US
FR
ES
Caddy
Mig C200i
Manuel d'instructions
Instrucciones de uso
Instruction manual
Valid for serial no. 026-xxx-xxxx0440 001 031 US FR ES 110222
AMERICAN 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRANÇAIS 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ESPAÑOL 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sous réserve de modifications sans avis préalable.
Reservado el derecho de cambiar las especificaciones sin previo aviso.
Rights reserved to alter specifications without notice.
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AMERICAN
1 USER RESPONSIBILITY 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 SAFETY PRECAUTIONS 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 SAFETY 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 INTRODUCTION 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Equipment 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 TECHNICAL DATA 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 INSTALLATION 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Lifting instruction 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Location 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Mains power supply 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 OPERATION 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Connection and control devices 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Operation 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.1 Manual mode 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2 QSet mode 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.3 Unit of measurement 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Error codes 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Inductance settings (Fe/SS) 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5 Polarity change 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6 Wire feed pressure 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.7 Replacing and inserting wire 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.7.1 Changing the feed roller groove 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.8 Shielding gas 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.9 Overheating protection 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 MAINTENANCE 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Inspection and cleaning 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Changing the wire liner 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 FAULT TRACING 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 ORDERING OF SPARE PARTS 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCHEMATIC DIAGRAM 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCHEMATIC DIAGRAM 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORDERING NUMBER 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WEAR COMPONENTS 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCESSORIES 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sous réserve de modifications sans avis préalable.
Reservado el derecho de cambiar las especificaciones sin previo aviso.
Rights reserved to alter specifications without notice.
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Be sure this information reaches the operator.
You can get extra copies through your supplier.
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the
principles of operation and safe practices for arc welding equipment, we urge you to read
our booklet, “Precations and Safe Practices for Arc, Cutting and Gouging, “Form 52-529.
Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT
attempt to install or operate this equipment until you have read and fully understand these
instructions. If you do not fully understand these instructions, contact your supplier for
further information. Be sure to read the Safety Precautions before installing or operating
this equipment.
1 USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and
accompanying labels and/or insert when installed, operated, maintained and repaired in accordance
with the instruction provided. This equipment must be checked periodically. Malfunctioning or poorly
maintained equipment should not be used. Parts that are broken, missing, worn, distorted or
contaminated should be replaced immediately. Should such repair or replacement become necessary,
the manufacturer recommends that a telephone or written request for service advice be made to the
Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the
manufacturer. The user of this equipment shall have the sole responsibility for any malfunction which
results from improper use, faulty maintenance, damage improper repair or alteration by anyone other
than the manufacturer or a service facility designated by the manufacturer.
2 SAFETY PRECAUTIONS
WARNING: These Safety Precautions are for your protection. They summarize precautionary
information from the references listed in Additional Safety Information section. Before performing any
installation or operating procedures, be sure to read and follow the safety precautions listed below as
well as all other manuals, material safety data sheets, labels, etc. Failure to observe Safety
Precautions can result in injury or death.
PROTECT YOURSELF AND OTHERS
Some welding, cutting and gouging precesses are noisy and require ear
protection. The arc, like the sun, emits ultraviolet (UV) and other radiation
and can injure skin and eyes. Hot metal can cause burns. Training in the
proper use of the processes and equipment is essential to prevent accidents.
Therefore:
1. Always wear safety glasses with side shields in any work area, even if welding helmets face
shields and goggles are also required.
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2. Use a face shield fitted with the correct filter and cover plates to protect your eyes, face, neck
and ears from sparks and rays of the arc when operating or observing operations. Warn
bystanders not to watch the arc and not to expose themselves to the rays of the electric-arc or
hot metal.
3. Wear flameproof gauntlet type gloves, heavy long-sleeve shirt, cuffless trousers, high-topped
shoes and a welding helmet or cap for protection, to protect against arc rays and hot sparks or
hot metal. A flameproof apron may also be desirable as protection against radiated heat and
sparks.
4. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves and collars
should be kept buttoned and open pockets eliminated from the front of clothing.
