MK Welding Multi-GMAW 200 LCD PFC User Manual
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MK Welding Multi-GMAW 200 LCD PFC User Manual

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Bedienungsanleitung
DE
EN
Multi-GMAW 200 LCD PFC
/ 250-3 LCD / 315-3 LCD
MIG/MAG, MMA, WIG Schweißinverter / MIG/MAG, MMA, TIG
IMPORTANT: Read this Owner's Manual Completely before attempting to use this
equipment. Save this manual and keep it handy for quick reference. Pay particular
attention to the safety instructions we have provided for your protection. Contact your
distributor if you do not fully understand this manual.
User Manual
Welding Inverter
1.0003.0551-MK / 1.0003.0571-MK / 1.0003.0538-E
V 2.3.22

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Summary of Contents for MK Welding Multi-GMAW 200 LCD PFC

  • Page 1 Bedienungsanleitung User Manual Multi-GMAW 200 LCD PFC / 250-3 LCD / 315-3 LCD MIG/MAG, MMA, WIG Schweißinverter / MIG/MAG, MMA, TIG Welding Inverter 1.0003.0551-MK / 1.0003.0571-MK / 1.0003.0538-E V 2.3.22 IMPORTANT: Read this Owner’s Manual Completely before attempting to use this equipment.

  • Page 2: Table Of Contents

    Inhaltsverzeichnis 1. Allgemeines 2. Sicherheitsanweisung 3. Betriebsbedingungen und Arbeitsumgebung 4. Technische Beschreibung 5. Technische Daten 6. Einschaltdauer 7. Geräteübersicht (250-3 LCD / 315-3 LCD) 8. Bedienpanel 9. Schweißen MIG/MAG Synergic MIG/MAG Manuell Schweißen MMA Schweißen WIG Schweißen Zünden mit Kontaktzündung Richtiges Schleifen der WIG Elektrode MIG/MAG Spool Gun Betrieb 10.

  • Page 3: Allgemeines

    1. Allgemeines Alle Personen, die mit diesem Gerät arbeiten, das Gerät bedienen, Wartungs- und oder Instandhaltungsarbeiten am Gerät durchführen, müssen - entsprechende Qualifikationen haben, - Kenntnisse vom Schweißen haben, - diese Bedienungsanleitung vollständig lesen, - die für Ihr Land gültigen Vorschriften beachten und einhalten. Bei Fehlbedienung, Missbrauch oder anderes besteht Gefahr für - Leib und Leben des Bedieners und Dritte, - Gerät und / oder Sachwerte.

  • Page 4: Sicherheitsanweisung

    2. Sicherheitsanweisung Die Anlage ist ausschließlich für das MIG/MAG, WIG, MMA Schweißen bestimmt. Das Bedienungspersonal muss über die Sicherheitshinweise unterrichtet werden. Die Anlage darf unter keinen Umständen von ungeschultem Personal bedient werden. Reparaturen im elektrischen Bereich dürfen nur von Elektrofachkräften ausgeführt werden. Bei Pflege-, Wartungs- und Reparaturarbeiten sowie vor Öffnen des Gehäuses immer Netzstecker ziehen.
  • Page 5 Warnung: Blanke Stellen ohne bzw. mit schadhafter Isolierung sind lebensgefährlich. Beschädigte Kabel bzw. Schlauchpakete sofort ersetzen! Beim Wechsel der Brennerteile die Anlage am Hauptschalter außer Betrieb setzen. Vor öffnen des Anlagengehäuses durch ein Fachpersonal, Netzstecker ziehen. Die Anlagen sind in regelmäßigen Abständen auf Ihren einwandfreien Zustand zu prüfen.
  • Page 6 Personen, die Herzschrittmacher oder Hörgeräte tragen, sollten sich vor Arbeiten in der Nähe der Maschinen, von einem Arzt beraten lassen. Achtung: Es ist möglich, dass im Bereich eines Krankenhauses oder ähnlichem durch den Betrieb der Anlage elektromedizinische, informationstechnische oder auch andere Geräte (EKG, PC, usw.) in ihrer Funktion beeinträchtigt werden können.

  • Page 7: Betriebsbedingungen Und Arbeitsumgebung

    Normen (EMC 2014/30/EU & LVD 2014/35/EU, EN 60974-10:2014 + A1:2015, EN60974- 1:2012). Das Multi-GMAW 200 LCD PFC / 250-3 LCD / 315-3 LCD Schweißgerät besitzt die modernste IGBT Technologien. Es hat mehr Leistung und höhere Effektivität so dass es mit üblichen Transformator Schweißgeräten nicht vergleichbar ist.

  • Page 8: Einschaltdauer

    6. Einschaltdauer Der Buchstabe „X“ steht für Multi-GMAW 250 LCD PFC Einschaltdauer (Duty Cycle). Hierbei handelt es sich um den Teil der Zeit, in der ein Schweißgerät innerhalb eines bestimmten Zeitzyklus (10 Minuten) kontinuierlich mit seinem Ausgangsnennstrom schweißen kann. Die Beziehung zwischen dem Arbeitszyklus "X"...

