Eastwood TIG 200 LCD (61500) - WELDER Manual

CONTENTS

(1) TIG 200 LCD Welder [A]
(1) Flex Head TIG Welding Torch/12 ft. [3.65m] and Cable Assembly with 3/32" Collet Body and Collet, #8 Gas Lens and Long Back Cap pre-installed [B]
(1) Ground Cable/Clamp Assembly, 9.5 ft. [2.9m] [C]
(1) Argon Regulator/Flowmeter [D]
(1) Shielding Gas Hose, 4.6 ft. [1.4m] [E]
(1) 240V NEMA 6-50R to 120V NEMA 5-15P Adapter Cord, 2 ft. [0.6m] [F]
(1) Foot Pedal with Cable Assembly, 16 ft. [4.85m] [G]
(1) 1/16" Collet [H]
(1) Spare #8 Gas Lens [J]
(1) 1/16" Collet Body, with Diffuser [K]
(1) Tungsten 3/32" x 6", Red [L]
(1) Tungsten 3/32" x 6", Green [M]

SPECIFICATIONS

Power voltage (V)	1 phase, 120 VAC/240 VAC, 50/60 Hz
Maximum Output No Load Voltage (V)	69V DC
Rated Input Current: TIG (Amps)	120V: 25.3 Amps 240V: 25.7 Amps
Rated Input Current: Stick (Amps)	120V: 42.5 Amps 240V: 35.0 Amps
Output Current Range: TIG (Amps)	120V: 5 to 120 Amps 240V: 5 to 200 Amps
Output Current Range: Stick (Amps)	120V: 20 to 120 Amps 240V: 20 to 180 Amps
Duty cycle (%), TIG 120V	20% @ 120 Amps 60% @ 70 Amps 100% @ 54 Amps
Duty cycle (%), Stick 120V	20% @ 120 Amps 60% @ 70 Amps 100% @ 54 Amps
Duty cycle (%), TIG 240V	20% @ 200 Amps 60% @ 115 Amps 100% @ 89 Amps
Duty cycle (%), Stick 240V	20% @ 180A 60% @ 103 Amps 100% @ 80 Amps
Pre Gas Flow (Sec) Post Gas Flow (Sec)	0.1 - 1.0 Sec 0 - 15 Sec
Maximum Material Thickness	1/4"
Programmable Preset Slots	5
Weight	34.17 LBS. [15.5KG]
Dimensions	18.27" x 8.39" x 15.94" [464mm x 213mm x 405mm]

DUTY CYCLE

The rated Duty cycle refers to the amount of welding that can be done within an amount of time. It is easiest to look at your welding time in blocks of 10 minutes and the Duty Cycle being a percentage of that 10 minutes. If welding at 115 Amps with a 60% Duty Cycle, within a 10 minute block of time you can weld for 6 minutes with 4 minutes of cooling for the Welder.

If the Duty Cycle is exceeded, and the built-in Breaker is tripped, allow the unit to cool for a minimum of 15 minutes. When a safe temperature has been reached, the Welder can be switched back on. To increase the duty cycle, turn down the Amperage Output Control. Going above 115 Amps will yield a lower Duty Cycle.

SAFETY INFORMATION

READ AND UNDERSTAND ALL INSTRUCTIONS AND PRECAUTIONS BEFORE PROCEEDING.
This unit emits a powerful high voltage and extreme heat which can cause severe burns, electrical shock and death.

These instructions are intended only to provide the user with some familiarity of the Eastwood TIG 200 LCD Welder.

Electric Welding is a highly complex procedure with many variables. If you have no prior experience with Electric Welding, it is extremely important to seek the advice of someone experienced in Electric Welding for instruction, enroll in a local technical school welding course or study a comprehensive how-to DVD and obtain a good quality reference book on Electric Welding as there is a moderate learning curve necessary before achieving proficiency in Welding different metals such as steel, stainless steel and aluminum. It is also strongly recommended that the user adhere to the American Welding Society guidelines, codes, and applications prior to producing welds where safety is affected.

Welding can be dangerous to you and other persons in the work area. Read and understand this instruction manual before using this Eastwood welding machine. Injury or death can occur if safe welding practices are not followed. Safety information is set forth below and throughout this manual. Save these instructions for future reference.

To learn more about welding safety, read OSHA Title 29 CFR 1910, available at www.osha.gov; ANSI Z49.1, "Safety in Welding, Cutting and Allied Processes," available at www.aws.org; and the consumable manufacturer's Safety Data Sheets.

The following explanations are displayed in this manual, on the labeling, and all other information provided with this product:

indicates a hazardous situation which, if not avoided, will result in death or serious injury.

indicates a hazardous situation which, if not avoided, could result in death or serious injury.

indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE is used to address practices not related to personal injury.

ELECTRIC SHOCK CAN CAUSE INJURY OR DEATH!

• Improper use of an electric Welder can cause electric shock, injury, and death! Read all precautions described in the Welder Manual to reduce the possibility of electric shock.
• Disconnect Welder from power supply before performing any assembly, disassembly, or maintenance of the TIG Torch.
• Always wear dry, protective clothing and leather welding gloves and insulated footwear. Use suitable clothing made from durable flame-resistant material to protect your skin.
• If other persons or pets are in the area of welding, use welding screens to protect bystanders from sparks.
• Always operate the Welder in a clean, dry, well-ventilated area. Do not operate the Welder in humid, wet, rainy, or poorly ventilated areas.
• The electrode and work (or ground) circuits are electrically "hot" when the Welder is on. Do not allow these "hot" parts to come in contact with bare skin or wet clothing.
• Stay separated from the welding circuit by using insulating mats to prevent contact from the work surface.
• Be sure that the work piece is properly supported and grounded prior to beginning an electric welding operation.
• Always attach the Ground Clamp to the piece to be welded and as close to the weld area as possible. This will give the least resistance and best weld.

