DeWalt DCW100 Instruction Manual

Page dimensions: A5 (8.2677 x 5.8268 inches)

DCW100

Portable Stick and TIG Welder Soldadora Portátil de Electrodo y TIG Soudeuse Portative à Électrode Enrobée et à Électrode de Tungstène

INSTRUCTION MANUAL GUIDE D’UTILISATION MANUAL DE INSTRUCCIONES

INSTRUCTIVO DE OPERACIÓN, CENTROS DE SERVICIO Y PÓLIZA DE GARANTÍA. ADVERTENCIA: LÉASE ESTE INSTRUCTIVO ANTES DE USAR EL PRODUCTO.

If you have questions or comments, contact us.

Pour toute question ou tout commentaire, nous contacter.

Si tiene dudas o comentarios, contáctenos.

1-800-4-DEWALT • www.dewalt.com

Page dimensions: A5 (8.2677 x 5.8268 inches)

English

Deﬁ nitions: Safety Guidelines

The definitions below describe the level of severity for each signal word. Please read the manual and pay attention to these symbols.

DANGER: Indicates an imminently hazardous situation

which, if not avoided, will result in death or seriousinjury.

WARNING: Indicates a potentially hazardous

situation which, if not avoided, could result in death or

seriousinjury.

CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderateinjury. NOTICE: Indicates a practice not related to personal injury which, if not avoided, may result in

propertydamage.

IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS OR ANY D

EWALT TOOL, CALL US TOLL FREE AT:

1-800-4-D

EWALT (1-800-433-9258).

FOR ALL SERVICE/REPAIR QUESTIONS ON THE WELDER, CALL 1-800-4-D

EWALT (1-800-433-9258). IF PRODUCT

NEEDS TO BE RETURNED FOR SERVICE, THE D

EWALT CALL

CENTER WILL PROVIDE PACKAGING FOR SHIPPING.

Important Safety Instructions

WARNING: Do not operate this unit until you have carefully read

and understand this instruction manual for safety rules, workplace preparation, assembly, operation and maintenance instructions.

WARNING: To reduce the risk of injury, read

the instructionmanual.

SAVE ALL WARNINGS AND INSTRUCTIONS

FOR FUTURE REFERENCE

Safety Rules and Warnings for Portable Welders

• ALWAYS wear regulation protective gear and clothing.

Protective visor, regulation filter, ear protection, goggles with side protection, insulated gloves and insulated footwear should be worn when welding.

DANGER: Heat, flying sparks, pieces of hot metal and arc

radiation can damage skin and eyes.

• ALWAYS wear protective helmet to protect eyes

and face from UV rays, heat and sparks.

• Wear regulation protective goggles with side protection and filter behind the protective visor.

• Wear correct eye, ear and body protection.

DANGER: Fumes produced during welding contain harmful gases and vapors and must not be breathed in. Welding fumes contain substances that may, under certain

circumstances, cause birth defects or cancer.

• NEVER use welder in poorly ventilated or

enclosed areas. Fumes produced during welding contain harmful gases and vapors can build up in these areas.

• Fumes and hazardous gases must be extracted from the work area using appropriate methods. If there is any doubt that extraction method is adequate, the measured toxic emission values must be compared to the permissible limit values.

• Ventilate the work area to ensure an adequate supply of fresh air. Otherwise, a protective mask with an air supply must be worn.

• Read all the relevant material safety data sheets and manufacturer's specifications for the listed components. Metals used for the workpiece, electrodes, coatings, cleaners, etc. can be responsible, amongst other things, for the degree of toxicity of welding fumes.

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DANGER: Flying sparks and hot pieces of metal may burn

operator, cause clothing to catch fire or cause explosions.

• ALWAYS wear protective equipment and proper

clothing. Do not wear clothing with cuffs or turnups that sparks could get into.

• Never weld near flammable materials. Flammable materials must be at least 36 feet away from the arc or properly protected by an approved cover.

• NEVER perform welding on containers that were used to store combustible materials (e.g. gases, propellants, oils). Material residues pose an exploding hazard.

• NEVER perform welding near areas subject to fire or near sealed tanks, vessels or pipes.

• A suitable, tested fire extinguisher must be nearby and ready for use when welding.

DANGER: Failed or damaged parts can explode or cause

other parts to explode when power is applied.

• Never expose the device to naked flames or permanent heat source. Excessive heat can cause the battery to explode or burst.

• ALWAYS wear welding helmet and long sleeves when servicing the unit.

DANGER: Electric current flowing through any conductor

causes localized Electric and Magnetic Fields (EMF). Electromagnetic fields may pose as yet unknown risks to health.

