Klutch 62498 Owner's Manual
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Klutch 62498 Owner's Manual

Klutch 62498 Owner's Manual

Mig/stick/tig mp200idv lcd 200 amp dual voltage multi-process welder
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MIG/Stick/TIG MP200iDV LCD 200 Amp
Dual Voltage Multi-Process Welder
Owner's Manual
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.
Item #62498
READ & SAVE THESE INSTRUCTIONS

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  • Page 1 Dual Voltage Multi-Process Welder Owner’s Manual 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. Item #62498 READ & SAVE THESE INSTRUCTIONS...
  • Page 2 ® Thank you very much for choosing a Klutch product! For future reference, please complete the owner’s record below: Serial Number/Lot Date Code: ________________________________ Purchase Date: ____________________________________________ Save the receipt, warranty, and this manual. It is important that you read the entire manual to become familiar with this product before you begin using it.

  • Page 3: Table Of Contents

    Table of Contents Intended Use ............................4 Packaging Contents ..........................4 Technical Specifications ........................5 Important Safety Information ....................... 5 Specific Operation Warnings ....................... 7 Main Parts of MP200iDV LCD ......................12 Setting Up Equipment ......................... 13 Assembly Instructions ........................19 Before Each Use ..........................

  • Page 4: Intended Use

    Intended Use The Klutch MIG/Stick/TIG MP200iDV is an inverter-powered, dual voltage, wire feed welder for flux core and MIG welding plus a DC stick welder. It uses a state of the art LCD control screen for easy set-up. 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 5: Technical Specifications

    Technical Specifications Property Specification Power Supply 120V, 20A, 50/60 Hz, Single Phase 230V, 36A, 50/60 Hz, Single Phase 66V DC with 120V Input Power No-Load Voltage 69V DC with 230V Input Power Output Range - MIG 40 to 90A DC with 120V Input Power 40 to 200A DC with 230V Input Power Output Range - STICK 10 to 70A DC with 120V Input Power...

  • Page 6: Work Area Safety

    ⚠WARNING  This product may contain chemicals known to the state of California to cause cancer, birth defects, or other reproductive harm.  Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to the state of California to cause cancer, birth defects, or other reproductive harm.

  • Page 7: Personal Safety

    ⚠WARNING PERSONAL SAFETY  Stay alert, watch what you are doing, and use common sense when operating the tool. Do not use the tool while you are tired or under the influence of drugs, alcohol, or medication. A moment of inattention while operating the tool may result in serious personal injury.
  • Page 8  Always have a qualified person install and operate this equipment.  Make sure the area is clean, dry, and ventilated. Do not operate the welder in humid, wet, or poorly ventilated areas.  Always have your welder maintained by a qualified technician in accordance with local, state and national codes.
  • Page 9 ⚠WARNING Electrical Shock Electric arc welders can produce a shock that can cause injury or death. Touching electrically live parts can cause fatal shocks and severe burns. While welding, all metal components connected to the wire are electrically hot. Poor ground connections are a hazard, so secure the ground lead before welding.
  • Page 10 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.  Use a lens that meets ANSI standards and safety glasses. For welders under 160 amps output, use a shade 10 lens;...
  • Page 11 ⚠CAUTION 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. ...

  • Page 12: Main Parts Of Mp200Idv Lcd

     Always secure cylinder upright to a cart or stationary object.  Keep cylinders away from welding or electrical circuits.  Use the proper regulators, gas hose, and fittings for the specific application.  Do not look into the valve when opening it. ...

  • Page 13: Setting Up Equipment

    Reference Subassembly MP220SIDV LCD MIG Torch Spool Gun Electrode Holder & Cable Ground Cable & Clamp Contact Tips Gas Hose Regulator/Flow Gauge 120V Power Cord Adapter Setting Up Equipment ⚠WARNING ELECTRIC SHOCK CAN KILL!  High voltage danger from power source! Consult a qualified electrician for proper installation of receptacle.
  • Page 14 Figure 2 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).
  • Page 15 NOTE: Before installing, make sure that you have removed any old wire from the torch assembly. This will help to prevent the possibility of the wire jamming inside the gun liner. NOTE: Be very careful when removing the welding nozzle. The contact tip on this welder is live whenever the torch trigger is pulled.
  • Page 16 v. The welder can use either 4 inch or 8 inch spools. See Figure 5 for additional reference. The wing nut controls the tension on the spool. 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.