  • Page 9: Geräteübersicht (250-3 Lcd / 315-3 Lcd)

    7. Geräteübersicht (250-3 LCD / 315-3 LCD) Bild 1 1. Euro Zentral Anschluss 2. Ausgang PLUS (+) 3. Gas Ausgang 4. Euro Zentral Anschluss Pol Kabel (250-3 LCD / 315-3 LCD) 4*. Euro Zentral Anschluss Polung (200 LCD PFC) 5. Steuerstecker WIG / Spool Gun 6.

  • Page 10: Bedienpanel

    7. Gas Eingang 8. EIN/AUS Schalter 9. Kabel 10. Bedienpanel 11. Drahtrollen Halter 12. Spannschraube, Drahtanpressdruck 13. Druckrollen 14. Drahtführungs Rohr 15. Draht Vorschubrolle 16. Draht Vorschubrolle 17. Vorschubmotor Je nach verwendetem Schweißdraht (siehe Hersteller Angaben, Schweißdraht) muss die Polung des Eurozentral Anschusses umgepolt werden, hierzu ist das Kabel mit Bajonett Stecker (Bild 1, 4) auf dem Plus Pol (Bild 1, 2) oder auf dem Minus Pol (Bild 1, 6) anzuschließen, das Massekabel wird je nach Polung des Euro Zentral Anschlusses auf den...
  • Page 11 8. Bedienpanel Bild 2 1 Einstellregler Links 2 Home Taster (Taste ist verknüpft mit dem Display Symbol) 3 Haupt Einstellregler 4 LCD Display 5 Einstellregler Rechts 6 Zurück Taster (Taste ist verknüpft mit dem Display Symbol) Display Symbole für die „Home Taste“ bzw. „Zurück Taste“ hier gelangen Sie in das Schweißmenü...

  • Page 12: Schweißen

    hier gelangen Sie einen Schritt zurück, zum vorherigen Menü. 9. Schweißen MIG/MAG Synergic Drehen Sie den Haupt Einstellregler (Bild 2, 3) bis der gewünschte Schweißmodus „MIG/MAG Synergic“ erscheint. Sollten Sie sich bereits in einem Schweißmodus befinden drücken Sie die Home Taste (Bild 2, 2) danach gelangen Sie zur Hauptansicht.
  • Page 13 Gas Menü Hier wird wieder mit dem Haupt Einstellregler (Bild 2, 3) das gewünschte Schweißgas auswählen, zum Bestätigen wieder den Regler Drücken. Je nach Schweißdraht Vorauswahl wird nur das passende Gas angezeigt. Nach dem Bestätigen der Gasauswahl gelangen Sie weiter zum Draht Durchmesser Menü. Draht Durchmesser Menü...

  • Page 14: Mig/Mag Manuell Schweißen

    Schweißparameter Menü Durch Drehen des Haupt Einstellregler (Bild 2, 3) können Sie den gewünschten Parameter auswählen und durch Drücken Bestätigen Sie die Auswahl. Wollen Sie zurück zum Schweißmenü Drücken Sie die Zurück Taste (Bild 2, 6) Nach Bestätigung gelangen Sie zum jeweiligen Einstellwert (z.B. Bild Einstellung 2T/4T) Einstellung 2T/4T Durch Drehen des Haupt Einstellreglers (Bild 2, 3) können Sie den Wert je nach Bedarf Einstellen, dieser Wert muss nicht bestätigt werden.
  • Page 15 Nach der Bestätigung gelangen Sie automatisch zum Schweißparameter Menü Schweißparameter Menü Durch Drehen des Haupt Einstellregler (Bild 2, 3) können Sie den gewünschten Parameter auswählen und durch Drücken Bestätigen Sie die Auswahl. Wollen Sie direkt weiter zum Schweißmenü Drücken Sie die Home Taste (Bild 2, 2) Nach Bestätigung gelangen Sie zum jeweiligen Einstellwert (z.B.

  • Page 16: Mma Schweißen

    MMA Schweißen Drehen Sie den Haupt Einstellregler (Bild 2, 3) bis der gewünschte Schweißmodus „Elektroden“ erscheint. Sollten Sie sich bereits in einem Schweißmodus befinden drücken Sie die Home Taste (Bild 2, 2) danach gelangen Sie zur Hauptansicht. Home Ansicht Bestätigen Sie den gewünschten Modus durch Drücken des Haupt Einstellreglers (Bild 2, 3) Nach der Bestätigung gelangen Sie automatisch zum Schweißparameter Menü...

  • Page 17: Wig Schweißen

    Schweißparameter Menü. Übersicht: Eingestellte Schweißparameter, Hot Start Arc Force Schweißmenü Den Schweißstrom können Sie durch Drehen des linken Einstellreglers (Bild 2, 1) einstellen. Wenn Sie die Schweißparameter ändern wollen Drücken Sie die Zurück Taste (Bild 2, 6). Der Elektrodenhalter und das Massekabel gehören je nachdem welche Elektrode verwendet wird laut Angaben des Elektroden Herstellers angeschlossen.
  • Page 18 Schweißparameter Menü Durch Drehen des Haupt Einstellregler (Bild 2, 3) können Sie den gewünschten Parameter auswählen und durch Drücken Bestätigen Sie die Auswahl. Wollen Sie direkt weiter zum Schweißmenü Drücken Sie die Home Taste (Bild 2, 2) Übersicht: Eingestellte Schweißparameter, 2T / 4T Gasnachströmzeit Down Slope Zeit...