• Wearers of pacemakers must seek medical advice before coming near the device or any welding operation in progress.

• For safety reasons, keep distances between the welding cables and the welder's head/torso as large as possible.

• Do not carry welder cables and hoses over the shoulders or wrap around any part of thebody.

DANGER: Noise generated from welding can be damaging

to eardrums and contribute to hearing loss.

• Always wear proper personal hearing

protection that conforms to ANSI S12.6 (S3.19) during use. Under some conditions and duration of use, noise from this product may contribute to hearing loss.

DANGER: Welding comes with the risk of electricution

from the mains connection and/or welding current.

• NEVER touch live parts inside or outside of the

the unit.

• Keep all panels and covers securely in place and disconnect power before servicing.

• ALWAYS wear suitable gloves (electrically insulated and providing protection against heat).

• ALWAYS ensure operator and others nearby are adequately protected and insulate from the work and ground.

• All cables and leads must be secure and insulated. Loose, scorched, or otherwise damaged cables must be repaired/replaced immediately.

• The electrode must never be immersed in liquid for cooling or touched when the power source is switched on.

DANGER: Electric shock can kill; significant DC voltage

exists after the removal of input power.

• ALWAYS wait 60 seconds after power is turned off before working on the unit.

• Check input capacitor voltage and be sure it is near 0 before touching any part of the welder.

English

CAUTION: Stipulated environmental temperatures must be

maintained during transport, storage or operation of the charger or else damage could result. The manufacturer shall not be held liable for any damage arising from such usage.

• Do not store or use the welder in locations

where the temperature may exceed 105°F (40 °C) or go below 14° F (40 °C) (such as outside sheds or metal buildings in summer).

For best battery life store in a cool, dry location.

• When storing or transporting the device, be sure the environment is not cooler than 68˚ F (20˚ C) or hotter than 131 °F (55 °C), the welder is fully charged before storage and is fully recharged every 6 months.

• Do not charge or use the welder in explosive atmospheres, such as in the presence of flammable liquids, gases ordust.

• The welder and charger should not be used be used at altitudes exceeding 2000 m (6561 ft. 8.16 in.)

CAUTION: Devices with a higher rating may affect the energy

quality of the mains due to their current input.

• The operator should check whether the device may be connected, where appropriate by discussing the matter with the power supply company.

• NOTE: Ensure that the mains connection is earthed properly

• Keep all persons, especially children, out of the working

area while any devices are in operation or welding is inprogress.

• Never use the device for thawing out pipes, charging batteries or starting engines.

Important Safety Instructions for Welder Battery

The welder battery is not fully charged out of the carton. Before using the welder, read the safety instructions below and then follow charging procedures outlined.

WARNING: Improper handling of rechargeable batteries

can cause injuries or damage. This device uses a lithium-ion batterypack.

• This manual contains important safety and operating instructions for battery charger model DCWB009.

• Before using battery charger, read all instructions and cautionary markings on battery charger, battery, and product using battery.

CAUTION: To reduce risk of injury, charge only lithium-ion

type rechargeable batteries. Other types of batteries may burst

causing personal injury and damage.

• Do not open the device or remove the battery. If the battery becomes damaged due to improper handling, poisonous substances can escape which may be harmful tohealth.

• Place the device on a solid, level surface so that it remains stable. A toppling device can cause life-threatening injuries. Do not allow the device to tilt past an angle 10˚.

• Do not use the handle strap to secure or hang the

welder or as a tether.

WARNING: Fire hazard. Never attempt to open the welder for

any reason. If the welder battery is cracked or damaged, do not use the welder.

• DO NOT splash or immerse in water or other liquids. This can cause a short circuit, even if the device is switched off. This in turn can cause the battery to become hot, ignite or burst.

• Charge the battery packs only with the designated D

EWALT

DCWB009 charger.

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WARNING: Improper handling can cause injuries or damage.

Do not open the device. The device may only be opened by D

EWALT service engineers. If you need a replacement battery,

hand the device over to a D

EWALT Service Partner. Changes or

modifications not expressly approved by the party responsible for compliance could void the user's authority to operate the equipment.

• This Class A digital apparatus complies with Canadian ICES-

003.

• This device complies with Part 15 of the FCC Rules and Industry Canada License-exempt RSS standard(s). Operation is subject to the following two conditions:

1) This device may not cause harmful interference, and

2) This device must accept any interference received, including

interference that may cause undesired operation.

NOTE: This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

– Reorient or relocate the receiving antenna. – Increase the separation between the equipment and

receiver.

- Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.

- Consult the dealer or an experienced radio/TV technician for help.

