WELDMARK TIG200 User manual

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WEM TIG200 AC/DC
Inverter Powered Dual Voltage
AC/DC TIG/Stick Welder
OWNER’S MANUAL
11/2020
WARNING:
Read carefully and understand all ASSEMBLY AND OPERATION
INSTRUCTIONS before operating. Failure to follow the safety rules and other
basic safety precautions may result in serious personal injury.

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WELDMARK WARRANTY
EFFECTIVE DECEMBER 1, 2017
LIMITED WARRANTY
This warranty applies to the original purchaser and is subject to the terms and conditions listed below. This Limited Warranty is for
new equipment sold after the above date, providing coverage for defects in material and workmanship at the time it is shipped from
the factory.
Limited to the warranty periods below, WELDMARK will repair or replace the item under warranty that fails due to defects in material
and workmanship. WELDMARK must be notified within 30 days of the failure, to provide instructions on how to proceed with the
repair of your welder and warranty claim processing. Warranty period begins atthe time the welder is purchased from an Authorized
Reseller of WELDMARK products. Keep your receipt as proof of purchase.
Warranty Periods
Limited Warranty is divided into three categories. No Warranty, 90 days and 3 year.
No Warranty
Normal wear items, TIG torch parts (Collet body, Nozzle, Collets, TIG Tungsten), ground clamps.
90 days
All parts exterior of the main welder unit except normal wear items as described above. This warranty covers the absence of, or
defective parts. These parts include the regulator, gas hose, ground cable and clamp, and the TIG Torch.
3 year
This 3 year warranty covers parts and Labor on items such as: transformer, reactor, rectifier, solenoid valve, PC Board, switches,
controls, gas valve, and any other component that requires the removal of the sheet metal to access. Any shipping related to warranty
repair is the responsibility of the customer.
Voiding Warranty
Warranty does not apply to: Shipping Damage, Misuse and abuse of the unit, alteration of the unit in any way.
Warranty Claim
This is a parts and labor warranty. Please contact the Authorized Weldmark Distributor that you purchased your unit from. Retain
your receipt in the case a warranty claim is needed. No warranty will be provided without the original receipt from an authorized
Weldmark Distributor.
Weldmark Distributor Warranty Process
The Weldmark Distributor Repair Center should contact Metal Man Work Gear at888-762-4045 to get needed warranty parts and
to file a warranty claim. Please have available, the original sale date and unit serial number for warranty verification.

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GENERAL SAFETY RULES
WARNING: Read and understand all instructions. Failure to follow all instructions listed
below may result in serious injury.
CAUTION: Do not allow persons to operate or assemble this unit until they have read
this manual and have developed a thorough understanding of how the unitworks.
WARNING: The warnings, cautions, and instructions discussed in this instruction
manual cannot cover all possible conditions or situations that could occur. It must be
understood by the operator that common sense and caution are factors which cannot be built into this
product but must be supplied by theoperator.
SAVE THESE INSTRUCTIONS
IMPORTANT SAFETY CONSIDERATIONS
1.1 Your Welding Environment
-Keep the environment you will be welding in free from flammable materials.
-Always keep a fire extinguisher accessible to your welding environment.
-Always have a qualified person install and operate this equipment.
-Make sure the area is clean, dry, and ventilated. Do not operate the welder in humid, wet, or poorly
ventilated areas.
-Always have your welder maintained by a qualified technician in accordance with local, state, and
national codes.
-Always be aware of your work environment. Be sure to keep other people, especially children,
away from you while welding.
-Keep harmful arc rays shielded from the view of others.
-Mount the welder on a secure bench or cart that will keep the welder secure and prevent it from
tipping over or falling.
1.2 Your Welder’s Condition
-Check ground cable, power cord and welding cable to be sure the insulation is not damaged.
Always replace or repair damaged components before using the welder.
-Check all components to ensure they are clean and in good operating condition before use.
1.3 Use of Your Welder
Do not operate the welder if the output cable, electrode, torch, wire, or wire feed system is wet. Do
not immerse them in water. These components and the welder must be completely dry before
attempting to use them.
-Follow the instructions in this manual.
-Keep welder in the off position when not in use.
-Connect ground lead as close to the area being welded as possible to ensure a good ground.
-Do not allow any body part to come in contact with the welding wire if you are in contact with the

