Most Fanmig 201 LCD User manual

User manual for MIG/MAG
semiautomatic welding machine
Fanmig 201 LCD MOST
Warning! A copy of this manual should be located in the
place of device use and should always remain available to the operator.
Original manual
Catalogue no: 51 00 023685
Operation Manual
Version 1.1 of 25-02-2019EN

Thank you for purchasing Fanmig 201 LCD a semi-automatic welding machine by MOST. We do
believe that this product will meet your requirements. Before starting the work and in order to
ensure correct use of the device please familiarize yourself with this User Manual
1. Health and Safety Manual
Warning! The device is may not be used for the purpose of pipe
defrosting! Information included on icons located on the device.
Use and maintenance of welding equipment may be dangerous. The user must
observe health and safety rules and regulations. Welding and cutting machines may be
used only by qualified personnel. Follow your local rules and regulations on working
with that type of devices and prevention of accidents.
Prior to starting your work remove all flammables from the welding area. Welding
inside tanks previously used as flammable liquids storage is forbidden. Place any
flammables in a safe location away from welding spatter.
Do not expose the device to rain, water vapour and do not spray water over it.
Do not start welding without proper eye protection equipment. Also protect other
people against generated radiation.
Use ventilation and filters in order to remove welding fumes from the work site. Use
individual filters if the filtering/ventilation system does not operate correctly or is not
available.
Stop your work immediately after finding damage to the power cords. Do not touch
the damaged cords. Prior a repair or maintenance disconnect the device from
power source. Never use the device with damaged power cords.
Keep a fire extinguisher close to the welding location. After finishing work
check the work station against fire hazards.
Never try to fix a damaged gas reducer on your own. In case
of malfunction replace the reducer to a fully functional one.
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Electromagnetic interference
The device may influence other devices sensitive to electro-
magnetic interference (robots, computers, etc.)
Always ensure that the devices within the welding work station are resistant to
interfe
rence.
For the purpose of limiting interference, it is recommended to use as short welding
cables as possible and arranged in parallel.
Always work in a distance at least 100 m from other sensitive devices.
Always make sure that the installation is grounded.
If there still are interference with other devices,
properly shield the cables or use appropriate filters.
INTRODUCTION
Commissioning and normal operation are possible only after reading the carefully reading following
manual. The MIG/MAG, TIG and MMA welding requires meeting the conditions corresponding to
electric arc welding and fire regulations.
Device operator should be equipped with appropriate personal health and safety equipment. It is
necessary to use a set of personal protective equipment in accordance with the provisions of Directive
of the Council Directive No. 2016/425. Personal protective equipment includes: welding mask, welding
gloves, protective apron, leather shoes, non-flammable welding clothing.
Despite the high technical standard of the device, the personnel should represent considerable
discipline in approach to health and safety requirements to protect against harmful and health
hazardous factors developed from welding technology.
OPERATING CONDITIONS
In order to ensure adequate service life and trouble-free operation it is recommended to:
- do not place or use this device on an inclined surface (of more than 15º),
- do not use the device for pipe defrosting,
- the device needs to be located in a place with free clean air circulation (to and from the fan without
obstacles). When connected to electrical network the device must not be covered (with, for example,
paper or cloth)
- minimize dirt and dust that can get into the device,
- device has an IP23S protection rating fo housing and may be exposed to direct atmospheric fallout
and is capable of operating outdoors.
- do not use the device for welding tanks previously used for flammable substances storing.
GASES AND FUMES
Using MIG / MAG, TIG and MMA techniques produces harmful gases and fumes containing ozone
and hydrogen as well as oxides or metal particles. Therefore, the welding work station should be
fitted with very good ventilation (dust and smoke extraction or airy location). Metal surfaces
intended for welding should be free from chemical contamination, especially degreasers (solvents)
that decompose during welding process and produce toxic gases. Welding of galvanized, cadmium-
coated or chromium-plated parts is permitted only when a suction and filtering device is fitted, and
with introduction of fresh air to the welding work station.
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RADIATION
Ultraviolet emission radiated when welding is harmful to eyesight and skin. Therefore a welding
mask with protective filters is required. Welding work station should meet certain requirements
and include:
• adequate lighting system, • fixed or movable protection screens, governing bystanders against
radiation effects (depending on requirements), location with wall colours providing appropriate
radiation absorption.
