www.r-techwelding.co.uk
I-MIG200 MIG/MMA WELDER
OPERATION INSTRUCTIONS
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Thank you for selecting the R-Tech I-MIG 200 Compact Inverter Mig Welder.
The I-Mig200 has many benefits over traditional transformer mig welders, including infinite
power control, adjustable arc force and features a heavy duty 4-roll geared wire feed
mechanism to provide very smooth wire feed and weld characteristics
Provides very smooth welds on all steels and aluminium due to its inverter technology, for
alloy welding just simply fit alloy rollers and a Teflon liner to torch
Ideal for automotive work with its minimum current of 30 Amps.
We want you to take pride in operating our I-MIG200 as much pride as we have taken in making
this product for you. Please read all information in this manual before operation
PLEASE EXAMINE THE CARTON AND EQUIPMENT FOR DAMAGE IMMEDIATELY
When this equipment is shipped, title passes to the purchaser upon receipt from the courier.
Consequently all claims for material damaged in shipment must be made by purchaser against
the transportation company used.
Please record your equipment identification below for future reference. This information can be
found on the data plate at rear of machine.
Product: I-MIG200
Serial No. ___________________________________
Date of Purchase _____________________________
Where Purchased _____________________________
Whenever you request replacement parts or information on this equipment please always
supply information you have recorded above.
This product is covered by a 2 year parts and labour warranty; we will cover the cost of collecting and
returning the item to you. External items, (torch, earth lead etc…) are covered by a 3 month warranty. Any
faults/damage found caused by a customer will be charged accordingly.
Pay particular attention to the safety instructions we have provided you for your protection
The level of seriousness to be applied to each section is explained below
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury.
CAUTION
This statement appears where the information must be following to avoid a minor personal injury or damage
to this equipment.
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Introduction
The R-Tech I-MIG 200 is a member of our field acclaimed family of welding products.
Premium features include:-
1. Inverter power source – more efficient to operate, provides smoother weld characteristics.
2. Heavy duty 4-Roll geared wire feed unit for long working life and consistent wire feeding.
3. Infinite welding voltage to allow fine tuning of weld characteristics
4. Adjustable arc force – controls splatter – ideal for thin materials
5. Adjustable burnback control
6. Spot welding & stitch welding facilities
7. Digital amp & volts meters
8. Euro type torch fittings for easy torch fitment/replacement
9. 35% Duty cycle at 200 Amps @ 40
Recommended Processes
The R-Tech I-MIG 200 is recommended for the MIG welding processes within its output capacity of
200 Amps DC
Equipment Limitations
The R-Tech I-MIG 200 is protected from overloads beyond the output ratings and duty cycle as per
machine specifications with thermostat protection of the output coils and rectifiers.
Welding Capability – Duty Cycle
The R-Tech I-M IG 200 is rated at 200 Amps at 35% duty cycle on a ten minute basis. If the duty cycle
is exceeded a thermal protector will shut machine off until the machine cools.
ºC
Technical Specifications
Model No. R-Tech I-MIG 200
Input 240V 1~ AC 50/60Hz
MIG Operation
Rated Input Current I-Eff 19 AMPS
Rated Output Current 200 AMPS
Duty Cycle @ 200 AMPS
Duty Cycle @ 155 AMPS
Output current Range 30-200 AMPS
No Load Voltage 55-75V MAX
Voltage Adjustment Range 14V – 26V +/- 3V
Suitable Wire Diameter - Steel 0.6mm, 0.8mm, 1.0mm
Suitable Wire Diameter - Alloy 0.8mm, 1.0mm, 1.2mm
Insulation Class F
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35% @ 40
60% @ 40
ºC
ºC
Safety Precautions
Read entire section before starting installation
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WARNING!
Electric Shock can kill – Only qualified personnel should perform this installation. Turn off input power
at the fuse box before working on this equipment. Do not touch electrically live parts. Always connect
the machine to an earthed mains supply as per national recommended standards.
Select suitable location
Place the welder where clean cooling air can freely circulate in and out of the front & rear louver vents.
Dirt, dust or any foreign material that can be drawn through vents into welder must be kept to a
minimum. Failure to observe these precautions can result in excessive operating temperatures which
can lead to plant failure.
Grinding
Do not direct grinding particles towards the welder. An abundance of conductive material can cause
plant failure.
Stacking
This machine cannot be stacked.
Transport – Unloading
Never underestimate the weight of equipment, never move or leave suspended in the air above
people. Use recommended lifting equipment at all times.
WARNING!
Falling Equipment can cause injury. Never lift welder with gas bottle attached. Never lift above
personnel.
Tilting
Machine must be placed on a secure level surface or on a recommended undercarriage/trolley. This
machine may topple over if this procedure is not followed.