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material being welded, ground or electrode from another welder.
-Do not weld if you are in an awkward position. Always have a secure stance while welding to
prevent accidents. Wear a safety harness if working above ground.
-Do not drape cables over or around your body.
-Wear a full coverage helmet with appropriate shade (see ANSI Z87.1 safety standard) and safety
glasses while welding.
-Wear proper gloves and protective clothing to prevent your skin from being exposed to hot metals,
UV, and IR rays.
-Do not overuse or overheat your welder. Allow proper cooling time between duty cycles.
-Keep hands and fingers away from moving parts and stay away from the drive rolls.
-Do not point MIG gun at any body part of yourself or anyone else.
-Always use this welder in the rated duty cycle to prevent excessive heat and failure.
1.4 Specific Areas of Danger, Caution or Warning
Electrical Shock
Electric arc welders can produce a shock that can cause injury or death. Touching
electrically live parts can cause fatal shocks and severe burns. While welding, all metal
components connected to the wire are electrically hot. Poor ground connections are a hazard, so
secure the ground lead before welding.
-Wear dry protective apparel: coat, shirt, gloves, and insulated footwear.
-Insulate yourself from the work piece. Avoid contacting the work piece or ground.
- Do not attempt to repair or maintain the welder while the power ison.
-Inspect all cables and cords for any exposed wire and replace immediately if found.
-Use only recommended replacement cables and cords.
-Always attach ground clamp to the work piece or worktable as close to the weld area as possible.
-Do not touch the welding wire and the ground or grounded work piece at the same time.
-Do not use a welder to thaw frozen pipes.
Fumes and Gases
-Fumes emitted from the welding process displace clean air and can result in injuryor death.
-Do not breathe in fumes emitted by the welding process. Make sure your breathing air is clean and
safe.
-Work only in a well-ventilated area or use a ventilation device to remove welding fumes from the
environment where you will be working.
-Do not weld on coated materials (galvanized,cadmium platedor containing zinc, mercury, orbarium).
They will emit harmful fumes that are dangerous to breathe. If necessary, use a ventilator, respirator
with air supply or remove the coating from the material in the weld area.
-The fumes emitted from some metals when heated are extremely toxic. Refer to the material safety
data sheet for the manufacturer’s instructions.
-Do not weld near materials that will emit toxic fumes when heated. Vapors from cleaners, sprays and
degreasers can be highly toxic when heated.

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UV and IR Arc Rays
The welding arc produces ultraviolet (UV) and infrared (IR) rays that can cause injury to
your eyes and skin. Do not look at the welding arc without proper eye protection.
-Always use a helmet that covers your full face from the neck to top of head and to the back of each
ear.
-Use a lens that meets ANSI standards and safety glasses. For welders under 160 Amps output, use
a shade 10 lens; for above 160 Amps, use a shade 12. Refer to the ANSI standard Z87.1 for more
information.
-Cover all bare skin areas exposed to the arc with protective clothing and shoes. Flame-retardant
cloth or leather shirts, coats, pants, or coveralls are available for protection.
-Use screens or other barriers to protect other people from the arc rays emitted from your welding.
-Warn people inyour weldingarea when you aregoing tostrike an arcso theycan protect themselves.
Fire Hazards
Do not weld on containers or pipes that contain or have had flammable, gaseous or liquid
combustibles in them. Welding creates sparks and heat that can ignite flammable and
explosive materials.
-Do not operate any electric arc welder in areas where flammable or explosive materials are
present.
-Remove all flammable materials within 35 feet of the welding arc. If removal is not possible, tightly
cover them with fireproof covers.
-Take precautions to ensure that flying sparks do not cause fires or explosions in hidden areas,
cracks, or areas you cannot see.
-Keep a fire extinguisher close in the case of fire.
-Wear garments that are oil-free with no pockets or cuffs that will collect sparks.
-Do not have on your person any items that are combustible, such as lighters or matches.
-Keep work lead connected as close to the weld area as possible to prevent any unknown,
unintended paths of electrical current from causing electrical shock and fire hazards.
-To prevent any unintended arcs, cut wire back to ¼" stick out after welding.
Hot Materials
Welded materials are hot and can cause severe burnsif handled improperly.
-Do not touch welded materials with bare hands.
-Do not touch MIG gun nozzle after welding until it has had time to cool down.
Sparks/Flying Debris
Welding creates hot sparks that can cause injury. Chipping slag off welds creates flying
debris.
-Wear protective apparel at all times: ANSI-approved safety glasses or shield, welder’s hat and ear
plugs to keep sparks out of ears and hair.

