WELDTECH BW-TIG200 ACDC User manual

#BW-TIG200 ACDC
200A - INVERTER TIG/ARC AC/DC PULSE WELDER
INSTRUCTION MANUAL
PLEASE READ THIS MANUAL CAREFULLY BEFORE
USING AND RETAIN FOR FUTURE REFERENCE.

CONTENTS
SAFETY INFORMATION .........................................................................................................................................................................................................................................................................................................................3
OVERVIEW ........................................................................................................................................................................................................................................................................................................................................................7
UNPACKING YOUR MACHINE ..........................................................................................................................................................................................................................................................................................................7
MACHINE SPECIFICATIONS ..............................................................................................................................................................................................................................................................................................................7
KNOW YOUR WELDER ...........................................................................................................................................................................................................................................................................................................................8
CONSUMABLES & ACCESSORIES ................................................................................................................................................................................................................................................................................................9
WELDER INSTALLATION ....................................................................................................................................................................................................................................................................................................................10
MMA WELDING OPERATION .........................................................................................................................................................................................................................................................................................................10
DC TIG WELDING OPERATION ......................................................................................................................................................................................................................................................................................................10
DC PULSE TIG WELDING OPERATION ....................................................................................................................................................................................................................................................................................10
AC TIG WELDING OPERATION ......................................................................................................................................................................................................................................................................................................10
AC PULSE TIG WELDING OPERATION ....................................................................................................................................................................................................................................................................................10
MMA WELDING GUIDE ......................................................................................................................................................................................................................................................................................................................11
MMAWELDING TROUBLESHOOTING ...................................................................................................................................................................................................................................................................................15
TIGWELDING GUIDE ............................................................................................................................................................................................................................................................................................................................16
TIG WELDING TROUBLESHOOTING .........................................................................................................................................................................................................................................................................................18
MACHINE CARE & MAINTENANCE ..........................................................................................................................................................................................................................................................................................19
CONGRATULATIONS ON THE PURCHASE OF YOUR NEW WELDTECH BW-TIG200ACDC DIGITAL
INVERTER 200 AMP TIG ACDC WELDING MACHINE.
PLEASE ENSURE YOU HAVE FAMILIARISED YOURSELF WITH THE INSTRUCTIONAL DVD AND READ THE
CONTENTS OF THIS MANUAL BEFORE USING YOUR MACHINE.
2
WARRANTY ...............................................................................................................................................................................................................................................................................................................................................20

SAFETY INFORMATION
STORE AND RETAIN THIS MANUAL
Retain this manual for the safety warnings and
precautions, assembly, operating, inspection,
maintenance and cleaning procedures. Write the
product’s serial number into the NOTES section at
the rear, and keep this manual and the receipt in a
safe and dry place for future reference.
IMPORTANT SAFETY INFORMATION
Failure to follow the warnings and instructions may
result in electric shock, fire, serious injury and/or
death. Save all warnings and instructions for future
reference.
This is the safety alert symbol to alert you to
potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.
DANGER indicates a hazardous situation
which, if not avoided, will result in death or serious
injury.
WARNING indicates a hazardous situation
which, if not avoided, could result in death or
serious injury.
CAUTION, used with the safety alert symbol,
indicates a hazardous situation which, if not
avoided, could result in minor or moderate injury.
NOTE, used to address practices not related to
personal injury.
CAUTION, without the safety alert symbol, is used to
address practices not related to personal injury.
GENERAL SAFETY WARNINGS
1. Maintain labels and nameplates on the welder.
These carry important information. If unreadable
ormissing, contact your nearest Weldtech Store
for a replacement.
2. Avoid unintentional starting. Make sure the welder
is setup correctly and you are prepared to begin work
before turning on the welder.
3. Unplug before performing maintenance. Always
unplug the Welder from its electrical outlet before
performing any inspection, maintenance, or clean-
ing procedures.
4. Never leave the welder unattended while ener-
gised. Turn power off before leaving the welder
unattended.
5. Do not touch live electrical parts. Wear dry,
insulating gloves. Do not touch the electrode or the
conductor tong with bare hands. Do not wear wet or
damaged gloves.
6. Protect yourself from electric shock. Do not use
the welder outdoors. Insulate yourself from the
work piece and the ground. Use non-flammable,
dry insulating material if possible, or use dry rubber
mats, dry wood or plywood, or other dry insulating
material large enough to cover the area of contact
with the work or the ground.
7. Avoid inhaling dust. Some dust created by power
sanding, sawing, grinding, drilling, cutting, welding
and other construction activities, contain chemicals
known to cause cancer, birth defects or other harm.
Your risk from these exposures varies, depending
on how often you do this type of work. To reduce
your exposure to these chemicals, work in a
well-ventilated area, and work with approved safety
equipment, such as dust masks that are specially
designed to filter out microscopic particles.
8. People with pacemakers should consult their
physician(s) before using this machine.
WARNING
Electromagnetic fields in close proximity to a heart
pacemaker could cause interference, or failure of
the pacemaker. The use of a Welder is NOT
RECOMMENDED for pacemaker wearers. Consult
your doctor.
9. Ensure that the unit is placed on a stable location
before use.
WARNING
If this unit falls while plugged in, severe injury,
electric shock, or fire may result.
10. Transportation Methods
CAUTION
Disconnect input power conductors from
de-energized supply line before moving the welding
power source.
Lift unit with the handles provided, or use a
handcart or similar device of adequate capacity.
If using a fork lift vehicle, secure the unit to a skid
before transporting.
11.Exericse good work practices. The warnings,
precautions, and instructions discussed in this
instruction manual cannot cover all possible
conditions and situations that may 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 considered by the operator.
WELDING SAFETY INSTRUCTIONS & WARNINGS
WARNING
PROTECT YOURSELF AND OTHERS FROM
POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. READ THE OPERATING/
INSTRUCTION MANUAL BEFORE INSTALLING,
OPERATING OR SERVICING THIS EQUIPMENT.
HAVE ALL INSTALLATION, OPERATION,
MAINTENANCE, AND REPAIR WORK PERFORMED
BY QUALIFIED PEOPLE.
If an operator does not strictly observe all safety
rules and take precautionary actions, welding
products and welding processes can cause serious
injury or death, or damage to other equipment or
property.
Safe practices have developed from past
experience in the use of welding and cutting.
These practices must be learned through study
and training before using this equipment. Some of
these practices apply to equipment connected to
power lines; other practices apply to engine driven
equipment. Anyone not having extensive training in
welding and cutting practices should not attempt
to weld.
Safe practices are outlined in the European
Standard EN60974-1 entitled: Safety in welding
and allied processes.
WARNING
Only use safety equipment that has been approved
by an appropriate standards agency. Unapproved
safety equipment may not provide adequate
protection. Eye and breathing protection must be
AS/NZS compliant for the specific hazards in the
work area.
DANGER
Always wear AS/NZS compliant safety glasses and
a full face shield fitted with the appropriate filter
shade number. (Refer Filter Table on page 6.)
CAUTION
Heavy-duty work gloves, non-skid safety shoes and
hearing protection used for appropriate conditions
will reduce personal injuries.
CAUTION
Have the equipment serviced by a qualified repair
person using identical replacement parts. This will
ensure that the safety of the power tool is
maintained.
3

