Inver ter Powered 200iDV AC/DC TIG OWNER’S MANUAL 04/2018 WARNING: Read carefully and understand all ASSEMBLY AND OPERATION INSTRUCTIONS before operating. Failure to follow the safety rules and other basic safety precautions may result in serious personal injury.
WARRANTY METAL MAN WORK GEAR CO EFFECTIVE JANUARY 1, 2013 LIMITED WARRANTY This warranty applies to the original purchaser and is subject to the terms and conditions listed below. This Limited Warranty is for new equipment sold after the above date, providing coverage for defects in material and workmanship at the time it is shipped from the factory.
GENERAL SAFETY RULES WARNING: Read and understand all instructions. Failure to follow all instructions listed below may result in serious injury. CAUTION: Do not allow persons to operate or assemble this Flux Core 125 until they have read this manual and have developed a thorough understanding of how the Flux Core 125 works. WARNING: The warnings, cautions, and instructions discussed in this instruction manual cannot cover all possible conditions or situations that could occur.
-Do not allow any body part to come in contact with the welding wire if you are in contact with the material being welded, ground or electrode from another welder. -Do not weld if you are in an awkward position. Always have a secure stance while welding to prevent accidents. Wear a safety harness if working above ground. -Do not drape cables over or around your body. -Wear a full coverage helmet with appropriate shade (see ANSI Z87.1 safety standard) and safety glasses while welding.
your eyes and skin. Do not look at the welding arc without proper eye protection. -Always use a helmet that covers your full face from the neck to top of head and to the back of each ear. -Use a lens that meets ANSI standards and safety glasses. For welders under 160 Amps output, use a shade 10 lens; for above 160 Amps, use a shade 12. Refer to the ANSI standard Z87.1 for more information. -Cover all bare skin areas exposed to the arc with protective clothing and shoes.
Electromagnetic Field -Electromagnetic fields can interfere with various electrical and electronic devices such as pacemakers. -Consult your doctor before using any electric arc welder or cutting device -Keep people with pacemakers away from your welding area when welding. -Do not wrap cable around your body while welding. -Wrap MIG gun and ground cable together whenever possible. -Keep MIG gun and ground cables on the same side of your body.
TECHNICAL SPECIFICATIONS Item Specification Output No Load Voltage 120V, 20A, 50/60 Hz, Single Phase 230V, 35A, 50/60 Hz, Single Phase 65V Rated Duty Cycle 35% @ 200A Power Supply DC TIG Output Range AC TIG Output Range Stick Welding Output Range Pulse Frequency AC Arc Frequency AC Arc Balance Control Weight Dimension L×W×H 10 - 95A with 120V Input Power 10 - 200A with 230V Input Power 20 - 95A with 120V Input Power 20 - 200A with 230V Input Power 20 - 65A with 120V Input Power 20 - 160A with 230V I
Weld Process Indicator Digital Functional Lights Meters Control Indicators Electrode Holder And Weld Cable Regulator/Flowgauge With Gas Hose Weld Parameter Setting Indicators Electrode Holder TIG Torch And Cable Remote Foot Pedal Control GROUND CABLE AND CLAMP The ground cable and clamp are attached to the work piece to complete the circuit allowing the flow of current needed to weld. REGULATOR/FLOWGAUGE AND GAS HOSE The regulator nstalls directly on the shielding gas cylinder.
ASSEMBLY Electrical Shock Can Kill! High voltage danger from power source! Consult a qualified electrician for proper installation of receptacle. This welder must be grounded while in use to protect the operator from electrical shock. Do not remove grounding prong or alter the plug in any way. Use only the supplied adapter between the welder's power cord and the power source receptacle.
5. TIG WELDING CONNECTION – DC TIG welding is generally performed DC Electrode negative. That means that the TIG torch and cable would be attached to the Negative (-) weld output connection and the ground cable and clamp would be attached to the Positive (+) weld output connection. Use this same connection when AC TIG welding. Connect the Remote Foot Pedal to the Remote connection on the lower front panel. Connect the TIG torch gas supply line to the Gas Outlet on the lower front panel.
