GENTRON 206 MS User manual

INTRODUCTION
Ⅰ
I
INVERTER Based Welding Machines
Top Gun 206 MS
IMPORTANT: Read this Owner’s Manual Completely before attempting to use this
equipment. Save this manual and keep it handy for quick reference. Pay particular
attention to the safety instructions we have provided for your protection. Contact your
distributor if you do not fully understand this manual.
OPERATORS’ MANUAL

CONTENT
- II -
CONTENT
§1 Safety.............................................................................................1
§1.1 Symbols Explanation................................................................................................... 1
§1.2 Machine Operating warnings!.................................................................................... 1
§1.3 EMC device classification ........................................................................................... 8
§1.4 EMC measure............................................................................................................... 9
§1.5 Warning label............................................................................................................. 10
§2 Overview..................................................................................... 11
§2.1 Brief Introduction.......................................................................................................11
§2.2 Working Principle...................................................................................................... 12
§2.3 Volt-Ampere Characteristic...................................................................................... 12
§2.4 Principles of welding ................................................................................................. 13
§3 Installation and Adjustment.....................................................14
§3.1 Parameters ................................................................................................................. 14
§3.2 Duty cycle and Over-heat.......................................................................................... 14
§3.3 Equipment Connection.............................................................................................. 15
§3.3.1 MIG Welding- Gas shielded wire.....................................................................................15
§3.3.2 MIG Welding- Gasless wire..............................................................................................16
§3.3.3 MMA Welding ...................................................................................................................16
§3.4 Maintenance of MIG Gun mechanism .................................................................... 17
§3.4.1 Dissection graphics for the MIG GUN ............................................................................17
§3.4.2 Parts list for the MIG GUN ..............................................................................................17
§3.4.3 the operation for the MIG GUN.......................................................................................18
§4 Operation....................................................................................20
§4.1 Machine Layout Description .................................................................................... 20
§4.2 Welding operation...................................................................................................... 22
§4.2.1 MIG mode operation.........................................................................................................22
§4.2.2 MMA mode operation .......................................................................................................22
§4.3 Welding parameters................................................................................................... 22
§4.4 Operation environment............................................................................................. 24
§4.5 Operation Notices ...................................................................................................... 24

CONTENT
- II -
§5 Maintenance & Troubleshooting .............................................25
§5.1 Maintenance............................................................................................................... 25
§5.2 Troubleshooting ......................................................................................................... 26
§5.3 List of error code ....................................................................................................... 28
§5.4 Electrical schematic drawing.................................................................................... 29

SAFETY
-1-
§1 Safety
Welding and cutting equipment can be dangerous to both the operator and people in
or near the surrounding working area, if the equipment is not correctly operated.
Equipment must only be used under the strict and comprehensive observance of all
relevant safety regulations. Read and understand this instruction manual carefully
before the installation and operation of this equipment.
§1.1 Symbols Explanation
 The above symbols mean warning!
Notice! Running parts, getting an electric shock or making contacts with thermal
parts will cause damage to your body and others. The underline message is as
follows:
Welding is quite a safe operation after taking several necessary protection
measures!
§1.2 Machine Operating warnings!
 The following symbols and words explanations are for some damages to your body
or others, which could happen during the welding operation. While seeing these
symbols, please remind yourself and others to be careful.
 Only people who are trained professionally can install, debug, operate, maintain
and repair the welding equipment covered with this Operator’s Manual!
 During the welding operation, non-concerned people should NOT be around,
especially children!
 After shutting off the machine power, please maintain and examine the equipment
according to §7 because of the DC voltage existing in the electrolytic capacitors at
the output of the power supply!