PERSONAL SAFETY
CAUTION
Keep the work area well lit. Make sure there
is adequate space surrounding the work area.
Always keep the work area free of obstructions,
grease, oil, trash, and other debris. Do not use
equipment in areas near flammable chemicals,
dust, and vapours. Do not use this product in a
damp or wet location.
1. Stay alert, watch what you are doing and use
common sense when operating equipment.
Do not use a tool while you are tired or under
the influence of drugs, alcohol or medication. A
moment of distraction when operating equipment
may result in serious personal injury.
2. Do not overreach. Keep proper footing and
balance at all times. This enables better control of
the power tool in unexpected situations.
ARC RAYS CAN BURN EYES AND SKIN
DANGER
Arc rays from the welding process produce
intense heat and strong ultraviolet rays that can
burn eyes and skin.
1. Use a Welding Helmet or Welding Face
Shield fitted with a proper shade filter
(refer AS 60974-1, AS/NZS 1337.1 and
AS/NZS 1338.1 Safety Standards) to protect
your face and eyes when welding or watching.
(See Filter Table on Page 6).
2. Wear approved safety glasses. Side shields
are recommended.
3. Use protective screens or barriers to protect
others from flash and glare; warn others not to
watch the arc.
4. Wear protective clothing made from durable,
flame-resistant material (wool and leather) and
foot safety protection.
5. Never wear contact lenses while welding.
NOISE CAN DAMAGE HEARING
CAUTION
Noise from some processes can damage
hearing. Use AS/NZS compliant ear plugs or ear
muffs if the noise level is high.
WORK ENVIRONMENT SAFETY
DANGER
Remove any combustible material from the work area.
1. When possible, move the work to a location well
away from combustible materials. If relocation
is not possible, protect the combustibles with a
cover made of fire resistant material.
2. Remove or make safe all combustible materials
for a radius of 10 meters around the work area.
Use a fire resistant material to cover or block all
doorways, windows, cracks, and other openings.
3. Enclose the work area with portable fire resistant
screens. Protect combustible walls, ceilings,
floors, etc., from sparks and heat with fire
resistant covers.
4. If working on a metal wall, ceiling, etc., prevent
ignition of combustibles on the other side by
moving the combustibles to a safe location.
If relocation of combustibles is not possible,
designate someone to serve as a fire watch,
equipped with a fire extinguisher, during the
welding process and well after the welding is
completed.
5. Do not weld or cut on materials having a
combustible coating or combustible internal
structure, as in walls or ceilings, without an
approved method for eliminating the hazard.
6. After welding, make a thorough examination for
evidence of fire. Be aware that visible smoke or
flame may not be present for some time after
the fire has started. Do not weld or cut in
atmospheres containing dangerously reactive
or flammable gases, vapours, liquids, and dust.
Provide adequate ventilation in work areas
to prevent accumulation of flammable gases,
vapours, and dust.
7. Do not apply heat to a container that has held an
unknown substance or a combustible material
whose contents, when heated, can produce
flammable or explosive vapours. Clean and purge
containers before applying heat. Vent closed
containers, including castings, before preheating,
welding, or cutting.
ELECTRICITY CAN KILL
DANGER
Touching live electrical parts can cause fatal
shocks or severe burns. The electrode and work
circuit is electrically live whenever the output
is on.
The input power circuit and machine internal
circuits are also live when power is on. In
semi-automatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal
parts touching the welding wire are electrically
live. Incorrectly installed or improperly grounded
equipment is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body
protection.
3. Insulate yourself from the work and the ground
using dry insulating mats or covers.
4. Disconnect input power before installing or
servicing this equipment. Lock input power,
disconnect switch open, or remove line fuses so
power cannot be turned on accidentally.
5. Properly install and ground this equipment
according to national, state, and local codes.
6. Turn off all equipment when not in use.
Disconnect power to equipment if it will be left
unattended or out of service.
7. Use fully insulated electrode holders. Never dip
the holder in water to cool it or lay it down on the
ground or the work surface. Do not touch holders
connected to two welding machines at the same
time or touch other people with the holder or
electrode.
8. Do not use worn, damaged, undersized, or poorly
spliced cables.
9. Do not wrap cables around your body.
10.Connect the work piece to a good electrical
ground.
11.Do not touch the electrode while in contact with
the work (ground) circuit.
12.Use only well-maintained equipment. Repair or
replace damaged parts as soon as practical.
13.In confined spaces or damp locations, do not use
a welder with AC output unless equipped with a
voltage reducer.
4

ARC RAYS CAN BURN EYES AND SKIN.
DANGER
Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin. Use the following table to select the appropriate shade
number for a Welding Helmet or Welding Face Shield.
1. Use a Welding Helmet or Welding Face Shield fitted with a proper shade of filter (see AS 60974-1, AS/NZS 1337.1 and AS/NZS 1338.1 Safety Standards) to protect
your face and eyes when welding or watching.
2. Wear approved safety glasses. Side shields are recommended.
3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc.
4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection.
5. Never wear contact lenses while welding.
Recommended Protective Filters for Electric Welding
Description of Process Approximate Range of
Welding Current in Amps Minimum Shade Number of Filter(s)
Manual Metal Arc Welding -
Covered Electrodes (MMA)
Less than or equal to 100 8
100 to 200 10
200 to 300 11
300 to 400 12
Greater than 400 13
Gas Metal Arc Welding (GWAW) (MIG)
other than Aluminium And Stainless Steel
Less than or equal to 150 10
150 to 250 11
250 to 300 12
300 to 400 13
Greater than 400 14
Gas Metal Arc Welding(GWAW) (MIG)
Aluminium and Stainless Steel
Less than or equal to 250 12
250 to 350 13
Gas Tungsten Arc Welding (GTAW) (TIG)
Less than or equal to 100 10
100 to 200 11
200 to 250 12
250 to 350 13
Greater than 350 14
Flux-Cored Arc Welding (FCAW) -
with or without Shielding Gas
Less than or equal to 300 11
300 to 400 12
400 to 500 13
Greater than 500 14
Air - Arc Gouging Less than or equal to 400 12
Plasma - Arc Cutting
50 to 100 10
100 to 400 12
400 to 800 14
Plasma - Arc Spraying — 15
Plasma - Arc Welding
Less than or equal to 20 8
20 to 100 10
100 to 400 12
400 to 800 14
Submerged - Arc Welding — 2 (5)
Resistance Welding — Safety Spectacles or Eye Shield
Refer to standard AS/NZS 1338.1 for comprehensive information regarding the above table.
5

FUMES AND GASES
WARNING
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
1. Keep your head out of the fumes. Do not breathe
the fumes.
2. If inside, ventilate the area and/or use an exhaust
at the arc to remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied
respirator.
4. Read the Safety Data Sheets (SDS) and the
manufacturer’s instruction for the metals,
consumables, coatings, and cleaners.
5. Work in a confined space only if it is well
ventilated, or while wearing an air-supplied
respirator. Shielding gases used for welding can
displace air causing injury or death. Be sure the
breathing air is safe.
6. Do not weld in locations near degreasing,
cleaning, or spraying operations. The heat and
rays of the arc can react with vapours to form
highly toxic and irritating gases.
7. Do not weld on coated metals, such as
galvanized, lead, or cadmium plated steel,
unless the coating is removed from the weld area,
the area is well ventilated, and if necessary, while
wearing an air- supplied respirator. The coatings
and any metals containing these elements can
give off toxic fumes if welded.
FIRE & EXPLOSIVE RISKS
WARNING
Sparks and spatter fly off from the welding arc.
The flying sparks and hot metal, weld spatter,
work piece, and hot equipment can cause fires
and burns.
Accidental contact of electrode or welding wire
to metal objects can cause sparks, overheating,
or fire.
1. Protect yourself and others from flying sparks
and hot metal.
2. Do not weld where flying sparks can strike
flammable material.
3. Remove all flammables within 10m of the
welding site.
4. Be alert that welding sparks and hot materials
from welding can easily go through small cracks
and openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher
nearby.
6. Be aware that welding on a ceiling, floor,
bulkhead, or partition can cause fire on the
hidden side.
7. Do not weld on closed containers such as tanks
or drums.
8. Connect the work lead/clamp to the job as close
to the welding area as practical to prevent
welding current from travelling long, possibly
unknown paths and causing electric shock and
fire hazards.
9. Do not use a welder to thaw frozen pipes.
10.Remove the stick electrode from the holder or
cut off the welding wire at the contact tip when
not in use.
SPARKS & HOT METAL
WARNING
Chipping and grinding causes flying metal, and as
welds cool they can throw off slag.
1. Wear an AS/NZS approved face shield or safety
goggles. Side shields are recommended.
2. Wear appropriate safety equipment to protect
the skin and body.
CYLINDERS
WARNING
Gas cylinders contain gas under high pressure.
If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
1. Protect compressed gas cylinders from
excessive heat, mechanical shocks, and arcs.
2. Install and secure cylinders in an upright position
by chaining them to a stationary support or equip-
ment cylinder rack to prevent falling or tipping.
3. Keep cylinders away from any welding or other
electrical circuits.
4. Never allow a welding electrode to touch any
cylinder.
5. Use appropriate shielding gas, regulators, hoses,
and fittings designed for the specific application;
maintain them and their associated parts in good
condition.
6. Turn your face away from the valve outlet when
opening the cylinder valve.
6

OVERVIEW
The Weldtech BW-TIG200ACDC is a feature packed TIG welding machine for
professional TIG welding results with a wide range of materials. AC/DC output
allows use on both ferrous and non-ferrous metals and their alloys. The pulse
feature gives the ultimate in weld control from welding the thinnest of
materials through to full power output. The inverter square wave technology
gives a very smooth and consistent arc, while keeping the power source down
to a very portable size and weight with powerful output and high duty cycle.
Added to this all is MMA capability. The ideal machine for precision
fabrication and repair across a wide range of metals.
UNPACKING YOUR MACHINE
When unpacking your machines, please inspect the machine and accessories
carefully to ensure all components have been received, as per the packing list
below.
Contents
Description Quantity
BW-TIG200ACDC Power Source 1
WP26 Ergo TIG Torch - 4m 1
MMA Lead & Electrode Holder - 3m 1
Work Lead & Clamp - 3m 1
Argon Gas Regulator 1
Gas Hose with clamps - 3m x 8mm 1
Instruction Manual 1
Instruction DVD 1
If you have any questions, please contact your nearest local Weldtech store.
MACHINE SPECIFICATIONS
Specifications
Model BW-TIG200ACDC
Rated Input Power Supply 230-240V 15A AC Single Phase 50Hz
No Load Output Voltage 56V
TIG Output Current Range 10A-200A
TIG Load Duty Cycle 35% @ 200A
TIG Arc Ignition System High Frequency
MMA Output Current Range 10A-170A
MMA Load Duty Cycle 35% @170A
Dimensions 493 x 330 x 320mm
Net Weight 20kg
Standard AS 60974.1-2006
DUTY CYCLE
The welding duty cycle is the percentage of actual welding time that can occur
in a ten minute cycle. eg. 35% at 200 amps - means the welder can weld at 200
amps for 3½ minutes and then the unit will need to be rested for 6½ minutes.
The unit has a rated duty cycle of 100% at a setting of 140 Amps.
NOTE: The duty cycle can be affected by the environment in which the welder
is used. In areas with temperatures exceeding 40°C, the duty cycle will be less
than stated. In areas less than 40°C higher duty cycles have been obtained.
All tests on duty cycles have been carried out at 40°C with 50% humidity.
7