Environmental Rating
The welding power source carries the IP21S rating. It may be used in normal industrial and
commercial environments. Avoid using in areas where water / rain is around.
Read and follow the ‘Electric Shock Warnings’ in the safety section if welding must be performed
under electrically hazardous conditions such as welding in wet areas or water on the work piece.
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Electrical Installation
WARNING!
ELECTRIC SHOCK CAN KILL
Machine grounding and High Frequency Interference Protection
This welder must be grounded to earth. See national electrical codes fro proper grounding methods.
The high frequency generator being similar to a radio transmitter may cause interference to radio, TV
and other electronic equipment. These problems may be the result of radiated interference. Proper
grounding methods can reduce or eliminate this.
Radiated interference can develop in the following ways
1. Direct interference from welder power source
2. Direct interference from the welding leads
3. Direct interference radiated from feedback into power lines
4. Interference from re-radiation by un-grounded metallic objects.
Keeping these contributing factors in mind, installing equipment as per following instructions should
minimize problems.
1. Keep the welder input power lines as short as possible and enclose as much of them as
possible in metal conduit or equivalent shielding. There should be a good electrical contact
between this conduit and ground (Earth).
2. Keep the work and electrode leads as short as possible. Tape the leads together where
practical.
3. Be sure the torch and earth leads rubber coverings are free from cuts and cracks that allow
welding power leakage
4. Keep earth lead connection to work in good condition – Clean area on workbench where earth
clamp is situated on a regular basis.
Input Connections
Make sure the voltage, phase and frequency of input power is as specified on machine rating plate
located at rea r of ma c hi n e.
Have a qualified electrician provide suitable input power as per national electrical codes. Make sure
machine is earthed / grounded.
Make sure fuse or circuit breaker is correct rating for machine. Using fuses or circuit breakers smaller
than recommended will result in ‘nuisance’ shut off from welder inrush currents even if welding at low
amperages.
Failure to follow these instructions can cause immediate failure within the welder and void machines
warranty.
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Turn the input power OFF at the mains switch & fuse box before working on this equipment.
Have a qualified electrician install & service this equipment.
Allow machine to sit for 5 minutes minimum to allow the power capacitors to discharge before working
inside this equipment. Do not touch electrically live parts
The I-MIG 200 Mig Welder requires a 240V 50/60Hz 1-Phase supply. It requires an 19A supply. It
comes with a 3 metre mains cable attached.
Connect wires according to national coding.
Brown wire – Live
Blue wire – Neutral
Green/Yellow Wire – Earth (Ground)
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Connecting to a mains electrical supply
THIS MACHINE IS OF AN INDUSTRIAL SPECIFICATION AND MUST BE FITTED
TO A 20AMP 240V MAINS INPUT
Failure to connect to correct supply will in-validate your warranty
DO NOT CONNECT TO A 13AMP DOMESTIC PLUG
Connecting to an Engine Driven Generator
If connecting this machine to an engine driven generator please ensure the
following
Minimum Generator KVA Output – 7 KVA continuous
Generator to be fitted with AVR (automatic voltage regulation)
DO NOT USE ON A GENERATOR WITHOUT AVR
Connecting to a generator without the above minimum requirements will in-
validate your warranty.
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Connections for I-Mig 200
Rear machine connections
1. Fuse Holder
Fuse for wire feed motor protection
2. Auxiliary AC output
For water cooler – Maximum load 3A – Do not connect to power tools etc
3. Gas inlet connection
Connect gas hose to rear of machine and then to regulator on gas bottle. Ensure all
connections are tight to ensure no loss of gas.
Make sure gas bottle is secured to machine securely using supplied chain to avoid injury.
4. Mains input cable
Fit required plug as per your electrical installation
Fig 1
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Front machine connections
1. Euro torch connector
Connect Euro type Mig torch to euro torch connector, align torch connector to machine
connector and then turn retaining ring clockwise to secure.
Ensure torch is secured tightly to avoid weld power problems
To avoid electric shock keep the Mig torch in good condition and replace if any of the
insulation is damaged.
2. Earth / Workpiece connector
Connect the earth lead (negative - ) to this connector.
Insert male connector into socket and twist clockwise until tight.
Secure other end of earth lead to Workpiece via the earth clamp.
Fig 2
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Controls and Settings
Fig3
1. Spot Welding
This adjusts the amount of time the weld will last. When you press the torch switch the
machine will do a single spot weld according to the time you have set and then stop, then
release torch switch. Press torch switch again to do another spot weld.
2. Arc Force
Gives further adjustment on weld characteristics, on traditional transformer machines this was
known as choke. Low setting is ideal for automotive work.