READ ALL INSTRUCTIONS

SPECIFIC SAFETY INSTRUCTIONS FOR LITHIUM ION (Li-Ion)

• Do not incinerate the battery even if it is severely damaged or is completely worn out. The battery can

explode in a fire. Toxic fumes and materials are created when lithium ion battery packs are burned.

• If battery contents come into contact with the skin, immediately wash area with mild soap and water. If battery liquid gets into the eye, rinse water over the open eye for 15 minutes or until irritation ceases. If medical attention is needed, the battery electrolyte is composed of a mixture of liquid organic carbonates and lithium salts.

• Contents of opened battery cells may cause respiratory irritation. Provide fresh air. If symptoms persist, seek medicalattention.

WARNING: Burn hazard. Battery liquid may be flammable if

exposed to spark or flame.

The RBRC™ Seal

The RBRC™ (Rechargeable Battery Recycling Corporation) Seal on the nickel cadmium, nickel metal hydride or lithium ion batteries (or battery packs) indicate that the costs to recycle these batteries (or battery packs) at the end of their useful life have already been paid by D

EWALT. In some areas, it is

illegal to place spent nickel cadmium, nickel metal hydride or lithium ion batteries in the trash or municipal solid waste stream and the RBRC program provides an environmentally conscious alternative. RBRC™, in cooperation with D

EWALT and other battery users, has

established programs in the United States and Canada to facilitate the collection of spent nickel cadmium, nickel metal hydride or lithium ion batteries. Help protect our environment and conserve natural resources by returning the spent nickel cadmium, nickel

English

SAVE THESE INSTRUCTIONS FOR

FUTURE USE

FEATURES (FIG. 1)

WARNING: Never modify any part of the welder, charger or

their accessories. Damage or personal injury could result.

WELDER COMPONENTS

A. (−) current socket B. (+) current socket C. Air filter D. Charger socket connection E. Carry strap F. Electrode holder G. Grounding clamp H. Setting value indicator I. Unit indicator

J. Batter capacity indicator K. Process indicator L. Welding process button M. LCD setting value display N. Status indicators O. Setting value button P. Adjusting dial Q. On/off Button

CHARGER COMPONENTS

R. Charger control panel S. Charger lead socket T. Mains cable U. Charging indicator V. Quick charging indicator

W. Completed indicator X. Error indicator Y. Mains indicator Z. Quick charge button

INTENDED USE

This portable welder is designed for professional STICK & TIG welding applications.

The device is intended solely for commercial use.

DO NOT use under wet conditions or in presence of flammable liquids or gases.

metal hydride or lithium ion batteries to an authorized DEWALT service center or to your local retailer for recycling. You may also contact your local recycling center for information on where to drop off the spent battery.

RBRC™ is a registered trademark of the Rechargeable Battery

Recycling Corporation.

• An extension cord must have adequate wire size (AWG or American Wire Gauge) for safety. The smaller the gauge number of the wire, the greater the capacity of the cable, that is 16 gauge has more capacity than 18 gauge. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. When using more than one extension to make up the total length, be sure each individual extension contains at least the minimum wire size. The following table shows the correct size to use depending on cord length and nameplate ampere rating. If in doubt, use the next heavier gauge. The smaller the gauge number, the heavier the cord.

Minimum Gauge for Cord Sets

Ampere Rating

Volts Total Length of Cord in Feet

(meters)

120 V 25 (7.6) 50

(15.2)

100

(30.5)

150

(45.7)

240 V 50

(15.2)

100

(30.5)

200

(61.0)

300

(91.4)

Than

Not More Than

AWG

0 6 18 16 16 14

610 18161412 10 12 16 16 14 12 12 16 14 12 Not

Recommended

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This portable welder is a professional power tool. DO NOT let children come into contact with the tool. Supervision is required when inexperienced operators use this tool. The device can be set up and operated outdoors in accordance with IP 23 degree of protection. The device is tested to IP 23 protection, meaning:

- protection against penetration by solid foreign bodies with diameters > 12.5 mm (0.49 in.)

- protection against direct sprays of water at any angle up to 60° from the vertical

Avoid direct wetting (e.g. from rain). The welder must be set up in such a way that cooling air can flow freely through the slots in the front and rear panels.

Charging the Welder

WARNING: Electric shock can be fatal. Do not open thecharger.

NOTICE: The onboard battery must be fully charged before using

the welder for the first time. The welder is designed to be connected to a power supply and charged exclusively via the D

EWALT DCWB009.

1. Connect the charger to a mains power supply.

2. Connect the charger to the connection socket (D) on the back panel of the welder.

NOTE: Once connected,

standard charging mode will start automatically. If Quick Charging is needed press the quick charge button (Z). For more details refer to Charger Operating Modes.

