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SERVICE
MANUAL
MIG (GMAW)
Flux cored (FCAW)
Stick (SMAW)
TIG (GTAW)
Symbole graphique
d’avertissement ! Attention ! Cette This group of symbols means Warning!
procedure comporte des risques Watch Out possible ELECTRIC SHOCK,
possibles ! Les dangers éventuels MOVING PARTS, and HOT PARTS hazards.
sont représentés par les symboles Consult symbols and related instructions
graphiques joints. below for necessary actions to avoid the
hazards
Marks a special safety message.
Ce groupe de symboles signifie
Indique un message de sécurité particulier
Avertissement! Attention! Risques
d’ÉLECTROCUTION, ORGANES MOBILES
Means “Note”; not safety related. et PARTIES CHAUDES. Consulter les
Signifie NOTE ; n’est pas relatif à la symboles et les instructions afferents
sécurité. ci-dessous concernant les mesures à
prendre pour supprimer les dangers.
1-2. Arc welding Hazards Dangers relatifs au soudage à l’arc
The symbols shown below are used y Do not touch live electrical parts.
throughout this manual to call attention y Wear dry, hole-free insulating gloves and
to and identify possible hazards. When body protection.
you see the symbol, watch out, and y Insulate yourself from work and ground
follow the related instructions to avoid using dry insulating mats or covers big
the hazard. enough to prevent any physical contact with
the work or ground.
Only qualified persons should service,
test, maintain, and re- pair this unit. y Do not use AC output in damp areas, if
movement is confined, or if there is a
During servicing, keep everybody, danger of falling.
especially children, away
y Use AC output ONLY if required for the
Les symboles représentés ci-dessous welding process.
sont utilisés dans ce manuelpour attirer
y If AC output is required, use remote output
l’attention et identifier les dangers
control if present on unit.
possibles. Enprésence de l’un de ces
symboles, prendre garde et suivre y Additional safety precautions are required
lesinstructions afférentes pour éviter when any of the following electrically
tout risque. Les instructions enmatière hazardous conditions are present: in damp
de sécurité indiquées ci-dessous ne locations or while wearing wet clothing; on
constituent qu’un sommaire des metal structures such as floors, gratings, or
instructions de sécurité plus complètes scaffolds; when in cramped positions such
fournies dans les normes de sécurité as sitting, kneeling, or lying; or when there
énumérées dans la Section 2-5. Lire et is a high risk of unavoidable or accidental
observer toutes les normes de sécurité. contact with the workpiece or ground. For
these conditions, use the following
Seul un personnel qualifié est autorisé à
equipment in order presented: 1) a
installer, faire fonctionner, entretenir et
semiautomatic DC constant voltage (wire)
réparer cet appareil.
welder, 2) a DC manual (stick) welder, or 3)
Pendant le fonctionnement, maintenir à an AC welder with reduced open-circuit
distance toutes les personnes, voltage. In most situations, use of a DC,
notamment les enfants de l’appareil. constant voltage wire welder is
recommended. And, do not work alone!
ELECTRIC SHOCK can y Disconnect input power or stop engine
before installing or servicing this equipment.
kill. Lockout/tagout input power according to
UNE DÉCHARGE OSHA 29 CFR 1910.147 (see Safety
ÉLECTRIQUE entraîner Standards).
la mort. y Properly install and ground this equipment
according to its Owner’s Manual and
Safety in Welding, Cutting, and Allied Processes, Code for Safety in Welding and Cutting, CSA
ANSI Standard Z49.1, from Global Engineering Standard W117.2, from Canadian Standards
Documents (phone: 1-877-413-5184, website: Association, Standards Sales, 178 Rexdale
www.global.ihs.com). Boulevard, Rexdale, Ontario, Canada M9W 1R3
(phone: 800−463−6727 or in Toronto
416−747−4044, website:
www.csa−international.org).
Safety in Welding, Cutting, and Allied Processes, Code for Safety in Welding and Cutting, CSA
ANSI Standard Z49.1, de Global Engineering Standard W117.2, de Canadian Standards
Documents (téléphone : 1-877-413-5184, site Association, Standards Sales, 178 Rexdale
Internet : www.global.ihs.com). Boulevard, Rexdale, Ontario, Canada M9W 1R3
(téléphone : 800-463-6727 ou à Toronto
416-747-4044, site Internet :
www.csa-international.org).