FIRE PROTECTION
Welding work station should be located at a safe distance from flammables placed especially on
the floor or walls. All flammables need fire protection against hot metal drops. It is
recommended to fit the work station with fire blankets and fire extinguishers.
PROTECTION AGAINST ELECTRIC SHOCK
It is unacceptable to connect the device to an improper installation or to an installation with
unverified zeroing efficiency. It is prohibited to use of device with shields removed or remove
the external shields while the device is connected to electric network. It is not allowed to work
on a suspended device (e.g. using a crane or a gantry). Only authorized persons should perform
maintenance and repair works keeping it in compliance with the safety conditions applicable to
renovation equipment.
2. Maintenance (power supply and wire feeder)
ATTENTION : In order to carry out any repair or maintenance activity, it is
recommended to
contact your nearest technical support of RYWAL-RHC (for list of company locations providing
technical support - see last page of this manual).
In the event of noticing any damage, the welder should stop working, disconnect the device from
power supply and report it to direct supervisor or appropriate service - RYWAL-RHC technical
support.
General maintenance (daily)
- check the condition of cables and connections, replace if necessary,
- remove spatter from the gas nozzle of the welding torch, spatter may transfer with the shielding
gas to the welding arc, tend to disrupt the shielding gas flow and can effect in a short circuit,
- check condition of welding torch, replace if necessary,
- check condition and operation of the cooling fan; keep the cooling air inlet and outlet
openings clean,
- keep the device clean.
Periodic maintenance (every 3 months at least)
Periodic maintenance frequency can be increased depending on the environment
in which the device is operating. Maintenance scope:
- using a stream of dry air (at low pressure) remove the dust from the outer parts of the casing
and from inside of the welding device,
- check and tighten all the screws,
- check the state of all electrical contacts and correct if necessary.
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ATTENTION : Electrical network must be disconnected from the device before any maintenance
and service work. After each repair, perform respective check to ensure safe use.
Mandatory device checks
According to the Labor Code provisions: "All responsibility for the safe use of machinery
and equipment shall be borne by the owner." This results in the obligation to perform periodic and
post-repair checks and inspections of equipment. Periodic tests are carried out at least once a year
(legal basis EN ISO 17662 clause 4.2), and post-repair tests after each repair that restored welding
functionality (legal basis: EN 60974-4 clause 4.6). All above services re performed by the technical
support of RYWAL-RHC.
3. Technical description and operating conditions
Fanmig 201 LCD is a cutting edge semi-automatic welding inverter machine designed for
MIG/MAG welding, TIG DC (scratch start) and MMA coated electrode welding. The device is operated
synergistically and includes a wide range of programmes for steel, stainless steel and aluminium. A
programme for brazing with CuSi3 fi 0,8 mm. solder is also available.
The device is powered from a single-phase 230V. A PFC (Power Factor Correction) filter has
been included in the device. The advantage of an inverter with PFC are: higher energetic
effectiveness, lower load for electric network, greater tolerance to current fluctuations and
less interference generated by the device.
The wire feeder enables wire welding with 5 kg / D200 spools. Recommended steel wire diameters
are 0.8 - 1.0 mm and 1.0 mm for aluminium. (gat AlMg5). After change to the polarisation it is
possible to apply self-shielding powder wires with a diameter of 0.8 mm or 0.9 mm.
The device is protected against overheating by a thermal sensor. Made in
accordance with EN 60974-1 standard.
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4. Technical data and completion
Parameter Unit Valuae
Electrical power supply V/Hz 1x230/50-60
Welding current range
MIG/MA
G TIG
MMA
A 20-200
10-200
10-200
Open circuit (MMA) U
0
V 67
Fuse A 16 (delayed)
Current I
eff
A 15.7
Current I
1max
A 30.5
Duty cycle: MIG/MAG
TIG
MMA
A/%
200 A/30%; 150 A/60%; 130 A/100%
200 A/35%; 150 A/60%; 140 A/100%
200 A/25%; 140 A/60%; 120 A/100%
Wire feeding speed m/min 1.5 – 17.0
Insulation class F
Protection class IP 23S
Rolls 30/22 (Cooptim type)
Dimensions mm 215x540x410
Weight kg 17.7
Catalogue no. 51 00 023685
Table 1: Technical parameters
The device is designed to be powered from a 1x110V single-phase network.
The connection should be equipped with a proper plug by a qualified elec-
trician. Technical data is subject to change - see name plate.
Device assembly:
Device is delivered with a mass cable and prepared for welding with a coated electrode, a gas
hose and an user manual. Wire feeder is equipped with standard 0.8-1.0 mm rolls for steel wire (51
13 007826).