3. Allow welder to charge until the COMPLETED indicator (W) on the charger is illuminated.

CHARGING

INDICATORS

Fully charged

75% capacity

50% capacity

25% capacity

Fully discharged

FIG. 1

English

FIG. 2

WELDER BATTERY PROTECTION (FIG. 1) Deep discharge protection:

The device has a deep discharge protector to warn the user if the state of charge of the battery is too low. When the battery capacity is fully depleted all the segments of the battery capacity indicator(J) will go out and 'Lo' will appear in the digital display(M).

CAUTION: Deep discharge can ruin the battery. If the deep

discharge protector is activated, recharge the device immediately.

Battery temperature monitoring:

Temperature monitoring prevents the battery from being charged or discharged if it is outside the permitted temperature range. If the battery exceeds or falls below the permitted temperature range, the temperature icon (

) of the status indicators (N) will

light up and welding or charging is not possible.

Automatic Switch-off:

Automatic switch-off avoids unnecessary power consumption and thereby extends the effective period of operation with one battery

On the welder, the battery capacity indicator (J) blinks while charging to show the current state of charge. All segments will be illuminated when the battery is full. The 'COMPLETED' indicator, on the charger, will light when the battery is fully charged and the charger switches to conservation charging mode. The welder charging system is completely generator-compatible, provided the maximum apparent power delivered by the generator is at least 2 kVA. This is also the case if the generator in question is an inverter.

CHARGER OPERATING MODES (FIG. 2) Standard (default) charging mode: This mode starts

automatically when the charger is connected to the welder and the mains supply. Both the charging indicator (W) and the mains indicator (Y) will light. NOTE: This mode charges the battery to its optimal charging power and maximizes the service life of the battery. Quick charging mode: For a faster maximum charge the quick charge button (Z) switches the charger into quick charging mode. Both the quick charging (V) and the mains indicator (Y) will be lit when in this mode. Pressing the quick charge button (Z) a second time will stop quick charging mode and standard charging mode will resume. Conservation charging mode: When the completed indicator (W) lights, the battery is fully charged and the charger switches to conservation charging mode. NOTE: In this mode, the welder can remain connected to the charger without being damaged. Hybrid mode: The charger enters this mode automatically when the welder is in use while charger feeds the battery. The quick charging (V) and the mains indicator (Y) will be lit when in this mode. Hybrid mode stops when the charger is disconnected from the welder or the workload ceases.

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CHANGING WELDING PARAMETERS (FIG. 3)

1. Turn the adjusting dial (R) to select the required parameter.

2. Press the adjusting dial to display the preset value of the parameter in the LCD (M).

3. Turn the adjusting dial (R) to change the value. – The new value becomes

effective immediately.

– Exception: when restoring the factory settings, press

the adjusting dial after changing the value to activate the newvalue.

4. Press the adjusting dial to return to the list of parameters.

EXITING THE SETUP MENU

Press the setting value or Welding process button to exit from the Setup menu.

Parameters for MMA Welding

Parameter Description Range Unit

Starting current duration (Hti)

for the SoftStart / HotStart function Factory setting: 0.5 seconds

0.1 - 2 Seconds

Anti-Stick (Ast)

When the anti-stick function is active, the arc is extinguished after

1.5 seconds in the event of a short circuit (sticking of the electrode) Factory setting: ON (activated)

On/Off

FIG. 3

charge. If the device is not used or operated for a specified period of time, it switches off automatically. NOTE: The factory setting for the automatic switch-off time is 15minutes. To reactivate the device, press the On/Off button (Q) for at least 2 seconds.

Overcharge protection:

Once the battery has been fully charged, the charger turns off automatically and switches to conservation charging mode. In this mode the device can remain connected to the charger for any period of time.

OPERATION

WARNING: ALWAYS Check the charger lead, welding torch,

welding cable and grounding (earthing) connection for damage before every use.

CAUTION: Check that the device has an all-round clearance

of 1 ft. 8 in. (0.5 m) to ensure that cooling air can flow in and out freely. Air inlets and outlets must never be covered, not even partially. NOTICE: The onboard battery must be fully charged before using the welder for the first time. Refer to Charging the Welder.

Setup Menu

ACCESSING THE SETUP MENU

1. Use the welding process button (L) to select the process whose setup parameters are to be changed: – MMA welding – MMA welding with cellulose electrode – TIG welding

2. Press the setting value (O) and welding process buttons together. After releasing the buttons, the code for the first parameter in the Setup menu is displayed.