Considerations About Welding And The Effects 1. Keep cables close together by twisting or
Of Low Frequency Electric And Magnetic Fields taping them.
Welding current, as it flows through welding 2. Arrange cables to one side and away from the
cables, will cause electro- magnetic fields. There operator.
has been and still is some concern about such
fields. However, after examining more than 500 3. Do not coil or drape cables around your body.
studies spanning 17 years of research, a special
blue ribbon committee of the National Research 4. Keep welding power source and cables as far
Council concluded that: “The body of evidence, in away from operator as practical.
the committee’s judgment, has not demonstrated
that exposure to power- frequency electric and 5. Connect work clamp to work piece as close to
magnetic fields is a human-health hazard.” the weld as possible.
However, studies are still going forth and
evidence continues to be examined. Until the About Pacemakers:
final conclusions of the research are reached,
you may wish to minimize your exposure to
Pacemaker wearers consult your doctor first. If
electromagnetic fields when welding or cutting. cleared by your doctor, then following the above
procedures is recommended
To reduce magnetic fields in the workplace, use
the following procedures:
Considérations sur le soudage et les effets de 2. Disposer les câbles d’un côté et à distance de
basse fréquence et des champs magnétiques et l’opérateur.
électriques.
3. Ne pas courber pas et ne pas entourer pas les
Le courant de soudage, pendant son passage dans câbles autour de votre corps.
les câbles de soudage, causera des champs
électromagnétiques. Il y a eu et il y a encore un 4. Garder le poste de soudage et les câbles le plus
certain souci à propos de tels champs. Cependant, loin possible de vous.
après avoir examine plus de 500 études qui ont été
faites pendant une période de recherché de 17 ans, 5. Connecter la pince sur la pièce aussi près que
un comité spécial ruban bleu du National Research possible de la soudure.
Council a conclu : « L’accumulation de preuves,
suivant le jugement du comité, n’a pas démontré En ce qui concer ne les sti mulateurs
que l’exposition aux champs magnétiques et cardiaques
champs électriques à haute fréquence représente
un risque à la santé humaine ». Toutefois, des Les porteurs de stimulateur cardiaque doivent
études sont toujours en cours et les preuves consulter leur médecin avant de souder ou
continuent à être examinées. En attendant que les d’approcher des opérations de soudage. Si le
conclusions finales de la recherché soient établies, médecin approuve, il est recommandé de suivre les
il vous serait souhaitable de réduire votre procédures précédentes
exposition aux champs électromagnétiques
pendant le soudage ou le coupage.
Table 2.1
Phase 1
Phase 1
Table 3.1
CAUTION
WELDING LONGER THAN RATED DUTY CYCLE CAN DAMAGE GUN AND VOID
WARRANTY.
Table 3.2
Gauge
Cylinder
Power
Cord
Torch
Earth
clamp
Figure 3.1
Gauge
Cylinder
Power
Cord
Torch
Earth
clamp
Figure 3.2
Table 3.3
3-5.2.Be sure machine is well grounded. Connect the bolt marked “earth ” with earth in
network, then connect to network firmly
3-5.3.Before starting a new machine or the machine idled for a period, check the
insulation resistance of circuit which is connected to the network. The resistance
must be higher than 2.5M Ω; otherwise the machine must be dried.
3-5.5.Make sure the spool gun selection switch set to “Mig Torch”. If this switch is set to
“spool gun”, the motor will not active when press the gun trigger.
3-5.6.Use Ф8 heat-resistant PVC hose connect the flow meter with the gas connection
nipple at rear of the machine.
3-5.7. Commission the machine after the machine is installed and tested:
Release the pressure roller in the wire feeder, push the torch switch, and adjust
voltage switch from low to high, Open circuit voltage should rise.
Evenly adjust the current knob, the wire feed speed should increase evenly.
