Metal Man 200iDV Owner'S Manual Download

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Page of 33

TROUBLESHOOTING

Failure

Possible Cause

Corrective Action

Unit does not power
up.

Unit is not plugged in.

Plug in unit.

Input power circuit breaker is not on.

Reset input power circuit breaker.

The main power switch is not working.

Replace main power switch.

Temperature indicator
is on.

The internal temperature is too high.

Leave power on and let the fan cool the unit.
Output will continue when the unit has cooled.

Cooling fan is damaged.

Replace cooling fan.

Alarm indicator is on.

Input power voltage is too high or too low.

Meter input power voltage. This unit must be used
with input voltage that ranges from 230V AC plus
or minus 15%. 120V plus or minus 15% when
operating on 120V.

TIG arc does not start.

Remote foot pedal control is broken.

Replace remote control.

Work piece is painted or rusty.

Remove all paint and rust.

Ground clamp is connected where there is paint or
rust.

Remove all paint and rust so ground clamp is
connected to bare metal.

Ground clamp is not electrically connected to the
work piece.

Make certain the ground clamp is connected to
the work piece.

Wrong shielding gas.

Check to make certain you are using 100% Argon
shielding gas.

Main PC Board has failed.

Replace the Main PC Board.

HF PC Board has failed.

Replace the HF PC Board.

Stick amperage seems
low.

Remote control is installed.

Remove remote control.

Amperage is set too low.

Increase the amperage. See the Setting-Up
Equipment section.

There is no shielding
gas.

Shielding gas bottle is empty.

Fill the shielding gas bottle.

Shielding gas bottle supply valve is off.

Open valve on shielding gas bottle.

Gas flow rate on regulator is off or very low.

Adjust gas flow rate to 20 CFH.

Gas valve has failed.

Replace gas valve.

Main PC Board has failed.

Replace Main PC Board.

Cooling fan is not
working.

Cooling fan has failed.

Replace cooling fan.

Cooling fan connections have come loose.

Inspect cooling fan connections and repair.

There is no display on
the digital meters.

The adjustment potentiometer has failed.

Replace the adjustment potentiometer.

The adjustment potentiometer connections have
come loose.

Inspect the adjustment potentiometer connections
and repair.

Main PC Board has failed.

Replace Main PC Board.

For assistance, contact the Welder Help Line at 888-762-4045

Summary of Contents for 200iDV

Page 1: ... TIG OWNER S MANUAL 04 2018 WARNING Read carefully and understand all ASSEMBLY AND OPERATION INSTRUCTIONS before operating Failure to follow the safety rules and other basic safety precautions may result in serious personal injury ...

Page 2: ...n liner drive roll electrode holder ground clamps Plasma torch parts nozzle electrode diffuser cover and TIG torch parts collet collet body tungsten backcap are considered consumable items and are not covered under warranty 90 days Parts for Metal Man Work Gear welding carts and welding cabinets This warranty covers the absence of or defective parts 3 year This 3 year warranty covers parts and Lab...

Page 3: ...dry and ventilated Do not operate the welder in humid wet or poorly ventilated areas Always have your welder maintained by a qualified technician in accordance with local state and national codes Always be aware of your work environment Be sure to keep other people especially children away from you while welding Keep harmful arc rays shielded from the view of others Mount the welder on a secure be...

Page 4: ...and insulated footwear Insulate yourself from the work piece Avoid contacting the work piece or ground Do not attempt to repair or maintain the welder while the power is on Inspect all cables and cords for any exposed wire and replace immediately if found Use only recommended replacement cables and cords Always attach ground clamp to the work piece or work table as close to the weld area as possib...

Page 5: ...mmable or explosive materials are present Remove all flammable materials within 35 feet of the welding arc If removal is not possible tightly cover them with fireproof covers Take precautions to ensure that flying sparks do not cause fires or explosions in hidden areas cracks or areas you cannot see Keep a fire extinguisher close in the case of fire Wear garments that are oil free with no pockets ...

Page 6: ...e proper regulators gas hose and fittings for the specific application Do not look into the valve when opening it Use protective cylinder cap whenever possible 1 5 Proper Care Maintenance and Repair Always have power disconnected when working on internal components Do not touch or handle PC board without being properly grounded with a wrist strap Put PC board in static proof bag to move or ship Do...

