Matco Tools MP200DVILCD Owner's Manual
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Matco Tools MP200DVILCD Owner's Manual

Matco Tools MP200DVILCD Owner's Manual

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MP200DVILCD
OWNER'S MANUAL
11/2018
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.
1812367-12

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Summary of Contents for Matco Tools MP200DVILCD

  • Page 1 MP200DVILCD OWNER’S MANUAL 11/2018 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. 1812367-12...

  • Page 2: Limited Warranty

    Limited to the warranty periods below, MATCO TOOLS will repair or replace the item under warranty that fails due to defects in material and workmanship. MATCO TOOLS must be notified within 30 days of the failure, so as to provide instructions on how to proceed with the repair of your welder and warranty claim processing.

  • Page 3: General Safety Rules

    GENERAL SAFETY RULES WARNING: Read and understand all instructions. Failure to follow all instructions listed below may result in serious injury or death. CAUTION: Do not allow persons to operate or assemble this unit until they have read this manual and have developed a thorough understanding of how this unit works. WARNING: The warnings, cautions, and instructions discussed in this instruction manual cannot cover all possible conditions or situations that could occur.
  • Page 4 -Connect ground lead as close to the area being welded as possible to ensure a good ground. -Do not allow any body part to come in contact with the welding wire if you are in contact with the material being welded, ground or electrode from another welder. -Do not weld if you are in an awkward position.
  • Page 5 UV and IR Arc Rays The welding arc produces ultraviolet (UV) and infrared (IR) rays that can cause injury to your eyes and skin. Do not look at the welding arc without proper eye protection. -Always use a helmet that covers your full face from the neck to top of head and to the back of each ear.
  • Page 6 Electromagnetic Field -Electromagnetic fields can interfere with various electrical and electronic devices such as pacemakers. -Consult your doctor before using any electric arc welder or cutting device. -Keep people with pacemakers away from your welding area when welding. -Do not wrap cable around your body while welding. -Wrap MIG gun and ground cable together whenever possible.

  • Page 7: Technical Specifications

    35 lbs. DESCRIPTION The MATCO MP200DVILCD is an inverter-powered, dual voltage, wire feed welder for flux core and MIG welding plus a DC stick welder. It features a Synergic LCD control that allows the operator to select process and weld settings. It comes complete with a regulator and gas hose for easy connection for MIG welding plus a weld cable and electrode holder for DC stick welding.
  • Page 8 Welding Voltage Control LCD Synergic Inert Gas Multi-Function Control Regulator Adjustment/Selector Knob Inert Gas Hose 120V Adapter Cord Electrode Holder MIG Torch Ground Cable and Cable and Clamp MIG TORCH The welding wire is driven through the welding cable and torch to the work piece. It is attached to the drive system.

  • Page 9: Installation

    INSTALLATION Electrical Shock  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 plasma cutter's power cord and the power source receptacle.
  • Page 10 a. Open the door to the welder drive compartment. b. Remove the drive tension by loosening the Drive Tension Adjuster (1) and moving the Drive Tension Adjustor away from the Drive Tension Arm (2). Lift the Drive Tension Arm away from the Drive Roller (3). c.
  • Page 11 ii. Make sure the proper groove on the drive roller is in place for the wire installed. If not, change the drive roller as described in INSTALL THE WIRE ROLLER above. iii. Remove the packaging from the spool of wire and then identify the leading end of the wire secured on the edge of the spool.
  • Page 12 4 Inch 8 Inch Figure 5 vi. Setting the wire spool tension. a) Turn the spool of wire with one hand. b) Increase the spool tension by tightening (turn clockwise) the wing nut while turning the spool. Turn the spool while tightening the wing nut until the spool slows down and you feel a slight drag.