English

Parameters for TIG Welding

Parameter Description Range Unit

Comfort Stop Sensitivity (CSS)

This parameter is only available when the tri parameter is set to OFF. Factory setting: 2.0

0.3 - 2.0 Volt

Break voltage (Uco)

Used to specify at which arc length the welding process is completed. The welding voltage increases as the length of the arc increases. The arc is extinguished when it reaches the voltage specified here. Factory setting: 15 volts

12 - 35 Volt

Software version (SOF)

The full version number of the currently installed software is contained in a number of displays and can be retrieved by turning the adjusting dial.

Automatic switch-off (tSd)

If the device is not used or operated for a specified period of time, it switches off automatically. Factory setting: 900 seconds.

300- 900 Seconds

Parameter Description Range Unit

Break voltage (Uco)

25 - 80 Volt

Software version (SOF)

The full version number of the currently installed software is contained in a number of displays and can be retrieved by turning the adjusting dial.

Automatic switch-off (tSd)

If the device is not used or operated for a specified period of time, it switches off automatically. Factory setting: 900 seconds.

300- 900 Seconds

Factory setting (FAC)

This can be used to reset the device to its factory settings.

- Cancel reset

- Reset the parameters for the selected welding process to their factory settings

- Reset the parameters for all welding processes to their factory settings

Resetting of the selected value to its factory setting must be confirmed by pressing the adjusting dial.

no YES ALL

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5. Insert the rod electrode into the electrode holder (F).

6. Press the On/Off button for at least 2 seconds to turn the welder on.

WELDING (FIG. 1)

1. Use the welding process button to select (illuminate) one of the following processes from the process indicator (H) section of the control panel:

MMA welding MMA welding with cellulose electrode

2. Press the setting value button until the welding current indicator( ) lights up.

3. Select the current using the adjusting dial (P).

4. Carry out welding.

SOFTSTART/HOTSTART FUNCTION (FIG. 1)

The SoftStart/HotStart function is used to set the starting current. At the start of the welding process, the welding current is reduced (SoftStart) or increased (HotStart) for 0.5 seconds, depending on the setting (Range: 0–200%).

1. Press the setting value button (O) until the SoftStart/HotStart indicator (

) lights up.

2. Turn the adjusting dial (P) until the desired value is reached on the LCD setting value display (M).

3. Carry out welding.

NOTE: The duration of the starting current can be changed in the setup menu using the Hti parameter. The maximum HotStart current is limited to the maximum current of the power source.

Example:

The change in the welding current is shown as a percentage of the main current. e.g. main current setting = 90 A

- 100 % starting current = 90 A (function deactivated)

- 80 % starting current = 72 A (SoftStart)

- 135 % starting current = 121 A (HotStart)

Parameter Description Range Unit

Factory setting (FAC)

This can be used to reset the device to its factory settings.

- Cancel reset

- Reset the parameters for the selected welding process to their factory settings

- Reset the parameters for all welding processes to their factory settings

Resetting of the selected value to its factory setting must be confirmed by pressing the adjusting dial.

no YES ALL

MMA Stick Welding

PREPARATION (FIG. 1)

WARNING: Risk of injury and damage from electric shock. As

soon as the power source is switched on, the electrode in the welding torch is live. Make sure the electrode does not touch any persons or electrically conducting or earthed parts (e.g. the housing, etc.).

1. Press the On/Off button (Q) for at least 2 seconds to turn off the welder. The indicators will go off.

2. Plug the grounding (earthing) cable (G) into the − (A) or + (B) current socket, depending on the type of electrode, and latch it in place.

3. Clamp the other end of the grounding (earthing) cable to establish a connection to the workpiece.

4. Plug the electrode holder (F) cable into the − (A) or + (B) current socket, depending on the type of electrode, and latch it in place.

English

CONNECTING THE GAS CYLINDER (FIG. 1, 4)

WARNING: If gas cylinders topple over, there is a risk of

very serious injury and damage. Place gas cylinders on a solid, level surface so that they remain stable. Secure gas cylinders to prevent them from falling over.

1. Secure the gas cylinder and take the protective cap off the gascylinder.

2. Briefly open the gas cylinder valve to remove any dust or dirt.

3. Check the seal on the pressure regulator.

4. Screw the pressure regulator onto the gas cylinder and tightenit.

5. Connect the TIG welding torch gas hose to the pressureregulator. (A connection example of TIG welding with gas-valve torch is shown in figure 4. The welder does not have an integrated gas connection.)

6. Open the gas cylinder valve.

7. Open the gas shut-off valve on the welding torch or, in the case of TIG devices, make contact with the component.

8. Set the desired gas flow rate on the pressure regulator.

PREPARATION (FIG. 1)

WARNING: Risk of injury and damage from electric shock. As

FIG. 4

ARC-FORCE DYNAMIC (FIG. 1)

To obtain optimum welding results, it will sometimes be necessary to adjust the arc-force dynamic.