5. Protect other personnel from arc rays and hot sparks with a suitable nonflammable partition or
curtains.
6. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be hot and
can fly far. Bystanders should also wear goggles over safety glasses.
FIRES AND EXPLOSIONS
Heat from flames and arcs can start fires. Hot slag or sparks can also cause
fires and explosions. Therefore:
1. Remove all combustible materials well away from the work area or cover the materials with a
protective nonflammable covering. Combusible materials include wood, clot, sawdust, liquid and
gas fuels, solvents, pants and coatings papper, etc.
2. Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a
hidden smoldering fire or fires on the floor below. Make certain that such openings are protected
from hot sparks and metal.
3. Do not weld, cut or perform other hot work until the workpiece has been completely cleaned so
that there are no substances on the workpiece which might produce flammable or toxic vapors.
Do not do hot work on closed containers. They may explode.
4. Have fire extinguishing equipment handy for instant use, such as a garden hose, water pail, sand
bucket, or portable fire extinguisher. Be sure you are trained in its use.
5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat
and create a fire hazard.
6. After completing operations, inspect the work area to make certain there are no hot sparks or hot
metal which could cause a later fire. Use fire watchers when necessary.
7. For additional information refer to NFPA Standard 51B, “Fire Prevention in Use of Cutting and
Welding Processes”, available from the National Fire Protection Association, Batterymarch Park,
Quincy, MA 02269.
ELECTRICAL SHOCK
Contact with live electrical parts and ground can cause severe injury or
death. DO NOT use AC welding current in damp areas, if movement is
confined, or if there is danger of falling. Therefore:
1. Be sure the power source frame (chassis) is connected to the ground system of the input power.
2. Connect the workpiece to a good electrical ground.
3. Connect the work cable to the workpiece. A poor or missing connection can expose you or others
to a fatal shock.
4. Use well-maintained equipment. Replace worn or damaged cables.
5. Keep everything dry, including clothing, work area, cables, torch/electrode holder and power
source.
6. Make sure that all parts of your bady are insulated from work and from ground.
7. Do not stand directly on metal or the earth while working in tight quarters or a damp area; stand
on dry boards or an insulating platform and wear rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the power.
9. Turn off the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on next page) for specific grounding
recommendations. Do not mistake the work lead for a ground cable.
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ELECTRIC AND MAGNETIC FIELDS
May be dangerous. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding and cutting current
creates EMF around welding cables and welding machines.
Therefore:
1. Welders having pacemakers should consult their physician before welding. EMF may interfere
with some pacemakers.
2. Exposure to EMF may have other health effects which are unknown.
3. Welders should use the following procedures to minimize exposure to EMF:
a. Route the electrode and work cables together. Secure them with tape when possible.
b. Never coil the torch or work cable around your body.
c. Do not place your body between the torch and work cables. Route cables on the same side
of your body.
d. Connect the work cable to the workpiece as close as possible to the area being welded.
e. Keep welding power source and cables as far away from your body as possible.
FUMES AND GASES
Fumes and gases, can cause discomfort or harm, particularly in confined
spaces. Do not breathe fumes and gases. Shielding gases can cause
asphyxiation.
Therfore:
1. Always provide adequate ventilation in the work area by natural or mechanical means. Do not
weld, cut or gouge on materials such as galvanized steel, stainless steel, cooper, zinc, lead
beryllium or cadmium unless positive mechanical ventilation is provided. Do not breathe fumes
from these materials.
2. Do not operate near degreasing and spraying operations. The heat or arc can react with
chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas and other irritant gases.
3. If you develop momentary eye, nose or throat irritation while operating, this is an indication that
ventilation is not adequate. Stop work and take necessary steps to improve ventilation in the work
area. Do not continue to operate if physical discomfort persists.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for specific ventilation recommendations.
5. WARNING: This product when used for welding or cutting, produces fumes or gases which
contain chemicals known to the State of Californa to cause birth defects and in some cases
cancer (California Health & Safety Code §25249.5 et seq.)
