mig sonic 200 cvcc service manual

7/25/2019 Mig Sonic 200 cvcc Service Manual

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MIG (GMAW)Flux cored (FCAW)

Stick (SMAW)

TIG (GTAW)

Arc Welding Power Source and Wire Feeder

Machine Number: _________________________________

Where Purchase: _________________________________

Date of purchased: _________________________________

MIGSONIC200 cvcc

SERVICE

MANUAL


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Table of Contents

SECTION 1 SAFETY PRECAUTIONS .............................................................................................. 1

SECTION 1 CONSIGNES DE SCURIT ............................................................................................. 1

1-1.

Symbol Usage Symboles utiliss................................................................ 1

1-2.

Arc welding Hazards Dangers relatifs au soudage larc.................. 1

1-3.

Safety Standards Normes de scurit........................................................... 6

1-4. EMF Information EMF Information.............................................................. 6

SECTION 2 PACKING LIST ............................................................................................................... 7

SECTION 3 INSTALLATIONS........................................................................................................... 8

3-1. Welding power source specifications........................................................... 8

3-2. Mig torch specifications.................................................................................... 9

3-3.

MIG/MAG welding connection diagram...................................................... 10

3-4.

MIG/MAG Process/Polarity Table.................................................................. 12

3-5. General Installation procedure for MIG/MAG welding............................ 12

3-6. How to Install the wire spool.......................................................................... 12

3-7.

How to Adjust wire feed pressure................................................................ 13

3-8.

How to Install spool gun(optional)............................................................... 13

3-9.

LIFT-TIG welding connection diagram........................................................ 14

3-10.

General installation procedure for Lift-TIG welding................................ 16

3-11.

STICK welding connection diagram(115V input)................... ................... 17

3-12.

General installation procedure for Stick welding.................. ................... 19

3-13.

Electric service guide ...................................................................................... 19

3-14.

Extension Cable Selection Chart.................................................................. 20

SECTION 4 OPERATION .................................................................................................................... 21

4-1

Front panel Layout ........................................................................................... 21

4-2

Operation(MIG/MAG)........................................................................................ 22

4-3 Operation(STICK/LIFT TIG)............................................................................. 22

4-4

Voltage/Wire speed selection chart................... .................... .................... ... 24

SECTION 5 THEORY OF OPERATION ............................................................................................ 25

SECTION 6 TROUBLE SHOOTING ................................................................................................... 27

6-1

General trouble shooting................................................................................ 27

6-2

MIG/MAG welding trouble shooting............................................................. 28

6-3

Stick/TIG welding trouble shooting................... .................... .................... ... 31


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6-4 Circuit board testing information................................................................. 33

SECTION 7

MAINTENANCE ............................................................................................................ 41

7.1

Maintenance ....................................................................................................... 41

7.2

Safety precaution.............................................................................................. 42

SECTION 8

ELECTRICAL DIAGRAMS ........................................................................................ 43

SECTION 9

PARTS LIST ................................................................................................................. 46

9-1

Power Source..................................................................................................... 46

9-2

Wire feeder.......................................................................................................... 53

9-3

Spool holder module........................................................................................ 55

9-4 Spool gun connector ....................................................................................... 56

9-5

Mig torch ............................................................................................................. 57

SECTION 10 WARRANTY POLICY ................................................................................................ 60

SECTION 11 AUTHORIZED SERVICE CENTER .......................................................................... 61


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Manual no: WM070502 Page1MIGSONIC200cvcc SERVICE MANUAL

SECTION 1 SAFETY PRECAUTIONS

SECTION 1 CONSIGNES DE SCURIT

1-1. Symbol Usage Symboles utiliss

Means Warning! Watch Out! There arepossible hazards with this procedure!The possible hazards are shown in theadjoining symbols.

Symbole graphiquedavertissement ! Attention ! Cetteprocedure comporte des risquespossibles ! Les dangers ventuelssont reprsents par les symbolesgraphiques joints.

Marks a special safety message.

Indique un message de scurit particulier

Means Note; not safety related.

Sign ifie NOTE ; n est p as relati f lascurit.

This group of symbols means Warning!Watch Out possible ELECTRIC SHOCK,MOVING PARTS, and HOT PARTS hazards.Consult symbols and related instructionsbelow for necessary actions to avoid thehazards

Ce groupe de symboles signifieAvertissement! Attention! RisquesdLECTROCUTION, ORGANES MOBILESet PARTIES CHAUDES. Consulter lessymboles et les instructions afferentsci-dessous concernant les mesures prendre pour supprimer les dangers.

1-2. Arc welding Hazards Dangers relatifs au soudage larc

The symbols shown below are usedthroughout this manual to call attentionto and identify possible hazards. Whenyou see the symbol, watch out, andfollow the related instructions to avoidthe hazard.

Only qualified persons should service,test, maintain, and repair this unit.

During servicing, keep everybody,especially children, away Les symboles reprsents ci-dessous

sont utiliss dans ce manuelpour attirerlattention et identifier les dangerspossibles. Enprsence de lun de cessymboles, prendre garde et suivrelesinstructions affrentes pour vitertout risque. Les instructions enmatirede scurit indiques ci-dessous neconstituent quun sommaire desinstructions de scurit plus compltesfournies dans les normes de scuritnumres dans la Section 2-5. Lire etobserver toutes les normes de scurit.

Seul un personnel qualifi est autoris installer, faire fonctionner, entretenir et

rparer cet appareil. Pendant le fonctionnement, maintenir

distance toutes les personnes,notamment les enfants de lappareil.

ELECTRIC SHOCK cankill.UNE DCHARGELECTRIQUE entranerla mort.

Do not touch live electrical parts.

Wear dry, hole-free insulating gloves andbody protection.

Insulate yourself from work and groundusing dry insulating mats or covers bigenough to prevent any physical contact withthe work or ground.

Do not use AC output in damp areas, ifmovement is confined, or if there is adanger of falling.

Use AC output ONLY if required for thewelding process.

If AC output is required, use remote outputcontrol if present on unit.

Additional safety precautions are requiredwhen any of the following electricallyhazardous conditions are present: in damplocations or while wearing wet clothing; onmetal structures such as floors, gratings, orscaffolds; when in cramped positions suchas sitting, kneeling, or lying; or when thereis a high risk of unavoidable or accidentalcontact with the workpiece or ground. Forthese conditions, use the followingequipment in order presented: 1) asemiautomatic DC constant voltage (wire)welder, 2) a DC manual (stick) welder, or 3)an AC welder with reduced open-circuitvoltage. In most situations, use of a DC,constant voltage wire welder isrecommended. And, do not work alone!

Disconnect input power or stop enginebefore installing or servicing this equipment.Lockout/tagout input power according toOSHA 29 CFR 1910.147 (see SafetyStandards).

Properly install and ground this equipmentaccording to its Owners Manual and


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national, state, and local codes.

Always verify the supply ground checkand be sure that input power cord groundwire is properly connected to groundterminal in disconnect box or that cord plugis connected to a properly groundedreceptacle outlet.

When making input connections, attachproper grounding conductor first

double-check connections. Frequently inspect input power cord for

damage or bare wiring replace cordimmediately if damaged bare wiring cankill.

Turn off all equipment when not in use.

Do not use worn, damaged, undersized, orpoorly spliced cables.

Do not drape cables over your body.

If earth grounding of the workpiece isrequired, ground it directly with a separatecable.

Do not touch electrode if you are in contactwith the work, ground, or another electrodefrom a different machine.

Do not touch electrode holders connectedto two welding machines at the same timesince double open-circuit voltage will bepresent.

Use only well-maintained equipment.Repair or replace damaged parts at once.Maintain unit according to manual.

Wear a safety harness if working abovefloor level.

Keep all panels and covers securely inplace.

Clamp work cable with good metal-to-metalcontact to workpiece or worktable as nearthe weld as practical.

Insulate work clamp when not connected toworkpiece to prevent contact with any metalobject.

Do not connect more than one electrode orwork cable to any single weld outputterminal.

SIGNIFICANT DC VOLTAGE existsafter removal of input power oninverters. Turn Off inverter, disconnect input power,

and discharge input capacitors according toinstructions in Maintenance Section beforetouching any parts.

Ne pas toucher aux pices lectriques soustension.

Porter des gants isolants et des vtements

de protection secs et sans trous. Sisoler de la pice couper et du sol en

utilisant des housses ou des tapis assezgrands afin dviter tout contact physiqueavec la pice couper ou le sol.

Ne pas se servir de source lectrique courant lectrique dans les zones humides,dans les endroits confins ou l o onrisque de tomber.

Se servir dune source lectrique courantlectrique UNIQUEMENT si le procd desoudage le demande.

Si lutilisation dune source lectrique

courant lectrique savre ncessaire, seservir de la fonction de tlcommande silappareil en est quip.

Dautres consignes de scurit sontncessaires dans les conditions suivantes :risques lectriques dans un environnementhumide ou si lon porte des vtementsmouills ; sur des structures mtalliquestelles que sols, grilles ou chafaudages ; en

position coince comme assise, genouxou couche ; ou sil y a un risque lev decontact invitable ou accidentel avec lapice souder ou le sol. Dans cesconditions, utiliser les quipements suivants,dans lordre indiqu : 1) un poste souderDC tension constante ( fil), 2) un poste souder DC manuel (lectrode) ou 3) unposte souder AC tension vide rduite.Dans la plupart des situations, lutilisationdun poste souder DC fil tensionconstante est recommande. En outre, nepas travailler seul !