1. Press the setting value button (O) until the arc-force dynamic indicator (

) lights up.

2. Turn the adjusting dial (P) until the desired correction value is reached on the LCD setting value display (M).

3. Carry out welding.

Operating principle:

At the moment of droplet transfer or in the event of a short circuit, the amperage is briefly increased in order to obtain a stable arc. If the rod electrode threatens to sink into the weld pool, this measure prevents the weld pool solidifying, as well as preventing a prolonged short-circuit of the arc. This largely prevents the rod electrode from sticking. NOTE: The maximum arc-force dynamic current is limited to 180A.

Examples:

• Arc-force dynamic = 0

- arc-force dynamic deactivated

- soft, low-spatter arc

• Arc-force dynamic = 20

- arc-force dynamic with 40 A current increase

- harder, more stable arc

• Set welding current = 100 A / arc-force dynamic = 60

- arc-force dynamic theoretically with 120 A current increase

- actual increase is just 80 A as the maximum current limit is reached.

TIG Welding

NOTICE: Do not use pure tungsten electrodes (color-coded green) if the TIG welding process has been selected.

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MAINTENANCE

WARNING: To reduce the risk of injury, turn unit off and disconnect it from power source before installing and removing accessories, before adjusting or when making repairs. An accidental start-up can cause injury.

EWALT recommends that a safety inspection of the device is

performed at least once every 12 months. Further details on safety inspection and calibration can be obtained by calling

1-800-4-D

EWALT (1-800-433-9258).

Cleaning (Fig. 5)

WARNING: Blow dirt and dust out of all air vents with clean, dry air at least once a week. To minimize the risk of eye injury, always wear ANSI Z87.1 approved eye protection when performing this.

WARNING: Never use solvents or other harsh chemicals for cleaning the non-metallic parts of the tool. These chemicals may weaken the plastic materials) used in these parts. Use a cloth dampened only with water and mild soap. Never let any liquid get inside the tool; never immerse any part of the tool into a liquid.

Under normal operating conditions, the device requires only a minimum of care and maintenance. However, it is vital to observe some important points to ensure the device remains in a usable condition for many years.

- Check the charger lead, welding torch, welding cable and

grounding (earthing) connection for damage.

- Check that the device has an all-round clearance of 0.5 m

(1 ft. 8 in.) to ensure that cooling air can flow in and out freely.

CAUTION: Air inlets and outlets must never be covered, not even partially.

Every 2 months. Clean all air filters (C).

1. Press the On/Off button (Q) for at least 2 seconds to turn off the welder. The indicators will go off.

2. Insert the current plug of the TIG welding torch into the (-)current socket (A) and turn it clockwise to latch it in place.

3. Set up the welding torch in accordance with the welding torch operating instructions.

4. Insert the current plug of the grounding (earthing) cable into the (+) current socket (B) and turn it clockwise to latch it inplace.

5. Use the other end of the grounding (earthing) cable to establish a connection to the workpiece.

6. Press the On/Off button (Q) for at least 2 seconds to turn on the power source.

TIG WELDING (FIG. 1)

1. Use the welding process button to select (illuminate) TIGwelding.

TIG welding

2. Press the setting value button until the welding current indicator(

) lights up.

3. Select the current using the adjusting dial (P).

4. Carry out welding.

IGNITING THE ARC

1. Place the gas nozzle down on the ignition location, ensuring there is a gap of approx. 2 to 3 mm (5/64 to 1/8 in.) between the tungsten electrode and the workpiece.

2. Operate the gas shut-off valve

3. Gradually tilt the welding torch up until the tungsten electrode touches the workpiece.

4. Raise the welding torch and rotate it into its normal position so that the arc ignites.

5. Carry out welding.

English

• FOR YOUR SAFETY: Registering your product will allow

us to contact you in the unlikely event a safety notification is required under the Federal Consumer Safety Act.

Three Year Limited Warranty

DEWALT will repair, without charge, any defects due to faulty materials or workmanship for three years from the date of purchase. This warranty does not cover part failure due to normal wear or tool abuse. For further detail of warranty coverage and warranty repair information, visit www.dewalt.com or call 1-800-4-D

EWALT (1-800-433-9258). This warranty does not

apply to accessories or damage caused where repairs have been made or attempted by others. This warranty gives you specific legal rights and you may have other rights which vary in certain states or provinces.

In addition to the warranty, D

EWALT tools are covered by our:

1 YEAR FREE SERVICE

EWALT will maintain the tool and replace worn parts caused by

normal use, for free, any time during the first year after purchase.

