Magnum WAVE 200KD User Manual
WE3107 v.110413
SAVE THIS MANUAL
You will need this manual for safety instructions, operating procedures, and warranty.
Put it and the original sales invoice in a safe, dry place for future reference.
CONSERVEZ CE GUIDE
Vous aurez besoin de ce guide pour les instructions de sécurité, les procédures d’utilisation et la garantie.
Conservez-le dans un endroit sûr et sec pour référence future.
QUESTIONS? 1-800-567-8979
Model
:
Our Customer Service staff are ready to provide assistance.
If a part is damaged or missing, replacement parts can be
shipped from our facility.
For help with assembly, or for additional product
information, call our North American toll-free number:
1-800-567-8979
Notre personnel de service à la clientèle sera prêt à
fournir assistance. Si une pièce est endommagée ou
manquante, des remplacements seront expédiés de notre
usine.
Pour de l’aide avec l’assemblage, ou pour des
informations additionnelles sur le produit, appeller notre
numéro sans frais nord-américain : 1-800-567-8979
WAVE 200KD
AC/DC Pulse TIG/ARC Welder
2
CATALOGUE
GENERAL SAFETY RULES
TECHNICAL SPECIFICATION
KNOW YOUR WELDER
INSTALLAT
ION
OPERATION
TROUB
LESHOOTING
DIAGRAM & PARTS LIST
WARRANTY
3
GENERAL SAFETY RULES
WARNING: Read and understand all instructions. Failure to follow all instructions listed below
may result in serious injury.
CAUTION: Do not allow persons to operate or assemble this WAVE 200KD until they have
read this manual and have developed a thorough understanding of how the WAVE 200KD works.
WARNING: The warnings, cautions, and instructions discussed in this instruction manual
cannot cover all possible conditions or situations that could occur. It must be understood by the
operator that common sense and caution are factors which cannot be built into this product, but must
be supplied by the operator.
1.1 Your Welding Environment
-Keep the environment you will be welding in free from flammable materials.
-Always keep a fire extinguisher accessible to your welding environment.
-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.
-Mount the welder on a secure bench
or cart that will keep the welder secure and prevent it from tipping over or falling.
1.2 Your Welder’s Condition
-Check ground cable, power cord and welding cable to be sure the insulation is not damaged. Always
replace or repair damaged components before using the welder.
-Check all components to ensure they are clean and in good operating condition before use.
1.3 Use of Your Welder
Do not operate the welder if the output cable, electrode, torch, wire or wire feed system is wet. Do not
immerse them in water. These components and the welder must be completely dry before attempting to
use them.
-Follow the instructions in this manual.
-Keep welder in the off position when not in use.
-Connect ground lead as close to the area being welded as possible to ensure a good ground.
-Do not allow any body part to come in contact with the welding wire if you are in contact with the
material being welded, ground or electrode from another welder.
-Do not weld if you are in an awkward position. Always have a secure stance while welding to prevent
accidents. Wear a safety harness if working above ground.
4
-Do not drape cables over or around your body.
-Wear a full coverage helmet with appropriate shade (see ANSI Z87.1 safety standard) and safety
glasses while welding.
-Wear proper gloves and protective clothing to prevent your skin from being exposed to hot metals, UV
and IR rays.
-Do not overuse or overheat your welder. Allow proper cooling time between duty cycles.
-Keep hands and fingers away from moving parts and stay away from the drive rolls.
-Do not point torch at any body part of yourself or anyone else.
-Always use this welder in the rated duty cycle to prevent excessive heat and failure.
1.4 Specific Areas of Danger, Caution or 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.
- Do not attempt to repair or maintain the welder while the power is on.
-Inspect all cables and cords for any exposed wire and replace immediately if found.
-Use only recommended replacement cables and cords.
-Always attach ground clamp to the work piece or work table as close to the weld area as possible.
-Do not touch the welding wire and the ground or grounded work piece at the same time.
-Do not use a welder to thaw frozen pipes.
Fumes and Gases
-Fumes emitted from the welding process displace clean air and can result in injury or death.
-Do not breathe in fumes emitted by the welding process. Make sure your breathing air is clean and
safe.
-Work only in a well-ventilated area or use a ventilation device to remove welding fumes from the
environment where you will be working.
-Do not weld on coated materials (galvanized, cadmium plated or containing zinc, mercury or barium).
They will emit harmful fumes that are dangerous to breathe. If necessary use a ventilator, respirator
with air supply or remove the coating from the material in the weld area.
-The fumes emitted from some metals when heated are extremely toxic. Refer to the material safety
data sheet for the manufacturer’s instructions.
-Do not weld near materials that will emit toxic fumes when heated. Vapors from cleaners, sprays and
degreasers can be highly toxic when heated.
UV and IR Arc Rays
The welding arc produces ultraviolet (UV) and infrared (IR) rays that can cause injury to
your 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
5
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. Flame-retardant cloth
or leather shirts, coats, pants or coveralls are available for protection.
-Use screens or other barriers to protect other people from the arc rays emitted from your welding.
-Warn people in your welding area when you are going to strike an arc so they can protect themselves.
Fire Hazards
Do not weld on containers or pipes that contain or have had flammable, gaseous or liquid
combustibles in them. Welding creates sparks and heat that can ignite flammable and
explosive materials.
-Do not operate any electric arc welder in areas where flammable or explosive materials are present.
-Remove all flammable materials within 35 feet of the welding arc. If removal is not possible, tightly
cover them with fireproof covers.
-Take precautions to ensure that flying sparks do not cause fires or explosions in hidden areas, cracks
or areas you cannot see.
