Matco Tools MM200 LCD User manual

Processes
MIG (GMAW)
TIG (GTAW)
STICK (SMAW)
OPERATORS’ MANUAL
INVERTER MULTMIG WELDER
MM200 LCD
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.

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CONTENT
§1 Safety ................................................................................2
§1.1 Signal Explanation....................................................................................... 2
§1.2 Arc Welding Damage ................................................................................... 2
§1.3 The knowledge of Electric and Magnetic Fields ........................................ 5
§2 Overview ...............................Error! Bookmark not defined.
§2.1 Brief Introduction.............................................. Error! Bookmark not defined.
§2.2 Working Principle......................................................................................... 6
§2.3 Volt-Ampere Characteristic ......................................................................... 6
§3 Installation and Adjustment ............................................7
§3.1 Parameters ................................................................................................... 7
§3.2 Duty cycle and Over-heat ............................................................................ 8
§3.3 Equipment Connection................................................................................ 8
§4 Operation ..........................................................................9
§4.1 Layout for the front and rear panel............................................................. 9
§4.2 Welding operation...................................................................................... 10
§4.3 Welding parameters................................................................................... 23
§4 .4Operation environment.............................................................................. 23
§4.5 Operation Notices ...................................................................................... 23
§5 Maintenance & Troubleshooting...................................25
§5.1 Maintenance ............................................................................................... 25
§5.2 Troubleshooting......................................................................................... 26
§5.3 Maintenance of MIG Gun mechanism....................................................... 27
§5.4Electrical schematic drawing ..................................................................... 28

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§1 Safety
§1.1 Signal Explanation
 The above signals mean warning! Notice! Running parts and getting an electric shock or thermal parts will
take damage for your body or others. The corresponding notices are as follows. It is quite a safe operation
after taking several necessary protection measures.
§1.2 Arc Welding Damage
 The following signals and word explanations are to some damages for your body or others happening on the
welding operation. While seeing these, please remind of yourself or others to be dangerous.
 Only ones who are trained professionally can install, debug, operate, maintain and repair the equipment.
 During the operation, non-concerned people should be lift, especially for children.
 After shut off the machine power, please maintain and examine the equipment according to §5 because of
the DC voltage existing in the electrolytic capacitors.
ELECTRIC SHOCK CAN KILL.
 Never touch electrical parts.
 Wear dry, hole-free gloves and clothes to insulate yourself.
 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.
 Take carefully when using the equipment in small place, falling-off and wet circumstance.
 Never close the machine power before installation and adjustment.
Ensure to install the equipment correctly and ground the work or metal to be welded to a good electrical
(earth) ground according the operation manual.
The electrode and work (or ground) circuits are electrically “hot” when the welder 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”.

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 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 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 a shock.
FUMES AND GASES CAN BE DANGEROUS.
 Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. When
welding, keep your head out of the fume. 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 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.
ARC RAYS CAN BURN.
 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 helpers
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.

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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 adds the 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.
WELDING SPARKS can cause fire or explosion.
 Remove fire hazards 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 ear plugs when welding out of
position or in confined places. Always wear safety glasses with side shields when in a welding area.

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 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 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.
-A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.
 Never allow the electrode or any other electrically “hot” parts to touch a 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.
§1.3 Knowledge of Electric and Magnetic Fields
HSW 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.
HSW 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 automatically to protect.
HSW 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 with IGBT technology, low power dissipation;
HSW SERIES arc welding machine is suitable for all positions welding for various plates made of stainless
steel, carbon steel, alloyed steel, copper, titanium, etc..

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§2.2 Working Principle
The working principle of MM SERIES arc welding machine is shown as the following figure. Single-phase
110V/220V work frequency AC is rectified into DC, then is converted to medium frequency AC 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
MM 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)
44
14
0600 Io（A）
Uo（V）
Working point
Volt-ampere characteristic The relation between the rated loading
voltage and welding current
Single-phase
110V 50/60Hz
Single-phase
220V 50/60Hz
Current sensor

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§3 Installation and Adjustment
§3.1 Parameters
Model
Parameters
MM200 LCD
Input Voltage（V）
1~110/120/130±10%
1~220/230/240±10%
Input Current（A）
37 MIG 28 MMA 28 TIG
28 MIG 32 MMA 22 TIG
Input Power（KW）
4.0 MIG 3.1 MMA 3.1 TIG
6.2 MIG 7.3 MMA 4.9 TIG
Welding Current（A）
25-140 (MIG)
10~140 (TIG)
10~100 (MMA)
25-200 (MIG)
10~200(MMA/TIG)
Welding Voltage（V）
10-27 (MIG)
No-load Voltage（V）
67 (MIG) 14 (TIG/MMA)
Power Factor
0.99
Duty cycle（40℃）
40%140
A
60%115
A
100%90
A
40%100
A
60%85A
100%65
A
40%140
A
60%115
A
100%90
A
40%200A
60%165A
100%130A
Diameter(mm)
Fe ：0.6、0.9、1.0 Ss ：0.8、0.9、1.0
Flux-Cored：0.6、0.8、0.9、1.0
Protection class
IP23
Insulation class
H
Cooling
AF
Dimensions（mm）
505*210*330
Weight（Kg）
15.5
Note: The above parameters are subject to change with the improvement of
machines.

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§3.2 CSA/UL Duty Cycle Rating
The letter “X” stands for the duty cycle, which is defined as the proportion of the time (10 minutes) that a
machine can work continuously at 100% of rated welding current in an ambient temperature of 105°F.
The relation between the duty cycle “X” and the
output current “I” is shown as the right figure.
If transformer is over-heat, the heat relay
inside it will open and will output an instruction to
circuit board, cut AC relay and the output welding
current, and brighten the over-heat pilot lamp in
the front panel. At this time, the machine should
be allowed to cool down for 10 minutes with the
fan. When operating the machine again, the
welding output current or the duty cycle should be reduced.
§3.3 Equipment Connection

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Operation Steps：
1、Connect the power source input cable of welding machine with the output port of air switch in electric box
on the spot.
2、Connect the cable plug of wire feeder to the positive output of welding machine.
3、Connect the control cable plug of wire feeder to the aero socket on the front board of welding machine.
4、Connect the negative pole of welding machine to the work piece (base metal).
5、Connect the output pipe of gas cylinder to the input joint of gas valve on the wire feeder and clamp it.
6、Insert the torch joint into the output of wire feeder unit and keep the wire aim at the wire feeder mouth.
Note: The plane of the joint should be aimed at screw, plugged tightly and rotated 90º, then screw the
bolt tightly to ensure the gun contacting closely.
7、Connect the shielded gas pipe of torch with the output of front panel on wire feeder.
8、Connect the control cable pin of torch with the two-lead aero socket of front panel on wire feeder.
9、Notice that the wire diameter should be accordant with the wire wheel and torch tip and press the wire
properly with the handle.
§4 Operation
§4.1 Layout for the front and rear panel:
1. MIG Gun Euro-connect socket.
2. Positive(+) polarity output socket
3. Control cable connector socket.
4. Shield gas connection fitting 5/8-18FRHT
5. Negative(-) polarity output socket
6. Wire Feeder / Spool Gun switch

MAINTENANCE AND TROUBLESHOOTING
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§4.2Welding operation：
Main Start-up Interface (MM200 LCD):
1. Function selection interface: Rotate R knob to FUNCTION icon. Rotate L Knob to
choose from 4 welding methods of MIG/MAG Synergic, MIG/MAG Manual, Stick & TIG Lift.
2. Synergic parameter selection interface: Rotate R knob to SYNERGIC icon. A synergic
parameter may be selected by rotating L Knob in the interface.
3. Welding parameter setting interface: Rotate R knob to PARAMETER icon. a welding
parameter and its corresponding value may be selected and set by rotating L Knob.
4. System setting interface: Rotate R knob to SYSTEM icon. A parameter and its
corresponding value may be selected and set by rotating L Knob.
5. Function icon display interface: an interface displaying the icon of the welding method
currently used.
6. Welding mode icon display interface: an interface displaying the icon of the welding
mode currently used (2T/4T).
7. Synergic parameter display interface: an interface displaying the synergic parameters
currently used (only available when MIG/MAG Synergic welding method is selected).
8. Multifunction display interface: an interface displaying the contents corresponding to
those selected by users, such as icons of welding method, welding mode and parameter,
parameter values, etc.

MAINTENANCE AND TROUBLESHOOTING
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§4.2.1Operation of MIG/MAG Synergic welding method:
1. Selection of the welding method:
1) In the main interface, press the MENU key to enter the function selection interface;
2) In the function selection interface, rotate L Knob to select the MIG/MAG Synergic welding
method and press the knob for confirmation in the interface shown below:
Fig. 1
2. Selection of synergic parameters:
1) In the main interface, press the MENU key to enter the synergic parameter selection;
2) In the synergic parameter selection interface, rotate L Knob to select the required synergic
parameters and press it for confirmation in the interface shown below:
3. Selection and setting of welding parameters:
1) In the main interface, press the MENU key to enter the welding parameter setting interface;
2) In the welding parameter setting interface, rotate L Knob to select the parameter as
required and rotate R Knob to set a value for the parameter. Press L Knob or R Knob for
confirmation in the interface shown below:

MAINTENANCE AND TROUBLESHOOTING
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Welding parameters
available by rotating L
Knob
Welding parameters
available by rotating R
Knob
Two/four Stroke
2T/4T
Burn Back
0-10
Slow Feed
0-10
Pre-flow
0-2 S
Post Flow
0-10 S
Inductance
0-10
Fig. 2
4. Selection of system setting parameters:
1) In the main interface, rotate the R knob to parameter setting interface;
2) Rotate L knob to select system settings:
5. Setting of welding current and voltage
1) Press the ENTER key to enter the welding interface shown below:

MAINTENANCE AND TROUBLESHOOTING
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2) In the welding interface, rotate L Knob to set the welding current, for which the adjustable
scope is different with the welding wires and gases as described in §4.3;
3) The welding voltage will be automatically set as the value corresponding to that of the
welding current set by rotating L Knob.
4) When the programmed welding current does not meet user requirements, the setting is
available by rotating R Knob;
5) After the setting, press L Knob and R Knob for confirmation;
§4.2.2Operation of the MIG/MAG Manual welding method:
1. Selection of the welding method:
1) In the main interface, press the MENU key to enter the function selection interface;
2) In the function selection interface, rotate L Knob to select the MIG/MAG Manual welding
method and press down it for confirmation as shown in Fig. 1;
3) In the wire cabinet, confirm “Selection Switch” is turn down to activate wire feed drive.
2. Selection and setting of welding parameters:
1) In the main interface, press the MENU key to enter the welding parameter setting interface;
2) In the welding parameter setting interface, rotate L Knob to select the parameter as
required and rotate R Knob to set a value for the parameter, afterwards, press L Knob or R
Knob for confirmation. Refer to Fig. 2;
3. Setting of wire feed rate and welding current:
1) Press the ENTER key to enter the welding interface shown below:

MAINTENANCE AND TROUBLESHOOTING
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2) In the welding interface, rotate L Knob to set the wire feed rate (1.5 - 13.0 m/min) and
rotate R Knob to set the welding current (10 - 27 V);
3) After the settings, press L Knob and R Knob for confirmation;
4. Selecting spool gun operation:
1) Install spool gun into Gun socket and set Switch to “Spool Gun”.

MAINTENANCE AND TROUBLESHOOTING
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§4.2.3 Operation of the Stick welding method:
1. Selection of the welding method:
1) In the main interface, press the MENU key to enter the function selection interface;
2) In the function selection interface, rotate L Knob to select the Stick welding method and
press it for confirmation. Refer to Fig. 1;
2. Selection and setting of welding parameters:
1) In the main interface, press the MENU key to enter the welding parameter setting interface;
2) In the welding parameter setting interface, rotate L Knob to select the parameter as
required and rotate R Knob to set a value for the parameter, afterwards, press L Knob or R
Knob for confirmation as shown below:
Welding parameters
available by rotating
L Knob
Welding parameters
available by rotating
R Knob
Hot Start
0-10
Arc Force
0-10
3. Setting of welding voltage:
1) Press the ENTER key to enter the welding interface shown below:
2) In the welding interface, rotate L Knob to set the welding current (10 - 200 A), and then
press it for confirmation;

MAINTENANCE AND TROUBLESHOOTING
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§4.2.4 Operation of the TIG Lift welding method:
1. Selection of the welding method:
1) In the main interface, press the MENU key to enter the function selection interface;
2) In the function selection interface, rotate L Knob to select the TIG Lift welding method and
press it for confirmation. Refer to Fig. 1;
2. Selection and setting of welding parameters:
1) In the main interface, press the MENU key to enter the welding parameter setting interface;
2) In the welding parameter setting interface, rotate L Knob to select the parameter as
required and rotate R Knob to set a value for the parameter, afterwards, press L Knob or R
Knob for confirmation as shown below:
Welding parameters
available by rotating
L Knob
Welding
parameters
available by
rotating R Knob
Two/four Stroke
2T/4T
Pre-flow
0-2 S
Down Slope
0-10 S
Post Flow
0-10 S
3. Setting of welding current:
1) Press the ENTER key to enter the welding
interface as shown below:
2) In the welding interface, rotate L Knob to set
the welding current (10 - 200 A), and then press
it for confirmation.

