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WeldKing Mig Sonic 252S Owner's Manual

Ss20 wire feeder
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MIGS
SONIC2
52S po
SS20
wire fe
eeder
MIG (GMAW)
M
Flux cored (FCA
F
AW)
Arc Weldin
ng Power Sour
rce and wire fe
Power
Source Se
erial Num
Wire fe
eeder Seria
al Numbe
Where
Purchase
e:
Date of
f purchase
ed:
ower so
urce
eder
ber: ___
__________
r:
___
__________
___
__________
___
__________
_________
_________
_________
_________
_________
_________
_________
_________
______
______
______
______

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Summary of Contents for WeldKing Mig Sonic 252S

  • Page 1 MIGS SONIC2 52S po ower so urce SS20 wire fe eeder MIG (GMAW) Flux cored (FCA Arc Weldin ng Power Sour rce and wire fe eder Power Source Se erial Num ber: ___ __________ _________ _________ ______ Wire fe eeder Seria al Numbe __________ _________...

  • Page 2: Table Of Contents

    Table of Contents SECTION 1 SAFETY PRECAUTIONS ....................1 SECTION 1 CONSIGNES DE SÉCURITÉ ..................... 1 1-1. Symbol Usage Symboles utilisés ..............1 1-2. Arc welding Hazards Dangers relatifs au soudage à l’arc ....1 1-3. Safety Standards Normes de sécurité ............6 1-4.

  • Page 3: Safety Precautions

    SECTION SAFETY Y PRECA AUTIONS ECTION ONSIGNE ES DE SÉ ÉCURITÉ É 1-1. mbol Usa mboles ut tilisés Means Warning! Wat tch Out! The re are possible hazards with this procedur re! The possible hazards are s shown in the ad djoining symbols Symbo...
  • Page 4 poorly spliced ca ables. situations, l’u utilisation d’un poste à souder DC à fil à tension n constante es st recommandé ée. En Do not drape ca ables over your b body. outre, ne pas s travailler seul f earth groundi ng of the workp piece is require Couper l’alim...
  • Page 5 Put on grounded d wrist strap BE EFORE handling boards or parts. MAGNETIC C FIELDS ca Use proper stat ic-proof bags an nd boxes to stor move, or ship P C boards. affect pace emakers. É Établir la conn nexion avec la arrette de ter LES CHAM avant de manipu...
  • Page 6 Plac cer les bouteille es debout en le es fixant dans u que des venti lateurs. pport stationnai re ou dans un n porte-bouteill Maintenir fe ermés et verr rouillés les p portes, ur les empêcher r de tomber ou d de se renverser panneaux, recouvrements...
  • Page 7 he possibility of f interference. et utiliser un e terre et un bli indage pour réd duire les interféren nces éventuelle Le rayonnemen nt haute fréque ence (HF) peu provoquer interférence avec READ IN NSTRUCTION é équipements radio-navig gation LIRE LES communication, les services de e sécurité...

  • Page 8: Safety Standards Normes De Sécurité

    1-3. Safety Standard ds Normes s de sécu rité d Processes, AN tting, CSA Stan dard Safety y in Welding, Cu utting, and Allied Code e for Safety in W Welding and Cut Standa ard Z49.1, from Global Enginee ering Document 7.2, from Canad dian Standards Association,...

  • Page 9: Packing List

    SECT TION 2 CKING L LIST MigSoni ic252S+SS2 20 package ( (Part No: 07 7000340) Desc cription Part t no ntity 07000 0342 MigS Sonic252S P Power sourc ce come wit th 10 ft. (3 M) Power c cord and N NEMA 6-50P P 230V AC P Plug...

  • Page 10: Installations

    SECT TION 3 INST TALLAT IONS 3-1. Welding g power so ource and d wire feed der specifi ications MigSonic c252S powe er source MIG/Fl lux cored wir re Mig Weld ding Process 0(208)V/230 Powe er supply Single Phas Rated d output curre ent(A)
  • Page 11 23.5(51.8lbs) Pack king weig ht(KG) Table 3.1 AUTION LDING LONG GER THAN R RATED DUT TY CYCLE C CAN DAMAG GE GUN AND D VOID RRANTY. -20 wire feed 24 V Volts DC Sin ngle Phase 6 60 Hz Type e of Input po ower 1.5-18(59...
  • Page 12 3-2. MIG torc ch specifi cations NT2-15E (Part no.070 000411) Mode 200A/CO 2,150A/MIX Rated d currency(A Rated d Duty cycle e (%) Air cooled Cool style 0.6-1.2(0. .023-0.045in Wire diameter(m 4.6(15ft) Cable e length(M) euro conn nection Conn nection Detailed gun n specificatio n please see e separate to...