Lower setting = softer weld with less splatter and less penetration – for thinner materials
Higher setting = harsher weld with more splatter and penetration – for thicker materials
3. Welding Voltage
This adjusts the welding voltage (weld power) from 0 to 10. Adjust knob for power output
required by job, preset welding voltage is shown in LED (Fig 3.7)
4. Stitch Welding
This is used in combination with the spot welding control. This sets the interval time between
spot welds.
When you press the torch switch the machine will do a spot weld as set by the spot welding
control knob (Fig 3.1) and then a delay time set on stitch welding knob and then another spot
weld is carried out. To stop stitch welding release the torch trigger.
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5. On/Off Power Switch
This turns the I-Mig200 Mig Welder on and off.
6. Wire Speed
This adjusts the wire feed speed from 0-100%
Adjust the wire speed to suit welding voltage (Fig 3.1) and job requirements
When adjusting the wire feed speed a value is shown in the amperage LED (Fig 3.8)
This feature allows you to record this value along with the preset welding voltage for easy
setup to specific job when several different welding jobs are being done
7. Voltage LED Display
This shows the preset welding voltage when no welding is being carried out
When welding this shows the actual welding voltag e
This allows the machine to be calibrated to BS if required by your company
8. Amperage LED Display
This shows the preset wire feed speed when no welding is being carried out
When welding this shows the actual welding amperage
This allows the machine to be calibrated to BS if required by your company
9. Warning LED
This warning light will come on under these situations
Duty cycle of machine has been exceeded, the machine will stop working and the fan will
continue to run until machine has cooled down. The light will go off and welding ma y be
carried out again.
If duty cycle has not been exceeded the warning light comes on to warn of either
low input voltage has been sensed or there is an internal fault with machine
10. Power LED
This lights when machine is switched on
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Cont….
Side Panel
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Wire Spool Adjustment
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Fig 4
1. Wire reel retainer
This screws onto wire reel holder to secure wire reel roll
2. Wire reel tensioner nut
This adjusts the tension on wire feed reel which stops the reel from over running and causing
wire to come of reel (birds nest) when torch switch is released. Some times known as reel
brake.
This is set in factory, if adjustment is required do not over tighten as this can cause stress to
wire feed motor.
Fig 5
1. Wire Feed Drive Assy
Make sure rollers are correct size for wire diameter selected, to change rollers release
retaining knurled head screw fit rollers onto shafts making sure the right size groove is in
line with wire and refit retaining screws.
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2. Burnback control knob
This sets amount of time welding power stays on after torch button released and wire feed
has stopped. If too little Burnback is set, wire may stick to work after trigger released, if
too much Burnback is set wire will Burnback into welding tip.
3. Wire tensioners
Do not over tighten wire feed pressure rollers as this can cause premature motor and
roller failure.
Correct way to adjust tensioners is to slacken off pressure so that wire does not feed,
slowly adjust pressure until wire feeds smoothly, you should be able to stop wire feeding
by holding wire and it should slip on rollers.
If you have too little pressure wire will slip when welding causing unwanted Burnback into
tips
If you have too much pressure wire can snag in rollers when wire hits work and cause
wire tangle by rollers.
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Cont….
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Operating machine
SAFETY PRECAUTIONS
WARNING!
ELECTRIC SHOCK CAN KILL
Do not touch electrically live parts or electrode with skin or wet clothing.
Insulate yourself from work and ground
Always wear dry insulating gloves
WARNING!
FUMES AND GASES can be dangerous
Keep your head out of fumes & gases produced from welding.
Use ventilation or exhaust to remove fumes & gases from breathing zone and general area.
WARNING!
WELDING SPARKS can cause fire or explosion
Keep flammab le material away from wor k area.
Do not weld on containers that have held combustibles
WARNING!
ARC RAYS can burn
Wear eye, ear and body protection – Make sure work area is protected by proper shielding to
avoid injury to passers by.
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Operating Machine
1. Ensure machine has been setup as previously stated
2. Fit reel of wire to machine, ensuring correct size rollers are fitted. For steel only use wire
of 0.6mm, 0.8mm and 1.0mm, for aluminium only use wire of 0.8mm, 1.0mm, 1.2mm.
DO NOT USE 1.2MM STEEL WIRE AS THIS WILL OVERLOAD MACHINE AND VOID
WARRANTY
3. Feed wire into wire feed assy and into guide tube, clamp down top pressure feed rollers
and set tensioner pressure.
4. Press torch switch and wire will feed to torch head (adjust wire feed speed to approx 3) –
When wire has come through torch to welding tip release trigger.