3-6.2.The drive roll has two grooves; the small groove feeds 0.035 in. diameter wire,
the large groove feeds 0.045 in. wire. The groove nearest the gear motor feeds
the wire.
3-6.3.Release pressure drive roll assembly and lift upward. Check that proper wire
diameter groove is in the inner position. Feed the wire from the spool through the
inlet guide, across the drive roll groove and into gun outlet guide. Lower
pressures roll assembly and secure. Check that the gears mesh. Feed wire
through to torch tip using the torch trigger.
Figure 3.3
3-8.1.Connect spool gun to the euro receptacle. Connect control cable to “spool gun”
receptacle.
3-8.2. Toggle the spool gun selection switch to “spool gun” selection(see figure 2.4)
Spool gun
selection switch
Figure 3.4
Gauge
Cylinder
Power
Cord
TIG Torch
Figure 3.5
Gauge
Cylinder
Power
Cord
Earth
clamp
TIG Torch
Figure 3.6
3-10.3.Connect the work lead cable to the positive output terminal, and the LIFT TIG
Torch cable to the negative output terminal. Refer to Figure 2.6. Insert torch/earth
clamp quick connector into receptacle and turn 90º clockwise.
3-10.4.Connect the gas line/hose to the proper shielding gas source. Refer to Figure
2.4 and 2.5).
3-10.5.Slowly open the Argon Cylinder Valve to the fully open position.
Power
Cord
Figure 3.7
Power
Cord
Electrode
holder
Earth
clamp
Figure 3.8
CAUTION
WARNING: THIS WELDING MACHINE MUST BE CONNECTED TO POWER
SOURCE IN ACCORDANCE WITH APPLICABLE ELECTRICAL CODES
Use 115 volt single phase input, 25 ampere individual branch circuit protected by
time-delay fuses or circuit breaker is required.
MigSonic200cvcc
Frequency(Hz) 60
Normal operation 35
Table 3.4
CAUTION
USE SHORTEST CABLE POSSIBLE
115V 230V
Table 3.5
2 3 4 5
10
12
11
Figure 4.1
6. Voltage adjustment knob (MIG) 11. Spool gun control receptacle (MIG)
7. Wire feed speed (MIG) and Current 12. MIG Torch receptacle (Euro style)
4-2.3 Set the welding voltage knob to proper position and wire feed speed knob to a
start value and refine during welding( referring to the voltage/wire feeding speed
selection chart)。
4-2.4 The display value of digital voltage meter will change when you turn the voltage
knob to pre-set the welding voltage. And during welding, the voltage meter will reflect
actual welding voltage. The display value of digital current meter will change when you
turn the wire feed knob to pre-set the wire feed speed. This value is estimated output
current. During welding, the current meter will reflect actual welding current.
4-2.5 Set the inductance knob at minimum value (far left) at start and you can adjust
the knob during welding to obtain best result. Inductance is the rate of current response
to a change in current. What this means is that when MIG welding with a short arc you
can adjust how fast current is applied to the shorts. The less inductance you have the
crisper the arc will appear and the wires will start easier. This will also make the bead
taller and narrower. More inductance will make the arc appear "softer" with a flatter
wider appearance and if too much is used, wires will stumble during starts. Typically
when short arcing steel only a little inductance is used in order to get a crisp arc. Low
thermal conductivity materials such as stainless need more inductance to get
acceptable wetting when short arcing.
4-2.6 Turn on the gas valve, adjust gas volume to 3-5L/MIN. Push the torch switch
check if wire feed and gas is normal, check if there is gas leaking.
4-2.7 Hold the torch and keep nozzle 8-12mm above the work piece, and tilt 10-20 ˚
to vertical direction. Aim wire to the welding seam.
4-2.8 Push torch switch, after arc is ignited, move the torch along seam evenly while
keeping the stick-out. Fine tune the welding parameter to obtain exquisite welding
seam. Release the torch switch to finish a welding cycle.
4-2.9 After finish operation, turn off the gas valve, loose the pressure handle at wire
feeder, push torch switch to clear the residual gas in the regulator. At the end, turn off
welding power source and wall switch.
