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Summary of Contents for WeldKing MigSonic145
- Page 1 Process: MIG (GMAW) Flux cored (FCAW) Arc Welding Power Source and Wire Feeder MIGSONIC145 SERVICE MANUAL www.weldking.com...
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Page 2: Table Of Contents
Table of Contents SECTION 1 SAFETY PRECAUTIONS ................. 1 SECTION 1 CONSIGNES DE SÉCURITÉ ................1 1-1. Symbol Usage ...................... 1 Symboles utilisés ........................1 1-2. Arc welding Hazards ..................1 Dangers relatifs au soudage à l’arc .................. 1 1-3. Safety Standards Normes de sécurité... -
Page 3: Safety Precautions
SECTION 1 SAFETY PRECAUTIONS SECTION 1 CONSIGNES DE SÉCURITÉ 1-1. Symbol Usage Symboles utilisés Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Symbole graphique Watch Out possible ELECTRIC SHOCK,... - Page 4 voltage. In most situations, use of a DC, utilisant des housses ou des tapis assez constant voltage wire welder grands afin d’éviter tout contact physique recommended. And, do not work alone! avec la pièce à couper ou le sol. Disconnect input power or stop engine Ne pas se servir de source électrique à...
- Page 5 temps à cause de la présence d’une Ne pas surcharger l’installation électrique − tension à vide doublée. s’assurer l’alimentation correctement dimensionnée et protégée N’utiliser qu’un matériel en bon état. avant de mettre l’appareil en service. Réparer ou remplacer sur-lechamp les pièces endommagées.
- Page 6 Le couvercle du détendeur doit toujours être if damaged. en place, sauf lorsque la bouteille est utilisée BOUTEILLES ou qu’elle est reliée pour usage ultérieur. peuvent exploser si elles Utiliser les équipements corrects, les bonnes sont endommagées. procédures et suffisamment de personnes pour soulever et déplacer les bouteilles.
- Page 7 The user is responsible for having a MOVING PARTS qualified electrician promptly correct any cause injury. interference problem resulting from the ORGANES installation. MOBILES peuvent If notified by the FCC about interference, stop using the equipment at once. provoquer Have the installation regularly checked blessures.
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Page 8: Safety Standards Normes De Sécurité
1-3. Safety Standards Normes de sécurité Code for Safety in Welding and Cutting, CSA Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Standard W117.2, from Canadian Standards Documents (phone: 1-877-413-5184, website: Association, Standards Sales, 178 Rexdale www.global.ihs.com). -
Page 9: Installations
SECTION 2 INSTALLATIONS 2-1. Welding power source specifications MIGSONIC145 Type 115V/60Hz 230V/60Hz Power supply Phase Input current @ Maximum output Rated input (Kva) Open circuit voltage(v) 40-110 40-180 Amperage range(A) 16-18.5 16-21.3 Welding voltage(V) Rated Duty cycle (%) Rated welding current(A) 40-310 (0.8-9.5 m/min) -
Page 10: Connection Diagram
2-2. Connection diagram MIGSONIC145 (115v input) Gauge Cylinder Power Cord To 115 volt, 20 ampere individual branch circuit Torch Figure 2.1 Page... - Page 11 MigSonic145(208/230V input) Gauge Cylinder Power Cord Torch Figure 2.2 Page...
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Page 12: Installing Welding Torch
2-3. installing welding torch Correct Incorrect Figure 2.3 Gun Securing Knob Gun End: Loose knob. Insert gun end through opening until it bottoms against drive assembly. Tighten knob. Gun Trigger connector: Insert into receptacle, and tighten. Close door. Page... -
Page 13: Ground Cable Installation
2-4. Ground cable installation Figure 2.4 Ground cable Output Terminal Block Insert ground cable through opening in front panel and route along back of front panel to output terminal block. Close door. 2-5. Process/Polarity Table Cable Connections Process Polarity Cable To Gun Cable To Work GMAW－Solid wire DCEP –... -
Page 14: Electric Service Guide
block. 2-6.5. Use Ф8 heat-resistant PVC hose connect the flow meter with the gas connection nipple at rear of the machine. 2-6.6. Install wire spool. 4 in (100mm) wire spool: Figure 2.5 8 in (200mm) wire spool: Figure 2.6 Commission the machine after the machine is installed and tested: Release the pressure roller in the wire feeder, push the torch switch, and adjust voltage switch from low to high, Open circuit voltage should rise. -
Page 15: Extension Cable Selection Chart
MigSonic145 Input voltage(V) Frequency(Hz) Input Amperes at rated output(A) Max recommended standard fuse Rating in Amperes Circuit breaker, time delay Normal operation Min input conductor size in AWG Min Grounding conductor Size in AWG Table 2.3 2-8. Extension Cable Selection Chart... -