Additional welding torches and accessories (optional) :
M24 SGRIP 3 m Welding Torch 55 08 302430
M24 SGRIP 4 m Welding Torch 55 08 302440
M24 SGRIP 5 m Welding Torch 55 08 302450
M15 SGRIP 3 m Welding Torch 55 08 301530
M15 SGRIP 4 m Welding Torch 55 08 301540
M15 SGRIP 5 m Welding Torch 55 08 301550
TIG SGT 17 4 m Welding Torch
17FSL4S
0.8-1.0 Roll 51 13 007826
0.6-0.8 Roll 51 13 007783
Accessories for aluminium welding and brazing (recommended wire diameter 1.0 mm) :
1.0AL-1.2AL Roll 51 13 007863
Brass tube for EURO connection: 51 13 008011
Oxygen inserts for welding torch: 55 13 013010 (3 m); 55 13 013020 (4 m); 55 13 013030 (5 m).
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5. Device construction
Figure 1: Fanmig 201 LCD construction
Figure 2: Fanmig 201 LCD control panel
Pos. Presentation
A1 MIG/MAG welding torch Eurosocket
A2 Current socket (-) or TIG torch socket
A3 Gas socket of the TIG torch
A4 Left hand wheel
A5 Display
A6 Right hand wheel
A7 Control socket of the TIG torch
A8 Current socket (+)
A9 Main switch ON/OFF
A10 Power cable
A11 Gas connection (quick coupling nipple)
A12 Top handle
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A13 Spool fixing bushing with a nut and internal brake
A14 Welding switch with connected MIG handle and spool in the handle
A15 MIG/MAG socket polarity reversing sockets
A16 Wire feeder
A17 Menu button
A18 Welding button
Table 2: Device part list according to Figure 1 and Figure 2
Figure 3: Wire feeding system
Pos. Presentation
E1 Pressure adjustment knob
E2 Pressure arm
E3 Entry sleeve
E4 MIG/MAG welding torch Euro socket
E5 Feeding roll
Table 3: Wire feeder parts list
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6. MIG/MAG welding technique
1 2 3 4
5 6 7 8
Figure 4: Main menu
Pos. Presentation
1 Choice of welding method
2 Selection of synergistic programs
3 Welding parameter settings
4
System settings
5 Selected welding method icon
6 Selected welding torch mode icon
7 Synergy program parameter (from left hand side: program number, material,
shielding gas and wire diameter)
8 Multifunction window - shows a current parameter
Table 4: Menu main functions
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Press A17 MENU button to navigate between various menu icons 1; 2; 3 or 4.
WELDING METHOD SELECTION (icon 1)
To select the welding method turn and then press the A4 knob.
Figure 5: Choice of welding method (selected: MIG/MAG Synergy)
Use the button on the upper right side of the panel A6 WELDING to display welding current and
voltage settings. Turn the A4 or A6 dials to change these parameters.
Figure 6: Welding parameter setting (program 03, intensity 85 A,
arc length correction +1.2)
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SELECTION OF SYNERGY PARAMETERS (WELDING PROGRAMS - icon 2)
The synergy parameters sub-menu are available only after selecting the MIG / MAG
Synergy method.
Turn and press the A4 dial to access the selection of synergy parameters
.
Figure 7: Selection of synergistic programs (Program 03 was chosen for 1.0 mm full steel
wire in the gas mix shielding)
Wire diameter
[mm]
Workpiece / wire type Gas
0.6 Full steel wire (program 01) MIX: 82%Ar+18%CO2
0.6 Full steel wire (program 04) CO2
0.8 Full steel wire (program 02) MIX: 82%Ar+18%CO2
0.8 Full steel wire (program 05) CO2
1.0 Full steel wire (program 03) MIX: 82%Ar+18%CO2
1.0 Full steel wire (program 06) CO2
0.8 Steel self-shielding powder wire
(program 07)
No gas shielding
0.8 Stainless steel (program 08) MIX: 97.5%Ar+2.5%CO2
1.0 Stainless steel (program 09) MIX: 97.5%Ar+2.5%CO2
1.0 Aluminium / AlMg (program 10) Argon
0.8 Galvanized steel / CuSi3 (program 11) Argon
Table 5: List of synergistic programs for the Fanmig 201 LCD.