4-3.2 Set Welding Current to desired value (refer to 3-4. Welding Parameter
selection chart).
4-3.3 The display value of digital amperage meter will change when you turn the
current adjustment knob to pre-set the welding current. And during welding, the
amperage meter will reflect actual welding current output, and the voltage meter will
reflect actual welding voltage.
4-3.5 When TIG welding. Turn on the gas valve on the torch; adjust gas volume to
3-5L/MIN. check if there is gas leaking.
4-3.6 Touch tungsten electrode to workpiece at weld start point. Hold electrode to
Workpiece for 1-2 seconds, and then slowly lift electrode. Arc is formed when
electrode is lifted. Aim Tungsten electrode to the welding seam.
4-3.7 After arc is ignited, move the torch along seam evenly. Fine tune the welding
parameter to obtain exquisite welding seam.
4-3.8 After finish operation, turn off the gas valve (for TIG). At the end, turn off
welding power source and wall switch.
Table 4.1
Power Light
18
12
Welding Welding
mode Current /wire Spool Gun
switch feed speed
Potentiometer
Figure 5.1
1 Power Indication lamp does not on after Loose contact at input Check contact
switch on the main switch lead situation
2 Cooling fan stops Power indication Cooling fan circuit Check fan circuit
to rotate after lamp on malfunction
machine has
Cool fan failure Check fan, replace
worked a period
if necessary
10 Power supply switch jump Rectifier short circuit Check and replace
Table 6.1
3 No gas flow out after pushing Gas pressure not enough Check gas pressure
the gun trigger
Poor gas hose connection Check gas connection
4 Failure of arc to ignite or does Fuse melt or poor contact Check and repair
not ignite properly
Main power switch failure Check, repair, replace
5 Unstable arc Gas hose not installed Connect the gas hose
properly, gas mixed by air firmly
6 Arc ignited but the wire does Rectifier tube failure Check, replace
not melt
Output reactor failure Check, replace
7 Wire does not feed while the Wire pressure not proper Adjust pressure
feed roller is rotating
Wire liner or contact tip Check, repair, replace
jammed
8 Cannot stop the gas Solenoid valve contaminated Check, repair, replace
solenoid
9 Wire feeding not stable Wire out of feeding roller Put wire back
groove
Table 6.2
4 Erratic or improper weld Wrong cable size Choose the right cable
output. size
Cable or receptacle too hot. Wrong electrode holder size Choose the right size
electrode holder
5 Failure of arc to ignite or Fuse melt or poor contact Check and repair
does not ignite properly
Main power switch failure Check, repair, replace
Table 6.3
Figure 6.1
Table 6.4
ZX7-400I-QQ-A2(Inverter PCB)
Table 6.5
MIG-270I-KZ-A0(Control PCB)
Table 6.6
MIG200-STICK-A0(Switch PCB)
Connector Pin Value
CN1 1 GND
2 DC+12V
CN2 1 Not used
2 AC230/115V switch signal
CN3 1 Positive output(output voltage feedback)
2 Not used
CN4 1 Connect to Wire feed motor (2.5V-17V)
2 Not used
3 Wire feed motor(2.5V-17V)
CN5 1 Auto reset toggle switch( torch/spool gun switch)
2 Auto reset toggle switch( torch/spool gun switch)
3 Auto reset toggle switch
CN6 1 Connect to pole 6 in spool gun receptacle( given voltage to
spool gun motor)
2 Not used
3 Connect to pole 9 in spool gun receptacle
CN7 1 DC+5V. connect to given welding current
2 connect to given welding current
3 connect to given welding current
CN8 1 DC+5V. connect to welding current potentiometer
2 connect to welding current potentiometer
Table 6.7
CAUTION
DISCONNECT POWER INPUT AND SWITCH OFF THE MAIN POWER SWITCH
BEFORE START OF MAINTENANCE.
• Clean spatter inside the nozzle when • Blow out with dry clean pressure air or
continuously use the machine. vacuum inside machine, especially
transformer coil and power
• Check liner frequently, change if it has component.
been contaminated by oil or worn out.