  • Page 19: Zünden Mit Kontaktzündung

    Zünden mit Kontaktzündung 1. Legen Sie den Brenner mit der Keramik wie im Bild (Abb.1) auf das Werkstück. 2. Drücken Sie den Startknopf auf dem WIG Brenner und halten Sie die Taste 3. Drehen Sie den Brenner wie im Bild (Abb.2) nach, bis ein Kontakt zwischen Werkstück und Elektrode entsteht.

  • Page 20: Mig/Mag Spool Gun Betrieb

    MIG/MAG Spool Gun Betrieb Drehen Sie den Haupt Einstellregler (Bild 2, 3) bis der gewünschte Schweißmodus „Spool Gun“ erscheint. Sollten Sie sich bereits in einem Schweißmodus befinden drücken Sie die Home Taste (Bild 2, 2) danach gelangen Sie zur Hauptansicht. Home Ansicht Bestätigen Sie den gewünschten Modus durch Drücken des Haupt Einstellreglers (Bild 2, 3) Nach der Bestätigung gelangen Sie automatisch zum Schweißparameter Menü...

  • Page 21: Menü Einstellungen

    Übersicht: Eingestellte Schweißparameter. Schweißmenü Die Schweißspannung kann mit dem rechten Einstellregler (Bild 2, 5) eingestellt werden. Die Drahtvorschubgeschwindigkeit wird mit dem linken Einstellregler (Bild 2, 1) eingestellt. Wenn Sie die Schweißparameter ändern wollen Drücken Sie die Zurück Taste (Bild 2, 6). 10.

  • Page 22: Job Speicher

    die Zurück Taste (Bild 2, 6) und Sie gelangen wieder zur Home Ansicht zurück. Nach Bestätigung der Auswahl gelangen Sie zum jeweiligen Einstellwert (z.B. Bild Einstellung Sprache) Einstellung Sprache Durch Drehen des Haupt Einstellreglers (Bild 2, 3) können Sie den Wert je nach Bedarf Einstellen, und durch Drücken des Reglers wird der Ausgewählte wert Bestätigt.

  • Page 23: Laden / Aufrufen

    Durch Drehen des Haupt Einstellregler (Bild 2, 3) können Sie den gewünschten Speicherplatz auswählen und durch Drücken des Reglers werden Ihre Werte in diesem Speicherplatz gespeichert. Laden / Aufrufen Um sein bereits Gespeichertes Programm aufzurufen gibt es 2 Möglichkeiten. Möglichkeit 1, man befindet sich in einem Schweißmenü (z.B. Bild Schweißmenü WIG) Aufrufen, Wird der rechte Einstellregler gedrückt wird der Wert „Aufrufen“...

  • Page 24: Wig Stecker Belegung

    12. WIG Stecker Belegung 10K Poti zum Reglen des Schweißstromes EIN/AUS Stecker Belegung...

  • Page 25: Spool Gun Stecker Belegung

    13. Spool GUN Stecker Belegung EIN/AUS Strom Regler Taster Stecker Belegung...

  • Page 26: Fehlerursachen - Behebung

    14. Fehlerursachen - Behebung Fehler Mögliche Ursache Behebung Netz angeschlossen und Netzsicherung hat ausgelöst Netzsicherung prüfen Netzschalter auf „I“ Display bleibt Netzanschluss unterbrochen Netzanschluss prüfen dunkel Alarmleuchte leuchtet (Siehe Gerät ist Überhitzt Der Alarm wird nach Ablauf der Fehlercode) Lüfterkühlung freigegeben und Sie können das Gerät neu starten Überstrom Die Alarmleuchte leuchtet...

  • Page 27: Fehler Codes

    15. Fehler Codes Fehler Typ Fehler Beschreibung LED Status Code Überhitzung (Erstes Thermo Relais) Gelbe LED (Überhitzungsschutz) Dauerlicht Überhitzung (Zweites Thermo Relais) Gelbe LED (Überhitzungsschutz) Dauerlicht Temperatur/ Überhitzung Überhitzung (Drittes Thermo Relais) Gelbe LED (Überhitzungsschutz) Dauerlicht Überhitzung (Viertes Thermo Relais) Gelbe LED (Überhitzungsschutz) Dauerlicht Überhitzung...

  • Page 28: Prüfen Und Warten

    16. Prüfen und Warten Intervall Zu Prüfen Täglich - Das Netzkabel, Verbindungskabel auf Beschädigungen Prüfen. (bei defekt autorisiertes Fachpersonal kontaktieren). - Massekabel, Schlauchpaket, Elektrodenhalter auf Beschädigungen Prüfen und bei Bedarf wechseln. - Gerät auf äußere Beschädigungen Prüfen. - Ein/ Ausschalter auf Beschädigung Prüfen. (bei defekt autorisiertes Fachpersonal kontaktieren).