Function Reference Table
No. Description No. Description
1 LCD Current Meter 14 Clean Area Width/AC Balance
Adjustment
2 TIG/MMA Mode Switch 15
Mains Power On Indicator Lamp
3 2T/4T Trigger Mode Switch 16
Overload Indicator Lamp
4 Pulse Welding Mode Switch 17 Mains Power Switch
5 AC/DC Output Mode Switch 18 Positive (+) Welding Power
Output Terminal
6 Gas Pre-Flow Time Adjustment 19 Remote Current Control
Connection Socket
7 Peak Current Adjustment 20 Torch Switch Remote Connec-
tion Socket
8 Base Current Adjustment 21 Shielding Gas Outlet
9 Down Slope Adjustment 22 Negative (-) Welding Power
Output Terminal
10 ARC Force Adjustment 23 Cooling Fans
11 Pulse Frequency Adjustment 24 Mains Power Input Cable
12 Pulse Duty Adjustment 25 Gas Inlet Connector
13 Gas After-Flow Adjustment 26 Data Plate
4T/2T Trigger Control Switch (Ref. 3) - This switch controls the trigger mode for
the TIG torch trigger. 2T mode the trigger is depressed and held on to activate
the welding circuit, when the trigger is released, the welding circuit stops. 4T
is known as ’latching’ mode. The trigger is depressed once and released to
activate the welding circuit, depressed and released again to stop the welding
circuit. This function is useful for longer welds as the trigger is not required to
be held on continuously.
AC/DC Output Mode Switch (Ref. 5) - DC (direct current) output mode is
suitable for TIG welding metals such as mild steel and stainless steel, copper
and titanium. TIG welding reactive metals such as aluminium, magnesium and
zinc requires AC (alternating current) output.
When reactive metals are exposed to air they form an oxide layer that
insulates the base metal and prevents welding current flowing, it also
contaminates the weld area. Reverse current flow is required to break
through/ clean off this oxide layer so that welding can take place, while the
current flow during the positive cycle does the majority of the heating of the
weld pool area.
Pulse Welding Mode (Ref. 4) - Switches the welding output between a higher
and lower current output in a cyclic manner. When used correctly this function
provides greater weld penetration for less work heat input and greater control
of the weld pool.
Gas Pre-flow Time Adjustment (Ref. 6) - When the trigger is depressed, this
adjustment controls how long the gas flows before the arc is initiated. This is
necessary when purging the start of the weld area of any atmospheric gases
before the arc starts.
Peak Current Adjustment (Ref. 7) - Provides adjustment for the output current.
Base Current Adjustment (Ref. 8) - When using pulse mode, this adjustment
sets the current for the low/base pulse with respect to the peak current.
This is a percentage adjustment. E.g with the peak current set at 160A and the
base current adjustment set at 50%, the base current pulse will be 80A. (160A
x 50%). The basic theory for setting the base current using pulse mode is that
the base current should be sufficient to maintain the existing molten weld pool,
while the peak current is sufficient to melt new metal in order to move/ expand
the molten weld pool.
Down Slope Adjustment (Ref. 9) - When the trigger is released, this adjustment
causes the current to gradually decrease from the peak amps to 0 over the set
time (in seconds). To turn the function off, set the adjustment to 0. This function
is useful to prevent an uneven finish to the weld or a ‘crater’ forming when the
weld current stops abruptly.
Arc Force Adjustment (Ref. 10) - this adjustment impacts MMA, and has little
effect in TIG mode. The adjustment changes the characteristic of the volts/amp
relationship during welding. When MMA welding, output current is constant
as set, while the voltage changes with the arc length (the distance from the
electrode to the work piece). A shorter arc length will give a narrower weld
with more penetration, while a longer arc length gives a wider ‘colder’ weld
pool. A shorter arc can be unstable if the voltage gets too low. Increased arc
force adjustment will boost the welding voltage when it drops with a shorter
arc, giving a more penetrating arc when used with short arc length.
A basic rule of thumb is increased arc force will give an arc characteristic that
feels more penetrating and tight, while decrease in arc force will give a softer,
less focused arc.
Pulse Frequency Adjustment (Ref. 11) - Pulse mode sets the rate that the
output current switches between high and low. Increased pulse frequency
will have the effect of making the arc more tightly focused, which is useful for
fine stainless work and similar. A slow pulse rate can be used to help move the
weld pool along, this technique is useful with welding Aluminium, as molten
Aluminium forms a more viscous ‘sticky’ weld pool.
Pulse Duty Adjustment (Ref. 12) - This adjustment sets the time proportion as
a percentage between the peak current and base current when using pulse
mode. Neutral setting is 50%, the time period of the peak current and base
current pulse is equal. Higher pulse duty setting will give greater heat input,
while lower pulse duty will have the opposite effect.
Clean Width Area/ AC Balance Adjustment (Ref. 14) - Sets the balance
between the forward and reverse current cycles when welding in AC output
mode. The reverse part of the cycle gives the ‘cleaning’ effect on the weld
material, while the forward cycle melts the weld material. Neutral setting is
50%. Increased reverse cycle bias will give greater cleaning effect, less weld
penetration and more heat in the torch tungsten, reducing the output current
that can be used for a given tungsten size. Increased forward cycle bias will
give the opposite effect, less cleaning effect, greater weld penetration and
less heat in the tungsten. Ideally for maximum effectiveness, the clean width/
AC balance should be set with as much forward cycle bias as possible, while
still maintaining a sufficient level of oxidisation removal for a contamination
free weld pool. The cleaner the metal, the more effective it is to weld.
Gas After-flow Adjustment (Ref. 13) - This adjustment sets the period of time
that the gas control valve stays open. It is important for TIG welding that that
the weld pool and the torch tungsten remain protected from atmospheric
contamination by the shielding gas until they have cooled sufficiently.
The tungsten should be able to be touched by hand before the shielding gas
stops flowing.
Remote Current Control Connection Socket (Ref. 19) - For connection of a
torch with external amperage control capability. Refer consumables and
accessories section for a suitable upgrade torch part number.
Overload Indicator Lamp (Ref. 16) - Lights when duty cycle is exceeded and
thermal protection is activated. When activated, welding output will
be disabled until machines cools sufficiently and overload indicator lamp
goes out.
KNOW YOUR WELDER
8

CONSUMABLES & ACCESSORIES
It is very important to recognise that welding torch consumables wear as part
of normal operation and should be replaced in a timely manner. Operating a
torch with worn consumables will cause poor welding results and possible
damage to the torch and machine itself.
4
3 2 1 5 6 7
TER26 TIG Torch Consumables
No. Description Code
1 TER26 Torch Head TER26
2 Torch Back Cap O-ring TOR98W18
3 Long Back Cap TCB57Y02
4 Short Back Cap TBC57Y04
5
Collet 1.6mm TC10N23
Collet 2.4mm TC10N24
Collet 3.2mm TC10N25
6
Collet Body 1.6mm TCB10N31
Collet Body 2.4mm TCB10N32
Collet Body 3.2mm TCB10N28
7
Ceramic Cup 1/2" Bore TCC10N46
Ceramic Cup 3/8" Bore TCC10N48
Ceramic Cup 5/16" Bore TCC10N45
These wearing torch consumables and the list of accessories following are all
available from your nearest Weldtech store.
Accessories / Consumables
Description Code
Welding Helmet Professional DW3000
Professional Welding Gloves AWG02
Argon Regulator GR101AR
Welding Magnet - 5" WMG02
1.6mm Thoriated TIG Tungsten, 3pk TT16-150
2.4mm Thoriated TIG Tungsten, 3pk TT24-150
3.2mm Thoriated TIG Tungsten, 3pk TT32-150
1.6mm Zirconiated TIG Tungsten, 3pk TZ16-150
2.4mm Zirconiated TIG Tungsten, 3pk TZ24-150
3.2mm Zirconiated TIG Tungsten, 3pk TZ32-150
TIG Rod 1.6mm Stainless Steel, 0.5kg TR16SS-316
TIG Rod 1.6mm Mild Steel, 1kg TR16MS-70S-6
Aluminium TIG rod 1.6mm/ 0.5kg TR16AL-5356
Stainless steel TIG rod 2.4mm/ 1kg TR24SS-316
Mild steel TIG rod 2.4mm/ 1kg TR24MS-70S-6
Aluminium TIG Rod 2.4mm/ 0.5kg TR24AL-5356
Stainless steel TIG rod 3.2mm/ 1kg TR32SS-316
Mild steel TIG rod 2.4mm 3.2/1kg TR32MS-70S-6
Aluminium TIG Rod 3.2mm/ 0.5kg TR32AL-5356
Foot Controller PPC2002
TIG Torch WB26 8m Variable Amperage Control TER26-25-2VA-EQ
400amp Electrode Holder S400EH
Strata 500A Rated Earth Clamp S500EC
Arc Lead Set 35-50mm 400A ALS3550
Electrodes 2.4mm General Purpose, 5kg ETCPH6825
Electrodes 3.2mm General Purpose, 5kg ETCPH6832
For all other spare parts and accessories, please contact your local
Weldtech store.
9