CYLINDER HANDLING
Cylinders, if mishandled, can rupture and violently release gas. Sudden
rupture of cylinder valve or relief device can injure or kill.
Therefore:
1. Use the proper gas for the process and use the proper pressure reducing regulator designed to
operate from the compressed gas cylinder. Do not use adaptors. Maintain hoses and fittings in
good condition. Follow manufacturer's operating instructions for mounting regulator to a
compressed gas cylinder.
2. Always secure cylinders in an upright position by chain or strap to suitable hand trucks,
undercarriages, benches, wall, post or racks. Never secure cylinders to work tables or fixtures
where they may become part of an electrical circuit.
3. When not in use, keep cylinder valves closed. Have valve protection cap in place if regulator is
not connected. Secure and move cylinders by using suitable hand trucks.
4. Locate cylinders away from heat, sparks and flames. Never strike an arc on a cylinder.
5. For additional information, refer to CGA Standard P-1, “Precations for Safe Handling of
Comporessed Gases in Cylinders”, which is available from Compressed Gas Association, 1235
Jefferson Davis Highway, Arlington, VA 22202.
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EQUIPMENT MAINTENANCE
Faulty or improperly maintained equipment can cause injury or death. Therefore:
1. Always have qualified personnel perform the installaion, troubleshooting and maintenance work.
Do not perform any electrical work unless you are qualified to perform such work.
2. Before performing any maintenance work inside a power source, disconnect the power source
from the incoming electrical power.
3. Maintain cables, grounding wire, connections, power cord and power supply in safe working
order. Do not operate any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keep equipment away from heat sources such as
furnaces, wet conditions such as water puddles, oil or grease, corrosive atmospheres and
inclement weather.
5. Keep all safety devices and cabinet covers in position and in good repair.
6. Use equipment only for its intended purpose. Do not modify it in any manner.
ADDITIONAL SAFETY INFORMATION
For more information on safe practices for electric arc welding and cutting equipment,
ask your supplier for a copy of “Precautions and Safe Practices for Arc Welding,
Cutting and Gouging”, Form 52-529.
The following publications, which are available from the American Welding Society, 550 N.W. LeJuene
Road, Miami, FL 33126, are recommended to you:
1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”
2. AWS C5.1 . “Recommended Practices for Plasma Arc Welding”
3. AWS C5.2 - “Recommended Practices for Plasma Arc Cutting“
4. AWS C5.3 - “Recommended Practices for Air Carbon, Arc Gouging and Cutting”
5. AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding”
6. AWS C5.6 - “Recommended Practices for Gas Metal Arc welding”
7. AWS SP - “Safe practices” - Reprint, Welding Handbook
8. ANSI/AWS F4.1 - “Recommended Safe Practices for Welding and Cutting of Containers That
Have Held Hazardous Substances”
MEANING OF SYMBOLS
As used throughout this manual: Means Attention! Be Alert!
Means immediate hazards which, if not avoided, will result in
immediate, serious personal injury or loss of life.
Means potential hazards which could result in personal injury or loss
of life.
Means hazards which could result in minor personal injury.
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1 SAFETY
Users of ESAB welding equipment have the ultimate responsibility for ensuring that anyone who
works on or near the equipment observes all the relevant safety precautions. Safety precautions
must meet the requirements that apply to this type of welding equipment. The following recommen
dations should be observed in addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well-acquainted with the operation of the welding
equipment. Incorrect operation of the equipment may lead to hazardous situations which can result
in injury to the operator and damage to the equipment.
1. Anyone who uses the welding equipment must be familiar with:
S its operation
S location of emergency stops
S its function
S relevant safety precautions
S welding
2. The operator must ensure that:
S no unauthorized person is stationed within the working area of the equipment when it is
started up.
S no-one is unprotected when the arc is struck
3. The workplace must:
S be suitable for the purpose
S be free from drafts
4. Personal safety equipment
S Always wear recommended personal safety equipment, such as safety glasses, flame-proof
clothing, safety gloves.
S Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions
S Make sure the ground cable is connected securely.
S Work on high voltage equipment may only be carried out by a qualified electrician.