SAFETY
-2-
ELECTRIC SHOCK CAN KILL.
Touching live electrical parts can cause fatal shocks or severe burns. The electrode
and work circuit is electrically live whenever the output is on. The input power
circuit and internal machine circuits are also live when power is on. In Mig/Mag
welding, the wire, drive rollers, wire feed housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly grounded
equipment is dangerous.
 Never touch live electrical parts.
 Wear dry, hole-free gloves and clothes to insulate your body.
 Be sure to install the equipment correctly and ground the work or metal to be
welded to a good electrical (earth) ground according to the operation manual.
The electrode and work (or ground) circuits are electrically “hot” when the
machine is ON. Do not touch these “hot” parts with your bare skin or wet clothing.
Wear dry, hole-free gloves to insulate hands.
 In semiautomatic or automatic wire welding, the electrode, electrode reel, welding
head, nozzle or semiautomatic welding gun are also electrically “hot”.
 Insulate yourself from work and ground using dry insulation. Make certain the
insulation is large enough to cover your full area of physical contact with work and
ground.
 Be Careful when using the equipment in small places, falling-off and wet
circumstance.
 Always be sure the work cable makes a good electrical connection with the metal
being welded. The connection should be as close as possible to the area being
welded.
Maintain the electrode holder, work clamp, welding cable and welding machine in
good, safe operating condition. Replace damaged insulation.
 Never dip the electrode in water for cooling.
 Never simultaneously touch electrically “hot” parts of electrode holders connected

SAFETY
-3-
to two welders because voltage between the two can be the total of the open
circuit voltage of both welders.
 When working above the floor level, use a safety belt to protect yourself from a
fall should you get an electric shock!
FUMES AND GASES CAN BE DANGEROUS.
Smoke and gas generated whilst welding or cutting can be harmful to people’s health.
Welding produces fumes and gases. Breathing these fumes and gases can be
hazardous to your health.
 Do not breathe the smoke and gas generated whilst welding or cutting, keep your
head out of the fumes. Use enough ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When welding with electrodes which
require special ventilation such as stainless or hard facing or on lead or cadmium
plated steel and other metals or coatings which produce highly toxic fumes, keep
exposure as low as possible and below the Threshold Limit Values using local
exhaust or mechanical ventilation. In confined spaces or in some circumstances,
outdoors, a respirator may be required. Additional precautions are also required
when welding on galvanized steel.
 Do not weld in locations near chlorinated hydrocarbon vapors coming from
degreasing, cleaning or spraying operations. The heat and rays of the arc can react
with solvent vapors to form phosgene, a highly toxic gas, and other irritating
products.
 Shielded gases used for arc welding can displace air and cause injury or death.
Always use enough ventilation, especially in confined areas, to insure breathing air
is safe.
 Read and understand the manufacturer’s instructions for this equipment and the
consumables to be used, including the material safety data sheet and follow your
employer’s safety practices.

SAFETY
-4-
ARC RAYS: Harmful to people’s eyes and skin.
Arc rays from the welding process produce intense visible and invisible ultraviolet
and infrared rays that can burn eyes and skin.
 Use a shield with the proper filter and cover plates to protect your eyes from
sparks and the rays of the arc when welding or observing open arc welding.
 Use suitable clothing made from durable flame-resistant material to protect your
skin and that of your coworkers from the arc rays.
 Protect other nearby personnel with suitable, non-flammable screening and /or
warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter
or metal.
SELF-PROTECTION
 Keep all equipment safety guards, covers and devices in position and in good
repair. Keep hands, hair, clothing and tools away from V-belts, gears, fans and all
other moving parts when starting, operating or repairing equipment.
 Do not put your hands near the engine fan. Do not attempt to override the governor
or idler by pushing on the throttle control rods while the engine is running.
DO NOT add any fuel near an open-flame welding arc or
when the engine is running. Stop the engine and allow it to cool before refueling to
prevent spilled fuel from vaporizing on contact with hot engine parts and igniting.
Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.