WELDER INSTALLATION
Electrical Connection
The BW-TIG200ACDC is designed to run on a standard 15A 230V AC power
supply. If an extension cord must be used, it should be no longer than 10m and
be a heavy duty industrial 15A version with a minimum cable core of 2.5mm2.
Operating Environment
Adequate ventilation is required to provide a proper cooling for the BW-
TIG200ACDC. Ensure that the machine is placed on a stable level surface
where clean cool air can easily flow across the unit. The BW-TIG200ACDC has
electrical components and control circuit boards which will be damaged by
excessive dust and dirt, a clean operating environment is essential.
MMA WELDING OPERATION
Connect the machine to suitable mains power using the Mains Input Power
Lead (24). Switch the Mains Power Switch (17) to ON to power up the machine.
Connect the Working Lead/Clamp Quick Connector to the Negative Welding
Power Output Socket (22.) Connect the Clamp to the work piece. Contact with
the work piece must be firm and contact clean, bare metal, with no corrosion,
paint or scale.
Insert an electrode into the Electrode holder and connect the Electrode Holder
and Work Lead to the Positive Welding Power Output Socket (18).
NOTE: This polarity connection configuration is valid for most GP (General
Purpose) MMA electrodes. There are variances to this. If in doubt, check the
electrode specifications or consult the electrode manufacturer.
Set the Welding Mode Switch (2) to MMA position, set the AC/DC Mode
Switch (5) to ‘DC’ position, set the Pulse Switch (4) to straight.
NOTE: some MMA electrodes are suitable for AC welding output, check the
electrode specifications or consult the electrode manufacturer.
Set the Peak Current Adjustment Knob (7) and Arc Force Adjustment Knob (10)
to the desired position.
You are now ready to weld!
DC TIG WELDING OPERATION
Connect the machine to suitable mains power using the Mains Input Power
Lead (24). Switch the Mains Power Switch (17) to ON to power up the machine.
Connect the Working Lead/Clamp Quick Connector to the Positive Welding
Power Output Socket (18) Connect the Clamp to the work piece. Contact with
the work piece must be firm and contact clean, bare metal, with no corrosion,
paint or scale.
Connect the TIG Torch Power Lead Quick Connector to the Negative Welding
Power Output Socket (22). Connect the Torch Gas Line to the Gas Outlet
Connector (21). Where applicable connect the Torch Remote Switch Plug to
the Switching Connection Socket (20).
Set the Welding Mode Switch (2) to TIG position, set the AC/DC Mode Switch
(5) to ‘DC’ position, set the Pulse Mode Switch (4) to straight/ non pulse, set the
Trigger Mode Switch (3) to 2T or 4T as desired.
Connect the gas regulator to an argon gas cylinder (not included with
machine) and connect the gas hose from the regulator to the gas inlet on
the rear of the machine (25). Ensure all hose connections are tight. Open gas
cylinder valve and adjust regulator, flow should be set between 5-15l/min for
most TIG welding applications. Re-check regulator flow pressure with torch
triggered as static gas flow setting may drop once gas is flowing.
Set the Peak Current Adjustment Knob (7), Gas Pre-flow Time Adjustment Knob
(6), Down Slope Adjustment Knob (9) and Gas After-flow Adjustment Knob (13)
to the desired position.
You are ready to weld!
DC PULSE TIG WELDING OPERATION
Connect the machine to suitable mains power using the Mains Input Power
Lead (24). Switch the Mains Power Switch (17) to ON to power up the machine.
Connect the Working Lead/Clamp Quick Connector to the Positive Welding
Power Output Socket (18) Connect the Clamp to the work piece. Contact with
the work piece must be firm and contact clean, bare metal, with no corrosion,
paint or scale.
Connect the TIG Torch Power Lead Quick Connector to the Negative Welding
Power Output Socket (22). Connect the Torch Gas Line to the Gas Outlet
Connector (21). Connect the Torch Remote Switch Plug to the Switching
Connection Socket (20).
Set the Welding Mode Switch (2) to TIG position, set the AC/DC Mode Switch
(5) to ‘DC’ position, set the Pulse Mode Switch (4) to pulse, set the Trigger
Mode Switch (3) to 2T or 4T as desired.
Connect the gas regulator to an argon gas cylinder (not included with
machine) and connect the gas hose from the regulator to the gas inlet on
the rear of the machine (25). Ensure all hose connections are tight. Open gas
cylinder valve and adjust regulator, flow should be set between 5-15l/min for
most TIG welding applications. Re-check regulator flow pressure with torch
triggered as static gas flow setting may drop once gas is flowing.
Adjust the Base Current (8), Pulse Frequency (11) and Pulse Duty (12) pulse
settings as desired.
Set the Peak Current Adjustment Knob (7), Gas Pre-flow Time Adjustment Knob
(6), Down Slope Adjustment Knob (9) and Gas After-flow Adjustment Knob (13)
to the desired position.
You are ready to weld!
AC TIG WELDING OPERATION
Connect the machine to suitable mains power using the Mains Input Power
Lead (24). Switch the Mains Power Switch (17) to ON to power up the machine.
Connect the Working Lead/Clamp Quick Connector to the Positive Welding
Power Output Socket (18) Connect the Clamp to the work piece. Contact with
the work piece must be firm and contact clean, bare metal, with no corrosion,
paint or scale.
Connect the TIG Torch Power Lead Quick Connector to the Negative Welding
Power Output Socket (22). Connect the Torch Gas Line to the Gas Outlet
Connector (21). Connect the Torch Remote Switch Plug to the Switching
Connection Socket (20).
Set the Welding Mode Switch (2) to TIG position, set the AC/DC Mode Switch
(5) to ‘AC’ position, set the Pulse Mode Switch (4) to straight/ non pulse, set the
Trigger Mode Switch (3) to 2T or 4T as desired.
Connect the gas regulator to an argon gas cylinder (not included with
machine) and connect the gas hose from the regulator to the gas inlet on
the rear of the machine (25). Ensure all hose connections are tight. Open gas
cylinder valve and adjust regulator, flow should be set between 5-15l/min for
most TIG welding applications. Re-check regulator flow pressure with torch
triggered as static gas flow setting may drop once gas is flowing.
Set the Peak Current Adjustment Knob (7), Clean Area Width/AC Balance
Adjustment (14), Gas Pre-flow Time Adjustment Knob (6), Down Slope
Adjustment Knob (9) and Gas After-flow Adjustment Knob (13) to the desired
position.
You are ready to weld!
AC PULSE TIG WELDING OPERATION
Connect the machine to suitable mains power using the Mains Input Power
Lead (24). Switch the Mains Power Switch (17) to ON to power up the machine.
Connect the Working Lead/Clamp Quick Connector to the Positive Welding
Power Output Socket (18) Connect the Clamp to the work piece. Contact with
the work piece must be firm and contact clean, bare metal, with no corrosion,
paint or scale.
Connect the TIG Torch Power Lead Quick Connector to the Negative Welding
Power Output Socket (22). Connect the Torch Gas Line to the Gas Outlet
Connector (21). Connect the Torch Remote Switch Plug to the Switching
Connection Socket (20).
Set the Welding Mode Switch (2) to TIG position, set the AC/DC Mode Switch
(5) to ‘AC’ position, set the Pulse Mode Switch (4) to pulse, set the Trigger
Mode Switch (3) to 2T or 4T as desired.
Connect the gas regulator to an argon gas cylinder (not included with
machine) and connect the gas hose from the regulator to the gas inlet on
the rear of the machine (25). Ensure all hose connections are tight. Open gas
cylinder valve and adjust regulator, flow should be set between 5-15l/min for
most TIG welding applications. Re-check regulator flow pressure with torch
triggered as static gas flow setting may drop once gas is flowing.
Adjust the Base Current (8), Pulse Frequency (11) and Pulse Duty (12) pulse
settings as desired.
Set the Peak Current Adjustment Knob (7), Clean Area Width/AC Balance
Adjustment (14), Gas Pre-flow Time Adjustment Knob (6), Down Slope
Adjustment Knob (9) and Gas After-flow Adjustment Knob (13) to the
desired position.
You are ready to weld!
10

