TOOLIOM TL-200T Digital Inverter Welder TIG User’s Manual

TOOLIOM TL-200T Digital Inverter Welder TIG

Note: Please read this user’s manual carefully before using this product.

DATA CHART (ALSO LOCATED ON TOP OF WELDER)

MATERIAL

| MATERIAL THICKNESS| ****

POLARITY

| ****

AMPERAGE

| TUNGSTEN COLOR| TUNGSTEN DIA.| FILLER METAL
---|---|---|---|---|---|---

Steel

| ****

1/16″

| ****

DC-

| ****

45-80

| Gray, Red White, Purple| ****

1/16″

| ****

ER70S-2

Steel

| ****

3/32″

| ****

DC-

| ****

70-110

| Gray, Red White, Purple| ****

1/16″

| ****

ER70S-2

Steel

| ****

1/8″

| ****

DC-

| ****

75-125

| Gray, Red White, Purple| ****

1/16″

| ****

ER70S-2

Steel

| ****

3/16″

| ****

DC-

| ****

110-200

| Gray, Red White, Purple| ****

3/32″

| ****

ER70S-2

Stainless Steel

| ****

1/16″

| ****

DC-

| ****

50-90

| Gray, Red White, Purple| ****

1/16″

| ****

ER308/308L

Stainless Steel

| ****

3/32″

| ****

DC-

| ****

80-120

| Gray, Red White, Purple| ****

1/16″

| ****

ER308/308L

Stainless Steel

| ****

1/8″

| ****

DC-

| ****

85-140

| Gray, Red White, Purple| ****

1/16″

| ****

ER308/308L

Stainless Steel

| ****

3/32″

| ****

DC-

| ****

125-200

| Gray, Red White, Purple| ****

3/32″

| ****

ER308/308L

FILLER METAL DIA.| PRE FLOW

(sec)

| POST FLOW

(sec)

| TORCH CUP SIZE| GAS FLOW

RATE (scfh)

| CLEARANCE EFFECT
---|---|---|---|---|---

1/16″

| ****

0.4

| ****

5

| ****

1/4 – 3/8″

| ****

12

| ****

0

1/16″

| ****

0.4

| ****

5

| ****

1/4 – 3/8″

| ****

12

| ****

0

3/32″

| ****

0.4

| ****

6

| ****

1/4 – 3/8″

| ****

12

| ****

0

1/8″

| ****

0.4

| ****

6

| ****

1/4 – 3/8″

| ****

14

| ****

0

1/16″

| ****

0.4

| ****

5

| ****

1/4 – 3/8″

| ****

12

| ****

0

1/16″

| ****

0.4

| ****

5

| ****

1/4 – 3/8″

| ****

12

| ****

0

3/32″

| ****

0.4

| ****

6

| ****

1/4 – 3/8″

| ****

12

| ****

0

1/8″

| ****

0.4

| ****

6

| ****

1/4 – 3/8″

| ****

14

| ****

0

TIG Welding is the most controllable, efficient, and versatile method of welding many metals including steel, stainless steel and more. Your TOOLIOM TIG 200 DC WELDER with High-Frequency Inverter Technology is capable of welding thin or heavy gauge steel with precision and ease. The voltage self­sensing circuitry automatically detects a power source range of 110 to 220 volts and delivers from 15 up to 200 Amps DC. The foot pedal (not included) can provide the operator with the start and stop arc control required when welding. A high-frequency start feature guarantees an instant arc strike with no tungsten contamination.

SPECIFICATIONS

Function

| Output Amperage Range| Maximum Output No Load Voltage|

Input Voltage

| ****

Rated Duty Cycle

| ****

Pre Gas Flow

| ****

Post Gas Flow

---|---|---|---|---|---|---

TIG

| ****

15-200A DC

| ****

75V DC

| 110/220

VAC

| 60%@

200 Amps

| ****

0.5 Sec

| ****

3 Sec

STICK

| ****

15-155A DC

| 110/220

VAC

| 60%@

155 Amps

| ****

NA

| ****

NA

DUTY CYCLE

The rated Duty cycle refers to the amount of welding that can be done within an amount of time. The TOOLIOM TIG 200 DC WELDER has a duty cycle of 60% at 200 Amps. It is easiest to look at your welding time in blocks of 1 O Minutes and the Duty Cycle being a percentage of that 1 O Minutes. If weld­ing at 200 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. To increase the duty cycle you can turn down the Amperage Output control. Going above 190 Amps will yield a lower duty cycle.

