Everlast PowerTig 200EX User manual

1
EVERLAST
Power TIG ® Series
Tig (GTAW) and mma (smaw)
Welders
Operator ’ s Manual for PowerTig® AC/DC Welders
Includes Power i-Tig® DC Models
Safety, Setup and General Use Guide
Rev. 1 0518-09

2
Thank you for purchasing an everlast product. We ap-
preciate your patronage and hope that you will enjoy
years of use from our product.
Please go directly to the Everlast website to register
your unit and receive your warranty information.
Your unit registration is important should any infor-
mation such as product updates or recalls be issued.
It is also important so that we may track your satis-
faction with Everlast products and services. If you
are unable to register by website, contact Everlast di-
rectly through the consumer department at the main
number. Your unit will be registered and warrantee
will be issued and in full effect.

3
Serial number: __________________________
Model number: ____________________________
Date of Purchase___________________________
EVERLAST
Contact Information
Everlast consumer satisfaction email: [e-mail]
Everlast Website: everlastwelders.com
Everlast Technical Support: [e-mail]
Main toll free number: 1-877-755 WELD ( 9353 ) 9am—5pm PST M-F
11am-4pm PST Sat.
FAX: [phone]
NOTES:

4
Table of contents
Section……………………………………………….Page
General ...……………………………………………
Safety Precautions..……………………………….
Introduction and Specifications…………………
Know Your Machine………………………………..
2.1 Panel Face and Functions……………………
2.2 Lower Panel and functions….………………
Getting Started……………………………………..
3.1 General Guidelines……………………………
3.2 Shielding Gas Selection………………………
3.3 Regulator/Flow meter Selection……………
3.4 Regulator Connection………………………...
3.5 Regulator Adjustment………………………..
3.6 Machine Setup………………………………….
3.7 Tungsten Selection……………………………
3.8 TIG Torch………………………………………..
3.9 TIG Welding Principles and Guide…………
3.13 MMA (Stick Welding)…………………………
Trouble Shooting……………………………………
5
6
9
19
19
22
23
23
23
23
23
23
24
24
26
26
28
30

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Everlast 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 deliv-
ering a satisfactory product to you. That is the reason we offer technical sup-
port to assist you with your needs should an occasion occur. With proper use
and care your product should deliver years of trouble free service.
Safe operation and proper maintenance is your responsibility.
We have compiled this operator’s manual, to instruct you in basic safety, op-
eration and maintenance of your Everlast product to give you the best possible
experience. Much of welding and cutting is based upon experience and com-
mon 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.
Please carefully read this manual before you operate your Everlast unit. This
manual is not only for the use of the machine, but to assist in obtaining the
best performance out of your unit. Do not operate the unit until you have read
this manual and you are thoroughly familiar with the safe operation of the unit.
If you feel you need more information please contact Everlast Support.
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 mal-
functioning 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 an electrician if distur-
bance is noted. Sometimes, improper wire routing or poor shielding may be
the cause.
HF can interfere with pacemakers. See EMF warnings in following safety sec-
tion for further information. Always consult your physician before entering an
area known to have welding or cutting equipment if you have a pacemaker.
General

6
SAFETY PRECAUTIONS
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 severe skin burn and damage. There are other potential hazards involved
with welding such as severe burns and respiratory related illnesses. Therefore ob-
serve the following to minimize potential accidents and injury:
Use appropriate safety glasses with wrap around shields while in the work area, even
under welding helmets to protect your eyes from flying sparks and debris. When chip-
ping slag or grinding, goggles 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 recommended. Shades greater than 9
may be required for high amperage welds. Keep filter lenses clean and clear for maxi-
mum visibility. It is also advisable to consult with your eye doctor should you wear
contacts 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 equip-
ment. If no protection is available, exclude them from the work area. Even brief expo-
sure to the rays from the welding arc can damage unprotected eyes.
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 ade-
quate 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 metal. 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 occur. Proper hand
protection is required at all times when working with welding or cutting machines!

7
SAFETY PRECAUTIONS
continued
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 minimize exposure:
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.
WARNING! Do not weld on galvanized steel, stainless steel, beryllium, titanium, cop-
per, cadmium, lead or zinc without proper respiratory equipment and or ventilation.
WARNING! This product when used for welding or cutting produces fumes and
gases which contains chemicals known to the State of California to cause birth de-
fects and in some cases cancer. (California Safety and Health Code §25249.5 et seq .)
WARNING! Do not weld or cut around Chlorinated solvents or degreasing areas.
Release of Phosgene gas can be deadly. Consider all chemicals to have potential
deadly results if welded on or near metal containing residual amounts of chemicals.
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.