5. Turn on gas and set fl ow rate to app rox 14 LPM
6. Set welding vo l t ag e a nd wire feed speed ac c or ding to thicknes s of job
7. Ensure you are wearing the correct safety clothes & equipment for welding (i.e welding
mask, glov es, apron etc)
8. Select welding voltage (power) required on front panel
9. Select wire feed speed required on ‘wire speed’ knob
10. Set ARC force switch to middle position for medium weld inductance (know as choke on
traditional welding power sources)
Low setting = Soft ARC (less splatter & penetration)
High setting = Strong ARC (more penetration)
11. Press torch trigger to start welding process.
Note: You can finely adjust the welding current knob to fine tune weld arc length to either
DIP or SPRAY welding
When welding actual voltage and amperage will be shown in corresponding LED display
meters on machine
Tips on welding aluminium
When welding aluminium as the wire is much softer than steel wire you have to fit a teflon
liner in place of the steel liner in mig torch, this is so the wire feeds much smoother and
stops it snarling at rollers.
To fit a teflon liner, remove steel liner from torch and fit teflon liner so you have about 10
inches left coming out en d of mig torch at the machin e end. In the b rass euro body where
torch fits onto you will see a brass guide tube, remove this tube and fit torch to machine
and cut off excess teflon liner as required. You want the teflon liner to get as close to the
wire feed rollers as possible. Best way to cut liner is with a sharp stanley knife blade.
Next you will need to fit U-Groove rollers made specifically for alloy wire to the feed unit.
These are available from R-Tech. Remove the steel rollers (V-Groove) from the machine
and fit U-Groove rollers ensuring correct size groove is in line with the welding wire
guides. For Aluminium you can use up to 1.2mm wire.
Adjust the wire tensioner to minimum pressure and tighten down until wire is gripped, too
much pressure will deform wire and end up with snarls by rollers.
Fit oversize welding tip. These are available and have and ‘A’ after tip size. I.E 1.0A where
as for steel wire it would just say 1.0
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Maintenance
Routine and periodic maintenance
WARNING!
ELECTRIC SHOCK CAN KILL
Turn the input power OFF at the mains switch & fuse box and remove mains plug from socket before
working on thi s eq ui p m e nt.
Have a qualified electrician install & service this equipment.
Allow machine to sit for 5 minutes minimum after disconnection from mains power to allow the power
capacitors to discharge before working inside this equipment.
Do not touch electrically live parts
1. Periodically (3-6 months depending on use / environment), remove the side/top panels of
machine and clean out machine with a low pressure dry air line paying particular attention to
PC Boards, Fan blades and switchgear
Failure to maintain plant can void manufacturers warranty.
2. Inspect input and output cables & hoses for fraying and cuts, replace if damaged present
3. Keep mig torch and earth cables in good condition
4. Clean air vents to ensure proper air flow and cooling
5. The fan motor has sealed bearings which requires no maintenance
Troubleshooting
Service & repair should only be performed by R-Tech welding trained personnel. Unauthorised repairs
performed on this equipment may result in danger or injury to the technician and machine operator
and will invalidate your warranty.
For your safety and to avoid electric shock, please observe all safety notes and precautions detailed
throughout this manual
The troubleshooting guide is provided to help you locate possible machine malfunctions
If fault / problem is not listed below check our Mig Welder Support
www.r-techwelding.co.uk/support.php
or contact R-Tech by phone. Contact details can be found on our website
page on our website
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Output Problems
• No output - Power light is not lit
Check machine on/off switch is in the ‘on’ position
Check Input power to machine
Check plug wiring
Check mains trip / fuses
• No output - Fan runs - Power light is lit
Check torch connections are secure and torch switch operation, try replacing mig torch.
• No output - Power light is lit - Warning light shows RED colour
Welding application may have exceeded recommended duty cycle, allow machine to cool
down until the warning light goes out.
• No output – Power light is lit – Warning light shows GREEN colour
Output overload problem – Output diodes or IGBT faulty – Contact R-Tech
• No output – Power light is lit – Gas at torch tip – No wire feed
Check wire feed unit protecting fuse on rear of machine, if blown
replace with new fuse of same rating, If fuse flows again contact R-Tech
• Machine keeps overheating - Warning light is lit RED on machine
Check if fan is running – if not contact R-Tech for repair
Check the cooling vents for obstruction, blow out machine with clean dry low pressure air
supply.
Check for adequate ventilation around machine
• Porosity in weld – No / low gas at torch tip
Check gas supply from gas bottle & check flow rate on regulator
Check gas hose for restrictions
Check for draughts in local area, open doors etc
Replace mig torch – may have gas restriction
• Poor weld penetration
Check condition of earth lead and clamp and ensure clamp is connection via a clean area on
work piece
Check condition of mig torch, try other mig torch
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Wiring Diagram
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