Matco Tools MULTIMIG 200 PRO Operator's Manual
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Matco Tools MULTIMIG 200 PRO Operator's Manual

Matco Tools MULTIMIG 200 PRO Operator's Manual

Synergic mig ac / dc tig & mma inverter welder
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Part # 521.0005
Processes
Synergic MIG (GMAW)
AC / DC TIG (GTAW)
AC / DC STICK (SMAW)
200S-
Synergic MIG
PRO
AC / DC TIG & MMA
Inverter Welder
OPERATORS' MANUAL
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.
04/2022

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  • Page 1 Part # 521.0005 Processes Synergic MIG (GMAW) AC / DC TIG (GTAW) AC / DC STICK (SMAW) 200S- Synergic MIG AC / DC TIG & MMA Inverter Welder OPERATORS’ MANUAL IMPORTANT: Read this Owner’s Manual Completely before attempting to use this equipment.

  • Page 2: Table Of Contents

    CONTENT CONTENT §1 Safety ......................... 1 §1.1 Symbols Explanation ....................1 §1.2 Machine Operating Warnings! ..................1 §1.3 EMC device classification .................... 7 §1.4 EMC measure ........................ 7 §1.5 Warning label ......................... 8 §2 Overview ........................9 §2.1 Features ......................... 9 §2.2 Technical Data ......................
  • Page 3 CONTENT §4.2.5 Tungsten Preparation ......................37 §4.2.6 TIG Torch Switch Controls ....................40 §4.3 Installation & Operation for MIG Welding ..............41 §4.3.1 Set up installation for MIG Welding ..................41 §4.3.2 Wire Feed Roller Selection ....................43 §4.3.3 Wire Installation and Set-Up Guide ..................44 §4.3.4 MIG Torch Liner Types and Information ................

  • Page 4: Safety

    SAFETY §1 Safety Notice: The instructions are for reference only. The manufacturer reserves the right to explain the differences between the description and the product due to product changes and upgrades! Welding and cutting equipment can be dangerous to both the operator and people in or near the surrounding working area.
  • Page 5 SAFETY  After shutting off the machine power, please maintain and examine the equipment according to §7 because of the DC voltage existing in the electrolytic capacitors at the output of the power supply! ELECTRIC SHOCK CAN KILL Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit may be electrically live whenever the output is ON.
  • Page 6 SAFETY 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. Breathing these fumes and gases can be hazardous to your health.  Do not breathe the smoke and gas generated whilst welding or cutting, keep your head out of the fumes.
  • Page 7 SAFETY MOVING PARTS REQUIRE SELF-PROTECTION  Keep all equipment safety guards, covers and devices in position and in good repair. Keep hands, hair, clothing and tools away from drive rolls, cooling fans and all other moving parts when starting, operating or repairing equipment. ...
  • Page 8 SAFETY  Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits.
  • Page 9 SAFETY  Shut off shielding gas supply when not in use.  Always ventilate confine spaces or use approved air-supplied respirator. ELECTROMAGNETIC FIELDS MAY BE DANGEROUS Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). The discussion on the effect of EMF is ongoing in the entire world. Up to now, no material evidence shows that EMF may have effects on health.

  • Page 10: Emc Device Classification

    SAFETY HOT PARTS MAY CAUSE BURNS Items being welded generate and retain heat that can cause severe burns. Do not touch hot parts with bare hands. Allow a cooling period before working on the welding gun. Use insulated welding gloves and clothing to handle hot parts and prevent burns. §1.3 EMC device classification Radiation Class A Device.

  • Page 11: Warning Label

    SAFETY  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. (i.e.: Add power filter.) b) Power and earth welding cables - Shorten the length of cables and maintain distance between cables to minimize interference.

  • Page 12: Overview

    OVERVIEW §2 Overview §2.1 Features ⚫ New larger LCD screen for accurate setting & feedback of welding output. ⚫ Full PWM technology and IGBT inverter technology. ⚫ Active PFC technology for increased duty cycle and energy efficiency. ⚫ Multi-voltage input 110–240VAC for maximum flexibility and portability. ⚫...