MMA WELDING GUIDE
MMA (STICK) BASIC WELDING TECHNIQUES
Size of Electrode
The electrode size is determined by the thickness of metals being joined and
can also be governed by the type of welding machine available. Small welding
machines will only provide current (amperage) to run smaller sized electrodes.
For thin sections, it is necessary to use smaller electrodes otherwise the arc may
burn holes through the job. A little practice will soon establish the most suitable
electrode for a given application.
Storage of Electrodes
Always store electrodes in a dry place and in their original containers.
Electrode Polarity
Electrodes are generally connected to the ELECTRODE HOLDER with the
Electrode Holder connected positive polarity. The WORK LEAD is connected
negative polarity and is connected to the work piece. If in doubt consult the
electrode data sheet.
EFFECTS OF MMA (STICK) WELDING VARIOUS MATERIALS
High Tensile and Alloy Steels
The two most prominent effects of welding these steels are the formation of
a hardened zone in the weld area, and, if suitable precautions are not taken,
the occurrence in this zone of under-bead cracks. Hardened zone and under-
bead cracks in the weld area may be reduced by using the correct electrodes,
preheating, using higher current settings, using larger electrodes sizes, short
runs for larger electrode deposits or tempering in a furnace.
Manganese Steels
The effect on manganese steel of slow cooling from high temperatures causes
embrittlement. For this reason it is absolutely essential to keep manganese steel
cool during welding by quenching after each weld or skip welding to distribute
the heat.
Cast Iron
Most types of cast iron, except white iron, are weldable. White iron, because
of its extreme brittleness, generally cracks when attempts are made to weld it.
Trouble may also be experienced when welding white-heart malleable, due to
the porosity caused by gas held in this type of iron.
Copper and Alloys
The most important factor is the high rate of heat conductivity of copper, making
pre-heating of heavy sections necessary to give proper fusion of weld and base
metal.
Types of Electrodes
Arc Welding electrodes are classified into a number of groups depending on
their applications. There are a great number of electrodes used for specialized
industrial purposes which are not of particular interest for everyday general
work. These include some low hydrogen types for high tensile steel, cellulose
types for welding large diameter pipes, etc. The range of electrodes dealt
with in this publication will cover the vast majority of applications likely to be
encountered; are all easy to use.
Metal Being Joined Electrode Comments
Mild Steel E6011
This electrode is used for all-position
welding or for welding on rusty, dirty, less-
than-new metal. It has a deep, penetrating
arc and is often the first choice for repair or
maintenance work.
Mild Steel E6013
This all-position, electrode is used for weld-
ing clean, new sheet metal. Its soft arc has
minimal spatter, moderate penetration and
an easy-to-clean slag.
Mild Steel E7014
All positional, ease to use electrode for use
on thicker steel than E6013. Especially suit-
able sheet metal lap joints and fillet welds,
general purpose plate welding.
Mild Steel E7018
A low-hydrogen, all-position electrode used
when quality is an issue or for hard-to-weld
metals. It has the capability of producing
more uniform weld metal, which has better
impact properties at low temperatures.
Cast Iron Eni-Cl Suitable for joining all cast irons except
white cast iron.
Stainless Steel E318L-16 High corrosion resistances. Ideal for dairy
work etc.
Flat Position, Down Hand Butt Weld (Fig 1-11)
Flat Position, Gravity Fillet Weld (Fig 1-12)
Horizontal Position, Butt Weld (Fig 1-13)
Horizontal-Vertical (HV) Position (Fig 1-14)
Vertical Position, Butt Weld (Fig 1-15)
Vertical Position, Fillet Weld (Fig 1-16)
Overhead Position, Butt Weld (Fig 1-17)
Overhead Position, Fillet Weld (Fig 1-18)
11

Joint Preparations
In many cases, it will be possible to weld steel sections without any special
preparation. For heavier sections and for repair work on castings, etc., it will
be necessary to cut or grind an angle between the pieces being joined to
ensure proper penetration of the weld metal and to produce sound joints.
In general, surfaces being welded should be clean and free of rust, scale,
dirt, grease, etc. Slag should be removed from oxy-cut surfaces. Typical joint
designs are shown in Figure 1-19.
Open Square Butt Joint (Fig 1-19a)
Gap varies from
1.6mm (1/16”) to
4.8mm (3/16”)
depending on
plate thickness
Single Vee Butt Joint (Fig 1-19b)
Not less than 45°
Single Vee Butt Joint (Fig 1-19c)
Not less than 70°
1.6mm (1/16”)
1.6mm (1/16”) max.
Double Vee Butt Joint (Fig 1-19d)
Not less than 70°
1.6mm (1/16”)
1.6mm (1/16”) max.
Lap Joint (Fig 1-19e)
Fillet Joint (Fig 1-19f)
Corner Weld (Fig 1-19g)
Tee Joints (Fig 1-19h)
Edge Joint (Fig 1-19i)
Plug Weld (Fig 1-19j)
Plug Weld (Fig 1-19j)
12

Arc Welding Technique - A Word for Beginners
For those who have not yet done any welding, the simplest way to commence
is to run beads on a piece of scrap plate. Use mild steel plate about 6.0mm
thick and a 3.2mm electrode. Clean any paint, loose scale or grease off the
plate and set it firmly on the work bench so that welding can be carried out in
the down hand position. Make sure that the Work Lead/Clamp is making good
electrical contact with the work, either directly or through the work table. For
light gauge material, always clamp the work lead directly to the job, otherwise
a poor circuit will probably result.
The Welder
Place yourself in a comfortable position before beginning to weld. Get a seat
of suitable height and do as much work as possible sitting down. Don’t hold
your body tense. A taut attitude of mind and a tensed body will soon make you
feel tired. Relax and you will find that the job becomes much easier. You can
add much to your peace of mind by wearing a leather apron and gauntlets.
You won’t be worrying then about being burnt or sparks setting alight to your
clothes.
Place the work so that the direction of welding is across, rather than to or
from, your body. The electrode holder lead should be clear of any obstruction
so that you can move your arm freely along as the electrode burns down. If the
lead is slung over your shoulder, it allows greater freedom of movement and
takes a lot of weight off your hand. Be sure the insulation on your cable and
electrode holder is not faulty; otherwise you are risking an electric shock.
Striking the Arc
Practice this on a piece of scrap plate before going on to more exacting work.
You may at first experience difficulty due to the tip of the electrode “sticking”
to the work piece. This is caused by making too heavy a contact with the work
and failing to withdraw the electrode quickly enough. A low amperage will
accentuate it. This freezing-on of the tip may be overcome by scratching the
electrode along the plate surface in the same way as a match is struck. As
soon as the arc is established, maintain a 1.6mm to 3.2mm gap between the
burning electrode end and the parent metal. Draw the electrode slowly along
as it melts down.
Another difficulty you may meet is the tendency, after the arc is struck, to
withdraw the electrode so far that the arc is broken again. A little practice will
soon remedy both of these faults.
Striking an Arc (Fig 1-20)
1.6mm (1/16”)
20o
Arc Length
The securing of an arc length necessary to produce a neat weld soon
becomes almost automatic. You will find that a long arc produces more heat.
A very long arc produces a crackling or spluttering noise and the weld metal
comes across in large, irregular blobs. The weld bead is flattened and spatter
increases. A short arc is essential if a high quality weld is to be obtained
although if it is too short there is the danger of it being blanketed by slag and
the electrode tip being solidified in. If this should happen, give the electrode
a quick twist back over the weld to detach it. Contact or “touch-weld”
electrodes such as E7014 Stick electrodes do not stick in this way, and make
welding much easier.
Rate of Travel
After the arc is struck, your next concern is to maintain it, and this requires
moving the electrode tip towards the molten pool at the same rate as it is
melting away. At the same time, the electrode has to move along the plate to
form a bead. The electrode is directed at the weld pool at about 20º from the
vertical. The rate of travel has to be adjusted so that a well-formed bead is
produced.
If the travel is too fast, the bead will be narrow and strung out and may even be
broken up into individual globules. If the travel is too slow, the weld metal piles
up and the bead will be too large.
Making Welded Joints
Having attained some skill in the handling of an electrode, you will be ready to
go on to make up welded joints.
A. Butt Welds
Set up two plates with their edges parallel, as shown in Figure 1-21, allowing
1.6mm to 2.4mm gap between them and tack weld at both ends. This is to
prevent contraction stresses from the cooling weld metal pulling the plates out
of alignment.
Plates thicker than 6.0mm should have their mating edges bevelled to form a
70º to 90º included angle. This allows full penetration of the weld metal to the
root. Using a 3.2mm E7014 Stick electrode at 100 amps, deposit a run of weld
metal on the bottom of the joint.
Do not weave the electrode, but maintain a steady rate of travel along the joint
sufficient to produce a well-formed bead. At first you may notice a tendency
for undercut to form, but keeping the arc length short, the angle of the
electrode at about 20º from vertical, and the rate of travel not too fast, will help
eliminate this.
The electrode needs to be moved along fast enough to prevent the slag pool
from getting ahead of the arc. To complete the joint in thin plate, turn the job
over, clean the slag out of the back and deposit a similar weld.
Butt Weld (Fig 1-21)
Tack Weld
Tack Weld
Electrode
20o- 30o
Weld Build Up Sequence (Fig 1-22)
Heavy plate will require several runs to complete the joint. After completing the
first run, chip the slag out and clean the weld with a wire brush. It is important
to do this to prevent slag being trapped by the second run. Subsequent runs
are then deposited using either a weave technique or single beads laid down
in the sequence shown in Figure 1-22. The width of weave should not be more
than three times the core wire diameter of the electrode.
When the joint is completely filled, the back is either machined, ground or
gouged out to remove slag which may be trapped in the root, and to prepare
a suitable joint for depositing the backing run. If a backing bar is used, it is
not usually necessary to remove this, since it serves a similar purpose to the
backing run in securing proper fusion at the root of the weld.
13

