McAnax MIG-160E User manual

Inverter DC MIG Welder Manual www.gentt.ie
Operator’s Manual
Inverter DC MIG Welder
(MIG-200)
With LED Display
Warning!
This machine should be operated and maintained by competent or
professionals. Repairs should only be carried out after reading the manual

Inverter DC MIG Welder Manual www.gentt.ie
CONTENTS
Safety……………………..………………..……………………............................... 2
General Description………..………………..……………………........................... 3
Main Parameter………..………………..………………..……............................... 5
Structure of Welder……..………………..….………………….............................. 6
Installation…………..…...……………..……………………................................... 9
Welder Settings Quick Reference Chart.....………………..………………........... 14
Range of Welding Current and Voltage in CO2 Welding………....………........... 19
Welding parameters table………..............................……..………….……........... 19
Caution…………..…...……………..……………………........................................ 22
Maintenance………..…...…………….....………………........................................ 23
Daily Checks………..…...……………………………............................................. 24
Connection Diagram of the Machine…………..………........................................ 22
Exploded Diagram......…..………………..….………………….............................. 6
Plug Installation..........…..………………..….………………….............................. 6
1

Inverter DC MIG Welder Manual www.gentt.ie
SAFETY
Welding and cutting is dangerous to the operator, people in or near the working area and the
surrounding area, if the machine is not correctly operated. Therefore, the performance of
welding/cutting must only be under the strict and comprehensive observance of all relevant safety
regulations. Please read carefully these instructions carefully before the installation and operation.
The switching of function modes is possibly damaging to the
machine, when done so while the machine is in operation.
• Disconnect the electrode-holder cable from the machine,
before the welding.
• A safety switch is necessary to prevent the machine
from electric-leakage.
• Welding tools should be of high quality.
• Operators should be qualied and competent
Electric shock: It could be fatal!
• Connect the earth cable according to standard regulation.
• Avoid all contact with live electrical parts of the welding
circuit, electrodes and wires with bare hands. It is
necessary for the operator to wear welding gloves while
they perform the welding task.
• The operator should keep the working piece insulated from
themelves.
Smoke and gas generated while welding or cutting is
harmful to people’s health.
• Avoid breathing the smoke and gas generated while
welding or cutting.
• Keep the working area well ventilated.
Arc rays are harmful to people’s eyes and skin.
• Wear welding helmet, anti-radiation glass and work
clothes while the welding operation is performed.
• Measures also should be taken to protect people in or
near the working area.
Fire hazard
• The welding splash may cause re, thus remove ammable
material away from the working place.
• Have a re extinguisher nearby, and have a trained person
ready to use it.
2

Inverter DC MIG Welder Manual www.gentt.ie
GENERAL DESCRIPTION
3
This welding machine is composed of the inverter MIG welder power supply with invariable voltage output
external characteristics manufactured with advanced IGBT inverter technology designed by THE company.
With high-power component IGBT, the inverter convert the DC voltage, which is rectied from input
50Hz/60Hz AC voltage, to high-frequency 20-50KHz AC voltage; as a consequence, the voltage is trans-
formed and rectied. The features of this machine are as follows:
● IGBT inverter technology, current control, high quality, stable performance;
● Closed feedback circuit, invariable voltage output, great ability of balance voltage up to ±15%;
● Electron reactor control, stable welding, little splash, deep molten pool, excellent welding bead shaping;
● Welding voltage can be preset, and the voltmeter displays the preset voltage value when not welding.
● Both welding current and welding voltage can be observed at the same time.
● Burn back time is adjustable.
● Slow wire feeding during arc starting, remove the melting ball after welding，reliable arc starting;
● Small-sized, light-weighed, easy to operate, economical, practical.
Unpacking your machine
When unpacking, inspect carefully for any damage that may have occurred during transit. Check
carefully to ensure all the contents on the list below have been received in good condition
Included items:
No. Description Qty.
1 MIG Welder 1 Set
2Operator’s
Manual 1 Piece
3 Electrode Holder 1 Piece
4 Earth Clamp 1 Piece
5 3m MIG torch 1 Piece