8
SAFETY PRECAUTIONS
continued
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 weld-
ing 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 ne-
cessitates 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 ca-
bles with appropriate restraints can help reduce trips and falls.
WARNING! Fire and explosions are real risks while welding or cutting. Always keep
fire extinguishers close by and additionally a water hose or bucket of sand. Periodi-
cally 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 flammable 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 han-
dling. Serious burns and injury can result if material is improperly handled.
WARNING! Faulty or poorly maintained equipment can cause injury or death.
Proper maintenance is your responsibility. Make sure all equipment is properly main-
tained 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 employees 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.
Further information can be obtained from The American Welding Society (AWS) that
relates directly to safe welding and plasma cutting. Additionally, your local welding
supply company may have additional pamphlets available concerning their products.
Do not operate machinery until your are comfortable with proper operation and are
able to assume inherent risks of cutting or welding.

9
Product Feature Comparison
Introduction and SpecificationsSection 1
Product Features EX Series
200/250
LX Series
200/250
DX Series
200/250
I-Tig
200/250
315 DX
Over Current Warning •••••
High Frequency Start •••••
High Frequency AC
(Aluminum)
••••
Pulse Frequency Control •••••
Pulse Ratio (Width) •••••
Base /Peak Ratio •••• * • *
Arc Force Control (Dig) ••
Tig and Stick (SMAW) •••••
AC Frequency Control ••••
AC Balance Control ••••
4t/2t Remote •••••
Spot Timer •
Pre-Gas Flow Timer •
Post-Flow Timer ••••** •
Start Current (initial) •
Up Slope Timer ••••
Down Slope Timer •••••
Crater Current (Final) •
Voltage 220-240 V
1ph (200)
1-3ph (250)
220/240 V
1ph
(200/250)
220/240 V
1ph
(200/250)
220-240V
(200) 1ph
110/220V
(250) 1ph
220/240V
3 ph only
Duty Cycle @ Rated Amps 60% 60% 35% 35%(200)
60% (250)
35%
*Base/Peak Ratio is controlled by setting independent Base
Amp and Peak Amp controls.
** Post Flow is controlled by selecting preset switch.

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Introduction and SpecificationsSection 1
PowerTig DX, LX and EX Models, I-Tig Models
PowerTig DX Series PowerTig LX Series
PowerTig EX Series Power I-Tig Series

11
Introduction and SpecificationsSection 1
PowerTig 315
Industrial
PowerTig TIG (GTAW)
WP 26 Torch Assembly
PowerTig TIG (GTAW)
Foot Pedal Assembly
PowerTig Deluxe
Stick (SMAW, MMA)
Electrode Holder
And Ground Clamp
For TIG and STICK
Operation
PowerTig TIG (GTAW)
Torch Accessory Pack

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1.1 This manual has been compiled to give
an overview of operation and is designed to
offer information centered around safe,
practical use of the machine. It is not in-
tended to teach welding technique. All
suggestions and techniques given are ap-
proximations and should be used as a gen-
eral guide only.
1.2 To ensure that your Everlast product is
in top condition, carefully inspect unit for
damage upon opening the box, looking for
damage on the surface of the unit and to
the machine itself and all its accessories.
Do this immediately upon receipt of prod-
uct. Any damage issues must be resolved
right away. It is further recommended that
the product be tested at the same time for
proper operation, even if it is to be stored
for a while. Check to make sure all pas-
sages, connections and fittings are clear of
any packing material or other obstruction.
Record the serial number on the page pro-
vided in this manual. Include purchase date
for warranty reference. Serial numbers are
located on the rear of the machine.
1.3 The PowerTig (includes I–Tig) units
are used daily in the industry performing
day to day fabrication and repair activities.
The exceptional arc characteristics are
provided by the inverter based technology
that employs the use of reliable IGBT tran-
sistors technology from Germany. Light-
weight inverters allow a machine to be
finely tuned for precise arc characteristics,
while consuming less power than the lar-
ger transformer based machines. Power-
Tig units allow non-contact starts, eliminat-
ing the problem of tungsten contamination.
Depending upon the unit, precise control
of the welding arc is allowed through the
adjustments available on the panel face.
The independent controls allow for a virtu-
ally limitless number of configurations to
suit every type metal and weld condition
encountered. The use of High Frequency
arc starting in AC and DC modes, greatly
simplifies the TIG(GTAW) process.
1.4 Be careful to observe duty cy-
cles of the machine posted in this
manual and on the machine itself.
A duty cycle is a rating of percentage of
time out of 10 minutes the machine can be
used at the rated power setting . Over-
heating may occur if the duty cycle is ex-
ceeded. On multi-voltage, multi-phased
machines, note that the rated duty cycle
will change.
1.5 The unit should be stored in a dry
place for long term storage. Humid/wet
conditions can contribute to the eventual
decay of the circuitry in the machine. For
safety reasons, do not use this machine
directly in the rain or with soaked clothing
or protective gear.
1.6 Use only the provided handles to lift the
unit. Do not suspend by cables or chains
or use fork trucks to lift the units. If neces-
sary, use two people to carry the unit.
1.7 Make sure that the units cooling fan
and exhaust vents are kept free of obstruc-
tion. Before every operation, inspect the
unit for unexpected obstructions such as
insect and rat nests. From time to time, a
cleaning of the machine with low pressure
air and a small plastic bristle brush is nec-
essary to ensure long life. On these occa-
sions only, unplug unit and remove cover
to access interior. Concentrate efforts on
aluminum heat sinks and panel vents to
remove dust and dirt.
1.8 Refer to the following pages to locate
your particular unit and its specifications.
Note that product specifications are sub-
ject to change without notice due to prod-
uct improvements. If any additional infor-
mation is needed contact Everlast. Sche-
matics are not offered due to the proprie-
tary information that they contain. How-
ever, simple wiring diagrams may be ob-
tained for basic diagnosis and may be ob-
tained from technical support.
Introduction and SpecificationsSection 1

