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

11
EZITIG200 AC/DC Welding Machine
www.weldtech.net.nz
Wiring Diagram

12
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)
MMA (Stick) Basic
Welding Guide
Size of Electrodes
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weld-
ingmachineswillonlyprovidecurrent(amperage)to
run smaller sized electrodes.
Forthinsections,itisnecessarytousesmallerelec-
trodes otherwise the arc may burn holes through
the job. A little practice will soon establish the most
suitableelectrode 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 to the negative polarity
and is connected to the work piece. If in doubt con-
sult the electrode data sheet.
Eects of MMA(Stick) Welding on
Various Materials
High Tensile and Alloy Steels
The two most prominent eects 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underbeadcracksintheweld
area may be reduced by using the correct elec-
trodes, preheating, using higher current settings,
using larger electrodes sizes, short runs for larger
electrode deposits or tempering in a furnace.
Manganese Steels
Theeectonmanganesesteelofslowcoolingfrom
hightemperaturescausesembrittlement.Forthis
reason it is absolutely essential to keep manganese
steelcool 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weld-
able. White iron, because of its extreme brittleness,

13
EZITIG200 AC/DC Welding Machine
www.weldtech.net.nz
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 rst choice for
repair or maintenance work.
E6013 - This all-position electrode is used for welding
clean, new sheet metal. Its soft arc has minimal spatter,
moderate penetration and an easy-to-clean slag.
E7014 - All positional, ease to use electrode for use on
thicker steel than E6013. Especially suitable for sheet metal
lap joints, llet welds and general purpose plate welding.
E7018 - A low-hydrogen, all-position electrode used when
quality is an issue or for hard-to-weld metals. It has the ca-
pability 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.
Electrodes for joining dierent metals:
Joint Preparations
In many cases, it will be possible to weld steel sec-
tions without any special preparation. For heavier
Open Square Butt Joint
(Fig 1-19a)
Gapvariesfrom1.6mm(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”)max.
1.6mm(1/16”)
Double Vee Butt Joint
(Fig 1-19d) Not less than 70°
1.6mm(1/16”)max.
1.6mm(1/16”)
Lap Joint (Fig 1-19e)
Fillet Joint (Fig 1-19f)
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 classied into a number
of groups depending on their applications. There are
a great number of electrodes used for specialised in-
dustrial 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 encoun-
tered; are all easy to use.
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.

14
Corner Weld
(Fig 1-19g)
Tee Joints
(Fig 1-19h)
Edge Joint
(Fig 1-19i)
Plug Welds
(Fig 1-19j)
Arc Welding Techniques
- 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otheplateand
set it rmly 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 be-
ginning 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 nd 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 worry-
ing 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 elec-
trode 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o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 rst experi-
ence diculty due to the tip of the electrode “stick-
ing”totheworkpiece.Thisiscausedbymakingtoo
heavy a contact with the work and failing to with-
draw the electrode quickly enough. A low amper-
age 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

15
EZITIG200 AC/DC Welding Machine
www.weldtech.net.nz
the parent metal. Draw the electrode slowly along
as it melts down.
Another diculty you may meet is the tendency, af-
ter 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.
20o
1.6mm(1/16”)
Striking an Arc
(Fig 1-20)
Arc Length
The securing of an arc length necessary to produce a
neat weld soon becomes almost automatic. You will
nd 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, ir-
regular blobs. The weld bead is attened 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 elec-
trode tip being solidied 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 main-
tain 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 ad-
justed 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 individ-
ual 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elec-
trode, 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 be-
tween 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 sucient to produce a
well-formed bead. At rst 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.
Tack Weld
Butt Weld
(Fig 1-21)
Electrode
20o- 30o
Tack Weld
Weld Build Up Sequence
(Fig 1-22)