B. Fillet Welds
These are welds of approximately triangular cross-section made by depositing
metal in the corner of two faces meeting at right angles. Refer to Figure 1-14,
1-23 and 1-24.
A piece of angle iron is a suitable specimen with which to begin, or two lengths
of strip steel may be tacked together at right angles. Using a 3.2mm E7014 Stick
electrode at 100 amps, position angle iron with one leg horizontal and the other
vertical. This is known as a horizontal-vertical (HV) fillet.
Strike the arc and immediately bring the electrode to a position perpendicular
to the line of the fillet and about 45º from the vertical. Some electrodes require
being sloped about 20º away from the perpendicular position to prevent slag
from running ahead of the weld. Refer to Figure 1-23.
Do not attempt to build up much larger than 6.4mm width with a 3.2mm
electrode, otherwise the weld metal tends to sag towards the base, and
undercut forms on the vertical leg. Multi-runs can be made as shown in Figure
1-24. Weaving in HV fillet welds is undesirable.
Electrode Position for HV Fillet Weld (Fig 1-23)
45o from vertical
60o-70o from
line of weld
Multi-Runs in HV Fillet Weld (Fig 1-24)
1
3
6
5
24
C. Vertical Welds
1. Vertical Up
Tack weld a three feet length of angle iron to your work bench in an upright
position. Use a 3.2mm E7014 Stick electrode and set the current at 100 amps.
Make yourself comfortable on a seat in front of the job and strike the arc in the
corner of the fillet. The electrode needs to be about 10º from the horizontal to
enable a good bead to be deposited. Refer Figure 1-25.
Use a short arc, and do not attempt to weave on the first run. When the first
run has been completed de-slag the weld deposit and begin the second run
at the bottom. This time a slight weaving motion is necessary to cover the first
run and obtain good fusion at the edges.
At the completion of each side motion, pause for a moment to allow weld metal
to build up at the edges, otherwise undercut will form and too much metal
will accumulate in the centre of the weld. Figure 1-26 illustrates multi-run
technique and Figure 1-27 shows the effects of pausing at the edge of weave
and of weaving too rapidly.
Single Run Vertical Fillet Weld (Fig 1-25)
Multi Run Vertical Fillet Weld (Fig 1-26)
Weaving motion
for second and
subsequent runs
Pause at edge
of weave
Examples of Vertical Fillet Welds (Fig 1-27)
CORRECT
Pause at edge of
weave allows weld
metal to build up and
eliminates undercut
Note weld contour
when insufficient
pause at edge of
weave
INCORRECT
2. Vertical Down
The E7014 Stick electrode makes welding in this position particularly easy. Use
a 3.2mm electrode at 100 amps. The tip of the electrode is held in light contact
with the work and the speed of downward travel is regulated so that the tip of
the electrode just keeps ahead of the slag. The electrode should point upwards
at an angle of about 45º.
3. Overhead Welds
Apart from the rather awkward position necessary, overhead welding is not
much more difficult that down hand welding.
Set up a specimen for overhead welding by first tacking a length of angle iron
at right angles to another piece of angle iron or a length of waste pipe. Then
tack this to the work bench or hold in a vice so that the specimen is positioned
in the overhead position as shown in the sketch.
The electrode is held at 45º to the horizontal and tilted 10º in the line of travel
(Figure 1-28). The tip of the electrode may be touched lightly on the metal,
which helps to give a steady run. A weave technique is not advisable for
overhead fillet welds.
Use a 3.2mm E6013 Stick electrode at 100 amps, and deposit the first run by
simply drawing the electrode along at a steady rate. You will notice that the
weld deposit is rather convex, due to the effect of gravity before the metal
freezes.
Overhead Fillet Weld (Fig 1-28)
45Oto plate
Tilted 10Oin
line of travel
Angle tacked to pipe
14

MMA WELDING TROUBLESHOOTING
Troubleshooting - MMA Weld Quality
Fault Cause Remedy
A gap is left by failure of the weld metal to
fill the root of the weld.
Welding current too low. Increase welding current.
Electrode too large for joint. Use smaller diameter electrode.
Insufficient gap. Allow wider gap.
Non-metallic particles are trapped in the
weld metal.
Non-metallic particles may be trapped in
undercut from previous run.
If a bad undercut is present clean slag bout and cover with a run from a
smaller gauge electrode.
Joint preparation too restricted. Allow for adequate penetration and room for cleaning out the slag.
Irregular deposits allow slag to be trapped. If very bad, chip or grind out irregularities.
Lack of penetration with slag trapped
beneath weld bead.
Use smaller electrode with sufficient current to give adequate penetra-
tion. Use suitable tools to remove all slag from comers.
Rust or mill scale is preventing full fusion. Clean joint before welding.
Wrong electrode for position in which
welding is done.
Use electrodes designed for position in which welding is done, otherwise
proper control of slag is difficult.
Incorrect SequenceFigure 1: Example of insufficient gap or incorrect sequence
Insufficient Gap
A groove has been formed in the base
metal adjacent to the toe of a weld and
has not been filled by the weld metal
(undercut).
Welding current is too high. Reduce welding current.
Welding arc is too long. Reduce the length of the welding arc.
Angle of the electrode is incorrect. Electrode should not be inclined less than 45° to the vertical face.
Joint preparation does not allow correct
electrode angle. Allow more room in joint for manipulation of the electrode.
Electrode too large for joint. Use smaller gauge electrode.
Insufficient deposit time at edge of weave. Pause for a moment at edge of weave to allow weld metal build-up.
Power source is set for MIG (GMAW)
welding. Set power source to STICK (MMA) mode.
Portions of the weld run do not fuse to the
surface of the metal or edge of the joint.
Small electrodes used on heavy cold plate. Use larger electrodes and preheat the plate.
Welding current is too low. Increase welding current.
Wrong electrode angle. Adjust angle so the welding arc is directed more into the base metal.
Travel speed of electrode is too high. Reduce travel speed of electrode.
Scale or dirt on joint surface. Clean surface before welding.
Figure 2: Example of Lack of Fusion
Lack of inter-run fusion
Lack of side fusion, scale dirt;
small electrode; amperage too low
Lack of fusion caused by dirt; electrode
angle incorrect; rate of travel too high
Lack of root fusion
Gas pockets or voids in weld metal
(porosity)
High levels of sulphur in steel. Use an electrode that is designed for high sulphur steels.
Electrodes are damp. Dry electrodes before use.
Welding current is too high. Reduce welding current.
Surface impurities such as oil, grease,
paint, etc. Clean joint before welding.
Welding in a windy environment. Shield the weld area from the wind.
Electrode damaged i.e. flux coating
incomplete.
Discard damaged electrodes and only use electrodes with a complete
flux coating.
Crack occurring in weld metal soon after
solidification commences
Rigidity of joint. Redesign to relieve weld joint of severe stresses or use crack resistance
electrodes.
Insufficient throat thickness. Travel slightly slower to allow greater build up in throat.
Weld current is too high. Decrease welding current.
Figure 3: Example of Slag Inclusion
Not cleaned, or incorrect electrode
Slag trapped
in undercut
Slag trapped in root
15