  • Page 13: Gas Installation

    -The welding wire is electrically hot when the power is on and the torch trigger is activated. xvii. Set the WIRE SPEED control to the middle of the wire speed range. xviii. Straighten the MIG torch cable and pull the trigger in the gun handle to feed the wire through the torch assembly.
  • Page 14 should be connected to the positive (+) weld output connection on the front of the machine. The ground cable would then be connected to the negative (-) weld output connection. ii. Electrode Negative for Flux Core Welding - The Weld Power Cable should be connected to the negative (-) weld output connection on the front of the machine.

  • Page 15: Mig Torch Assembly

    NOTE: Slowly open the cylinder valve by turning it counter-clockwise until the cylinder pressure gauge registers on the first gauge of the regulator. Turn the adjustment knob clockwise (right) slowly to increase gas flow to 20 CFH. To reduce the gas flow, turn the adjustment counter-clockwise (left). The gas valve is located on the back panel of the welder and activated by the trigger.
  • Page 16 Socket 5-Pin Trigger Receptacle Negative (-) Weld Output Connection Positive (+) Weld Power Weld Output Cable Connection Figure 8 3. Insert the back end of the MIG torch into the MIG socket on the front of your machine (Figure 8). Make certain to completely slide the torch all the way in.
  • Page 17 Figure 9 3. We recommend removing the MIG torch when the Spool Gun is connected to avoid accidental arcing. Loosen the wing nut retaining bolt and slide the MIG torch out of the front of the machine. Disconnect the 5-Pin trigger connection on the front of the machine. 4.
  • Page 18 DC STICK WELDING ASSEMBLY - Be aware that the ELECTRODE HOLDER will be electrically HOT when the Input Power Switch on the welder is turned ON. 1. Install the ground cable quick connector to the negative (-) Weld Output Connector (Figure 8). 2.

  • Page 19: Understanding The Front Panel

    OPERATING INSTRUCTIONS  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 plasma cutter's power cord and the power source receptacle.
  • Page 20 2. GENERAL SYSTEM SET-UP a. Press the START BUTTON b. Turn the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB to the SETTING selection c. Push in the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB. d. LANGUAGE i. English is the default selection ii. To change selection, Press the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB.
  • Page 21 Feed Welding screen is displayed. i. MIG Steel - Choose this option if you are MIG welding steel with a shielding gas or flux core welding steel. 1. Use the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB to select your shielding gas. Press the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB to confirm your selection.
  • Page 22 KNOB. Wire Speed will no longer be highlighted, but will have a box around it. Turn the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB to go through other options. Press the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB to adjust the highlighted Option. iii. MIG Al – Choose this option if you are MIG welding Aluminum 1.
  • Page 23 b. With a spool gun: i. Use the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB to select the wire alloy to be used. ii. Connect the Weld Power Cable (See Figure 8 or follow the onscreen visual) to the Positive (+) Weld Output Connection. Press the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB to confirm your selection.
  • Page 24 3. Use the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB to select the thickness of material to be welded. Press the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB to confirm your selection. 4. This machine is now set to weld. a. Use the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB to fine tune wire feed speed. b.

  • Page 25: Arc Force

    1. Press the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB to deselect the wire speed feed parameter adjustments 2. Turn the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB until you get to MEMORY LOAD. 3. Press the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB to access the MEMORY LOAD. 4. Turn the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB to choose the file number you wish to use to load.

  • Page 26: Vrd - Voltage Reduction Device

    i. VRD – VOLTAGE REDUCTION DEVICE i. This unit can be set up as a voltage reduction device (VRD) if needed. VRD reduces the Open Circuit Voltage (OCV) that is available at the weld output connectors, while not welding. ii. Press the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB to exit the Amperage Adjustment Mode.

