a very wide range of materials; the machine
also has mma capability. The following features are fitted as standard:- ac-dc, downslope, infinitely
variable amps with remote socket for footpedal etc, 2T-4T, post flow timer, mma, digital ampmeter
with real and set, and inbuilt pulser. This model also has ac balance for producing optimum welds on
especially difficult to weld materials.

Technical Specifications

ACDC206i

Current range
Max open circuit voltage
Duty cycle
Mains input voltage
Mains input fuse

5 200A AC DC 10-250A
80 V
80 V
200A @ 60%
250A @ 60%
230 V 50HZ
400V 50HZ
16A or 13A slow blow
16A

ACDC256T

When using the 206i with a 13A fuse above 150A MMA or 180A on TIG the fuse may blow occasionally.

Safety
Before using make sure all operators are familiar with the welding process and have had
appropriate training relating to the risks involved.
The Health and Safety Executive publish documents regarding this such as ISBN 0 7176 0704 6
(Electrical safety in arc welding), and many others.
When welding or cutting in an environment with increased risk of electric shock extra
precautions must be observed. Typical conditions with increased risk of electric shock are
working in wet or damp conditions, working inside vessels, working in cramped conditions and
exposed to conductive parts, etc. DO NOT TAKE ANY RISKS
This machine is designed for use indoors and must not be used in the rain or a wet environment.
Declaration of conformity
This equipment is manufactured to comply with 93/68/EEC, BS EN 60974-1
This equipment is manufactured to comply with 89/336/EEC, BS EN 50199
The equipment is CE marked
Date20/11/2007
R P Rycroft

Pre installation & EMC information

The installer of this equipment must make an assessment of the area before installing.
It is the users responsibility to ensure that if any electromagnetic disturbances are detected to resolve
this before continuing.
As with other AC DC tig welding machines it is preferable to use this machine as far away as possible
from sensitive electrical or electronic equipment such as computers, telecomm equipment, safety
critical equipment, transmitters and receiving equipment etc.
There is a risk to sensitive equipment from radiated or conducted emissions from this machine.
This machine is designed for use in industrial premises, when used in other environments there could
be potential difficulties with electromagnetic interference with other equipment.
Consideration must be also given to other premises as the emissions may not be limited to the installed
premises.
The following are methods to reduce emissions.
1) Keep all welding cables short close together and at ground level.
2) Equipotential bonding of metal components in the work area and bonding of the work piece
can be considered however there are electrical safety implications for the operator with
increased risk of shock if the electrode is touched; therefore it is important the operator is
aware and adequately protected from making contact with the work and the electrode. Before
bonding the area and work piece consult an experienced electrician.
3) This equipment must be properly maintained and all screws holding the sides etc kept in
place.
4) Sometimes it may be necessary to fit additional mains input filters or even screen the cables
and / or work area. This will involve consulting an experienced engineer.

Description of controls
3

15

11
12

4
20

14
1

10

19
18
13
17

3
5

7
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)
16)

17)

16

On/off switch - isolates all internal circuits.