• Check the electric connection of
• Check and change broken contact tip input/output bar to avoid bad contact
and nozzle to avoid damage to the caused by loose or rusted screw.
torch and machine.
• Check the lubrication of the gear box
• Check the function of all switches. in the feeder, replace or fill lubricates
oil if necessary.
• Check if the fan rotates properly and if
there is air venting out from back of • Check and clean the oil or other
the machine contamination in the feeding roller and
feeding tube. If the V grooves have
• Pay Attention to the abnormal worn out change feeding roller
vibration, noise, smell and gas immediately to avoid slipping or
leakage during operation unstable feeding
Table 7.1
7.2.3 Gas cylinder must be located at a safe and steady place to avoid injury others.
7.2.4 Keep finger, hair and clothing away from the rotating fan.
7.2.6 Welding machine should not work in a flammable and toxic environment,
avoid moisture, rain, and do not directly expose to sun.
7.2.7 Periodically maintain the machine and clean the dust inside.
Table 7.2
ZX7-400I-QQ-A0
2
A P1
7 IGBT:FGL60N600BNTD
INPUT 115V/230V 6 1 1
5
B CN103
P2 4
VH-07
3
1 2
2
3
2
3
2 1
3
1 1
4
5
6
BRIDGE1 CN101
7
VH-10
3
8 X1 X1
9 VH-05(4) VH-05(4)
10
1
2
3
4
5
1
2
3
4
5
1
2 3
CN105
3 2
VH-03
4 1
CN102
5
VH-10
6
BRIDGE1
7
1
2
3
4
5
1
2
3
4
5
8 CN104 3 1
CN13
9 VH-03 2 X13 X13
VH-03(2)
10 1 3 VH-05(4) VH-05(4)
M2 JP2 CZ-02
4
12038 DC24V/0.5A
3
2
CN19
VH-04 J1 CZ-03 MIG-270I-
1 风风
JP2 CZ-02
1
CN17
2
VH-03(2)
3
CN16 CN15 CN14 CN11 CN12 CN4 C
XH-02 XH-03 VH-02 VH-03(2) VH-02 XH-04 X
2
1
1
2
3
2
1
1
2
3
1
2
1
2
3
4
7
6
3
2
1
7
M2
DC24V,ZCT-2.5
LED2 L
2W/1K 1 2
1 CN1
3
2
1
3
2
1
2
1
2
1
2
XH-02 CN7 CN8 CN14 CN15
XH-03 XH-03 XH-02 XH-02
CN2
1
XH-02
2
1 CN3
2 XH-02
1 CN16
2
VH-03
3 CN5 CN9 CN12
VH-03 XH-03 XH-06
1
2
3
1
2
3
1
2
B B
STICK
Figure 8.1
3
MIG-270I-XS-A0
2
1 4
OUT +
ESA D92-02
R1 C1
MIG200-XH-A0
2 3 300R
472/3KV
BYQ5
R2
MIG-400I-ZL-A0 300R C2
472/3KV
M1
OUT
_
1
2
1
2
3
4
5
1
2
1
2
3
7
6
3
2
1
L3
LED1
RT1 RT2
2W/10K 2W/10K
M1
CN4 3
2
1
VH-03 2
M
CN11
1
XH-02 SSJ-18
CN13 2
XH-02 1 1
2
3
3
CN10 4
2
XH-03 5
1
6
7
3 8
CN16
2 9
VH-03
1
3
4
5
6
K/CO2/TIG
Figure 8.2
Table 9.1
13
Figure 9.2
47
41
15
Figure 9.3
28
17
27
12
26
10
7
48
36
Figure 9.4
13
35
49
Figure 9.5
Figure 9.6
Table 9.2
Table 9.3
Figure 9.7
2 Washer 6 n/a 1
3 spring 2401710 1
6 Washer 2401707 1
8 Spring 2401706 1
13 Axle 2401703 1
Table 9.4
Trigger switch
Potentiometer
Motor drive
10 pin connector
Figure 9.8
4 Not used
7 Not used
10 Not used
Table 9.5
Figure 9.9
Nozzles
Table 9.6
Table 9.7
Liners
Table 9.8
* Default
Component
Table 9.9
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