MIG/Stick/TIG MP200iDV LCD 200 Amp Dual Voltage Multi-Process Welder Owner’s Manual WARNING: Read carefully and understand all ASSEMBLY AND OPERATION INSTRUCTIONS before operating. Failure to follow the safety rules and other basic safety precautions may result in serious personal injury.
® Thank you very much for choosing a Klutch product! For future reference, please complete the owner’s record below: Serial Number/Lot Date Code: ________________________________ Purchase Date: ____________________________________________ Save the receipt, warranty, and this manual. It is important that you read the entire manual to become familiar with this product before you begin using it. This welder is designed for certain applications only.
Table of Contents Intended Use .......................................................................................................................................... 4 Packaging Contents .............................................................................................................................. 4 Technical Specifications ...................................................................................................................... 5 Important Safety Information .................
Intended Use The Klutch MIG/Stick/TIG MP200iDV is an inverter-powered, dual voltage, wire feed welder for flux core and MIG welding plus a DC stick welder. It uses a state of the art LCD control screen for easy set-up. It comes complete with a regulator and gas hose for easy connection for MIG welding plus a weld cable and electrode holder for DC stick welding. Directly connect this unit to a 230V NEMA 6-50R receptacle, or attach the supplied 120V adapter cord to operate off of 120V power.
Technical Specifications Property Power Supply No-Load Voltage Output Range - MIG Output Range - STICK Duty Cycle-MIG Duty Cycle-STICK Suggested Wire Suggested Wire Diameter Suggested Electrodes Electrode Diameter Dimensions Weight Specification 120V, 20A, 50/60 Hz, Single Phase 230V, 36A, 50/60 Hz, Single Phase 66V DC with 120V Input Power 69V DC with 230V Input Power 40 to 90A DC with 120V Input Power 40 to 200A DC with 230V Input Power 10 to 70A DC with 120V Input Power 10 to 180A DC with 230V Input Pow
⚠WARNING This product may contain chemicals known to the state of California to cause cancer, birth defects, or other reproductive harm. Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to the state of California to cause cancer, birth defects, or other reproductive harm.
⚠WARNING PERSONAL SAFETY Stay alert, watch what you are doing, and use common sense when operating the tool. Do not use the tool while you are tired or under the influence of drugs, alcohol, or medication. A moment of inattention while operating the tool may result in serious personal injury. Dress properly. Do not wear loose clothing, dangling objects, or jewelry. Keep your hair, clothing and gloves away from moving parts. Loose clothes, jewelry, or long hair can be caught in moving parts.
Always have a qualified person install and operate this equipment. Make sure the area is clean, dry, and ventilated. Do not operate the welder in humid, wet, or poorly ventilated areas. Always have your welder maintained by a qualified technician in accordance with local, state and national codes. Always be aware of your work environment. Be sure to keep other people, especially children, away from you while welding. Keep harmful arc rays shielded from the view of others.
⚠WARNING Electrical Shock Electric arc welders can produce a shock that can cause injury or death. Touching electrically live parts can cause fatal shocks and severe burns. While welding, all metal components connected to the wire are electrically hot. Poor ground connections are a hazard, so secure the ground lead before welding. Wear dry protective apparel: coat, shirt, gloves and insulated footwear. Insulate yourself from the work piece. Avoid contacting the work piece or ground.
eyes and skin. Do not look at the welding arc without proper eye protection. Always use a helmet that covers your full face from the neck to top of head and to the back of each ear. Use a lens that meets ANSI standards and safety glasses. For welders under 160 amps output, use a shade 10 lens; for above 160 amps, use a shade 12. Refer to the ANSI standard Z87.1 for more information. Cover all bare skin areas exposed to the arc with protective clothing and shoes.
⚠CAUTION Electromagnetic Field Electromagnetic fields can interfere with various electrical and electronic devices such as pacemakers. Consult your doctor before using any electric arc welder or cutting device. Keep people with pacemakers away from your welding area when welding. Do not wrap cable around your body while welding. Wrap the torch and ground cable together whenever possible. Keep the torch and ground cables on the same side of your body. H.F.
Always secure cylinder upright to a cart or stationary object. Keep cylinders away from welding or electrical circuits. Use the proper regulators, gas hose, and fittings for the specific application. Do not look into the valve when opening it. Use a protective cylinder cap whenever possible.