Couper lalimentation ou arrter le moteuravant de procder linstallation, larparation ou lentretien de lappareil.Dverrouiller lalimentation selon la norme

OSHA 29 CFR 1910.147 (voir normes descurit).

Installer le poste correctement et le mettre la terre convenablement selon lesconsignes du manuel de loprateur et lesnormes nationales, provinciales et locales.

Toujours vrifier la terre du cordondalimentation. Vrifier et sassurer que le filde terre du cordon dalimentation est bienraccord la borne de terre du sectionneurou que la fiche du cordon est raccorde une prise correctement mise la terre.

En effectuant les raccordements dentre,fixer dabord le conducteur de mise laterre appropri et contre-vrifier lesconnexions.

Vrifier frquemment le cordon

dalimentation afin de sassurer quil nestpas altr ou nu, le remplacerimmdiatement sil lest. Un fil nu peutentraner la mort.

Lquipement doit tre hors tension lorsquilnest pas utilis.

Ne pas utiliser des cbles uss,endommags, de grosseur insuffisante oumal pisss.

Ne pas enrouler les cbles autour du corps.

Si la pice soude doit tre mise la terre,le faire directement avec un cble distinct.

Ne pas toucher llectrode quand on est encontact avec la pice, la terre ou unelectrode provenant dune autre machine.

Ne pas toucher des porte lectrodes

connects deux machines en mmetemps cause de la prsence dunetension vide double.

Nutiliser quun matriel en bon tat.Rparer ou remplacer sur-lechamp lespices endommages. Entretenir lappareilconformment ce manuel.

Porter un harnais de scurit si lon doittravailler au-dessus du sol.

Sassurer que tous les panneaux etcouvercles sont correctement en place.

Fixer le cble de retour de faon obtenirun bon contact mtal-mtal avec la pice


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souder ou la table de travail, le plus prspossible de la soudure.

Isoler la pince de masse quand pas mis lapice pour viter le contact avec tout objetmtallique.

Ne pas raccorder plus dune lectrode ouplus dun cble de masse une mmeborne de sortie de soudage.

Il reste une TENSION DC NONNGLIGEABLE dans les sources desoudage onduleur quand on a coupelalimentation. Arrter les convertisseurs, dbrancher le

courant lectrique et dcharger lescondensateurs dalimentation selon lesinstructions indiques dans la partieEntretien avant de toucher les pices.

STATIC (ESD) candamage PC boards.LES CHARGESLECTROSTATIQUESpeuvent endommager

les circuits imprims. Put on grounded wrist strap BEFORE

handling boards or parts.

Use proper static-proof bags and boxes tostore, move, or ship PC boards.

tablir la connexion avec la arrette de terreavant de manipuler des cartes ou despices.

Utiliser des pochettes et des botesantistatiques pour stocker, dplacer ouexpdier des cartes PC.

FIRE OR EXPLOSIONhazard.

Risque DINCENDIE OUDEXPLOSION.

Do not place unit on, over, or nearcombustible surfaces.

Do not service unit near flammables

Do not overload building wiring be surepower supply system is properly sized,rated, and protected to handle this unit.

Ne pas placer lappareil sur, au-dessus ou proximit de surfaces inflammables.

Ne pas installer lappareil proximit deproduits inflammables.

Ne pas surcharger linstallation lectrique sassurer que lalimentation estcorrectement dimensionne et protgeavant de mettre lappareil en service.

FLYING METAL caninjure eyes.DES PARTICULESVOLANTES peuventblesser les yeux.

Wear safety glasses with side shields orface shield during servicing.

Be careful not to short metal tools, parts, orwires together during testing and servicing.

Le soudage, lcaillement, le passage de lapice la brosse en fil de fer, et le meulagegnrent des tincelles et des particulesmtalliques volantes. Pendant la priodede refroidissement des soudures, ellesrisquent de projeter du laitier.

Porter des lunettes de scurit avec cranslatraux ou un cran facial.

HOT PARTS can causesevere burns.DES PICES CHAUDESpeuvent provoquer desbrlures graves.

Do not touches hot parts bare handed.

Allow cooling period before working onwelding gun or torch

Ne pas toucher des parties chaudes mains nues.

Prvoir une priode de refroidissementavant dutiliser le pistolet ou la torche.

MAGNETIC FIELDS canaffect pacemakers.LES CHAMPSMAGNTIQUESpeuvent affecter lesstimulateurscardiaques.

Pacemaker wearers keep away. Wearers should consult their doctorbefore going near arc welding, gouging,or spot welding operations.

Porteurs de stimulateur cardiaque, rester distance.

Les porteurs dun stimulateur cardiaquedoivent dabord consulter leur mdecinavant de sapprocher des oprations desoudage larc, de gougeage ou desoudage par points.

CYLINDERS can explodeif damaged.LES BOUTEILLESpeuvent exploser si ellessont endommages.

Shielding gas cylinders contain gas under highpressure. If damaged, a cylinder can explode.Since gas cylinders are normally part of thewelding process, be sure to treat them carefully.

Protect compressed gas cylinders fromexcessive heat, mechanical shocks, physicaldamage, slag, open flames, sparks, and arcs.

Install cylinders in an upright position by


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securing to a stationary support or cylinderrack to prevent falling or tipping.

Keep cylinders away from any welding orother electrical circuits.

Never drape a welding torch over a gascylinder.

Never allow a welding electrode to touch anycylinder.

Never weld on a pressurized cylinder explosion will result.

Use only correct shielding gas cylinders,regulators, hoses, and fittings designed for thespecific application; maintain them andassociated parts in good condition.

Turn face away from valve outlet whenopening cylinder valve.

Keep protective cap in place over valve exceptwhen cylinder is in use or connected for use.

Use the right equipment, correct procedures,and sufficient number of persons to lift andmove cylinders.

Read and follow instructions on compressedgas cylinders, associated equipment, andCompressed Gas Association (CGA)publication P-1 listed in Safety Standards.

Des bouteilles de gaz protecteur contiennent dugaz sous haute pression. Si une bouteille estendommage, elle peut exploser. Du fait que lesbouteilles de gaz font normalement artie duprocd de soudage, les manipuler avecprcaution.

Protger les bouteilles de gaz comprim dunechaleur excessive, des chocs mcaniques,des dommages physiques, du laitier, desflammes ouvertes, des tincelles et des arcs.

Placer les bouteilles debout en les fixant dansun support stationnaire ou dans unporte-bouteilles pour les empcher de tomberou de se renverser.

Tenir les bouteilles loignes des circuits de

soudage ou autres circuits lectriques. Ne jamais placer une torche de soudage sur

une bouteille gaz.

Une lectrode de soudage ne doit jamaisentrer en contact avec une bouteille.

Ne jamais souder une bouteille pressurise risque dexplosion.

Utiliser seulement des bouteilles de gazprotecteur, rgulateurs, tuyaux et raccordsconvenables pour cette application spcifique ;les maintenir ainsi que les lments associsen bon tat.

Dtourner votre visage dudtendeur-rgulateur lorsque vous ouvrez lasoupape de la bouteille.

Le couvercle du dtendeur doit toujours tre

en place, sauf lorsque la bouteille est utiliseou quelle est relie pour usage ultrieur.

Utiliser les quipements corrects, les bonnesprocdures et suffisamment de personnespour soulever et dplacer les bouteilles.

Lire et suivre les instructions sur les bouteillesde gaz comprim, lquipement connexe et ledpliant P-1 de la CGA (Compressed Gas

Association) mentionn dans les principalesnormes de scurit.

FALLING UNIT cancause injury.LA CHUTE DELAPPAREIL peutblesser.

Use lifting eye to lift unit only, NOT runninggear, gas cylinders, or any otheraccessories.

Use equipment of adequate capacity to liftand support unit.

If using lift forks to move unit, be sure forksare long enough to extend beyond oppositeside of unit

Utiliser lanneau de levage uniquementpour soulever lappareil, NON PAS leschariots, les bouteilles de gaz ou tout autreaccessoire.

Utiliser un quipement de levage decapacit suffisante pour lever lappareil.

En utilisant des fourches de levage pourdplacer lunit, sassurer que les fourchessont suffisamment longues pour dpasserdu ct oppos de lappareil.

MOVING PARTS cancause injury.DES ORGANESMOBILES peuventprovoquer desblessures.

Keep away from moving parts such as fans.

Keep all doors, panels, covers, and guardsclosed and securely in place.

Have only qualified persons remove doors,panels, covers, or guards for maintenanceas necessary.

Reinstall doors, panels, covers, or guards

when maintenance is finished and beforereconnecting input power.

Sabstenir de toucher des organes mobilestells que des ventilateurs.

Maintenir ferms et verrouills les portes,panneaux, recouvrements et dispositifs deprotection.

Seules des personnes qualifies sontautorises enlever les portes, panneaux,recouvrements ou dispositifs de protectionpour lentretien.

Remettre les portes, panneaux,recouvrements ou dispositifs de protectionquand lentretien est termin et avant derebrancher lalimentation lectrique.