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CHOICE OF AUXILIARY WELDING PARAMETERS (icon 3)
Turn the A4 dial and then press the A6 knob to access the auxiliary parameter settings.
Figure 8: Selection of other welding parameters (2-step mode selected)
Auxiliary welding
parameters
MIG / MAG welding
parameters (default)
Welding parameters
TIG (default)
MMA welding parameters
(default)
Work 2/4 measure 2T/4T (2T) 2T/4T (2T) -
Burning time of the
tip
i
0-100 - -
Free extension 0-10 (0) - -
Gas flow 0-2 s (0 s) - -
Gas flow 0-10 (0 s) 0-10 (0 s) -
Inductance 0-10 (5) - -
Current drop time - 0-10 s (0 s)
Hot Start - - 0-10 (0)
Arc Force - - 0-10 (0)
Table 6: Auxiliary parameters for different welding methods
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SYSTEM SETTINGS (icon 4)
Turn the A4 dial and then press the A6 knob to access the auxiliary system parame
ters.
The last item in the system settings submenu is Restoring factory settings. (RESET).
Press the A6 knob to restore factory settings .
Figure 9: System settings submenu (Polish language selected)
The following system settings are available:
- Language selection.
- Units (metric / imperial (inch).
- Sound for settings (on / off).
- Display brightness.
- RESET to factory settings.
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6.1 Selection of the wire feeder
In all Fanmig devices, two-groove rolls are used. The grooves serve to
feed wire with two different diameters (e.g., 0.8 and 1.0 mm). In order to change the diameter of the roll,
pressure knob E1 must be released first (according to Fig. 3), so the pressure arm E2 will lift up. Then
unscrew the roll fastening E5 and turn it 180 degrees. Alternatively replace it with the right wire for the
given diameter. Rolls intended for wire feeding must correspond to the diameter and workpiece of the
wire to be welded. Only such compatibility ensures equal wire feeding. Disturbances in wire feeding
lead to poor welding quality and wire deformation.
A
Correct
B
Incorrect
C
Incorrect
E4 Euro socket
E5
Roll
A B C
∅1,0
1,0

0.8

1.2

Figure 10: The influence of the roll groove on welding wire.
6.2 Device adjustment for aluminium welding
When feeding with aluminium wire, it is necessary to use a U-profile roll (e.g. 51 13 007863). To avoid
problems with wire feeding, use 1.0 mm AIMg or AlSi wire. Al99 alloy wires are too soft, so their use
can be problematic.
For aluminium welding, an additional Teflon insert of welding torch and a special current tip should
be applied. It is not recommend to use a welding torch longer than 3 m. Pay high attention to roll
pressure adjustments. Pressure should not be too high, as it can cause wire deformation. Always use
argon as shielding gas.
Figure 11: Adaptation of the aluminium wire feeder.
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G1 Euro socket
G2 Rolls (upper pressure and lower U-type)
G3 Collet (included with guide insert)
G4
O-ring 3.5 x 1.5mm prevents gas escaping (included with the guide insert)
G5
Nut
G6 Teflone insert (see chapter 4: Equipment)
G7
Brass tube stiffening Teflon insert (51 13 008011)
Table 7: Parts for adaptation of aluminium welding tray.
6.3 Installation of the wire spool (according to figures 1 and 3)
1. Open the side cover of the wire feeder housing.
2. Place the wire spool on the A13 spool clamping reel and secure it with the mounting nut. When
using a 300 spool type (15 or 18 kg) use a suitable adapter, e.g. 50 00 001103. The hole in the back
of the adapter must match the pin on the wire spool clamping sleeve!
3. Cut off the end of the wire and pull the wire through the input sleeve E3, the roll and then through
the bushing in welding torch socket (~5 cm). Check if the applied groove is correct.
4. Lower the pressure arm E2 to match the teeth, gears and lock the arm by positioning the E1 lever
vertically.
5. Adjust the pressing force of the E1 clamping nut to ensure constant wire travel and prevent
causing deformation. The adjustment screw is located under the E1 plastic screw.
6. The brake on the spool inside sleeve A13 is set by the manufacturer. If necessary, the brake can be
adjusted by means of a screw, so when stopping the feed, the wire also stops at the same time
(thus avoiding excessive wire development). Remember that a too-tight brake causes excessive
resistance at unwinding and this can lead to wire rolls slippage.
6.4 Adjustment of wire feeding rolls pressure
It is very important to properly adjust the rolls pressure to ensure reliable operation of the wire feed
mechanism. The pressure depends on the type of wire. In case of aluminium or powder wire, less
pressure is required.
