ionMig 200 PFC ionMig 200 PFC INVERTER IBGT – MIG WELDING MACHINE OPERATION MANUAL IMPORTANT: Read this Owner’s Manual Completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. Contact your distributor if you do not fully understand this manual. Copyright © Mundaka Welding & Gases, Inc.
ionMig 200 PFC CONTENT 1. Safety .............................................................................................................................................. 3 1.1 Signal Explanation....................................................................................................................... 3 1.2 Arc Welding Damage ................................................................................................................... 5 1.
ionMig 200 PFC 1. Safety 1.1 Signal Explanation Welding is dangerous, and may cause damage to you and others, so take good protection when welding. For details, please refer to the operator safety guidelines in conformity with the accident prevention requirements of the manufacturer. Professional training is needed before operating the machine. ·Use labor protection welding supplies authorized by national security supervision department.
ionMig 200 PFC Improper operation may cause fire or explosion. ·Welding sparks may result in a fire, so please make sure no combustible materials nearby and pay attention to fire safety. ·Have a fire extinguisher nearby, and have a trained person to use it. ·Airtight container welding is forbidden ·Pipe thaw with this machine is forbidden. Hot workpiece may cause severe scalding. ·Don’t contact hot workpiece with bare hands. ·Cooling is needed during continuous use of the welding torch.
ionMig 200 PFC 1.2 Arc Welding Damage The following signals and word explanations are to some damages for your body or others happening on the welding operation. While seeing these, please remind of yourself or others to be dangerous. Only ones who are trained professionally can install, debug, operate, maintain and repair the equipment. During the operation, non-concerned people should be lift, especially for children.
ionMig 200 PFC 2. Overview 2.1 Brief Introduction MIG SERIES arc welding machine adopts the latest pulse width modulation (PWM) technology and insulated gate bipolar transistor (IGBT) power module, which can change work frequency to medium frequency so as to replace the traditional hulking work frequency transformer with the cabinet medium frequency transformer. Thus, it is characterized with portable, small size, light weight, low consumption and etc.
ionMig 200 PFC installment, mold mend, petrochemical, architecture decoration, car repair, bicycle, handicraft and common manufacture. MAG--Metal Active Gas Welding MIG--Metal Insert Gas Welding 2.2 Working Principle The working principle of MIG SERIES arc welding machine is shown as the following figure.
ionMig 200 PFC 2.3 Volt-Ampere Characteristic MIG SERIES welding machine has an excellent volt-ampere characteristic, whose graph is shown as the following figure. The relation between the rated loading voltage U2 and welding current I2 is as follows: U2=14+0.05I2(V) Uo（V） Volt-ampere characteristic Working point The relation between the rated loading voltage and welding current 44 14 0 Copyright © Mundaka Welding & Gases, Inc.
ionMig 200 PFC 2.4 Principles of welding Copyright © Mundaka Welding & Gases, Inc.
ionMig 200 PFC 3. Installation and Adjustment 3.1 Parameters Model MultiMIG200PFC MultiMIG250PFC Parameters Input Voltage（V） 1-110±10% 1-220±10% 1-110±10% 1-220±10% Input Current（A） MIG MMA TIG 31.7 32 19 MIG MMA TIG 26 30 19.5 MIG 43 MMA 37 TIG 32 MIG MMA TIG 43 44 36 Input Power（KW） MIG MMA TIG 3.4 3.5 2.1 MIG MMA TIG 26 30 19.5 MIG MMA TIG MIG MMA TIG 9.4 9.6 7.
ionMig 200 PFC 3.2 Duty cycle and Over-heat The letter “X” stands for the duty cycle, which is defined as the proportion of the time that a machine can work continuously within a certain time (10 minutes). The rated duty cycle means the proportion of the time that a machine can work continuously within 10 minutes when it outputs the rated welding current. The relation between the duty cycle “X” and the output welding current “I” is shown as the right figure.
ionMig 200 PFC 3.3 Equipment Connection Operation Steps： 1. Connect the power source input cable of welding machine with the output port of air switch in electric box on the spot. 2. Connect the cable plug of wire feeder to the positive output of welding machine. 3. Connect the control cable plug of wire feeder to the aero socket on the front board of welding machine. 4. Connect the negative pole of welding machine to the work piece (base metal). 5.
ionMig 200 PFC 8. Connect the control cable pin of torch with the two-lead aero socket of front panel on wire feeder. 9. Notice that the wire diameter should be accordant with the wire wheel and torch tip and press the wire properly with the handle. 3.4 Maintenance of MIG Gun mechanism 3.4.1 Dissection graphics for the MIG GUN 4 5 6 9 11 10 3 2 1 3.