MOVING PARTS cancause injury.DES ORGANESMOBILES peuventprovoquer desblessures.

Keep away from moving parts

Keep away from pinch points such as driverolls

Ne pas sapprocher des organes mobiles.


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Ne pas sapprocher des points decoincement tels que des rouleaux decommande.

OVERUSE can causeOVERHEATING.LEMPLOI EXCESSIFpeut SURCHAUFFER

LQUIPEMENT. Allow cooling period; follow rated duty

cycle.

Reduce current or reduce duty cycle beforestarting to weld again.

Do not block or filter airflow to unit

Prvoir une priode de refroidissement ;respecter le cycle opratoire nominal.

Rduire le courant ou le facteur de marcheavant de poursuivre le soudage.

Ne pas obstruer les passages dair duposte.

H.F. RADIATION cancause interference.LE SOUDAGE LARCrisque de provoquerdes interfrences.

High-frequency (H.F.) can interfere withradio navigation, safety services,computers, and communicationsequipment.

Have only qualified persons familiar withelectronic equipment perform thisinstallation.

The user is responsible for having aqualified electrician promptly correct any

interference problem resulting from theinstallation.

If notified by the FCC about interference,stop using the equipment at once.

Have the installation regularly checkedand maintained.

Keep high-frequency source doors andpanels tightly shut, keep spark gaps atcorrect setting, and use grounding andshielding to minimize the possibility ofinterference.

Le rayonnement haute frquence (HF)peut provoquer des interfrences avec lesquipements de radio-navigation et de

communication, les services de scuritet les ordinateurs.

Demander seulement des personnesqualifies familiarises avec desquipements lectroniques de fairefonctionner linstallation.

Lutilisateur est tenu de faire corrigerrapidement par un electrician qualifi lesinterfrences rsultant de linstallation.

Si le FCC signale des interfrences,arrter immdiatement lappareil.

Effectuer rgulirement le contrle etlentretien de linstallation.

Maintenir soigneusement ferms lesportes et les panneaux des sources dehaute frquence, maintenir les clateurs

une distance correcte et utiliser une terreet un blindage pour rduire lesinterfrences ventuelles.

READ INSTRUCTIONS.LIRE LESINSTRUCTIONS. Consult the Owners

Manual for welding safetyprecautions.

Use only genuine replacement parts

Lire le manuel dutilisation avant dutiliserou dintervenir sur lappareil.

Utiliser uniquement des pices derechange.


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1-3. Safety Standards Normes de scurit

Safety in Welding, Cutting, and Allied Processes,

ANSI Standard Z49.1, from Global EngineeringDocuments (phone: 1-877-413-5184, website:www.global.ihs.com).

Code for Safety in Welding and Cutting, CSAStandard W117.2, from Canadian Standards

Association, Standards Sales, 178 RexdaleBoulevard, Rexdale, Ontario, Canada M9W 1R3(phone: 8004636727 or in Toronto4167474044, website:

www.csainternational.org).

Safety in Welding, Cutting, and Allied Processes,ANSI Standard Z49.1, de Global EngineeringDocuments (tlphone : 1-877-413-5184, siteInternet : www.global.ihs.com).

Code for Safety in Welding and Cutting, CSAStandard W117.2, de Canadian Standards

Association, Standards Sales, 178 RexdaleBoulevard, Rexdale, Ontario, Canada M9W 1R3(tlphone : 800-463-6727 ou Toronto416-747-4044, site Internet :www.csa-international.org).

1-4. EMF Information EMF Information

Considerations About Welding And The EffectsOf Low Frequency Electric And Magnetic Fields

Welding current, as it flows through weldingcables, will cause electro- magnetic fields. Therehas been and still is some concern about suchfields. However, after examining more than 500studies spanning 17 years of research, a specialblue ribbon committee of the National ResearchCouncil concluded that: The body of evidence, inthe committees judgment, has not demonstratedthat exposure to power- frequency electric andmagnetic fields is a human-health hazard.However, studies are still going forth andevidence continues to be examined. Until thefinal conclusions of the research are reached,you may wish to minimize your exposure toelectromagnetic fields when welding or cutting.

To reduce magnetic fields in the workplace, usethe following procedures:

1. Keep cables close together by twisting ortaping them.

2. Arrange cables to one side and away from theoperator.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as faraway from operator as practical.

5. Connect work clamp to work piece as close tothe weld as possible.

About Pacemakers:

Pacemaker wearers consult your doctor first. Ifcleared by your doctor, then following the aboveprocedures is recommended

Considrations sur le soudage et les effets debasse frquence et des champs magntiques etlectriques.

Le courant de soudage, pendant son passage dansles cbles de soudage, causera des champslectromagntiques. Il y a eu et il y a encore uncertain souci propos de tels champs. Cependant,aprs avoir examine plus de 500 tudes qui ont tfaites pendant une priode de recherch de 17 ans,un comit spcial ruban bleu du National ResearchCouncil a conclu : Laccumulation de preuves,suivant le jugement du comit, na pas dmontrque lexposition aux champs magntiques etchamps lectriques haute frquence reprsente

un risque la sant humaine . Toutefois, destudes sont toujours en cours et les preuvescontinuent tre examines. En attendant que lesconclusions finales de la recherch soient tablies,il vous serait souhaitable de rduire votreexposition aux champs lectromagntiquespendant le soudage ou le coupage.

Pour rduire les champs magntiques sur le postede travail, appliquer les procdures suivantes :

1. Maintenir les cbles ensemble en les tordant ouen les enveloppant.

2. Disposer les cbles dun ct et distance deloprateur.

3. Ne pas courber pas et ne pas entourer pas lescbles autour de votre corps.

4. Garder le poste de soudage et les cbles le plusloin possible de vous.

5. Connecter la pince sur la pice aussi prs quepossible de la soudure.

En ce qui concer ne les sti mulateurscardiaques

Les porteurs de stimulateur cardiaque doiventconsulter leur mdecin avant de souder oudapprocher des oprations de soudage. Si lemdecin approuve, il est recommand de suivre lesprocdures prcdentes


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SECTION 2 PACKING LIST

Table 2.1

MIGSONIC200cvcc package (Part No: 07000385)

Model Part no Quantity

MigSonic200cvcc Power source n/a 1

WeldKingTM12 ft.(3.5 M) NT1-4E Mig torch,Euro connection with Tweco styleconsumables

07000412 1

Spare Contact tips:

Tweco 1 series 0.035/0.9 tip

Tweco 1 series 0.045/1.2 tip

11-35

11-45

1

1

Argon Regulator / Gauge 07000510 1

10 ft. (3M) gas hose with Male 5/8-18 gasconnector on both end

n/a 1

200 Amp electrode holder with 10 ft. (3 M)lead

07000460 1

300 Amp ground clamp with 10 ft. (3 M)lead

07000461 1

Owners Manual 07000416 1

10 ft. (3 M) Power cord with NEMA 5-15P115V AC Plug

n/a 1

Adapter cable 115V NEMA 5-15R to 230VNEMA 6-50P, 2. Ft. (0.6 M)

07001820 1


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SECTION 3 INSTALLATIONS

3-1. Welding power source specifications

MIGSONIC200cvcc (Part No: 07000385)

Welding Process MIG/Flux cored wire Mig

Power supply 115V/60Hz 230V/60Hz

Phase 1

Input current @ Maximum output 25 25

Rated input (Kva) 2.8 5.6

Open circuit voltage(V) 62 62

Amperage range(A) 40-120 40-200

Welding voltage(V) 16-20 16-24

Rated Duty cycle (%) 60 60

Rated welding current(A) 120 200

Wire feed speed(M/MIN) 1-13 (40-500 IPM)

Wire Diameter(MM) Steel /Stainless Steel

Solid: 0.6-0.9mm (0.023-0.035in)

Flux cored: 0.8-1.2mm (0.030-0.045in)

Welding Process STICK/TIG

Power supply 115V/60Hz 230V/60Hz

Phase 1

Input current @ Maximum output 25 25

Rated input (Kva) 2.5 5.0

Open circuit voltage(V) 62 62

Amperage range(A) STICK:12-90TIG: 12-110

STICK:12-160TIG: 12-160

Welding voltage(V) STICK:20.5-23.6TIG: 10.5-14.4

STICK:20.5-26.4TIG: 10.5-16.4

Rated Duty cycle (%) 60 60

Rated welding current(A) 110 160


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Power source Dimension (HxWxD)(CM) 62 x41 x57(24.4x16.1x22.4in)

Power source Weight(KG) 25(55lbs)

Packing Dimension(HxWxD)(CM) 69 48 63 (27.2x18.9x24.8in)

Packing Weight(KG) 35.5(78.1lbs)

Operating temperature(C) -20 to +40 (-4F to 104F)

Storage temperature(C) -40 to +40 (-40F to 185F)

Table 3.1

CAUTIONWELDING LONGER THAN RATED DUTY CYCLE CAN DAMAGE GUN AND VOIDWARRANTY.

