Migomag SIM 200 LCD User manual

Migomag SIM 200 LCD DC MIG DC,
TIG / MMA Arc Welder
Part Number: ASIM200LCD
Operators Manual
MIGOMAG
SIM 200 LCD
Multi Process 3 in 1 Welding Inverter with PFC
(Internal Wirefeeder)

THANK YOU FOR YOUR BUSINESS!
Congratulaons on your new MIGOMAG MACHINE. We are proud to have you as our
customer and will strive to provide you with the best service and reliability in the welding
industry. This product is backed by our extensive warranty.
To locate your nearest distributor or repair agent please call +03 9313 3100, or visit us on
the web at www.migomag.com.au.
This Operang Manual has been designed to instruct you on the correct use and operaon
of your Migomag Welder. Your sasfacon with this product and its safe operaon is our
ulmate concern. Therefore please take the me to read the enre manual, especially
the Safety Precauons. They will help you to avoid potenal hazards that may exist when
working with this product.
Migomag your Welding Industrial Specialist - we are the right choice for all your welding
needs.
Migomag is one of the Market Leaders of Arc Welding Products for welders
needs from Light Industrial to Heavy industrial.
Migomag Welding Supplies
Your Welding Industrial Specialist
668 Somerville Road, Sunshine VIC 3020
03 9313 3100
inf[email protected]
www.migomag.com.au
A division of Wesfarmers Industrial & Safety
Record the following informaon for Warranty purposes:
Where Purchased: _____________________________________________________
Purchase Date: ________________________________________________________
Equipment Serial #: ____________________________________________________

Table of Contents
Secon Page
General Safety Rules 1
Descripon 7
Unpacking 7
Specicaons 8
Know your Welder 9
Interface Descripon 11
Recommended Welding Wires and Gas Mixes 15
Installaon 16
Operaon 20
External Trouble Shoong 31
Main Circuit Diagram 33
Spare Part Diagram 34
Drive Bracket Assembly Part Diagram 35
Spare Part List 36
Drive Bracket Assembly Part List 37
Service, Maintenance, Transportaon and Storage 38
Warning Label 38
Warranty 38
Terms & Condions 39
Migomag MIG Torch 41

Operators Manual
1
General Safety Rules
WARNING: Read and understand all instrucons. Failure to follow all instrucons listed
below may result in serious injury.
CAUTION: Do not allow persons to operate or assemble this SIM 200 unl they have
read this manual and have developed a thorough understanding of how the SIM 200
works.
WARNING: The warnings, cauons, and instrucons discussed in this instrucon manual
cannot cover all possible condions or situaons that could occur. It must be understood
by the operator that common sense and cauon are factors which cannot be built into
this product, but must be supplied by the operator.
1. Your Welding Environment
• The welding machine is not suitable for use in rain
• Keep the environment you will be welding in free from ammable materials
• Always keep a re exnguisher accessible to your welding environment
• Always have a qualied person install and operate this equipment
• Make sure the area is clean, dry and venlated. Do not operate the welder in humid,
wet or poorly venlated areas
• Always have your welder maintained by a qualied technician in accordance with local,
state and naonal codes
• Always be aware of your work environment. Be sure to keep other people, especially
children, away from you while welding
• Keep harmful arc rays shielded from the view of others
• Mount the welder on a secure bench or cart that will keep the welder secure and
prevent it from pping over or falling
2. Your Welder’s Condion
• Check ground cable, power cord and welding cable to be sure the insulaon is not
damaged. Always replace or repair damaged components before using the welder
• Check all components to ensure they are clean and in good operang condion before
use
3. Use of Your Welder
CAUTION! Do not operate the welder if the output cable, electrode, torch, wire or wire
feed system is wet. Do not immerse them in water. These components and the welder
must be completely dry before aempng to use them.