  • Page 27: Mig Operation

    MIG OPERATION  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 plasma cutter's power cord and the power source receptacle.
  • Page 28 e. Connect the Ground Clamp to a scrap piece of the same type of material which you will be welding. It should be equal to or greater than the thickness of the actual work piece, and free of oil, paint, rust, etc. f.
  • Page 29 Travel direction is the direction the torch is moved along the weld joint in relation to the weld puddle. The torch is either PUSHED into the weld puddle or PULLED away from the weld puddle. For most welding jobs you will pull the torch along the weld joint to take advantage of the greater weld puddle visibility.
  • Page 30 The HORIZONTAL POSITION is performed very similarly to the flat weld except that angle B (see HOLDING THE TORCH) is such that the wire, directed more toward the metal above the weld joint, is to help prevent the weld puddle from running downward while still allowing slow enough travel speed.
  • Page 31 edges of the material to be joined by grinding a bevel on the edge of one or both pieces of the metal being joined. When this is done, a “V” is created between the two pieces of metal that will have to be welded closed. In most cases more than one pass or bead will need to be laid into the joint to close the “V”.

  • Page 32: Spot Welding Instructions

    e. Spot Welding There are three methods of spot welding: Burn-Through, Punch and Fill, and Lap. Each has advantages and disadvantages depending on the specific application as well as personal preference. i. The BURN-THROUGH METHOD welds two overlapped pieces of metal together by burning through the top piece and into the bottom piece.

  • Page 33: Setting Up The Work Piece

    DC STICK OPERATION  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 plasma cutter's power cord and the power source receptacle.

  • Page 34: Ground Clamp Connection

    2. GROUND CLAMP CONNECTION Clear any dirt, rust, scale, oil, or paint on the ground clamp. Make certain you have a good solid ground connection. A poor connection at the ground clamp will waste power and heat. Make sure the ground clamp touches the metal. 3.
  • Page 35 ii. The arc will be difficult to maintain. c. When the rod is too large: i. The arc will burn through light metals. ii. The bead will undercut the work. iii. The bead will be flat and porous. iv. The rod may be freeze or stick to the work piece. Note: The rate of travel over the work also affects the weld.
  • Page 36 It is important that the gap be maintained during the welding process and it shouldn’t be too wide or too narrow. If it’s too narrow, the rod will stick to the work piece. If it’s too wide, the arc will be extinguished.
  • Page 37 d. Welding position Flat position is the easiest of the welding positions and is most commonly used. It is best if you can weld in the flat position if at all possible as good results are easier to achieve. Flat Position Horizontal Position The horizontal position is performed very much the same as the flat weld except that the angle is different such that the electrode, and therefore the arc force, is directed more...
  • Page 38 PEENING THE SLAG FROM A WELD JOINT CAUSES SMALL CHIPS OF METAL TO FLY THROUGH THE AIR! Metallic chips flying through the air can cause eye injury or injury to other parts 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.
  • Page 39 8.2 Rest the TIG torch nozzle on the work piece taking care to not touch the installed tungsten electrode. 8.3 Twist the torch to make contact between the work piece and the tungsten. 8.4 Lift torch away from the work piece about 1/8 inch. 8.5 Move down the joint to be welded by pushing the torch.

  • Page 40: Maintenance

    MAINTENANCE • 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. •...
  • Page 41 Symptom Possible Cause Corrective Action Cannot create an Work piece is painted or rusty. Remove all paint and rust. Arc. Ground clamp is connected where there is Remove all paint and rust so ground paint or rust. clamp is connected to bare metal. Ground clamp is not electrically connected Make certain the ground clamp is to the work piece.
  • Page 42 MAIN CIRCUIT CHART Page of 45 1812367-12...

  • Page 43: Spare Parts List

    SPARE PARTS LIST Page of 45 1812367-12...
  • Page 44 SUPPLIER PART REFERENCE DESCRIPTION NUMBER 165200036 Handle 165200037 Enclosure 105200211 Power Cord 105200046 Power switch 105200313 Back plate 105200047 Gas valve 165200038 Rear Bezel 165200039 Fan Mounting Plate 165200040 165200041 Main PCB 105200234 Main PCB Support 165200042 Control PCB 105500033 Feet 105200317 Output reactor...
  • Page 45 Distributed by Matco Tool 4403 Allen Road Stow OH 44224 w w w . m a t c o t o o l s . c o m Made in China to Matco specifications Page of 45 1812367-12...

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