MAINTENANCE AND TROUBLESHOOTING
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Note: 1. In the welding process, press the MENU key to return to the main interface
and re-set parameters, and then press the ENTER key to enter the welding
interface;
2. In the function selection interface, rotate L Knob to select a welding method
as required and press L Knob two times to directly enter the welding interface.
§4.3Welding parameters
Material
Wire diameter (mm)
GAS
Welding current
(A)
Fe-metal Solid-cored
0.6
CO2
25-90
Fe-metal Solid-cored
0.8
CO2
40-150
Fe-metal Solid-cored
0.9
CO2
50-180
Fe-metal Solid-cored
1.0
CO2
60-200
Fe-metal Solid-cored
0.6
MIX
25-110
Fe-metal Solid-cored
0.8
MIX
40-180
Fe-metal Solid-cored
0.9
MIX
50-200
Fe-metal Solid-cored
1.0
MIX
60-200

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Fe-metal Flux-cored
0.8
CO2
60-160
Fe-metal Flux-cored
0.9
CO2
60-180
Fe-metal Flux-cored
1.0
CO2
70-200
Ss-metal Solid -
cored
0.8
MIX
60-160
Ss-metal Solid -
cored
0.9
MIX
70-170
Ss-metal Solid -
cored
1.0
MIX
70-200
AL-Mg Solid -cored
0.9
Ar
100-170
§4 .4Operation environment
▲ Height above sea level ≤1000 M
▲ Operation temperature range -10～+40℃.
▲ Air relative humidity is below 90 %( 20℃).
▲ Preferable site the machine some angles above the floor level, the maximum angle does
not exceed 15℃.
▲ Protect the machine against heavy rain or in hot circumstance against direct sunshine.
▲ The content of dust, acid, corrosive gas in the surrounding air or substance can not
exceed normal standard.
▲ Take care that there is sufficient ventilation during welding. There is at least 30cm free
distance between the machine and wall.
§4.5 Operation Notices
▲ Read §1 carefully before attempting to use this equipment.
▲Connect the ground wire with the machine directly and refer to §3.5.
▲ Ensure that the input is single-phase:50/60Hz, 110V/220V±10%.
▲Before operation, clear others from area and do not watch the arc with unprotected eyes.
▲ Ensure good ventilation of the machine to improve duty ratio.
▲When power switch shuts off protectively, don’t restart it until problem is resolved.
● Warning: For safety while maintaining the machine, please shut off the supply
power and wait for 5 minutes, until capacity voltage drops to safe voltage 36V.

MAINTENANCE AND TROUBLESHOOTING
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Date
Maintenance items
Daily
examination
Observe that whether panel knob and switch in the front and at the
back of arc welding machine are flexible and put correctly in place. If
the knob has not been put correctly in place, please correct; If you
can't correct or fix the knob , please replace immediately;
If the switch is not flexible or it can't be put correctly in place, please
replace immediately; Please get in touch with maintenance service
department if there are no accessories.
After turn-on power, watch/listen to that whether the arc welding
machine has shaking, whistle calling or peculiar smell. If there is one of
the above problems, find out the reason to get rid of; if you can't find
out the reason, Please contact local this area agent or the branch
company.
Observe that whether the display value of LED is intact. If the display
number is not intact, please replace the damaged LED. If it still doesn’t
work, please maintain or replace the display PCB.
Observe that whether the min/max value on LED accords with the
set value. If there is any difference and it has affected the normal
welding craft, please adjust it.
Check up that Whether fan is damaged and is normal to rotate or
control. If the fan is damaged, please change immediately. If the fan
does not rotate after the arc welding machine is overheated , observe
that whether there is something blocked in the blade, if it is blocked,
please get rid of ; If the fan does not rotate after getting rid of the
above problems, you can poke the blade by the rotation direction of
fan. If the fan rotates normally, the start capacity should be replaced; If
not, change the fan.
Observe that whether the fast connector is loose or overheated. if
the arc welding machine has the above problems, it should be
fastened or changed.
Observe that Whether the current output cable is damaged. If it is
damaged, it should be wrapped up, insulated or changed.
Monthly
examination
Using the dry compressed air to clear the inside of arc welding
machine. Especially for clearing up the dusts on radiator, main voltage
transformer, inductance, IGBT module, the fast recover diode and
PCB, etc.
Check up the bolt in arc welding machine, if it is loose, please screw
down it. If it is skid, please replace. If it is rusty, please erase rust on
bolt to ensure it works well.
Quarter-
yearly
examination
Whether the actual current accords with the displaying value. If they
did not accord, they should be regulated. The actual current value can
be measured by the adjusted plier-type ampere meter.
Yearly
examination
Measure the insulating impedance among the main circuit, PCB and
case, if it below 1MΩ, insulation is thought to be damaged and need to
change and need to change or strengthen insulation.