  • Page 29: Schematischer Schaltplan

    17. Schematischer Schaltplan Multi-GMAW 250 LCD PFC (230V)
  • Page 30 CONTENT §1 Safety ..................... 1 §1.1 Symbols Explanation ....................1 §1.2 Machine Operating warnings! ..................1 §1.3 EMC device classification ................... 8 §1.4 EMC measure....................... 8 §2 Overview ....................9 §2.1 Brief Introduction ......................9 §2.2 Technical Data ......................10 §2.3 Duty cycle and Over-heat ...................
  • Page 31 CONTENT §4.2.1 Set up installation for Stick Welding ..............42 §4.2.2 Operation of the Stick welding method ..............43 §4.2.3 Stick（MMA）Welding ..................43 §4.2.4 Stick（MMA）Welding Fundamentals ..............46 §4.3 Installation & Operation for TIG Welding ............. 48 §4.3.1 Set up installation for TIG Welding ..............48 §4.3.2 Operation of the TIG Lift welding method ............

  • Page 32: Safety

    SAFETY §1 Safety Welding and cutting equipment can be dangerous to both the operator and people in or near the surrounding working area, if the equipment is not correctly operated. Equipment must only be used under the strict and comprehensive observance of all relevant safety regulations.
  • Page 33 SAFETY ELECTRIC SHOCK CAN KILL. Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and internal machine circuits are also live when power is on. In Mig/Mag welding, the wire, drive rollers, wire feed housing, and all metal parts touching the welding wire are electrically live.
  • Page 34 SAFETY  When working above the floor level, use a safety belt to protect yourself from a fall should you get an electric shock! FUMES AND GASES CAN BE DANGEROUS. Smoke and gas generated whilst welding or cutting can be harmful to people’s health. Welding produces fumes and gases.
  • Page 35 SAFETY  Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding.  Use suitable clothing made from durable flame-resistant material to protect your skin and that of your coworkers from the arc rays.
  • Page 36 SAFETY welding  Remove fire hazards material from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
  • Page 37 SAFETY condition.  Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.  Cylinders should be located: Away from areas where they may be struck or subjected to physical damage. At a safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.
  • Page 38 SAFETY Gas build up. The build up of gas can causes a toxic environment, deplete the oxygen content in the air resulting in death or injury. Many gases use in welding are invisible and odourless.  Shut off shielding gas supply when not in use. ...

  • Page 39: Emc Device Classification

    SAFETY Protect others in the workplace.  Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels. Hot parts. Items being welded generate and hold high heat and can cause severe burns. Do not touch hot parts with bare hands.

  • Page 40: Overview

    SAFETY  Power line, Signal transmission line and Date transmission line  Date processing equipment and telecommunication equipment  Inspection and calibration device The effective measures avoid the problem of EMC： a) Power source Even though the power source connection meet rules, we still need to take additional measure to remove the electromagnetic interference.

  • Page 41: Technical Data

    OPERATION MIG series of welding machines has built-in automatic protection functions to protect the machines from over-voltage, over-current and over-heat. If any one of the above problems happens, the LCD on the front panel will be display error code and output current will be shut off automatically for the machine to protect itself and prolong the equipment using life.

  • Page 42: Duty Cycle And Over-Heat

    OPERATION Note: The above parameters are subject to change with the improvement of machines. §2.3 Duty cycle and Over-heat The letter “X” stands for Duty Cycle, which is Relation of welding current and duty defined as the portion of the time a welding machine cycle for Multi-GMAW 250 LCD can weld continuously with it’s rated output current within a certain time cycle (10 minutes).

  • Page 43: Volt-Ampere Characteristic

    OPERATION three-phase Single-phase AC Current Rectifier Inverter Transformer Rectifier Hall 400V 220V 50Hz sensor 50/60Hz Current Feedback control CPU control Voltage Feedback control Welding current PWM signal regulate Wire feeder motor (Wire feed speed) §2.5 Volt-Ampere Characteristic MIG series of welding machines has an excellent volt-ampere characteristic, whose graph is shown as the following figure.
  • Page 44 OPERATION 1. MIG torch euro connector. 2. Positive (+) welding power output connection socket. 3. TIG torch gas connector. 4. MIG Torch Polarity Change Power Connection. 5. Remote connection plug. 6. Negative (-) welding power output connection socket. 7. Gas inlet connector. 8.

  • Page 45: Control Panel Of Welding Machine

    OPERATION §3.2 Control Panel of welding machine Main Start-up Interface 1. Function selection interface: rotate L Knob in the interface to choose from the four welding methods of MIG/MAG Synergic, MIG/MAG Manual, Stick and TIG Lift. 2. Synergic parameter selection interface: a synergic parameter may be selected by rotating L Knob in the interface.
  • Page 46 OPERATION used. 6. Welding mode icon display interface: an interface displaying the icon of the welding mode currently used (2T/4T). 7. Synergic parameter display interface: an interface displaying the synergic parameters currently used (only available when MIG/MAG Synergic welding method is selected). 8.