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Electromagnetic Field
-Electromagnetic fields can interfere with various electrical and electronic devices such as
pacemakers.
-Consult your doctor before using any electric arc welder or cutting device
-Keep people with pacemakers away from your welding area when welding.
-Do not wrap cable around your body while welding.
-Wrap MIG gun and ground cable together whenever possible.
-Keep MIG gun and ground cables on the same side of your body.
Shielding Gas Cylinders Can Explode
High pressure cylinders can explode if damaged, so treat them carefully.
-Never expose cylinders to high heat, sparks, open flames, mechanical shocks or arcs.
-Do not touch cylinder with MIG gun.
-Do not weld on the cylinder
-Always secure cylinder upright to a cart or stationary object.
-Keep cylinders away from welding or electrical circuits.
-Use the proper regulators, gas hose and fittings for the specific application.
-Do not look into the valve when opening it.
-Use protective cylinder cap whenever possible
1.5 Proper Care, Maintenance and Repair
-Always have power disconnected when working on internal components.
-Do not touch or handle PC board without being properly grounded with a wrist strap. Put PC board in
static proof bag to move orship.
-Do not put hands or fingers near moving parts such as drive rolls or fan
USE AND CARE
•Do not modify this unit in any way. Unauthorized modification may impair the function and/or
safety and could affect the life of the equipment. There are specific applications for which this unit
was designed.
•Always check for damaged or worn out parts before using this unit. Broken parts will affect
the unit’s operation. Replace or repair damaged or worn partsimmediately.
•Store idle. When this unit is not in use, store it in a secure place out of the reach of children.
Inspect it for good working condition prior to storage and beforere-use.