Page 16: Operation
SECTION 3 OPERATION Front panel Layout Figure 3.1 1. Power indicator 5. Control receptacle 2. welding current adjust knob 6. Earth clamp 3. Over-heat protection indicator 7. Main switch 4. Torch terminal 8. Voltage adjust knob Page... -
Page 17: Operation
Operation 3-2.1 Check the connection of work piece, earth cable, welding torch, wire feeder, gas cylinder, regulator and hose, make sure they are firm and reliable. 3-2.2 Install the wire spool to the wire spool spin, select correct feeding roller and tip according to the wire diameter. -
Page 18: Voltage/Wire Speed Selection Chart
Voltage/Wire speed selection chart 200/19 ∅ Voltage “V” Wire feed speed setting not recommended The setting in the following chart is just for start only and can be fine tune during welding. MIGSONIC145 Material Steel Stainless steel Wire type Solid ER70S-6(DCEP) -
Page 19: Section 4 Theory Of Operation
SECTION 4 THEORY OF OPERATION Power switch Rectifier PCB CapacitorPCB Inverter PCB Main Secondary MIG145C-ZL MIG145C-DR MIG145C-NB transformer rectifier fuse 115V/230V power input Reactor Ignition resistance Fan Motor CONTROL PCB MIG200-KZ-A Polarity Voltage potentiometer Feed motor Torch trigger Mig torch Work Piece Wire speed... - Page 20 (1) Control PCB (MIG200-KZ-A): Supply drive and control voltage to Inverter Model. Supply control signal to capacitor PCB indicate input voltage(110V or 230V). Control fan motor, Torch trigger, Solenoid valve, power light and protection light. Take signal from Voltage control and Wire speed control potential meter. Controls wire feed speed by changing pulse width modulation signal, there by providing more or less voltage to the feed motor.
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Page 21: Trouble Shooting
SECTION 5 TROUBLE SHOOTING Trouble shooting check list Problem Cause Solution Power Indication lamp does not on Loose contact at input lead Check contact after switch on the main switch situation Lamp malfunction, poor Check contact contact situation. Replace lamp Main switch malfunction Check switch Cooling fan stops to... - Page 22 valve Gas passage problem Check and repair the gas passage Torch gas hose problem Check and repair torch cable Control circuit failure Replace circuit board Control transformer failure Replace transformer Failure of arc to ignite or does not Fuse melt or poor contact Check and repair ignite properly Main power switch failure...
- Page 23 Main transformer failure or Check, repair, poor contact replace Unstable arc Gas hose not installed Connect the gas properly, gas mixed by air hose firmly Gas not pure Changes gas Wire liner or gun cable Check, repair, broken and leak cause replace insufficient gas volume.
- Page 24 Output capacitor failure Check, replace Wire does not feed while the feed Wire pressure not proper Adjust pressure roller is rotating Wire liner or contact tip Check, repair, jammed replace Used wrong groove at the Use the right feeding roller groove Can not stop the gas Solenoid valve...
- Page 25 meter failure replace Circuit board plug socket Check and repair not properly contacted or replace Control circuit failure Check and repair or replace Welding hose deformed Check and replace Input voltage fluctuated Use under rated input voltage Power supply switch jump Rectifier short circuit Check and replace...
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Page 26: Circuit Board Testing Information
Circuit board testing information CN118 CN111 CN112 CN113 CN109 CN110 CN101 CN117 MIG-200C-KZ-A CN107 CN115 CN108 CN105 CN116 CN122 CN103 CN106 CN102 CN104 CN114 Figure 5.1 Page... - Page 27 MIG-200C-KZ-A CONNECTOR VALUE CN101 Circuit common Not used DC +325V, reference to CN101-1 CN102 Motor power supply(DC+2V-19V),reference to CN102-3 and CN102-4 Motor power supply(DC+2V-19V), reference to CN102-3 and CN102-4 Motor power supply(DC-2V-19V),reference to CN102-1 and CN102-2 Motor power supply(DC-2V-19V), reference to CN102-1 and CN102-2 CN103 Short to CN103-3 Not used...
- Page 28 Circuit common Not used Circuit common CN114 Drive signal(DC16.5V when gun trigger closed),reference to CN114-2 Drive signal(DC16.5V when gun trigger closed), reference to CN114-1 300:1 inductor signal feed back(Voltage signal) 300:1 inductor signal feed back(Voltage signal) CN115 Power supply to solenoid valve. When gun trigger closed, DC+24V,refence to CN115-2 When gun trigger closed.
- Page 29 CN107 CN106 CN301 DVI200-DR-A CN105 MIG175-ZL-A CN302 CN102 1 2 3 4 5 6 7 8 9 10 CN103 1 2 3 4 5 6 7 8 9 10 Figure 5.2 Page...