Migomag SIM 200 LCD
Model No ASIM200LCD 2
• Follow the instrucons in this manual
• Keep welder in the o posion when not in use
• Connect ground lead as close to the area being welded as possible to ensure a good
ground
• Do not allow any body part to come in contact with the welding wire if you are in
contact with the material being welded, ground or electrode from another welder
• Do not weld if you are in an awkward posion. Always have a secure stance while
welding to prevent accidents. Wear a safety harness if working above ground
• Do not drape cables over or around your body
• Wear a full coverage helmet with appropriate shade (see ANSI Z87.1 safety standard)
and safety glasses while welding
• Wear proper gloves and protecve clothing to prevent your skin from being exposed to
hot metals, UV and IR rays
• Do not overuse or overheat your welder. Allow proper cooling me between duty
cycles
• Keep hands and ngers away from moving parts and stay away from the drive rolls
• Do not point torch at any body part of yourself or anyone else
• Always use this welder in the rated duty cycle to prevent excessive heat and failure
4. Specic Areas of Danger, Cauon or Warning
Electrical Shock
WARNING! Electric arc welders can produce a shock that can cause injury or death.
Touching electrically live parts can cause fatal shocks and severe burns. While welding, all
metal components connected to the wire are electrically hot. Poor ground connecons
are a hazard, so secure the ground lead before welding.
• Wear dry protecve apparel: coat, shirt, gloves and insulated footwear
• Insulate yourself from the work piece. Avoid contacng the work piece or ground
• Do not aempt to repair or maintain the welder while the power is on
• Inspect all cables and cords for any exposed wire and replace immediately if found

Operators Manual
3
• Use only recommended replacement cables and cords
• Always aach ground clamp to the work piece or work table as close to the weld area
as possible
• Do not touch the welding wire and the ground or grounded work piece at the same
me
• Do not use a welder to thaw frozen pipes
Fumes and Gases - WARNING!
• Fumes emied from the welding process displace clean air and can result in injury or
death
• Do not breathe in fumes emied by the welding process. Make sure your breathing air
is clean and safe
• Work only in a well-venlated area or use a venlaon device to remove welding
fumes from the environment where you will be working
• Do not weld on coated materials (galvanized, cadmium plated or containing zinc,
mercury or barium). They will emit harmful fumes that are dangerous to breathe. If
necessary use a venlator, respirator with air supply or remove the coang from the
material in the weld area
• The fumes emied from some metals when heated are extremely toxic. Refer to the
material safety data sheet for the manufacturer’s instrucons
• Do not weld near materials that will emit toxic fumes when heated. Vapors from
cleaners, sprays and degreasers can be highly toxic when heated
UV and IR Arc Rays
DANGER! The welding arc produces ultraviolet (UV) and infrared (IR) rays that can cause
injury to your eyes and skin. Do not look at the welding arc without proper eye protecon.
• Always use a helmet that covers your full face from the neck to top of head and to the
back of each ear
• Use a lens that meets ANSI standards and safety glasses. For welders under 160 Amps
output, use a shade 10 lens; for above 160 Amps, use a shade 12. Refer to the ANSI
standard Z87.1 for more informaon

Migomag SIM 200 LCD
Model No ASIM200LCD 4
• Cover all bare skin areas exposed to the arc with protecve clothing and shoes. Flame-
retardant cloth or leather shirts, coats, pants or coveralls are available for protecon
• Use screens or other barriers to protect other people from the arc rays emied from
your welding
• Warn people in your welding area when you are going to strike an arc so they can
protect themselves
Fire Hazards
WARNING! Do not weld on containers or pipes that contain or have had ammable,
gaseous or liquid combusbles in them. Welding creates sparks and heat that can ignite
ammable and explosive materials.
• Do not operate any electric arc welder in areas where ammable or explosive
materials are present
• Remove all ammable materials within 35 feet of the welding arc. If removal is not
possible, ghtly cover them with reproof covers
• Take precauons to ensure that ying sparks do not cause res or explosions in hidden
areas, cracks or areas you cannot see
• Keep a re exnguisher close in the case of re
• Wear garments that are oil-free with no pockets or cus that will collect sparks
• Do not have on you any items that are combusble, such as lighters or matches
• Keep work lead connected as close to the weld area as possible to prevent any
unknown, unintended paths of electrical current from causing electrical shock and re
hazards
• To prevent any unintended arcs, cut wire back to ¼” sck out aer welding
Hot Materials
CAUTION! Welded materials are hot and can cause severe burns if handled improperly.
• Do not touch welded materials with bare hands
• Do not touch TIG gun nozzle aer welding unl it has had me to cool down