Inverter DC MIG Welder Manual www.gentt.ie
Operating environment
Adequate ventilation is required to provide proper cooling for the MIG machine. Ensure that the machine
is placed on a stable level surface where clean cool air can easily ow through the unit. The MIG machine
has electrical components and control circuit .boards which will be damaged by excessive dust and dirt, so
a clean operating environment is essential.
Block Diagram
INPUT
LIFT TIG also called the contact type arcing TIG.
Required items: inverter welder with LIFT TIG function, contact type TIG gun with one output power cable
and one air tube.
Setting up of LIFT TIG is shown below:
The output power cable connects with the negative output terminal, and the air tube connects with the
gas meter on the argon gas bottle. There is a nut cover on the air tube, which can connect with the gas
meter. The thread specication for the gas meter and the nut should be the same. Then open the valve of
the argon gas bottle and open the valve of the gas meter, we can control the gas ow by adjusting the gas
regulating valve on the TIG gun. Make the tungsten needle touch the work piece, lift the TIG gun up by a
little amount, then we can see the arcing.
CONTROL
GENERAL DESCRIPTION
4

Inverter DC MIG Welder Manual www.gentt.ie
MAIN PARAMETER
MODEL MIG-160E MIG-200E
Power Supply
Voltage 220±10% 220±10%
Rated Input
Capacity 6.3 4.7 6.9 8.5 6.4 7.5
Rated Input Current 28 21 32 39 29 34
Output Current
Range 50-160 10-160 10-150 50-200 10-200 10-160
Function MIG TIG MMA MIG TIG MMA
Duty Cycle(40℃
10min)
30% 160A 30% 160A 30% 150A 20% 200A 20% 200A 20% 160A
60% 113A 60% 113A 60% 106A 60% 115A 60% 115A 60% 92A
100% 88A 100% 88A 100% 82A 100% 89A 100% 89A 100% 72A
No Load Voltage 50 50
Efciency 77% 77%
Power Factor 0.73 0.73
IP 21S 21S
Insulation Class H H
Cooling Way FAN & AIR FAN & AIR
Dimension 445*185*290 445*185*290
Wire Diameter 0.6-0.8-1.0 Ø2.5,Ø3.2 0.6-0.8-1.0 Ø2.5,Ø3.25,Ø4.0
Net Weight 10 10
Note:
The welding duty cycle is the percentage of actual continuous welding time that can occur in a ten minute cycle.
For example: 15% at 200amps - this means the welder can weld continuously at 200 amps for 1.5 minutes and
then the unit will need to be rested for 8.5 minutes. The duty cycle can be affected by the environment in which
the welder is used. In areas with temperatures exceeding 40 degrees, the duty cycle will be less than stated. In
areas less than 40 degrees, higher duty cycles have been obtained.
All tests on duty cycles have been carried out at 40 degrees with a 50%. So in practical working conditions the
duty cycles will be much greater than those stated above.
5KG Wire Spool Models
5

Inverter DC MIG Welder Manual www.gentt.ie
STRUCTURE OF WELDER
1Voltage Meter\Voltage rene Meter
2 Gas selection button
3 VRD/2T/4T selection button
4 Welding mode selection button
5Amperage\Inductance\Wire-feeding
Speed Meter
6 Wire diameter selection butoon
7 Gas check button
8 Wire check button
9 Spool gun button
10 Multifunction knob
11 MIG Torch ‘Euro Style’ Connection Socket
12 Positive (+) Welding Output Terminal
13 Negative (-) Welding Output Terminal
14 Polar conversion line
15 Spool gun socket
1
2
3
4
11
14
15
13
14
12
10 9
8
7
6
5
18 17
19
16
16 Rating label
17 Power switch
18 Welding gas inlet
19 Power cable
20 Rating label
21 Power switch
22 Welding gas inlet
23 Power cable
24 Drive roller retainer
25 Wire spool retainer
26 Spool brake adjustment
6

Inverter DC MIG Welder Manual www.gentt.ie
STRUCTURE OF WELDER
27 Torch trigger switch
28 Torch “Euro” connector
29 Work piece earth clamp
30 Earth lead quick connector
31 Conical gas nozzle/shroud
32 Welding tip
33 Shroud spring
34 Tip adapter
27 Torch trigger switch
28 Torch “Euro” connector
29 Work piece earth clamp
30 Earth lead quick connector
31 Conical gas nozzle/shroud
32 Welding tip
33 Shroud spring
34 Tip adapter
4.3 Welding parameters
4.4 Operation 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 oor 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 cannot exceed normal standard.
• Take care that there is sufcient ventilation during welding. There is at least 30cm free distance between
• the machine and wall.
4.5 Operation environment
• Read 1. Safety, carefully before attempting to use this equipment.
• Install the recommended 3 pin 16 amp plug to power cable as instructed at the back of the manual.
• Ensure that the input is single-phase:50/60Hz, 220/230/240V ±10%.
• Before operation, no concerned people should be left. Do not watch the arc in unprotected eyes.
• Ensure good ventilation of the machine to improve duty ratio.
• Turn off the engine when the operation nished for economize energy sources.
• When power switch shuts off protectively because of failure. Don’t restart it until problem is resolved.
• Otherwise, the range of problem will be extended.
• In case of problems, contact your local dealer if no our authorized maintenance man.
7