13
Introduction and SpecificationsSection 1
PowerTig EX Models
Table 1.1
MODEL
PowerTig 200EX PowerTig 250EX
INPUT Voltage 1ph 230V 50/60Hz 1 or 3 ph230V50/60Hz
Open Current Voltage 60 - 80V
MMA
Welding Current Range
5A( ± 3)~160A 5( ± 3)~200A
Rated Output Current 160A 200A
Rated Duty Cycle 60%
Open Current Voltage 60 - 80V
AC
Welding Current Range
5( ± 3)-200A 5( ± 3)~250A
AC balance 10%~90 %
TIG
AC Square Wave Frequency 20~250Hz
Rated Duty Cycle 60%
Pulse Current Range
5( ± 3)~200A 5( ± 3)-250A
Rated Duty Cycle 60%
DC
Current Up /Down-Slope Time 0~10S
Base /Peak Ratio 5%-95%(minimum base current 5A)
Pulse Width Ratio 10%~90%
Pulse Frequency (L/H) 0.2-20Hz/5-500Hz
TIG
Pre gas /Post Flow Time 0s-10s/0s~30s
Start Current/Crater Current
5A( ± 3)-100A
Spot Timer 0s-10s
Arc Starting Method High Frequency
Power Efficiency
≥ 83%
Weight 55 lbs (25kg)
Protection Class of Enclosure IP21S
Outline Dimensions 20.2x8.6xx15.5 inches (515x220x395 mm)

14
MODEL
PowerTig200LX PowerTig250LX
INPUT Voltage 1ph 230V 50/60Hz 1ph 230V 50/60Hz
Open Current Voltage
60 - 80V
MMA
Base Current 5A~160A 20~200A
Rated Output Current 160A 200A
Rated Duty Cycle 60%
Open Current Voltage
60 - 80V
AC
Base Current 20A~200A 20~250A
AC balance 30%~70 %
TIG
AC Square Wave Frequency 10~200Hz
Rated Duty Cycle 60%
Pulse Current 5~200A 20-250A
Rated Duty Cycle 60%
DC Current Up/Down-Slope 0~10S
Base /Peak Ratio Adjusting Range 10%-95%(minimum base current 5A)
Pulse Width Ratio 10%-90% (0.1~0.9)
TIG
Pulse Frequency 0.5~25Hz
Post Flow Time 1~25s
Arc Starting Method High Frequency
Power Efficiency
≥ 83%
Weight 55 lbs (25kg)
Protection Class of Enclosure IP21S
Outline Dimensions mm
3
20.2x8.6x15.5 in. 515x220x395
Introduction and SpecificationsSection 1
Table 1.2
PowerTig LX Models