SAFETY
-5-
WELDING SPARKS can cause fire or explosion.
Welding on closed containers, such as tanks, drums, or pipes, can cause them to
explode. Flying sparks from the welding arc, hot work piece, and hot equipment can
cause fires and burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is safe before
doing any welding
 Remove fire hazards material from the welding area. If this is not possible, cover
them to prevent the welding sparks from starting a fire. Remember that welding
sparks and hot materials from welding can easily go through small cracks and
openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire
extinguisher readily available.
 Where compressed gases are to be used at the job site, special precautions should
be used to prevent hazardous situation.
 When not welding, make certain no part of the electrode circuit is touching the
work or ground. Accidental contact can cause overheating and create a fire hazard.
 Do not heat, cut or weld tanks, drums or containers until the proper steps have
been taken to insure that such procedures will not cause flammable or toxic vapors
from substances inside. They can cause an explosion even though they have been
“cleaned”.
 Vent hollow castings or containers before heating, cutting or welding. They may
explode.
 Sparks and spatter are thrown from the welding arc. Wear oil free protective
garments such as leather gloves, heavy shirt, cuff less trousers, high shoes and a cap
over your hair. Wear earplugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a welding area.
 Connect the work cable to the work as close to the welding area as practical. Work
cables connected to the building framework or other locations away from the
welding area increase the possibility of the welding current passing through lifting

SAFETY
-6-
chains, crane cables or other alternate circuits. This can create fire hazards or
overheat lifting chains or cables until they fail.
Rotating parts may be dangerous.
 Use only compressed gas cylinders containing the correct shielding gas for the
process used and properly operating regulators designed for the gas and pressure
used. All hoses, fittings, etc. should be suitable for the application and maintained in
good condition.
 Always keep cylinders in an upright position securely chained to an undercarriage
or fixed support.
 Cylinders should be located:
-Away from areas where they may be struck or subjected to physical damage.
-At a safe distance from arc welding or cutting operations and any other source
of heat, sparks, or flame.
 Never allow the electrode, electrode holder or any other electrically “hot” parts to
touch a gas cylinder.
 Keep your head and face away from the cylinder valve outlet when opening the
cylinder valve.
 Valve protection caps should always be in place and hand tight except when the
cylinder is in use or connected for use.
Gas Cylinders.
Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can
explode. Because gas cylinders are normally part of the welding process, be sure to
treat them carefully. CYLINDERS can explode if damaged.
 Protect gas cylinders from excessive heat, mechanical shocks, physical damage,
slag, open flames sparks, and arcs.

SAFETY
-7-
 Insure cylinders are held secure and upright to prevent tipping or falling over.
 Never allow the welding electrode or earth clamp to touch the gas cylinder, do not
drape welding cables over the cylinder.
 Never weld on a pressurised gas cylinder, it will explode and kill you.
Open the cylinder valve slowly and turn your face away from the cylinder outlet
valve and gas regulator.
Gas build up.
The build up of gas can causes a toxic environment, deplete the oxygen content in
the air resulting in death or injury. Many gases use in welding are invisible and
odourless.
 Shut off shielding gas supply when not in use.
 Always ventilate confine spaces or use approved air-supplied respirator.
Electric and Magnetic Fields.
Electric current flowing through any conductor causes localized Electric and
Magnetic Fields (EMF). The discussion on the effect of EMF is ongoing in the entire
world. Up to now, no material evidences show that EMF may have effects on health.
However, the research on the effect of EMF is still ongoing. Before any conclusion,
we should minimize exposure to EMF as few as possible.
In order to minimize EMF, we should use the following procedures:
 Route the electrode and work cables together – Secure them with tape when
possible.
 All cables should be put away and far from the operator.
 Never coil the power cable around your body.
 Make sure welding machine and power cable to be far away from the operator as
far as possible according to the actual circumstance.