  • Page 47: Installation & Operation

    OPERATION §4 Installation & Operation §4.1 Installation & Operation for MIG Welding §4.1.1 Set up installation for MIG/MAG Welding (1) Insert the earth cable plug into the negative socket on the front of the machine and tighten it. (2) Plug the welding torch into the MIG torch connection socket on the front panel and tighten it. IMPORTANT : When connecting the torch be sure to tighten the connection.
  • Page 48 OPERATION into the torch receptacle. Check that the drive roller size is compatible with the wire diameter, replace the roller if necessary. (9) Align the wire into the groove of the drive roller and close down the top roller making sure the wire is in the groove of the bottom drive roller, lock the pressure arm into place.

  • Page 49: Operation Of Mig/Mag Synergic Welding Method

    OPERATION (11) Pull the trigger to feed the wire down (12) Fit the correct size contact tip over the the torch cable through to the torch head. wire and fasten tightly into the tip holder. (13) Fit the gas nozzle to the torch head. (14) Carefully open the gas cylinder valve and set the required gas flow rate.
  • Page 50 OPERATION 1) In the main interface, press the MENU key to enter the synergic parameter selection interface; 2) In the synergic parameter selection interface, rotate L Knob to select the required synergic parameters and press it for confirmation in the interface shown below: 3.

  • Page 51: Operation Of The Mig/Mag Manual Welding Method

    OPERATION 2) In the welding interface, rotate L Knob to set the welding current, for which the adjustable scope is different with the welding wires and gases; 3) The welding voltage will be automatically set as the value corresponding to that of the welding current set by rotating L Knob.

  • Page 52: Wire Feed Roller Selection

    OPERATION 3) After the settings, press L Knob and R Knob for confirmation; §4.1.4 Wire Feed Roller Selection The importance of smooth consistent wire feeding during MIG welding cannot be emphasized enough. Simply put the smoother the wire feed then the better the welding will be. Feed rollers or drive rollers are used to feed the wire mechanically along the length of the welding gun.

  • Page 53: Wire Installation And Set Up Guide

    OPERATION groove wire can also be used for flux core wire without the wire particles coming of the wire surface. However it is considered that the knurled roller will give a more positive feed of flux core wire without any deformation of the wire shape. §4.1.5 Wire Installation and Set Up Guide Again the importance of smooth consistent wire feeding during MIG welding cannot be emphasized enough.
  • Page 54 OPERATION tube of the wire feed unit. (5) Feed the wire through the drive roller (6) Lock down the top pressure roller and apply and into the outlet guide tube of the wire a medium amount of pressure us-ing the tension feeder.

  • Page 55: Mig Torch Liner Installation

    OPERATION §4.1.6 MIG Torch Liner Installation (1) Lay the torch out straight on the ground and remove the front end parts. (2) Remove the liner retaining nut. (3) Carefully pull the liner out of the torch cable assembly. (4) Select the correct new liner and carefully unravel avoiding putting any kinks in the liner, if you kink the liner it will make it no good and will require replacement.

  • Page 56: Mig Torch Liner Types And Information

    OPERATION (5) Carefully feed in the new liner down the torch (6) Fit the liner retaining nut and screw lead all the way to exit the torch neck. only 1/2 way down. (7) Snip the liner off 3mm past the end of the (8) Replace the front end parts.
  • Page 57 OPERATION teflon or Polyamide line. The internal diameter of the liner is important and releative to the wire diameter being used and will assit in smooth feeding and prevention of the wire kinking and birdnesting at the drive rollers. Also bending the cable too tightly during welding increases the friction between the liner and the welding wire making it more difficult to push the wire through the liner resulting in poor wire feeding, prematureliner wear and birdnesting.

  • Page 58: Torch & Wire Feed Set Up For Aluminium Wire

    OPERATION Teflon Liners Blue-0.6mm-0.8mm Red - 0.9mm - 1.2mm Yellow - 1.6mm PA Liner Black-1.0mm-1.6mm opper - Brass Neck Liners For high heat applications fitting brass or copper wound jumper or neck liner on the end of the liner at the neck end will increase the working temperature of the liner as well as improve the electrical conductivity of the welding power transfer to the wire.
  • Page 59 OPERATION drive roller. (1) Remove mig torch front end parts. (2) Remove the liner retaining nut. (3) Carefully pull out and completely remove (4) Carefully unravel the new liner. the liner. (5) Carefully feed in the new liner in short forward (6) Fit the liner collet, liner O-ring and movements down the torch lead all the way to exit liner retaining nut.

  • Page 60: Set Up Installation For Spool Gun

    OPERATION (8) Replace the front end parts. (10) Install a U groove drive roller of the size for the diameter wire being used. (11) Place aluminium wire onto spool holder. Feed the wire through the inlet guide tube on to the drive roller. §4.1.9 Set up installation for Spool Gun (1) Insert the earth cable plug into the Negative socket on the front of the machine and tighten it.
  • Page 61 OPERATION IMPORTANT : When connecting the torch be sure to tighten the connection. A loose connection can result in the connector arcing and damaging the machine and gun connector. (3) Connect the Spool Gun control cable to the multipin receptacle on the front panel . (4) Connect the MIG power connection lead to the positive welding power output socket.