S Appropriate fire extinquishing equipment must be clearly marked and close at hand.
S Lubrication and maintenance must not be carried out on the equipment during operation.
DO NOT USE THE POWER SOURCE FOR THAWING FROZEN PIPES.
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ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE
PRECAUSIONS WHEN WELDING. ASK FOR YOUR EMPLOYER'S SAFETY PRACTICES
WHICH SHOULD BE BASED ON MANUFACTURERS' HAZARD DATA.
ELECTRIC SHOCK - CAN KILL
S INSTALL AND EARTH THE WELDING UNIT IN ACCORDANCE WITH APPLICABLE
STANDARDS.
S DO NOT TOUCH LIVE ELECTRICAL PARTS OR ELECTRODES WITH BARE SKIN,
WET GLOVES OR WET CLOTHING.
S INSULATE YOURSELF FROM EARTH AND THE WORKPIECE.
S ENSURE YOUR WORKING STANCE IS SAFE.
FUMES AND GASES - CAN BE DANGEROUS TO HEALTH
S KEEP YOUR HEAD OUT OF THE FUMES.
S USE VENTILATION, EXTRACTION AT THE ARC, OR BOTH, TO TAKE FUMES AND
GASES AWAY FROM YOUR BREATHING ZONE AND THE GENERAL AREA.
ARC RAYS - CAN INJURE EYES AND BURN SKIN.
S PROTECT YOUR EYES AND BODY. USE THE CORRECT WELDING SCREEN AND
FILTER LENS AND WEAR PROTECTIVE CLOTHING.
S PROTECT BYSTANDERS WITH SUITABLE SCREENS OR CURTAINS.
FIRE HAZARD
S SPARKS (SPATTER) CAN CAUSE FIRE. MAKE SURE THEREFORE THAT THERE ARE
NO INFLAMMABLE MATERIALS NEARBY.
NOISE - EXCESSIVE NOISE CAN DAMAGE HEARING
S PROTECT YOUR EARS. USE EARMUFFS OR OTHER HEARING PROTECTION.
S WARN BYSTANDERS OF THE RISK.
MALFUNCTION - CALL FOR EXPERT ASSISTANCE IN THE EVENT OF MALFUNCTION.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
This product is solely intended for arc welding. Any other use may result in personal
injury and / or equipment damage.
Class A equipment is not intended for use in residential locations
where the electrical power is provided by the public low-voltage
supply system. There may be potential difficulties in ensuring
electromagnic compatibility of class A equipment in those locations,
due to conducted as well as radiated disturbances.
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Read and understand the instruction manual
before installing or operating.
Dispose of electronic equipment at the recycling facility!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic
Equipment and its implementation in accordance with national law, electrical and/or
electronic equipment that has reached the end of its life must be disposed of at a
recycling facility.
As the person responsible for the equipment, it is your responsibility to obtain
information on approved collection stations.
For further information contact the nearest ESAB dealer.
ESAB can provide you with all necessary welding protection and accessories.
2 INTRODUCTION
Mig C200i is a portable welding power source in a compact design, intended for
GMA welding.
It is possible to switch between welding with solid wire/shielding gas and welding
with selfshielded cored wire without gas.
The power source operates with wire diameters from .024 to .040”. Pure argon,
mixed gas or pure CO2 may be used as shielding gases.
2.1 Equipment
The power source is supplied with:
S Instruction manual
S Welding gun MXLTM 180 (9.8 ft, fixed)
S Return cable with clamp (9.8 ft, fixed)
S Mains cable (9.8 ftm, fixed, with plug)
S Shoulder strap (see page 12)
S Gas hose with quick connection (14.8 ft)
ESAB's accessories for the product can be found on page 69.