TIG WELDING GUIDE
TIG WELDING FUSION TECHNIQUE
Manual TIG welding is often considered the most difficult of all the
welding processes. Because the welder must maintain a short arc length,
great care and skill are required to prevent contact between the electrode
and the work piece. Similar to Oxygen Acetylene torch welding, TIG welding
normally requires two hands and in most instances requires the welder to
manually feed a filler wire into the weld pool with one hand while manipulating
the welding torch in the other. However, some welds combining thin materials
can be accomplished without filler metal like edge, corner, and butt joints.
This is known as Fusion welding where the edges of the metal pieces are
melted together using only the heat and arc force generated by the TIG arc.
Once the arc is started the torch tungsten is held in place until a weld pool is
created, a circular movement of the tungsten will assist is creating a weld pool
of the desired size. Once the weld pool is established tilt the torch at about
a 75° angle and move smoothly and evenly along the joint while fusing the
materials together.
TIG WELDING WITH FILLER WIRE TECHNIQUE
In many situations with TIG welding, it is necessary to add a filler wire into the
weld pool to build up weld reinforcement and create a strong weld. Once the
arc is started the torch tungsten is held in place until a weld pool is created,
a circular movement of the tungsten will assist is creating a weld pool of
the desired size. Once the weld pool is established tilt the torch at about a
75° angle and move smoothly and evenly along the joint. The filler metal is
introduced to the leading edge of the weld pool. The filler wire is usually held
at about a 15° angle and fed into the leading edge of the molten pool, the arc
will melt the filler wire into the weld pool as the torch is moved forward. Also a
dabbing technique can be used to control the amount of filler wire added, the
wire is fed into the molten pool and retracted in a repeating sequence as the
torch is moved slowly and evenly forward. It is important during the welding to
keep the molten end of the filler wire inside the gas shield as this protects the
end of the wire from being oxidised and contaminating the weld pool.
PULSE TIG WELDING
Pulse TIG welding is when the current output (amperage) changes between
high and low current.
Electronic controls within the welding machine create the pulse cycle.
Welding is done during the high-amperage interval (this high amperage is
referred to as peak current). During the low amperage period, the arc is
maintained but the current output of the arc is reduced (this low amperage is
referred to as base current). During pulse welding the weld pool cools during
the low amperage period. This allows a lower overall heat input into the base
metal. It allows for controlled heating and cooling periods during welding
providing better control of heat input, weld penetration, operator control and
weld appearance.
There are 4 variables within the pulse cycle:
Peak Current - Base Current - Pulse Frequency - Pulse Width
Setting and manipulation of these variables will determine the nature of the
weld current output and is at the discretion of the operator.
Peak Current is the main welding current (amps) set to melt the material being
welded and works much the same as setting maximum amperage values for
regular DC TIG: as a guide use 30-40 amps for every 1mm of material thickness.
Base Current is the set level of background current (amps) which cools the
weld puddle and affects overall heat input. Background Amps is a percentage
of peak amperage. As a rule, use enough background current to reduce the
weld pool to about half its normal size while still keeping the weld pool fluid. As
a guide start by setting the background amperage at 20 to 30 percent of peak
amperage.
Pulse Frequency is the control of the amount of times per second (Hz) that the
welding current switches from Peak Current to Base Current. DC Pulse TIG
frequency generally ranges from 20 to 300 HZ depending on the job application.
Control of the pulse frequency also determines the appearance of the weld.
Pulse Width is the control of the percentage of time during one pulsing cycle
the power source spends at the peak current (main amperage). Example is
with the Pulse Width set at 80 percent and a rate of 1 pulse per second (PPS),
the machine will spend 80% of the pulse at peak amperage and 20% at the
base current. Increasing the pulse width percentage adds more heat to the
job, while decreasing pulse width percentage reduces heat.
Pulse TIG welding allows faster welding speeds with better control of the heat
input to the job, reducing the heat input minimising distortion and warping of
the work and is of particular advantage in the welding of thin stainless steel
and carbon steel applications. The high pulse frequency capability of the
advanced inverter agitates the weld puddle and allows you to move quickly
without transferring too much heat to the surrounding metal. Pulsing also
constricts and focuses the arc thus increasing arc stability, penetration and
travel speeds.
TUNGSTEN ELECTRODES
Tungsten is a rare metallic element used for manufacturing TIG welding
electrodes. The TIG process relies on tungsten’s hardness and high-
temperature resistance to carry the welding current to the arc. Tungsten has
the highest melting point of any metal at 3410 degrees Celsius.
Tungsten electrodes are non-consumable and come in a variety of sizes, they
are made from pure tungsten or an alloy of tungsten and other rare earth
elements. Choosing the correct tungsten depends on the material being
welded, the amount of amps required and whether you are using AC or DC
welding current.
Tungsten electrodes are colour-coded at the end for easy identification.
Thoriated
Thoriated tungsten electrodes (AWS classification EWTh-2) contain a
minimum of 97.30 percent tungsten and 1.70 to 2.20 percent thorium and are
called 2 percent thoriated. They are the most commonly used electrodes today
and are preferred for their longevity and ease of use. Thorium increases the
electron emission qualities of the electrode, which improves arc starts and
allows for a higher current-carrying capacity. This electrode operates far
below its melting temperature, which results in a considerably lower rate of
consumption and eliminates arc wandering. Compared with other electrodes,
thoriated electrodes deposit less tungsten into the weld puddle, so they cause
less weld contamination.
Travel Direction
Travel Direction
Gas
shield
Form a weld pool
Form a weld pool
Retract the filler wire
Angle Torch
Angle Torch
High
Frequency
Pulsing
High
Frequency
Pulsing
No pulse No pulse
Move the torch forward to the
front of the weld pool
Move the Torch slowly and
evenly forward
Add TIG filler wire
Repeat the process
75˚
75˚
15˚
16

Thorium is a low-level radioactive hazard and many users have switched
to other alternatives. Thorium is an alpha emitter but when enclosed in a
tungsten matrix, the risks are negligible.
Thus holding a stick of Thoriated tungsten in your hand should not pose a great
threat unless a welder has open cuts on their skin. Thoriated tungsten should
not get in contact with open cuts or wounds. The more significant danger to
welders can occur when thorium oxide gets into the lungs. This can happen
from the exposure to vapours during welding or from ingestion of material/
dust in the grinding of the tungsten. Follow the manufacturer’s warnings,
instructions, and the Safety Data Sheet (SDS) for its use.
Zirconiated (Color Code: White)
Zirconiated tungsten electrodes (AWS classification EWZr-1) contain a
minimum of 99.10 percent tungsten and 0.15 to 0.40 percent zirconium. Most
commonly used for AC welding Zirconiated tungsten produces a very stable
arc and is resistant to tungsten spitting. It is ideal for AC welding because it
retains a balled tip and has a high resistance to contamination. Its current-
carrying capacity is equal to or greater than that of thoriated tungsten.
Zirconiated tungsten is not recommended for DC welding.
Tungsten Electrode Current Ranges
Tungsten
Diameter
DC Current Amps
Torch Negative
2% Thoriated
AC Current Amps
Balanced Wave
0.8% Zirconiated
1.0mm 15 - 80 20 - 60
1.6mm 70 - 150 60 - 120
2.4mm 150 - 250 100 - 180
3.2mm 250 - 400 160 - 250
4.0mm 400 - 500 200 - 320
TUNGSTEN PREPARATION
Always use DIAMOND wheels when grinding and cutting. While tungsten is a
very hard material, the surface of a diamond wheel is harder, and this makes
for smooth grinding. Grinding without diamond wheels, such as aluminium
oxide wheels, can lead to jagged edges, imperfections, or poor surface
finishes not visible to the eye that will contribute to weld inconsistency and
weld defects.
Always grind the tungsten in a longitudinal direction. Tungsten electrodes are
manufactured with the molecular structure of the grain running lengthwise
and thus grinding crosswise is “grinding against the grain.” If electrodes are
ground crosswise, the electrons have to jump across the grinding marks and
the arc can start before the tip and wander. Grinding longitudinally with the
grain, the electrons flow steadily and easily to the end of the tungsten tip. The
arc starts straight and remains narrow, concentrated, and stable.
Electrode Tip/Flat
The shape of the tungsten electrode tip is an important process variable in
precision arc welding. A good selection of tip/flat size will balance the need for
several advantages. The bigger the flat, the more likely arc wander will occur
and the more difficult it will be to arc start. Increasing the flat to the maximum
level that still allows arc start and eliminates arc wonder will improve the weld
penetration and increase the electrode life. Some welders grind electrodes to
a sharp point, which makes arc starting easier but can contribute to decreased
welding performance due to the tip melting and falling into the weld pool.
Electrode Included Angle/Taper - DC Welding
Tungsten electrodes for DC welding should be ground longitudinally and
concentrically with diamond wheels to a specific included angle in conjunction
with the tip/flat preparation. Different angles produce different arc shapes
and offer different weld penetration capabilities. In general, electrodes that
have an appropriate included angle and a suitable flat on the tip, exhibit the
following benefits:
• Last Longer
• Have better weld penetration
• Have a narrower arc shape
• Can handle more amperage without eroding.
Sharper electrodes with smaller included angle provide:
• Offer less arc weld
• Have a wider arc
• Have a more consistent arc
The included angle determines weld bead shape and size. Generally, as the
included angle increases, penetration increases and bead width decreases.
Tungsten Electrode Preperation
Tungsten
Electrode
Diameter
(mm)
Flat Spot
Diameter
at the Tip
(mm)
Tip Included
Angle
(Degrees)
Current
Range
(Amps)
Current
Pulsed
(Amps)
1.6
.500 25 08 - 50 05 - 100
.800 30 10 - 70 10 - 140
2.4
.800 35 12 - 90 12 - 180
1.100 45 15 - 150 15 - 250
3.2
1.100 60 20 - 200 20 - 300
1.500 90 25 - 250 25 - 350
17