3-2. Mig torch specifications

Model NT1-4E (Part no.07000412 )

Rated currency(A) 200A/CO2,180A/MIX

Rated voltage(V)


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3-3. MIG/MAG welding connection diagram

MIGSONIC200cvcc (115v input)

Figure 3.1

To 115 volt, 20 ampereindividual branch circuit

PowerCord

Cylinder

Gauge

Torch

Earthclamp


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MigSonic200cvcc (208/230V input)

Figure 3.2

PowerCord

Cylinder

Gauge

Torch

Earthclamp


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3-4. MIG/MAG Process/Polarity Table

Process PolarityCable Connections

Cable To Gun Cable To Work

GMAWSolid wirewith shielding gas

DCEP Reversepolarity

Connect to positive(+) outputterminal

Connect to negative(-)outputterminal

FCAW Self-shieldingwire- no shielding gas

DCENStraightPolarity

Connect to negative(-) outputterminal

Connect to positive(+)outputterminal

Table 3.3

3-5. General Installation procedure for MIG/MAG welding

3-5.1.Welding machine should be installed in a stable position and with good ventilation.Avoid direct sun outdoors. Use forklift to move, avoid transport in invert or sideposition.

3-5.2.Be sure machine is well grounded. Connect the bolt marked earth with earth innetwork, then connect to network firmly

3-5.3.Before starting a new machine or the machine idled for a period, check theinsulation resistance of circuit which is connected to the network. The resistancemust be higher than 2.5M ; otherwise the machine must be dried.

3-5.4.Connect torch, earth cable, wire, regulator, cylinder according to connectiondiagram. Note: Connection hardware must be tightened with proper tools.Do not just hands tighten hardware! A loose electrical connection willcause poor weld performance and excessive heating at the terminal block.

3-5.5.Make sure the spool gun selection switch set to Mig Torch. If this switch is set tospool gun, the motor will not active when press the gun trigger.

3-5.6.Use 8 heat-resistant PVC hose connect the flow meter with the gas connectionnipple at rear of the machine.

3-5.7. Commission the machine after the machine is installed and tested:

Release the pressure roller in the wire feeder, push the torch switch, and adjustvoltage switch from low to high, Open circuit voltage should rise.

Evenly adjust the current knob, the wire feed speed should increase evenly.

3-6. How to Install the wire spool

3-6.1.Install a spool of welding wire on the hub as follows: Unscrew spool nut from hub.Place wire spool on hub to rotate clockwise as wire is unwound; hub pin mustengage hole in spool. Install spool nut.

3-6.2.The drive roll has two grooves; the small groove feeds 0.035 in. diameter wire,the large groove feeds 0.045 in. wire. The groove nearest the gear motor feedsthe wire.

3-6.3.Release pressure drive roll assembly and lift upward. Check that proper wirediameter groove is in the inner position.Feed the wire from the spool through theinlet guide, across the drive roll groove and into gun outlet guide. Lowerpressures roll assembly and secure. Check that the gears mesh. Feed wirethrough to torch tip using the torch trigger.


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3-7. How to Adjust wire feed pressure

Make sure that the wire moves smoothly through the wire guide. Then set thepressure of the wire feeders pressure rollers. It is important that the pressureis not too high. Feed out the wire against an insulated object, e.g. a piece ofwood. When you hold the gun approx. 5 mm from the object, the feed rollersshould slip. When hold the guan approx. 50mm from the object, the wire

should be fed out and band. Now the pressure is properly set. See Figure 2.3.

Figure 3.3

3-8. How to Install spool gun(optional)

MigSonic200CVCC use WeldKing SpoolKing-24D (Part no. 07NS1000)only. Use other model may not work properly.

3-8.1.Connect spool gun to the euro receptacle. Connect control cable to spool gunreceptacle.

3-8.2. Toggle the spool gun selection switch to spool gun selection(see figure 2.4)

3-8.3.Install wire and commission according to spool gun instruction manual.

Figure 3.4

Spool gunselection switch


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3-9. LIFT-TIG welding connection diagram


Figure 3.5


PowerCord

Cylinder

Gauge

Earthclamp

TIG Torch


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MIGSONIC200cvcc (208/230v input)

Figure 3.6

PowerCord

Cylinder

Gauge

Earthclamp

TIG Torch


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3-10. General installation procedure for Lift-TIG welding

3-10.1.Welding machine should be installed in a stable position and with goodventilation. Avoid direct sun outdoors. Avoid transport in invert or side position.

3-10.2.Switch the ON/OFF Switch (located on the rear panel) to OFF.

3-10.3.Connect the work lead cable to the positive output terminal, and the LIFT TIGTorch cable to the negative output terminal. Refer to Figure 2.6. Insert torch/earthclamp quick connector into receptacle and turn 90 clockwise.

3-10.4.Connect the gas line/hose to the proper shielding gas source. Refer to Figure2.4 and 2.5).

3-10.5.Slowly open the Argon Cylinder Valve to the fully open position.

3-10.6.Connect the work lead clamp to your work piece.


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3-11. STICK welding connection diagram(115V input)


Figure 3.7


PowerCord

Earthclamp

Electrodeholder


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MIGSONIC200cvcc (208/230v input)

Figure 3.8

PowerCord

Earth

clamp

Electrodeholder


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3-12. General installation procedure for Stick welding

3-12.1.Welding machine should be installed in a stable position and with goodventilation. Avoid direct sun outdoors. Avoid transport in invert or side position.

3-12.2.Switch the ON/OFF Switch (located on the rear panel) to OFF.

3-12.3.Connect electrode holder, earth cable, according to connection diagram (refer toFiguar2.6 and 2.7). Insert Electrode holder/earth clamp quick connector intoreceptacle and turn 90 clockwise.

3-13. Electric service guide

CAUTIONWARNING: THIS WELDING MACHINE MUST BE CONNECTED TO POWER

SOURCE IN ACCORDANCE WITH APPLICABLE ELECTRICAL CODES

AVERTISSEMENT: LE RACCORDEMENT DE CETTE MACHINE DE SOUDAGE LALIMENTATION DOIT TRE CONFORME AUX CODES D LECTRICITPERTINENTS

Use 115 volt single phase input, 25 ampere individual branch circuit protected bytime-delay fuses or circuit breaker is required.

Extension cord: 14 AWG

Extension length: 8m with 14AWG, 12 AWG for up to 10 m.

MigSonic200cvcc

Input voltage(V) 230

Frequency(Hz) 60

Input Amperes at maximum output(A) 25

Max recommended standard fuseRating in Amperes

Circuit breaker, time delay

Normal operation

25

35

Min input conductor size in AWG 14

Min Grounding conductor Size in AWG 14

Table 3.4


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3-14. Extension Cable Selection Chart

CAUTIONUSE SHORTEST CABLE POSSIBLE

Input Conductor Size inAWG (mm2) Maximum Cord Length allowed in Ft(M)

115V 230V

14(2.08) 23(7) 56(17)

12(3.31) 29(9) 90(27)

10(5.26) 43(13) 131(40)

8(8.36) 72(22) 160(50)

6(13.29) 105(32) 243(74)

Table 3.5


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SECTION 4 OPERATION

4-1 Front panel Layout

Figure 4.1

1. Welding voltage meter (digital)

2. Welding current meter (digital)

3. Welding process selector

4. Protection indication light

5. Power indication light

6. Voltage adjustment knob (MIG)

7. Wire feed speed (MIG) and Current

(Stick/TIG) adjustment knob

8. Inductance adjustment knob (MIG)

9. Earth clamp (MIG/Stick) or TIG torchreceptacle (TIG)

10. Electrode holder(STICK) or earthclamp receptacle (TIG)

11. Spool gun control receptacle (MIG)

12. MIG Torch receptacle (Euro style)

1

2 3 4 5

6

7

8

9

11

10

12


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4-2 Operation(MIG/MAG)

USE SINGLE PHASE 115/208/230V POWER SUPPLY.

4-2.1 Switch on the power source.

4-2.2 Select MIG mode with the process selection control.

4-2.3 Set the welding voltage knob to proper position and wire feed speed knob to astart value and refine during welding( referring to the voltage/wire feeding speedselection chart)

4-2.4 The display value of digital voltage meter will change when you turn the voltageknob to pre-set the welding voltage. And during welding, the voltage meter will reflectactual welding voltage. The display value of digital current meter will change when youturn the wire feed knob to pre-set the wire feed speed. This value is estimated outputcurrent. During welding, the current meter will reflect actual welding current.

4-2.5 Set the inductance knob at minimum value (far left) at start and you can adjustthe knob during welding to obtain best result.Inductance is the rate of current responseto a change in current. What this means is that when MIG welding with a short arc youcan adjust how fast current is applied to the shorts. The less inductance you have thecrisper the arc will appear and the wires will start easier. This will also make the beadtaller and narrower. More inductance will make the arc appear "softer" with a flatterwider appearance and if too much is used, wires will stumble during starts. Typicallywhen short arcing steel only a little inductance is used in order to get a crisp arc. Lowthermal conductivity materials such as stainless need more inductance to getacceptable wetting when short arcing.

4-2.6 Turn on the gas valve, adjust gas volume to 3-5L/MIN. Push the torch switchcheck if wire feed and gas is normal, check if there is gas leaking.

4-2.7 Hold the torch and keep nozzle 8-12mm above the work piece, and tilt 10-20

to vertical direction. Aim wire to the welding seam.

