Download  Print this page

Everlast PowerTig 200DX-DV Operator's Manual

Dual voltage ac/dc pulse tig/stick welder safety, setup and general use guide
Hide thumbs

Advertisement

EVERLAST
POWERTIG 200DV
Dual Voltage AC/DC Pulse TIG/Stick Welder
CC
GTAW-P
SMAW
IGBT
1
~
PHASE
AC/DC
120V
240V
Operator's Manual for the PowerTig 200DX-DV
Safety, Setup and General Use Guide
Rev. 2
0 00816-14
everlastwelders.com
Specifications and Accessories subject to change without notice.
1-877-755-9353
329 Littlefield Ave. South San Francisco, CA 94080 USA

Advertisement

Table of Contents
loading

  Related Manuals for Everlast PowerTig 200DX-DV

  Summary of Contents for Everlast PowerTig 200DX-DV

  • Page 1 GTAW-P SMAW IGBT PHASE AC/DC 120V 240V Operator’s Manual for the PowerTig 200DX-DV Safety, Setup and General Use Guide Rev. 2 0 00816-14 everlastwelders.com Specifications and Accessories subject to change without notice. 1-877-755-9353 329 Littlefield Ave. South San Francisco, CA 94080 USA...
  • Page 2: Table Of Contents

    The owner of this product as- sumes all liability for its use and maintenance. Everlast Power Equipment INC. does not warrant this product or this document for fitness for any particular purpose, for performance/accuracy or for suitability of application.
  • Page 3 Your unit registration is important should any information such as product updates or re- calls be issued. It is also important so that we may track your satisfaction with Everlast products and services. If you are unable to register by website, contact Everlast directly through the sales department through the main customer service number in your country.
  • Page 4 Serial number: __________________________ Model number: ____________________________ Date of Purchase___________________________ Contact Information Everlast US: Everlast consumer satisfaction email: sales@everlastwelders.com Everlast Website: everlastwelders.com Everlast Technical Support: support@everlastwelders.com Everlast Support Forum: http://www.everlastgenerators.com/forums/index.php Main toll free number: 1-877-755 WELD (9353) 9am—5pm PST M-F 11am-4pm PST Sat.
  • Page 5: Safety Precautions

    Safe operation and proper maintenance is your responsibility. We have compiled this operator’s manual, to instruct you in basic safety, oper- ation and maintenance of your Everlast product to give you the best possible experience. Much of welding and cutting is based upon experience and com- mon sense.
  • Page 6 SAFETY PRECAUTIONS These safety precautions are for protection of safety and health. Failure to follow these guidelines may result in serious injury or death. Be careful to read and follow all cautions and warnings. Protect yourself and others. Welding and cutting processes produce high levels of ultraviolet (UV) radiation that can cause severe skin burn and damage.
  • Page 7 SAFETY PRECAUTIONS WARNING! Persons with pacemakers should not weld, cut or be in the welding area until they consult with their physician. Some pacemakers are sensitive to EMF radiation and could severely malfunction while welding or while being in the vicinity of someone welding.
  • Page 8 SAFETY PRECAUTIONS continued WARNING! Electrical shock can kill. Make sure all electrical equipment is properly grounded. Do not use frayed, cut or otherwise damaged cables and leads. Do not stand, lean or rest on ground clamp. Do not stand in water or damp areas while weld- ing or cutting.
  • Page 9: Introduction And Specifications

    Section 1 Introduction and Specifications PowerTIG 200DX Water-cooled, 26 Series Torch Assembly 12 Ft (3 m) with built in 2T/4T switch (Style may vary) Argon Regulator Work Clamp Consumable Kit (Does not include Tungsten) 47K Ω Stick Electrode Holder Foot Pedal Assembly NOTE: Accessory and consumable style and quantities are subject to change without notice.
  • Page 10 Section 1 Introduction and Specifications PowerTIG 200 DV TIG/Stick Welder Specification Process AC/DC GTAW-P/DC SMAW Inverter Type Analog, IGBT Construction Minimum/Maximum Rated Output TIG 240 V: DC: 5 A/10.2 V - 200 A/18V AC: 20 A/10.8 V - 200 A/18 V 120 V: DC : 5A/10.2 - 120 A/14.8V AC : 20 A /10.8 - 120A/14.8V) Minimum/Maximum Rated Output Stick 240 V: DC: 5 A/20.2 V - 160 A /26.4 V AC: 20 A/ 10.8 V-160 A/26.4 V...
  • Page 11: General Overview

    Introduction and Specifications Section 1 General overview: The PowerTIG 200 DV features AC/ charge. Severe shock and/or death can occur. DC pulse TIG and Stick welding capability. With an IGBT inverter design, this welder is designed for years of use. Do not restrict air flow or movement of air around the The PowerTIG 200DV model is an improved design of the welder.
  • Page 12 (usually rated at 5% or less). Clean power represents a purer AC sine wave without significant spikes and noise. Everlast does not maintain an approved list of clean power generators. Directly consult the man- ufacturer of the generator for information regarding clean power output.
  • Page 13 If using a water cooler, note that the power outlet when operating on 120V input, will only supply a 110V current. Everlast strongly suggests purchasing a dual TORCH (-) voltage water cooler if a water cooler is to be used to be able to operate with both 110V and 220V current.
  • Page 14: Quick Setup Guide, Stick Polarity

