2023-12-06-CTB-TL-200M.txt Tooliom TL-200 Corrections When I got my TL-200M, I was totally disappointed that it was for 0.030 inch solid wire and 0.035 inch Flux-core wire! Since it is a Synergic Welding System, the meter reads in Amps and NOT wire feed speed! The Welder Setting Chart clearly shows the settings are: "Ampere/Volts" and NOT wire feed and volts! For welding, I have to use a generator but for testing a welder without striking an arc I can use an inverter running off some batteries. Since I am living out in my field, my power is from a 2500 watt, modified sine wave inverter: 117.4 - 117.6 volts, 60 Hz. TL-200M Set on Flux 0.9 mm (0.035") AC 110 volts, 60 Amps on display: idle: 10.9 - 11.0 watts, 62.7 Hz., 2T, Feeding wire: 24 - 26 watts for 60 seconds gives 38 inches of wire. Dropping the feed tension, I wound the wire back in, and set the machine for both DCEN and DCEP. Both ran 38 inches of wire in 60 seconds. Set on 80-20 argon 0.8 mm (0.030") AC 110 60 Amps on display: idle: 11.1 - 11.3 watts 62.8 Hz., 2T, Feeding wire: 30.2 - 31.1 watts for 60 seconds gives 103 inches of wire with both DCEP and DCEN machine settings. Set on C100 0.8 mm (0.030") AC 110 volts, 60 Amps on display: idle: 11.1 - 11.3 watts 62.8 Hz., 2T, Feeding wire: 30.5 - 31.0 watts for 60 seconds gives 103 inches of wire with both DCEP and DCEN machine settings. Tooliom TL-135M: Idle: 10.4 - 10.7 watts. Flux Core 0.8 mm (0.030") @ 60 Amps, 25.7 - 26.3 watts, 118 inches in 60 seconds, Flux Core 0.9 mm (0.035") @ 60 Amps, 25.3 - 26.4 watts, 84 inches in 60 seconds, An electric arc has a non-linear relationship between current and voltage. Once the arc is established (either by progression from a glow discharge[12] or by momentarily touching the electrodes then separating them), increased current results in a lower voltage between the arc terminals. This negative resistance effect requires that some positive form of impedance (as an electrical ballast) be placed in the circuit to maintain a stable arc. This property is the reason uncontrolled electrical arcs in apparatus become so destructive since once initiated, an arc will draw more and more current from a fixed-voltage supply until the apparatus is destroyed. (Electric arc - Wikipedia). The wave form for an electric arc is more like a square wave and far from a sine wave. The extra current is sort of like the extra power one needs to go up a hill and when one goes down the other side, the hill supplies some power, likewise the arc will return some power into the system. When using a welder on a generator, the generator has to be able to provide more than the Maximum Supply Current (power) required even though some of that power is returned. The result is the Effective Supply Current. I1 max (Rated Maximum Supply Current) I1 eff (Maximum Effective Supply Current) I1 eff divided by I1 max will give a percentage. If say 1000 watts is divided by this percentage, that will give how many watts will be required to get 1000 watts output. TL-200M: eff 23.2 A / max 30 A = 0.7733333 then 1000 watts / 0.7733333 = 1293.1035 watts. TL-135M: eff 19.3 A / max 25 A = 0.772 then 1000 watts / 0.772 = 1295.3367 watts. Lincoln 210MP @ 120 Volts: eff 15 A / max 21.5 A = 0.6976744 then 1000 watts / 0.6976744 = 1433.3333 Watts. Lincoln 210MP @ 230 Volts: eff 14.7 A / 27 A = 0.5444444 then 1000 watts / 0.5444444 = 1836.7348 watts. Miller Dynasty 200 DX @ 1 phase 115 volts: eff 25 A / max 32 A = 0.78125 then 1000 watts / 0.78125 = 1280 watts. Miller Dynasty 200 DX @ 1 phase 230 volts: eff 16 A / 35 A = 0.4571428 then 1000 watts / 0.4571428 = 2187.5002 watts. Miller Dynasty 200 DX @ 3 phase 230 volts: eff 10 A / max 21 A = 0.4761904 then 1000 watts / 0.4761904 = 2100.0003 watts. Miller Dynasty 200 DX @ 3 phase 400 volts: eff 6 A / max 12 A = 0.5 then 1000 watts / 0.5 = 2000 watts Miller Dynasty 200 DX @ 3 phase 460 volts: eff 5 A / max 10 A = 0.5 then 1000 watts / 0.5 = 2000 watts. Forney Easy Weld 100ST @ 120 volts: eff 11.1 A / max 25 A = 0.444 then 1000 watts / 0.444 = 2252.2522 watts. Eastwood Mig 180 Welder #33990 @ 120 volts: eff 13.3 A /max 24 A = 0.5541666 then 1000 watts / 0.5541666 = 1804.5114 watts. Tooliom TL-135S @ 110 volts: eff 25.5 A / max 33 A = 0.7727272 then 1000 watts / 0.7727272 = 1294.1177 watts. Tooliom TL-135S @ 220 volts: eff 17.8 A / max 25.4 A = 0.7007874 then 1000 watts / 0/7007874 = 1426.9662 watts. Tooliom TL-250M @ 110 volts: eff 34.8 A / 45 A = 0.7733333 then 1000 watts / 0.7733333 = 1293.1035 watts. Tooliom TL-250M @ 220 volts: eff 25.5 A / 33 A = 0.7727272 then 1000 watts / 0.7727272 = 1294.1177 watts. Almost all of the Tooliom machines have a percentage of 0.77XXXX and they are proud enough of their machines that they show the electrical specs for them in their advertising. Their duty cycle is also 60% at rated amperage and voltage. I was amazed when I opened my $67.89 Tooliom 135A 110/\V/220V Stick