WELDING SPARKS CAN CAUSE FIRE OR EXPLOSION!

• Electric welding produces sparks which can be discharged considerable distances at high velocity igniting flammable or exploding vapors and materials
  DO NOT operate electric arc Welder in areas where flammable or explosive vapors are present.
  DO NOT use near combustible surfaces. Remove all flammable items from the work area where welding sparks can reach (minimum of 35 feet).
• Always keep a fire extinguisher nearby while welding.
• Use welding blankets to protect painted and or flammable surfaces, rubber weather-stripping, dash boards, engines, etc.

ELECTROMAGNETIC FIELDS CAN BE A HEALTH HAZARD!

• The electromagnetic field that is generated during arc welding may interfere with various electrical and electronic devices such as cardiac pacemakers. Anyone using such devices should consult with their physician prior to performing any electric welding operations.
• Exposure to electromagnetic fields while welding may have other health effects which are not known.

ARC RAYS CAN INJURE EYES AND BURN!

• Arc rays produce intense ultraviolet radiation which can burn exposed skin and cause eye damage. Use a shield with the proper filter (a minimum of #11) to protect your eyes from sparks and the rays of the arc when welding or when observing open arc welding (see ANSI Z49.1 and Z87.1 for safety standards).
• Use suitable clothing made from durable flame-resistant material for skin protection.
• If other persons or pets are in the area of welding, use welding screens to protect bystanders from sparks and arc rays.

FUMES AND WELDING GASES CAN BE A HEALTH HAZARD!

• Fumes and gasses released during welding are hazardous. Do not breathe fumes that are produced by the welding operation.
• Prolonged inhalation of welding fumes above safety exposure limits can injure the lungs and other organs.
• Use enough ventilation and/or exhaust at the arc to keep fumes and gases from your breathing area.
• Use an OSHA approved respirator when welding in confined spaces or where there is inadequate ventilation.
• Never weld coated materials including but not limited to: cadmium plated, galvanized, lead based paints.

BUILDUP OF GAS CAN INJURE OR KILL!

• Shut off gas supply when not in use.
• Ensure adequate ventilation
• Do not weld in confined areas.
• Always turn your face away from valve outlet when opening cylinder valve.

CYLINDERS CAN EXPLODE IF DAMAGED!

Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. As gas cylinders are a normal component of the welding process, use extra care to handle them carefully.

• Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs. Keep away from any welding or other electrical circuits.
• Install cylinders in an upright position by securing to a specifically designed rack, cart, or stationary support to prevent falling or tipping over.
• Never weld on a pressurized cylinder or explosion will occur.
• Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and all related components in good condition.
• Keep protective cap in place over valve except when cylinder is in use.
• Use proper equipment, procedures and have adequate help when moving or lifting cylinders.

HOT METAL AND TOOLS WILL BURN!!

• Electric welding heats metal and tools to temperatures that will cause severe burns!
• Use protective, heat resistant gloves and clothing when using Eastwood or any other welding equipment.
  Never touch welded work surface, the TIG Torch, nozzle or tungsten until they have completely cooled.

FLYING METAL CHIPS CAN CAUSE INJURY!

• Grinding and sanding will eject metal chips, dust, debris, and sparks at high velocity. To prevent eye injury wear approved safety glasses.
• Wear an OSHA-approved respirator when grinding or sanding.
• Read all manuals included with specific grinders, sanders or other power tools used before and after the welding process. Be aware of all power tool safety warnings.

NOTICE: FIRST AID

• If exposed to excessive fumes move to an area with fresh air. Follow safety information on the tungsten electrode, filler rod and stick electrode manufacturers' Safety Data Sheets.
• For other injuries follow basic first aid techniques and call physician or emergency medical personnel.

CONNECTING THE WELDER TO A POWER SOURCE

The Eastwood TIG 200 LCD Welder requires a dedicated 240 VAC, 50 AMP, circuit breaker protected outlet. The plug installed on the Welder is a NEMA 6-50P and should be used with a NEMA 6-50R receptacle.

As an alternative, by using the included Adapter Cord, the TIG 200 AC/DC can be used with a 120 VAC, 20 AMP, 60HZ grounded NEMA 5-15R outlet protected by a circuit breaker.

If using an extension cord, we recommend using our Welder Extension Cords for optimal performance: Eastwood items #31739, #20029, and #20285.

CONTROL AND DISPLAY PANEL

FRONT UPPER PANEL

(FIG 1)

1. Navigation Knob: Rotate Knob clockwise and counterclockwise to scroll right and left, respectively. Press Knob to select or confirm highlighted option.
2. Return Button: Press Button to return to the previous screen or exit an option.
3. LCD Screen: The LCD display screen is where all welder settings and options are accessed.

NOTE: The LCD display is NOT a touch screen. Excessive pressure to the screen may result in damage.

FRONT LOWER PANEL

(FIG 2)

1. TIG Torch connection
2. Ground connection
3. TIG Trigger and Foot Pedal connection
4. Electrode Holder connection

REAR PANEL

(FIG 3)

5. 240 VAC Power Cord
6. Shielding Gas connection
7. ON/OFF Switch

TIG 200 LCD WELDER SET-UP

The Eastwood TIG 200 LCD is factory set-up for TIG Welding use with a 3/32" Tungsten (included, not installed) and 100% Argon Shielding Gas (not included).
The procedure for configuring to Stick Welding use is covered further on in this Manual.