  • Page 17: Gas Installation

    xvi. Plug in the welder power cord and turn the welder ON. Set the voltage switch to the voltage setting recommended for the gauge metal that is to be welded. Refer to the set-up chart on the back side of the drive compartment door. ⚠CAUTION ...
  • Page 18  Keep cylinders away from welding or electrical circuits.  Use the proper regulators, gas hoses, and fittings for the specific application. a. Polarity Changing - When MIG wire is used, shielding gas is required and the polarity on this unit needs to be electrode positive. i.

  • Page 19: Assembly Instructions

    the connection. Connect the regulator to the gas bottle connection. Use a wrench to snug up the connection. vi. Open the Gas Bottle Valve on the cylinder of gas. vii. Turn the Gas Flow Adjuster on the regulator so that the gas flow rate is set at approximately 20 CFH.
  • Page 20 Figure 7 Make note of the retaining groove on the back end of the MIG torch (Figure 7). Socket Negative (-) 5-Pin Trigger Weld Output Receptacle Connection Positive (+) Weld Output Connection Weld Power Cable Figure 8 3. Insert the back end of the MIG torch into the MIG socket on the front of your machine (Figure 8).
  • Page 21 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 22: Before Each Use

    DC STICK WELDING ASSEMBLY ⚠CAUTION 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 3). 2.

  • Page 23: Operating Instructions

    Operating Instructions ⚠WARNING High voltage danger from power source!  Consult a qualified electrician for proper installation of receptacle at the power source. This welder must be grounded while in use to protect the operator from electrical shock. If you are not sure if your outlet is properly grounded, have it checked by a qualified electrician.

  • Page 24: General System Setup

    GENERAL SYSTEM SET-UP 1. Press the START BUTTON. 2. Turn the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB to the SETTING selection. 3. Push in the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB. 4. Language a. The language function is not active on this unit. b. Turn the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB to ENGLISH. c.

  • Page 25: Multi-Function

    i. Connect the Pigtail to the Negative (-) Weld Output Connection ii. Connect the Ground Cable to the Positive (+) Weld Output Connection 4. Push in the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB. a. Use the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB to select your wire size.

  • Page 26: Stick Welding Set-Up

    iv. Choose the “√” to indicate “Yes” to using a spool gun. v. Push in the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB to confirm your selection. c. Preflow – You can set a time amount for how long you would like the welder to flow gas prior to the arc starting.

  • Page 27: Control Knob

    item you are welding. 11. Push in the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB to confirm your selection. 12. This machine is now set to weld. 13. If you wish to adjust the amperage, turn the WIRE FEED SPEED AND AMPERAGE CONTROL KNOB. a.

  • Page 28: Welding Techniques

    different positions until you find the one that seems to work best for you. 3. POSITION OF THE TORCH TO THE WORK PIECE - There are two angles of the torch nozzle in relation to the work piece that must be consider when welding. a.
  • Page 29  Prolonged exposure to the welding arc can cause blindness and burns. Never strike an arc or begin welding until you are adequately protected. Wear flame-proof welding gloves, a heavy long sleeved shirt, trousers without cuffs, high topped shoes, and an ANSI approved welding helmet. ⚠WARNING ELECTRIC SHOCK CAN KILL! ...

  • Page 30: Welding Positions

    The WEAVE BEAD is used when you want to deposit metal over a wider space than would be possible with a stringer bead. It is made by weaving from side to side while moving with the torch. It is best to hesitate momentarily at each side before weaving back the other way.

  • Page 31: Multiple Pass Welding

    The OVERHEAD POSITION is the most difficult welding position. Angle A (see HOLDING THE TORCH) should be maintained at 60 degrees. Maintaining this angle will reduce the chances of molten metal falling into the nozzle. Angle B should be held at zero degrees so that the wire is aiming directly into the weld joint.

