WELDTECH EZITIG 200AC/DC User manual

OPERATING INSTRUCTIONS
EZITIG 200AC/DC
200A MULTI-PROCESS TIG WELDER
www.weldtech.net.nz

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Congratulations on your new Weldtech product!
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to produce welding products that combine market leading value and features with
durability. Designed for discerning operators who seek professional results and
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www.strata.co.nz
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We Appreciate Your Business!

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EZITIG200 AC/DC Welding Machine
www.weldtech.net.nz
Contents
KnowYourMachine..............................................5
Controls Explained.................................................6
Tips & Tricks.................................................................8
QuickStartGuide....................................................8
Care&Maintenance..............................................9
Available Parts & Accessories........................10
Wiring Diagram.....................................................10
MMA(Stick)BasicWeldingGuide................12
MMA(Stick)Troubleshooting.......................18
TIGBasicWeldingGuide...................................19
TIGTroubleshooting...........................................21
Knowledge&Resources..................................22
Safety .........................................................................22
Warranty....................................................................27

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4 Sensor Auto Helmet
with grind
function
(#DW3000)
2 Sensor Auto Helmet
(#DW2500)
Flip Front Helmet
(#AFF1000)
Optional accessories to help you get the job done!
Tungsten Electrodes - 150mm
• Thoriated for use on stainless and mild steel
• Zirconiated for use on aluminium.
Standard Collets
1.6 (#TCB10N23)
2.4 (#TCB10N24)
3.2 (#TCB10N25)
Standard Collet Bodies
1.6 (#TCB10N31)
2.4 (#TCB10N32)
3.2 (#TCB10N28)
Standard Ceramic Cups
1/2” (#TCC10N46)
7/16” (#TCC10N47)
3/8” (#TCC10N48)
Mild Steel TIG Rods - 1m
ER70S Grade
1.6 (#TR16MS-70S-6)
2.4 (#TR24MS-70S-6)
3.2 (#TR32MS-70S-6)
Aluminium TIG Rods - 1m
5356 Grade
1.6 (#TR16AL-5356)
2.4 (#TR24AL-5356)
3.2 (#TR32AL-5356)
Stainless Steel TIG Rods - 1m
316 Grade
1.6 (#TR16SS-316)
2.4 (#TR24SS-316)
3.2 (#TR32SS-316)
Thoriated
1.6 (#TT16-150)
2.4 (#TT24-150)
3.2 (#TT32-150)
Zirconiated
1.6 (#TZ16-150)
2.4 (#TZ24-150)
3.2 (#TZ32-150)

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EZITIG200 AC/DC Welding Machine
www.weldtech.net.nz
Know Your Machine
Explanations of control functions on following pages
1. Positive (+) welding power output connection socket
2. TIG torch gas connector
3. Negative (-) welding power output connection socket
4. TIG torch remote connection socket
Control Panel Detail
5. Trigger Mode Selection Button
6. 2T trigger mode indicator
7. 4T trigger mode indicator
8. AC/DC output mode selection button
9. AC output mode indicator
10. DC Output mode indicator
11. Welding mode selection button
12. HF TIG mode indicator
13. Lift TIG mode Indicator
14. MMA Mode Indicator
15. Pre gas ow setting indicator
16. Start current setting indicator
17. Up slope setting indicator
18. TIG peak welding current setting indicator
19. TIG base welding current setting indicator
20. Down slope setting indicator
21. End current setting indicator
22. Post gas ow setting indicator
23. Pulse mode ‘o’ indicator
24. Pulse mode ‘on’ indicator
1
42
3
5
8
7
10
96
13
15
16
17
18
23
26
25
24
30
31
32
33
29
11
12
14
19 20 21 22
27
28
25. Pulse width setting indicator
26. Pulse frequency setting indicator
27. Clean width area/ AC Balance adjustment
28. LCD Multifunction Display
29. MMA hot start setting indicator
30. MMA welding current indicator
31. MMA Arc Force setting indicator
32. Error/ Overload Indicator
33. Parameter select/ adjust knob