4-2.8 Push torch switch, after arc is ignited, move the torch along seam evenly whilekeeping the stick-out. Fine tune the welding parameter to obtain exquisite weldingseam. Release the torch switch to finish a welding cycle.

4-2.9 After finish operation, turn off the gas valve, loose the pressure handle at wirefeeder, push torch switch to clear the residual gas in the regulator. At the end, turn offwelding power source and wall switch.

4-3 Operation(STICK/LIFT TIG)

USE SINGLE PHASE 115/208/230V POWER SUPPLY.4-3.1 Switch on the power source.

4-3.2 Set Welding Current to desired value (refer to 3-4. Welding Parameterselection chart).

4-3.3 The display value of digital amperage meter will change when you turn thecurrent adjustment knob to pre-set the welding current. And during welding, theamperage meter will reflect actual welding current output, and the voltage meter willreflect actual welding voltage.


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4-3.4 When stick welding, drag electrode across workpiece like striking a match; liftelectrode slightly after touching work. If arc goes out electrode was lifted too high. Ifelectrode sticks to workpiece, use a quick twist to free it.

4-3.5 When TIG welding. Turn on the gas valve on the torch; adjust gas volume to3-5L/MIN. check if there is gas leaking.

4-3.6 Touch tungsten electrode to workpiece at weld start point. Hold electrode toWorkpiece for 1-2 seconds, and then slowly lift electrode. Arc is formed whenelectrode is lifted. Aim Tungsten electrode to the welding seam.

4-3.7 After arc is ignited, move the torch along seam evenly. Fine tune the weldingparameter to obtain exquisite welding seam.

4-3.8 After finish operation, turn off the gas valve (for TIG). At the end, turn offwelding power source and wall switch.


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4-4 Voltage/Wire speed selection chart

Table 4.1


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SECTION 5 THEORY OF OPERATION

Figure 5.1

19

18

17 16 15

14

13

5431 2

115V/230V

power input

CONTROL PCB MIG-270I-KZ-A0

Power switch Primary

Rectifier

Main

transformer

Capacitor PCB

DVI200-DR-B

Inverter PCB

ZX7-400I-QQ-A2

Power Light

Fan Motor

Solenoid valve

Welding

Current /wirefeed speed

Potentiomete

ThermostatVoltage

potentiometer

Induction

potentiometer

DCeliminate

PCB

Switch PCB (MIG200-

STICK-A0)

Welding

modeswitch

Protection

light

Amperage

meter

Voltage

meter

20

21

24

22

23

26

25

Torch

Trigger

27


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(1) Power switch: control unit and fan motor on/off.(2) Rectifier: Primary rectifier converts AC input into DC.(3) Capacitor PCB (DVI200-DR-B): Smooth current from Primary Rectifier and Supply drive and

control voltage to Inverter Model and control PCB.(4) Inverter PCB (ZX7-400I-QQ-A2): Convert DC current to high frequency (19 kHz) AC current,

output to main transformer. High frequency current can greatly reduce the size and weight ofthe transformer and increase the machine efficiency.

(5) Main transformer: transform to welding voltage.(6) Secondary rectifier: turn high frequency ac current from Inverter module into DC.(7) Reactor: further smooth welding current.(8) Polarity Switch: Polarity Changeover Block(9) Feed motor: feed wire with the speed set by wire speed potential meter. Active by gun trigger.(10) Spool gun selection switch: select use Mig torch or spool gun. Switch sent signal to Switch

PCB (MIG200- STICK-A0) and then control the wire feeding motor on/off.(11) MIG torch.(12) Spool gun.(13) Welding Current Potentiometer: located in the front panel, adjust the output current in Stick/TIG

mode and wire feeding speed in MIG mode by providing a reference voltage to Switch PCB(MIG200- STICK-A0).

(14) Welding mode switch: located in the front panel. Switch welding mode betweenTIG/STICK/MIG.

(15) Thermostat: measure the temperature of the main transformer and provide reference voltage toControl PCB(MIG-270I-KZ-A0)

(16) Voltage potentiometer: Located in the front panel, adjust the welding voltage by providing areference voltage to Control PCB (MIG-270I-KZ-A0)

(17) Induction potentiometer: located in the front panel. Adjust induction of the power source in MIGmode.

(18) Power light: will turn on/off when machine is turned on/off(19) Protection light: this light will turn on when machine is over heat and automatically shut off.(20) Fan motor: Controlled by main power switch and power supplied direct with 230V AC. Fan

cools internal components(21) Solenoid valve: Controls compressed air flow. Pressing gun trigger opens valve.(22) Amperage meter: Digital meter display the actual welding current during welding. Receive

signal from Control PCB (MIG-270I-KZ-A0)(23) Voltage meter: Digital meter display the actual welding voltage during welding and preset

welding voltage in MIG mode. Receive signal from Control PCB (MIG-270I-KZ-A0)(24) Control PCB (MIG-270I-KZ-A0): Supply drive and control voltage to Inverter Model. Supply

control signal to capacitor PCB indicate input voltage (110V or 230V). Control solenoid valve,power light and protection light. Take signal from Voltage control and induction control potentialmeter. Control welding voltage and induction in MIG mode. Supply signal to digital currentmeter and voltage meter in all welding mode.

(25) DC eliminates PCB: eliminate a DC offset from the high frequency AC wave out of IGBTmodule.

(26) Switch PCB (MIG200- STICK-A0): Control fan motor, receive on/off signal from torch trigger(both MIG torch and spool gun torch), On MIG mode, take signal from wire feed speed/Currentpotential meter. Control wire feed speed by changing pulse width modulation signal, therebyproviding more or less voltage to the feed motor. On TIG/STICK mode, take signal fromCurrent/Wire feed speed potential meter and set CC current output. Take signal from weldingmode selection switch to change welding mode. Take signal from spool gun selection switch to

decide the wire is feed through machine motor or gun motor.(27)Gun trigger.


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SECTION 6 TROUBLE SHOOTING

6-1 General trouble shooting

No. Problem Cause Solution

1 Power Indication lamp does not on after

switch on the main switch

Loose contact at input

lead

Check contact

situation

Lamp malfunction,

poor contact

Check contact

situation. Replace

lamp

Main switch

malfunction

Check switch,

replace if

necessary

2 Cooling fan stops

to rotate after

machine has

worked a period

Power indication

lamp on

Cooling fan circuit

malfunction

Check fan circuit

Cool fan failure Check fan, replace

if necessary

Power indication

lamp off

See No. 1

11 Overheat light on Work excess the rate

duty circle

Use under rate

duty circle

Input voltage is too

high

Use under rate

input voltage

10 Power supply switch jump Rectifier short circuit Check and replace


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Main transformer short

circuit

Check and replace

Control transformer

short circuit

Check and replace

Solenoid valve short

circuit

Check and replace

Cooling fan short

circuit

Check and replace

Table 6.1

6-2 MIG/MAG welding trouble shooting


3 No gas flow out after pushing

the gun trigger

Gas pressure not enough Check gas pressure

Poor gas hose connection Check gas connection

Gun trigger failure Check gun trigger

Solenoid valve failure Check and replace

Solenoid valve

Gas passage problem Check and repair the

gas passage


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Torch gas hose problem Check and repair

torch cable

Control circuit failure Replace circuit board

Control transformer failure Replace transformer

4 Failure of arc to ignite or does

not ignite properly

Fuse melt or poor contact Check and repair

Main power switch failure Check, repair, replace

Control circuit board failure Check and repair the

circuit board

Welding cable broken or poor

contact

Check the connection

Gun trigger wire broken Replace cable

Gun cable broken Replace cable

Voltage adjustment knob

failure or poor contact

Check, repair, replace

Control transformer failure Check, repair, replace

Main transformer failure or

poor contact


5 Unstable arc Gas hose not installed

properly, gas mixed by air

Connect the gas hose

firmly

Gas not pure Changes gas

Wire liner or gun cable broken

and leak cause insufficient gas

volume.


Wire pressure not setup

properly

Adjust pressure

Wire feed speed not stable See No.9

Control circuit failure Check, repair, replace

circuit board


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Gas heating failure Check 20A Fuse,

repair, replace

the work piece surface

contaminated by oil

Clean the workpiece

surface

Poor contact inside the gun Check, repair, replace

6 Arc ignited but the wire does

not melt

Rectifier tube failure Check, replace

Output reactor failure Check, replace

Output capacitor failure Check, replace

7 Wire does not feed while the

feed roller is rotating

Wire pressure not proper Adjust pressure

Wire liner or contact tip

jammed


Used wrong groove at the

feeding roller

Use the right groove

8 Cannot stop the gas Solenoid valve contaminated Check, repair, replace

solenoid

Contactor failure Check, replace the

contactor

Control board failure Check, repair, replace

9 Wire feeding not stable Wire out of feeding roller

groove

Put wire back

Wire feed pressure not set

properly

Adjust pressure

Feeding roller deformed Check and replace

Pressure roller deformed Check and replace

Feeding motor failure Check and replace

Current adjust potential meter

failure

Check and replace

Circuit board plug socket not Check and repair or


34/65


properly contacted replace

Control circuit failure Check and repair or

replace

Welding hose deformed Check and replace

Input voltage fluctuated Use under rated input

voltage

Table 6.2

6-3 Stick/TIG welding trouble shooting


4 Erratic or improper weld

output.