INSTALLING THE TIG TORCH

• Thread the power and gas lead onto the TIG Torch connection (FIG 4).
  
  
  The connection of the TIG Torch Hose/Wire Cable [B] MUST BE fully threaded and snugged onto Gas/Power Connection Socket or gas may leak.
• Plug the TIG Torch Trigger Connector in and fasten the Security Lock (FIG 4).

INSTALLING THE GROUND CABLE AND CLAMP

• Locate the Ground Cable/Clamp Assembly [C] and connect the plug on the brass end to the Positive Ground Cable Connection (+) on the Welder [b]. Align the key of the brass ferrule with the notch of the receptacle at the 12:00 position, insert the plug and twist clockwise ½ turn until it is tight (FIG 4).

INSTALLING THE FOOT PEDAL

• Unfasten the TIG Torch Trigger Connector Security Lock and remove the TIG Torch Trigger Connector.
• Insert the Foot Pedal Connector. Fasten the Security Lock (FIG. 5).
  

INSTALLING THE SHIELDING GAS SUPPLY

NOTE: The following steps cover the installation of the Shielding Gas Regulator/Flowmeter, Hose and Tank (not included).
See "Shielding Gas Flow Adjustment" under: "PREPARING TO TIG WELD".

BUILDUP OF GAS CAN INJURE OR KILL!

• Shut off shielding gas supply when not in use.
• Always ventilate confined spaces or use approved air-supplied respirator.
• Always turn your face away from valve outlet when opening cylinder valve.

CYLINDERS CAN EXPLODE IF DAMAGED!

• Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. As gas cylinders are a normal component of the welding process, use extra care to handle them carefully.
• Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs. Keep away from any welding or other electrical circuits.
• Install cylinders in an upright position by securing to a specifically designed rack, cart, or stationary support to prevent falling or tipping over.
• Never weld on a pressurized cylinder or explosion will occur.
• Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and all related components in good condition.
• Keep protective cap in place over valve except when cylinder is in use.
• Use proper equipment, procedures and have adequate help when moving or lifting cylinders.

A Shielding Gas Bottle is NOT INCLUDED with the Eastwood TIG 200 LCD Welder but is necessary to weld using the TIG torch. It can be bought at most local Welding Supply Stores. Eastwood recommends the use of 100% Argon for all TIG welding applications.

• Place the Eastwood TIG 200 LCD Welder in a secure dedicated area or on a welding cart (not included).
• Secure the Shielding Gas Bottle to a stationary object or mount to a specifically designed welding cart, equipped to hold one so that the cylinder cannot fall over.
• Remove the cap from the Shielding Gas Bottle.
• Insert the large male fitting on the Argon Regulator/Flowmeter [D] into the female fitting on the Shielding Gas Bottle (not included).

NOTICE: Do not use White Thread Sealing Tape on this connection as it is an inert gas fitting and does not require it, if you have a leak check for burrs or dirt in the threads or on the spherical joint.

• Tighten the fitting with a wrench until snug, do not over tighten (FIG 6).
  
• Connect either end of the Shielding Gas Hose [E] included with the Eastwood TIG 200 LCD Welder to the fitting on the Regulator and wrench tighten until snug (FIG 6).
• Connect the other end of the Shielding Gas Hose to the fitting on the rear of the Eastwood TIG 200 LCD Welder and wrench tighten until snug (FIG 3).
• Check the gas connections for leaks by slowly opening the valve on the gas bottle. When welding, the valve on the bottle should always be fully open. Close it when done welding to avoid loss of gas.

PREPARING TO TIG WELD

TORCH DISASSEMBLY

• Make sure the Welder is turned off and unplugged.
• Remove the Back Cap from the Torch.
• If there is a Tungsten installed in the Torch, pull it out from the front of the Torch.
• Slide the Collet out of the Torch rear.
• Unscrew and remove the Gas Nozzle.
• Unscrew and remove the Collet Body (FIG 7).
  
  (FIG.7)

TORCH ASSEMBLY

• Select the Collet Body that matches your Tungsten diameter and thread it back into the front of the Torch.
• Select a Collet that matches your Tungsten diameter size. Insert the Tungsten into the Collet and put the Collet and Tungsten back into the Torch.
• The Gas Nozzle size should be selected according to shielding gas requirements for the material being welded. This size can be referenced on the suggested settings chart. Select the correct Gas Nozzle and thread it onto the Collet Body.
• Reinstall the Back Cap to lock the Tungsten in place. Always make sure the Tungsten protrudes 1/8" to 1/4" beyond the Gas Nozzle.

SHARPENING THE TUNGSTEN

To avoid contamination of the Tungsten and ultimately the weld, it is imperative to have a dedicated grinding wheel used for Tungsten grinding only. A fine grit standard 6" synthetic stone grinding wheel on a bench top grinder is sufficient, or a dedicated Tungsten Grinder (#33307 Corded or #58878 Cordless) is optionally available.

• Shut off the Welder.
• Make sure the Tungsten and Torch are sufficiently cooled for handling, then loosen and remove the Back Cap. Remove the Tungsten from the front of the Torch (Removing from the rear of the Torch will damage the Collet). Remove the Collet.
• If the Tungsten is used and the end is contaminated, use pliers or a suitable tool to grip the Tungsten above the contaminated section and snap off the end of the Tungsten.
• Holding the Tungsten tangent to the surface of the grinding wheel, rotate the Tungsten while exerting light pressure until a suitable point is formed (FIGS 8 & 9).
  