  • Page 13: Technical Data

    OVERVIEW §2.2 Technical Data Models MULTIMIG 200 PRO Parameters Input Voltage (V) 1-110± 10% 1-230± 10% Frequency (HZ) 50/60 Input Current (A) 37.9 34.8 35.0 37.6 40.3 27.2 21.6 21.8 28.2 31.4 Input Power (KW) Welding Current (A) 30~140 10~160...

  • Page 14: Duty Cycle And Over Temperature

    OVERVIEW frequency. The stick (MMA) welding capability delivers easy electrode welding in DC or AC output with high quality results on mild steel, cast iron, stainless and low hydrogen material. An additional feature is the spool gun ready function that allows the simple connection of spool gun for the use of thin or softer wires that don’t have the column strength to feed through MIG torches, such as aluminum and silicone bronze wire.

  • Page 15: Working Principle

    OVERVIEW §2.5 Working Principle The working principle of MULTIMIG-PRO series welding machine is shown as the following figure. Single-phase 110V/230V work frequency AC is rectified into DC (530V), then is converted to medium frequency AC (about 20KHz) by inverter device (IGBT), after reducing voltage by medium transformer (the main transformer) and rectifying by medium frequency rectifier (fast recovery diodes) and is outputted by inductance filtering.

  • Page 16: Panel Functions & Descriptions

    PANEL FUNCTIONS & DESCRIPTIONS §3 Panel Functions & Descriptions §3.1 Machine Layout Description Front and rear panel layout of welding machine 1. Positive (+) welding power output connection socket. 2. Polarity switching cable. 3. MIG torch euro connector. 4. Negative (-) welding power output connection socket.

  • Page 17: Layout Of Control Panel

    PANEL FUNCTIONS & DESCRIPTIONS §3.2 Layout of Control Panel §3.2.1 Control panel 1. MENU Button: Press it to select welding modes: Stick DC, Stick AC, TIG HF, TIG Lift-arc, MIG Manual or MIG Synergic. 2. 2T / 4T Button: Press it to select 2T (ON/OFF) or 4T (LATCHING) trigger mode. 3.

  • Page 18: Mma Ac/Dc Display Introduction

    PANEL FUNCTIONS & DESCRIPTIONS §3.2.2 MMA AC/DC Display introduction 1. MENU Button: Press it to select Stick DC or Stick AC welding mode. 2. L Knob: Turn it to set welding current parameter. 3. R Knob: Press it to select Hot Start or Arc Force and turn to adjust values. Hot Start Hot start provides extra power when the weld starts to counteract the high resistance of the electrode and workpiece as the arc is started.

  • Page 19: Tig Hf / Lift-Arc Display Introduction

    PANEL FUNCTIONS & DESCRIPTIONS §3.2.3 TIG HF / Lift-Arc Display introduction 1. MENU Button: Press it to enter TIG HF or TIG Lift welding mode. 2. 2T / 4T Button: Press it to select 2T or 4T trigger mode. 3. PARA Button: Press it to enter the function interface parameter. 4.
  • Page 20 PANEL FUNCTIONS & DESCRIPTIONS Process Set-Up Functional Interface: 1. Output waveform: Press it to select DC output or AC wave output. 2. Pulse mode: ON or OFF. 3. Trigger mode: 2T/ 4T/ Spot weld. (Spot is only available in TIG HF welding mode.) * 4.
  • Page 21 PANEL FUNCTIONS & DESCRIPTIONS 2T Mode (3) The trigger is pulled and held on to activate the welding circuit, when the trigger is released, the welding circuit stops. Introduction: (1) 0: Press the gun switch and hold it. Electromagnetic gas valve is turned on. The shielding gas stars to flow.
  • Page 22 PANEL FUNCTIONS & DESCRIPTIONS 4T Mode (3) This is known as ’latching’ mode. The trigger is pulled once and released to activate the welding circuit, pulled and released again to stop the welding circuit. This function is useful on longer welds as the trigger is not required to be held on continuously. The start current and crater current can be pre-set.