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3 TECHNICAL DATA
Mig C200i
Mains voltage 230 V, 1 50/60 Hz
Permissible load at
25 % duty cycle
60 % duty cycle
100 % duty cycle
Setting range 30 A - 200 A
Open circuit voltage 60 V
Open circuit power 15 W
Efficiency at maximum current 82%
Power factor at maximum current 0.99
Wire feed speed 6.6 - 39.4”/min
Wire diameter
Fe
Cored wire
Ss
Al
180 A
120 A
100 A
.024 - .040”
.030 - .040”
.030 - .040”
.40”
Max. diameter wire bobbin 7.9”
Continual sound pressure at no-load < 70 dB
Dimensions lxwxh 17.7 x 7.8 x 13.7”
Weight 26.5 lbs
Operating temperature 14 - 104° F
Transportation temperature -4 - 131°F
Enclosure class IP 23C
Application classification
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld at a cer
tain load without overloading. The duty cycle is valid for 104° F.
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid
objects or water. Equipment marked IP23C is designed for indoor and outdoor use.
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.
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4 INSTALLATION
The installation must be done by a professional.
Mains supply requirements
High power equipment may, due to the primary current drawn from the mains supply, influence the
power quality of the grid. Therefore connection restrictions or requirements regarding the
maximum permissible mains impedance or the required minimum supply capacity at the interface
point to the public grid may apply for some types of equipment (see technical data). In this case it
is the responsibility of the installer or user of the equipment to ensure, by consultation with the
distrubution network operator if necessary, that the equipment may be connected.
4.1 Lifting instruction
The power source is lifted by the handle or by the shoulder strap, supplied with the
power source. The strap is fastened as shown in the picture below.
4.2 Location
Position the welding power source such a way that its cooling air inlets and outlets
are not obstructed.
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4.3 Mains power supply
Check that the unit is connected to the correct mains power supply voltage, and that
it is protected by the correct fuse size. A protective earth connection must be made,
in accordance with regulations.
Rating plate with supply connection data
Recommended fuse sizes and minimum cable area
Mig C200i
Mains voltage 230 V 15% 150/60 Hz
Mains cable area 3G.060”
Phase current, I
Fuse anti-surge 16 A
eff
10 A
2
NOTE! The mains cable areas and fuse sizes as shown above are in accordance with Swedish
regulations. Use the power source in accordance with the relevant national regulations.
Extension cable
If needed, it is recommended to use an extension cable, 3G0.1”2 of maximum length
164ft.
Supply from power generators
The power source can be supplied from different types of generators. However,
some generators may not provide sufficient power for welding. The generators with
AVR, equivalent or better type of regulation with rated power 5.5...6.5 kW are
recommended to supply the power source within it's full capacity.
It is also possible to use generators with lower rated power, starting from 3.0kW, but
in that case the setting must be proportionally limited. The power source is protected
against undervoltage. If the power supplied by the generator is not sufficient, the
welding is interrupted. Especially the welding start could be disturbed. In case of
disturbed welding process, either adjust the welding parameters or change to a more
powerful generator.
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5 OPERATION
General safety regulations for the handling of the equipment can be found on
page 4. Read through before you start using the equipment!
When moving the equipment use intended handle. Never pull on the gun.
ROTATING PARTS CAN CAUSE INJURY, TAKE GREAT CARE.
ASSURE THAT THE SIDE PANELS ARE CLOSED DURING OPERATION.
RISK OF CRUSHING WHEN REPLACING THE WIRE BOBBIN!
DO NOT USE SAFETY GLOVES WHEN INSERTING THE WELDING WIRE
BETWEEN THE FEED ROLLERS..
LOCK THE BOBBIN IN ORDER TO PREVENT IT
FROM SLIDING OFF THE HUB.
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5.1 Connection and control devices
1 Mains supply switch 4 Return cable
2 Display 5 Mains cable
3 Welding gun 6 Gas connection
2
1
6
5
3
4
5.2 Operation
The power source is not powered instantly when the mains switch (1) is turned on.
After approximately 2 seconds the display (2) indicates that the power source is
ready.
If the welding gun trigger is pressed while the power source is being turned on, the
operation is disabled, until the trigger is released.
The return cable (4) must be reliably connected to the workpiece or to the welding
table.
The side panel covering the wire feeder must be closed prior to the welding.