• The ideal tip will have the length of the conical portion of the sharpened area at 2-1/2 times the Tungsten rod diameter (FIG 10).
  
• Replace the Tungsten in the Collet with the tip extending 1/8"-1/4" beyond the Gas Nozzle, then re-tighten the Back Cap.

SHIELDING GAS FLOW ADJUSTMENT

After connecting the Argon Regulator/Flowmeter, the gas flow rate needs to be adjusted so that the proper amount of Shielding Gas is flowing over the weld. If there is too little gas flow, there will be porosity in the resulting welds as well as excessive spatter.

If there is too much gas flow, this will be wasting gas and may affect the weld quality. The included Regulator has 2 indicators on it; the gauge on the right is Tank Pressure while the indicator on the left is the Gas Flow Meter.

• Open the Shielding Gas tank valve all the way (FIG 6).
• After the Welder is turned on (described in following section), the Trigger of the TIG Torch or Foot Pedal will control the internal gas flow.
• As the unit is triggered, the Gas Flow Meter ball will rise to a steady reading. The SCFH (Standard Cubic Feet per Hour) can be read from the scale. 20 SCFH is the most typical flow rate, but it may need to be adjusted in some cases depending on if there is a slight breeze or some other instance where additional shielding gas is required to prevent porosity in the weld.
• When finished welding, the Valve on the Gas Bottle must be closed.

GRAPHICAL USER INTERFACE (GUI) NAVIGATION AND SETTING SELECTION

Navigation of the GUI is controlled by the Navigation Knob and the Return Button. Rotating the Navigation Knob clockwise scrolls the selection right, and counterclockwise scrolls the selection left. Pressing the Navigation Knob will select the option highlighted. Pressing the Return Button will revert to the previous screen or cancel the selected option. The different menus and settings are described in detail below.

PROCESS SELECTION

• Upon powering up the Welder the LCD Screen will briefly show a loading screen (FIG 11). After loading, the process selection screen will be displayed.
  
• Here DC Stick, AC Stick, DC TIG, AC TIG, and Presets can be selected via the Navigation Knob. In (FIG 12) the highlighted process is DC TIG because the DC TIG icon is shown enlarged in the middle of the screen and the small DC TIG icon at the bottom is bright white.
  
• To select a highlighted process or the Presets Menu press the Navigation Knob.
• If the process you selected is DC or AC Stick Welding continue below. If you selected DC or AC TIG Welding skip to the Trigger Mode section, and if Presets were selected skip to the Presets section.

DC STICK WELDING PARAMETERS

This mode is for direct current stick welding. The parameter functions are detailed below (FIG 13).

To change a parameter setting, scroll, using the Navigation Knob, until the parameter text is blue, indicating it is selected. Now the Navigation Knob can be pressed, and the displayed parameter will change from white text to blue text, indicating it can be changed via the Navigation Knob. Remember to press the Navigation Knob to confirm the setting before welding. Any change in progress can be cancelled using the Return Button.

• Hot Start: The Hot Start increases amperage over the set point when the arc is initiated. This makes it easier to start and maintain an arc, especially in adverse conditions.
• Welding Amps: Amperage output of the machine while welding.
• Force: The Force setting, also known as Arc Force, or Dig, allows for a tighter arc to the workpiece without extinguishing. This is accomplished by dynamically adjusting the amperage upward as the voltage of the arc drops when the stick is moved closer to the workpiece in order to maintain the same overall power output. The higher the set number, the greater this effect is.

SETTING	RANGE	ADJUSTMENT	UNIT
Hot Start	Off, 1 - 10	1	-
Welding Amps	240V: 20 - 180A 120V: 20 - 120A	1A	Ampere
Force	OFF, 1 - 10	1	-

AC STICK WELDING PARAMETERS

This mode is for alternating current stick welding. The parameter functions are detailed below (FIG 14).

To change a parameter setting, scroll, using the Navigation Knob, until the parameter text is blue, indicating it is selected. Now the Navigation Knob can be pressed, and the displayed parameter will change from white text to blue text, indicating it can be changed via the Navigation Knob. Remember to press the Navigation Knob to confirm the setting before welding. Any change in progress can be cancelled using the Return Button.

• Hot Start: The Hot Start increases amperage over the set point when the arc is initiated. This makes it easier to start and maintain an arc, especially in adverse conditions.
• Welding Amps: Amperage output of the machine while welding.
• Force: The Force setting, also known as Arc Force, or Dig, allows for a tighter arc to the workpiece without extinguishing. This is accomplished by dynamically adjusting the amperage upward as the voltage of the arc drops when the stick is moved closer to the workpiece in order to maintain the same overall power output. The higher the set number, the greater this effect is.

SETTING	RANGE	ADJUSTMENT	UNIT
Hot Start	Off, 1 - 10	1	-
Welding Amps	120V: 20 - 120A 240V: 20 - 180A	1A	Ampere
Force	OFF, 1 - 10	1	-

TRIGGER MODE

• After selecting DC or AC TIG welding, the next screen will allow the Trigger Mode to be selected (FIG 15). This is in the same fashion as Process Selection.
  
  2T: This is the standard welding Trigger Mode: Depress and hold trigger to keep welding.
  4T: This is useful for welding long stretches or in awkward areas where it may be hard to keep the trigger depressed. Depress the trigger to start welding and then release. To stop welding depress the trigger and release again.
  Foot Pedal: When utilizing the included Foot Pedal this mode must be used.
• To select the highlighted process, press the Navigation Knob.