90 DAY MONEY BACK GUARANTEE

If you are not completely satisfied with the performance of your D

EWALT Power Tool, Laser, or Nailer for any reason, you can

return it within 90 days from the date of purchase with a receipt for a full refund – no questions asked. LATIN AMERICA: This warranty does not apply to products sold in Latin America. For products sold in Latin America, see country specific warranty information contained in the packaging, call the local company or see website for warranty information. FREE WARNING LABEL REPLACEMENT: If your warning labels become illegible or are missing, call 1-800-4-D

EWALT

(1-800-433-9258) for a free replacement.

FIG. 5

Accessories

Recommended accessories for use with your tool are available at extra cost from your local dealer or authorized service center. If you need assistance in locating any accessory, please contact D

EWALT Industrial Tool Co., 701 East Joppa Road, Baltimore,

MD 21286, call 1-800-4-D

EWALT (1-800-433-9258) or visit our

website: www.dewalt.com.

Repairs

FOR ALL SERVICE/REPAIR QUESTIONS ON THE WELDER, CALL 1-800-4-D

EWALT (1-800-433-9258). IF PRODUCT

NEEDS TO BE RETURNED FOR SERVICE, THE D

EWALT CALL

CENTER WILL PROVIDE PACKAGING FOR SHIPPING. To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustment should be performed by a D

EWALT factory service

center.

Thank you for your purchase. Register your product now for:

• WARRANTY SERVICE: Registering your product will help

you obtain more efficient warranty service in case there is a problem with your product.

• CONFIRMATION OF OWNERSHIP: In case of an insurance

loss, such as fire, flood or theft, your registration of ownership will serve as your proof of purchase.

Page dimensions: A5 (8.2677 x 5.8268 inches)

English

TROUBLESHOOTING GUIDE

MANY COMMON PROBLEMS CAN BE SOLVED EASILY BY UTILIZING THE CHART BELOW. FOR MORE SERIOUS OR PERSISTENT

PROBLEMS, CONTACT A D

EWALT SERVICE CENTER OR CALL 1-(800)-4-DEWALT.

SYMPTOM CAUSE FIX

Over temperature

Device is too hot. Check/reduce ambient temperature, allow device to

cool down.

Deep discharge protection

Battery discharged, deep discharge protection has been activated.

Charge the battery immediately. Battery operation is possible again above 25%

capacity.

Error number

e.g.

Internal machine fault. An error number (e.g. E02) appears in

the display.

Contact authorized service center.

The device cannot be switched on. The battery has entered a state of deep

discharge as it has been stored for too long without being charged.

Charge the battery now. Battery operation is possible again above 25%

capacity. If charging is no longer possible, contact authorized

service center.

Control panel defective. Contact authorized service center.

Battery is not charged:

Device is connected to the charger, charger is connected to the mains

Device is too hot. Check/reduce ambient temperature, allow battery to

cool down.

No welding current.

Device switched on, indicator for the selected welding process is lit.

Break in the welding cable connection. Check the plug connections. Poor or no earth. Establish a connection to the workpiece. There is a break in the power cable in the

welding torch or electrode holder

Replace welding torch or electrode holder.

Page dimensions: A5 (8.2677 x 5.8268 inches)

English

SYMPTOM CAUSE FIX

No welding current.

Device switched on, indicator for the selected welding process is lit, overtemperature indicator lit.

Duty cycle exceeded - device overloaded

- fan running.

Keep within duty cycle.

Thermostatic automatic circuit breaker has tripped.

Wait until the power source automatically comes back

on after the end of the cooling phase. The fan in the power source is faulty. Contact authorized service center. Insufﬁ cient cooling air intake. Ensure adequate air supply. Dust ﬁ lter or power module dirty. See the Maintenance section.

No welding current.

Device switched on, indicator for the selected welding process is lit, overtemperature indicator flashing.

Power module error Turn off the device, then turn it on again.

If the error occurs frequently, contact authorized

service center.

No welding current.

When the device is switched on, all the indicators come on and stay on (for more than 2 seconds).

Short circuit (secondary side) Eliminate the short circuit (disconnect the rod

electrode or grounding (earthing) cable from the

current socket)

If the error recurs, contact authorized service center.

Poor ignition properties during MMA stick welding.

Incorrect welding process selected. Select "MMA welding" or "MMA welding with Cel

electrode" process. Starting current too low; electrode

sticking during ignition.

Increase starting current using HotStart function.

Starting current too high; electrode consumed too quickly during ignition or is generating a lot of spatter.

Reduce starting current using SoftStart function.

In some cases, arc breaks during welding.

