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Magnum MIG200L PRO DUAL PULSE, Operation Manual

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OPERATION MANUAL

Contents

SAFETY

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1

CAUTION

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3

MIG-200L TECHNICAL DATA

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5

MIG INSTALLATION

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6

LIFT TIG INSTALLATION

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9

MMA INSTALLATION

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10

OPERATION PANEL INSTRUCTION

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11

MEMORY FUNCTION

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12

LIFT TIG SETTING GUIDE

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19

MMA SETTING GUIDE

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21

TROUBLE SHOOTING

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24

MAINTENANCE

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26

CIRCUIT

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27

WARRANTY INFORMATION

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28

Summary of Contents for MIG200L PRO DUAL PULSE

Page 1: ...OPERATION MANUAL MIG200L PRO DUAL PULSE ...

Page 2: ...200L TECHNICAL DATA 5 MIG INSTALLATION 6 LIFT TIG INSTALLATION 9 MMA INSTALLATION 10 OPERATION PANEL INSTRUCTION 11 MEMORY FUNCTION 12 LIFT TIG SETTING GUIDE 19 MMA SETTING GUIDE 21 TROUBLE SHOOTING 24 MAINTENANCE 26 CIRCUIT 27 WARRANTY INFORMATION 28 ...

Page 3: ...rease and protected from hot metal and sparks Frequently inspect input power cable for wear and tear replace the cable immediately if damaged bare wiring is dangerous and can kill Do not use damaged under sized or badly joined cables Do not drape cables over your body We recommend RCD safety switch is used with this equipment to detect any leakage of current to earth Fumes and gases are dangerous ...

Page 4: ...ng or welding They may explode Do not weld cut where the atmosphere may contain flammable dust gas or liquid vapours such as petrol Have a fire extinguisher nearby and know how to use it Be alert that welding cutting sparks and hot materials from welding cutting can easily go through small cracks and openings to adjacent areas Be aware that welding cutting on a ceiling floor bulkhead or partition ...

Page 5: ... in structure and of excellent performance in amperage output The fan is used to dissipate heat generated by this equipment during the welding cutting operation Important Maintain good ventilation of the louvres of this equipment The minimum distance between this equipment and any other objects in or near the working area should be 30 cm Good ventilation is of critical importance for the normal pe...

Page 6: ...gauge on the regulator if the needle drops away towards zero there is a gas leak Sometimes a gas leak can be slow and to identify it will require leaving the gas pressure in the regulator and line for an extended time period In this situation it is recommended to open the cylinder valve set the flow rate to 8 10 L min close the cylinder valve and check after a minimum of 15 minutes 5 If there is a...

Page 7: ... case of self shielded wires by gases generated by the wire core The process is very versatile in that by selection of the correct wire composition diameter and shielding gas it can be used for applications ranging from sheet metal to heavy plate and metals ranging from carbon steel to aluminum alloys TECHNICAL DATA MIG200L Power Supply Phases 240V 15 50 60Hz Rated input power MIG 40 200 MMA 30 20...

Page 8: ...lder Feed the wire into the wire feeder inlet guide tube through to the drive roller 6 At the wire feed assembly release the compression screw by swivelling it outwards This allows the top roller arm to spring to the open position The end of the welding wire can now be passed through the inlet guide over the bottom driven roller and into the output wire guide tube 7 Check that the drive roll groov...

Page 9: ...ike Aluminum requires a U shape groove Aluminum wire has a lot less column strength can bend easily and is therefore more difficult to feed Soft wires can easily buckle at the wire feeder where the wire is fed into inlet guide tube of the torch The U shaped roller offers more surface area grip and traction to help feed the softer wire Softer wires also require less tension from the top pressure ro...

Page 10: ...he wire conduit up to the retaining nipple and screw down nut and tighten it using a multiple wrench 7 Screw in contact tip and attach gas nozzle PA LINER NOTICE New and unused PA liners must be shortened to the actual length of the cable assembly For PA liners with an outer diameter of 4 00 mm the capillary tube in the distance adaptor must be replaced with a guide tube We recommend that you shar...

Page 11: ... of the edges of both welded elements The mechanical properties of the additive material should be similar to the properties of the welded parts The role of shielding gas is always played by pure argon supplied in quantities depending on the welding current set 1 Connect the welding torch into the Euro MIG torch connection socket on the front panel and tighten it 2 Insert the earth cable plug into...

Page 12: ...ectrode as it melts into the workpiece so as to maintain a constant arc length and at the same time moves its melting end along the welding line The melting coating of the electrode gives off protective gases that protect the liquid metal from the influence of the surrounding atmosphere and then solidifies and forms a slag on the surface of the lake which protects the coagulating weld from cooling...

Page 13: ... to default setting 3 Data adjusting knob According left or right button to switch the relative menu and turn this knob to adjust the data Quick turning Press down and turn the knob at the same time for quick adjusting Fine turning Adjust the knob normally for precise adjusting slower 4 Execute button press it to go into sub menu or execute the current operation Press over 5 seconds will save curr...

Page 14: ...ss and the wire diameter then you can start your welding the machine will recommend the welding current voltage and the wire feeding speed for you Of cause you can adjust them yourself according the welding needs Note Re set the material and thickness the system will recover to default data In synergy mode 4T is not available Please choose MIG mode for 4T control steps Synergy is specially recomme...