DC TIG WELDING PARAMETERS

Direct Current TIG Welding is commonly used for steel and stainless steel. The parameter functions are detailed below (FIG 16). To change a parameter setting scroll, using the Navigation Knob, until the parameter text is blue, indicating it is selected. Now the Navigation Knob can be pressed, and the displayed parameter will change from white text to blue text, indicating it can be changed via the Navigation Knob. Remember to press the Navigation Knob to confirm the setting before welding. Any change in progress can be cancelled using the Return Button. For suggested settings refer to the Data Chart on the Welder.

• Pre-Flow: Amount of time gas flows out before the arc starts. This helps ensure the arc is fully shielded by gas in a steady flow state as it starts which minimizes workpiece contamination, tungsten contamination, and tungsten burnout.
• Start Amps: This is the amperage the arc will start with. It will ramp up until reaching the Peak Amps setting over the amount of time set by Up Slope.
• Up Slope: The amount of time over which the amperage will ramp to the Peak Amps setting. To turn this off set to zero and the arc will initiate at the set Peak Amps.
• Peak Amps: The main amperage setting at which the welder operates during the majority or all of the welding time, depending to what extend the other amperage modifiers are set.
• On Peak Time: Percentage of time the welder is outputting the Peak Amps set point when pulsing between that and the Base Amps. For example, if at 60%, then 60% of the cycle time will be at the Peak Amps, and 40% will be at the Base Amps. With a 1Hz Pulse Frequency 0.6s will be at Peak Amps and 0.4s will be at Base Amps.
• Pulse Frequency: The frequency at which the welder will repeat the pulsing cycle. 0.5Hz is a two second cycle time, 1Hz is a one second cycle time, 2Hz is a half second cycle time, and so on. To turn off pulsing, scroll the number down until you see OFF.
• Base Amps: The alternate amperage setting when using pulse mode.
• Down Slope: Similar to Up Slope, but after releasing the trigger this is the amount of time over which the amperage will ramp down to the End Amps.
  Once at the End Amps, the arc will be ended. Turn to zero for the arc to end immediately at the Peak Amps.
• End Amps: The amperage the arc will end with after the Down Slope is completed.
• Post Flow: Amount of time gas keeps flowing after the arc is closed. Like Pre-Flow, it minimizes workpiece contamination, tungsten contamination, and tungsten burnout. The continuation of gas flow also protects the weld puddle and electrode against oxidization while cooling after welding.

FIG. 16

SETTING	RANGE	ADJUSTMENT	UNIT	PRESET 1 DC TIG – Foot Pedal
Pre-Flow	0.1 - 1.0s	0.1s	Second	0.5s
Start Amps	120V: 5 - 120A 240V: 5 - 200A	1A	Ampere	30A
Up Slope	0 - 15s	1s	Second	0s
Peak Amps	120V: 5 - 120A 240V: 5 - 200A	1A	Ampere	100A
On Peak Time	10 - 90%	1%	Percent	50%
Pulse Frequency	OFF, 0.5 - 1.0HZ, 1.0 - 200HZ	0.1Hz, 1 Hz	Hertz	Off
Base Amps	5 - 95%	1%	Percent	70%
Down Slope	0 - 25s	1s	Second	0s
End Amps	120V: 5 - 120A 240V: 5 - 200A	1A	Ampere	30A
Post Flow	0.0 - 15.0s	0.1s	Second	3.0s

AC TIG WELDING PARAMETERS

Alternating Current TIG Welding is commonly used for aluminum. The parameter functions are detailed below (FIG 17). To change a parameter setting, scroll, using the Navigation Knob, until the parameter text is blue, indicating it is selected. Now the Navigation Knob can be pressed, and the displayed parameter will change from white text to blue text, indicating it can be changed via the Navigation Knob. Remember to press the Navigation Knob to confirm the setting before welding. Any change in progress can be cancelled using the Return Button. For suggested settings refer to the Data Chart on the Welder.

• Pre-Flow: Amount of time gas flows out before the arc starts. This helps ensure the arc is fully shielded by gas in a steady flow state as it starts which minimizes workpiece contamination, tungsten contamination, and tungsten burnout.
• Start Amps: This is the amperage the arc will start with. This will ramp up until reaching the Peak Amps setting over the amount of time set by Up Slope.
• Up Slope: The amount of time over which the amperage will ramp to the Peak Amps setting. To turn this off set to zero and the arc will initiate at the set Peak Amps.
• Peak Amps: The main amperage setting at which the welder operates during the majority or all of the welding time, depending to what extend the other amperage modifiers are set.
• On Peak Time: Percentage of time the welder is outputting the Peak Amps set point when pulsing between that and the Base Amps. For example, if at 60%, then 60% of the cycle time will be at the Peak Amps, and 40% will be at the Base Amps. With a 1Hz Pulse Frequency 0.6s will be at Peak Amps and 0.4s will be at Base Amps.
• Pulse Frequency: The frequency at which the welder will repeat the pulsing cycle. 0.5Hz is a two second cycle time, 1Hz is a one second cycle time, 2Hz is a half second cycle time, and so on. To turn off pulsing, scroll the number down until you see OFF.
• Base Amps: The alternate amperage setting when using pulse mode.
• Down Slope: Similar to Up Slope, but after releasing the trigger this is the amount of time over which the amperage will ramp down to the End Amps. Once at the End Amps, the arc will be ended. Turn to zero for the arc to end immediately at the Peak Amps.
• End Amps: The amperage the arc will end with after the Down Slope is completed.
• Post Flow: Amount of time gas keeps flowing after the arc is closed. Like Pre-Flow it minimizes workpiece contamination, tungsten contamination, and tungsten burnout. The continuation of gas flow also protects the weld puddle and electrode against oxidization while cooling after welding.
• AC Balance: This adjusts the percentage of time the current is electrode positive. High percentages result in more cleaning effect and a smoother weld seam. However, weld penetration will be shallower. Also, the tungsten gets hotter and takes in more contaminants. If you wish to ball the tungsten end, set to 70%. Lower balance settings (30 - 50%) are generally suggested for most welding situations. If black spots appear in the puddle, the balance setting is too low. Turn the balance up until the black spots are no longer present.
• AC Frequency: Higher frequency creates a more intense and concentrated arc with a smoother weld seam. This is great for working in a tight area where you don't want to damage nearby features. A good starting frequency for these qualities is 120Hz. Lower AC frequencies create a wider weld seam. We recommend starting around 80Hz as a lower baseline to adjust from.