  • Page 13: Mig Torch Specifications

    3-3. MIG wel lding conn nection di agram gSonic252S (208/230v in nput) Gauge Cylinder To gas regul ator Power cord To main pow Contro ol cable Earth cabl Gas hose MIG to orch Work piece Figure 3.1 anual no: W M070101 Page1 MIGS...

  • Page 14: Mig/Mag Process/Polarity Table

    3-4. MIG/MA AG Proces s/Polarity Table Process Pola arity Cable Co onnections Cable To o Gun Cabl e To Work EP – Connect to p positive(+) onnect to GMAW W－Solid w verse output te rminal negative(- )output term minal with shielding ga pola arity...

  • Page 15: How To Adjust Wire Feed Pressure

    groove is in the inner po osition. Feed the wire from m the spool th hrough the in nlet guide, ac cross the drive rol ll groove and d into gun ou utlet guide. Lo ower pressu res roll asse mbly and sec cure.

  • Page 16: How To Install Spool Gun(Optional)

    3-8. How to Install spo ool gun(op ptional) MigS Sonic252S u use WeldKi ng® SpoolK King-24DL (Part no. 0 07NS1010) o only. Use o other mode el may not w work proper rly. 3-8.1 .Connect sp pool gun to t the euro rec ceptacle.
  • Page 17 Min i nput condu uctor size in AW Min G Grounding c conductor Size in AWG Table 3.5 anual no: W M070101 Page1 15 MIGS SONIC252S O OWNER’S MA ANUAL...

  • Page 18: Extension Welding Cable Selection Chart

    3-10 0. Extensio on Weldin ng Cable S Selection C Chart UTION! USE SHORT TEST CABLE E POSSIBLE Welding Amperes (A Cable S Size (AWG) Maximum Cable Leng allowed in W Weld Circuit t* (Ft) <=10 00 (30 m) 4 (20mm2 3 (30 0 mm2) 3 (30 mm2...

  • Page 19: 7-Pin Link Cord Receptacle

    Not used Not used Table 3 3-12 2. 7-pin lin nk cord rec ceptacle Figure 3.6 Notes cket pin unction Drive motor ground Black Solenoid val lve ground Mig gun swit 2.5V- -24V DC Voltage and wire feeding g speed signa refer rence to pin 1 Common gro...

  • Page 20: Power Source Panel Layout And Description

    ECTION ERATIO 4-1. Power s source pa anel layou t and desc cription 1. We elding voltag e meter (dig ital) Current disp play indicatio on light 2. We elding curren nt/wire feedin ng speed Power indic ation light mete r (digital) Protection in ndication ligh...
  • Page 21 8. Ne egative outpu ut (Earth clam 0. Positive ou utput (to wire e feeder) conne ection . Power cord 9. 9 p pin control co onnection (to o wire feeder 2. Main switc Figure 4.1 anual no: W M070101 Page1 MIGS SONIC252S O...

  • Page 22: Ss-2- Wire Feeder Panel Layout And Description

    4-2. SS-2- w wire feeder r panel lay yout and d descriptio 1. We elding voltag e adjustmen nt knob 3. Jog toggle switch 2. We elding curren nt/wire feedin ng speed 4. Purge togg gle switch adjus stment knob 5.

  • Page 23: Operation

    4-3. Operati USE SING GLE PHAS E 208/230V V POWER SU UPPLY. 4-3.1 .Switch on th he power sou urce. 4-3.2 .Set the weld ding voltage knob to prop per position a and wire feed d speed kno b to a start v value and refine d during weldin...