SAFETY
-8-
 Connect the work cable to the workpiece as close as possible to the area being
welded.
 The people with heart-pacemaker should be away from the welding area.
Noise can damage hearing.
Noise from some processes or equipment can damage hearing. You must protect
your ears from loud noise to prevent permanent loss of hearing.
 To protect your hearing from loud noise, wear protective ear plugs and/or earmuffs.
Protect others in the workplace.
 Noise levels should be measured to be sure the decibels (sound) do not exceed safe
levels.
Hot parts.
Items being welded generate and hold high heat and can cause severe burns. Do not
touch hot parts with bare hands. Allow a cooling period before working on the
welding gun. Use insulated welding gloves and clothing to handle hot parts and
prevent burns.
§1.3 EMC device classification
Radiation Class A Device.
 Only can be used in the industrial area
 If it is used in other area, it may cause connection and
radiation problems of circuit.
Radiation Class B device.
 It can meet the radiation requirements of residential area and industrial area. It also
can be used in residential area which power is supplied by public low voltage circuit.
EMC device can be classified by power nameplate or technical data.

SAFETY
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hanker welding machines belong to Class A.
§1.4 EMC measure
In the special situation, The specified area may be affected, the
standard of radiation limit value has been complied with (eg: The
device, which is easy effected by electromagnetism, is used at the
installation location, or there is radio or TV near the installation location). In this
condition, the operator should adopt some appropriate measures to remove
interference.
Accoring to the domestic and international standards, the ambient devices’
electromagnetism situation and anti-interference ability must be checked：
 Safety device
 Power line, Signal transmission line and Date transmission line
 Date processing equipment and telecommunication equipment
 Inspection and calibration device
The effective measures avoid the problem of EMC：
a) Power source
Even though the power source connection meet rules, we still need to take
additional measure to remove the electromagnetic interference. (eg: Use the right
power filter. )
b) The welding line
 Try to shorten the length of cable
 Put the cable together
 Be Far away from other cable
c) Equipotential connection
d) Ground connection of work-piece
 When necessary, use appropriate capacitance to connect the ground.
e) Shielding, when necessary
 Shield the ambient devices

SAFETY
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 Shield the whole welding machine
§1.5 Warning label
The device with a warning label. Do not remove、destroy or cover this label. These
warnings are intended to avoid incorrect device operations that could result in
serious personal injury or property damage.

OVERVIEW
-11-
§2 Overview
§2.1 Brief Introduction
MIG SERIES arc welding machine adopts the latest pulse width modulation (PWM)
technology and insulated gate bipolar transistor (IGBT) power module, which can change work
frequency to medium frequency so as to replace the traditional hulking work frequency
transformer with the cabinet medium frequency transformer. Thus, it is characterized with
portable, small size, light weight, low consumption and etc.
MIG SERIES arc welding machine uses Mix gas as shielded gas to realize gas shielded
welding, active gas（Ar+O2、Ar+CO2） as shielded gas to realize MAG welding and inactive gas
（Ar）as shielded gas to realize MIG welding.
MIG SERIES arc welding machine has automatic protection functions with intelligent to
over-voltage, over-current and over-heat. If any one of the above problems happens, the alarm
lamp on the front panel will be lighted and output current will be shut off automatically to protect
itself and prolong the equipment using life.
MIG SERIES Features:
1. Digital control system, real-time display the welding parameters;
2. High performance multifunction power source (MMA/MIG/MAG);
3. Waveform control, stable welding arc;
4. IGBT technology, low power dissipation;
5. Rated duty circle is 40%(40℃).
MULTIMIG 160/200 has another feature: Synergic control of the welding current and voltage.
MIG SERIES arc welding machine is suitable for all positions welding for various plates made
of stainless steel, carbon steel, alloyed steel, copper, titanium, etc, which is also applied to pipe
installment, mould mend, petrochemical, architecture decoration, car repair, bicycle, handicraft
and common manufacture.
MAG--Metal Active Gas Welding
MIG--Metal Insert Gas Welding