FIG. 17

SETTING	RANGE	ADJUSTMENT	UNIT	PRESET 2 AC TIG – Foot Pedal
Pre-Flow	0.1 - 1.0s	0.1s	Second	0.5s
Start Amps	120V: 5 - 120A 240V: 5 - 200A	1A	Ampere	30A
Up Slope	0 - 15S	1s	Second	0s
Peak Amps	120V: 5 - 120A 240V: 5 - 200A	1A	Ampere	120A
On Peak Time	10 - 90%	1%	Percent	50%
Pulse Frequency	OFF, 0.5 - 1.0HZ, 1.0 - 200HZ	0.1Hz, 1 Hz	Hertz	Off
Base Amps	5 - 95%	1%	Percent	70%
Down Slope	0 - 25s	1s	Second	0s
End Amps	120V: 5 - 120A 240V: 5 - 200A	1A	Ampere	30A
Post Flow	0.0 - 15.0s	0.1s	Second	3.0s
AC Balance	20 - 80%	1%	Percent	50%
AC Frequency	40 - 200Hz	1 Hz	Hertz	80Hz

NOTE: When scrolling through or adjusting the setting parameters, if no activity is detected for ten seconds the machine will automatically return to the peak amps setting.

PRESETS

The Eastwood Elite TIG 200 LCD is equipped with five fully programmable Preset Slots. The first two Presets are configured from the factory for a quick start into AC or DC welding at 100A with the Foot Pedal. The default settings of these profiles are shown in the previous tables in the right most column. Saving and loading Presets is covered below.

• To save your current welding settings as a Preset: scroll to the "Save to Preset" parameter in the bottom right of the screen and press the Navigation Knob to select it. Now the mode and settings can be saved to any of the five slots. Note that it will overwrite Presets without asking for confirmation.
• To load a Preset: access the Preset selection menu (FIG 18) from the Process Selection screen (FIG 12) by scrolling and selecting "Presets". The Preset Selection Menu will open, and any saved Preset can be loaded by selecting it and pressing the Navigation Knob.
  

OPERATING THE TIG 200 LCD WELDER

OVERLOAD PROTECTION

The Eastwood TIG 200 LCD Welder is equipped with an overload protection. This device will protect the Welder if the duty cycle is exceeded. If the output is exceeded, the breaker will trip, the parameter value will be replaced with ERR flashing rapidly, and cut off the power supply to the TIG Torch, although the fan will still run to cool the unit. This protection circuit must be reset manually by switching the unit back ON. Before restarting the unit, allow the Welder to cool for a minimum of 15 minutes or until the ERR message goes out.

These instructions are intended only to provide the user with some familiarity of the Eastwood TIG 200 LCD. TIG welding is a highly complex procedure with many variables. If you have no experience with TIG welding; it is extremely important to seek the advice of someone experienced in TIG welding for instruction, enroll in a local technical school welding course or study a comprehensive how-to DVD and obtain a good quality reference book on TIG welding as there is a moderate learning curve necessary before achieving proficiency in TIG Welding. Before attempting to use this unit on an actual project or object of value, practice on a similar material as there are many variables present and settings required when TIG welding different metals such as steel or aluminum. It is also strongly recommended that the user adhere to the American Welding Society guidelines, codes, and applications prior to producing welds where safety is affected.

ELECTRIC SHOCK CAN CAUSE INJURY OR DEATH!

• Improper use of an electric Welder can cause electric shock, injury, and death! Read all precautions described in the Welder Manual to reduce the possibility of electric shock.
• Disconnect Welder from power supply before assembly, disassembly, or maintenance of the MIG Gun, contact tip and when installing or removing nozzles.
• Always wear dry, protective clothing and leather welding gloves and insulated footwear. Use suitable clothing made from durable flameresistant material to protect your skin.
• Always operate the Welder in a clean, dry, well-ventilated area. Do not operate the Welder in humid, wet, rainy, or poorly ventilated areas.
• The electrode and work (or ground) circuits are electrically "hot" when the Welder is on. Do not allow these "hot" parts to come in contact with bare skin or wet clothing.
• Separate yourself from the welding circuit by using insulating mats to prevent contact from the work surface.
• Be sure that the work piece is properly supported and grounded prior to beginning an electric welding operation.
• Always attach the ground clamp to the piece to be welded and as close to the weld area as possible. This will give the least resistance and best weld.

WELDING SPARKS CAN CAUSE FIRE OR EXPLOSION!