Reference 1 2 3 4 5 6 7 8 9 Subassembly MP220SIDV LCD MIG Torch Spool Gun Electrode Holder & Cable Ground Cable & Clamp Contact Tips Gas Hose Regulator/Flow Gauge 120V Power Cord Adapter Setting Up Equipment ⚠WARNING ELECTRIC SHOCK CAN KILL! High voltage danger from power source! Consult a qualified electrician for proper installation of receptacle. This welder must be grounded while in use to protect the operator from electrical shock. Do not remove grounding prong or alter the plug in any way.
2 1 3 Figure 2 a. Open the door to the welder drive compartment. b. Remove the drive tension by loosening the Drive Tension Adjuster (1) and moving the Drive Tension Adjustor away from the Drive Tension Arm (2). Lift the Drive Tension Arm away from the Drive Roller (3). c. If there is wire already installed in the welder, roll it back onto the wire spool by handturning the spool clockwise. Be careful not to let all the wire come out of the rear end of the inlet guide tube.
NOTE: Before installing, make sure that you have removed any old wire from the torch assembly. This will help to prevent the possibility of the wire jamming inside the gun liner. NOTE: Be very careful when removing the welding nozzle. The contact tip on this welder is live whenever the torch trigger is pulled. Make certain power is turned OFF. i. Remove the nozzle and contact tip from the end of the torch assembly. See Figure 3. ii.
v. The welder can use either 4 inch or 8 inch spools. See Figure 5 for additional reference. The wing nut controls the tension on the spool. 4 Inch 8 Inch Figure 5 vi. Setting the wire spool tension. a) Turn the spool of wire with one hand. b) Increase the spool tension by tightening (turn clockwise) the wing nut while turning the spool. Turn the spool while tightening the wing nut until the spool slows down and you feel a slight drag.
xvi. Plug in the welder power cord and turn the welder ON. Set the voltage switch to the voltage setting recommended for the gauge metal that is to be welded. Refer to the set-up chart on the back side of the drive compartment door. ⚠CAUTION The welding wire is electrically hot when the power is on and the torch trigger is activated. xvii. Set the WIRE SPEED control to the middle of the wire speed range. xviii.
Keep cylinders away from welding or electrical circuits. Use the proper regulators, gas hoses, and fittings for the specific application. a. Polarity Changing - When MIG wire is used, shielding gas is required and the polarity on this unit needs to be electrode positive. i. Electrode Positive for MIG Welding - The Weld Power Cable (see Figure 8) should be connected to the positive (+) weld output connection on the front of the machine.
the connection. Connect the regulator to the gas bottle connection. Use a wrench to snug up the connection. vi. Open the Gas Bottle Valve on the cylinder of gas. vii. Turn the Gas Flow Adjuster on the regulator so that the gas flow rate is set at approximately 20 CFH. Make certain you are reading the correct scale on the gauge. NOTE: Slowly open the cylinder valve by turning it counter-clockwise until the cylinder pressure gauge registers on the first gauge of the regulator.
Figure 7 2. Make note of the retaining groove on the back end of the MIG torch (Figure 7). MIG Socket Negative (-) Weld Output Connection 5-Pin Trigger Receptacle Positive (+) Weld Output Connection Figure 8 Weld Power Cable 3. Insert the back end of the MIG torch into the MIG socket on the front of your machine (Figure 8). Make certain to completely slide the torch all the way in. Slightly twist to assist with pushing the torch to the back of the receptacle.
Figure 9 3. We recommend removing the MIG torch when the Spool Gun is connected to avoid accidental arcing. Loosen the wing nut retaining bolt and slide the MIG torch out of the front of the machine. Disconnect the 5-Pin trigger connection on the front of the machine. 4. Carefully slide the gas connector and the weld power connection through the weld cable access opening in the front of the machine (Figure 10). Weld Cable Access Opening Figure 10 5. Open the wire compartment door. 6.
DC STICK WELDING ASSEMBLY ⚠CAUTION Be aware that the ELECTRODE HOLDER will be electrically HOT when the Input Power Switch on the welder is turned ON. 1. 2. 3. 4. Install the ground cable quick connector to the negative (-) Weld Output Connector (Figure 3). Secure the ground clamp to the work piece. Install the electrode cable quick connector to the positive (+) Weld Output Connector. Follow the STICK WELDING SET-UP instructions in the Operating Instructions section.
Operating Instructions ⚠WARNING High voltage danger from power source! Consult a qualified electrician for proper installation of receptacle at the power source. This welder must be grounded while in use to protect the operator from electrical shock. If you are not sure if your outlet is properly grounded, have it checked by a qualified electrician.