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TECHNICAL SPECIFICATIONS
Item
Specification
Power Supply
120V, 20A, 50/60 Hz, Single Phase
230V, 36A, 50/60 Hz, Single Phase
No-Load Voltage
58V DC
Output Range - STICK
10 to 80A DC with 120V Input Power
10 to 160A DC with 230V Input Power
Output Range –TIG DC
10 to 125A with 120V Input Power
10 to 200A with 230V Input Power
Output Range –TIG AC
15 to 125A with 120V Input Power
15 to 200A with 230V Input Power
Duty Cycle - STICK
35% @ 80A with 120V Input Power
20% @ 160A with 230V Input Power
Duty Cycle- TIG AC/DC
35% @ 125A with 120V Input Power
20% @ 200A with 230V Input Power
Pulse Frequency
0.2Hz to 500Hz
AC Arc Frequency
50 Hz to 150Hz
AC Arc Balance Control
50% to 85% EN
Weight
31.97 lb.
Dimensions
19.69 in X 9.45 in X 16.14 in
DESCRIPTION
The Weldmark Inverter Powered TIG 200 AC/DC is a dual voltage, inverter powered AC and DC TIG, Pulse TIG and
DC Stick welder. This unit is intended to be used on a 50-amp 230V AC circuit or 120V, 20A AC Circuit, without the
use of an extension cord. This machine comes complete with a TIG Torch, a Foot Pedal, regulator/flowmeter with inert
gas hose, a ground cable and clamp, and an Electrode Holder with cable.
The TIG 200 AC/DC is the ideal Stick and TIG welder for every shop. The DC stick mode allows you to stick weld
when your application requires it. In the DC TIG mode, you can TIG weld metals such as steel and stainless steel. In
the AC TIG mode, you can TIG weld non-ferrous metals such as Aluminum. This unit is equipped with advanced TIG
capabilities including Pulse, AC Arc Frequency Control, AC Arc Balance Control, and Auto Balance/Frequency
Control. There is an optional thumb/fingertip control available through IWDC under part number WEM AMTCV-10-1-
MMW. The advanced inverter technology that powers the Weldmark TIG 200 AC/DC provides for better arc control,
lower power consumption, in a lighter more portable unit.
DIGITAL METERS
Digital meters display welding amperage and voltage while welding.
FUNCTIONAL CONTROL
Use the Functional Control dial to increase and decrease the value of the function you are setting. An indicator light
will then illuminate showing which function you are setting.
WELD PARAMETER SETTING INDICATORS
When the push button below this set of indicators lights is pushed, the operator can sequence through the different
welding parameters. Use the Functional control to adjust the parameter setting indicated on the digital meters.
REMOTE FOOT PEDAL CONTROL
The foot pedal is used to start the arc and manually adjust the amperage while TIG welding. The cord will attach to
the 5-Pin connector on the front of the unit. There is an optional thumb/fingertip control available through IWDC
under part number WEM AMTCV-10-1-MMW.

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STYLE 17 TIG TORCH
The TIG torch transfers welding power from the welding power source to the tungsten for the purpose of TIG welding. It
also delivers the shielding gas from the welding power source to the welding zone. This style 17 torch uses the same
common parts as other Style 17 TIG torches
GROUND CABLE AND CLAMP
The ground cable and clamp are attached to the work piece to complete the circuit allowing the flow of current needed to
weld.
REGULATOR/FLOWGAUGE AND GAS HOSE
The regulator installs directly on the shielding gas cylinder. Required for TIG welding. The regulator controls the
compressed gas and allows you to adjust the flow rate of the gas. The gas hose connects to the regulator/flow gauge and
delivers the shielding gas from the shielding gas bottle to the welder.
ELECTRODE HOLDER AND CABLE
The electrode holder and weld cable transfers welding power from the welding power source to the electrode for the
purpose of stick welding.
WELD PROCESS INDICATORS
When the push button below this set of indicator lights is pushed, the operator can sequence through the different welding
processes.
INDICATOR LIGHTS
The indicator lights can be used to help with troubleshooting the welder. When the power indicator light is on, input power
is supplied to the main transformer and control circuit. When the work indicator is on, it is indicating welding current is
activated. When the temperature indicator is on, the machine has gone into protection mode and requires the internal
temperature to cool. When the power protection light is on, the machine has gone into protection mode and requires that
the input voltage stabilize to within 15% of the rated input voltage.