  • Page 23: Pulse Frequency

    PANEL FUNCTIONS & DESCRIPTIONS Pulse Frequency (9) Only available when pulse mode is selected. Set the rate that the welding output alternates between the peak and base current settings. Duty Cycle (10) Only available when pulse mode is selected. Set the time proportion as a percentage between the peak current and base current when using pulse mode.
  • Page 24 PANEL FUNCTIONS & DESCRIPTIONS Function Interface for TIG Spot-Weld: 1. Post Flow: 0.1~2s. 2. Welding current: 10~200A. 3. T time: 0.2~1s. 4. T time: 0~10s. 5. Post Flow: 0.1~10s. Spot Weld trigger mode: Spot weld Gun Switch Gas Supply Wire Feed Output Voltage Output Current Spot Weld Time...

  • Page 25: Mig Manual Display Introduction

    PANEL FUNCTIONS & DESCRIPTIONS §3.2.4 MIG Manual Display introduction 1. MENU Button: Press it to select MIG Manual welding mode. 2. 2T / 4T Button: Press it to select 2T or 4T trigger mode. 3. PARA Button: Press it to enter the function parameter interface. 4.

  • Page 26: Function Interface

    PANEL FUNCTIONS & DESCRIPTIONS Function interface: 1. Trigger mode: 2T or 4T. 2. Burnback: 0~10. 3. Pre Flow: 0.1~10s. 4. Post Flow: 0.1~10s. 5. Slow Feed: 0~10. 6. Spool Gun: off/ on. Burnback Short-circuit between welding wire and molten pool leads to the increase of current, which leads to the melting speed of welding wire being too fast and the wire feeding speed cannot keep up which makes the welding wire and workpiece disconnect.

  • Page 27: Mig Syn Display Introduction

    PANEL FUNCTIONS & DESCRIPTIONS §3.2.5 MIG SYN display introduction The operator simply selects a program by material & wire type, wire diameter and shielding gas. Operator set material thickness and the machine calculates the optimal voltage and wire speed for the welding application. Obviously other variables such as welding joint type and thickness, air temperature affect the optimal voltage and wire feed setting, so the program provides a voltage fine tuning function for the synergic program selected.

  • Page 28: Job Display Introduction

    PANEL FUNCTIONS & DESCRIPTIONS §3.2.6 JOB display introduction 1. JOB Button: Press it for 3s to enter JOB programs and press it for 1s to save parameters. 2. Parameters Display: Displays the parameters selected by the operator. 3. JOB Number Display: Displays the corresponding JOB number assigned. 4.

  • Page 29: Installation & Operation

    INSTALLATION & OPERATION §4 Installation & Operation §4.1 Installation & Operation for MMA Electrode Welding §4.1.1 Set-Up Installation Two sockets are available on this welding machine with Positive (+) or Negative (-) polarity to connect the electrode holder cable and earth clamp cable. Various electrodes require different polarity for optimum results and careful attention should be paid to the polarity, refer to the electrode manufacturer’s information for the correct polarity.

  • Page 30: Stick (Mma) Electrode Welding

    INSTALLATION & OPERATION §4.1.2 Stick (MMA) Electrode Welding 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’.

  • Page 31: Stick (Mma) Welding Fundamentals

    INSTALLATION & OPERATION Stick electrodes serve many purposes in addition to filler metal to the molten pool. These additional functions are provided mainly by the various coverings on the electrode. §4.1.3 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.
  • Page 32 INSTALLATION & OPERATION 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; it should be the shortest arc that gives a good surface to the weld. An arc too long reduces penetration, produces spatter and gives a rough surface finish to the weld.

  • Page 33: Installation & Operation For Tig Hf/Lift-Arc

    INSTALLATION & OPERATION §4.2 Installation & Operation for TIG HF/LIFT-ARC §4.2.1 Set-Up for TIG Welding (1) Insert the earth cable plug into the positive socket on the front of the machine and twist to lock in place. (2) Plug the welding torch into the negative socket on the front panel and twist to lock. (3) Connect the gas line of TIG torch to outlet gas connector on the front of the machine.
  • Page 34 INSTALLATION & OPERATION (12) Assemble front end parts of the TIG torch, fitting a sharpened tungsten suitable for the material to be welded. (13) Lay the outside edge of the cup on (14) With a small movement rotate the gas work piece with the tungsten Electrode cup forward so that the tungsten electrode 1~2mm from the work piece.