  • Page 24: Voltage/Wire Speed Selection Chart

    4-4. Voltage e/Wire spe eed select tion chart : setting not recommend ded. The setting in n the followin ng chart is jus st for start on nly and can b be fine tune d during weldin 6.5(Wire feed d speed∅)/4. 5(Voltage “V V”)/7.5(Induct tion)

  • Page 25: Trouble Shooting

    SECTIO ON 5 TROUB LE SHOO OTING 5-1. Genera al trouble s shooting Problem ause Solu ution Power Indicat tion lamp doe es not on Loose con ntact at Check co ontact fter switch o n the main s witch input lead situation Lamp mal...

  • Page 26: Gmaw/Fcaw Welding Trouble Shooting

    Control tra ansformer Check an short circu replace Solenoid v valve short Check an circuit replace Cooling fa an short Check an circuit replace Table 5-2. GMAW/ /FCAW we elding trou uble shoo oting blem Cause Soluti No gas flow o out after Gas pr ressure not e...
  • Page 27 replace Contro ol circuit boar rd failure Check and r repair the circuit bo oard Weldin ng cable brok ken or Check the poor co ontact connection Gun tri igger wire br oken Replace cab Gun ca able broken Replace cab Voltage e adjustment t knob...
  • Page 28 Cannot stop t the gas Soleno oid valve Check, repa air, contam minated replace sole enoid Contac ctor failure Check, repla ace the contactor Contro ol board failur Check, repa air, replace Wire feeding not stable Wire o ut of feeding g roller Put wire bac groove...

  • Page 29: Maintenance

    SECT TION 6 INTENAN 6-1. Mainten nance Perio odic maintena ance is nece essary for kee eping the ma achine work properly. UTION! DISC CONNECT P POWER INPU UT AND SW WITCH OFF THE MAIN POWER SW WITCH BEF STAR RT OF MAIN NTENANCE.

  • Page 30: Maintenance

    6 Mo nth Routine Maintenance 6 Mo onth Routine e Maintenan • Blo ow out with d ry clean pres ssure air or v vacuum insid de machine, e especially tra ansformer co oil and wer compone ent. • Che eck the elect tric connectio on of input/o...

  • Page 31: Parts List

    CTION 7 PARTS LI MigSo nic252S P Power Sou urce Item Order No Description Note 7.305.132 hunt FL-1 75mv 300A A short MIG 2 250F-1 c/w 8.055RM .227-CA ottom plate (S.004 4RM.227) MIG 2 250F-1 c/w 8.065RM .078-B ront output p panel (S.004 4RM.227-CA...
  • Page 32 7.425RM .001 ingle IGBT FGH6 0N60SMD 7.411.010 Rectifier bridg GBPC C5010(plug ty yple) TH-B2 2D75̊ - K （c/w metal press 7.231.061 hermostat (c constant ope plate ） （SY） 7.155.021 Cable bracket M2012 2B6-12 7.205.212 Circuit breake DZ47- -60-2P 63A/(60A) UL.SJ 00W 12/3AW WG (300V) 105/X...
  • Page 33 6.185RM .206 Main transform MIG-2 250S c/w 3.00 04RM.206 270mm m length with h cable 7.321.130 nductor 0.3sq mm 200roun MIG-2 250 c/w 3.004 4RM.023 6.271RM .203 nductance 3.004R RM.204 7.731.031 Control transf former 220V input, 36V ou utput(50W) ush-pull gun n/spool gun W.496RM M.387...
  • Page 34 Figure 7.1 Manual no: W W M070101 Page e32 MIG SONIC252S OWNER’S M M ANUAL...

  • Page 35: Wire Feeder

    SS-20 Wire feed Item Orde er No. Descri iption Note Right side pla S.054RM. .901-CA rig ght side 8.051RM .901-CA plate Hinge 7.686.048 CL219-3 b black matt(ou ubao) Left side plat S.054RM. .901-CA side 8.050RM .901-CA plate Latch 7.686.300 MS725-2 electric cabin net lock Toggle switc...
  • Page 36 wire feeder 8.177RM .203-A Connection b S.054RM. .901 wire feeder 8.178RM .203-A Wire guide tu S.054RM. .901 WEIPU receptacle 8.462RM .030 ocking nut M21*1 S2 8.940.00 Copper nut M10×1 Euro conne ector attach 8.123RM .920-A plate ABS with attach hole 7.682.112 caster 2#Polyure...
  • Page 37 wire feeder 8.303RM .901 Middle separ rating plate S.054RM. .901 S.054RM. .901-CA REAR 8.068RM .901-CA Rear plate PLATE 7.941.009 GB/T6170 0 M12 8.462.64 Gas inlet GT-2000 Table 7.2 Manual no: W WM070101 Page SONIC252S OWNER’S M MANUAL...
  • Page 38 Figure 7.2 Manual no: W W M070101 Page e36 MIG SONIC252S OWNER’S M M ANUAL...

