Megmeet RevoTig Series - User Manual

The RevoTig Series Full-digital Inverter DC TIG & AC/DC TIG Welding Power Source, manufactured by Megmeet Welding Technology Co.,Ltd., is a versatile welding machine designed for both DC argon arc welding and AC/DC argon arc welding. This series includes models such as MetaTig 500/400/315DC and MetaTig 500/400/315ACDC.

Function Description

The RevoTig series offers a comprehensive set of functions for precise and efficient welding. Key features include:

• Multiple Waveforms: Supports sine wave, triangle wave, trapezoidal wave, and square wave, allowing for adaptability to various welding requirements and materials.
• High-Frequency Inverter Switching: Operates at 110KHz, providing ultra-low output ripple current for stable and consistent welding.
• Adaptive Circuitry: Adopts a unique arc stabilizing circuit to ensure the arc is almost continuous under any waveform.
• Dynamic Response: Features high-frequency AC output with high dynamic response and zero-crossing arc stability.
• AC TIG Frequency: AC TIG frequency can reach 300Hz, and the arc can start and weld at 10A.
• DC Pulse TIG: Pulse frequency can reach 3000Hz, which helps stabilize arc starting and welding.
• Gas Flow Detection: Allows users to check for protective gas and set the gas flow on the regulator. The machine automatically shuts down after 5 minutes of inactivity (default, adjustable in internal menu).
• Gas Preflow/Postflow: Adjustable pre-gas time (0-25s) and post-gas time (0-250s) to ensure proper gas coverage before and after welding, protecting the weld pool and electrode.
• HF Impulse (High-Frequency Arc Ignition): Enables non-contact arc ignition using high frequency and high voltage, which is the default setting.
• Lifting Arc Start: An alternative arc starting method (scratch ignition) suitable for special welding occasions, activated by turning off HF Impulse.
• Mode Control: Supports various welding control modes including 2-step, 4-step, special 4-step, spot welding, and continuous spot welding.
  • 2-Step Mode: Synchronized with the ON/OFF operation of the welding torch switch. Press and hold to start, release to stop.
  • 4-Step Mode: Arc starting time is determined by the panel setting, and arc ending time is determined by the torch switch press.
  • Special 4-Step Mode: Arc start and end times are decided by the duration the torch switch is held.
  • Spot Welding: Allows setting spot welding time (0.1-25s) for precise spot welds.
  • Continuous Spot Welding: Enables continuous spot welding with independently adjustable spot welding time (0.1-25s) and interval time (0.1-10s).
• Welding Sequence: Parameters such as initial current, rise time, fall time, arc end current, MMA arc length, and thrust current can be adjusted.
• Arc Selection: Allows selection of waveform parameters including hardness, frequency, intensity, and duty cycle.
  • Softness and Hardness (DC TIG): Offers square wave, triangular wave, trapezoidal wave, and sine wave options.
    • Square wave: Fast polarity switching, good arc stability, good dynamics.
    • Triangular wave: Short peak time, low heat input, suitable for heat-sensitive metals and thin plates.
    • Trapezoidal wave: Smooth polarity switching, soft arc, good wetting effect, suitable for groove and overhead welding.
    • Sine wave: Rectangular transition at zero-crossing, low welding noise, softer arc.
  • Frequency: Adjustable pulse frequency (0.1-3000Hz for DC, 20-300Hz for AC) to control arc concentration and penetration.
  • Intensity: Sets the percentage of pulse base current, affecting heat input and fish scale pattern.
  • Duty Cycle: Proportion of peak current action time in a pulse cycle, influencing heat input and fish scale pattern.
• Cleaning Width (AC TIG): Adjustable cleaning width (5-70%, default 30%) for welding aluminum alloys to remove oxide film, making welding easier.
• Welding Program Selection: Choose between TIG, TIG-PULSE, and MMA welding methods.
  • TIG-PULSE: Low-frequency pulse TIG welding (0.1-100Hz).
  • MMA: Manual Metal Arc welding, with DC and AC options.
• Internal Menu: Provides access to advanced settings and parameters (e.g., factory reset, VRD mode, smart fan control, robot communication settings).
• Save and Recall: Allows saving up to 50 sets of welding parameters (JOB 0-49) for quick recall.