  • Page 35: Dc Tig Welding

    INSTALLATION & OPERATION §4.2.2 DC TIG Welding The DC power source uses what is known as DC (direct current) in which the main electrical component, known as electrons, flow in only one direction from the negative terminal (-) to the positive terminal (+). In the DC electrical circuit there is an electrical principle at work which provides that, in a DC circuit, 70% of the energy (heat) is always on the positive side.

  • Page 36: Tig Welding Fusion Technique

    INSTALLATION & OPERATION LIFT ARC IGNITION for TIG Welding Lift Arc is a form of arc ignition where the machine has 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).
  • Page 37 INSTALLATION & OPERATION 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 38: Tungsten Electrodes

    INSTALLATION & OPERATION §4.2.4 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.
  • Page 39 INSTALLATION & OPERATION Ceriated (Grey) Ceriated tungsten electrodes (AWS classification EWCe-2) contain a minimum of 97.30 percent tungsten and 1.80 to 2.20 percent cerium and are referred to as 2% ceriated. Ceriated tungsten performs best in DC welding at low current settings. They have excellent arc starts at low amperages and become popular in such applications as orbital tube welding, thin sheet metal work.

  • Page 40: Tungsten Preparation

    INSTALLATION & OPERATION Tungsten Electrodes Rating for Welding Currents 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...
  • Page 41 INSTALLATION & OPERATION Electrode Shape & Angle 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.
  • Page 42 INSTALLATION & OPERATION Sharper electrodes with smaller included angle provide: ⚫ Offer less arc weld ⚫ Have a wider arc ⚫ Have a more consistent arc Tungsten Diameter at Constant Included Current Range Current Range Diameter the Tip - mm Angle - Degrees Amps Pulsed Amps...

  • Page 43: Tig Torch Switch Controls

    INSTALLATION & OPERATION §4.2.6 TIG Torch Switch Controls Gun Switch Socket Pin Function Not connected Trigger Switch Input Trigger Switch Input Not connected 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...

  • Page 44: Installation & Operation For Mig Welding

    INSTALLATION & OPERATION §4.3 Installation & Operation for MIG Welding §4.3.1 Set up installation for MIG Welding (1) Insert the earth cable plug into the Negative (-) socket and twist to tighten. (2) Plug the MIG welding gun into MIG torch euro-connector on the front panel and tighten locking nut securely.
  • Page 45 INSTALLATION & OPERATION (7) Place wire onto spool holder - (spool retaining nut is left hand thread) Feed wire through the inlet guide tube on to the drive roller. (8) Feed wire over drive roller into outlet guide wire tube, push wire through approximately 150mm. (9) Close down the top roller bracket and clip the pressure arm into place with a medium amount of pressure applied.

  • Page 46: Wire Feed Roller Selection

    INSTALLATION & OPERATION (14) Fit the gas nozzle to the torch head. (15) Carefully open the gas cylinder valve, set the required gas flow rate on the regulator. (16) Select the desired MIG function, Select program number to suit the wire diameter and gas type being used as shown on the display.

  • Page 47: Wire Installation And Set-Up Guide

    INSTALLATION & OPERATION deforming the shape of the wire, too much tension will push the wire out of shape and cause it to catch in the contact tip. Flux Core/ Gasless Wire - These wires are made up of a thin metal sheath that has flux and metal compounds layered onto the surface and then rolled into a cylinder to form the finished wire.
  • Page 48 INSTALLATION & OPERATION (1) Remove the spool retaining nut. (2) Note the tension spring adjuster and spool locating pin. (3) Fit the wire spool onto the spool holder (4) Snip the wire carefully, be sure to hold fitting the locating pin into the location hole the wire to prevent the spool uncoiling.
  • Page 49 INSTALLATION & OPERATION (5) Feed the wire through the drive roller (6) Lock down the top pressure roller and and into the outlet guide tube of the wire apply a medium amount of pressure using feeder. the tension adjustment knob. (7) Check that the wire passes through the center of the outlet guide tube without touching the sides.

  • Page 50: Mig Torch Liner Types And Information

    INSTALLATION & OPERATION (9) The weight and speed of the wire spool turning creates an inertia that can cause the spool to run on and the wire loop over the side of the spool and tangle. If this happens increase the pressure on the tension spring inside the spool holder assembly using the tension adjustment screw.
  • Page 51 INSTALLATION & OPERATION 1.2mm through 2.4mm have much higher columnar strength but it is important to make sure the liner has enough internal diameter clearance. Most manufacturers will produce liners sized to match wire diameters and length of welding torch cable and most are color coded to suit.