Operators Manual
5
Sparks/Flying Debris
CAUTION! Welding creates hot sparks that can cause injury. Chipping slag o welds
creates ying debris.
• Wear protecve apparel at all mes: ANSI-approved safety glasses or shield, welder’s
hat and ear plugs to keep sparks out of ears and hair
Electromagnec Field - CAUTION!
• Electromagnec elds can interfere with various electrical and electronic devices such
as pacemakers
• Consult your doctor before using any electric arc welder or cung device
• Keep people with pacemakers away from your welding area when welding
• Do not wrap cable around your body while welding
• Wrap TIG gun and ground cable together whenever possible
• Keep TIG gun and ground cables on the same side of your body
Shielding Gas Cylinders can Explode
WARNING! High pressure cylinders can explode if damaged, so treat them carefully.
• Never expose cylinders to high heat, sparks, open ames, mechanical shocks or arcs
• Do not touch cylinder with TIG gun
• Do not weld on the cylinder
• Always secure cylinder upright to a cart or staonary object
• Keep cylinders away from welding or electrical circuits
• Use the proper regulators, gas hose and ngs for the specic applicaon
• Do not look into the valve when opening it

Migomag SIM 200 LCD
Model No ASIM200LCD 6
• Use protecve cylinder cap whenever possible
5. Proper Care, Maintenance and Repair
• Always have power disconnected when working on internal components
• Do not touch or handle PC board without being properly grounded with a wrist strap.
Put PC board in stac proof bag to move or ship
• Do not put hands or ngers near moving parts such as drive rolls of fan
MOM SIM 200 USE AND CARE
• Do not modify the MOM SIM 200 LCD in any way. Unauthorized modicaon may
impair the funcon and/or safety and could aect the life of the equipment. There are
specic applicaons for which the MOM SIM 200 LCD was designed
• Always check of damaged or worn out parts before using the MOM SIM 200 LCD.
Broken parts will aect the MOM SIM 200 LCD operaon. Replace or repair damaged
or worn parts immediately
• Store idle MOM SIM 200 LCD. When MOM SIM 200 LCD is not in use, store it in a
secure place out of the reach of children. Inspect it for good working condion prior to
storage and before re-use
Noce:
• If the welder connues to work for to long, the (Protecon Indicator) on the panel
would be on, indicang that the inner temperature rise inside the welder had exceed
the designed permied temperature. At this me, stop the welding work, wait unl
the welder has cooled inside and the (Protecon Indicator) has turned o, then
connue to work again
• Cut o the power switch and gas cylinder before leaving the welding place temporarily
or aer the welding worked nished
• Welders should wear canvas work clothes and welding face shield to prevent arc light
and heat radiaon
• Put light-proof screen around the work area to prevent others inuenced by the arc
lights
• Flammable, explosive items could not be put near the welding area
• Every outlet of the welder should be connected and earthed correctly
Noce: The cover protecon degree of the MOM series SIM 200 LCD welder is IP21S.
When the welder is operated, do not insert nger or round sck diameter less than
12.5mm (especially metal sck) into the welder; Do not allow to press heavily onto the
welder.

Operators Manual
7
Please read through this owner’s manual carefully before using product. Protect yourself
and others by observing all safety informaon, warnings, and cauons. Failure to comply
with instrucons could result in personal injury and/or damage to product or property.
Please retain these instrucons for future reference.
Descripon
The SIM 200 LCD series is a DC inverter 3 in 1 MIG welder. This unit uses 1~Phase 240V,
50/60HZ AC power. A 25 amp me delay fuse or circuit breaker is recommended. The SIM
200 LCD series is ideal for light industrial. MIG/MAG welding carbon steel, stainless steel,
aluminium, silicon bronze.
Unpacking
1. Remove cartons, bags or styrofoam containing the welder machine and accessories.
2. Check the contents with the packing list below.
ITEM QTY.
SIM 200 LCD Inverter MIG Welder 1 unit
MIG gun MMPRO 24 3MT 1pcs
TIG Torch MM17FXV 1pcs
Earth cable with clamp 1pcs
Gas hose ф6 5m
MIG Tip ф0.8 1pcs
Gas Regulator 1pcs
Operator’s Manual 1set
Drive Roller 0.6, 0.8 V, 0.9, 1.0V, 0.9-1.0U
3. Aer unpacking unit, inspect carefully for any damage that may have occurred during
transit. Check for loose, missing, or damaged parts.