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TIG 2T/4T Trigger Control (5 - 7)
In2TModethetriggerispulledandheldontoacti-
vate the welding circuit, when the trigger is released,
the welding circuit stops. 4T is known as ’latching’
mode. The trigger is pulled once and released to ac-
tivate the welding circuit, pulled 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.TheEZITIG200AC/DCalsohas
more advanced current controls that can be used in
4T mode.
AC/DC Output Modes (8 - 10)
DC (Direct Current)Welding Output is suitable for
TIGweldingferrous(ironbased)metalssuchasmild
steel and stainless steel, copper and titanium.
TIG welding reactive metals such as Aluminium,
Magnesium and Zinc requires AC (alternating cur-
rent) output.When reactive metals are exposed to
air they form an oxide layer that insulates the base
metal and prevents welding current owing, it also
contaminatestheweldpool.Reversecurrentowis
requiredtobreakthrough/cleanothisoxidelayer
so that welding can take place, while the current
ow during the positive cycle does the majority of
the heating of the weld pool area.
TIG HF/ Lift Ignition Modes (12 - 13)
ForTIGweldingprocess,contactofthetorchtung-
sten to the workpiece will cause contamination of
the tungsten and the workpiece that will adversely
aecttheweldquality,especiallywhenthetungsten
iselectricallyenergised.HF(highfrequency)ignition
sends a pulse of high energy electricity through the
torch system that is capable of ‘jumping’ between
the tungsten and the workpiece, ensuring arc start-
ing without any contact between the tungsten and
workpiece.The disadvantage of HF ignition is that
the high energy electrical pulse creates signicant
electrical and radio signal interference, which limits
its use around sensitive electronic equipment such
as computers.
Lift TIG ignition is a compromise that minimises
tungsten contamination while eliminating the elec-
tricalinterferenceofHFstartsystems.Liftarcstart-
ing works by lightly resting the tungsten on the work
Controls Explained piece, activating the torch trigger signal and then
liftingthetungsteno.Thecontrolcircuitwillsense
when the tungsten is removed from the work piece
and send a low powered pulse of electricity through
thetungstenthatwillcausetheTIGarctoinitiate.Be-
cause the tungsten is not ‘live’ when it is in contact
with the work, contamination is minimised.
Pre Flow (15)
Pre ow controls the period shielding gas will ow
for when the torch is triggered before the arc starts.
This purges the work area of atmospheric gas which
could contaminate the weld before the weld starts.
Start Current Setting (16)
Available in 4T trigger mode only, sets a welding cur-
rent5-100%ofthemain weldingcurrentactivated
when the trigger is held on, to ‘latch’ the trigger
before the main weld current is started. Once the
trigger is released, the current will go through the
upslope(17)periodifitisset,tothemainwelding
current(18).
Up Slope (17)
When the trigger is activated, the welding current
will increase gradually over the time selected up to
thesetmainweldingcurrent(18).
Down Slope (20)
When the trigger is released, the welding current will
reduce gradually over the time selected down to 0.
This allows the operator to complete the weld with-
out leaving a ‘crater’ at the end of the weld pool.
End Current Setting (21)
Available in 4T trigger mode only, sets a welding cur-
rent5-100%ofthemain weldingcurrentactivated
when the trigger is held on, to ‘unlatch’ the trigger
beforetheweldisnished.Ifdownslope(20)isset,
the current will go through the downslope period
before going to the end current set. When the trig-
ger is released, the arc will stop.
Post Flow Gas (22)
Controls the period of time the shielding gas contin-
ues to ow for after the arc is stopped. This protects