  • Page 62: Mig Torch /Spool Gun Control

    OPERATION (11) Feed the wire through the drive roller into (12) Pull the trigger to drive the wire through the inlet guide tube. Swing back and clip down the neck until it exits the contact tip holder. the wire tension swing arm. §4.1.10 MIG Torch /Spool Gun control Dissection graphics for the MIG GUN IFT0063...
  • Page 63 OPERATION Euro-rear thimble Screw M4*6 UNI 6107 Torch locknut /plastic screw thread Euro-main socket/flexibility pin Feeding pipe locknut Insulating feed pipe 0.6-0.8 3m, Blue Spanner for the electric nozzle The operation for the MIG GUN 1. Service the wire feed mechanism at least every time the reel is changed. ·Check the wear of the feed roll groove and change the feed roll when necessary.
  • Page 64 OPERATION Spool Gun Gun switch Spool cover switch Adjust current button Remote Control Socket Socket Pin Function Spool gun motor Not connected Not connected Spool gun motor 10k ohm (maximum) connection to 10k ohm remote control potentiometer. Zero ohm (minimum) connection to 10k ohm remote control potentiometer. Wiper arm connection to 10k ohm remote control potentiometer.

  • Page 65: Mig Welding

    OPERATION §4.1.11 MIG Welding Definition of MIG Welding MIG (metal inert gas) welding also known as GMAW (gas metal arc welding) or MAG (metal active gas welding), is a semi-automatic or automatic arc welding process in which a continuous and consumable wire electrode and a shielding gas are fed through a welding gun.
  • Page 66 OPERATION Principles of welding Short Circuit Transfer - Short circuit transfer is the most common used method whereby the wire electrode is fed continuously down the welding torch through to and exiting the contact tip. The wire touches the work piece and causes a short circuit the wire heats up and begins to form a molten bead, the bead separates from the end of the wire and forms a droplet that is transferred into the weld pool.
  • Page 67 OPERATION The wire approaches the The wire cannot support The current flow creates work piece and touches the current flow, magnetic field that work creating a short circuit resistance builds up and begins pinch between the wire and the the wire becomes hot and melting wire forming it base metal, because there is weak and begins to melt.
  • Page 68 OPERATION wire is directed at the base metal, the angle and travel direction chosen. Travel speed and work angle will determine the characteristic of the weld bead profile and degree of weld penetration Push Technique - The wire is located at the leading edge of the weld pool and pushed towards the un-melted work surface.
  • Page 69 OPERATION Travel Angle - Travel angle is the right to left angle relative to the direction of welding. A travel angle of 5°- 15° is ideal and produces a good level of control over the weld pool. A travel angle greater that 20°...
  • Page 70 OPERATION penetration and even fusion. Too short stick out will cause an unstable weld pool, produce spatter and over heat the contact tip. Too long stick out will cause an unstable arc, lack of penetration, lack of fusion and increase spatter. Normal stick Too long...
  • Page 71 OPERATION fusion. The energy from the arc dwells on top of the weld pool rather than penetrating the base metal. This produces a wider weld bead with more deposited weld metal per mm than is required resulting in a weld deposit of poor quality. Too Slow Travel Speed large wide bead porosity...
  • Page 72 OPERATION WELDING WIRE DIAMETER CHART MATERIALTHICKNESS RECOMMENDED WIRE DIAMETERS 0.8mm 0.9mm 1.0mm 1.2mm 1.6mm 2.0mm 2.5mm 3.0mm 4.0mm 5.0mm 6.0mm 8.0mm 10mm 14mm 18mm 22mm For material thickness of 5.0mm and greater, multi-pass runs or a beveled joint design may be required depending on the amperage capability of your machine.

  • Page 73: Installation & Operation For Stick Welding

    OPERATION Argon Co2 Penetration Pattern Steel §4.2 Installation & Operation for Stick Welding §4.2.1 Set up installation for Stick Welding Connection of Output Cables Connection of Output Cables Two sockets are available on this welding machine. For MMA welding the electrode holder is shown be connected to the positive socket, while the earth lead (work piece) is connected to the negative socket, this is known as DCEP.

  • Page 74: Operation Of The Stick Welding Method

    OPERATION §4.2.2 Operation of the Stick welding method 1. Selection of the welding method: 1) In the main interface, press the MENU key to enter the function selection interface; 2) In the function selection interface, rotate L Knob to select the Stick welding method and press it for confirmation.
  • Page 75 OPERATION One of the most common types of arc welding is manual metal arc welding (MMA) or stick welding. An electric current is used to strike an arc between the base material and a consumable electrode rod or ‘stick’. The electrode rod is made of a material that is compatible with the base material being welded and is covered with a flux that gives off gaseous vapours that serve as a shielding gas and providing a layer of slag, both of which protect the weld area from atmospheric contamination.
  • Page 76 OPERATION •The arc is initiated by momentarily touching the electrode to the base metal. • The heat of the arc melts the surface of the base metal to form a molten pool at the end of the electrode. • The melted electrode metal is transferred across the arc into the molten pool and becomes the deposited weld metal.