Electrode (e.g. grooved electrode) voltage too high.

If possible, use alternative electrode or a more

powerful power source. Break voltage (Uco) set too low. Increase break voltage (Uco) in Setup menu

Rod electrode tends to stick. Value of arc-force dynamic parameter

(MMA stick welding) set too low.

Increase value of arc-force dynamic parameter.

English

SYMPTOM CAUSE FIX

Poor weld properties (severe spattering)

Incorrect electrode polarity. Reverse electrode polarity (refer to manufacturer's

instructions). Poor grounding (earthing) connection. Fasten earthing clamps directly to workpiece. Set-up parameters not ideal for selected

welding process.

Select best setting in set-up menu for selected

welding process.

Tungsten electrode melting (Tungsten inclusions in base metal

during the ignition phase)

Incorrect tungsten electrode polarity. Connect the TIG welding torch to the (-) current

socket. Incorrect (or no) shielding gas. Use inert shielding gas (argon).

CHARGER TROUBLESHOOTING GUIDE

WARNING: An electric shock can be fatal. Do not open the device.

An error is signalled by the following indicators flashing or lighting up:

SYMPTOM/ERROR CAUSE FIX

Error ﬂ ashing, mains lit Battery fault. Contact After-Sales Service. Error ﬂ ashing, mains ﬂ ashing Mains fault (overvoltage or undervoltage) Check mains supply voltage Error lit, mains lit Charger fault Contact After-Sales Service Mains fuse or automatic circuit

breaker trips

Mains fuse underrated/incorrect circuit breaker

Fuse mains correctly

Mains fuse trips in open circuit Contact After-Sales Service

Page dimensions: A5 (8.2677 x 5.8268 inches)

Français

Déﬁ nitions: lignes directrices en

matière de sécurité

Les définitions ci-dessous décrivent le niveau de danger pour chaque mot-indicateur employé. Lire le mode d’emploi et porter une attention particulière à ces symboles.

DANGER : indique une situation dangereuse imminente

qui, si elle n’est pas évitée, entraînera la mort ou des

blessures graves.

AVERTISSEMENT: indique une situation potentiellement dangereuse qui, si elle n’est pas évitée, pourrait entraîner la mort ou des blessures graves.

ATTENTION : indique une situation potentiellement

dangereuse qui, si elle n’est pas évitée, pourrait entraîner des blessures légères ou modérées.

AVIS : indique une pratique ne posant aucun risque de dommages corporels mais qui par contre, si rien n’est fait pour l’éviter, pourrait poser des risques de dommages matériels.

POUR TOUTE QUESTION OU REMARQUE AU SUJET DE CET OUTIL OU DE TOUT AUTRE OUTIL D

EWALT, COMPOSEZ LE

NUMÉRO SANS FRAIS : 1-800-4-D

EWALT (1-800-433-9258).

POUR TOUTE QUESTION RELATIVE À LA MAINTENANCE/ RÉPARATION DE LA SOUDEUSE, APPELER LE 1-800-4-D

EWALT

(1-800-433-9258). POUR RETOURNER UN PRODUIT POUR

MAINTENANCE, LE CENTRE D’APPEL D

EWALT VOUS

PROCURERA LE CONDITIONNEMENT NÉCESSAIRE POUR L’ENVOI.

Consignes de sécurité importantes

AVERTISSEMENT: ne pas utiliser cet appareil sans avoir, au

préalable, lu soigneusement et compris ce manuel de l’utilisateur et toutes ses directives de sécurité, d’assemblage, d’utilisation et de maintenance.et de préparation du lieu de travail.

AVERTISSEMENT: pour réduire tout risque

de dommages corporels, lire le manuel de l’utilisateur.

CONSERVER TOUTES CES DIRECTIVES

ET CONSIGNES POUR FUTURE

RÉFÉRENCE

Directives de sécurité et avertissements propres aux postes à souder portatifs

• Porter SYSTÉMATIQUEMENT des dispositifs et vêtements de protection homologués. Visière de

protection, filtre homologué, protection auditive, lunettes avec protections latérales, gants isothermes, chaussures isolantes doivent être portés pendant le soudage.

DANGER: chaleur, étincelles, morceaux de métal et «coup

d’arc» peuvent provoquer des lésions de la peau et des yeux.

• Porter SYSTÉMATIQUEMENT un casque de

protection pour protéger les yeux et le visage des rayons UV, de la chaleur et des étincelles.

• Porter des lunettes de protection homologuées avec protections latérales et un filtre derrière une visière de protection.

• Porter une protection oculaire, auditive et corporelle adéquates.

+ 44 hidden pages

DeWalt DCW100 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual