Hyundai MIG-160 User manual

DC INVERTER MIG WELDER
MIG-
160/200
User Manual
Original Instructions
For Your Safety
Read and understand this manual
before use. Keep this manual for future
reference.

We are still constantly improving this welder, therefore, some partsof this welder may be changed in order to
achieve the better quality, but the main functions andoperations will not be alternated and changed.
Your understanding wouldbe greatly appreciated.
MIG-160/200

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Safety ............................................................................................................................................................
General Description .....................................................................................................................................
Main Parameters ..........................................................................................................................................
Electric Block Diagram ................................................................................................................................
Operation Control and Description .............................................................................................................
Installation Debugging and Operation .........................................................................................................
Caution .........................................................................................................................................................
Maintenance .................................................................................................................................................
Troubleshooting ............................................................................................................................................
Exploded Drawing ........................................................................................................................................
2
4
4
5
6
7
9
10
11
13
Table of Contents

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Welding is dangerous, and may cause damage to you and others, so take good protection when welding. For
details, please refer to the operator safety guidelines in conformity with the accident prevention requirements
of the manufacturer.
Professional training is needed before operatingthe machine.
● Use labor protection welding supplies authorized by national security supervision department.
● The operator must be qualified personnel with a valid “metal welding (OFC) operations” operation certificate.
● Cut off power before maintenance or repair.
Electric shock—may lead toserious injury or even death.
● Install earth device according to the application criteria.
● Never touch the live parts when skin bore or wearing wet gloves/clothes.
● Make sure thatyou are insulated from the ground and work piece.
● Make sure thatyour working position is safe.
Smoke & gas—may be harmful tohealth.
● Keep the headawayfrom smoke and gas to avoid inhalation of exhaust gas from welding.
● Keep the working environment in good ventilation with exhaust or ventilation equipment when welding.
Arc radiation—may damage eyes or burn skin.
● Wear suitable welding masksandprotective clothing to protect your eyes and body.
● Use suitable masksor screens to protect spectatorsfrom harm.
Improper operation may cause fire or explosion.
●
Welding sparksmay result in a fire, so please make sure no combustible materials nearby and pay attention
to fire hazard.
● Have a fire extinguisher nearby, and have a trained person to use it.
● Airtight container welding is forbidden
●
Must not use the machinesfor other purposes except welding, such as pipe thawing,batterycharging,
heating.
1. Safety

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Hot work piecemay cause severe scalding.
● Do not contact hotwork piece with bare hands.
● Cooling is neededduring continuoususe of the welding torch.
Magnetic fields affect cardiac pacemaker.
● Pacemaker users shouldbeaway from the welding spot before medical consultation.
Moving parts may lead to personal injury.
● Keep yourself awayfrom moving parts such as fan.
● All doors,panels,coversand other protectivedevices should be closed during operation.
Please seek professional help when encountering machine failure.
● Consult the relevant contentsof this manual if you encounter any difficulties in installation and operation.
●
Contact the service center of your supplier to seek professional help ifyou still cannot fully understand after
reading the manualor still cannot solvethe problemaccording to the manual.
Safe use of the welding torch.
●
Parts of the machine,such as the end of the filler wire and welding torch become burning hotduring use.
The wire is also sharp andmoves quickly, so be careful when threading it to place.
●
Never carry the machine on your shoulder during welding, but place it on an even surface. Also, do not store
the machine byhanging itfrom the shoulderstrap. The shoulder strap is for carrying only.
● Do not keep the machine near or on hotobjects, asthe plastic cover may melt.
●
Do not move the shielding gas bottle when the control valveisin place. Fix thegas bottle securely in an
upright position to a separate wall rack or bottlecart.
● Always close the gas bottle after use.