OVERVIEW
-12-
§2.2 Working Principle
The working principle of MIG SERIES arc welding machine is shown as the following figure.
Single-phase 220V work frequency AC is rectified into DC（350V）, then is converted to medium
frequency AC (about 40KHz) by inverter device (IGBT), after reducing voltage by medium
transformer (the main transformer) and rectifying by medium frequency rectifier (fast recovery
diodes), and is outputted by inductance filtering. The circuit adopts current feedback control
technology to insure current output stably when MMA or TIG. And adopts voltage feedback
control technology to insure voltage output stably when MIG. Meanwhile, the welding current
parameter can be adjusted continuously and infinitely to meet with the requirements of welding
craft.
Rectifier Inverter Transformer Rectifier Hall
Current
Feedback
control
Single-phase AC DC AC DC
220V 50Hz
AC DC
Welding current
regulate
(Wire feed speed) Wire feeder
motor
PWM signal
CPU control
Voltage
Feedback
control
§2.3 Volt-Ampere Characteristic
MIG series welding machine has an excellent volt-ampere characteristic, whose graph is shown
as the following figure. The relation between the rated loading voltage U2 and welding current I2
is as follows: U2=14+0.05I2(V)
Current sensor

OVERVIEW
-13-
44
14
0600 Io（A）
Uo（V）
Working point
Volt-ampere characteristic The relation between the rated loading
voltage and welding current
§2.4 Principles of welding

OVERVIEW
-14-
§3 Installation and Adjustment
§3.1 Parameters
Model
Parameters
MIG 206 MS
Input Voltage (V)
1~240±10%
Input Current (A)
38 MIG
46 MMA
Input Power (KW)
5.1 MIG
4.7 MMA
Welding Current (A)
40-200 MIG
10-200MMA
No-load Voltage (V)
69
Duty cycle（40℃）
25% 200A
60% 155A
100%120A
10% 200A
60% 130A
100%100A
Welding Current Range (A)
40-200 MIG
10-200 MMA
Welding Voltage Range (V)
16-24
20.4-28
Diameter (mm)
0.6、0.8、0.9、1.0
(Fe /Ss/Flux-Cored)
Protection class
IP23
Insulation class
H
Power factor
0.65
Efficiency (%)
85%
Dimensions (mm)
450*215*400
Weight (Kg)
12
Note: The above parameters are subject to change with future machine improvement!
§3.2 Duty cycle and Over-heat
The letter “X” stands for Duty Cycle, which is
defined as the portion of the time a welding
machine can weld continuously with it’s rated
output current within a certain time cycle (10
minutes).
The relation between the duty cycle “X” and the
output welding current “I” is shown as the right
T
he Relation of welding current
duty and cycle for MIG 250

OVERVIEW
-15-
figure.
If the welding machine is overheating, the IGBT over-heat protection sensing will send a signal
to the welding machine control unit to cut the output welding current OFF and light the over-heat
pilot lamp on the front panel. In that case, the machine should not be welding for 10-15 minutes
to cool down with the fanrunning. When operating the machine again, the welding output current
or the duty cycle should be reduced.
§3.3 Equipment Connection
§3.3.1 MIG Welding- Gas shielded wire
(1) Insert the earth cable plug into the negative socket on the front of the machine and tighten it.
(2) Plug the welding torch into the MIG torch connection socket on the front panel and tighten
it.
IMPORTANT : When connecting the torch be sure to tighten the connection. A loose connection
can result in the connector arcing and damaging the machine and gun connector.
(3) Connect the MIG power connection lead to the positive welding power output socket.
Note if this connection is not made, there will be no electrical connection to the welding torch!
(4) Connect the gas regulator to the Gas Cylinder and connect the gas line to the Gas Regulator.
Check for Leaks!
(5) Connect the gas line to gas connector on the rear panel. Check for Leaks!
(6) Connect the power cable of welding machine with the output switch in electric box on site.

