Magnum MIG200L PRO DUAL PULSE User manual

OPERATION MANUAL
MIG200L PRO DUAL PULSE

OPERATION MANUAL
Contents
SAFETY...............................................................................................................1
CAUTION............................................................................................................3
MIG-200L TECHNICAL DATA........................................................................ 5
MIG INSTALLATION.........................................................................................6
LIFT TIG INSTALLATION................................................................................. 9
MMA INSTALLATION.....................................................................................10
OPERATION PANEL INSTRUCTION.......................................................... 11
MEMORY FUNCTION....................................................................................12
LIFT TIG SETTING GUIDE.............................................................................19
MMA SETTING GUIDE.................................................................................. 21
TROUBLE SHOOTING...................................................................................24
MAINTENANCE...............................................................................................26
CIRCUIT............................................................................................................27
WARRANTY INFORMATION........................................................................ 28

MIG200L PRO DUAL PULSE
1
Machine Operating Safety
• Do not switch the function modes while the machine is operating. Switching of the function
modes during welding can damage the machine. Damage caused in this manner will not be
covered under warranty.
• Disconnect the electrode-holder cable from the machine before switching on the machine,
to avoid arcing should the electrode be in
contact with the work piece.
• Operators should be trained and or qualified.
Electric shock: It 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.
• Connect the primary input cable according to Australian and New Zealand standards and
regulations.
• Avoid all contact with live electrical parts of the welding/cutting circuit, electrodes and wires
with bare hands.
• The operator must wear dry welding gloves while he/she performs the welding/cutting task.
• The operator should keep the work piece insulated from himself/herself.
• Keep cords dry, free of oil and grease, and protected from hot metal and sparks.
• Frequently inspect input power cable for wear and tear, replace the cable immediately if
damaged, bare wiring is dangerous and can kill.
• Do not use damaged, under sized, or badly joined cables.
• Do not drape cables over your body.
• We recommend (RCD) safety switch is used with this equipment to detect any leakage of
current to earth.
Fumes and gases are 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
• Keep the working area well ventilated, use fume extraction or ventilation to remove
welding/cutting fumes and gases.
• In confined or heavy fume environments always wear an approved air-supplied respirator.
• Welding/cutting fumes and gases can displace air and lower the oxygen level causing injury
or death. Be sure the breathing air is safe.
• Do not weld/cut in locations near degreasing, cleaning, or spraying operations. The heat
and rays of the arc can react with vapours to form highly toxic and irritating gases.
• Materials such as galvanized, lead, or cadmium plated steel, containing elements that can
give off toxic fumes when welded/cut. Do not weld/cut these materials unless the area is very
well ventilated, and or wearing an air supplied respirator.
Arc rays: harmful to people’s eyes and skin. Arc rays from the welding/cutting process

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produce intense visible and invisible ultraviolet
and infrared rays that can burn eyes and skin.Always wear a welding helmet with correct
shade of filter lens and suitable protective clothing including welding gloves whilst the
welding/cutting operation is performed.
• Measures should be taken to protect people in or near the surrounding working area. Use
protective screens or barriers to protect
others from flash,glare and sparks; warn others not to watch the arc.
Fire hazard. Welding/cutting on closed containers, such as tanks,drums, or pipes, can
cause them to explode. Flying sparks from the
welding/cutting 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/cutting.
• The welding/cutting sparks & spatter may cause fire, therefore remove any flammable
materials well away from the working area. Cover flammable materials and containers with
approved covers if unable to be moved from the welding/cutting area.
• Do not weld/cut on closed containers such as tanks, drums, or pipes, unless they are
properly prepared according to the required Safety Standards to insure that flammable or
toxic vapours and substances are totally removed, these can cause an explosion even
though the vessel has been “cleaned”. Vent hollow castings or containers before heating,
cutting or welding. They may explode.
• Do not weld/cut where the atmosphere may contain flammable dust, gas, or liquid vapours
(such as petrol)
• Have a fire extinguisher nearby and know how to use it. Be alert that welding/cutting sparks
and hot materials from welding/cutting can easily go through small cracks and openings to
adjacent areas. Be aware that welding/cutting on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
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/cutting 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.
• Insure cylinders are held secure and upright to prevent tipping or falling over.
• Never allow the welding/cutting electrode or earth clamp to touch the gas cylinder, do not
drape welding cables over the cylinder.
• Never weld/cut 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/cutting are invisible
and odourless.
• Shut off shielding gas supply when not in use.
• Always ventilate confined spaces or use approved air-supplied respirator.
Electronic magnetic fields. MAGNETIC FIELDS can affect Implanted Medical Devices.
• Wearers of Pacemakers and other Implanted Medical Devices should keep away.

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• Implanted Medical Device wearers should consult their doctor and the device manufacturer
before going near any electric welding, cutting or heating operation.
Noise can damage hearing. Noise from some processes or equipment can damage
hearing.
• Wear approved ear protection if noise level is high.
Hot parts. Items being welded/cut 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/cutting gun. Use insulated welding gloves
and clothing to handle hot parts and prevent burns.
CAUTION
1. Working Environment.
i. The environment in which this welding/cutting equipment is installed must be free of grinding dust,
corrosive chemicals, flammable gas or
materials etc, and at no more than maximum of 80% humidity.
ii. When using the machine outdoors protect the machine from direct sun light, rain water and snow etc; the
temperature of working environment
should be maintained within -10°C to +40°C.
iii. Keep this equipment 30cm distant from the wall.
iv. Ensure the working environment is well ventilated.
2. Safety Tips.
i. Ventilation
This equipment is small-sized, compact in structure, and of excellent performance in amperage output. The
fan is used to dissipate heat generated by this equipment during the welding/cutting operation. Important:
Maintain good ventilation of the louvres of this equipment. The minimum distance between this equipment
and any other objects in or near the working area should be 30 cm. Good ventilation is of critical importance
for the normal performance and service life of this equipment.
ii. Thermal Overload protection.
Should the machine be used to an excessive level, or in high temperature environment, poorly ventilated area
or if the fan malfunctions the
Thermal Overload Switch will be activated and the machine will cease to operate. Under this circumstance,
leave the machine switched on to
keep the built-in fan working to bring down the temperature inside the equipment. The machine will be ready
for use again when the internal
temperature reaches safe level.
iii. Over-Voltage Supply
Regarding the power supply voltage range of the machine, please refer to “Main parameter” table. This
equipment is of automatic voltage
compensation, which enables the maintaining of the voltage range within the given range. In case that the
voltage of input power supply
amperage exceeds the stipulated value, it is possible to cause damage to the components of this equipment.
Please ensure your primary
power supply is correct.

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iv. Do not come into contact with the output terminals while the machine is in operation. An electric shock
may possibly occur.
ATTENTION! - CHECK FOR GAS LEAKAGE
At initial set up and at regular intervals we recommend to check for gas leakage
Recommended procedure is as follows:
1. Connect the regulator and gas hose assembly and tighten all connectors and clamps.
2. Slowly open the cylinder valve.
3. Set the flow rate on the regulator to approximately 8-10 L/min.
4. Close the cylinder valve and pay attention to the needle indicator of the contents pressure gauge on the
regulator, if the needle drops away towards
zero there is a gas leak. Sometimes a gas leak can be slow and to identify it will require leaving the gas
pressure in the regulator and line for an
extended time period. In this situation it is recommended to open the cylinder valve, set the flow rate to 8-10
L/min, close the cylinder valve and check
after a minimum of 15 minutes.
5. If there is a gas loss then check all connectors and clamps for leakage by brushing or spraying with soapy
water, bubbles will appear at the leakage
point.
6. Tighten clamps or fittings to eliminate gas leakage.
IMPORTANT! - We strongly recommend that you check for gas leakage prior to operation of your machine.
We recommend that you close the cylinder valve when the machine is not in use.

5
MIG-200L TECHNICAL DATA
Gas Metal Arc Welding (GMAW) is an arc
welding process where a consumable wire is fed by motor driven feed
rolls to a welding gun, and where welding current is supplied from the
welding power source. The welding arc is struck between the work piece
and the end of the wire, which melts into the weld pool. The arc and the
weld pool are both shielded by gas flow from the gun, or in the case of
“self shielded” wires, by gases generated by the wire core. The process is
very versatile in that by selection of the correct wire composition,
diameter and shielding gas, it can be used for applications ranging from
sheet-metal to heavy plate, and metals ranging from carbon steel to
aluminum alloys.
TECHNICAL DATA MIG200L
Power Supply / Phases
240V +/- 15% 50/60Hz
Rated input power
MIG:40-200
MMA:30-200
TIG:20-200
Duty cycle
60%
Feeding mode
ALL IN ONE
Wire feeding speed
2-15M/min
Welding plate Thickness
0.5-5mm
Welding wire diameter
0.8-1.2
Size (mm)
460x220x375mm
Weight (kg)
15.6kg
Warranty
2 years warranty

OPERATION MANUAL
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MIG INSTALLATION
1.Connect the welding torch into the Euro MIG torch connection socket on the front panel, and tighten it.
2.Insert the earth cable plug into the required polarity and tighten -negative for gas shielded wires positive for
gas less wires. + postive for gas wire. The weld power cable goes into the opposing negative or positive
socket.
3.Connect Gas Line to Gas Regulator and connect the gas regulator to the Gas Cylinder. Carefully open the
valve of the gas cylinder, set the flow to 5 l/min.
4.Fit the correct type and size of drive rollers (see the chapter of wire feed roller selection)
5.Place the Wire Spool onto the Spool Holder. Feed the wire into the wire feeder inlet guide tube through to
the drive roller.
6.At the wire feed assembly, release the compression screw by swivelling it outwards. This allows the top
roller arm to spring to the open position.The end of the welding wire can now be passed through the inlet
guide, over the bottom driven roller, and into the output wire guide tube.
7.Check that the drive roll groove is correct for the wire in use. The appropriate size is stamped on the visible
side of the installed roller. Check also that the correct size contact tip is fitted at the gun end.
8.Return the top roller arm to the closed position and adjust the compression screw to provide sufficient
clamping of the drive roll to achieve constant wire feeding. Do not over tighten.
9.With the equipment energised, operate the gun switch to feed wire through the gun cable.

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WIRE FEED ROLLER SELECTION
Solid Hard Wire - like Steel, Stainless Steel require a drive roller with a V shape groove for optimum grip and drive
capability. Solid wires can have more tension applied to the wire from the top pressure roller that holds the wire in
the groove and the V shape groove is more suited for this. Solid wires are
more forgiving to feed due to their higher cross sectional column strength, they are stiffer and don’t bend so easy.
Soft Wire - like Aluminum requires a U shape groove. Aluminum wire has a lot less column strength, can bend
easily and is therefore more difficult to feed. Soft wires can easily buckle at the wire feeder where the wire is fed
into inlet guide tube of the torch. The U-shaped roller offers more surface area grip and traction to help feed the
softer wire. Softer wires also require less tension from the top pressure roller to avoid deforming the shape of the
wire, too much tension will push the wire out of shape and cause it to catch in the contact tip.
Accessories:
V GROOVE DRIVE ROLLER - STEEL WIRE
1 x 0.8-0.9 V
U GROOVE DRIVE ROLLER - ALUMINUM WIRE
1 x 1.0-1.2 U
KNURLED ROLLER
1 x 0.8-0.9 KNURLED ROLLER

OPERATION MANUAL
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LINER INSTALLATION
LINER
NOTICE
•New and unused spiral liners must be shortened to the actual length of the cable
assembly.
•To install the wire guide with some tension, excess length of 14 mm is required.
To be used for steel wires.
1 Lay down the cable assembly straight and unscrew gas nozzle and contact tip from the torch
neck.
2 Unscrew nut from the central connector and slide liner through the wire conduit up to the
retaining nipple.
3 Screw down nut again by hand and cut off excess length of the liner flush with the torch neck
or tip adaptor.
4 Unscrew nut and pull out liner.
5 Sharpen the liner beginning to an angle of approx. 40°and debur the edge.
6 Slide sharpened liner through the wire conduit up to the retaining nipple and screw down
nut and tighten it using a multiple wrench.
7 Screw in contact tip and attach gas nozzle.
PA LINER
NOTICE
•New and unused PA liners must be shortened to the actual length of the cable
assembly.
•For PA liners with an outer diameter of 4.00 mm, the capillary tube in the distance
adaptor must be replaced with a guide tube.
•We recommend that you sharpen the PA liner to an angle of 40°.
To be used for aluminium, copper, nickel and stainless steels.
1 Sharpen beginning of PA liner using the ABICOR BINZEL sharpener at an angle of
about 40°and slide PA liner through the wire conduit until a noticeable resistance is felt in
the contact tip.
2 Slide clamp nipple, O-ring and nut onto PA liner and tighten the nut under tension.
3 Mark overlength of the PA liner in front of the wire feed rolls and cut it off at the mark using
the cutter.
4 Sharpen the cutting point.

MIG 200L
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LIFT TIG INSTALLATION
In the TIG (Tungsten Inert Gas) method, the electric arc strikes under an inert gas (argon) shield, between the
welded element and the non-fusible electrode made of pure tungsten or tungsten with additives.
The TIG method is especially recommended for aesthetic and high-quality joining of metals, without
laborious mechanical treatment after welding. However, this requires proper preparation and cleaning of the
edges of both welded elements. The mechanical properties of the additive material should be similar to the
properties of the welded parts. The role of shielding gas is always played by pure argon, supplied in
quantities depending on the welding current set.
1.Connect the welding torch into the Euro MIG torch connection socket on the front panel, and tighten it.
2.Insert the earth cable plug into the positive socket. The TIG torch plug into negative socket.
3.Connect Gas Line from the torch to Gas Regulator and connect the gas regulator to the Gas Cylinder.
Carefully open the valve of the gas cylinder, set the flow to 5 L/min.

MIG 200L
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MMA INSTALLATION
Arc welding is also called the MMA (Manual Arc Welding) method and is the oldest and most versatile arc
welding method.
The MMA method uses a coated electrode, consisting of a metal core covered with a lagging. An electric arc
is created between the end of the electrode and the material being welded. Arc ignition is created by
touching the electrode with the end of the workpiece. The welder feeds the electrode as it melts into the
workpiece so as to maintain a constant arc length and at the same time moves its melting end along the
welding line. The melting coating of the electrode gives off protective gases that protect the liquid metal from
the influence of the surrounding atmosphere, and then solidifies and forms a slag on the surface of the lake,
which protects the coagulating weld from cooling too quickly and harmful environmental influences.
Connect the welding and mass leads to the appropriate output connectors of the welder, according to the
polarity recommended by the manufacturer of the electrodes you intend to weld.

MIG200L PRO DUAL PULSE
200L
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OPERATION PANEL INSTRUCTION
1
Function switch button to the left menu. Press over 5 seconds switch to data recall page.
Function selection: When you choose a function, the relative icon will be highlighted.
2
Return button, switch to the parent menu, or return. Press over 5 seconds resume to
default setting.
3
Data adjusting knob. According left or right button, to switch the relative menu, and turn
this knob to adjust the data. Quick turning：Press down and turn the knob at the same
time for quick adjusting.
Fine turning：Adjust the knob normally for precise adjusting, slower.
4
Execute button, press it to go into sub-menu, or execute the current operation. Press
over 5 seconds will save current data.
5
Function switch button to the right menu. Press over 5 seconds switch to data storage
page.
6
5
1
2
5
3
4

OPERATION MANUAL
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1.WELDING MODE SETTING
Press button or to select the welding mode, then press to next step.
Synergy mode
MIG mode
TIG mode
MMA mode
2. Synergy MODE
Under the Auto mode, you can select the material, thickness and the wire diameter, then you can start your
welding, the machine will recommend the welding current, voltage and the wire feeding speed for you. Of
cause you can adjust them yourself according the welding needs.
Note：
Re-set the material and thickness, the system will recover to default data.
In synergy mode, 4T is not available. Please choose MIG mode for 4T control steps.
Synergy is specially recommend to welding freshman.

MIG200L PRO DUAL PULSE
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1.Selection of material
Spin the knob to select welding
material. Number on the right
correspond to the material on the
left.
2.Select of plate thickness
Spin the knob to adjust plate
thickness from 0.5-5mm.
3.Selection of wire diameter
Select the corresponding wire
diameter. Selection from 0.8-1.2mm
available. The device will
recommend the right voltage and
current for you.