  • 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

    c. Hold the nozzle piece completely perpendicular to and about 1/4 inch off the work piece. d. Pull the trigger on the torch and release it when it appears that the desired penetration has been achieved. e. Make practice spot welds on scrap metal, varying the length of time you hold the trigger, until a desired spot weld is made.

  • 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 a. When the proper rod is used: i. The bead will lay smoothly over the work without ragged edges. ii. The base metal puddle will be as deep as the bead that rises above it. iii. The welding operation will make a crackling sound similar to the sound of eggs frying.
  • Page 36 ⚠WARNING EXPOSURE TO A WELDING ARC IS EXTREMELY HARMFUL TO THE EYES AND SKIN!  Prolonged exposure to the welding arc can cause blindness and burns. Never strike an arc or begin welding until you are adequately protected. Wear flame-proof welding gloves, a heavy long sleeved shirt, trousers without cuffs, high topped shoes, and an ANSI approved welding helmet.
  • Page 37 Stringer Bead Weave Bead The weave bead is used when you want to deposit metal over a wider space than would be possible with a stringer bead. It is made by weaving from side to side while moving with the electrode. It is best to hesitate momentarily at each side before weaving back the other way.
  • Page 38 ⚠WARNING ELECTRIC SHOCK CAN KILL! To prevent ELECTRIC SHOCK, do not perform any welding while standing, kneeling, or lying directly on the grounded workpiece. Finish the bead As the coating on the outside of the electrode burns off, it forms an envelope of protective gases around the weld.
  • Page 39 ⚠CAUTION Be aware that the TIG torch will be electrically HOT when the Input Power Switch on the welder is turned on. 1. Remove the ground cable and the electrode holder from the weld output connections. Install the ground cable to the Positive (+) weld output connection. 2.

  • Page 40: After Each Use

    After Each Use ⚠CAUTION Hot Materials - Welded materials are hot and can cause severe burns if handled improperly.  Do not touch welded materials with bare hands.  Do not touch the torch nozzle after welding until it has had time to cool down. 1.

  • Page 41: Troubleshooting

    Maintenance Interval Maintenance Point Inspect all cords and power cables. Replace any cords or power cables Before Each Use that are damaged or cracked. Inspect all warning and caution labels affixed to this unit. If they are Every 3 Months worn, torn or otherwise unreadable, then replace the warning labels.
  • Page 42 Failure Possible Cause Corrective Action Wire feed speed control at zero. Increase wire feed speed control. Wire will feed only when trigger is Trigger is not mashed. mashed. Wire drive motor does not turn. Wire drive motor Is damaged. Replace wire drive motor. See installation section to correctly Feed roller is not correctly installed.

  • Page 43: Parts Diagram

    Failure Possible Cause Corrective Action recommendations. For assistance, contact the Welder Help Line at 877-304-0294. Parts Diagram Parts List Reference Part Number Part Description Quantity 105300105 HANDLE 125200064 ENCLOSURE 105200041 MIG WARNING LABEL 145200001 WELDER HELP LABEL 105200211 POWER CORD 105200212 POWER CORD ADAPTER 120V 105400050...
  • Page 44 Reference Part Number Part Description Quantity 105200314 FAN SUPPORT PANEL 105200306 105200315 MAIN PC BOARD 105200234 MAIN PC BOARD SUPPORT 105200316 CONTROL PC BOARD 105500033 FEET 105200317 REACTOR 105200318 BOTTOM 105100075 HINGE 105200319 FRONT PLASTIC BEZEL 105200320 LCD CONTROL PCB 105200058 WELD POWER CONNECTOR 105200059...

  • Page 45: Replacement Parts

    Replacement Parts  For replacement parts and technical questions, please call Customer Service at 1-800-222-5381.  Not all product components are available for replacement. The illustrations provided are a convenient reference to the location and position of parts in the assembly sequence. ...

  • Page 46: Limited Warranty

    Northern Tool and Equipment Company, Inc. ("We'' or "Us'') warrants to the original purchaser only ("You'' or "Your") that the Klutch product purchased will be free from material defects in both materials and workmanship, normal wear and tear excepted, for a period of three years from date of purchase.
  • Page 47 Distributed by: Northern Tool & Equipment Company, Inc. Burnsville, Minnesota 55306 www.northerntool.com Made in China Page 47 of 47...

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