- Page 30 DVI200-DR-A CONNECTOR VALUE CN102 DC-325V, reference to CN102-4,5 DC-325V, reference to CN102-4,5 Not used DC +325V, reference to CN102-1,2 DC +325V, reference to CN102-1,2 Not used AC 230V/115V, DC-325V, reference to CN103-7,8,9,10 AC230V/115V, DC-325V, reference to CN103-7,8,9,10 AC 230V/115V, DC-325V, reference to CN103-7,8,9,10 AC230V/115V, DC-325V, reference to CN103-7,8,9,10 CN103 DC-325V, reference to CN103-4,5...
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Page 31: Section 6 Maintenance
SECTION 6 MAINTENANCE 6.1. Maintenance Periodic maintenance is necessary for keeping the machine work properly. CAUTION DISCONNECT POWER INPUT AND SWITCH OFF THE MAIN POWER SWITCH BEFORE START OF MAINTENANCE. Regular Check and Inspection 6 Month Routine Maintenance • Clean spatter inside the nozzle when •... -
Page 32: Safety Precaution
6.2. Safety precaution 5.2.1. Welders must be equipped with welding mask, gloves and tie the sleeves and collar properly. There should be an arc shield around welding field to protect others from arc shock. 5.2.2. Do not weld near flammable, explosive materials or gases. 5.2.3. -
Page 33: Electrical Diagrams
SECTION 7 ELECTRICAL DIAGRAMS S25VB POWER SWITCH Port CN107 CN203 INPUT 115V/230V MIG 145 inverter board Port MIG 145 capacitor board S25VB CN101 CN106 CN202 CN204 Voltage regulator 2W10K the input side of transformer CN104 CN303 CN101 CN118 CN114 Port Current regulator 2W1K CN111... - Page 34 NOTES WELDKING™ MIGSONIC145 Page...
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Page 35: Parts List
SECTION 8 PARTS LIST Item Order No. Description Note Quantity Y0161001 Potentiometer WH118 2W 1K carbon film Y0161002 Potentiometer WH118 2W 10K carbon film B0103030 MIG-200C Control MIG200-KZ-B B0100025 MIG-145C Inverter MIG-145C Y0701015 Mosfet FMH23N50E Y1602003 Solenoid Valve VZCT-2.5 DC24V(copper base∅6) Y2515009 Gas inlet... - Page 36 Figure 8.1 Page...
- Page 37 Figure 8.2 Page...
- Page 38 Figure 8.3 Page...
- Page 39 Wire feeder(HANWAN-4D/24V) , Order No. 2611017 Figure 8.4 ITEM DESCRIPTION ORDER NO. QUANTITY Clamp 200A(Black) 2301006 Electric Machinery 26110171 Gearbox 26110172 #18 Bracket 26110173 Roller(0.6/0.8mm)(.023/.030) Y2517047 #18 Pressure shell components 26110175 #6 Pressure 26110176 Page...
- Page 40 WeldKing NT1 Mig Torch, Order No. 07000422 Figure 8.5 Nozzles ITEM DESCRIPTION ORDER NO. Nozzle Self Insulated 21-37 Nozzle Self Insulated 21-50* Nozzle Self Insulated 21-62 Nozzle Self Insulated 21-37F Nozzle Self Insulated 21-50F Nozzle Self Insulated 21-62F Nozzle Self Shielding...
- Page 41 Contact Tip 0.030”/0.8mm Ecu 11-30* Contact Tip 0.035”/0.9mm Ecu 11-35 Contact Tip 0.040”/1.0mm Ecu 11-40 Contact Tip 0.045”/1.2mm Ecu 11-45 Liners ITEM DESCRIPTION ORDER NO. Steel Liner 0.030”-0.035”/0.8-0.9mm X15ft 42-3035-15 Teflon Liner 0.030”-0.035”/0.8-0.9mm X15ft 42T-3035-15 * Default Component ITEM DESCRIPTION PART No.
- Page 42 NOTES WELDKING™ MIGSONIC145 Page...
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Page 43: Warranty Policy
Welding Products this limited warranty and is free of defects in Ltd.(WELDKING™ ), in appropriate cases, (3) the material and workmanship at the time it is shipped. reasonable cost of repair or replacement at an THERE ARE NO WARRANTIES WHICH EXTEND authorized service station;... -
Page 44: Authorized Service Center
SECTION 9 AUTHORIZED SERVICE CENTER Please go to our website www.weldking.com to fill the warranty registration form. Malo Welding Products Ltd. will not distribute of disclose customer's private information to any third party and will not sent promotion material to the customer. - Page 45 MALO WELDING PRODUCTS LTD. 3275, 14 Ave, Unit A, Markham, On, L6G 1B1 Tel: 1 866 686 5088 Fax: 1 866 686 5090 www.malowelding.com Printed April 13, 2011...
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