  • Page 77: Stick（Mma）Welding Fundamentals

    OPERATION additional functions are provided mainly by the covering on the electrode. §4.2.4 Stick（MMA）Welding Fundamentals Electrode Selection As a general rule, the selection of an electrode is straight forward,in that it is only a matter of selecting an electrode of similar composition to the parent metal. However, for some metals there is a choice of several electrodes, each of which has particular properties to suit specific classes of work.
  • Page 78 OPERATION through the work, over-heating the electrode or producing a rough spattered surface.The table shows current ranges generally recommended for a general purpose type 6013 electrode. Arc Length To strike the arc, the electrode should be gently scraped on the work until the arc is established. There is a simple rule for the proper arc length;...

  • Page 79: Installation & Operation For Tig Welding

    OPERATION §4.3 Installation & Operation for TIG Welding §4.3.1 Set up installation for TIG Welding (1) Insert the earth cable plug into the positive socket on the front of the machine and tighten it. (2) Plug the welding torch into the negative socket on the front panel, and tighten it. (3) Connect the control cable of torch switch to 9 pin socket on the front of the machine .
  • Page 80 OPERATION 2) In the function selection interface, rotate L Knob to select the TIG Lift welding method and press it for confirmation. Refer to Fig. 1; 2. Selection and setting of welding parameters: 1) In the main interface, press the MENU key to enter the welding parameter setting interface; 2) In the welding parameter setting interface, rotate L Knob to select the parameter as required and rotate R Knob to set a value for the parameter, afterwards, press L Knob or R Knob for confirmation as shown below:...
  • Page 81 OPERATION DC welding. 5. Lay the outside edge of the Gas Cup on the work piece with the Tungsten Electrode 1- 2mm from the work piece. Press and hold the torch switch to activate to gas flow and welding power. 6.

  • Page 82: Dc Tig Welding

    (4) Assemble front end parts of the TIG (5) Lay the outside edge of the Gas Cup on the torch, fitting a sharpened tungsten suitable work piece with the Tungsten Electrode 1- 2mm for DC welding. from the work piece. Press and hold the trigger button on TIG torch to start the gas flow.
  • Page 83 The DC power source uses what is known as DC (direct current) in which the main electrical component known as electrons flowin only one direction from the negative pole (terminal) to the positive pole (terminal). In the DC electrical circuit there is an electrical principle at work which should always be taken into account when using any DC circuit.

  • Page 84: Tig Welding Fusion Technique

    Lift Arc is a form of arc ignition where the machines has low voltage on the electrode to only a few volts, with a current limit of one or two amps (well below the limit that causes metal to transfer and contamination of the weld or electrode). When the machine detects that the tungsten has left the surface and a spark is present, it immediately (within microseconds) increases power, converting the spark to a full arc.
  • Page 85 together. TIG Welding with Filler Wire Technique It is necessary in many situations with TIG welding to add a filler wire into the weld pool to build up weld reinforcement and create a strong weld. Once the arc is started the torch tungsten is held in place until a weld pool is created, a circular movement of the tungsten will assist is creating a weld pool of the desired size.

  • Page 86: Tungsten Electrodes

    §4.3.5 Tungsten Electrodes Tungsten is a rare metallic element used for manufacturing TIG welding electrodes. The TIG process relies on tungsten’s hardness and high-temperature resistance to carry the welding current to the arc. Tungsten has the highest melting point of any metal, 3,410 degrees Celsius. Tungsten electrodes are nonconsumable and come in a variety of sizes, they are made from pure tungsten or an alloy of tungsten and other rare earth elements.
  • Page 87 energy output, E3 Tungsten Electrodes run cooler than 2% thoriated tungsten, thereby extending overall tip lifetime. E3 Tungsten Electrodes work well on AC or DC. They can be used DC electrode positive or negative with a pointed end, or balled for use with AC power sources.

  • Page 88: Tungsten Preparation

    Tungsten DC Current Amps AC Current Amps AC Current Amps Diameter Torch Negative Un-Balanced Wave Balanced Wave 2% Thoriated 0.8% Zirconiated 0.8% Zirconiated 1.0mm 15-80 15-80 20-60 1.6mm 70-150 70-150 60-120 2.4mm 150-250 140-235 100-180 3.2mm 250-400 225-325 160-250 4.0mm 400-500 300-400 200-320...
  • Page 89 The shape of the tungsten electrode tip is an important process variable in precision arc welding. A good selection of tip/flat size will balance the need for several advantages. The bigger the flat, the more likely arc wander will occur and the more difficult it will be to arc start. However, increasing the flat to the maximum level that still allows arc start and eliminates arc wonder will improve the weld penetration and increase the electrode life.

  • Page 90: Tig Gun Switch Control

    1.6mm .500 08 - 50 05 - 100 1.6mm .800 10 - 70 10 - 140 2.4mm .800 12 - 90 12 - 180 2.4mm 1.100 15 - 150 15 - 250 3.2mm 1.100 20 - 200 20 - 300 3.2mm 1.500 25 - 250...