OVERVIEW
-16-
§3.3.2 MIG Welding- Gasless wire
§3.3.3 MMA Welding
Connection of Output Cables Two sockets are available on this welding machine. For MMA
welding the electrode holder is shown be connected to the positive socket, while the earth lead
(work piece) is connected to the negative socket, this is known as DCEP. However various
electrodes require a different polarity for optimum results and careful attention should be paid to
the polarity, refer to the electrode manufacturers information for the correct polarity.
DCEP: Electrode connected to “+”output socket.
DCEN: Electrode connected to“-” output socket.
Switch the ON/OFF Switch (located on the rear panel) to OFF.
(1) Connect the earth lead to “-”, tighten clockwise;
(2) Connect the earth clamp to the work piece. Contact with the work piece must be firm contact
with clean, bare metal, with no corrosion, paint or scale at the contact point.
(3) Connect the electrode lead to “+”, tighten clockwise;
(4) Each machine is equipped with a power cable should be based on the input voltage welding
power cable connected to the appropriate position, not to pick the wrong voltage;
(5) With the corresponding input power supply terminal or socket good contact and prevent
oxidation;
(6) With a multi meter measure the input voltage is within the fluctuation range;
(7) The power ground is well grounded.

OVERVIEW
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§3.4 Maintenance of MIG Gun mechanism
§3.4.1 Dissection graphics for the MIG GUN
标准化
工艺
批准
日期
设计
制图
校对
审合
处数
标记 更改文件号 重量(g)
共页共
日期
签字
上海亿诺科技有限公司
零部件描述 参考编号 材料
公差选择范围
页
外形尺寸
ICT2098
描 述
图 号
序号 备 注
焊枪15/3米/弹性针/蓝色手柄 -------
上海市顾戴路2535弄99号3号楼2楼
16
图 号
序号
1
2
9
3
6
7
8
11
10
12
13
描 述 数量 备 注
12
34
7
11
1213
14
15
1617
ICS0063
ICU0003-08
ICZ6087
ICV0685
IHQ0070
IFT0874
IHJ0715
IHJ0782
14
IHJ0028
IHJ0645
IFT0063
IZT0071
1
1
1
1
3
1
1
1
1
1
1
1
18
17 送丝管锁紧螺母
带绝缘层送丝管0.6-0.8 3米 蓝色IIC0500
导电嘴 0.8/M6*25
喷嘴 D.12 14-15AK
螺丝 M4X6 UNI 6107
15AK 枪颈(包括六角适配器和塑料适配器)
MIG蓝色手柄
焊枪用开关 21.8mm
螺丝 D.3x10
电缆护套 12-16-25 MMQ
电缆支撑用球节 15AK
手柄锁紧环
二氧化碳欧式后把套
数量
1
1
19
18
10
95 6
8
塑料适配器
六角适配器
IZH0667
IHJ0030
5
4
1
15
ITB0059 欧式中央插头/弹性针 1
ICG6000
19 导电嘴扳手 1
IHJ0063 焊枪锁紧螺母/塑料螺纹 1
ICN0663 同轴电缆组/16mmq/3米 1
3.1 ICZ0087 15AK 枪颈 1
3.1
§3.4.2 Parts list for the MIG GUN
NO.
Description
QTY.
Remark
1
Tip D.12 14-15AK
1
2
Electric nozzle 0.8/M6*25
1
3
15AK Goose gun neck（Hexangular adapter and Plastic adapter）
1
3.1
15AK Goose gun
1
4
Hexangular adapter
1
5
Plastic adapter
1
6
MIG blue handle
1
7
Torch Switch 21.8mm
1
8
Screw D.3*10
3
9
Handle locking ring
1
10
Cable fixing joint 15AK
1
11
Coaxial cable team /16mmq/3m
1
12
Cable thimble 12-16-25 MMQ
1
13
CO2 Euro-rear thimble
1
14
Screw M4*6 UNI 6107
1
15
Torch locknut /plastic screw thread
1
16
Euro-main socket/flexibility pin
1
17
Feeding pipe locknut
1
18
Insulating feed pipe 0.6-0.8 3m, Blue
1
19
Spanner for the electric nozzle
1