ESAB MXL 200 User manual

Instruction manual
0459 560 101 GB 20170322
MXL™150v,MXL™200,
MXL™270,MXL™340

TABLE OF CONTENTS
0459 560 101 © ESAB AB 2017
1SAFETY ......................................................................................................... 4
1.1 Meaning of symbols ................................................................................. 4
1.2 Safety precautions ................................................................................... 4
2INTRODUCTION............................................................................................ 7
3SHIPMENT AND PACKAGING ..................................................................... 8
4TECHNICAL DATA ........................................................................................ 9
5OPERATION .................................................................................................. 10
5.1 Fitting the liner.......................................................................................... 10
5.2 Assembling the swan neck ..................................................................... 10
5.3 Fitting the central adaptor assembly to the equipment........................ 11
5.4 Setting the level of shielding gas............................................................ 11
5.5 Checklist ................................................................................................... 11
5.6 Changing wire........................................................................................... 11
6MAINTENANCE............................................................................................. 12
6.1 Overview ................................................................................................... 12
6.2 Cable assembly ........................................................................................ 12
6.3 Cleaning the wire feed ............................................................................. 12
6.4 Spiral liner / PTFE liner ............................................................................ 12
6.5 Cleaning the swan neck........................................................................... 13
7FAULT-TRACING........................................................................................... 14
8DISASSEMBLY AND DISPOSAL.................................................................. 15
9IN THE EVENT OF AN EMERGENCY .......................................................... 16
10 ORDERING SPARE PARTS .......................................................................... 17
ORDERING NUMBERS........................................................................................ 18
SPARE PARTS LIST............................................................................................. 19
WEAR PARTS....................................................................................................... 21
ACCESSORIES .................................................................................................... 23
Rights reserved to alter specifications without notice.

1 SAFETY
0459 560 101 -4- © ESAB AB 2017
1 SAFETY
1.1 Meaning of symbols
As used throughout this manual: Means Attention! Be Alert!
DANGER!
Means immediate hazards which, if not avoided, will result in immediate,
serious personal injury or loss of life.
WARNING!
Means potential hazards which could result in personal injury or loss of
life.
CAUTION!
Means hazards which could result in minor personal injury.
WARNING!
Before use, read and understand the instruction manual
and follow all labels, employer´s safety practices and Safety
Data Sheets (SDSs).
1.2 Safety precautions
Users of ESAB 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 equipment. The following
recommendations 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
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 equipment must be familiar with:
○ its operation
○ location of emergency stops
○ its function
○ relevant safety precautions
○ welding and cutting or other applicable operation of the equipment
2. The operator must ensure that:
○ no unauthorised person is stationed within the working area of the equipment
when it is started up
○ no-one is unprotected when the arc is struck or work is started with the
equipment
3. The workplace must:
○ be suitable for the purpose
○ be free from drafts

1 SAFETY
0459 560 101 -5- © ESAB AB 2017
4. Personal safety equipment:
○ Always wear recommended personal safety equipment, such as safety glasses,
flame-proof clothing, safety gloves
○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which
could become trapped or cause burns
5. General precautions:
○ Make sure the return cable is connected securely
○ Work on high voltage equipment may only be carried out by a qualified
electrician
○ Appropriate fire extinguishing equipment must be clearly marked and close at
hand
○ Lubrication and maintenance must not be carried out on the equipment during
operation
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting.
ELECTRIC SHOCK - Can kill
• Install and ground the unit in accordance with instruction manual.
• Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing.
• Insulate yourself from work and ground.
• Ensure your working position is safe
ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health
• Welders having pacemakers should consult their physician before welding.
EMF may interfere with some pacemakers.
• Exposure to EMF may have other health effects which are unknown.
• Welders should use the following procedures to minimize exposure to
EMF:
○ Route the electrode and work cables together on the same side of
your body. Secure them with tape when possible. Do not place your
body between the torch and work cables. Never coil the torch or
work cable around your body. Keep welding power source and
cables as far away from your body as possible.
○ Connect the work cable to the workpiece as close as possible to the
area being welded.
FUMES AND GASES - Can be dangerous to health
• Keep your head out of the fumes.
• 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
• Protect your eyes and body. Use the correct welding screen and filter lens
and wear protective clothing.
• Protect bystanders with suitable screens or curtains.
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.