OPERATION MANUAL
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3.MIG MODE SETTING
Selection of handle methods
2-step welding: When you press the
button of the torch, it start to weld by
holding the button, when release, it
stop welding.
4-step welding: When you press the
torch and then release, it start to weld.
When press again, it stop welding. 4T
mode is recommended in long time
welding situation.
Selection of welding pulse
1. For no pulse selection, please
choose the first one.
2. For single pulse selection, please
choose the second one.
3. For double pulse selection, please
choose the third one.
Selection of welding material
MIG machine can weld 5 kinds of
materials. Carbon steel, stainless steel,
Al-Mg, Al-Si, Cu-Si.
Welding pure Aluminum please choose
Al-Si material.

MIG200L PRO DUAL PULSE
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Selection of wire diameter
Spin the knob to select wire diameter
from 0.8-1.2mm.
Selection of wire feeding speed
Adjust the wire feeding data from
2-15M/min. Wire feeding speed change
along with welding current.
If burn back happen, means the current
is too high. Please minor adjust the
voltage to -5%~ -10% until burn back
disappear.
Selection of Voltage
At the beginning, please adjust the
data to “0”, and try welding. If the arc
too short, please adjust it higher. If
burn back happen, please adjust
voltage to -5% or lower.

OPERATION MANUAL
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Inductance
At the first, please adjust the data to
“0” then try welding, if arcing is too
soft, you can adjust the inductance to
negative; on the contrary, adjust it to
positive.
Note：Inductance had set up well by
system, if no other special
technological needed, there is no
need to change it.
Select the “Peak feeding” function
Adjust the data until the left-top data
match the thickness of the work piece.
Selection of dual pulse frequency
Recommend range is 1-2Hz according
your welding swing.

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Selection of dual pulse duty cycle
Recommend to be used in range of
30%-40%. The higher you choose, the
metal bead interval will be larger in the
same welding speed.
Selection of Base feeding function
Adjust the data. It’s recommended to
adjust within 70%-90% of the peak
feeding speed.
MEMORY FUNCTION
MIG-200L possess 18 sets memories.
Long press 3 seconds to restore current setting.
Long press 3 seconds to recall setting.

MIG200L PRO DUAL PULSE
200L
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MIG Welding Current-Wire Diameter And Plate Thickness Chart
Wire diameter
Plate thickness
1mm
2mm
3mm
4mm
5mm
AL-Si1.0/(4043) (DCEP)
Wire speed（M/min）
2.0
4.2
5.8
7.0
8.5
Welding current (A)
24
58
85
107
133
Arc voltage
16.0
18.3
19.2
21.0
22.5
AL-Si1.2/(4043) (DCEP)
Wire speed（M/min）
1.5
3.0
4.5
6.5
7.8
Welding current (A)
27.0
64
100
143
173
Arc voltage
16.5
17.8
19.5
22.5
24.5
Al-Mg1.0/(5356) (DCEP)
Wire speed（M/min）
2.5
6.0
8.0
11.0
12.5
Welding current (A)
30
70
95
130
148
Arc voltage
14.8
18.3
19.8
22.8
23.4
Al-Mg1.2/(5356) (DCEP)
Wire speed（M/min）
2.2
4.0
5.3
7.5
8.5
Welding current (A)
33
65
89
128
141
Arc voltage
15.7
17.2
17.7
19.3
20.0
AL1.0/(1070) (DCEP)
Wire speed（M/min）
2.8
5.3
7.0
8.5
10.0
Welding current (A)
37
77
107
133
160
Arc voltage
16.9
18.9
21.0
22.5
23.6
Al-Si 1.2/(1070) (DCEP)
Wire speed（M/min）
1.7
3.2
4.0
5.8
6.9
Welding current (A)
30.0
68.0
88.0
127.0
152.0
Arc voltage
16.7
18.0
18.8
21.6
22.9
Cu-Si 1.0/(CuSi) (DCEP)
Wire speed（M/min）
4.0
9.0
12.0
14.0
16.0
Welding current (A)
70.0
156.0
200.0
237.0
260.0
Arc voltage
19.0
23.8
25.5
27.0
29.0
Cu-Si 1.2/(CuSi) (DCEP)
Wire speed（M/min）
2.8
5.4
6.8
8.5
9.4
Welding current (A)
72.0
153.0
194.0
220.0
241.0
Arc voltage
19.7
23.5
25.6
28.5
29.6
Instruction：Al and Al-Si wire both use Al-Si Function.