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EZITIG200 AC/DC Welding Machine
www.weldtech.net.nz
the weld area and torch tungsten from contamina-
tion while it is still hot enough to react with atmos-
pheric gases, after the weld is nished.
Pulse Settings
Onlyavailablewhenpulsemode(24)isselected.
Base Current (19)
Setsthecurrentofthelow/basepulse.
Pulse Width (25)
Setsthetimeproportionasapercentagebetween
the peak current and base current when using pulse
mode. Neutral setting is 50% and 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eect.
Pulse Frequency (26)
Setstheratethattheweldingoutputalternatesbe-
tween the peak and base current settings.
Clean Width Area / AC Balance
Adjustment (27)
Adjusts the balance as a percentage between the for-
ward and reverse current cycles when welding in AC
output mode. The reverse part of the AC cycle gives
the‘cleaning’eectontheweldmaterial,whilethe
forward cycle melts the weld material. Neutral set-
ting is 0. Increased reverse cycle bias will give greater
cleaningeect,lessweldpenetrationandmoreheat
in the torch tungsten. This gives the disadvantage of
reducing the output current that can be used for a
given tungsten size to prevent the tungsten over-
heating.
Increased forward cycle bias will give the opposite
eect,lesscleaningeect,greaterweldpenetration
and less heat in the tungsten. Ideally for maximum
eectiveness, the clean width/ AC balance should
be set with as much forward cycle bias as possible,
while still maintaining a sucient level of oxidisa-
tion removal for a contamination free weld pool. The
cleaner the non-ferrous metal is before welding, the
moreeective it isto weld.This eectcanalso be
used to reduce heat in the tungsten, allowing use of
a pointed tungsten tip shape for a more dened arc.
LCD Multi-function Display (28)
Before welding displays the setting selected/being
adjustedusingthecontrolknob(33).Duringweld-
ing, displays welding current. The parameter setting
displayedisindicatedbytheLEDsbesidethedisplay;
Time(S),percentage(%),Frequency(Hz),Current(A),
Voltage(V)Ifleftinactiveforseveralseconds,display
will revert back to main welding current setting. Also
displayserrorcodesiftheprotectionsystem(32)is
activated.
MMA Settings
Hot start (29)
Hotstartprovidesextrapowerwhentheweldstarts
to counteract the high resistance of the electrode
and workpiece as the arc is started.
Arc Force (31)
AnMMAweldingpowersourceisdesignedtopro-
duceconstantoutputcurrent(CC).Thismeanswith
dierenttypesofelectrodeandarclength;theweld-
ing voltage varies to keep the current constant. This
can cause instability in some welding conditions as
MMAweldingelectrodeswillhaveaminimumvolt-
age they can operate with and still have a stable arc.
Arc Force control boosts the welding power if its
senses the welding voltage is getting too low. The
higher the arc force adjustment, the higher the mini-
mum voltage that the power source will allow. This
eectwillalsocausetheweldingcurrenttoincrease.
0isArcForceo,10ismaximumArcForce.Thisis
practically useful for electrode types that have a
higher operating voltage requirement or joint types
that require a short arc length such as out of position
welds.
Error Indicator (32)
Lightswhenovervoltage,overcurrentorelectrical
overheating(duetoexceedingdutycycle)isdetect-
ed and protection is activated. When protection is
activated, welding output will be disabled until the
safety system senses the overload has reduced suf-
cientlyandindicatorlampgoesout.Mayalsotrig-
ger if machine experiences an internal power circuit
failure.

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Parameter Select/ Adjust Knob (33)
Switch between welding parameter settings by
pressing this knob, adjust by turning the knob. Value
oftheparameterselectedwillbeshownontheLCD
display(28).
Quick Start Guide
Electrical Connection
The EZITIG 200AC/DC is designed to operate on
a15A230VACpowersupply.Ifanextensioncord
must be used, it should be a heavy duty version with
aminimumcablecoresizeof2.5mm2.Itisrecom-
mendedtousetheEuroquipindustrialduty15Aex-
tensionlead,partnumber;16895.
Operating Environment
Adequate ventilation is required to provide proper
coolingfortheEZITIG200AC/DC.Ensurethat the
machine is placed on a stable level surface where
clean cool air can easily ow through the unit. The
EZITIG200 AC/DC has electrical components and
control circuit boards which may be damaged by
excessive dust and dirt, so a clean operating environ-
ment is important for reliable product life.
Basic Operation - MIGWelding
1. ARC/MMA Welding Operation
1.1 Connect the earth cable quick connector to the
negative welding power output socket (3) Con-
nect the earth clamp to the work piece. Contact
with the work piece must be rm contact with
clean, bare metal, with no corrosion, paint or scale
at the contact point.
1.2 Insert an electrode into the electrode holder and
connect the electrode holder and work lead to the
positiveweldingpoweroutputsocket(1).
NOTE: This polarity connection conguration is valid for
most GP (General Purpose) MMA electrodes. There are vari-
ances to this. If in doubt, check the electrode specications
or consult the electrode manufacturer.
1.3 Connect the machine to suitable mains power us-
ingthemainsinputpowerlead.Switchthemains
Pulse Welding
Pulse welding mode switches the welding output
between a high and low current output in a cyclical
manner. When used correctly this function has sub-
stantialbenetsintheTIGweldingprocessincluding
greater weld penetration for less work heat input and
greater control of the weld pool.
The basic theory for setting the base current using
pulse mode is that the base current should be suf-
cient to maintain the existing molten weld pool,
while the peak current is sucient to melt new metal
inordertomove/expandthemoltenweldpool.In-
creasedpulsefrequencywillhavetheeectofmak-
ing the arc more tightly focused which is useful for
ne stainless work and similar.
Pulsing can also be used to help move the weld pool,
this technique is useful for welding out of position or
with materials that have higher viscosity weld pool.
Higherpulsedutysettingwillgivegreaterheatinput,
whilelowerpulsedutywillhavetheoppositeeect.
Remote Current Control
The EZITIG 200 AC/DC can accept remote current
control from a potentiometer/ analogue signal or
adigitalup/downbutton signal.Potentiometer re-
mote control will change the current from the 5A
minimum to the maximum set using the machine
currentcontrol(30).Usinganup/downbuttonre-
mote signal, the current may be increased or de-
creased in 1A increments, or ‘scrolls’ up to 30A at a
time if the button is held down. This is very useful
forprecision work. Refer to theaccessoriessection
further on in this manual for the options available.
Duty Cycle Rating
Welding duty cycle is the percentage of actual weld-
ing time that can occur in a ten minute cycle. E.g.
20%at160amps-thismeanstheweldercanweldat
160 amps for 2 minutes and then the unit will need
Tips & Tricks
to be rested for 8 minutes. All duty cycle ratings are
based on an ambient air temperature of 40°C with
50% humidity, which is the international standard
for such a rating. In an environment with tempera-
tures exceeding 40°C, the duty cycle will be less than
stated. In ambient temperature less than 40°C, duty
cycle performance will be higher.