Wrong cable size Choose the right cable

size

Cable or receptacle too hot. Wrong electrode holder size Choose the right size

electrode holder

Poor contact between welding or

earth cable and receptacle at

machine

Clean and tighten all

weld connections

Poor connection between

electrode hold and welding

cable

Clean and tighten

5 Failure of arc to ignite or

does not ignite properly

Fuse melt or poor contact Check and repair

Main power switch failure Check, repair, replace

Control circuit board failure Check and repair the

circuit board

AC Contactor failure Check, repair, replace

Welding cable broken or poor

contact

Check the connection


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Gun cable broken Replace cable

Control transformer failure Check, repair, replace

Main transformer failure or poor

contact


6 Unstable or wandering arc Gas not pure Changes gas

Gas pressure too high Reduce pressure

Control circuit failure Check, repair, replace

circuit board

Welding cable size or type is not

proper

See table 2.3

Electrode selection is not proper See Table 3.2

the work piece surface

contaminated by oil

Clean the workpiece

surface

Poor contact inside the gun Check, repair, replace

Rectifier tube failure Check, replace

Output reactor failure Check, replace

Output capacitor failure Check, replace

Remote control failure Check resistance and

connections for

remote Amperage

control potentiometer

7 Tungsten electrode

oxidizing( not bright) after

welding

Gas shield inadequate check nozzle

Gas not pure Check if there is water

in torch and repair.

Check and tight all

gas fitting

Gas pressure inadequate Increase gas pressure

Table 6.3


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6-4 Circuit board testing information

Figure 6.1

DVI200-DR-B (Capacitor PCB)

Connector Pin ValueCN101 1 AC 230V/115V, (reference to CN102-1,2,3,4)

2 AC 230V/115V

3 AC 230V/115V4 AC 230V/115V5 Not used6 DC +325V (voltage output rectified by rectifier)7 DC +325V8 Not used9 DC -325V(voltage output rectified by rectifier)

10 DC 1325VCN102(similarto CN101)

1 AC 230V/115V

2 AC 230V/115V3 AC 230V/115V4 AC 230V/115V5 Not used6 DC +325V7 DC +325V8 Not used9 DC -325V10 DC -325V

CN105 1 DC +24V2 GND3 AC230V/115V switch signal

CN104 1 DC -325V(Common ground)


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2 Not used3 DC +325V

CN103 1 DC -325V2 DC -325V3 DC -325V4 Not used5 DC 325V

6 DC 325V7 DC 325V

Table 6.4


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Figure 6.2

ZX7-400I-QQ-A2(Inverter PCB)

Connector Pin ValueCN1 1 Connect to IGBT drive wire from Control PCB (DC12V)

2 Connect to IGBT drive wire from Control PCB (DC12V)3 Not used4 Connect to IGBT drive wire from Control PCB (DC12V)5 Connect to IGBT drive wire from Control PCB (DC12V)

CN2 1 Connect to IGBT drive wire from Control PCB (DC12V)2 Connect to IGBT drive wire from Control PCB (DC12V)3 Not used4 Connect to IGBT drive wire from Control PCB (DC12V)5 Connect to IGBT drive wire from Control PCB (DC12V)

Table 6.5


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Figure 6.3

MIG-270I-KZ-A0(Control PCB)

Connector Pin ValueCN1 1 GND

2 GND3 GND4 Connect to current meter5 DC+5V Connect to current meter

CN2 1 Not used2 GND. Connect to negative output (voltage feedback)3 Connect positive output


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4 Connect to shunt(current feedback)5 Connect to shunt

CN3 1 Connect to IGBT drive wire from Control PCB (DC12V)2 Connect to IGBT drive wire from Control PCB (DC12V)3 Not used4 Connect to IGBT drive wire from Control PCB (DC12V)5 Connect to IGBT drive wire from Control PCB (DC12V)

CN4 1 GND. Connect to voltage meter2 GND. Connect to voltage meter3 Connect to voltage meter4 DC+5V. Connect to voltage meter

CN5 1 Induction adjustment potentiometer2 Induction adjustment potentiometer

CN6 1 Welding voltage adjustment potentiometer2 Welding voltage adjustment potentiometer3 DC+5V. Welding voltage adjustment potentiometer

CN7 1 Connect to over-current protection coil2 Connect to over-current protection coil

CN8 1 DC+24V. Connect to protection light2 Connect to protection light. DC +24V with thermostat open.

3 DC+24V. Connect to power light4 Connect to power light

CN9 1 Connect to thermostat. Short to CN9-2 with thermostatclosed.

2 Connect to thermostatCN10 1 Connect to CV/CC switch wire(This wire connect to CN11 and

then CN12 in MIG200-STICK-A0)2 DC+24V. Connect to CV/CC switch wire

CN11 1 Connect to torch switch2 Not used3 Connect to torch switch

CN12 1 Short to CN12-2 2 Short to CN12-1

CN13 1 GND2 Not used3 Auxiliary power input. DC+325V

CN14 1 GND. Connect to solenoid valve

2 Connect to solenoid valve. DC+24V

CN15 1 Given welding current(TIG/STICK)

2 Given welding current(TIG)

3 DC+5V. Given welding current

CN16 1 Not used in this model

2 Not used in this model

CN17 1 Giving voltage for wire feed motor

2 Not used

3 Giving voltage for wire feed motor

CN17 1 GND

2 DC+12V

3 DC-12V

4 DC+24V

CN18 1 Connect to IGBT drive wire from Control PCB (DC12V)


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2 Connect to IGBT drive wire from Control PCB (DC12V)

3 Not used



Table 6.6


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Figure 6.4

MIG200-STICK-A0(Switch PCB)Connector Pin Value

CN1 1 GND

2 DC+12V

CN2 1 Not used

2 AC230/115V switch signal

CN3 1 Positive output(output voltage feedback)

2 Not used

CN4 1 Connect to Wire feed motor (2.5V-17V)

2 Not used

3 Wire feed motor(2.5V-17V)

CN5 1 Auto reset toggle switch( torch/spool gun switch)

2 Auto reset toggle switch( torch/spool gun switch)

3 Auto reset toggle switch

CN6 1 Connect to pole 6 in spool gun receptacle( given voltage tospool gun motor)

2 Not used

3 Connect to pole 9 in spool gun receptacle

CN7 1 DC+5V. connect to given welding current

2 connect to given welding current

3 connect to given welding current

CN8 1 DC+5V. connect to welding current potentiometer

2 connect to welding current potentiometer


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3 connect to welding current potentiometer

CN9 1 Auto reset toggle switch(torch/spool gun switch)(+5V)

2 Auto reset toggle switch(torch/spool gun switch)

3 Auto reset toggle switch(torch/spool gun switch)

CN10 1 Connect to pole 8 in spool gun receptacle( given current to

spool gun) (+5V)2 Connect to pole 2 in spool gun receptacle


CN11 1 DC+24V. Connect to CC/CV switch wire from CN10 ofMIG-270I-KZ-A0

2 Connect to CC/CV switch wire

CN12 1 Connect to LIFT TIG/MIG/STICK switch

2 DC+24V. Connect to LIFT TIG/MIG/STICK switch

3 Connect to LIFT TIG/MIG/STICK switch

4 Connect to LIFT TIG/MIG/STICK switch

5 DC+24V. Connect to LIFT TIG/MIG/STICK switch

6 Connect to LIFT TIG/MIG/STICK switchCN13 1 Connect to MIG torch trigger

2 Connect to MIG torch trigger

CN14 1 Connect to pole 5 in spool gun receptacle


CN15 1 Connect to Spool gun trigger

2 Connect to Spool gun trigger

CN16 1 Connect wire feed motor given voltage2 Not used3 Connect wire feed motor given voltage

Table 6.7


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SECTION 7 MAINTENANCE

7.1 Maintenance

Periodic maintenance is necessary for keeping the machine work properly.

CAUTION

DISCONNECT POWER INPUT AND SWITCH OFF THE MAIN POWER SWITCHBEFORE START OF MAINTENANCE.

Regular Check and Inspection 6 Month Routine Maintenance

Clean spatter inside the nozzle whencontinuously use the machine.

Check liner frequently, change if it hasbeen contaminated by oil or worn out.

Check and change broken contact tipand nozzle to avoid damage to thetorch and machine.

Check the function of all switches.

Check if the fan rotates properly and ifthere is air venting out from back ofthe machine

Pay Attention to the abnormalvibration, noise, smell and gasleakage during operation

Check if the welding cables are overheated?

Check if the cable connections areover heated?

Check if the cable is connected firmlyand properly, if it is broken and causebad insulation?

Check the cover grounded properly

Blow out with dry clean pressure air orvacuum inside machine, especiallytransformer coil and powercomponent.

Check the electric connection ofinput/output bar to avoid bad contactcaused by loose or rusted screw.

Check the lubrication of the gear boxin the feeder, replace or fill lubricatesoil if necessary.

Check and clean the oil or othercontamination in the feeding roller andfeeding tube. If the V grooves haveworn out change feeding rollerimmediately to avoid slipping orunstable feeding

Table 7.1


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7.2 Safety precaution

7.2.1 Welders must be equipped with welding mask, gloves and tie the sleeves andcollar properly. Use Table 5.2 to choose proper glass shade, also can referenceto ANSI Z49.1 listed in Safety Standards. There should be an arc shield aroundwelding field to protect others from arc shock.