1 SAFETY
0459 560 101 -6- © ESAB AB 2017
MOVING PARTS - Can cause injuries
• Keep all doors, panels and covers closed and securely in place. Have only
qualified people remove covers for maintenance and troubleshooting as
necessary. Reinstall panels or covers and close doors when service is
finished and before starting engine.
• Stop engine before installing or connecting unit.
• Keep hands, hair, loose clothing and tools away from moving parts.
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure that there are no inflammable
materials nearby.
• Do not use on closed containers.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding.
WARNING!
Do not use the power source for thawing frozen pipes.
CAUTION!
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 electromagnetic compatibility of class
A equipment in those locations, due to conducted as well
as radiated disturbances.
NOTE!
Dispose of electronic equipment at the recycling
facility!
In observance of European Directive 2012/19/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 has an assortment of welding accessories and personal protection equipment
for purchase. For ordering information contact your local ESAB dealer or visit us on
our website.

2 INTRODUCTION
0459 560 101 -7- © ESAB AB 2017
2 INTRODUCTION
The MIG / MAG welding torches of this series are exclusively intended for shielded- arc
welding using inert gas (MIG) or active gas (MAG) for industrial and commercial use by
suitably trained employees. The torches are only available in manual versions.

3 SHIPMENT AND PACKAGING
0459 560 101 -8- © ESAB AB 2017
3 SHIPMENT AND PACKAGING
The components are carefully checked and packaged however damage may occur during
shipping.
Checking procedure on receipt of goods
Check that the shipment is correct by referring to the shipping note.
In case of damage
Check the package and components for damage (visual inspection).
In case of complaints
If the package and/or components have been damaged during shipment:
• Contact with the last carrier immediately.
• Keep the packaging (for possible inspection by the carrier or supplier, or for returningn
the goods).
Storage in an enclosed space
Ambient temperature for shipment and storage: -25°C to +55°C
Relative air humidity: up to 90% at a temperature of 20 °C

4 TECHNICAL DATA
0459 560 101 -9- © ESAB AB 2017
4 TECHNICAL DATA
Welding torch MXL 150v MXL 200 MXL 270 MXL 340
Type of cooling Air Air Air Air
Permitted load at 20% intermittence *
Carbon dioxide CO2150 A
Mixed gas, Ar/CO2150 A
Permitted load at 35% intermittence *
Carbon dioxide CO2120 A 200 A 270 A 340 A
Mixed gas, Ar/CO2120 A 170 A 260 A 320 A
Recommended gas flow 8-15
l/min
10-18
l/min
10-18
l/min
10-20
l/min
Max pressure 2.5 bar
Wire diameter 0.6-0.8 mm 0.6-1.0 mm 0.8-1.2 mm 0.8-1.2 mm
Weight
2.5 m hose package 1.1 kg − − −
3.0 m hose package − 1.6 kg 2.2 kg 2.6 kg
4.0 m hose package − 2.0 kg 2.6 kg 3.7 kg
Cable assembly
Standard length 2.5 m 3.0 m / 4.0 m 3.0 m / 4.0 m 3.0 m / 4.0 m
Standard−control cable 2−pole 2−pole 2−pole 2−pole
* The capacity my be reduced up to 30% when pulse welding.
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or
cut at a certain load without overloading. The duty cycle is valid for 40°C/104°F, or below.
General torch data with reference to IEC/EN 60 974−7
Type of voltage: DC voltage
Wire type: Standard round wire
Voltage measurement: Peak value of 113V
Connection protection equipment side (EN 60
529):
IP3X
Shielding gas: CO2or Ar/CO2

5 OPERATION
0459 560 101 - 10 - © ESAB AB 2017
5 OPERATION
General safety regulations for handling the equipment can be found in the "SAFETY"
chapter of this manual. Read it through before you start using the equipment!
CAUTION!
This product is intended for industrial use. In a domestic environment this product
may cause radio interference. It is the user's responsibility to take adequate
precautions.
MXL welding torches can be used in any welding position.
The torch switch in the MXL handle is suitable for 42 V, maximum 1 A.
5.1 Fitting the liner
Fit the correct wire guide liner for the application, as needed to suit the wire type and
diameter. See chapter "MAINTENANCE" section "Spiral liner / PTFE liner".
NOTE!
For information on how to install new liners and about correct assembly
procedure, see the chapter entitled “Maintenance”
Spiral liner = for steel wires
PTFE−liner = for aluminium, copper, nickel and stainless steel wires
5.2 Assembling the swan neck
The following figures indicate how to assemble the different welding torch types.
1. Gas nozzle 4. Tip adaptor
2. Contact tip 5. Gas diffusor
3. Nozzle spring