The power source is instantly switched off by means of the mains switch (1).
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5.2.1 Manual mode
A - Welding voltage
B - Welding current
C - Wire feed speed
F - Voltage setting knob
G - Manual/QSet mode button
H - Inductance setting button
I - Wire feed speed setting
knob
The operator must set appropriate values for the wire feed speed and welding
voltage.
5.2.2 QSet mode
A - Welding voltage
B - Welding current
A
E
F
C - Wire feed speed
D - Plate thickness
B
E - QSet value
C
D
F - QSet value setting knob
G - Manuel/QSet mode button
H - Material selection/
I
GH
Inductance setting button
I - Plate thickness setting knob
In QSet mode the appropriate welding voltage is automatically set by the power
source. QSet monitors the welding arc and continuously adjusts the voltage to
maintain the optimal setting.
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Calibration
The first time you use QSet mode, and when you change welding wire, material or
shielding gas, you need to allow QSet to calibrate. This is done by making a test
weld (min. 6 seconds). Simply start welding and let QSet find the correct parameter
settings.
Material selection
Since different materials have different heat dispersion, it is necessary to select the
right material group (H) so that a correct plate thickness value can be calculated.
Settings for cored wire is done only in manual mode.
Plate thickness setting
Set the plate thickness of the object you want to weld using the plate thickness
setting knob (I). This knob sets the wire feed speed (C). A suitable voltage setting is
automatically calculated by QSet. The recommended plate thickness for the set wire
feed speed is displayed simultaneously (D). The plate thickness recommendation is
calculated for a fillet weld using the following wire dimensions: Fe/Ss and CuSi -
.030”, Al - .40”. If you use a smaller diameter wire you should set a slightly higher
value for plate thickness than what you are going to weld. If you use a larger
diameter wire set a slightly lower value.
Heat input adjustment
The heat input can be adjusted with the QSet knob (F) in steps from -9 to +9 to make
the weld hotter or colder. A higher value gives a hotter, more concave, weld (longer
arc length) for more penetration. A lower value gives a colder, more convex, weld
(shorter arc length) to prevent burning through the workpiece. Typically the QSet
value should be set to 0 which gives you an average heat input that is suitable in
most cases. The heat input setting is symbolised with a thermometer indicating
hotter or colder settings.
5.2.3 Unit of measurement
The setting of the unit of measurement is a hidden fuction. The default value for the
power source is mm. This can be changed to inch by pressing the pushbuttons G
and H and holding them pressed in 5 sec. With the help of the knob (I) the required
unit of measurement is selected.
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5.3 Error codes
If an error occurs, only the error code will be visible.
Error No. Description Action
1 Program related error
2 Hardware related error
3 Hardware related error
5 Program related error
4 Thermal protection Do not switch the power source OFF, let it to cool down.
Switch the machine OFF, wait 30 sec. and switch it ON.
Call for service if the error
remains.
5.4 Inductance settings (Fe/SS)
In certain cases especially for mild steel welding in different gases the quality of
welding may be improved by changing the inductance settings of the power source.
The inductance function is normally hidden, but can be invoked by the pressing and
keeping pressed the pushbutton (H) for 5s or more. When this setting is available,
all graphics from the right side of the display disappears, and only number from 00 to
10 is displayed. This number corresponds to the inductance value. 00 means that
the inductance is low and the welding arc is ”sharp”, 10 means that the inductance is
high and the welding arc is ”soft”.
The value of the inductance can be set by means of the knob (I). Default setting is
05.
Recommendations:
S When the CO2 is used it is recommended to set lower inductance then 05, for
instance from 03 down to 00.
S When the Ar/CO2 mixture is used, the operator should set higher inductance
from 05 up to 10.
The display goes back to the regular appearance 10s after the last movement of the
knob (I) or pressing pushbutton (H). The return to the regular mode can accelerate
by again pressing and keeping the pushbutton (H) pressed for 5s.
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5.5 Polarity change
+/- TERMINALS
The power source is delivered with the welding wire connected to the plus pole.