9
EZITIG200 AC/DC Welding Machine
www.weldtech.net.nz
powerswitchto‘on’topowerupthemachine.Set
MMAweldingmode(14).
1.4 Settheweldingparametersasrequiredfollowing
the instructions in the previous section. You are
now ready to weld!
2. TIG Operation
NOTE: TIG operation requires an argon gas supply.
2.1 Connect the earth cable quick connector to the
positiveweldingpoweroutputsocket(1).Connect
the earth clamp to the work piece. Contact with
the work piece must be rm contact with clean,
bare metal, with no corrosion, paint or scale at the
contact point.
2.2 InsertTIGtorchpowerconnectionintothenega-
tiveweldingpoweroutputsocket(3).ConnectTIG
torchremoteplugtoremotesocket(4)andtorch
gasconnectiontotheTIGgasoutlet(2).
2.3 Connect the machine to suitable mains power us-
ingthemainsinputpowerlead.Switchthemains
powerswitchto‘on’topowerupthemachine.Set
theweldingmodeto‘LiftTIG’(13)or‘HFTIG’(12).
2.4 Assemble the female gas quick connector to the
gas line and to the regulator outlet tting. Connect
thegasregulatortoa gas cylinder(not included
withmachine)andconnectthefemalequickcon-
nector to the male gas inlet on the rear of the ma-
chine.Ensureallconnectionsaretight.Opengas
cylinder valve and adjust regulator, ow should be
between 5-10 l/min depending on application.
Re-check regulator ow pressure with the torch
triggered as static gas ow setting may drop once
gas is owing.
2.5 Settheweldingparametersasrequiredfollowing
the instructions in the previous section. You are
now ready to weld!
Care &
Maintenance
Keep your Welding Machine
in Top Condition
TheEZITIG200AC/DCdoes not requireany special
maintenance, however the user should take care of
the machine as follows:
• 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torchconsumablepartsinatimely
manner.
• Replacewornwiredrivecomponents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.
If damaged, before further use, the welder must be
carefully checked by a qualied person to determine
that it will operate properly. Check for breakage of
parts, mountings and other conditions that may
aectitsoperation.
Haveyourwelderrepairedbyanexpert.Anauthorised
service centre should properly repair a damaged
part. 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. Do not use modied or
non-genuine parts.
Storing the Welder
When not in use the welder should be stored in the
dry and frost-free environment.
WARNING! Before performing cleaning/main-
tenance, replacing cables / connections , make
sure the welding machine is switched o and
disconnected from the power supply.