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ASSEMBLY
Electrical Shock Can Kill!
• High voltage danger from power source! Consult a qualified electrician for properinstallation
of receptacle. This welder must be grounded while in use to protect the operator from
electrical shock.
• Do not remove grounding prong or alter the plug in any way. Use only the supplied adapter
between the welder's power cord and the power source receptacle. Make sure the POWER
switch is OFF then connect your welder's power cord to a properly grounded 230 VAC(220V
- 240V), 60 HZ, single phase, 50-amp power source. If operating on 120V, attach the 120V
Adapter cord to the unit power cord and then connect the assembly to a properly grounded
120 VAC (110V-130V), 60 Hz, single phase, 20-amp power source.
1. POWER REQUIREMENT 230V - AC single phase 230V (220-240V) 50/60 HZ fused with a 50-amp
time delayed fuse or circuit breaker is required. DO NOT OPERATE THIS UNIT if the ACTUAL power
source voltage is less than 215 volts AC or greater than 240 volts AC.
2. POWER REQUIREMENT 120V - AC single phase 120V (110-130V) 50/60 HZ fused with a 20-amp
time delayed fuse or circuit breaker is required. DO NOT OPERATE THIS UNIT if the ACTUAL power
source voltage is less than 110 volts AC or greater than 130 volts AC.
2.1 When connecting this unit to 120V power, connect the 120V adapter cord to the
power cord pigtail that is attached to the machine.
3. EXTENSION CORD - We do not recommend an extension cord because of the voltage drop they produce.
This drop in voltage can affect the performance of the welder. If you need to use an extension cord, we
recommend you check with a qualified electrician and your local electrical codes for your specific area. Do
not use an extension cord over 25 ft. in length.
4. STICK WELDING CONNECTION –DC Stick welding is generally performed DC Electrode Positive. That
means that the electrode holder and cable would be attached to the Positive (+) weld output connection
and the ground cable and clamp would be attached to the Negative (-) weld output connection.
Positive (+) Weld
OutputConnection
Negative (-) Weld
OutputConnection

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5. TIG WELDING CONNECTION –DC TIG welding is generally performed DC Electrode negative. That
means that the TIG torch and cable would be attached to the Negative (-) weld output connection andthe
ground cable and clamp would be attached to the Positive (+) weld output connection. Use this same
connection when AC TIG welding. Connect the Remote Foot Pedal to the Remote connection on the lower
front panel. Connect the TIG torch gas supply line to the Gas Outlet on the lower frontpanel.
6. BACK PANEL CONNECTIONS
Remote Foot
Pedal Connection
TIG Torch
Gas Connection
Power
Switch
Shielding Gas
Connection
Power
Cord

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7. GAS INSTALLATION
Shielding gas cylinders and high-pressure cylinders can explode if damaged, so treat them
carefully.
•Never expose cylinders to high heat, sparks, open flames, mechanical shocks or arcs.
•Do not weld on the cylinder.
•Always secure cylinder upright to a cart or stationary object.
•Keep cylinders away from welding or electrical circuits.
•Use the proper regulators, gas hose and fittings for the specific application.
a. Connect one end of the gas hose to the gas hose connection on the back of the welder. Use a
wrench to snug up the connection.
b. Connect the other end of the gas hose to the gas hose connection on the supplied rear mount
regulator/flow gauge. Use a wrench to snug up the connection.
c. Before installing the regulator, it is good practice to make certain no debris is in the gas bottle
connection. Rotate the bottle so the gas connection is not pointing toward you or any other person.
Turn the valve on the gas bottle clockwise and quickly close. This quick thrust of gas will clear any
debris in the connection. Connect the regulator to the gas bottle connection. Use a wrench to snug
up the connection.
d. Open the Gas Bottle Valve on the cylinder of gas.
e. Turn the Gas Flow Adjuster on the regulator so that the gas flow rate is set at approximately 20
CFH. Make certain you are reading the correct scale on the gauge.
NOTE: Slowly open the cylinder valve by turning it counterclockwise until the cylinder pressure gauge registers on
the first gauge of the regulator. Turn the adjustment knob clockwise (right) slowly to increase gas flow to 20 CFH.
Toreduce the gas flow, turn the adjustment counterclockwise (left). The gas valve is located on the back panel of
the welder and activated by the remote control. Gas flow should be heard when the remote is activated. No gas
flow will result in a harsh arc.

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Gas selection:
Except for very specialized TIG welding applications, TIG welding can be done with 100% Argon.
Consult your gas supplier for more information.
8. REMOTE CONTROL INSTALLATION
NOTE: When stick welding, remove all remote controls. Failure to do this will result in minimal welding
output only.
Remote Contactor and Amperage Control –This unit comes standard with a remote foot pedal control.
The remote foot pedal is used to initiate the arc and then vary the amperage during your weld. Connect
the remote foot pedal control to the Foot Pedal Connection on the front of the unit.
Remote Foot
Pedal Connection
EQUIPMENT SET-UP
Electrical Shock Can Kill!
• High voltage danger from power source! Consult a qualified electrician for properinstallation
of receptacle. This welder must be grounded while in use to protect the operator from
electrical shock.
• Do not remove grounding prong or alter the plug in any way. Use only the supplied adapter
between the welder's power cord and the power source receptacle. Make sure the POWER
switch is OFF then connect your welder's power cord to a properly grounded 230 VAC(220V
- 240V), 60 HZ, single phase, 50-amp power source. If operating on 120V, attach the 120V
Adapter cord to the unit power cord and then connect the assembly to a properly grounded
120 VAC (110V-130V), 60 Hz, single phase, 20-amp power source.
1. PROCESS SELECTION
AVOID ACCIDENTAL ARCING
•When in the STICK welding mode, the weld output connections of this unit are electrically hot.
Toavoid accidental arcing, be mindful of the welding accessories that are connected to the

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weld output connections.
•Make certain the welding accessories connected to this unit are not touching each otherand
are not electrically connected to each other.
a. With the input power switch turned ON, observe which of the Weld ProcessIndicator
Lights is on.
b. Press the button under the weld process indicators until the WeldProcess Indicator Light
next to your desired weld process is on.
2. DC STICK SET-UP
AVOID ACCIDENTAL ARCING
•When in the STICK welding mode, the weld output connections of this unit are electricallyhot.
Toavoid accidental arcing, be mindful of the welding accessories that are connected to the weld
output connections.
•Make certain the welding accessories connected to this unit are not touching each otherand
are not electrically connected to each other.

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a. See the ASSEMBLY section for the correct welding accessories connections for DCStick
Welding.
b. Turn the input power switch ON.
c. Press the button below the weld process indicators until the weld process indicatorlight
next to DC Stick is on.
d. Press the button below the weld parameter indicator lights until the Indicator Light isON
for the Current (A) Weld Parameter.
e. The Digital Meter is displaying the Current (A) setting.
f. Turn the Parameter Adjustment Control until the Digital Meter displays the desiredCurrent
(A) setting.
3. DC TIG SET-UP
a. See the ASSEMBLY section for the correct welding accessories connections for DC TIG
Welding.
b. Turn the input power switch ON.
c. Press the Weld Process Selector button until the Weld Process Indicator Light next toDC
TIG is on.
i. If the operator wants to use Pulse DC TIG, press the Weld Process Selectoruntil
the Weld Process Indicator Light next to Pulse DC TIG is on.
d. Press the Weld Parameter Selector button until the Indicator Light is ON for theCurrent
(A) Weld Parameter.
e. The Digital Meter is displaying the Current (A) setting.

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f. Turn the Parameter Adjustment Control until the Digital Meter displays the desired Current
(A) setting. This is the current setting that the operator wants when the foot pedal is
completely pressed to the maximum. The operator will then have control of the Current
(A) output from minimum amperage to this maximum setting by varying the amount the
operator is pressing down on the foot pedal.
i. If the operator is using Pulse DC TIG, this setting will be the maximum peak
amperage, or the amperage that the welder will pulse up to when the footpedal
is completely pressed to the maximum.
ii. As the operator varies the amount, they are pressing down on the foot pedal,
the peak amperage and background amperage will automatically be adjusted
proportionally.
g. If the operator is using Pulse DC TIG, they will need to adjust the number of times per
second that the welder will pulse between the peak amperage (high end amperage)and
the background amperage (low end amperage).
i. Press the weld parameter selector button until the indicator light in front ofthe
Pulse Frequency (HZ) is on.
ii. The Digital Meter is now displaying the Pulse Frequency (HZ) setting.
iii. Turn the Parameter Adjustment Control until the Pulse Frequency (Hz)display
shows the desired setting.
NOTE: When adjusting the Pulse Frequency (HZ) parameter, this unit will automatically default back to
the Current (A) parameter after 5 seconds on no parameter changes.
a. See the ASSEMBLY section for the correct welding accessory connections for AC TIG
Welding.

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b. Turn the input power switchON.
c. Press the Weld Process Selector button until the Weld Process Indicator Light nextto
AC TIG is on.
i. If the operator wants to use Pulse AC TIG,press the Weld ProcessSelector
until the Weld Process Indicator Light next to Pulse AC TIG ison.
d. AUTO BALANCE/FREQUENCY
Note: For most AC TIG welding applications, we recommend the use of the Auto
Balance/Frequency Weld Parameter. This allows the welder to automatically control the AC Arc
Frequency and the AC Balance automatically based on the amperage the operator is welding at.
i. Press the Weld Parameter Selector button until the Indicator Light is On for
the AUTO Balance/Frequency Weld Parameter. You will notice that both the
AUTO Balance/Frequency Indicator and the Current (A) Indicators areon.
ii. The Digital Meter is displaying the Current (A) setting.
iii. Turn the Parameter Adjustment Control until the Digital Meter displays the
desired Current (A) setting. This is the current setting that the operator wants
when the foot pedal is completely pressed to the maximum. The operator will
then have control of the Current (A) output from minimum amperage tothis
maximum setting by varying the amount the operator is pressing down on
the foot pedal.
1. If the operator is using Pulse AC TIG, this setting will be the
maximum peak amperage, or the amperage that the welder will
pulse up to when the foot pedal is completely pressed to the
maximum.
2. As the operator varies the amount, they are pressing down on

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the foot pedal, the peak amperage and background amperage
will automatically be adjusted proportionally.
e. CURRENT (A)
i. Press the Weld Parameter Selector button until the Indicator Light is Onfor
the Current (A) Weld Parameter.
ii. The Digital Meter is displaying the Current (A) setting.
iii. Turn the Parameter Adjustment Control until the Digital Meter displays the
desired Current (A) setting. This is the current setting that the operator wants
when the foot pedal is completely pressed to the maximum. The operator will
then have control of the Current (A) output from minimum amperage to this
maximum setting by varying the amount the operator is pressing down on
the foot pedal.
1. If the operator is using Pulse AC TIG, this setting will be the
maximum peak amperage, or the amperage that the welder will
pulse up to when the foot pedal is completely pressed to the
maximum.
2. As the operator varies the amount, they are pressing down on
the foot pedal, the peak amperage and background amperage
will automatically be adjusted proportionally.
DC STICK OPERATION
•High voltage danger from power source! Consult a qualified electrician for proper installation of
receptacle. This cutter must be Grounded while in use to protect the operator from electrical shock.
•Do not remove grounding prong or alter the plug in any way. Use only the supplied adapter
between the welder's power cord and the power source receptacle. Make sure the POWER switch
is OFF when connecting your plasma cutter's power cord directly to a properly grounded 120 VAC,
60 Hz, single phase, 20-amp input power supply.
1. SETTING UP THE WORK PIECE
1.1 Welding positions
There are two basic positions, for welding: Flat and Horizontal. Flat welding is generally easier,
faster, and allows for better penetration. If possible, the work piece should be positioned so that
the bead will run on a flat surface.
1.2 Preparing the Joint:
Before welding, the surface of work piece needs to be free of dirt, rust, scale, oil or paint or it will
create brittle and porous welds. If the base metal pieces to be joined are thick or heavy, it may
be necessary to bevel the edges with a metal grinder, the correct bevel should be around 60
degrees. See following picture:

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Based on different welding positions, there are different welding joints. See following images for
more information.
2. GROUND CLAMP CONNECTION
Clear any dirt, rust, scale, oil or paint on the ground clamp. Make certain you have a good solid
ground connection. A poor connection at the ground clamp will waste power and heat. Make sure the
ground clamp touches the metal.
3. ELECTRODE
The welding electrode is a rod coated with a layer of flux. When welding, electrical current flows
between the electrode (rod) and the grounded metal work piece. The intense heat of the arc
between the rod and the grounded metal melts the electrode and the flux.
4. SELECTING THE PROPER ELECTRODE
There is no golden rule that determines the exact rod or heat setting required for every situation. The
type and thickness of metal and the position of the work piece determine the electrode type and the

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amount of heat needed in the welding process. Heavier and thicker metals required more amperage. It is
best to practice your welds on scrap metal which matches the metal you intend to work with to determine
correct heat setting and electrode choice. See the following helpful trouble shooting tips to determine if
you are using a correct electrode.
4.1 When proper rod is used:
4.1a. The bead will lay smoothly over the work without ragged edges
4.1b. The base metal puddle will be as deep as the bead that rises above it
4.1c. The welding operation will make a crackling sound like the sound of eggsfrying
4.2 When too small of a rod is used:
4.2a. The bead will be high and irregular
4.2b. The arc will be difficult to maintain
4.3 When the rod is too large:
4.3a. The arc will burn through light metals
4.3b. The bead will undercut the work
4.3c. The bead will be flat and porous
4.3d. Rod may freeze or stick to work piece
Note: Rate of travel over the work also affects the weld. To ensure proper penetration and enough
deposit of rod, the arc must be moved slowly and evenly along the weld seam.
5. SETTING THE AMPERAGE CONTROL
The welder has current control that is infinitely adjustable within its range. It is capable of welding with
electrodes up to 3/32ʺ diameter. There is no golden rule that determines the exact amperage required
for every situation. It is best to practice your welds on scrap metal which matches the metals you intend
to work with to determine correct setting for your job. The electrode type and the thickness of the work
piece metal determine the amount of heat needed in the welding process.
Heavier and thicker metals require more voltage (amperage), whereas lighter and thinner metals
require less voltage (amperage). Consult the welding electrode packaging for recommended welding
amperage range.
6. WELDING TECHNIQUES
The best way to teach yourself how to weld is with short periods of practice at regular intervals. All
practice welds should be done on scrap metal that can be discarded. Do not attempt to make any
repairs on valuable equipment until you are satisfied that the appearance of your practice welds is of
good appearance and free of slag or gas inclusions.
6.1 Holding the electrode:
The best way to grip the electrode holder is the way that feels most comfortable to you. Position
the Electrode to the work piece when striking the initial arc, it may be necessary to hold the
electrode perpendicular to the work piece. Once the arc is started, the angle of the electrode in
relation to the work piece should be between 10 and 30 degrees. This will allow for good
penetration, with minimal spatter.

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6.2 Striking the arc
EXPOSURE TO A WELDING ARC IS EXTREMELY HARMFUL TO THE EYES AND SKIN!
Prolonged exposure to the welding arc can cause blindness and burns. Never strike an arc or begin
welding until you are adequately protected. Wear flame-proof welding gloves, a heavy long-sleeved
shirt, trousers without cuffs, high topped shoes, and an ANSI approved welding helmet.
Scratch the work piece with the end of electrode to start arc and then raise it quickly about 1/8-
inch gap between the rod and the work piece. See following picture
It is important that the gap be maintained during the welding process and it should be neither too
wide nor too narrow. If too narrow, the rod will stick to the work piece. If too wide, the arc will be
extinguished. It takes much practice to maintain the gap. The beginners may get stuck or arc will
be extinguished. When the rod is stuck to the work piece, gently rock it back and forth to make
them separate. If not, a short circuit will occur, and it will break the welder. A good arc is
accompanied by a crisp, cracking sound. The sound is like that made by eggs frying. To lay a
weld bead, only 2 movements are required; downward (as the electrode is consumed) and in the
direction the weld is to be laid, as in following figure:
6.3 Types of weld bead:
The following paragraphs discuss the most used arc welding beads.
The stringer bead: Formed by traveling with the electrode in a straight line while keeping
the electrode centered over the weld joint.