• Electric welding produces sparks which can be discharged considerable distances at high velocity igniting flammable or exploding vapors and materials.
• Do not operate electric arc Welder in areas where flammable or explosive vapors are present.
• Do not use near combustible surfaces. Remove all flammable items within 35 feet of the welding area.
• Always keep a fire extinguisher nearby while welding.
• Use welding blankets to protect painted and or flammable surfaces, rubber weather-stripping, dash boards, engines, etc.
• If other persons or pets are in the area of welding, use welding screens to protect bystanders from sparks and UV radiation.

ELECTROMAGNETIC FIELDS CAN BE A HEALTH HAZARD!

• The electromagnetic field that is generated during arc welding may interfere with various electrical and electronic devices such as cardiac pacemakers. Anyone using such devices should consult with their physician prior to performing any electric welding operations.
• Exposure to electromagnetic fields while welding may have other health effects which are not known.

ARC RAYS CAN BURN!

• Arc rays produce intense ultraviolet radiation which can burn exposed skin and cause eye damage. Use a shield with the proper filter (a minimum of #11) to protect your eyes from sparks and the rays of the arc when welding or when observing open arc welding (see ANSI Z49.1 and Z87.1 for safety standards).
• Use suitable clothing made from durable flame-resistant material to protect your skin.
• If other persons or pets are in the area of welding, use welding screens to protect bystanders from sparks and arc rays.

FUMES AND WELDING GASES CAN BE A HEALTH HAZARD!

• Fumes and gasses released during welding are hazardous. Do not breathe fumes that are produced by the welding operation. Wear an OSHA-approved respirator when welding.
• Always work in a properly ventilated area.
• Never weld coated materials including but not limited to: cadmium plated, galvanized, lead based paints.

HOT METAL AND TOOLS WILL BURN!

• Electric welding heats metal and tools to temperatures that will cause severe burns!
• Use protective, heat resistant gloves and clothing when using Eastwood or any other welding equipment. Never touch welded work surface, MIG Gun tip or nozzle until they have completely cooled.

FLYING METAL CHIPS CAN CAUSE INJURY!

• Grinding and sanding will eject metal chips, dust, debris, and sparks at high velocity. To prevent eye injury wear approved safety glasses.
• Wear an OSHA-approved respirator when grinding or sanding.
• Read all manuals included with specific grinders, sanders or other power tools used before and after the welding process. Be aware of all power tool safety warnings.

TIG WELDING

• Turn the Power Switch to the "ON" position.
• Slowly open the gas cylinder valve.
  NOTE: Always open valve fully to avoid shielding gas leakage.
• Depress Torch Trigger switch or Foot Pedal and adjust the Flow Meter/Regulator. (Refer to Data Chart for actual settings).
• Grounding is very important, place the Ground Cable Clamp on a clean, bare area of your work piece as close to the welding area as possible to minimize the chance of shock. Scrape, wire brush, file or grind a bare area to achieve a good ground to assure safety.
• Use a dedicated stainless-steel brush or flap-disc to clean the areas to be welded. This is particularly critical on aluminum as a microscopic layer of oxidation can prevent an arc and actually produce a poor-quality, contaminated weld. Do not use the brush or flap-disc for any other purpose and keep one for steel and one for aluminum.
• Make sure all your safety gear is in place (Welding Mask, Welding Gloves, Non-Flammable Long Sleeve Apparel) and the area is completely free of flammable material.
• Although it is a matter of developing a personal style, a good starting point for best results is achieved by holding the tip at a 75° angle. Hold the Filler Metal Rod at a 90° angle to the Tungsten Tip (FIG 19).
  
  Never allow the Tungsten Tip to touch the welding surface or material rod. Doing so will quickly destroy the tip and contaminate the weld. If this happens, remove the Tungsten, and regrind the tip. It is best to hold the Tungsten 1/8" from the surface.
• With your Welding Shield and all safety gear in place, depress the Foot Pedal or Torch Trigger and practice "Forming A Puddle" with the Tungsten tip. Once you become familiar with this step, practice the "Dip and Pull" technique with the Filler Metal Rod and Torch. "Dip and Pull" is the practice of forming a puddle, moving the Torch while maintaining the puddle and adding filler rod metal to the puddle by "dipping and pulling" as you go; being careful not to allow the Tungsten to contact the puddle or rod.
• Keep in mind that you MUST let the shielding gas flow over the weld after releasing the Torch Trigger or Foot Pedal. Failure to do so will allow the welded area to oxidize compromising the weld integrity.
• Constantly be aware that TIG welding quickly generates heat in the work piece and torch. Severe burns can quickly occur by contacting hot metal pieces.
• When done, shut off the Power Switch and close the Shielding Gas Tank valve completely.

STICK WELDING

With an optional Eastwood #20517 Electrode Holder (not included), the TIG 200 LCD Welder can be used as a stick welding machine.

• Connect the Electrode Holder and select AC or DC Stick Welding mode (FIG 20).
  
• An Electrode can now be installed in the Electrode Holder. Make sure the Electrode or "Stick" is not making contact with the grounded workpiece.
• Switch the Power Switch to "On".
• While wearing a properly functioning Auto Darkening Welding Helmet, lightly drag the tip of the Welding Rod along the workpiece surface to start an arc.
• Feed the Welding Rod into the workpiece joint at a 15° angle.
• Lift rod from workpiece when weld bead is completed.
• Turn off Welder power switch.
• Set the Electrode or "Stick" Holder on a safe, non-flammable, surface.