Some wires, e.g. shelfshielded cored wires, are recommended to be welded with
negative polarity. Negative polarity means that the wire is connected to the minus
pole and the return cable to the plus pole. Check the recommended polarity for the
welding wire you want to use.
The polarity can be changed as follows:
1. Switch off the power source and disconnect the mains cable.
2. Open the side panel.
3. Bend the rubber covers back to give access to the +/- terminals.
4. Remove the nuts and washers. Note the correct order of the washers.
5. Change the position of the cables to the desired polarity (see marking).
6. Install the washers in correct order and tighten the nuts to spanner tightness.
7. Make sure the rubber covers are covering the +/- terminals.
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5.6 Wire feed pressure
Start by making sure that the wire moves smoothly through the wire guide. Then
set the pressure of the wire feeder's pressure rollers. It is important that the
pressure is not too great.
Fig 1 Fig 2
To check that the feed pressure is set correctly, you can feed out the wire against
an insolated object, e.g. a piece of wood.
When you hold the gun approx. 0.2” (5 mm) from the piece of wood (fig. 1) the
feed rollers should slip.
If you hold the gun approx. 2” (50 mm) from the piece of wood, the wire should be
fed out and bend (fig. 2).
5.7 Replacing and inserting wire
1. Open the side panel.
2. Place the spool on the hub and secure it with the lock.
3. Disconnect the pressure arm by folding it sidewards, the pressure roller slides
away.
4. Straighten out the new wire 3.9 - 7.9”. File away burrs and sharp edges from the
end of the wire before inserting it into the wire feeder.
5. Make sure that the wire goes properly into the feed roller groove and into the
outlet nozzle and the wire liner.
6. Secure the pressure arm.
7. Close the side panel.
Feed the wire through the welding gun until it comes out through the nozzle. This
operation should be carried out carefully, as the wire is ready for welding and an
unintentional arc may occur. Keep the gun off conducting parts during feeding the
wire through and terminate wire feeding instantly when the wire comes out.
See Technical Data, chapter 3, for suitable wire dimensions for each wire type.
Use only 7.9” spools. Note! j3.9”/2.2lbs spools are not applicable.
WARNING!
Do not keep the torch near the ears or the face during wire feeding, as this
may result in personal injury.
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NOTE.
Remember to use the correct contact tip in the welding gun for the wire diameter
used. The torch is fitted with a contact tip for .030” wire. If you use another
diameter you must change the contact tip. The wire liner fitted in the gun is
recommended for welding with Fe and Ss wires. Change the liner to the PTFE type
for welding Al or Brazing (CuSi). See 6.2 regarding how to change the wire liner.
5.7.1 Changing the feed roller groove
The power source is delivered with the feed roller set for .030”/.040” welding wire.
If you want to use it for .024” wire you must change the groove in the feed roller.
1. Fold back the pressure arm to release the pressure roller.
2. Switch on the power source and press the gun trigger to position the feed roller
so that the locking screw is visible.
3. Switch off the power source.
4. Use a 2mm Allen key to open the locking screw about half a turn.
5. Pull the feed roller off the shaft and turn it around. See marking on the side of the
feed roller for suitable wire diameters.
6. Put the roller back on the shaft and make sure it goes all the way in. You may
need to turn the roller to position the locking screw over the flat surface of the
shaft.
7. Tighten the locking screw.
5.8 Shielding gas
The choice of suitable shielding gas depends on the material. Typically mild steel is
welded with mixed gas (Ar + CO2) or carbon dioxide. Stainless steel can be welded
with mixed gas (Ar + CO2 or Ar + O2) and Aluminium with pure argon. MIG/MAG
brazing (CuSi) uses pure argon or mixed gas (Ar + O2). Check the recommended
gas for the welding wire you want to use. In the QSett mode (see chapter 5.2.2)
the optimal welding arc with the gas you use will be automatically set.
5.9 Overheating protection
Overheating is indicated on the display (2) with error code E4. A thermal overload fuse
protects the unit against overheating by disabling the welding if overheating occurs. The
fuse resets automatically when the unit has cooled down.
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