  • Page 52: Torch & Wire Feed Set-Up For Aluminum Wire

    INSTALLATION & OPERATION improve the electrical conductivity of the welding power transfer to the wire. It is recommended for all Aluminum and Silicone Bronze welding applications. Copper Neck Liner §4.3.5 Torch & Wire Feed Set-Up for Aluminum Wire The same method is used for Teflon and/or Polyamide Liners (PA). §4.3.6 MIG Welding Definition of MIG Welding MIG (metal inert gas) welding also known as GMAW (gas metal arc welding) or MAG...
  • Page 53 INSTALLATION & OPERATION The wire touches the work The wire cannot support The current flow creates creating short circuit. all the current flow so a magnetic field that Because there is no space resistance builds up and begins pinch between the wire and the the wire begins to melt.
  • Page 54 INSTALLATION & OPERATION Perpendicular Technique - The wire is fed directly into the weld, this technique is used primarly for automated situations or when conditions make it necessary. The weld profile is generally taller and a deeper penetration is achieved. Drag Technique - The gun and wire are dragged away from the weld bead.
  • Page 55 INSTALLATION & OPERATION Angle 5° ~15° Not enough angle Angle more than 20° Good level of control over Less control over the weld Poor control, unstable arc, the weld pool, even flat pool more spatter. less penetration, lots of weld. spatter.
  • Page 56 INSTALLATION & OPERATION Normal stick out Too short Too long Even arc, good Unstable arc, spatter, Unstable arc, spatter, penetration even over heat contact tip. poor penetration and fusion, good finish. fusion. Travel Speed - Travel speed is the rate that the gun is moved along the weld joint and is usually measured in inches per minute (IPM).
  • Page 57 INSTALLATION & OPERATION Too Slow Travel Speed large wide bead porosity lack of fusion cold lap lack of joint penetration Correct Travel Speed - The correct travel speed keeps the arc at the leading edge of the weld pool allowing the base metal to melt sufficiently to create good penetration, fusion and wetting out of the weld pool producing a weld deposit of good quality.
  • Page 58 INSTALLATION & OPERATION Argon/CO Penetration Pattern for Steel Argon gas at 100% mixture is good for aluminum and silicone bronze applications. It offers good penetration and weld control. CO is not recommended for these metal alloys. Wire types and sizes - Use the correct wire type for the base metal being welded. Use stainless steel wire for stainless steel, aluminum for aluminum and steel wires for steel.

  • Page 59: Installation & Operation For Spool Gun

    INSTALLATION & OPERATION §4.4 Installation & Operation for Spool Gun §4.4.1 Set up installation for Spool Gun (1) Insert the earth cable plug into the negative (-) socket on the front of the machine and twist to tighten. (2) Plug the Spool Gun into the euro-connect socket on the front panel and tighten. IMPORTANT: When connecting the torch be sure to tighten the adaptor nut completely tight.
  • Page 60 INSTALLATION & OPERATION (8) Remove the spool cover by pressing (9) Place a spool of wire inside the button and lifting off the cover. spool holder on post. (11) Pull the trigger to drive the wire down (10) Feed the wire through the drive the neck until it exits the contact tip.

  • Page 61: Spool Gun Control

    INSTALLATION & OPERATION §4.4.2 Spool Gun Control 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.

  • Page 62: Welding Parameters

    INSTALLATION & OPERATION §4.5 Welding Parameters Process reference for CO butt welding of low carbon steel solid welding wire Material Wire Welding Welding Welding Gas-flow Root gap thickness diameter current voltage speed rate G (MM) (MM) (MM) (CM/MIN) (L/MIN) 60~70 16~16.5 50~60 75~85...

  • Page 63: Operation Environment

    INSTALLATION & OPERATION §4.6 Operation Environment ▲ Height above sea level ≤1000 M. ▲ Operation temperature range: 14~104° F (-10 ~ +40° C). ▲ Air relative humidity is below 90%. ▲ Preferable site the machine some angles above the floor level does not exceed 15° . ▲...