7. GAS INSTALLATION Shielding gas cylinders and high pressure cylinders can explode if damaged, so treat them carefully. Never expose cylinders to high heat, sparks, open flames, mechanical shocks or arcs. Do not weld on the cylinder. Always secure cylinder upright to a cart or stationary object. Keep cylinders away from welding or electrical circuits. Use the proper regulators, gas hose and fittings for the specific application. a.
heard when the remote is activated. No gas flow will result in a harsh arc. Gas selection: Except for very specialized TIG welding applications, TIG welding can be done with 100% Argon. Consult your gas supplier for more information. 8. REMOTE CONTROL INSTALLATION NOTE: When stick welding, remove all remote controls. Failure to do this will result in minimal welding output only. Remote Contactor and Amperage Control – This unit comes standard with a remote foot pedal control.
1. PROCESS SELECTION AVOID ACCIDENTAL ARCING When in the STICK welding mode, the weld output connections of this unit are electrically hot. To avoid accidental arcing, be mindful of the welding accessories that are connected to the weld output connections. Make certain the welding accessories connected to this unit are not touching each other and are not electrically connected to each other. Weld Process Indicator Lights Push to Sequence Through Weld Processes a.
Weld Parameter Indicator Lights Weld Process Indicator Lights Push to Sequence Through Weld Processes Weld Parameter Adjustment a. See the ASSEMBLY section for the correct welding accessories connections for DC Stick Welding. b. Turn the input power switch ON. c. Press the button below the weld process indicators until the weld process indicator light next to DC Stick is on. d. Press the button below the weld parameter indicator lights until the Indicator Light is ON for the Current (A) Weld Parameter.
Weld Parameter Indicator Lights Weld Process Indicator Lights Push to Sequence Through Weld Processes Weld Parameter Adjustment f. Turn the Parameter Adjustment Control until the Digital Meter displays the desired Current (A) setting. This is the current setting that the operator wants when the foot pedal is completely pressed to the maximum.
4. AC TIG SET-UP a. See the ASSEMBLY section for the correct welding accessory connections for AC TIG Welding. b. Turn the input power switch ON. c. Press the Weld Process Selector button until the Weld Process Indicator Light next to AC TIG is on. i. If the operator wants to use Pulse AC TIG, press the Weld Process Selector until the Weld Process Indicator Light next to Pulse AC TIG is on.
maximum setting by varying the amount the operator is pressing down on the foot pedal. 1. If the operator is using Pulse AC TIG, this setting will be the maximum peak amperage, or the amperage that the welder will pulse up to when the foot pedal is completely pressed to the maximum. 2. As the operator varies the amount they are pressing down on the foot pedal, the peak amperage and background amperage will automatically be adjusted proportionally. e. CURRENT (A) i.
DC STICK OPERATION • High voltage danger from power source! Consult a qualified electrician for proper installation of receptacle. This cutter must be Grounded while in use to protect the operator from electrical shock. • Do not remove grounding prong or alter the plug in any way. Use only the supplied adapter between the welder's power cord and the power source receptacle.
2. GROUND CLAMP CONNECTION Clear any dirt, rust, scale, oil or paint on the ground clamp. Make certain you have a good solid ground connection. A poor connection at the ground clamp will waste power and heat. Make sure the ground clamp touches the metal. 3. ELECTRODE The welding electrode is a rod coated with a layer of flux. When welding, electrical current flows between the electrode (rod) and the grounded metal work piece.
4.1. When proper rod is used: 4.1.a. The bead will lay smoothly over the work without ragged edges 4.1.b. The base metal puddle will be as deep as the bead that rises above it 4.1.c. The welding operation will make a crackling sound similar to the sound of eggs frying 4.2. When a rod too small is used: 4.2. a. The bead will be high and irregular 4.2. b. The arc will be difficult to maintain 4.3. When the rod is too large: 4.3. a. The arc will burn through light metals 4.3. b.
work piece should be between 10 and 30 degrees. This will allow for good penetration, with minimal spatter. 6.2 Striking the arc EXPOSURE TO A WELDING ARC IS EXTREMELY HARMFUL TO THE EYES AND SKIN! Prolonged exposure to the welding arc can cause blindness and burns. Never strike an arc or begin welding until you are adequately protected. Wear flame-proof welding gloves, a heavy long sleeved shirt, trousers without cuffs, high topped shoes, and an ANSI approved welding helmet.