Page 7: ... stainless steel In the AC TIG mode you are able to TIG weld non ferrous metals such as Aluminum This unit is equipped with advanced TIG capabilities including Pulse AC Arc Frequency Control AC Arc Balance Control and Auto Balance Frequency Control The advanced inverter technology that powers the 200iDV AC DC provides for better arc control lower power consumption in a lighter more portable unit D...

Page 8: ...below this set of indicators lights is pushed the operator can sequence through the different welding processes INDICATOR LIGHTS The indicator lights can be used to help with troubleshooting the welder When the power indicator light is on input power is supplied to the main transformer and control circuit When the work indicator is on it is indicating welding current is activated When the temperat...

Page 9: ...s less than 215 volts AC or greater than 240 volts AC 2 POWER REQUIREMENT 120V AC single phase 120V 110 130V 50 60 HZ fused with a 20 amp time delayed fuse or circuit breaker is required DO NOT OPERATE THIS UNIT if the ACTUAL power source voltage is less than 110 volts AC or greater than 130 volts AC a When connecting this unit to 120V power connect the 120V adapter cord to the power cord pigtail ...

Page 10: ...nd cable and clamp would be attached to the Positive weld output connection Use this same connection when AC TIG welding Connect the Remote Foot Pedal to the Remote connection on the lower front panel Connect the TIG torch gas supply line to the Gas Outlet on the lower front panel 6 BACK PANEL CONNECTIONS Remote Foot Pedal Connection TIG Torch Gas Connection Power Cord Power Switch Shielding Gas C...

Page 11: ...he gas connection is not pointing toward you or any other person Turn the valve on the gas bottle clockwise and quickly close This quick thrust of gas will clear any debris in the connection Connect the regulator to the gas bottle connection Use a wrench to snug up the connection 1 Gas Bottle Valve 2 Gas Flow Gauge Set at 20 CFH 3 Gas Pressure Gauge 4 Regulator 5 Gas Flow Adjuster 6 Gas Hose Conne...

Page 12: ...l to the Foot Pedal Connection on the front of the unit EQUIPMENT SET UP Electrical Shock Can Kill High voltage danger from power source Consult a qualified electrician for proper installation of receptacle This welder must be grounded while in use to protect the operator from electrical shock Do not remove grounding prong or alter the plug in any way Use only the supplied adapter between the weld...

Page 13: ...ve which of the Weld Process Indicator Lights is on b Press the button under the under the weld process indicators until the Weld Process Indicator Light next to your desired weld process is on 2 DC STICK SET UP AVOID ACCIDENTAL ARCING When in the STICK welding mode the weld output connections of this unit are electrically hot To avoid accidental arcing be mindful of the welding accessories that a...

Page 14: ...ays the desired Current A setting 3 DC TIG SET UP a See the ASSEMBLY section for the correct welding accessories connections for DC TIG Welding b Turn the input power switch ON c Press the Weld Process Selector button until the Weld Process Indicator Light next to DC TIG is on i If the operator wants to use Pulse DC TIG press the Weld Process Selector until the Weld Process Indicator Light next to...

Page 15: ...the peak amperage and background amperage will automatically be adjusted proportionally g If the operator is using Pulse DC TIG they will need to adjust the number of times per second that the welder will pulse between the peak amperage high end amperage and the background amperage low end amperage i Press the weld parameter selector button until the indicator light in front of the Pulse Frequency...

Page 16: ...uency and the AC Balance automatically based on the amperage the operator is welding at i Press the Weld Parameter Selector button until the Indicator Light is On for the AUTO Balance Frequency Weld Parameter You will notice that both the AUTO Balance Frequency Indicator and the Current A Indicators are on ii The Digital Meter is displaying the Current A setting iii Turn the Parameter Adjustment C...

Page 17: ...al Meter is displaying the Current A setting iii Turn the Parameter Adjustment Control until the Digital Meter displays the desired Current A setting This is the current setting that the operator wants when the foot pedal is completely pressed to the maximum The operator will then have control of the Current A output from minimum amperage to this maximum setting by varying the amount the operator ...

Page 18: ...r supply 1 SETTING UP THE WORK PIECE 1 1 Welding positions There are two basic positions for welding Flat and Horizontal Flat welding is generally easier faster and allows for better penetration If possible the work piece should be positioned so that the bead will run on a flat surface 1 2 Preparing the Joint Before welding the surface of work piece needs to be free of dirt rust scale oil or paint...

Page 19: ...arc between the rod and the grounded metal melts the electrode and the flux 4 SELECTING THE PROPER ELECTRODE There is no golden rule that determines the exact rod or heat setting required for every situation The type and thickness of metal and the position of the work piece determine the electrode type and the amount of heat needed in the welding process Heavier and thicker metals required more am...

