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

5 OPERATION
0459 560 101 - 11 - © ESAB AB 2017
5.3 Fitting the central adaptor assembly to the equipment
1. Check that the wire guide liner is fitted correctly.
2. Insert the central plug into the socket on the wire feed unit and secure it by tightening
the adaptor nut firmly.
5.4 Setting the level of shielding gas
Set the quantity of gas required on the gas regulator. The type and quantity of gas to be used
depend on the welding task to be performed.
5.5 Checklist
Check the cable assembly before connecting it to the wire feed unit to confirm the wire liner
is suitable for the wire diameter and type.
Check the fixed end consumable parts on the swan neck, whether the correct contact tip etc.
is being used for the wire diameter and type.
5.6 Changing wire
When changing the wire, ensure that the end of the wire is deburred.
Insert the wire into the wire feeding unit in accordance with the operating instructions.
When inserting the wire, press the wire jog button on the wire feed unit.

6 MAINTENANCE
0459 560 101 - 12 - © ESAB AB 2017
6 MAINTENANCE
6.1 Overview
NOTE!
Regular maintenance is important for safe and reliable operation.
Welding torch
Cleaning and replacement of the welding torch’s wear parts should take place at regular
intervals in order to achieve trouble−free wire feed. Blow the wire guide clean regularly and
clean the contact tip.
WARNING!
Before carrying out cleaning, servicing and repair work, the following shutdown
procedure must be followed.
1. Switch off the power supply.
2. Close off the gas supply.
Make sure that the power supply and gas remain turned off all the time while
servicing the equipment.
6.2 Cable assembly
Check that all the nuts are tight.
Replace the liner if it is worn or dirty.
Replace damaged, deformed or worn parts.
6.3 Cleaning the wire feed
Disconnect the torch cable assembly from the equipment and lay it out straight.
Unscrew the nut and pull out the wire guide liner. Remove other parts from the swan neck.
Blow compressed air through the wire conduit from both ends in order to remove wire
shavings.
Insert the liner into the wire conduit and screw the nut back on.
NOTE!
New liners must be cut to the correct length. Follow the following tips and
suggestions:
6.4 Spiral liner / PTFE liner
1. Unscrew all the fittings from the swan neck.
2. Unscrew the union nut on the central plug.
3. Remove the old liner, and then push the guide spiral liner through the hose as far as it
will go.
Make sure the cable is stretched out more or less straight.
4. Tighten the union nut by hand.
5. Cut the overhang off the spiral at the swan neck and remove the guide spiral liner
again.
6. For a smooth transition to the contact tip, grind the end of the spiral to an angle of
approx. 40°. Deburr the cutting edge.
7. Push the sharpened guide spiral liner through the hose to the holder nipple.

6 MAINTENANCE
0459 560 101 - 13 - © ESAB AB 2017
8. Screw the union nut into position and tighten it using the multiple spanner.
9. Screw the fittings back on again.
6.5 Cleaning the swan neck
• Clean the inside of the gas nozzle regularly to remove welding spatter and spray with
ESAB® anti-spatter agent.
• Check the consumables for visible damage and replace if necessary.

7 FAULT-TRACING
0459 560 101 - 14 - © ESAB AB 2017
7 FAULT-TRACING
If the measures described below are not successful, consult your dealer or the manufacturer.
Read the operating instructions for the welding components, e.g. power source and wire feed
unit.
Problem Cause Solution
Torch becomes too hot • Contact tip / Collets not
tight enough
• Current connections on the
torch side and to the work
piece are loose
• Check and tighten
• Check and tighten
No switch function • Control cable
interrupted/faulty.
• Check/repair.
Wire burnt back onto the
contact tip
• Wrong parameter setting
• Worn contact tip.
• Check or correct the
setting
• Replace
Irregular wire feed • Liner blocked
• Contact tip and wire
diameter do not match one
another
• Wrong tension set on the
wire feed unit
• Blow through in both
directions.
• Replace contact tip
• Correct according to
manufacturer's instructions
Short arc between the gas
nozzle and workpiece
• Spatter bridge between the
contact tip and the gas
nozzle
• Clean and spray the inside
of the gas nozzle
Variable arc • Contact tip does not match
the wire diameter, or the
contact tip is worn
• Incorrect welding
parameters set
• Liner worn
• Check and replace the
contact tip.
• Correct the welding
parameters.
• Replace the wire guide
Porous welds • Large amount of spatter in
the gas nozzle.
• Insufficient or total lack of
gas shield
• Draught is disturbing the
shielding gas
• Clean the gas nozzle
• Check contents of the gas
bottle/hoses and the
pressure setting
• Shield welding area with
protective screens

8 DISASSEMBLY AND DISPOSAL
0459 560 101 - 15 - © ESAB AB 2017
8 DISASSEMBLY AND DISPOSAL
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.
The welding torch system is mainly made from steel, plastics and non-ferrous metal, and
must be disposed of in accordance with local environmental regulations.

9 IN THE EVENT OF AN EMERGENCY
0459 560 101 - 16 - © ESAB AB 2017
9 IN THE EVENT OF AN EMERGENCY
In the event of an emergency, the power supply must be switched off immediately.
For further action in such circumstances, consult the `Power source' Instruction manual.

10 ORDERING SPARE PARTS
0459 560 101 - 17 - © ESAB AB 2017
10 ORDERING SPARE PARTS
MXL 150v, MXL 200, MXL 270, MXL 340 is designed and tested in accordance with the
international and European standards 60974- 7 and . It is the obligation of the service
unit which has carried out the service or repair work to make sure that the product
still conforms to the said standard.
Spare parts and wear parts can be ordered through your nearest ESAB dealer, see the back
cover of this document. When ordering, please state product type, serial number, designation
and spare part number in accordance with the spare parts list. This facilitates dispatch and
ensures correct delivery.

ORDERING NUMBERS
0459 560 101 - 18 - © ESAB AB 2017
ORDERING NUMBERS
Ordering number Type Description Notes
0700 200 001 MXL™ 150v Welding torch 2.5 m with fixed connection
0700 200 002 MXL™ 200 Welding torch 3.0 m EURO Connection
0700 200 003 MXL™ 200 Welding torch 4.0 m EURO Connection
0700 200 004 MXL™ 270 Welding torch 3.0 m EURO Connection
0700 200 005 MXL™ 270 Welding torch 4.0 m EURO Connection
0700 200 006 MXL™ 340 Welding torch 3.0 m EURO Connection
0700 200 007 MXL™ 340 Welding torch 4.0 m EURO Connection

SPARE PARTS LIST
0459 560 101 - 19 - © ESAB AB 2017
SPARE PARTS LIST
Pos Denomination Ordering no. MXL
150v
MXL
200
MXL
270
MXL
340
Notes
101 Head insulator 0700 200 096 x x
102 Swan neck
Standard
0700 200 050 x
103 Swan neck
Standard
0700 200 051 x
104 Swan neck
Standard
0700 200 052 x
105 Swan neck
Standard
0700 200 053 x
106 Trigger 2 pol 0700 200 077 x MXL 150v
106 Trigger 2 pol 0700 200 095 x x x MXL 200/ 270/
340
107 Handle complete 0700 200 093 x MXL 150v
Incl trigger pos
106
107 Handle complete 0700 200 094 x x x MXL 150v
Incl trigger pos
106
108 Adaptor nut
complete
0700 200 097 x x x
109 Liner lock nut 0700 200 098 x x x M10x1
110 Central connector 0700 200 101 x x x Incl. control leads
111 Support sleeve 0700 200 150 x x x x

SPARE PARTS LIST
0459 560 101 - 20 - © ESAB AB 2017