-Keep a fire extinguisher close in the case of fire.
-Wear garments that are oil-free with no pockets or cuffs that will collect sparks.
-Do not have on your person any items that are combustible, such as lighters or matches.
-Keep work lead connected as close to the weld area as possible to prevent any unknown, unintended
paths of electrical current from causing electrical shock and fire hazards.
-To prevent any unintended arcs, cut wire back to ¼" stick out after welding.
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 MIG gun nozzle after welding until it has had time to cool down.
Sparks/Flying Debris
Welding creates hot sparks that can cause injury. Chipping slag off welds creates flying
debris.
-Wear protective apparel at all times: ANSI-approved safety glasses or shield, welder’s hat and ear
plugs to keep sparks out of ears and hair.
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 MIG gun and ground cable together whenever possible.
-Keep MIG gun and ground cables on the same side of your body.
6
Shielding Gas Cylinders Can Explode
High pressure cylinders can explode if damaged, so treat them carefully.
-Never expose cylinders to high heat, sparks, open flames, mechanical shocks or arcs.
-Do not touch cylinder with MIG gun.
-Do not weld on the cylinder
-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 protective cylinder cap whenever possible
1.5 Proper Care, Maintenance and Repair
-Always have power disconnected when working on internal components.
- Do not touch or handle PC board without being properly grounded with a wrist strap. Put PC board in
static proof bag to move or ship.
-Do not put hands or fingers near moving parts such as drive rolls of fan
WAVE 200KD USE AND CARE
• Do not modify the WAVE 200KD in any way. Unauthorized modification may impair the function
and/or safety and could affect the life of the equipment. There are specific applications for which the
WAVE 200KD was designed.
• Always check of damaged or worn out parts before using the WAVE 200KD. Broken parts will
affect the WAVE 200KD operation. Replace or repair damaged or worn parts immediately.
• Store idle WAVE 200KD. When WAVE 200KD is not in use, store it in a secure place out of the
reach of children. Inspect it for good working condition prior to storage and before re-use.
Notice: * If the welder continues to work too long time, the 【Protection Indicator】on the panel
would be on, indicating that the inner temperature rise inside the welder had exceed the
designed permitted temperature. At this time, stop the welding work, wait until the welder cooled inside
and the 【Protection Indicator】 turned off, then continue to work again;
* Cut off the power switch and Argon valve, before leaving the welding place temporarily or after the
welding worked finished;
* Welders should wear canvas work clothes and welding face shield to prevent arc light and heat
radiation;
* Put light-proof screen around the work area to prevent others influenced by the arc lights.
* Flammable, explosive items could not be put near the welding area;
* Every outlet of the welder should be connected and earthed correctly.
Notice: The cover protection degree of the WAVE series Square Wave AC/DC pulsed inverter
TIG welder is IP21S.When the welder is operated, do not insert finger or round stick diameter less than
12.5mm (especially metal stick) into the welder; Do not allow to press heavily onto the welder.
7
TECHNICAL SPECIFICATION
TERM UNIT WAVE 200KD
Rated Input Voltage V 220
Power Frequency Hz 50/60
Rated Input Capacity KVA 7.9
Rated Input Current A 36
Output No Load Voltage V 65
Rated Working Voltage V 18
DC Argon Welding Current A 5～200
AC Argon Welding Current A 10～200
Stick Welding Current A 5～170
Current Up Time S 0～ 15
Current Drop Time S 0～ 25
Pulse Frequency Hz 0.5～ 250
Pulse Width Adjustment
(DC)
%
15～ 85
Clear Area Control（ AC） % 15～ 65
Gas Stop Delay Time S 0～30
Rated Duty Cycle % 35
Cooling Type Air cooling
Effiency η ≥ 85%
Power Factor Cosφ 0.92
Insulation Degree H
Cover Protection Degree IP IP21S
Weight kg 19.5
Dimension L×W×H mm 500*240*410
No special advice on above parameter. The nameplate parameter on the welder is prior.
8
Welding regulations parameter table (only for reference)
Mode
Material
Typ e
Designe
d Joint
WORK
Thicknes
s
(mm)
Wire
Dia
Φ
(mm)
Welding
Current
(A)
Polarity
Argon
Flow
(dm
3
/mi
n)
Tun gst e
n Stick
Dia Φ
(mm)
Angle
Top Dia
Φ
(mm)
Vertical
Joint
1.6~3.0 50~90 1.0 12~20° 0.12~0.25
V groove
＞3.0~6.0
1.6~2.5
70~120
8~12
1.6 25~30° 0.50~0.75
DC
Stainless
Steel
X groove
＞6.0~12
2.5~3.2 100~150
DC
Positive
10~14 2.4 35~45° 0.75~1.10
Vertical
Joint
1~2.5 1.6~2.5 45~90 2~6 2~3
V groove 3~6 2~4 90~180 10~12 3~4
AC
Pure
Aluminium,
Alu-Mag
Alloy
X groove 8~12 4~5 150~220
Positive
12~16 4~5
90° 1.50
KNOW YOUR WELDER
Description
WAVE200KD is a digitization model can be used for MMA、ACTIG 、DCTIG and PULSE TIG, the
parameters can be preset and showed, welding current and voltage can real-time display, this is very
easy operation.
1. Front panel
1. 1. Know the Front panel
1.2. Current display
To show the preset current when setting and the welding current when working.
Voltage disply
Status indicator
Procedure parameter
2T/4T switch
Gas check knob
Parameter positive
knob
AC/DC transfer knob
Pulse switch
Current display
Parameter knob
Adjustment knob
Welding mode knob
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