Page 15: ...on the right correspond to the material on the left 2 Select of plate thickness Spin the knob to adjust plate thickness from 0 5 5mm 3 Selection of wire diameter Select the corresponding wire diameter Selection from 0 8 1 2mm available The device will recommend the right voltage and current for you ...

Page 16: ...o weld When press again it stop welding 4T mode is recommended in long time welding situation Selection of welding pulse 1 For no pulse selection please choose the first one 2 For single pulse selection please choose the second one 3 For double pulse selection please choose the third one Selection of welding material MIG machine can weld 5 kinds of materials Carbon steel stainless steel Al Mg Al S...

Page 17: ... from 2 15M min Wire feeding speed change along with welding current If burn back happen means the current is too high Please minor adjust the voltage to 5 10 until burn back disappear Selection of Voltage At the beginning please adjust the data to 0 and try welding If the arc too short please adjust it higher If burn back happen please adjust voltage to 5 or lower ...

Page 18: ...ve on the contrary adjust it to positive Note Inductance had set up well by system if no other special technological needed there is no need to change it Select the Peak feeding function Adjust the data until the left top data match the thickness of the work piece Selection of dual pulse frequency Recommend range is 1 2Hz according your welding swing ...

Page 19: ...se the metal bead interval will be larger in the same welding speed Selection of Base feeding function Adjust the data It s recommended to adjust within 70 90 of the peak feeding speed MEMORY FUNCTION MIG 200L possess 18 sets memories Long press 3 seconds to restore current setting Long press 3 seconds to recall setting ...

Page 20: ...Al Mg1 2 5356 DCEP Wire speed M min 2 2 4 0 5 3 7 5 8 5 Welding current A 33 65 89 128 141 Arc voltage 15 7 17 2 17 7 19 3 20 0 AL1 0 1070 DCEP Wire speed M min 2 8 5 3 7 0 8 5 10 0 Welding current A 37 77 107 133 160 Arc voltage 16 9 18 9 21 0 22 5 23 6 Al Si 1 2 1070 DCEP Wire speed M min 1 7 3 2 4 0 5 8 6 9 Welding current A 30 0 68 0 88 0 127 0 152 0 Arc voltage 16 7 18 0 18 8 21 6 22 9 Cu Si ...

Page 21: ...t laborious mechanical treatment after welding However this requires proper preparation and cleaning of the edges of both welded elements The mechanical properties of the additive material should be similar to the properties of the welded parts The role of shielding gas is always played by pure argon supplied in quantities depending on the welding current set Selection of welding mode Choose TIG w...

Page 22: ...e on the handle press the button then gently rub the tungsten electrode against the workpiece and raise the torch lightly so that the arc ignites Releasing the switch button ends the welding process 2T An example of a welding gun for the TIG lift method with a valve in the torch ATTENTION The TIG torch is not standard equipment of the set TIG WELDING CURRENT AND PLATE THICKNESS CHART Tungsten Diam...

Page 23: ... welder feeds the electrode as it melts into the workpiece so as to maintain a constant arc length and at the same time moves its melting end along the welding line The melting coating of the electrode gives off protective gases that protect the liquid metal from the influence of the surrounding atmosphere and then solidifies and forms a slag on the surface of the lake which protects the coagulati...

Page 24: ... welding HOT CURRENT A function that makes welding easier When the arc strikes the welding current is temporarily increased to heat up the material and electrode at the tip of contact and to properly shape the penetration and weld face at the initial stage of welding Force current Stabilizes the arc regardless of fluctuations in its length reduces the amount of spatter and avoid the electrode from...

Page 25: ...ING ELECTRODE DIAMETER PLATE THICKNESS AND CURRENT DIAMETER Eelectrode Diameter Plate Thickness 2 5mm Amps 3 2mm Amps 4mm Amps 17ga 1 5mm 30 14ga 2 0mm 50 50 1 8 ga 3 0mm 70 70 70 5 36 ga 4 0mm 90 90 90 1 16 5 0mm 140 140 1 4 6 0mm 200 ...

Page 26: ... circuit or badness of connect at the joint of output terminal The control cable on the torch is broken off or the switch is damaged The control circuit is damaged contact to dealers the meter shows Fan works normally Abnormal indicator lights It might be over current protection please turn off the power switch restart the machine after the abnormal indicator light winked It might be overheating p...

Page 27: ...lug in voltage of multi meter to MOS panel should be about DC308V The auxiliary power on MOS panel has a green indicator light If the light is not on the auxiliary power is not working Control circuit problem find the cause or contact the dealer to cut the control line on the gun Cutting gun cable is broken Output current during cutting is not stable or not controlled by the potentiometer Potentio...

Page 28: ...you notice rust and loose the connection remove the rust or oxide coating with sandpaper reconnect and tighten Avoid situations where water or steam can enter the device If the welder gets wet dry it and then check the insulation of the device also between joints and contacts After checking that everything is OK you can continue working SET CONTAINS I Gas shielded welding gun Binzel MB24 3 meters ...

Page 29: ...MIG 200L DUAL PULSE 27 CIRCUIT ...

Page 30: ...OPERATION MANUAL 28 WARRANTY INFORMATION 2 Years Warranty Parts and Labor Magnum Welders Pty Ltd Graeme Helen McLaren PO Box 65 17 Station Street Cobden VIC 3266 Ph 03 5595 1273 www magnumwelders com au ...

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