2T-4T switch - only active in tig mode, allows torch trigger latching (4T) where you
can continue to weld after releasing the torch switch until pressing again, or standard
on/off trigger function (2T).
Amps knob - gives full adjustment range from minimum current to
Maximum current and is also the peak current when welding on pulse.
Gas preflow selects the time between 0 2 seconds from pressing the torch switch
and getting gas to the arc establishing for perfect clean starts.
Post flow knob adjusts length of time (0-10 seconds) which gas continues to flow
to prevent contamination to weld pool and tungsten at the end of a weld.
Work socket - must connect directly to welding work with correct size cable etc.
Tig torch connector welding current outlet for tig torch.
Remote 5w socket - used for start stop signal (trigger) from tig torch
which is pins 1 and 2.
Remote 5w socket, used for a foot pedal to control welding current remotely.
TIG / MMA switch selects the welding process required
Slope down control (0-10seconds) allows for slope down of welding current at the
finish of welding for crater filling and perfect finishes to the weld.
AC DC switch selects the output current required, normally AC for aluminum and
alloys and DC for stainless and other steels.
Pulse on/off switch. The solid line indicates normal welding, the castellated line for
pulse welding. Pulse welding can be useful to reduce the heat input on some types of
welds and materials.
Digital Ammeter- this shows the set current before actually welding, then when an
arc strikes it displays the actual welding current flowing.
Pulse base current setting - when the machine is set to pulse this sets the low value of
current which flows, this is adjustable between 20% and 90% of the main current.
Balance knob - only for use on ac welding, allows a greater positive welding current
at the electrode, or balanced positive and negative, or a greater negative current at the
electrode. This can be useful for welding some special materials, where greater
cleaning is required (more positive control turn clockwise) or greater penetration is
required (more negative control turn anticlockwise). For most AC applications this
should be set to half way ie 50%
Pulse duty cycle setting (time at peak current in relation to time at low current). This
is adjustable from 10% peak time and therefore 90% base time to 90% peak time and
10% base time.

18)
19)

20)

Pulse welding frequency control sets the repetition rate for the pulses from 0.5 HZ
which is 1 pulse every 2 seconds up to a maximum frequency of 300 HZ which is
300 pulses per second.
Arc force setting for MMA welding - this changes the characteristic to give an
increase in current as the arc voltage falls below about 20V this results in a more
forceful arc depending on where the control is set, this can be useful for some stick
welding applications. This control should be set to 0 for all TIG welding.
Warning lights the left one indicates the machine internals have overheated, in
which case leave the machine switched on for the fans to cool the machine and try to
work with a lower amperage so the machine is not so stressed. The right hand light
indicates a fault has occurred like over voltage etc or a major internal problem.

Electrical Installation
Do not connect this machine to any voltage other than 230V for the 206i & 400V for the 256T
The ACDC206i will work from a good quality generator of at least 7KVA rating, and if using a
generator make sure that the voltage is stable and constant at 230V many small generators are
not suitable for supplying inverter welding machines due to fluctuating voltages which can cause
damage to machines.
Faults caused by incorrect input voltage or voltage surges from generators etc are not covered by
warranty
This machine must be connected to the electricity supply by a competent person
Connect the input flex to a suitable supply. Make sure this supply voltage matches the voltage model of
the Machine. For single phase 230V machines ensure the green/yellow wire is connected to the earth
terminal in the mains plug or a good earth point in the machine the other two are normally blue and
brown wires which must be connected to the appropriate voltage, the blue is neutral and the brown is
live. For the three phase 256T ensure the green/yellow wire is connected to the earth the other three
connect to the three phases in any order.
If in doubt consult a qualified electrician.

Connecting the welding torch

Connect up the welding torch to the fittings at the bottom of the front panel as follows.
The power cable connects to the power socket no.7, the gas is a push fitting.
The torch trigger connects to the 5 pin torch switch connector, (1 and 2 are the trigger pins for the
welding torch).

Welding return earth

This connects to the socket marked 6 on the diagram. A good welding earth is essential for correct
operation.

Gas
The hose at the rear should connect to a gas regulator suitable for the welding process and the pressure
and flow set to give good coverage of the welding arc, too little gas flow will result in a black dirty
weld, too much and the arc can become unstable and harsh. The gas normally used for TIG welding is
pure argon. Other gasses are also available but consult your gas supplier before using anything
other than argon.

Welding with this machine

This machine is designed to be used by operators who have knowledge of welding it is strongly
recommended that inexperienced operators are trained before using this machine.
It is not practical to try and explain how to weld is this manual.

DO NOT TAKE ANY RISKS

MAINTENANCE
The operator should carry out daily checks of all cables and connections etc; any faults must be
reported to a competent person and the machine taken out of service until repaired.
It is necessary for a comprehensive service inspection and test to be carried out at regular intervals by a
competent person and documented. This should be no less than every six months and sooner in harsh
operating conditions. If the machine is correctly maintained this machine should give a long trouble
free life.