7.2.2 Do not weld near flammable, explosive materials or gases.

7.2.3 Gas cylinder must be located at a safe and steady place to avoid injury others.

7.2.4 Keep finger, hair and clothing away from the rotating fan.

7.2.5 The power source must be grounded when welding.

7.2.6 Welding machine should not work in a flammable and toxic environment,avoid moisture, rain, and do not directly expose to sun.

7.2.7 Periodically maintain the machine and clean the dust inside.

Lens Shade Selector Guide

Operation/Process

Electrode Size in.(mm)

Arc Current(Amperes)

MinimumProtectiveShade

Suggested*Shade No.(Comfort)

Shielded metalarc welding

(SMAW)

Less than 3/32(2.5)3/325/32 (2.54)5/321/4 (46.4)

More than 1/4 (6.4)

Less than 6060160160250250550

781011

101214

Gas metal arcwelding

(GMAW) andflux cored arc

welding(FCAW)

Less than 6060160160250250550

7101010

111214

Gas tungsten

arc welding(GTAW)

Less than 50

50

150150500

8

810

10

1214AWS F2.2:2001 (R2010), Adapted with permission of the American Welding Society(AWS), Miami, Florida

Table 7.2


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SECTION 8 ELECTRICAL DIAGRAMS

1 2 3 4 5

X13

VH-05(4)

1

3

CN13VH-03(2)

1234

CN19VH-04

2W/1K

MIG-270I

M2

12038 DC24V/0.5A

1

2

3

IGBT:FGL60N600BNTD

1

2

3

A

ZX7-400I-QQ-A0

B

1 2 3 4 5

X1VH-05(4)

M2DC24V,ZCT-2.5

12

CN14

VH-02

12

CN16

XH-02

JP2 CZ-02

J1 CZ-03

1

2

3

1

2

3

1 2 3 4 5

X1VH-05(4)

1 2 3 4 5

X13

VH-05(4)

123

CN17VH-03(2)

1 2 3

CN15XH-03

1 2 3

CN11VH-03(2)

1 2

1 2

CN12VH-02

1237 6

LED2

1 2 3 4

CN4XH-04

JP2 CZ-02

BRIDGE1

BRIDGE1

123456789

10

CN102

VH-10

12345678910

CN101

VH-10

P1

P2

1

23CN104

VH-03

1234567

CN103VH-07

123

CN105VH-03

12

CN1

XH-02

12

CN2XH-02

12

CN3XH-02

123

CN8XH-03

12

CN15XH-02

1 2 3

CN5

VH-03

123

CN7XH-03

12

CN14XH-02

123

CN16

VH-03

1 2 3

CN9

XH-03

B B

1 2

CN12

XH-06

STIC

INPUT 115V/230V

Figure 8.1


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+

_1 2CN7VH-02

D4

RT12W/10K

RT22W/10K

MM1

SSJ-18

KZ-A0

O.C

M1

300A/75mV

1 2

34

T38x22x15 T=300:1

MIG-270I-XS-A0

ESA D92-02

OUT

MIG-400I-ZL-A0

L35uH

OUT

R1300R

R2300R

C1

472/3KV

C2

472/3KV

MIG200

-XH

-A0

75

L3

1236

ED1

1 2 3 4 5

N1H-05

1 2 3 4 5

CN2VH-05

1 2

CN5XH-02

1 2 3

CN6XH-03

1234

CN8XH-04

12CN9

VH-02

123

CN10XH-03

123CN4

VH-03

12CN13

XH-02

12

3

CN16VH-03

12

CN11XH-02

3 4 5 6

12345678

9

/CO2/TIG

12

CN10

CN10

POWER

1

2

4

3BYQ5

Figure 8.2


48/65


NOTES

WELDKING MIGSONIC200cvcc


49/65


SECTION 9 PARTS LIST

9-1 Power Source

Item Order No. Description Note Quantity

1 Y16010440 Frontpanel(grey/Canada)

JKJ-A241-A1(AH2351)(SY-A1134-A1) 1

2 Y09020014 Digital display panel LX5135V-2V 2

3 Y08070008 Knob RN-110ZDADANMAI(black/red)

3

4 Y07060002 Quick connector 10-25 2

5 Y07080007 Control receptacle 10P 1

6 Y16030499 Left panel(blue/MigSonic200cvcc)

JKJ-A237-A1(CH4198)(without silk screen)

1

7B03011011

ReactorZX7-300C(DKQ-008) 1

8 Y25050047 MIG270I rib JYJ-A129-A1 2

9 B01031042 Rectifier PCB ZX7-400I(export) 1

10 Y23010107 Heat sink(Migsonic200cvcc)

SRQ-A041-A1 1

11 Y26030001 ZX7-400C(fix bar) WJJ-252 2

12 B01081019 Full bridge Rectifier PCB S200I 1

13 Y22030016 Driving system with

central connection(eurostyle)

SSJ-18with0.035/0.045Vgroove driver roller (guidetube length 120mm)

1

14 B03041024 Main transformer MigSonic 200 CVCC(Canada)(37:7)

1

15 Y22010004 Fan 12038 DC24V/0.5A 1

16 Y16020186 Rearpanel(grey/Canada)

JKJ-A242-A1(AH2351)(SY-A2067-A2)

1

17 Y21010029 Solenoid valve ZCT-2.5/DC24V(brassbas,6)

1

18 Y26050021 CUT45-Switch bracket WJJ-115 1

19

Y08030006

air-break switch

DZ47-40/2P 1

20 Y16050074 middlepanel(grey/Canada)(1)

JKJ-A244-A1(AH2351) 1

21 Y16050071 middlepanel(grey/Canada)(2)

JKJ-A245-A1(AH2351) 1

22 B02030041 MIG200fastener(1) LJJ-A041-A1 1


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23 Y10030017 Shunt 300A-75mV(non-standard) 1

24 B02030041 MIG200fastener(1) LJJ-A041-A1 1

25 Y25050514 Plastic connection panel 1

26 B01051010 Absorb PCB MIG200 1

27 B01081021 Lift-arc strike PCB MIG200I 1

28 B01041032 Control PCB MIG-270I 1

29 Y25050544 Damping wire spool MIG-270I (hole 4*8. Albase, black plastic bar,open style)

1

30 Y26090008 MIG-270 (Handle(grey) WJJ-A286-A1(AH2351) 1

31 Y16030499 Right panel(blue/MigSonic200cvcc)

JKJ-A237-A1(CH4198)(nosilk screen)

1

32 Y16030500 Right bottom panel

(blue/MigSonic200cvcc)

JKJ-A236-A1(CH4198) 1

33 Y16040178 Bottom panel(grey/Canada)

JKJ-A243-A2(AH2351) 1

34 B01051009 Absorb PCB MIG270I Absorb PCB 1

35 B01021012 Capacitor PCB DVI200 1

36 B0108100 DC isolation PCB ZX7-250I 1

37 Y27020012 HF transformer EER43-140:20:11:10 1

38 Y27020030 HF transformer EI33-40:20:20:20:20 1

39 Y22020001 Fan protection screen 120mm 1

40 Y25050516 Wire fixer SR-T83 1

41 Y26100003 Gas inlet CONNECTOR(EXPORT)-01-A1(CGA5/8"-18Unf)

1

42 Y25050507 Foot Pad 50*35 4

43 Y25050545 Wire guide tube M10*15 1

44 Y08060002 Toggle switch KN3-3 220V3A(6pin/2position)

1

45 Y07100020 luminescent diode 5mm 2

46 Y08060009 Toggle switch T80-T 1

47 Y12060163 Power cable AWG14-3 1

48 Y02010018 CBB Capacitor 106/630V 1

49 Y04070001 Rectifier bridge 25A/1000V(square) 2

Table 9.1


51/65


Figure 9.1


52/65


Figure 9.2

13

5

4

3

2

4546


53/65


Figure 9.3

29

15

41

47

19


54/65


Figure 9.4

28

17

12

48

36

10

27

26

7

23


55/65


Figure 9.5

25

35

49

9

14

13

44


56/65


9-2 Wire feeder

SSJ-18 with bracket, Order No. Y22030016

Figure 9.6

ITEM DESCRIPTION QUANTITY

1 Protection cap 1

2 Euro connection 1

3 Drive roller bracket 1

4 Pressure adjustment component 1

5 50W Motor 1

6 Wire in guide hose L=120mm 1

7 Bracket 1

8 Support 1

9 Shaft sleeve 1

10 Roller(0.9/0.8mm/1.2)(.035/.045) 1

11 Drive roller press nut 1

12 Protect plate 1

Table 9.2


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Drive roller selection

ITEM DESCRIPTION ORDER NO NOTE

1 V groove (0.9/1.2mm)(0.035/0.045)(default) 072611020 For solid wire

2V groove (0.6/0.8mm)(0.023/0.030)

072611021For solid wire

3 Knurled groove (0.9/1.2mm)(0.035/0.045) 072611022 For flux cored wire

Table 9.3


58/65


9-3 Spool holder module

(SSJ-18 with bracket) , Order No. Y22030016

Figure 9.7

ITEM DESCRIPTION ORDER NO QUANTITY

1 axle cap 2401709 1

2 Washer 6 n/a 1

3 spring 2401710 1

4 Screw M6x25 n/a 1

5 Cap bracket 2401708 1

6 Washer 2401707 1

7 Screw M8x30 n/a 1

8 Spring 2401706 1

9 Separation ring 2401705 110 Shaft sleeve 2401704 1

11 Nut M14 n/a 1

12 Axle seat 2401701 1

13 Axle 2401703 1

Table 9.4


59/65


9-4 Spool gun connector

Figure 9.8

SOCKET PIN FUNCTION

1 Spool gun C.C.W potentiometer(3)

2 Spool gun wiper potentiometer(2)

3 Spool gun switch

4 Not used

5 Spool gun switch

6 Spool gun motor (+)

7 Not used

8 Spool gun C.W potentiometer(1)

9 Spool gun motor (-)

10 Not used

Table 9.5

Trigger switch

Motor drive

Potentiometer

10 pin connector


60/65


9-5 Mig torch

WeldKingTMNT1-4E, Order No. 07000412

Figure 9.9

Nozzles

ITEM DESCRIPTION ORDER NO.