Migomag SIM 200 LCD
Model No ASIM200LCD 8
Specicaons
Manufactured to Australian Standard
AS60974-1: 2006
AS610003.3
Primary Voltage
240 Vac, 50/60 Hz
Rated Primary Current (I e)
15 Amps
Maximum Primary Current (I max)
36 Amps
Recommended Generator kVA
9.0 kVA
Rated Output 15% @ 40 Deg
Duty cycle based on 10 minute cycle me
MIG
200 Amp, 24 V, 15% duty
77 Amp, 17.9 V, 100% duty
Sck
180 Amp, 27.2 V, 15% duty
69 Amp, 22.8 V, 100% duty
DC TIG
200 Amp, 18 V, 15% duty
77 Amp, 13.1 V, 100% duty
Welding Current
10 - 200 Amps
Open Circuit Voltage
71 V
VRD 12.7 V
Shipping weight
22 kg - Includes leads
16 kg - Power Source only
Mains Circuit Breaker Rang
36 Amps
Supply plug
15 Amp
Rang
IP21S
Fied Supply Cable
2.5 mm2 Three Core, Heavy Duty PVC
1PH
Cooling
Fan cooled, air drawn in through front of
machine
Insulaon
Class H, 140°C Rise
Spool Sizes
5 kg
Wirespeed RangeF
(0 - 14 Metres per min.)
Wire Size Range
0.6mm - 1.0mm Mild Steel
0.6mm - 1.0mm Stainless Steel
1.0mm Aluminium
0.8 - 1.0mm Silicon Bronze
If the supply cable is damaged it must
be replaced by the manufacturer, their
service agent or a similarly qualied
person.

Operators Manual
9
Know your Welder
Factory standard: EN60974-1
1. PRIMARY INPUT CABLE
2. ON/OFF - In the “OFF” posion no power is being supplied. In the “ON” posion
power is supplied to the main transformer and control circuit
3. REGULATOR FLOW METER
4. GAS HOSE - Used to connect the welding machine to the regulator
5. TIG TORCH - For DC Tig welding with Argon gas
6. MIG TORCH - MMPRO 24 3MT The welding wire is driven through the welding torch
to the work piece
7. EARTH CABLE WITH CLAMP - Use earth clamp to connect to work piece
8. POLARITY CHANGE CABLE - To change the polarity of machine from DC - to DC +
9. EARTH LEAD CONNECTION DC
10. EURO MIG TORCH CONNECTION
11. OPERATION PANEL
12. GAS HOSE CONNECTION
5
4
3
1
6
7
10
8
2
9

Migomag SIM 200 LCD
Model No ASIM200LCD 10
Front Control Panel
1. LCD: Shows all process from funcon selecon to welding.
2. Gas-check buon: press the buon to check gas ow.
3. Wire-check buon:press the buon to feed wire.
4. Mul-funcon adjusng knob: For funcon selecon; Press for conrming. Allows
user to adjust the current and wire feeding speed accurately.
5. Home Key: Keep pressing home key, return to home page
6. Return: Return to the previous step.
1
2
4
36
5

Operators Manual
11
Interface Descripon
1. Mul-funcon selecon: Process Selecon Mode DC MIG, DC TIG & MMA
2. Polarity setup: Shows connecon for dierent welding polarity, for dierent processes.
MIG
Gasless MIG

Migomag SIM 200 LCD
Model No ASIM200LCD 12
MMA
DC TIG
3. Welding display: Shows all selected parameters.
a. Under MIG welding
Welding process mode
Wire feed speed Amps when welding & aer
Sengs
Trigger mode
Arc control
Voltage aer welding
Set voltage
Process selecon Trigger selecon mode
Arc control for MIG

Operators Manual
13
b. TIG welding display, user can set current parameter.
c. Sck welding, user can set current to arc force parameter.
4.Seng screen: It shows language, units, light seng, informaon and recover seng.
Amps
Volts
Sengs
Process selecon
Amps
Volts
VRD mode
Arc force & dynamics
Sengs
Process selecon
Language
Units measure Trouble shoong
Screen brightness Factory reset
Program version
seriel number

Migomag SIM 200 LCD
Model No ASIM200LCD 14
5. Alarm interface:It shows the machine is overloaded and the internal temperature is
too high. Weld output will turn o automacally but the fan will sll be working. When
the internal temperature is decreased, the alarm interface will turn o and the machine
will be ready to weld.

Operators Manual
15
Recommended Welding Wires and Gas Mixes
FE= Mild Steel Mig welding wire. The recommended wire grade is ER70S6 Kiswel KC 28
Mig wire.
Mild steel Mig welding Gas recommendaon for Fe/Mild steel is Coregas 5/2.
The gas mix is 93% argon 5% Co2 and 2% O2.
SS= Stainless Steel Mig welding wire. The recommended wire grades are Kiswel
316lsi,308lsi,309lsi Mig wire.
Stainless Steel Mig welding Gas recommendaon is Coregas Shieldpro 20.
The gas mix is 98% argon 2% Co2.
AL= Aluminum Mig welding wire, The recommended wire grades are ER5356, 5183 and
4043 Mig wire.
Aluminum Mig welding Gas recommendaon is Coregas Pure argon. The gas mix is 100%
argon.
CUSI= Silicon bronze welding wire, The recommended wire grades are Kiswel ERCuSi-A
Mig wire.
Silicon bronze welding Gas recommendaon is Coregas Pure argon.
The gas mix is 100% argon.

Migomag SIM 200 LCD
Model No ASIM200LCD 16
Installaon
1. Power Requirement
AC single phase 240V, 50/60HZ fused with a 25 amps me delayed fuse or 36 AMP circuit
breaker is required. Check with local requirements for your situaon.
WARNING:
• High voltage danger from power source! Consult a qualied electrician for proper
installaon of receptacle. This welder must be grounded while in use to protect the
operator from electrical shock.
• Do not remove grounding pin on plug in any way. This will void your warranty. Do not
use any adapters between the welder’s power cord and the power source receptacle.
Make sure the POWER switch is OFF when connecng your welder’s power cord to a
proper power point 240Vac, 50/60Hz, single phase, 15 amp power source.
2. Extension Cord
During normal use an extension cord is not necessary. It is strongly recommended that
an extension cord should be 15 AMP. This drop in voltage can aect the performance of
the welder. If you need to use an extension cord it must be a 15 AMP power lead at the
smallest 2.5m sq cable.
• Do not use an extension cord over 50 . in length
3. Seng up the Work Piece
3.1 Welding posions
There are two basic posions for welding: Flat and Horizontal. Flat welding is generally
easier, faster, and allows for beer penetraon. If possible, the work piece should be
posioned so that the bead will run on a at surface.
3.2 Preparing the Joint
Before welding, the surface of work piece needs to be free of dirt, rust, scale, oil or paint.
Or it will create a brile and porous weld. If the base metal pieces to be joined are thick
or heavy, it may be necessary to bevel the edges with a metal grinder. The correct bevel
should be around 60 degrees.
See following picture:

Operators Manual
17
Based on dierent welding posions, there are dierent welding joints, see following images
for more informaon.
Connecon to Electrical Mains Power Supply
The SIM 200 LCD is factory ed with a 3 metre, 3 core 2.5mm2 Heavy Duty PVC
mains power supply cable with moulded 3 pin, 15 Amp, Single Phase plug.
A 15 Amp plug and socket is recognisable by a wide Earth pin. Power Supply authories
require that equipment ed with a 15 Amp plug shall ONLY be connected to a 240 Volt, 15
Amp power point. DO NOT modify the plug.
The minimum capacity of the mains wiring and power outlet supplying a welder is
selected according to the eecve primary current of the equipment. The eecve
primary current for the SIM 200 LCD is 15 Amps.
The minimum recommended mains circuit breaker rang for a SIM 200 LCD is
36 Amps. Note : Due to normal variaons of sensivity, the tripping me of some
36 Amp circuit breakers may limit the duty cycle available from the SIM
200 LCD. A higher rated circuit breaker can be selected, but the mains wiring capacity must
be rated to suit.