  • Page 39: Wire Driving System

    Wire d riving sys stem del 60/76ZY-0 01 with brack ket. Figure 7.3 ITEM SCRIPTION RDER NO QUANTIT NOTE Motor 2010019 60/76ZY 01 servo mo otor Handle a assembly 603033 Pressure e roller assem mbly 603035 Inlet wire e guide 603019 Hex nut 911019...
  • Page 40 Drive rol 507xxx Default0.9/ /1.2(0.035/0. .045) connecti on sleeve 603015 Insulatio n sleeve 603022 Bracket 603031 Torch conne ection 603017 Table 7.3 Drive e roller selec ction SCRIPTION ORDE ER NO NOTE V groov ve (0.9/1.2m mm)(0.035/0.0 045)(default) 0726 61030 For solid wi V groov ve (0.6/0.8m...

  • Page 41: Spool Holder Module

    . Spool h older mod dule Figure 7.4 ESCRIPTION RDER NO QUANTIT Axle 071709 Axle s seat inside 071715 Axle s seat outside 071710 Damp ping washer 071711 Cap b bracket 071708 Lock s spring 071707 Lock n 071703 071706 Table 7.5 MIG to orch...
  • Page 42 Figure 7.5 Nozz zles DESCRIP PTION ORDER N Nozzle Adjustable 22-50* Nozzle Adjustable 22-62 Nozzle Self Insulate 22-50F Nozzle Fixed Coars se Thread 24CT60 Nozzle Fixed Coars se Thread 24CT62 Nozzle Fixed Coars se Thread 24CT75 Nozzle Self Shieldi 23-50 Nozzle Self Insulate 23-62...
  • Page 43 Nozzle Adjustable 24A50 Nozzle Adjustable 24A62 Nozzle Adjustable 24A75 Table 7.6 Contac ct Tips DESCRIP PTION ORDER Contac ct Tip 0.023”/ /0.6mm Ecu 14-23 Contac ct Tip 0.030”/ /0.8mm Ecu 14-30 Contac ct Tip 0.035”/ /0.9mm Ecu 14-35* Contac ct Tip 0.040”/ /1.0mm Ecu 14-40 Contac...
  • Page 44 Gas D Diffuser Gas D Diffuser Jacke eted goose he eck 45̊ 2A45J Jacke eted goose he eck 60̊ 2A60J* goose e heck 45̊ 2A45 goose e heck 60̊ 2A60 Gas N Nipple EF2212 O-Rin g 8x1.5 508015S Handl EH2101 Hange er Hook EG2001...
  • Page 45 NOTES ELDKING® M MigSonic252 2S power so ource and S S20 wire fee eder Manual no: W WM070101 Page MIGSONIC252S OWNER’S M MANUAL...

  • Page 46: Electric Diagram

    SECTIO ON 8 ELECT TRIC DIA AGRAM Figure 8.1 Manual no: W WM070101 Page e44 MIG SONIC252S OWNER’S M MANUAL...
  • Page 47 Figure 8.2 Manual no: W W M070101 Page e45 MIG SONIC252S OWNER’S M M ANUAL...

  • Page 48: Warranty Policy

    includ...

  • Page 49: Authorized Service Center

    CTION 1 UTHORI IZED SE RVICE C CENTER Pleas se go to o our websit te www.we eldking.co om to fill th he warran ty registra ation form Malo o Welding Products Ltd. will n not distrib bute of dis sclose cus stomer's p private...
  • Page 50 271, A Amber Street t, Unit#10,M Markham, ON N L3R 3J7 Tel: 1 866 686 5088 Fax: 1 866 686 5090 www.w weldking.co Printe d February 6, 2015 Manu ual no: WM0 0 70301 PULSE EWAVE200 O OWNER’S MA ANUAL...

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