ionMig 200 PFC 3.4.2 The parts list for the MIG GUN NO. 1 2 3 3.1 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Description Tip D.12 14-15AK Electric nozzle 0.8/M6*25 15AK Goose gun neck（Hexangular adapter and Plastic adapter） 15AK Goose gun Hexangular adapter Plastic adapter MIG blue handle Torch Switch 21.8mm Screw D.
ionMig 200 PFC Remove the welding gun’s gas nozzle, contact tip and contact tip’s adapter. With a pneumatic pistol, blow compressed air through the wire guide. Blow the wire feed mechanism and reel housing clean with compressed air. Reattach the welding gun’s parts. Tighten the contact tip and contact tip’s adapter to spanner tightness. 3.
ionMig 200 PFC 4. Operation 4.1 Layout for the front and rear panel Copyright © Mundaka Welding & Gases, Inc.
ionMig 200 PFC 1. Choose welding mode key: On TIG or MIG, Pressing the key can choose 2T or 4T welding mode. 2. Choose welding method key: Pressing the key can choose three function, MMA/TIG/MIG. 3. Welding current knob: Set the welding current. 4. Current display: Welding Current display when machine is working, Set current display before welding. Unit：A. 5. Current LED： When the current LED is on, it display the actual output welding current(MIG). 6.
ionMig 200 PFC 16. Output anode: When TIG mode, this polarity must connect the work piece 17. Remote Switch 18. Spool Gun Switch 19. Burn back knob 20. Slow feed knob 21. Manual wire switch & air check switch: up for manual wire and down for air check. 22. Post flow knob 23. Pre-flow knob 4.2 Welding operation For example MULTIMIG 200 4.2.1 MIG mode operation: 1.
ionMig 200 PFC 2) Spool Gun Switch turn off (down). 3) Manual wire switch & air check switch，Burn back adjust，Slow feed adjust, post flow adjust, Pre-flow knob adjust； 4) Press the welding mode key, choose 2T or 4T； Copyright © Mundaka Welding & Gases, Inc.
ionMig 200 PFC 5) Spool Gun Switch turn on (up): 3. Adjust Welding parameter 1) Different wire diameter, the minimum welding current is different； 2) Adjust the current knob, the corresponding welding voltage is changed automatically； 3) When the programmable welding voltage isn’t the perfect for the operator, the voltage can be changed by adjusted the knob； 4) If the operator adjust the wave control knob, the arc characteristics can be controlled. Copyright © Mundaka Welding & Gases, Inc.
ionMig 200 PFC 4.2.2 TIG mode operation: 1. Press the weld manner key, choose TIG manner and the TIG LED is lighted； 2. Press the welding mode key, choose 2T or 4T； 3. Adjust the current knob to control the welding current； 4. Adjust the down slope knob to control the welding current descend time. Copyright © Mundaka Welding & Gases, Inc.
ionMig 200 PFC 4.2.3 MMA mode operation: 1. Press the weld manner key, choose MMA manner and the MMA LED is lighted； 2. Adjust the current knob to control the welding current； 3. Adjust the welding arc force knob to control the arc force current. Note：The current display is preset current before welding and is welding current when welding. The voltage display is real voltage. 4.3Welding parameters Wire diameter (mm) Welding current (A) Plate thickness (mm) 0.6 25-110 1.0-1.6 0.8 35-160(200) 1.0-2.
ionMig 200 PFC normal standard. ▲ Take care that there is sufficient ventilation during welding. There is at least 30cm free distance between the machine and wall. ▲ Preferable site the machine some angles above the floor level, the maximum angle does not exceed 15℃. ▲ Protect the machine against heavy rain or in hot circumstance against direct sunshine. ▲ The content of dust, acid, corrosive gas in the surrounding air or substance cannot exceed normal standard.
ionMig 200 PFC been put correctly in place, please correct; If you can't correct or fix the knob , please replace immediately; If the switch is not flexible or it can't be put correctly in place, please replace immediately; Please get in touch with maintenance service department if there are no accessories. After turn-on power, watch/listen to that whether the arc welding machine has shaking, whistle calling or peculiar smell.
ionMig 200 PFC examination below 1MΩ, insulation is thought to be damaged and need to change, and need to change or strengthen insulation. 5.2 Troubleshooting Before arc welding machines are dispatched from the factory, they have already been debugged accurately. So forbid anyone who is not authorized by our company to do any change to the equipment! Maintenance course must be operated carefully.
ionMig 200 PFC Output gas when test gas Wire reel doesn’t work 4 5 Wire-feeder doesn’t work Wire works reel No striking arc and no output voltage 6 Welding stops, and alarm light is on 7 Welding current is run away and can be not controlled Control switch damaged Repair the switch Motor damaged Check and change it Control circuit damaged Check the board The press wheel is loosen or weld wire skids Press it tightly again The wheel doesn’t fit with the diameter of weld wire Change the whee
ionMig 200 PFC 5.3 Electrical schematic drawing Copyright © Mundaka Welding & Gases, Inc.