  • Page 91: Operation Environment

    10k ohm (maximum) connection to 10k ohm remote control potentiometer Zero ohm (minimum) connection to 10k ohm remote control potentiometer Not connected Wiper arm connection to 10k ohm remote control potentiometer Not connected §4.4 Operation environment ▲ Height above sea level ≤1000 M ▲...

  • Page 92: Welding Trouble Shooting

    §5 Welding trouble shooting §5.1 MIG welding trouble shooting The following chart addresses some of the common problems of MIG welding. In all cases of equipment malfunction, the manufacturer’s recommendations should be strictly adhered to and followed. Trouble Possible Reason Suggested Remedy Wire feed speed set too high Select lower wire feed speed...
  • Page 93 Check that the correct gas is being Wrong gas used Check the gas is connected, check hoses, gas valve and torch are not restricted. Set the gas flow Inadequate gas flow or too much gas between 10 - 15 l/min flow rate. flow Check hoses and fittings for holes, leaks etc .Protect the welding zone...

  • Page 94: Mig Wire Feed Trouble Shooting

    melting through base metal Material thick. Joint preparation and design needs to allow access to bottom of groove while maintaining proper welding wire extension Poor in incorrect joint preparation characteristics Keep the arc at the Lack leading edge of the weld pool and Penetration −...

  • Page 95: Dc Tig Welding Trouble Shooting

    Incorrect wire speed setting Adjust the wire feed speed Voltage setting incorrect Adjust the voltage setting Small diameter wires and soft wires like aluminium don’t feed well through long Mig torch lead too long torch leads - replace the torch with a lesser length torch Mig torch lead kinked or too sharp Remove the kink, reduce the angle or...
  • Page 96 Check and change the tungsten type Incorrect tungsten being used if necessary Keep shielding gas flowing 10–15 Tungsten being oxidised after seconds after arc stoppage. 1 second weld is finished for each 10amps of weld current. Keep tungsten from contacting weld Touching tungsten into the puddle.

  • Page 97: Mma Welding Trouble Shooting

    Check that correct type of tungsten is Tungsten incorrect or in poor being used. Remove 10mm from the condition weld end of the tungsten and re sharpen the tungsten Grind marks should run lengthwise Poorly prepared tungsten with tungsten, not circular. Use proper grinding method and wheel.
  • Page 98 metal Damp electrodes Use only dry electrodes Decrease the amperage or choose a Amperage too high larger electrode Excessive Spatter Arc length too long Shorten the arc length Increase the amperage or choose a Insufficient heat input larger electrode Remove moisture and materials like Work piece dirty,...

  • Page 99: Maintenance & Troubleshooting

    §6 Maintenance & Troubleshooting §6.1 Maintenance In order to guarantee safe and proper operation of welding machines, they must be maintained regularly. Let customers understand the maintenance procedure of welding machines. Enable customers to carry on simple examination and inspections. Do your best to reduce the fault rate and repair times of welding machines to lengthen service life of arc welding machine.

  • Page 100: Troubleshooting

    tight. If it is shaved, please replace. If it is rusty, please erase rust on all bolts to ensure it works well. Quarter- Check whether the actual current accords with the displaying value. If they did yearly not accord, they should be regulated. The actual welding current value can be examinati measured by and adjusted by plier-type ampere meter.
  • Page 101 power light isn’t on Fuse damaged Change it Input power damaged Change it After welding machine is Fan damaged Change it over-heat, the fan doesn’t The cable is loose Screw the cable tight work No gas in the gas cylinder Change it output Press the...

  • Page 102: List Of Error Code

    §6.3 List of error code Error Type Error code Description Lamp status Yellow lamp(thermal Over-heating(1st thermal relay) protection) always on Yellow lamp(thermal Over-heating(2nd thermal relay) protection) always on Yellow lamp(thermal Thermal relay Over-heating(3rd thermal relay) protection) always on Yellow lamp(thermal Over-heating(4th thermal relay) protection) always on Yellow...

  • Page 103: Electrical Schematic Drawing

    §6.4 Electrical schematic drawin...
  • Page 104 Radlpaßstraße 21 A-8551 Wies Produkt Marke: MK Welding Produkt Gruppe: Schweißgerät Produkt Type: MIG/MAG, WIG, MMA Schweißgerät Bezeichnung des Produktes: Multi-GMAW 200 LCD PFC Multi-GMAW 250-3 LCD Seriennummer*: 1.0003.0551-MK____________________ 1.0003.0571-MK____________________ 1.003.0538-E_______________________ Baujahr*: 20_________ (Ersichtlich anhand der Seriennummer) * anhand des Typenschildes am Gerät Auszufüllen Das oben genannte Erzeugnis stimmt mit den Vorschriften folgender Europäischen Richtlinien überein:...

This manual is also suitable for:

Multi-gmaw 250-3 lcdMulti-gmaw 315-3 lcdMulti-gmaw 315-3 lcd synergic

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