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This is an easy-to-use MIG welding machine suitable for both hobby and professional use. Before using
or doing any maintenance work on the machine, please read theoperating manual and keep it for further
reference.
● This machine has the functions of MIG and MMA.
● IGBT power device with unique control mode improves the reliability of machine.
● High duty cycle ensures long time operation.
●
Closed loop feedback control, constant voltage output, workable under mains voltagefluctuation within
±15%.
● Adjustablewelding voltage and current, excellent welding performance.
●
Adopting unique welding dynamiccharacteristic control circuit in MIG, stable arc, little spatter, beautiful
weld bead,high efficiency.
●
Removing tip ball after welding; high no-load voltage and soft start wire feeding resultin high successful
rate of arc ignition.
● Stable welding current in MMA, excellent arc ignition.
2. General Description
3. Main Parameters
Model MIG-160MIG-200
Rated Input Voltage (V)1P AC 230V, 50Hz
Rated Input Power (KVA) 5.77.2
Rated Input Current (A)24.7 31.3
Rated Output Current & Voltage 160A/23V 190A/24.5V
Output Current (A) MIG
50~160
MMA
20~140
MIG
50~190
MMA
20~160
No-load Voltage (V)65±5 65±5
Rated Duty Cycle (%) 3520
Efficiency (%)85 85
Power Factor (cosø) 0.73 0.73
Protection ClassIP21S IP21S
Insulation ClassF F
Wire FeedingSpeed (m/min) 2~15 2~15
Welding Wire Diameter (mm)0.6/0.8/1.0 0.6/0.8/1.0

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4. Electric Block Diagram

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5. Operation Control and Description
●
Front panel
a) Overheating LED
b) Power LED
c) Feed wire adjust
d) MMA current / MIG voltage adjust knob
e) MMA/MIG shift switch
f) Quick socket (-)
g) Quick socket (+)
h) European connector of the welding torch in MIG
●
Back panel
i) Gasin
j) Power switch : Power on/off
k) Power input cable
l) Fan
m) Grounding screw

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Warning
Please installthe machine strictly according to the following steps.
The protection class of this machine is IP21S,so avoid using it in rain.
Before using, please make sure the input voltage isin voltage range (200-240V). Otherwise, the machinewill
be damaged.
6.1 Connection ofinput cable
1) A primary power supply cable is available for this welding machine. Connect the power input cable to the
rated input power. (Ground connection is needed for safety purpose.)
2) The primary cable should be tightly connectedto the correct socket to avoid oxidization.
3) Check whether the voltage value varies in acceptable range witha multi-meter.
6.2 MMA installation
1) Two quick plugs are available for this machine. Insert the quick plugs into thequick socketson the front
panelof the machine, and tighten them to ensure good contact. Otherwise, the plugs and sockets will be
burnt if the working time is long and the working current is high.
2) Insert the cable plug with electrodeholder into the “+” output terminal “g” on the frontpanel of the ma-
chine, and tighten it clockwise.Insert the cable plug with work clamp into the “-” output terminal“f” on the
front panelof the machine, and tighten it clockwise.
3) Generally, DCEP connection and DCEN connection are available in MMA.
DCEP: Connect theelectrode holder to “+” output terminal, and the work clamp to “-” output terminal.
DCEN: Connect theelectrode holder to “-” output terminal, and thework clamp to “+” output terminal.
Operatorsmay choose DCEP/DCEN according to workpiece and electrode application requirement. Phe-
nomena such asunstable arc, excessive spatter, and electrode sticking will occur when improper polarity is
selected.Change the connection by exchanging the quick plugs to solve the problem.
4) Select cable with larger cross-section to reduce the voltage drop if the secondary cables (welding cable
and earth cable) are long.
6.3. Operation method
1) After being installed according to the above method, and with the power switch on, the machine starts with
the power LED on and the fan working.
2) Turn on the MMA/MIG shift switch to MMA mode, and adjust the welding current with the current control
knob according to the electrode diameter and the thickness of workpiece.
3) Generally, welding current should be as below according to the electrode diameter.
Φ2.5: 70-100A; Φ3.2: 110-160A; Φ4.0: 170-200A; Φ5.0: 230-280A
6. Installation Debugging and Operation

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6.4 MIG installation
1) Insert the welding torch into the “ ” output socketon the front panel of the machine, and tighten it.
Meanwhile, manually thread the welding wire into the torch body.
2) -
en it clockwise.
3) Insert the quick plug of the wire feeder into the “ +”,“g” (“GAS”) on the mid-clapboard of the welding ma-
chine, and tighten it clockwise.
4) Install the wire spool on the spindle adapter, ensuring that the groove size in the feeding position on the
drive rollmatches the contact tip size of the welding torch and the wire size. Release the pressure arm of
the wire feeder to thread the wire through the guide tube, and into the drive roll groove.Adjust the pressure
arm, ensuring no sliding of the wire. Too high pressure will leadto wire distortion, which will affect wire
feeding. Press the manual wire feeding button to thread the wire out of the torch contact tip.
5) Connect the cylinder equipped with the gas regulator to the gas inlet on theback panel of themachine with
a gashose.
6.4.1 Sketch map of installation