The weave bead: Used when you want to deposit metal over a wider space than would be possible with a stringer bead. It is made by weaving from side to side while moving with the electrode. It is best to hesitate momentarily at each side before weaving back the other way. 6.4 Welding position Flat position: It is easiest of the welding positions and is most commonly used. It is best if you can weld in the flat position if at all possible as good results are easier to achieve.
accumulation of dirty metal scale on the finished weld. Slag should be removed by using a chipping hammer. PEENING THE SLAG FROM A WELD JOINT CAUSES SMALL CHIPS OF METAL TO FLY THROUGH THE AIR! Metallic chips flying through the air can cause eye injury or injury to other parts of the head, hands or exposed portions of the body.
BASIC TIG WELDING OPERATION High voltage danger from power source! Consult a qualified electrician for proper installation of receptacle at the power source. This welder must be grounded while in use to protect the operator from electrical shock. If you are not sure if your outlet is properly grounded, have it checked by a qualified electrician. Do not cut off the grounding prong or alter the plug in any way and do not use any adapter between the welder's power cord and the power source receptacle.
Guide for Selecting F iller W ire Diameter Tungsten Electrode T ypes Aluminum W elding Material W elding Rate Page 25 of 33
TIG W elding is generally regarded as a sp ecialized p rocess tha t requires operato r competenc y. W hile many of the p rinciples outlined in th e pre vious Arc W elding section a re a pplicable a comprehensive outline of the TIG W elding process is outside th e scope of this O pe ra ting Manual .
MAINTENANCE • High voltage danger from power source! Consult a qualified electrician for proper installation of receptacle. This cutter must be Grounded while in use to protect the operator from electrical shock. • Do not remove grounding prong or alter the plug in any way. Use only the supplied adapter between the plasma cutter's power cord and the power source receptacle.
TROUBLESHOOTING Failure Possible Cause Unit does not power up. Temperature indicator is on. Alarm indicator is on. TIG arc does not start. Stick amperage seems low. There is no shielding gas. Cooling fan working. is not There is no display on the digital meters. Corrective Action Unit is not plugged in. Plug in unit. Input power circuit breaker is not on. Reset input power circuit breaker. The main power switch is not working. Replace main power switch.
MAIN CIRCUIT CHART Page 29 of 33
DIAGRAM & PARTS LIST Page 30 of 33
Reference 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 Part Number 105500121 145500001 105500087 145200001 105500123 105500094 105500095 105500096 105200212 105400098 105300116 105500124 105500125 105500101 105200116 105500097 105500102 105500104 105500030 105500103 105500126 105500127 105500107 105500106 105500033 105500108 105500128 105500109 105500129 105500037 105200131 105200136 105500131 105500132 145500002 105500113 145500003 1055
Reference # Part# 1 105500012 NOZZLE #5 1 1 105500013 NOZZLE#6 1 1 105500014 NOZZLE#7 1 2 105500078 COLLET BODY 1 3 105500010 COLLET 1 4 105500079 TORCH HEAD 1 5 105500080 SHORT BACK CAP 1 105500081 LONG BACK CAP 1 6 105500082 CONNECTOR ASSEMBLY 1 7 105500083 TIG TORCH HANDLE 1 8 105500084 TIG TORCH GAS HOSE 1 9 105500085 TIG TORCH CONTROL CABLE 1 10 105500086 M10 X 1 TORCH CONNECTOR 1 Description Page 32 of 33 Qty.
Metal Man Work Gear Company 1760 Prospect Ct #120 Appleton, WI 54914 ww w . m e ta l m a n g e a r.