1 Nozzle Self Insulated 21-37 A

2 Nozzle Self Insulated 21-50* A

3 Nozzle Self Insulated 21-62 A

4 Nozzle Self Insulated 21-37F A



7 Nozzle Self Shielding LA8201 B

Table 9.6


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Contact Tips


1 Contact Tip 0.023/0.6mm Ecu 11-23 C

2 Contact Tip 0.030/0.8mm Ecu 11-30* C




Table 9.7

Liners


1 Steel Liner 0.030-0.035/0.8-0.9mm X15ft 42-3035-12* C

2 Teflon Liner 0.030-0.035/0.8-0.9mm X15ft 42T-3035-12 C

Table 9.8* Default

Component

ITEM DESCRIPTION PART No. QTY

1 Gas Diffuser 51 1

2 Goose neck(45) 61-45 1

Goose neck(55) 61-55 1

3 Handle locking Nut EH1111 1

4 Gun Handle (Front) EH1101 15 Trigger Assembly EJ0003 1

6 Gun &Cable Assembly.3.65M TEL1012-H 1

7 Rear spring protective sleeve ES2201

8 Rear cover EH2201 1

9 Screw(M4X6) EH2211 1

10 Rear lock nut EP2001 1

11 Euro connector(Tweco) ETU001 1

12 O ring 4x1 Q504010 113 O ring 4x8 Q504018 1

14 Nut M11X1 TEU1011 1

Table 9.9


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NOTESWELDKING MIGSONIC200cvcc


63/65


SECTION 10 WARRANTY POLICY

Malo Welding Products Ltd., Warranty Policy

Effective August 1st, 2004, revision at April 1st, 2011LIMITED WARRANTY - Subject to the terms andconditions below, Malo Welding ProductsLtd.(WELDKING ) endeavors to provide high qualityproducts and product support to its customers andtherefore backs up all of its new products purchased fromMalo Welding Products Ltd.(WELDKING ) or anyauthorized Malo Welding Products Ltd.(WELDKING )distributor/service center after the effective date of thislimited warranty and is free of defects in material andworkmanship at the time it is shipped. THERE ARE NOWARRANTIES WHICH EXTEND BEYOND THE FACE OFTHE MALO WELDING PRODUCTS LTD.(WELDKING )WARRANTY. MALO WELDING PRODUCTSLTD.(WELDKING ) DISCLAIMS ALL OTHERWARRANTIES, EXPRESS OR IMPLIED, REGARDINGTHE PRODUCTS, INCLUDING ANY IMPLIED

WARRANTIES OF MERCHANTABILITY, FITNESS FOR APARTICULAR PURPOSE OR NONINFRINGEMENT. INTHE UNITED STATES, SOME STATES DO NOT ALLOWTHE EXCLUSION OF THE IMPLIED WARRANTIES, SOTHE ABOVE EXCLUSION MAY NOT APPLY TO YOU.

Malo Welding Products Ltd.(WELDKING ) shall honorwarranty claims on warranted equipment listed below in theevent of such a failure within the warranty time periods. Allwarranty time periods start on the date that the equipmentwas delivered to the original retail purchaser, or one yearafter the equipment is sent to a North American distributor.

(1) 3 Years - Parts and Labor

Power Sources

Wire Feeders

(2) 90 Days - Parts (No Labor)Guns

Remote Controls

Accessory Kits

Replacement Parts (No labor)

Malo Welding Products Ltd.(WELDKING )'s limitedWarranty shall not apply to:

(1) Consumable components; such as contact tips, cuttingnozzles, contactors, brushes, slip rings, relays or parts thatfail due to normal wear.

(2) All limited warranties are void for, and Malo WeldingProducts Ltd.(WeldKing ) does not warrant in any way,any product that evidences misapplication, improper

installation, abuse, lack of maintenance, negligence in useor care, abnormal use, alteration of design, use ofincompatible or corrosive chemicals, and/or servicing,installation of parts, or repairs by anyone other than MaloWelding Products Ltd.(WELDKING ) or a Malo WeldingProducts Ltd.(WELDKING ) authorized distributor orservice center. Malo Welding Products Ltd.(WELDKING )may make changes in products it manufactures andmarkets at any time; these changes are made withoutobligation to change, retrofit, or upgrade any productpreviously sold or manufactured.

MALO WELDING PRODUCTS LTD.(WELDKING) 'S

PRODUCTS ARE FOR COMMERCIAL/INDUSTRIAL USEAND PERSONS TRAINED AND EXPERIENCED IN THEUSE AND MAINTENANCE OF WELDING/PLASMACUTTING EQUIPMENT.

In the event of a warranty claim covered by this warranty,the exclusive remedies shall be, at Malo Welding ProductsLtd.(WELDKING )'s option: (1) repair; or (2) replacement;or, where authorized in writing by Malo Welding ProductsLtd.(WELDKING ), in appropriate cases, (3) thereasonable cost of repair or replacement at an authorizedservice station; or (4) payment of or credit for the purchaseprice (less reasonable depreciation based upon actual use)upon return of the goods at customer's risk and expense.No compensation or reimbursement for transportationcosts of any kind will be allowed.

LIMITATION OF DAMAGES: THE REMEDY OFREPLACEMENT OR REPAIR OF ANY DEFECTIVEGOODS SHALL BE THE EXCLUSIVE REMEDY UNDER

ANY WARRANTY MADE BY MALO WELDINGPRODUCTS LTD.(WELDKING ), WHETHER EXPRESSOR IMPLIED. IN NO EVENT SHALL MALO WELDINGPRODUCTS LTD.(WELDKING ) BE LIABLE FOR ANYINCIDENTAL OR CONSEQUENTIAL DAMAGES,PROPERTY DAMAGES, OR PERSONAL INJURIES.

ANY EXPRESS WARRANTY NOT PROVIDED HEREINAND ANY IMPLIED WARRANTY, GUARANTY ORREPRESENTATION AS TO PERFORMANCE, AND ANYREMEDY FOR BREACH OF CONTRACT TORT OR ANYOTHER LEGAL THEORY WHICH, BUT FOR THISPROVISION, MIGHT ARISE BY IMPLICATION,OPERATION OF LAW, CUSTOM OF TRADE OR

COURSE OF DEALING, INCLUDING ANY IMPLIEDWARRANTY OF MERCHANTABILITY OR FITNESS FORPARTICULAR PURPOSE, WITH RESPECT TO ANY AND

ALL EQUIPMENT FURNISHED BY MALO WELDINGPRODUCTS LTD.(WELDKING ), IS EXCLUDED ANDDISCLAIMED BY MALO WELDING PRODUCTSLTD.(WELDKING ).

If any provision or portion of this limited warranty policy isfound to be unenforceable, then the remaining provisionsand portions shall remain valid and enforceable. If anyprovision or portion of this limited warranty policy is foundto be limited by law, then that provision or portion shall beconstrued to make it effective within the bounds of law.

To obtain warranty service you must active yourproduct(s)'s warranty online at weldking.com or mail theproduct registration card included in the package to Malo

Welding Products Ltd.(WELDKING ) right after thepurchase. When there is a warranty issue, return thedefective welding machine or plasma cutting machinealong with proof of purchase to any WeldKing

Authorized Warranty Depot. For the location of thenearest WeldKing Authorized Warranty depot or forservice information in the United States or Canada,please telephone toll free: 1-866-686-5088 or visit www.weldking.com (USA & Canada).available, but may varyfrom province to province.


64/65


SECTION 11 AUTHORIZED SERVICE CENTER

Please go to our website www.weldking.com to fill the warranty registrationform. Malo Welding Products Ltd. will not distribute of disclose customer's

private information to any third party and will not sent promotion material to thecustomer.

Find your nearest warranty center at:

http://www.weldking.com/servicelocations.aspx


65/65

MALO WELDING PRODUCTS LTD.

3275, 14th ave, Unit A, Markham, Ontario, Canada, L3R 0H3

Tel: 1 866 686 5088

Fax: 1 866 686 5090

www.malowelding.com

Printed November 29, 2012