SAFETY INFORMATION

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

• DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
• WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
• CAUTION used with the safety alert symbol, 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.

READ INSTRUCTIONS

Thoroughly read and understand this manual before using. Save for future reference.

DANGER 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 torch, 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 flame-resistant 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 your 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.

DANGER 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 (min. of 35 feet).
• Always keep a fire extinguisher nearby while welding.
• Use welding blankets to protect painted and or flammable surfaces; rubber weather­stripping, dash boards, engines, etc.
• Ensure power supply has properly rated wiring to handle power usage.

WARNING ELECTROMAGNETIC FIELDS CAN BE A HEAL TH 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.

SAFETY INFORMATION

WARNING FUMES AND WELDING GASES CAN BE A HEAL TH 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.

WARNING BUILDUP OF GAS CAN INJURE OR KILL!

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

WARNING 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.
• 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.

CAUTIONS 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 TOOLIOM or any other welding equipment. Never touch welded work surface, torch tip or nozzle until they have completely cooled.

WARNING  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 249.1 and 287.1 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.

CAUTIONS 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.

REQUIRED ITEMS

Before you begin using the TOOLIOM TL-200T, make sure you have the following:

• A properly grounded 110-120 VAC 50/60 Hz. 30 Amp Circuit or a 220-240 VAC 50/60 Hz. 50 Amp Circuit.
  NOTE: Unit must be grounded to work properly and safely!

• A clean, safe, well-lit, dry, and well-ventilated work area.

• A non-flammable, long sleeve shirt or jacket

• Heavy-Duty Welding Gloves

• An Auto Darkening Welding Mask to provide eye protection during welding operations.
  NOTE: MUST be a #10 lens or darker.

• A compressed gas cylinder containing 100% Argon (must be used when TIG welding and is avail­able at any welding supply facility).

• Dedicated stainless steel wire welding brushes for each material to be welded.

• A dedicated fine grit synthetic stone grinding wheel or a Tungsten Sharpener.

BEFORE YOU BEGIN

Remove all items from the box. Compare with list below to make sure unit is complete.

• (1) TOOLIOM TL-200T Welder
• (1) Shielding Gas Hose
• (1) Ground Cable with Clamp (10′)
• (1) WP #17 TIG Torch (14′)
• (1) Electrode(Stick)Holder (1 O’)
• (1) Instruction Manual
• (1) Brush
• (3) Gas Nozzzle
• (3) Collect
• (1) Collect Body
• (2) Back Cap

COMPONENTS AND CONTROLS

1. Power Switch – The Power Switch is located at the right of the back panel (FIG. A-2).
2. Amperage (Front Panel) – Set the Output Amperage Knob marked “A” (FIG. A-1) located at right of the front panel to an appropriate setting based on the thickness and type of the metal be­ing welded. (Refer to Data Chart for actual settings).
3. TIG/MMA Switch – The TIG/MMA Switch allows selection between TIG Welding or Stick Welding configuration.
4. Torch Switch – The switch on the torch (FIG. C) controls starting and stopping the arc. When using the torch switch the Amperage is set on the adjustment knob on the front panel of the welder.
5. Foot Pedal (Not included) – The foot pedal is for starting and stopping the arc.(FIG. B)

SETUP

SHIELDING GAS CONNECTION ****

WARNING BUILDUP OF GAS CAN INJURE OR KILL! Shut off shielding gas supply when not in use. Ensure adequate ventilation. Do not weld in confined spaces. Always turn your face away from valve outlet when opening cylinder valve.

A Shielding Gas Bottle is not included with your TL- 200T but is necessary while TIG welding. A Shielding Gas Bottle can be bought at most local Welding Supply Stores. TOOLIOM recommends the use of 100% Argon shielding gas when TIG welding Steel and Stainless Steel.

1. Place the TOOLIOM TL-200T in its dedicated area or on a welding cart.
2. Secure your Shielding Gas Bottle to a stationary object or mount to your welding cart if it is equipped to hold one so that the cylinder cannot fall over.
3. Remove the cap from the Shielding Gas Bottle.
4. Insert the large brass male fitting on the Shielding Gas Regulator into the female fitting on the Shielding Gas Bottle (FIG. D).
5. Tighten the fitting with a wrench till snug, do not over tighten.
6. Connect either end of the Gas Line (included) with your TOOLIOM TL-200T to the fitting on the regulator and tighten with a wrench until snug. Torch 0.. Flow Switch Through Connection Power Cable (BtACK)
7. Connect the other end of the gas line to the fitting on the rear of the TOOLIOM TL-200T and tighten with a wrench until snug (FIG. E).

Electrode Selection

Before beginning welding with your TOOLIOM TL-200T, you will need to purchase electrodes as these are a consumable item in the ARC welding process. There are a variety of different types of rods available and should be selected depending on the project on hand. The chart below is an overview of some of the most popular electrodes.

suit­ able for moderate penetration.

POLARITY SELECTION

The TOOLIOM TL-200T can weld in both Direct Current Electrode Positive (DCEP) and Direct Current Electrode Negative (DCEN). The electrode, or rod, when welding in DCEP is positive and the grounded surface is negative. This polarity is used with electrodes that specify it and is usually the most commonly used polarity when ARC welding for general purpose use. The electrode when weld­ing in DCEN is negative and the grounded surface is positive. This polarity is used with electrodes that require using this polarity and is usually used for building up heavy deposits of material with less pene­tration.

To use the TOOLIOM TL-200T in DCEP:

• Locate the Ground Clamp with Cable and connect the plug on the cable end to the Ground Cable Connector (-) on the Welder. To connect the plug line up the key on the plug with the keyway on the socket of the Welder, insert the plug and twist until it is tight.
• Locate the Electrode Holder with Cable and connect the plug on the cable end to the Electrode Holder Connector (+) on the Welder. To connect the plug line up the key on the plug with the keyway of the socket on the Welder, insert the plug and twist until it is tight.

To use the TOOLIOM TL-200T in DCEN:

• Locate the Ground Clamp with Cable and connect the plug on the cable end to the Positive Connector(+) on the Welder. To connect the plug line up the key on the plug with the keyway on the socket of the Welder, insert the plug and twist until it is tight.
• Locate the Electrode Holder with Cable and connect the plug on the cable end to the Negative Connector (-) on the Welder. To connect the plug line up the key on the plug with the keyway on the socket of the Welder, insert the plug and twist until it is tight.

HF TIG WELDING SET-UP

DANGER ELECTRIC SHOCK CAN CAUSE INJURY OR DEATH!

• Disconnect Welder from power supply before beginning.
• Set the Welder on a flat surface in the general area where the Welder will be used. A dedicated cart is best.
• Set the TIG/MMA Switch on the Front Panel to “TIG”.
• Insert the Brass Connector of the TIG Torch Cable into the Gas Flow Power Cable on the Lower Left Front Panel of the Welder. To connect the plug line up the key on the plug with the keyway on the socket of the Welder, insert the plug and twist until it is tight.
• Insert the Brass Connector of the Ground Cable into the Positive (Red+) on the Lower Right Front  Panel of the Welder. To connect the plug line up the key on the plug with the keyway on the socket of the Welder, insert the plug and twist ½ turn until it is tight.
• Connect the Welder to a power source. This Welder requires a minimum (30 Amp @ 120V/ 20 Amp @ 230V), 50/60 Hz Protected Circuit.
• Make sure electrode holder without connection on the front panel during HF TIG process.
• Connect the Ground Clamp to a clean bare metal surface of the part to be welded.
• Turn on the Power Switch at the back Panel of the Welder.
• The Welder is now ready for use.

TIG TORCH CONNECTION

WARNING ELECTRIC SHOCK CAN CAUSE INJURY OR DEATH! Disconnect Welder from power aupply before assembly or disassembly of Torch and Cables.

1. Install the plastic connection cover onto the brass torch fitting on the torch cable.
2. Connect the female brass filing on the torch cable to the male brass fitting(Torch Switch) on the welder (FIG. F).
3. Use a wrench and tighten until snug. DO NOT OVERTIGHTEN.
4. Connect the metal plug to the Torch Switch Connection as shown (FIG. F).
   NOTE: Omit this step if you will be using the foot pedal for Amperage control

STICK WELD CONNECTION

1. Disconnect and remove the TIG Torch/Foot Pedal Connections if in place.
2. Insert the BLACK Stick Weld Connector into the BLACK Stick Weld Connection located at the far left of the Front Panel (FIG. F). With the Key of the Connector at the 12:00 position, push in and rotate 180° Clockwise to lock the connector in.
3. Insert the RED Ground Connector into the RED Ground Connection located at the far right of the Front Panel (FIG. F). With the Key of the Connector at the 12:00 position, push in and rotate 180° Clockwise to lock the connector in. NOTE: The above connections are the standard default for Stick Welding. If your material or rod preference dictates it, the Stick Weld and Ground Connections may safely be reversed.

PREPARING TO TIG WELD

TORCH DISASSEMBLY

WARNING ELECTRICS HOCK CAN CAUSE INJURY O R D EATH! Disconnect Welder from power supply before assembly or disassembly of Torch and Cables.

1. Make sure the welder is turned off and unplugged.
2. Remove the back cap from the torch.
3. If there is a tungsten installed in the torch pull it out of the front of the torch.
4. Slide the collet out of the torch.
5. Unscrew and remove the gas nozzle.
6. Unscrew and remove the collet body

TORCH ASSEMBLY

1. Select a collet body that matches your tungsten diameter size and thread it back into the front of the torch.
2. 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.
3. The nozzle size should be changed 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.
4. 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 specifically designed Tungsten Grinders are available.

1. Shut off the welder.
2. Make sure the Tungsten and Torch are suffi­ciently cooled for handling then loosen and re­move the Back Cap, then the Collet (FIG. G) and remove the Tungsten from the FRONT of the Torch only (Removing from the rear will dam­age the Collet).

CAUTION 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 specifi c grinders, sanders or other power tools used before and after the welding process. Be aware of all power tool safety warnings.

• 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 (FIG. H).
• 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. I).
• Replace the Tungsten in the Collet with the tip extending 1/8″-1/4″ beyond the Gas Nozzle, then re-tighten the Back Cap.

SETTINGS SELECTION

With the materials selected of which you will be welding you can begin to set up the welder for the specific material.

1. Amperage – If welding using the switch on the torch to start and stop the arc, set the Output Amperage Knob marked “A”(FIG. A) located at upper left of the top panel to an appropriate set­ting based on the thickness and type of the metal being welded (Refer to Data Chart for actual settings) If welding using the foot pedal to start and stop the arc, it uses the same operation as the panel control (FIG. B).
2. Power Switch – Once all of the settings have been selected and the torch assembled and ready to use, the welder can be plugged in and turned on.

SHIELDING GAS FLOW ADJUSTMENT

WARNING BUILDUP OF GAS CAN INJURE OR KILL!

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

After connecting your Shielding Gas Regulator, the gas flow rate needs to be adjusted so that the proper amount of Shielding Gas is flowing over your weld. If there is too little gas flow there will be po­rosity in your welds as well as excessive spatter, if there is too much gas flow you will be wasting gas and may affect the weld quality.

1. Open your Shielding Gas tank valve all the way.
2. Adjust the knob on the regulator to 20 CFH.
3. Turn on the welder and trigger the torch switch which will start the gas flow.
4. As you trigger the torch switch you will notice that as the gas flow starts, the needle on the gauge drops to a steady reading. The reading while flowing is the value you want to read.
5. The gas flow should be set to 12-20 CFH while flowing. The CFH (Cubic Feet per Hour) scale is the inside scale in red on your flow gauge. 20 CFH is the most typical flow rate but it may need to be adjusted in some cases depending if there is a slight breeze or some other instance where additional shielding gas is required to prevent porosity in the weld.
6. When finished welding remember to close the gas valve on the bottle.

TIGWELDING

IMPORTANT NOTE: These instructions are intended only to provide the user with some familiarity of the TOOLIOM TL-200T. 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 and stainless steel. 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.

WARNING 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 weather­stripping, dash boards, engines, etc.
• Ensure power supply has properly rated wiring to handle power usage.

WARNING FUMES & WELDING GASES CAN BE A HEAL TH 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.

WARNING ELECTRIC SHOCK CAN CAUSE INJURY OR DEATH!

• Improper use of an electric welder can cause electric shock, injury and death! Read ell 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 torch, contact tip and
• when installing or removing nozzles.
• Always wear dry, protective clothing end leather welding gloves and insulated footwear. Use suitable clothing made from durable flame-resistant material to protect your skin.
• If other persona 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 your bare akin 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 beat weld.

CAUTIONS HOT METAL & TOOLS WILL BURN!

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

WARNING 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 ere in the area of welding, use welding screens to protect by­standers from sparks and arc rays.

1. Turn the Power Switch to the on position.

2. Slowly open the gas cylinder valve.
   NOTE: Always open valve fully to avoid shield­ing gas leakage.

3. Depress gun trigger switch or foot pedal and ad­ just the flow regulator. (Refer to Data Chart for actual settings).

4. 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.

5. Use a dedicated stainless steel brush or flap­ disc to clean the areas to be welded. Do not use the brush or flap-disc for any other purpose.

6. Making 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.

7. 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 back­ ward and approx. 20° opposing the direction of travel. Hold the Filler Metal Rod at a 90° angle to the Tungsten Tip ( FIG. J ). Never allow the Tungsten Tip to touch the welding surface or ma­ terial rod. Doing so will quickly destroy the tip and contaminate the weld. If this happens, re­ move the Tungsten and regrind the tip. It is best to hold the tungsten tip 1/8″ from the surface.

8. With your Welding Shield and all safety gear in place, depress the foot pedal or 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.

9. Keep in mind that you MUST let the shielding gas flow over the weld after releasing the trigger or pedal. Failure to do so will allow the welded area to oxidize compromising the weld integrity.

10. 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.

11. When done, shut off the Power Switch and close the Shielding Gas Tank valve completely.

WELDER CARE & MAINTENANCE

• Constantly inspect the torch tip for excessive erosion, molten metal accumulation burning. If damaged, it must be replaced.
• Before each use, inspect ALL electrical connections, cables, supply line, torch, air supply, housing and controls for damage. If any damage or wear is noted, DO NOT USE THE UNIT.
• If the welder requires service, it should be performed by a certified repair facility using only authorized replacement parts to maintain full safety and performance integrity of the welder.
• Always store the unit in a safe, clean and dry environment.

WARNING ELECTRIC SHOCK CAN CAUSE INJUUY OR DEATH!

Disconnect welder from power supply before assembly, disasaembly or maintenance of the torch, contact tip and when installing or removing nozzles.

TIG TROUBLESHOOTING

Arc is triggered but will not start

| ****

Incomplete Circuit

| Check Ground connection. 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 E3 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.
 | Poorly prepped

tungsten

| Follow guidelines for prepping tungsten.
 | Poor Gas Flow| Adjust the flow rate of the shielding gas(refer to setting

chart). Check for loose fittings where gas could be leaking.

Arc wanders and it is hard| Contaminated Tungsten| Remove tungsten from torch and break off contaminated section and resharpen.
to concentrate

heat in a

| Incorrect arc length| Make sure the tungsten is held 1/8 to 1/4 inch off the work piece.
specific area|  |

Incomplete Circuit

| Check Ground connection. 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.

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 COiiet.

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.
Wrong Size Tungsten| Increase tungsten diameter. Refer to chart for proper siz­ ing.
Incorrect Shielding Gas| Only use 100% Argon when TIG Welding.
Poor

Penetration

| Low Voltage| Voltage 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 tung­ sten comes in contact break off end and resharpen imme- diately.

Poor Weld Appearance

| ****

Incorrect positioning

| The angle between the filler metal and the torch must be less than 90 degrees other wise the filler metal will prema­ turely 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 tung­ sten.
---|---|---
Not Enough Filler Material| Reduce current 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 require­ ments)
Incorrect Filler Wire| Use appropriate filler wire type and diameter for the joint be­ ing 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 devel­ oped.

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 tech­ niques, alternating sides, and/or taking your time and al­ lowing the pieces to cool between passes.

STICK WELDING

WARNING 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 weather­stripping, dash boards, engines, etc.
• Ensure power supply has properly rated wiring to handle power usage.

WARNING FUMES & WELDING GASES CAN BE A HEAL TH 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.

WARNING 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 Manuel to reduce the possibility of electric shock. Disconnect welder from power supply before assembly, disassembly or maintenance of the torch, contact tip and when installing or removing nozzles.
• Always wear dry, protective clothing end leather welding gloves and insulated footwear. Use suitable clothing made from durable flame-resistant material to protect your skin.
• If other persons or pets ere 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” perts to come in contact with your 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 es close to the weld area as possible. This will give the least resistance and best weld.

WARNING HOT METAL & 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 TOOLIOM or any other welding equipment. Never touch welded work surface, torch tip or nozzle until they have completely cooled.

WARNING ARC RAYS CAN BURN!

• Arc rays produce intense ultraviolet radiation which can burn exposed skin end 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.

1. Plug the power cord into a properly grounded, 110-120 Volt AC, 50/60Hz, 20 Amp or a 220-240 Volt AC 50/60Hz. 30-50 Amp circuit.
2. Move the TIG/Stick Switch to the “MMA” position.
3. Make sure the Electrode or “Stick” is not touching with the grounded workpiece.
4. Switch the Power Switch to “On”.
5. 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.
6. Feed the Welding Rod into the workpiece joint at a 15° angle.
7. Lift rod from workpiece when weld bead is completed.
8. Turn off Welder power switch.
9. Set the Electrode or “Stick” Holder on a safe, non-flammable, surface.

FREQUENTLY ASKED QUESTIONS

What is the TOOLIOM TL-200T Digital Inverter Welder TIG?

The TOOLIOM TL-200T is a digital inverter welder designed for TIG (Tungsten Inert Gas) welding. It offers advanced features for precision welding applications.

How does the TOOLIOM TL-200T operate?

The TOOLIOM TL-200T operates as a TIG welder, utilizing advanced inverter technology to provide a stable welding arc. It is suitable for welding various metals, including stainless steel and aluminum.

Is the TOOLIOM TL-200T suitable for both professional and DIY welding?

Yes, the TOOLIOM TL-200T is designed to meet the needs of both professional welders and DIY enthusiasts. It offers versatile features and ease of use for a wide range of welding projects.

What types of metals can the TOOLIOM TL-200T weld?

The TOOLIOM TL-200T is suitable for welding various metals, including stainless steel, aluminum, and other alloys commonly used in welding applications.

Does the TOOLIOM TL-200T support DC or AC TIG welding?

The TOOLIOM TL-200T typically supports DC (Direct Current) TIG welding. Users should refer to the product specifications for details on the supported welding modes.

What is the welding thickness capacity of the TOOLIOM TL-200T?

The welding thickness capacity of the TOOLIOM TL-200T may vary. Users can find this information in the product specifications, helping determine the welder's capabilities for different material thicknesses.

Is the TOOLIOM TL-200T easy to set up and use?

Yes, the TOOLIOM TL-200T is typically designed for ease of setup and use. It often features user-friendly controls and comes with a user manual that provides step-by-step guidance on setting up and using the welder.

Does the TOOLIOM TL-200T have adjustable welding parameters?

Yes, the TOOLIOM TL-200T usually offers adjustable welding parameters, allowing users to customize settings such as welding current, pulse frequency, and arc force to suit different welding requirements.

What is the duty cycle of the TOOLIOM TL-200T?

The duty cycle of the TOOLIOM TL-200T may vary, and users can find this information in the product specifications. The duty cycle indicates the amount of time the welder can operate continuously before requiring a cooldown period.

Can the TOOLIOM TL-200T be used for both TIG and stick welding?

The TOOLIOM TL-200T is primarily designed for TIG welding. Users should check the product specifications to determine if it supports stick welding or if it is specifically tailored for TIG applications.

Is the TOOLIOM TL-200T suitable for mobile welding applications?

The suitability of the TOOLIOM TL-200T for mobile welding applications may depend on factors such as its weight, portability features, and power requirements. Users should refer to the product specifications for information on its mobility.

What is the input power requirement for the TOOLIOM TL-200T?

The TOOLIOM TL-200T typically requires a specific input power, usually specified in voltage and amperage. Users should check the product specifications to ensure compatibility with their power source.

Does the TOOLIOM TL-200T come with a warranty?

Yes, the TOOLIOM TL-200T usually comes with a warranty. The warranty typically range from 1 year to 2 years.

Is technical support available for the TOOLIOM TL-200T?

Many manufacturers provide technical support and customer assistance for the TOOLIOM TL-200T to address setup, usage, and troubleshooting questions. Users can reach out to the manufacturer's support channels for assistance.

Can the TOOLIOM TL-200T be used with generators for remote welding?

The ability of the TOOLIOM TL-200T to be used with generators for remote welding depends on its power requirements and compatibility. Users should check the product specifications for information on generator compatibility.

What safety features does the TOOLIOM TL-200T have?

The TOOLIOM TL-200T may include various safety features such as overheat protection, voltage fluctuation protection, and others. Users should refer to the product specifications for details on the safety features implemented in the welder.

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