15
Introduction and SpecificationsSection 1
MODEL
PowerTig200DX PowerTig250DX
INPUT Voltage 1ph 230V 50/60Hz
1ph 230V 50/60Hz
Open Current Voltage
60 - 80V
MMA
Base Current 5A~160A 20~200A
Rated Output Current 160A 200A
Rated Duty Cycle 35%
Open Current Voltage
60 - 80V
AC
Base Current 20~200A 20~250A
AC balance 30%~70 %
TIG
AC Square Wave Frequency 20~100Hz
Rated Duty Cycle 35%
Pulse Current 5~200A 20-250A
Rated Duty Cycle 35%
DC Current Down-Slope Time 0~10S
Base Current 5A~200A 250A
Pulse Width Ratio 10%-90% (0.1~0.9)
TIG Pulse Frequency 0.5~25Hz
Post Flow Time 1~25s
Arc Starting Method High Frequency
Power Efficiency
≥ 83%
Weight 55 lbs (25kg)
Protection Class of Enclosure IP21S
Outline Dimensions 20.2x8.6x15.5 in. 515x220x395(mm)
PowerTig DX Models
Table 1.3

16
MODEL
PowerTig315DX
INPUT Voltage 3 ph 230V 50/60Hz
Open Current Voltage 60 - 80V
MMA
Base Current 20~250A
Rated Output Current 250 A
Rated Duty Cycle 35%
Open Current Voltage 60 - 80V
AC
Base Current 20-315 A
AC balance 30%~70 %
TIG
AC Square Wave Frequency 20~100Hz
Rated Duty Cycle 35%
Pulse Current 20-315A
Rated Duty Cycle 35%
DC
Current Down-Slope Time 0~10S
Base Current 20-315A
Pulse Width Ratio 10%~90%(.1-.9)
TIG
Pulse Frequency 0.5~25Hz
Post Flow Time 1~25s
Arc Starting Method
High Frequency
Power Efficiency
≥ 83%
Weight 55 lbs (25kg)
Protection Class of Enclosure IP21S
Outline Dimensions
20.2x8.6x15.5 in.
515x220x395mm
Introduction and SpecificationsSection 1
Table 1.4 PowerTig DX Model 315

17
Model Power I-Tig 200
Power Supply Voltage AC 220/230/240V 50-60 Hz
Open Current Voltage 60-80 V(DC)
Rated Output Current 200A
Rated Duty Cycle 35%
Base Current
5-200A(TIG)
5-160A(Stick)
Base Amps 5-200A
Start current (fixed) 15A(fixed)
Crater-Fill Current (fixed) 15A(fixed)
Pulse Width Ratio 10%-90% (.1-.9)
Pulse Frequency 0.5 - 25Hz
TIG Arc Starting Method High Frequency
Up-slope, Down-slope 0-5 Sec
Post Flow Time 5S/10S
Weight 36 lbs (16kg)
Protection Class of Enclosure I P21S
Outline Dimensions 17x8x12.5 in (425×195×310 mm)
Introduction and SpecificationsSection 1
Power I-Tig 200
DC Output Only
Table 1.5

18
Introduction and SpecificationsSection 1
Model Power I-Tig 250
Power Supply Voltage AC 110V/220V AC 50-60 Hz
Open Current Voltage 60-80V (DC)
Rated Output Current 150A (110V) 250A (220V)
Rated Duty Cycle 60%
Base Current
5-150A(TIG)
5-250A(TIG)
5-125A(Stick)
5-200A(Stick)
Start Current (fixed) 15A(fixed)
Crater-Fill Current (fixed) 15A(fixed)
Pulse Width Ratio 10%-20% (.1-.9)
Pulse Frequency 0.5 - 25Hz
TIG Arc Starting Method High Frequency
Up/Down-slope time 0-5 Sec
Post Flow Time 5S/10S
Weight 16kg
Protection Class of en-
closure I P21S
Outline Dimensions
17x8x12.5 in
425×195×310
mm
Power I-Tig 250 Dual Voltage
DC Output Only
Table 1.6