Page 20: ...ge required for every situation It is best to practice your welds on scrap metal which matches the metals you intend to work with to determine correct setting for your job The electrode type and the thickness of the work piece metal determine the amount of heat needed in the welding process Heavier and thicker metals require more voltage amperage whereas lighter and thinner metals require less vol...

Page 21: ...process and it should be neither too wide nor too narrow If too narrow the rod will stick to the work piece If too wide the arc will be extinguished It takes much practice to maintain the gap The beginners may get stuck or arc will be extinguished When the rod is stuck to the work piece gently rock it back and forth to make them separate If not a short circuit will occur and it will break the weld...

Page 22: ...eing perpendicular to the work piece 6 5 Judge the good weld bead When the trick of establishing and holding an arc has been learned the next step is learning how to run a good bead The first attempts in practice will probably fall short of acceptable weld beads Too long of an arc will be held or the travel speed will vary from slow to fast see following A Weld speed is too fast B Weld speed is to...

Page 23: ...ts of the head hands or exposed portions of the body Wear goggles or safety glasses with side shields and protect the hands and other exposed parts of the body with protective garments or if possible work with a shield between the body and the work piece The intense heat produced at the arc sets up strains in the metal joined by welding Peening the weld not only removes the scale left behind in th...

Page 24: ...HE EYES AND SKIN Prolonged exposure to the welding arc can cause blindness and burns Never strike an arc or begin welding until you are adequately protected Wear flame proof welding gloves a heavy long sleeved shirt trousers without cuffs high topped shoes and an ANSI approved welding helmet Be aware that the TIG torch will be electrically LIVE when the Input Power Switch on the welder is turned o...

Page 25: ...Page of 33 25 Guide for Selecting Filler Wire Diameter Tungsten Electrode Types Aluminum Welding Material Welding Rate ...

Page 26: ...ed as a specialized process that requires operator competency While many of the principles outlined in the previous Arc Welding section are applicable a comprehensive outline of the TIG Welding process is outside the scope of this Operating Manual ...

Page 27: ...s power cord directly to a properly grounded 120 VAC 60 Hz single phase 20 amp input power supply Maintain your welder It is recommended that the general condition of any welder be examined before it is used Keep your welder in good repair by adopting a program of conscientious repair and maintenance Have necessary repairs made by qualified service personnel Periodically clean dust dirt grease etc...

Page 28: ... certain the ground clamp is connected to the work piece Wrong shielding gas Check to make certain you are using 100 Argon shielding gas Main PC Board has failed Replace the Main PC Board HF PC Board has failed Replace the HF PC Board Stick amperage seems low Remote control is installed Remove remote control Amperage is set too low Increase the amperage See the Setting Up Equipment section There i...

Page 29: ...Page of 33 29 MAIN CIRCUIT CHART ...

Page 30: ...Page of 33 30 DIAGRAM PARTS LIST ...

Page 31: ...NK INSULATOR 1 22 105500033 FEET 4 23 105500108 MAIN CONTROL TRANSFORMER 1 24 105500128 OUTPUT ABSORBER PC BOARD 1 25 105500109 COUPLING TRANSFORMER BRACKET 1 26 105500129 COUPLING TRANSFORMER 1 27 105500037 GAS CONNECTOR 1 28 105200131 REMOTE CONTROL CONNECTOR 1 29 105200136 WELD OUTPUT QUICK CONNECTOR 2 30 105500131 POTENTIOMETER KNOB 1 31 105500132 FRONT PANEL 1 145500002 FRONT PANEL DECAL 200i...

Page 32: ...ZLE 7 1 2 105500078 COLLET BODY 1 3 105500010 COLLET 1 4 105500079 TORCH HEAD 1 5 105500080 SHORT BACK CAP 1 105500081 LONG BACK CAP 1 6 105500082 CONNECTOR ASSEMBLY 1 7 105500083 TIG TORCH HANDLE 1 8 105500084 TIG TORCH GAS HOSE 1 9 105500085 TIG TORCH CONTROL CABLE 1 10 105500086 M10 X 1 TORCH CONNECTOR 1 ...

Page 33: ...Page of 33 33 Metal Man Work Gear Company 1760 Prospect Ct 120 Appleton WI 54914 ww w m e ta l m a n g e a r c o m 8 8 8 7 6 2 4 0 4 5 ...

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