Welder MMA ARC Welder Machine DC Inverter Welder with Digital Display Portable Welding Machine that weighs only 4.8 lbs. October 01, 2022. When I opened it to put some 1/8 inch wire screen on the ends so wasps (paper) and and mud dabber (wasps that use mud) could not enter and build nests in it, I was surprised to see a little cardboard covering a circuit board with half a dozen inspection stamps on it. I was also impressed with the quality of the build and of the materials that were used in the construction of this welder. These machines are a lot better and less expensive than Harbor Freight models and other name brand machines. I have bought almost every model Tooliom has and many of them many times. I feel these machines are a lot better buy than putting money into gold or silver! I did find that if the wire in the wire feed machines is shorted to ground, the machine will not feed or produce a voltage. It needs to be open so the feed can start. I ran some tests on some 20 ga. galvanizes sheet metal just to see the differences in some machines: TL-200M: 20 ga. (0.0375") Flux core 0.035" Lincoln Electric Intershield NR-211-MP (e71T-11) that came with my Lincoln 210MP welder several years ago. Running 75 Amps with good penetration on the back side. TL-250M: 20 ga. (0.0375") ER70S-6 0.023" inweldcorporation.com (Made in Turkey) 11# spool. 100% CO2 15 cu.ft./hr. 75 amps. A little better penetration on the back side. Lincoln 210MP: 20 ga. (0.0375") ER70S-6 -.023" Harbor Freight "Chicago Welding" 2# spool, 100% CO2 15 cu.ft./hr. Chart showed: 120 inches/16.0 volts. After pass, showed 33 Amps. and 17.0 volts. Changed volts to 17.0 and ran again, this time 33 Amps, and 17.0 volts. Both times ran with very minimal penetration on back side. The first time I tried to use this machine it sounded more like popcorn trying to pop! The numbers suggested never matched the results I got and I thought maybe it had a bad board so I put a couple of short wires on the leads so I could attach my digital oscilloscope to see what was happening and it showed that the boards were OK. When trying to spot weld two pieces together there never was enough penetration to get them to stick very good. I can see the chart is designed for minimal penetration now! From www.lncolnelectric.com Welding Consumables Catalog / C1.10: Pgs. B-9 a& B-10: Superarc L-56 AWS ER70S-6 bottom reference: CTWD(5) (Contact Tip to Work Distance). Subtract 1/4 inch (6.4 mm) to calculate Electrical Stick-out. 0.025 inch (0.6 mm), DC+ CTWD 9 - 12 mm (3/8 - 1/2 inch) 0.030 inch (0.8 mm), DC+ CTWD 9 - 12 mm (3/8 - 1/2 inch) 0.035 inch (0.9 mm), DC+ CTWD 9 - 12 mm (3/8 - 1/2 inch) Pgs. D-9 & D-10: Innershield NR-211-MP AWS E71T-11 (-11 is for all positions, -GS is for single pass only) 0.030 inch (0.8 mm), DC- CTWD 13 mm (1/2 inch) 0.035 inch (0.9 mm), DC- CTWD 13 - 16 mm (1/2 - 5/8 inch) For solid wire that would leave 1/8 - 1/4 inch past the contact tip, and for Flux Core 1/4 inch or 1/4 to 3/8 inch past the contact tip! I was surprised to find the sound from the Tooliom machines sounded more like searing a steak on a hot pan rather than bacon frying! I have been using 100% CO2 for welding since the 1980s and find it works fantastic. I think if the CTWD is observed there will be very little spatter. On a lot of videos I see the wire sticking out of the nozzle a lot longer than it should be! CO2 bottles are supposed to be filled by weight since its critical temperature is 87.5 degrees F. The specific volume is 8.7719 cu.ft./lb. which would give a 20# tank 175.438 cu.ft.of gas at normal temperature and pressure (70 degrees F. and 1 atmosphere (sea level)). The vapor pressure is 830 psig. CO2 does not work for TIG because it breaks down into carbon monoxide and oxygen and the oxygen just burns up the tungsten rod! Since your welder has a NEMA 14-50R outlet, you should get a NEMA 14-50P to Four 5-15/20R Adapter Cord, 50Amp to 20Amp, 4 Prong, 1.5 FT, mine are (UL) SJTW 4/C 10AGW and split the two hot legs into two 120 Volt outlets. which would have 50 Amps for each leg. It would probably be a good idea to use a 10 ga. extension cord on it if you are running very far to reduce voltage drop. On my Tooliom TL-200M, 110 volts is limited to 162 amps, and 220 volts will go to 200 amps. I would really like to hear from you and see how much difference there is if one runs the TL-200M with the right settings. My phone is 435-210-0710, my e-mail is ac0xl.ham@gmail.com (alpha,charlie,zero,x-ray, Lima) my ham call sign. My web site is: http://162.250.19.7/ which will come up with a green background and a directory listing. To build a bullet proof web server for pennies the directions are in "freedom.zip" and I tried to make it easy enough that a third or fourth grader should be able the "copy, paste, enter" the directions. God Bless, Frank Anderson, ac0xl e-mail: ac0xl.ham@gmail.com MagicJack phone: 435-210-0710 *