TIG WELDING TROUBLESHOOTING
Troubleshooting - TIG Weld Quality
Fault Cause Remedy
Tungsten burning away quickly Incorrect gas Check that pure Argon is being used
No gas Check the gas cylinder contains gas and is connected
Inadequate gas flow Check the gas is connected, check hoses, gas valve and torch are not
restricted. Set the gas flow between 10 - 15 l/min flow rate
Back cap not fitted correctly Ensure the torch back cap is fitted so that the o-ring is inside the torch
body
Torch connected to DC + Connect the torch to the DC- output terminal
Incorrect tungsten being used Check and change the tungsten type if necessary
Tungsten being oxidised after weld is
finished
Keep shielding gas flowing 10–15 seconds after arc stoppage. 1 second
for each 10 amps of weld current.
Tungsten melting back into the nozzle on
AC welding
Check that correct type of tungsten is being used. Check the balance
control is not set too high on the balance - reduce to a lower setting
Contaminated Tungsten Touching tungsten into the weld pool Keep tungsten from contacting weld puddle. Raise the torch so that the
tungsten is off of the work piece 2 - 5mm
Touching the filler wire to the tungsten Keep the filler wire from touching the tungsten during welding, feed the
filler wire into the leading edge of the weld pool in front of the tungsten
Tungsten melting into the weld pool Check that correct type of tungsten is being used. Too much current for
the tungsten size so reduce the amps or change to a larger tungsten
Porosity - Poor weld appearance
and colour
Incorrect gas Check that pure Argon is being used
Inadequate gas flow / gas leaks Check the gas is connected and cylinder valve open, check hoses, gas
valve and torch are not restricted. Set the gas flow between 10 - 15 l/min
Moisture on the base metal Remove all moisture from base metal before welding
Contaminated base metal Remove materials like paint, grease, oil, and dirt, including mill scale
Contaminated filler wire Remove all grease, oil, or moisture from filler metal.
Incorrect filler wire Check the filler wire and change if necessary
Yellowish residue / smoke on the
alumina nozzle & discoloured tungsten
Incorrect Gas Use pure Argon gas
Inadequate gas flow Set the gas flow between 10 - 15 l/min flow rate
Inadequate post flow gas Increase the post flow gas time
Alumina gas nozzle too small for size of
tungsten being used Increase the size of the alumina gas nozzle
Unstable Arc during welding Torch connected to DC + Connect the torch to the DC- output terminal
Contaminated base metal Remove materials like paint, grease, oil, and dirt, including mill scale
Tungsten is contaminated Remove 10mm of contaminated tungsten and re grind the tungsten
Arc length too long Lower torch so that the tungsten is off of the work piece 2 - 5mm
HF present but no welding power Incomplete welding circuit Check earth lead is connected. Check all cable connections. If using a
water cooled torch check that the power cable is not separated.
No gas Check the gas is connected and cylinder valve open, check hoses, gas
valve and torch are not restricted. Set the gas flow between 10 - 15 l/min
Tungsten melting into the weld pool Check that correct type of tungsten is being used. Too much current for
the tungsten size so reduce the amps or change to a larger tungsten
Arc wanders during welding Poor gas flow Check and set the gas flow between 10 - 15 l/min flow rate
Incorrect arc length Lower torch so that the tungsten is off of the work piece 2 - 5mm
Tungsten incorrect or in poor condition Check that correct type of tungsten is being used. Remove 10mm from the
weld end of the tungsten and re sharpen the tungsten
Poorly prepared tungsten Grind marks should run lengthwise with tungsten, not circular. Use proper
grinding method and wheel.
Contaminated base metal Remove contaminating materials like paint, grease, oil, and dirt, including
mill scale from base metal.
Contaminated filler wire Remove all grease, oil, or moisture from filler metal.
Incorrect filler wire Check the filler wire and change if necessary
18

Troubleshooting - TIG Weld Quality (Continued)
Fault Cause Remedy
Arc difficult to start or will not
start welding
Incorrect machine set up Check machine set up is correct
No gas, incorrect gas flow Check the gas is connected and cylinder valve open, check hoses, gas
valve and torch are not restricted. Set the gas flow between 10 - 15 l/min
Tungsten is contaminated Remove 10mm of contaminated tungsten and re grind the tungsten
Incorrect tungsten size and or tungsten
being used Check and change the size and or the tungsten if required
Loose connection Check all connectors and tighten
Earth clamp not connected to work Connect the earth clamp directly to the work piece wherever possible
Loss of high frequency Check torch and cables for cracked insulation or bad connections. Check
spark gaps and adjust if necessary
MACHINE CARE & MAINTENANCE
WARNING!
BEFORE REPLACING CABLES / CONNECTIONS MAKE SURE THE WELDING MACHINE IS SWITCHED OFF AND DISCONNECTED FROM THE POWER SUPPLY OUTLET.
Ensure the items are disconnected from the electrical supply and cannot operate accidentally when, servicing or cleaning.
The machine does not require any special maintenance; however the user must be aware of the following:
• Regularly clean the ventilation slots.
• Keep the casing clean.
• Check all cables before use.
• Check electrode holders, work lead/clamps and welding torches before use.
• Replace worn electrode holders and earth clamps, which do not provide a good connection.
• Replace worn consumable parts in a timely manner.
• Replace worn wire drive rollers in a timely manner
• Use a soft cloth or brush to clean electrical components. Do not use liquid cleaning products, water or especially solvents.
• Do not use compressed air to clean electrical components as this can force dirt and dust further into components, causing electrical short circuits.
Check for damaged parts
Do not use the welder with damaged parts, before further use a damaged welder must be carefully checked by a qualified person to determine that it will operate
properly. Check for breakage of parts, mountings and other conditions that may affect its operation. An authorised service centre should properly repair a damaged
part.
Have your welder repaired by an expert
This appliance is manufactured in accordance with relevant safety standards. Only experts must carry out repairing of electrical appliances, otherwise considerable
danger for the user may result. Use only genuine replacement parts, which are available from your nearest Weldtech store. Do not use modified or non-genuine
parts.
Storing the Welder
When not in use the welder should be stored in the dry, out of reach of children and in a frost-free environment.
19

1. DURATION: The manufacturer warrants that it will repair, at no charge for parts or labour, the Welding Machine, Welding Gun, or Cables,
proven defective in material or workmanship, during the following time period after date of original retail purchase:
For 1 Year: The entire Welder and Arc Leads
2. WHO GIVES THIS WARRANTY
(Warrantor): EUROQUIP
109 Bolt Road
Stoke, Nelson
New Zealand 7011
Euroquip NZ: ++64 3 547 8409
Euroquip Australia: 1-800 -040947
3. WHO RECEIVES THIS WARRANTY (Purchaser): The original purchaser of this STRATA Welder.
4. WHAT IS COVERED UNDER THIS WARRANTY:
Defects in material and workmanship which occur within the duration of the warranty period. This warranty extends to the Welding
Machine, the Welder’s Transformer and Rectifier, Welding Gun or Electrode Holder and Cables only.
5. WHAT IS NOT COVERED UNDER THIS WARRANTY:
A. Implied warranties, including those of merchantability and FITNESS for a particular purpose are limited in duration to this express
warranty. After this period, all risks of loss, from whatever reason, shall be on the purchaser.
B. ANY INCIDENTAL, INDIRECT, OR CONSEQUENTIAL LOSS, DAMAGE, OR EXPENSE THAT MAY RESULT FROM ANY DEFECT, FAILURE OR
MALFUNCTION OF THIS PRODUCT.
C. This warranty does not apply to any accessory items included with the product which are subject to wear from usage; the repair or
replacement of these items shall be at the expense of the owner. These Mig items include, but are not limited to: Contact Tips, Nozzles, Gun
Liners, Drive Rollers, Felt Wire Cleaner. In addition, this warranty does not extend to any damage caused by the untimely replacement or
maintenance of any of the previously listed CONSUMABLE parts.
E. Pre-delivery service, i.e. assembly and adjustment.
6. RESPONSIBILITIES OF WARRANTOR UNDER THIS WARRANTY:
Repair or replace, at Warrantor’s option, products or components which have failed within duration of the warranty period.
7. RESPONSIBILITIES OF PURCHASER UNDER THIS WARRANTY:
A. Please call the store where purchased, or nearest available branch, or the numbers listed above for warranty assistance.
B. Provide dated proof of purchase and maintenance records.
C. All welders must be delivered or shipped to the nearest Service Agent, store where purchased or nearest available branch. Freight
costs, if any, must be borne by the purchaser.
D. Use reasonable care in the operation and maintenance of the products as described in the owner’s manual(s).
8. WHEN WARRANTOR WILL PERFORM REPAIR OR REPLACEMENT UNDER THIS WARRANTY: Repair or replacement will be scheduled and
serviced according to the normal work flow at the servicing location and depending on the availability of replacement parts.
WARRANTY
D. Any failure that results from accident, purchaser’s abuse, neglect or failure to operate products in accordance with instructions
provided in the owner’s manual(s) supplied with the product.
20
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