Inverter DC MIG Welder Manual www.gentt.ie
INSTALLATION
5.1 MIG Welding Set Up & Operation
5.1.1 Fitting the spool
5.1.1.1 Open the cover door for the wire feed compartment. Remove the wire spool retainer (24) by
threading off anti clockwise.
5.1.1.2 Fit the 200mm diameter wire spool to the spool holder, ensuring the end of the wires exits towards the
wire feeder from the bottom of the spool. Ret the wire spool retainer (25) and tighten hand tight.
5.1.1.3 Set the spool brake tension by rotating the adjustment screw (26) using an Allen Key wrench. Clockwise
to increase brake tension, anti-clockwise to decrease brake tension. The spool brake tension should be set so
that the spool can rotate freely, but does not continue to rotate once the wire feed stops. This may need to be
adjusted as the wire is used up and the spool weight decreases.
5.1.2 Loading wire feeder
5.1.2.1 Release the wire feeder tension arm (21) by pivoting the wire feed tension adjuster (20) as pictured
below.
5.1.2.2 Check the wire drive roller (23) groove matches the selected MIG wire type and size. The drive roller will
have two different sized grooves; the size of the groove in use is stamped on the side of the drive roller. For ux
cored ‘soft’ wire, such as that used in gas less MIG welding, the drive roller groove has a serrated prot. For solid
‘hard’ MIG wire, the roller groove has a ‘v’ shaped prole.
5.1.2.3 The drive roller (23) is removed by threading the drive roller retainer(24) off in the anti-clockwise
direction. Once the correct drive roller prole is selected, re-t the drive roller.
5.1.2.4 Thread the MIG wire from the spool through the input guide tube (22), through the roller groove and into
the outlet guide tube.
5.1.2.5 Replace the tension arm (21) and the tension adjustment (20). Double check the wire has located
correctly in the drive roller groove.
5.1.2.6 Adjusting wire feed tension: this is accomplished by winding the knob on the wire tension adjustment
arm (20). Clockwise will increase tension, anti-clockwise will decrease tension. There is a numbered scale on
the tensioner to indicate the position. Ideal tension should be as little as possible, while maintaining a consistent
wire feed with no drive roller slippage. Check all other possible causes of slippage, such as; incorrect/ worn drive
roller, worn/ damaged torch consumables, blocked/ damaged torch feed liner, before increasing feed tension.
8

Inverter DC MIG Welder Manual www.gentt.ie
INSTALLATION
Warning! - Before changing the feed roller or wire spool, ensure that the mains power is
switched off
Warning! - The use of excessive feed tension will cause rapid and premature wear of the
drive roller, the support bearing and the drive motor.
!
5.1.3 Loading wire feeder
5.1.3.1 Connect the MIG Torch Euro Connector (28) to the torch socket on the front of the welder (11).
Secure by rmly hand tightening the threaded collar on the MIG Torch Euro Connector clockwise.
5.1.3.2 Check that the correct ux cored, gas less wire, matching drive roller (23) and welding tip (32)
are tted.
5.1.3.3 Connect Torch Connection Power Lead (14) to the negative (-) welding output terminal (13).
5.1.3.4 Connect Earth Lead Quick Connector (30) to the positive (+) output welding terminal (12).
See picture below:
5.1.4 Setup for gas shielded MIG welding operation
5.1.4.1 Connect the MIG Torch Euro Connector (28) to the torch socket on the front of the welder (11).
Secure by rmly hand tightening the threaded collar on the MIG Torch Euro Connector clockwise.
5.1.4.2 Check that the correct gas shielded wire; matching drive roller (23) and welding tip (32) are tted.
5.1.4.3 Connect Torch Connection Power Lead (14) to the positive (+) welding output terminal (12).
5.1.4.4 Connect Earth Lead Quick Connector (30) to the negative (-) output welding terminal (13).
See picture below:
5.1.4.5 Connect Earth Clamp (29) to the work piece. Contact with work piece must be strong contact with
clean, bare metal, with no corrosion, paint or scale at the contact point.
5.1.4.6 Connect the gas regulator (optional) and gas line to the inlet on the rear panel (18). If the regulator is
equipped with a ow gauge, the ow should be set between 8 – 15 L/minute depending on application. If gas
regulator is not equipped with a ow gauge, adjust pressure so gas can just be heard coming out of the torch
conical nozzle (31). It is recommended that gas ow is checked again, just prior to starting weld this can be
done by triggering the MIG torch with the unit powered up.
!
9