Important Technical Specifications

The RevoTig series boasts robust technical specifications:

• Control Mode: Digital IGBT control.
• Input Voltage: Three-phase AC 380 V (+/-25%).
• Input Frequency: 40-70Hz.
• Inverter Switching Frequency: 110KHz.
• Rated Input Capacity:
  • RevoTig 500 ACDC/DC: 19KVA/17.7KW
  • RevoTig 400 ACDC/DC: 13.1KVA/12.3KW
  • RevoTig 315 ACDC/DC: 10.2KVA/9.3KW
• Constant No-Load Voltage: 68V.
• Rated Output Current:
  • RevoTig 500 ACDC/DC: 500A
  • RevoTig 400 ACDC/DC: 400A
  • RevoTig 315 ACDC/DC: 315A
• Rated Output Voltage:
  • RevoTig 500 ACDC/DC: 30V
  • RevoTig 400 ACDC/DC: 26V
  • RevoTig 315 ACDC/DC: 22.6V
• Duty Cycle:
  • RevoTig 500 ACDC/DC: 20%@500A, 100%@350A (DC TIG), 40%@500A, 100%@400A (AC TIG)
  • RevoTig 400 ACDC/DC: 60%@400A, 100%@350A (DC TIG), 100%@400A, 100%@350A (AC TIG)
  • RevoTig 315 ACDC/DC: 100%@350A (DC TIG), 100%@350A (AC TIG)
• Output Current Range:
  • DC TIG: 3-500A (500 series), 3-400A (400 series), 3-315A (315 series)
  • AC TIG: 4-500A (500 series), 4-400A (400 series), 4-315A (315 series)
  • MMA: 30-500A
• Power Factor Efficiency: 0.94, with efficiencies ranging from 87% to 91% depending on the model and current.
• DC Pulse Frequency: 0.1-3000Hz.
• AC Pulse Frequency: 20-300Hz.
• Pulse Width: 1-99%.
• Arc Ignition Method: High frequency arc ignition/lifting arc ignition.
• Parameter JOB: 50 JOBs.
• Adjustments:
  • Rise time: 0-20s (0.1s increments).
  • Fall time: 0-20s (0.1s increments).
  • Pregas time: 0-25s (0.1s increments).
  • Post gas time: 0-25s (0.1s increments).
• Output Terminals: Quick plug.
• Foot Pedal Signal: Can be adapted to foot pedal.
• Enclosure Rating: IP23 S.
• Insulation Class: H.
• Cooling Method: Forced air cooling.

Usage Features

The RevoTig welding machine is designed for user-friendliness and safety:

• Intuitive Operation Panel: The front panel features clear indicators and knobs for easy selection and adjustment of welding parameters.
• Foot Pedal Compatibility: Allows for control of welding current and switch operation via an optional foot pedal. The foot pedal can adjust current in 2-step mode and acts as a switch in 4-step, special 4-step, and spot welding modes.
• Water Cooler Connection: Integrated water cooler connection for water-cooled welding torches, with a high-voltage AC380V power supply.
• Gas Hose Connection: Simple connection of gas flow meter to the gas cylinder and welding power source.
• Input Power Cable Connection: Designed for three-phase AC 380V input, with specific cable size recommendations (6mm² for 315/400 series, 10mm² for 500 series).
• Safety Precautions: Emphasizes strict adherence to safety guidelines, including cutting off power before handling, proper grounding, avoiding contact with live terminals, and using protective equipment.
• Error Indication: The red indicator light on the panel illuminates when an error occurs, and error codes are displayed on the digital tubes for troubleshooting.
• Welding Condition Setting: A structured process for setting arc starting method, gas preflow/postflow times, initial current, rise/fall times, and arc end current.

Maintenance Features

Regular maintenance is crucial for the longevity and performance of the RevoTig welding machine:

• Daily Checks:
  • Welding Power Source: Inspect for damaged or loose mechanical appliances, tight cable connections, fault LED status, intact input power terminal cover, unobstructed air inlet, loose eye bolts, damaged/loose wheel feet, and side panel integrity.
  • Cable: Check for detached positive power cable.
  • Routine: Observe for discoloration/overheating, normal fan sound, peculiar smells, abnormal vibrations/noise during operation.
• Regular Checks (every 6 months):
  • Internal Dust Removal: Disassemble the top cover and side panel to remove dust from the radiator and internal components using dry compressed air.
  • Welding Power Source Inspection: Check for signs of discoloration, overheating, or damage, and ensure all connections are secure.
  • Cable, Trachea Inspection: Inspect safety grounding wires, cables, air pipes, etc., for damage and ensure proper tightening.
  • Withstand Voltage Tests: Conduct withstand voltage tests and insulation tests by qualified personnel.
  • Discharge Spark Plug Cleaning: Clean the spark plug of the welding power source.
• Troubleshooting Guide: The manual provides a comprehensive table of error codes (E1-E65) and common welding issues (e.g., arc start failure, difficulty in arc starting, tungsten electrode burn, unstable arc, welding porosity, poor fusion, tungsten inclusion, weld undercut, crack, welding nodules/burn-through), along with their probable causes and corresponding countermeasures.
• Warranty: The product comes with a 24-month warranty under normal use. Warranty service is provided free of charge for failures or damages occurring within this period, provided the machine is operated according to the user manual.
• Customer Support: Megmeet Welding Technology Co.,Ltd. offers technical support through local dealers and company headquarters, with a customer service hotline and email for inquiries.