    Section 2 QUICK SETUP AND USE GUIDE QUICK SETUP GUIDE: STICK POLARITY AND CONNECTIONS CONTROL TORCH (+) WORK (-)
  • Page 15 CONTACT EVERLAST TO PURCHASE AN ADAPTER IF NEEDED. GREEN GROUND (220/240V 1 and 3 phase) 120V/220V COOLER OUTLET. RECOMMENDED FOR DUAL VOLT- AGE EVERLAST POWERCOOL WC 300 ONLY. WARNING: DO NOT USE THIS OUTLET FOR ANY OTHER APPLICATION OR SERVICE! L1,BLACK; HOT(240V 1 or 3 phase) L2,WHITE;...
  • Page 16: Front Panel Features And Controls

    Section 2 QUICK SETUP AND USE GUIDE FRONT PANEL FEATURES AND CONTROLS 1. PROTECTIVE COVER 20. AMP DISPLAY 19. AMP CONTROL 2. 2T/PEDAL/ OR 4T SWITCH 18. ON/TEMP/O.C 17. HF/LIFT /STICK 16. ARC FORCE (DIG) STICK 3. DOWN SLOPE (2T/4T) 15.
  • Page 17 Section 2 QUICK SETUP AND USE GUIDE FRONT PANEL FEATURES AND CONTROLS CONTINUED POWERTIG 200 DX FEATURES PARAMETERS PURPOSE 1. Protective Cover Clear hinged cover protects panel from damage. Keep closed during welding operations. 2. 2T/4T Sequencer Switch 2T -Pedal/4T Used with the torch switch function.
  • Page 18 Everlast. Over Current Indicator: Lights up when a voltage /amp surge has sur- passed the units capabilities. Eliminate the source of the surge and manually cycle the power switch to reset.
  • Page 19: Rear Panel Features And Controls

    Section 2 QUICK SETUP AND USE GUIDE REAR PANEL FEATURES AND CONTROLS 5. 3-POLE POWER SWITCH 4. POWER CABLE 1x110V/220V AC 110V 1. HF GROUND BOLT AC 220V GAS INLET 1x110/220 V 2. WATER COOLER RECEPTACLE 3. ARGON GAS INLET 120/240 V WATER COOLER ONLY!
  • Page 20 Less than 5% is preferred. Operating the unit on square wave output or modified sine wave generators is strictly prohibited. Contact the manufacturer of the generator for this information. Everlast does not maintain an “approved” list of generators. But, if the generator is not listed as clean power by its manufacturer, then it should not be used.
  • Page 21: Welder Function Summary And Explanations

    Section 3 Basic theory and function Welder Function Summary and Explanations. The 2T/4T section on the welder panel are devoted to the use of the 2T/4T operation and should not be used 1. 2T/4T sequencer. The 2T/4T feature allows op- with foot pedal.
  • Page 22 Section 3 Basic theory and function Cleaning/Frosted Area of Aluminum running parallel to the side of the weld. Not all weld conditions will be alike, so more cleaning is 30% EP required at times than others. Similarly, more pen- Narrow bead/etching/sharp tungsten etration will be required at times than others.
  • Page 23 Section 3 Basic theory and function 5. Pulse. The pulse creates two amp values, a high EXAMPLE 1 and a low value that cycle back and forth between Welding Amps: 100 amps, each other while welding. The upper amperage is PulseAmps: 50% called the “welding amps”...
  • Page 24 The foot need a new one for your torch or damage yours, consult Everlast. Do not use a nipple that is scarred, bent or other- pedal also controls both Welding Amps, and Pulse Amps through the ratio established by selecting the wise deformed.
  • Page 25: Tungsten Preparation

    Section 3 Basic theory and function TUNGSTEN PREPARATION 1. Use a dedicated grinding wheel or contamination may re- sult. Do not breath grinding dust!  Wear eye protection and gloves. 2. Hold Tungsten firmly. 3. Grind perpendicular to grind- ing wheel face. Allow tungsten to grind away slowly, creating point.
  • Page 26: High Frequency Start Tig Operation

    Section 3 Basic theory and function LIFT START TIG OPERATION Note: A Lift TIG start should be done with a nearly seamless motion. Use a light touch and a quick motion for best results. FOR DC USE. NOT RECOMMENED FOR AC. <1/8”...
  • Page 27 Section 3 Basic theory and function STICK OPERATION STARTING METHODS Tapping Method Scratch/Match Method 1. Turn on the power switch on the rear of the unit. Allow unit to cycle through its start up program. 2. Select the Stick mode with the HF/Lift Start/Stick selector switch. 3.
  • Page 28 Section 3 Basic theory and function GENERAL POLARITY RECOMMENDATIONS* *Follow manufacturer of stick electrode for complete polarity recommendations PROCESS TORCH POLARITY WORK POLARITY TIG (GTAW) STICK (SMAW) TIG (GTAW) OPERATION GUIDE FOR STEEL (ALUMINUM)* *As a general rule, set amperage using 1 amp for every .001” of metal thickness for aluminum. Less is required for DC. METAL THICKNESS WELDING AMPS TUNGSTEN DIA.
  • Page 29: Expanded View Of Tig Torch

    Section 3 Basic theory and function EXPANDED VIEW OF TIG TORCH (Actual appearance may vary slightly from what is listed.) 5/8” PARTS FOR 26 Series Torch ( STYLE MAY VARY) QTY. Long Back Cap with O-Ring Short Back Cap Opt. Torch Head Insulator Collet 1/16 or 3/32...
  • Page 30 Section 3 Basic theory and function 7 PIN CONNECTOR FOR 47K Ω FOOT PEDAL AND REMOTE AMP CONTROLLER ON OPTIONAL TORCH Bridge to 7 To Pedal or Torch Switch Bridge to 6 To Pedal or Torch Switch...
  • Page 31: Troubleshooting

    Check gas flow. Adjust for higher flow of gas. Listen for audible click of gas solenoid. If no click is heard, then contact Everlast Support. Clean weld properly, especially in Aluminum. Too short of post flow. Check tungsten stick out.