19
Section 2 Know Your machine
PowerTig
1
2
3
4 5 6 7
8
9 10 11 12 13 14 15
16 17 18 19 20 21 22
2.1 Panel Face. The following is a unit panel
face from an EX series unit. Depending upon
your unit, the panel face may vary with regard
to quantity and location of controls and fea-
tures. Use the appropriate referenced num-
ber to refer to equivalent features on your
unit. Names or designation of control features
may slightly vary. I-tig model layout varies
slightly.
1. On lamp. This light illuminates while the
machine is powered on.
2. Over Current/Overheat lamp. This lamp
illuminates when the duty cycle has been ex-
ceeded or the machine has overheated due to
improper ventilation. Discontinue use until
lamp goes out. Allow the fan to continue to
run. Once lamp goes out, you may resume
using the unit. If frequent or continuous over-
heating is encountered, contact Everlast.
3. Digital Display. The display posts the ap-
proximate welding amps.
4. Pulse control*. This 3 position rocker switch
allows for use of the built in pulser. You may
select: Off, Low (L), or High (H). This feature
pulses (cycles) the amperage between base
and peak amps to maintain fine control of weld-
ing on thin materials or on out-of-position welds.
Noticeable fluctuation of the arc intensity oc-
curs when the pulsing mechanism is on.
*Note: On DX , LX Models having only 2 position
rocker switches, a straight line and a square
sine wave denotes off and on positions, respect-
ively. I-Tig models select for DC or Pulse DC
only. Model 315 DX has no dedicated switch
control for the pulse. Turn the pulse off by turn-
ing the pulse amps control to lowest setting and
use only the base amps to select amperage.
5. Pulse Frequency. The pulse frequency con-
trols the number of pulse cycles per second
(Hz). Where applicable, when the pulse is se-
lected for Low, the inner numbers are read. (.2
-20 cycles per second). When the pulse is se-
lected for High, read the outer numbers. (5-500)

20
6. Base/Peak Ratio. This proportions the
base amperage with the peak amperage of
the pulse cycle, expressed as a percentage
or decimal fraction of the peak amperage.
Example: If the peak amperage is set for
100 amps, and the base/peak control knob
is set for 95% (.9), then the low (base) am-
perage cycle of the pulse will be approxi-
mately 95 (90) amps. Regardless of no-
menclature, the basic function of the con-
trol is the same. The Model 315 DX ratio is
adjusted by using the independent Base
Amp and Peak Amp controls. Adjust the
peak amps above the base amps for proper
control of the pulse cycle.
7. Pulse Ratio. Some models: Pulse Width.
This allows the relative amount of time that
the pulse spends in the base (low) current
stage during a defined cycle to be ad-
justed. For example: A control knob set-
ting of 90% or .9 will signal the pulser to
spend 90% as long in the base (low) cur-
rent stage as spends in the peak (high) cur-
rent stage of the pulse cycle.
Note: The Pulse Ratio does not control the
overall length of the pulse. The pulse fre-
quency setting sets the cycle length,
thereby determining the overall length of
each leg of the cycle. Within each cycle
length, there is a certain amount (ratio) of
time that the pulse spends in the base (low)
amperage stage of the cycle and in the
peak (high) amperage stage of the cycle.
As the cycle frequency (Hz) increases,
overall cycle length is shortened, thereby
compressing the exact amount of time that
the cycle spends in each stage. However,
the pulse ratio continues to function within
the compressed cycle proportionately.
8. Main Amperage Control. Some models:
Welding Amps or Welding Current (DX/LX).
Locations may vary. This control knob al-
lows for precise control over the welding
current. This control knob also is used in
conjunction with the pulser to select the
peak amps.
9. Arc Force. This controls the dig of the
arc. The dig is a term used to describe the
intensity of the arc. It determines how hard
Section 2 Know Your machine
continued
the arc penetrates the metal when the arc
is held short. This is an exceptionally help-
ful feature in MMA (SMAW) operation. It
helps hold the molten metal in place in out-
of-position welds by providing a crisp,
forceful arc. Or, it can provide a soft, but-
tery arc that easily washes the metal into
the toes of the weld. This is a matter of op-
erator preference. Rotating the knob
clockwise increases dig. There are no
recommended settings regarding this fea-
ture. Skill, operating styles and electrode
selection are controlling variables that help
determine the optimum setting of the arc
force. With a little experimentation, the
proper setting can be found for each task.
10. AC Frequency Control. This control
narrows the welding arc and helps to con-
trol penetration and weld shape.
Image 2.1.10–Frequency effects on weld puddle.
200 AC Hz 20 AC Hz
11. AC Balance. This control determines
the amount of time the AC cycle spends in
DCEN (-) or DCEP (+). More DCEN is pre-
ferred for cleaning oxidation, particularly
in aluminum. More DCEP is preferred for
better penetration. A 50% setting equal-
izes the time spent in both. Try this setting
first as a starting point for adjustment.
12. AC/DC Rocker Switch. This switch se-
lects the use of either AC or DC current.
AC current is used primarily when TIG
welding aluminum. Certain stick electrodes
can be welded in this mode to prevent arc
blow and increase penetration.
13. 4T/2T or Rocker Switch. This
switch selects for control of the TIG weld
cycle via the TIG torch trigger. In the 2T
mode, simply touch and hold the trigger to
start the arc and continue holding while
welding. The machine will cycle automati-
cally according to the settings selected on
the machine. Release trigger the to finish.