GENERAL SYSTEM SET-UP 1. 2. 3. 4. 5. 6. 7. 8. Press the START BUTTON. Turn the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB to the SETTING selection. Push in the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB. Language a. The language function is not active on this unit. b. Turn the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB to ENGLISH. c. Press the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB. Units a. Turn the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB until UNITS screen is displayed. b.
4. 5. 6. 7. 8. 9. 10. 11. 12. i. Connect the Pigtail to the Negative (-) Weld Output Connection ii. Connect the Ground Cable to the Positive (+) Weld Output Connection Push in the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB. a. Use the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB to select your wire size. b. Push in the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB to confirm your selection. c. Use the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB to select the thickness of the item you are welding. d.
iv. Choose the “√” to indicate “Yes” to using a spool gun. v. Push in the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB to confirm your selection. c. Preflow – You can set a time amount for how long you would like the welder to flow gas prior to the arc starting. Some operators like to have the shielding gas covering the area at the start of the arc to minimize arc starting issues and possible contamination. Set in increments of .1 second (not needed for Flux Core welding). d.
item you are welding. 11. Push in the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB to confirm your selection. 12. This machine is now set to weld. 13. If you wish to adjust the amperage, turn the WIRE FEED SPEED AND AMPERAGE CONTROL KNOB. a. Counter Clockwise to decrease amperage. b. Clockwise to increase amperage. Note the Green Range on the Amperage Range. This is the “sweet” spot for that welding electrode. i.
different positions until you find the one that seems to work best for you. 3. POSITION OF THE TORCH TO THE WORK PIECE - There are two angles of the torch nozzle in relation to the work piece that must be consider when welding. a. Angle a can be varied, but in most cases the optimum angle will be 60 degrees, the point at which the torch angle is parallel to the work piece. If angle A is increased, penetration will increase. If angle A is decreased, penetration will decrease also. b.
Prolonged exposure to the welding arc can cause blindness and burns. Never strike an arc or begin welding until you are adequately protected. Wear flame-proof welding gloves, a heavy long sleeved shirt, trousers without cuffs, high topped shoes, and an ANSI approved welding helmet. ⚠WARNING ELECTRIC SHOCK CAN KILL! To prevent ELECTRIC SHOCK, do not perform any welding while standing, kneeling, or lying directly on the grounded workpiece. a.
The WEAVE BEAD is used when you want to deposit metal over a wider space than would be possible with a stringer bead. It is made by weaving from side to side while moving with the torch. It is best to hesitate momentarily at each side before weaving back the other way. See the following illustration. c. Welding Positions The FLAT POSITION is the easiest of the welding positions and is most commonly used.
The OVERHEAD POSITION is the most difficult welding position. Angle A (see HOLDING THE TORCH) should be maintained at 60 degrees. Maintaining this angle will reduce the chances of molten metal falling into the nozzle. Angle B should be held at zero degrees so that the wire is aiming directly into the weld joint. If you experience excessive dripping of the weld puddle, select a lower heat setting. Also, the weave bead tends to work better than the stringer. d.
e. Spot Welding There are three methods of spot welding: Burn-Through, Punch and Fill, and Lap. Each has advantages and disadvantages depending on the specific application as well as personal preference. i. The BURN-THROUGH METHOD welds two overlapped pieces of metal together by burning through the top piece and into the bottom piece. With the burn-through method, larger wire diameters tend to work better than smaller diameters. Wire diameters that tend to work best, with the burn-through method are 0.
c. Hold the nozzle piece completely perpendicular to and about 1/4 inch off the work piece. d. Pull the trigger on the torch and release it when it appears that the desired penetration has been achieved. e. Make practice spot welds on scrap metal, varying the length of time you hold the trigger, until a desired spot weld is made. f. Make spot welds on the actual work piece at desired locations.
2. GROUND CLAMP CONNECTION Clear any dirt, rust, scale, oil, or paint on the ground clamp. Make certain you have a good solid ground connection. A poor connection at the ground clamp will waste power and heat. Make sure the ground clamp touches the metal. 3. ELECTRODE The welding electrode is a rod coated with a layer of flux. When welding, electrical current flows between the electrode (rod) and the grounded metal work piece.
a. When the proper rod is used: i. The bead will lay smoothly over the work without ragged edges. ii. The base metal puddle will be as deep as the bead that rises above it. iii. The welding operation will make a crackling sound similar to the sound of eggs frying. b. When a rod is too small is used: i. The bead will be high and irregular. ii. The arc will be difficult to maintain. c. When the rod is too large: i. The arc will burn through light metals. ii. The bead will undercut the work. iii.