10
17827 Pro-Grip26TorchX12Ft,TgcEnd(LargeDinse)M12
17401 StrataTIGFootControl
AAL3550 ArcLead16mm2cable,35-70mmplug,4m
AEL3550 EarthLead16mm2cable,35-70mmplug,3m
17403 StrataWaterCoolingUnit230V
17384 StrataCompactWeldingMachineTrolley
ALS3550 MMALeadSet300A3+3m1/2”DinseConnectors
S400EH 400AScrewTypeElect.Holder
S500EC Strata500aEarthClamp
CP3550 CablePlug-35-50mm³-Male
DW3000 AutoDarkeningHelmet,Shade9-13
DW4000 AutoDarkeningHelmet,Shade9-13w/GrindingVisor
DW7000 AutoDarkeningHelmet,Shade9-13w/GrindingVisor
 andPRSLFiltrationSystem.
GR101AR ArgonTwinGaugeRegulator
GR101ARFL ArgonGasRegulatorc/wFlowMeter
GR101AR-2FL ArgonRegulatorc/wTwinFlowMeter
16895 15mH/D15AExtensionLead(3x2.5mm2wiring)
TBC57Y02 LongBlackCap
TC10N23 Collet1/16(1.6mm)(2pk)
TC10N24 Collet3/32(2.4mm)(2pk)
TC10N25 Collet1/83.2mm(2pk)
TCB10N31 Colletbody1/16(1.6mm)(2pk)
TCB10N32 Colletbody3/32(2.4mm)(2pk)
TCB10N28 Colletbody1/8(3.2mm)(2pk)
TCC10N48 Std.ceramiccup3/8bore#6(2pk)
TCC10N47 Std.ceramiccup7/16bore#7(2pk)
TCC10N46 Std.ceramiccup1/2bore#8(2pk)
TCC10N45 Std.ceramiccup5/8bore#10(2pk)
TT16-150 ThoriatedTungstenElectrode1.6mm(3pk)
TT24-150 ThoriatedTungstenElectrode2.4mm(3pk)
TT32-150 ThoriatedTungstenElectrode3.2mm(3pk)
TZ16-150 ZirconiatedTungstenElectrode1.6mm(3pk)
Available Parts & Accessories
These accessories listed are available from your Weldtech Supplier. Refer to the Weldtech Product
Brochure, your Weldtech Supplier or look online at www.weldtech.net.nz for other accessories and
consumables available.
EZITIG 200AC/DC:
TZ24-150 ZirconiatedTungstenElectrode2.4mm(3pk)
TZ32-150 ZirconiatedTungstenElectrode3.2mm(3pk)
ACDCKIT AC/DCTIGStarterKit-WP17,WP18,WP26
TR16MS-70S-6 MildSteelTIGRod1.6mm/1kg
TR24MS-70S-6 MildSteelTIGRod2.4mm/1kg
TR32MS-70S-6 MildSteelTIGRod3.2mm/1kg
TR16SS-316 StainlessSteelTIGRod1.6mm
TR24SS-316 StainlessSteelTIGRod2.4mm
TR32SS-316 StainlessSteelTIGRod3.2mm
TR16AL-5356 AluminiumTIGRod1.6mm/0.5kg
TR24AL-5356 AluminiumTIGRod2.4mm/0.5kg
TR32AL-5356 AluminiumTIGRod3.2mm/0.5kg
TZ16-150 ZirconiatedTungstenElectrode1.6mm(3pk)
TZ24-150 ZirconiatedTungstenElectrode2.4mm(3pk)
TZ32-150 ZirconiatedTungstenElectrode3.2mm(3pk)
ETCPH4825 OvercordR922.5mmElectrodes(350mm)
ETCPH4832 OvercordR923.2mmElectrodes(350mm)
ETCPH4840 OvercordR924.0mmElectrodes(350mm)
ETCPH6825 Overcord2.5mmElectrodes(350mm)
ETCPH6832 Overcord3.2mmElectrodes(350mm)
ETCPH6840 Overcord4.0mmElectrodes(350mm)
ETCPH6850 Overcord5.0mmElectrodes(350mm)
ETCPH7725 Supercito2.5mmElectrodes(350mm)
ETCPH7732 Supercito3.2mmElectrodes(450mm)
ETCPH7740 Supercito4.0mmElectrodes(450mm)
ETCPH7750 Supercito5.0mmElectrodes(450mm)
ETCPH56S25 Tenax56S2.5mmElectrodes(350mm)
ETCPH56S32 Tenax56S3.2mmElectrodes(350mm)
ETCPH56S40 Tenax56S4.0mmElectrodes(450mm)
ETCPH56S50 Tenax56S5.0mmElectrodes(450mm)
PDL15 Plug,3Pin15A250V-Straight
17844 GasInletQC
17847 12PinStrataTIGRemoteConnectionPlug