TORCH MAINTENANCE

The Eastwood TIG 200 LCD Welder has a number of consumable parts that will need to be replaced over time. If wear or slag build up is noticed on any of the Torch components, replace them immediately to avoid damage to the Torch. Worn components will also contribute to poor performance. See the Torch components (FIG 7) exploded view for a reference of all of the components and the assembly order.

DATA CHART

TROUBLESHOOTING

PROBLEM	CAUSE	CORRECTION
Arc is Triggered but Will Not Start	Incomplete Circuit	Check Ground connection. Verify polarity is correct for the application. All TIG welding and most stick welding is done with the ground cable installed to the Positive (+) connector at the front panel. Make sure that the ground is on a freshly cleaned surface and close to the welding area. It is suggested to weld towards the ground connection.
	Incorrect Tungsten	Consult chart for proper tungsten for the base metal being welded. In most cases Thoriated will be used for all steels.
	No Shielding Gas	Make sure the shielding gas cylinder is turned all the way open and set at the correct flow rate.
	Wrong Polarity	Make sure polarity is set for the correct material. AC should be used for aluminum while DC should be used for steel.
Arc Wanders and it is Hard to Concentrate Heat in a Specific Area	Poorly Prepped Tungsten	Follow guidelines for prepping tungsten.
	Poor Gas Flow	Adjust the flow rate of the shielding gas (refer to settings chart). Check for loose fittings where gas could be leaking.
	Contaminated Tungsten	Remove tungsten from torch and break off contaminated section and resharpen.
	Incorrect Arc Length	Make sure the Tungsten is held 1/8 to 1/4 inch off the work piece.
	Incomplete Circuit	Check Ground connection. Verify polarity is correct for the application. All TIG welding and most stick welding is done with the ground cable installed to the Positive (+) connector at the front panel. Make sure that the ground is on a freshly cleaned surface and close to the welding area. It is suggested to weld towards the ground connection.
	Contaminated Base Metal	Clean base metal making sure to remove any oil, debris, coatings, or moisture. If base metal is aluminum, make sure all of the oxide is removed using either a dedicated stainless brush or flap wheel.
	Incorrect A/C Balance	Decrease A/C Balance to increase penetration and decrease cleaning effect.
Porosity in Weld Bead	Poor Gas Flow	Adjust the flow rate of the shielding gas (refer to settings chart). Check for loose fittings where gas could be leaking.
	Contaminated Filler Metal	Clean filler metal making sure to remove any oil, debris, or moisture.
	Contaminated Base Metal	Clean base metal making sure to remove any oil, debris, coatings, or moisture.
	Poor Shielding	Make sure to be in an area with no wind and with any fans turned off. Wind or fans will blow the shielding gas away from the weld causing porosity.
	Incorrect Tungsten Stick Out	Adjust the tungsten so that 1/8 to 1/4 inch is sticking out of the collet.
Contamination in Weld Bead	Contaminated Tungsten	Remove tungsten from torch and break off contaminated section and resharpen.
	Contaminated Filler Metal	Clean filler metal making sure to remove any oil, debris, or moisture.
	Contaminated Base Metal	Clean base metal making sure to remove any oil, debris, coatings, or moisture. If base metal is cold rolled steel, make sure to remove any mill scale.
Melting Tungsten	Poor Gas Flow	Adjust the flow rate of the shielding gas (refer to settings chart). Check for loose fittings where gas could be leaking.
	Incorrect A/C Balance	Decrease A/C Balance to increase penetration and decrease cleaning effect.
	Wrong Size Tungsten	Increase tungsten diameter. Refer to chart for proper sizing.
	Incorrect Shielding Gas	Only use 100% Argon when TIG Welding.
Poor Penetration (Aluminum)	Low Amperage	Amperage setting is too low for material/thickness. Increase as needed and reference chart on welder.
	Incorrect A/C Balance	Decrease A/C Balance to increase penetration and decrease cleaning effect.
Poor Penetration (Steel)	Low Amperage	Amperage setting is too low for material/thickness. Increase as needed and reference chart on welder.
Tungsten Contaminated	Contact of Tungsten with Base Metal	Keep tungsten 1/8 to 1/4 inch from the base metal. If tungsten comes in contact break off end and resharpen immediately.
Poor Weld Appearance	Incorrect Positioning	The angle between the filler material and torch must be less than 90 degrees otherwise the filler metal will prematurely melt and glob off causing poor weld appearance.
Crater in the End of the Weld Bead	Insufficient Shielding	Keep the torch on the base metal while the post flow shielding gas flows to protect and cool the metal and tungsten.
	Not Enough Filler Material	Reduce current with pedal and add more filler at end of weld. It may also be beneficial to back step to ensure no crater will form.
Weld Bead is Cracking	Too much heat in material	Reduce heat and allow more time between passes.
	Base Metal is absorbing too much heat	Preheat base metal (consult welding codes for requirements)
	Incorrect Filler Wire	Use appropriate filler wire type and diameter for the joint being welded.
Material is Warping	Insufficient Clamping	Clamp work piece tightly and weld while clamps are in place.
	Insufficient Tack Welds	Add more tack welds until rigidity and stiffness is developed.
	Too Much Heat in Material	To reduce heat, it is best to spread the welding out around the area. This can be done by using stitch welding techniques, alternating sides, and/or taking your time and allowing the pieces to cool between passes.

To order parts and supplies: 800.343.9353
www.eastwood.com

Documents / Resources

References

• American Welding Society (AWS) - Welding Excellence Worldwide
• Eastwood Auto Restoration Supplies - Eastwood Auto

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