  • Page 64: Diagram For Guns

    DIAGRAM FOR GUNS §5 Diagram for Guns §5.1 SL15 MIG Torch...

  • Page 65: Sl17 Tig Torch

    DIAGRAM FOR GUNS §5.2 SL17 TIG Torch...

  • Page 66: Sg226 Spool Gun

    DIAGRAM FOR GUNS §5.3 SG226 Spool Gun...

  • Page 67: Maintenance & Troubleshooting

    MAINTENANCE & TROUBLESHOOTING §6 Maintenance & Troubleshooting §6.1 Maintenance The operator must understand the maintenance procedure of inverter welding machine and carry out simple examinations, cleanings and inspections. Do your best to protect the machine from contamination environment and leaving unit ON when not in use to lengthen service life of inverter arc welding machine.

  • Page 68: Welding Trouble Shooting

    MAINTENANCE & TROUBLESHOOTING Check the screws and bolts in the machine. If any are loose, please tighten. Check all torches, earth clamp and hose connections to insure they are securely in place. Loose connections can cause major failures. Quarter- Check whether the actual current accords with the displaying value. If they did not yearly accord, they should be regulated.

  • Page 69: Mig Welding - Trouble Shooting

    MAINTENANCE & TROUBLESHOOTING output shielded test gas. Electromagnetic valve damaged. Change it. gas. Output gas Control switch damaged. Repair the switch. when test Control circuit damaged. Check the PCB. gas. Wire reel Motor damaged. Check and change it. doesn’t Control circuit damaged. Check the PCB.
  • Page 70 MAINTENANCE & TROUBLESHOOTING metal. Use clean, dry, rust free wire. Do not Contaminated MIG wire. lubricate the wire with oil, grease etc. Check the gas is connected, check hoses, gas valve and torch are not Inadequate gas flow or too much restricted.

  • Page 71: Mig Wire Feed - Trouble Shooting

    MAINTENANCE & TROUBLESHOOTING using weaving technique. Excessive Penetration − Select a lower voltage range and /or weld metal Too much heat. adjust the wire speed to suit Increase melting through travel speed. base metal. Material too thick. Joint preparation and design needs to allow access to bottom of groove while maintaining proper Poor in incorrect joint...

  • Page 72: Dc Tig Welding - Trouble Shooting

    MAINTENANCE & TROUBLESHOOTING Small diameter wires and soft wires like aluminum 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 angle being held.
  • Page 73 MAINTENANCE & TROUBLESHOOTING Make sure the torch back cap is fitted Back cap not fitted correctly. so that the O-ring is inside the torch body. Connect the torch to the DC- output Torch connected to DC+. terminal. Check and change the tungsten type if Incorrect tungsten being used.

  • Page 74: Mma Welding - Trouble Shooting

    MAINTENANCE & TROUBLESHOOTING Lower torch so that the tungsten is off Incorrect arc length. the work piece 2~5mm. 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 rod.
  • Page 75 MAINTENANCE & TROUBLESHOOTING 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 Weld sits on top, Work piece dirty, contaminated paint, grease, oil, and dirt, including...

  • Page 76: List Of Error Codes

    MAINTENANCE & TROUBLESHOOTING §6.3 List of Error Codes Error Type Code Description Over-heating (1st thermal relay) Over-heating (2nd thermal relay) Thermal relay Over-heating (3rd thermal relay) Over-heating (4th thermal relay) Over-heating (Program default) Phase loss No gas Welding Under voltage machine Over voltage Over current...

  • Page 77: Machine Parts Drawing

    MAINTENANCE & TROUBLESHOOTING §6.4 Machine Parts Drawing # PART NO. DESCRIPTION # PART NO. DESCRIPTION 1 520.3010 HANDLE - MACHINE 28 521.0321 FRAME - FRONT 200-P 2 521.0360 CABINET - COVER 200-P 29 521.0322 COVER PLATE - ADAPTOR 200-P 3 521.0361 CABINET - DOOR 200-P 30 521.2543 EURO SOCKET FLANGE 4 538.0017 LATCH WIRE FEED DOOR 31 520.3021 WIRE GUIDE...

  • Page 78: Electrical Schematic Drawing

    MAINTENANCE & TROUBLESHOOTING §6.5 Electrical Schematic Drawing...

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