⚠WARNING EXPOSURE TO A WELDING ARC IS EXTREMELY HARMFUL TO THE EYES AND SKIN! Prolonged exposure to the welding arc can cause blindness and burns. Never strike an arc or begin welding until you are adequately protected. Wear flame-proof welding gloves, a heavy long sleeved shirt, trousers without cuffs, high topped shoes, and an ANSI approved welding helmet. b.
Stringer Bead Weave Bead The weave bead is used when you want to deposit metal over a wider space than would be possible with a stringer bead. It is made by weaving from side to side while moving with the electrode. It is best to hesitate momentarily at each side before weaving back the other way. d. Welding position Flat position is easiest of the welding positions and is most commonly used.
⚠WARNING ELECTRIC SHOCK CAN KILL! To prevent ELECTRIC SHOCK, do not perform any welding while standing, kneeling, or lying directly on the grounded workpiece. f. Finish the bead As the coating on the outside of the electrode burns off, it forms an envelope of protective gases around the weld. This prevents air from reaching the molten metal and creating an undesirable chemical reaction. The burning coating, however, forms slag.
⚠CAUTION Be aware that the TIG torch will be electrically HOT when the Input Power Switch on the welder is turned on. 1. Remove the ground cable and the electrode holder from the weld output connections. Install the ground cable to the Positive (+) weld output connection. 2. Secure the ground clamp to the work piece. 3. Connect a regulator to a bottle of ARGON gas. Then connect the gas connection from the TIG torch to the regulator. 4.
After Each Use ⚠CAUTION Hot Materials - Welded materials are hot and can cause severe burns if handled improperly. Do not touch welded materials with bare hands. Do not touch the torch nozzle after welding until it has had time to cool down. 1. Turn Off the power switch when not using the equipment. 2. Turn Off any shielding gases you may have used during the operation of this equipment. 3. Inspect all cords and power cables. Replace any cords or power cables that are damaged or cracked. 4.
Maintenance Interval Maintenance Point Before Each Use Inspect all cords and power cables. Replace any cords or power cables that are damaged or cracked. Every 3 Months Inspect all warning and caution labels affixed to this unit. If they are worn, torn or otherwise unreadable, then replace the warning labels. Inspect and clean and tighten all weld power connections. Troubleshooting ⚠WARNING ELECTRIC SHOCK CAN KILL! Touching live electrical parts can cause fatal shocks or severe burns.
Failure Wire drive motor does not turn. Wire feeds inconsistently. Possible Cause Wire feed speed control at zero. Increase wire feed speed control. Trigger is not mashed. Wire will feed only when trigger is mashed. Wire drive motor Is damaged. Replace wire drive motor. Feed roller is not correctly installed. See installation section to correctly install the drive roller. Torch liner is plugged. Clear or replace torch liner.
Failure Possible Cause Corrective Action recommendations. For assistance, contact the Welder Help Line at 877-304-0294.
Reference 8 9 10 11 12 13 14 15 16 17 18 19 20 21 ** 22 23 ** ** ** 24 25 ** 26 27 28 29 ** ** ** ** ** 30 ** 31 ** ** ** ** ** 32 33 34 35 ** ** ** ** Part Number 105200314 105200306 105200315 105200234 105200316 105500033 105200317 105200318 105100075 105200319 105200320 105200058 105200059 105200103 105200069 105200057 105200061 105200062 105200070 105200043 105200321 105200322 125200067 105200323 105200324 105200055 105200053 105200071 105200072 105200083 105200084 105200086 105200325 105200085 1052000
Replacement Parts For replacement parts and technical questions, please call Customer Service at 1-800-222-5381. Not all product components are available for replacement. The illustrations provided are a convenient reference to the location and position of parts in the assembly sequence. When ordering parts, the following information will be required: item description, item model number, item serial number/item lot date code, and the replacement part reference number.
Limited Warranty Northern Tool and Equipment Company, Inc. ("We'' or "Us'') warrants to the original purchaser only ("You'' or "Your") that the Klutch product purchased will be free from material defects in both materials and workmanship, normal wear and tear excepted, for a period of three years from date of purchase. The foregoing warranty is valid only if the installation and use of the product is strictly in accordance with product instructions.
Distributed by: Northern Tool & Equipment Company, Inc. Burnsville, Minnesota 55306 www.northerntool.