16
Heavyplatewillrequireseveralrunstocompletethe
joint. After completing the rst 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 sec-
ond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 lled, 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.
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)llet.
Strikethearcandimmediatelybringtheelectrodeto
a position perpendicular to the line of the llet 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llet welds is
undesirable.
Electrode Position
for HV Fillet Weld
(Fig 1-23)
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 llet. The
electrode needs to be about 10º from the horizontal to
enableagoodbeadtobedeposited.ReferFig.1-25.
Multi-Runs in HV Fillet Weld
(Fig 1-24)
Single Run Vertical Fillet Weld
(Fig 1-25)
Weaving motion for
second and subsequent
runs
Pause at edge
of weave
Multi Run Vertical Fillet Weld
(Fig 1-26)
Useashortarc,anddonotattempttoweaveonthe
rst run. When the rst run has been completed de-
slag the weld deposit and begin the second run at
the bottom. This time a slight weaving motion is nec-
essary to cover the rst 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 edg-
es, 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eectsofpausingattheedgeofweave
and of weaving too rapidly.

17
EZITIG200 AC/DC Welding Machine
www.weldtech.net.nz
Examples of Vertical Fillet Welds
(Fig 1-27)
Pause at edge of weave
allows weld metal to build
up and eliminates undercut
Note: Weld contour
when insucient pause
at edge of weave
CORRECT INCORRECT
2. Vertical Down
TheE7014Stickelectrodemakesweldinginthispo-
sition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 up-
wardsatanangleofabout45º.
3. Overhead Welds
Apart from the rather awkward position necessary,
overhead welding is not much more dicult that
downhandwelding.Setupaspecimenforoverhead
welding by rst 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 llet welds.
Usea3.2mmE6013Stickelectrodeat100amps,and
deposit the rst run by simply drawing the electrode
along at a steady rate. You will notice that the weld
depositisratherconvex,duetotheeectofgravity
before the metal freezes.
Tilted 10oin
line of travel
Overhead Fillet Weld
(Fig 1-28)
Angle tacked to pipe
45oto plate

18
MMA (Stick) Troubleshooting

19
EZITIG200 AC/DC Welding Machine
www.weldtech.net.nz
TIG Basic Welding
Guide
TIGWeldingisafusionprocedurethatusesanelec-
tricARCcreatedbetweenaninfusibletungstenelec-
trodeandbasematerialtobewelded.ForTIGweld-
inganinertgasmustbeused(Argon)whichprotects
the welding bead. If lling material is used, it is made
up of rods suitable to the material to be welded
(steel,stainlesssteel,copperetc).
Electric Current
InertGas
Tungsten Electrode
Deposit
MeltedArea
Penetration
BaseMaterial
ProtectiveGas
Rod
Torch
TIG Welding
(Fig 15)
InTIGmode,weldingispossibleinallpositions:at,
angle,ontheedge,vertical andoverhead.Further-
more, with respect to other types of welding, the
welding joint has greater mechanical resistance,
greater corrosion resistance and limited heating in
the welded area which limits distortion. Welding can
be done even without weld material, guaranteeing a
smooth, shiny weld with no impurities or slag.
Tig Electrode Selection
and Preparation
Electrode Polarity
ConnecttheTIGtorchtothenegative(-)torchtermi-
nalandtheworkleadtothepositive(+)worktermi-
nal for direct current straight polarity. Direct current
straight polarity is the most widely used polarity for
DCTIG welding. It allows limited wear of the elec-
Tungsten Electrode
Tapered End
2.5xElectrodeDiameter
(Fig 16-1)
Preparing Tungsten for DC Electrode Negative
(DCEN) Welding
2.5 x Electrode Diameter
Grind end of tungsten on ne grit, hard abrasive
wheel before welding. Do not use wheel for other
jobs or tungsten can become contaminated causing
lower weld quality.
(Fig 16-2)
StableARC
Grinding
Wheel
Ideal Tungsten Preparation - Stable ARC
Diameter of the at determines amperage capacity.
Flat
StraightGround
trodesince70%oftheheatisconcentratedatthe
work piece.

20
(Fig 17)
Pointing the Electrode
The electrode should be pointed according to the
welding current.
(Fig 16-3) ARCWelder
Point
Grinding
Wheel
RadialGround
Wrong Tungsten Preparation - Wandering ARC
Diameter of the at determines amperage capacity.