Application of excessive pressure force leads to greater wear of the mechanical bearings and may
damage the device.
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6.5 Inserting the wire into welding torch and connecting the ground
cable
Attention!
Do not point the welding torch towards the face when inserting the wire!
1. Connect the ground clamp to the welding machine and the workpiece to be welded.
2. Screw the welding torch (B6) to the device euro socket (B8). The device must be switched on
3. Remove the gas nozzle from the welding torch.
4. Unscrew the current tip.
5. Connect the power supply to the device (B1
).
6. Set the main switch on the rear panel to ON.
7. Press the welding torch button. The welding wire is fed to the welding torch. Tighten the current
tip and the gas nozzle after the wire exits the torch.
8. Spray an anti-stick agent into the gas nozzle before welding to prevent damaged from splinters.
Figure 12: Connecting the MIG / MAG welding torch and ground cable.
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6.6 Gas flow adjustment
The welding arc and a cooling down weld must be in the inert gas shield. Too little gas does
not provide a protective atmosphere.
Attention:
The gas cylinder must be adequately protected against falling. This manual
does not cover the protection of gas cylinders. Information on cylinder
protection can be obtained from the technical gas supplier.
1. Attach the gas hose to A11 plug (fig 1) on the back panel of the device.
2. Turn the adjusting screw F7 located at the lower part of reduction valve until the F6 meter shows
the required flow. Then press the welding torch button. The optimum flow rate is 10-15 l/min
depending on wire diameter and the nozzle used.
3. The pipes should be purged with shielding gas before starting welding after a prolonged period of
device being out of service or after replacing the welding torch.
Figure 13: Shielding gas flow settings.
F1 Gas cylinder
F2 Cylinder valve
F4 Pressure reducer
F5 High pressure manometer
F6 Low pressure manometer
F7 Adjustment knob
F8 Gas outlet
Table 8: Gas connection components
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6.7 Welding parameter settings
ADJUSTMENT OF WELDING PARAMETERS IN THE MIG SYN
METHOD (SYNERGY PROGRAMS)
1. Find the right program number in the synergy parameters submenu. (For example, when
planning to weld steel with a SOLID WIRE of 0.8 mm diameter and a gas mixture of 82% Ar
+ 18% CO2, use the program No. 01 - see Figure 7)
2. Select the synergy parameter using the A4 dial and press the A4 knob to confirm the selection.
3. Then select the appropriate welding parameters using the A4 and A6 knobs.
4. Recommendation: in case of manual tacking (eg for car body repairs) use the machine in manual
MIG mode.
ADJUSTMENT OF MIG MAN WELDING PARAMETERS (MANUAL)
1. Approximate current and voltage settings for MIG/MAG welding correspond to empirical ratio U2
= 14 +0.05 I2. This empirical ratio allows to determine the required voltage.
2. Set a correct voltage
3. Then select the appropriate wire feed speed.
4. Adjust the arc by changing throttle levels in welding parameter settings submenu.
Wire diameter
[mm]
Welding current
[A]
Workpiece
thickness [mm]
0.6 25 - 110 1.0 - 1.6
0.8 35 - 160 1.0 - 2.3
0.9 45 - 160 1.0 - 2.3
1.0 45 - 200 1.2 - 7.0
Table 9: Approximate parameter settings for MIG MAN welding (manual)
6.8 Cored wire - polarity settings for the MIG / MAG torch
1. In most cases, it is recommended to set positive polarity on the MIG / MAG torh when welding with
solid welding wire. The welder uses device standard setting.
2. For welding with the core wire, it may be necessary to set negative polarity of the MIG/MAG torch.
3. Middle K2 connector is attached to central euro socket on the MIG/MAG torch..
By default, K2 is connected to the (+) K4 connector .
4. In case of welding with a negative polarity core wire (-), connect
K2 using the K3 bridge to the K1 connector.
5. Check the correct hitch of connectors.
6. Connect the ground cable to (+) socket
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Figure 14: Connectors for changing the polarization of MIG/MAG torch
Pos. Presentation
K1 Top connector (-)
K2 Middle connector
K3 Bridge
K4 Lower connector (+)
Table 10: Polarization change components for the MIG/MAG method
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7. TIG welding
Figure 15: Connection of ground cable and torch
1. Connect the TIG B12 torch to socket (-) B13, to gas socket B14 and control socket B10.
2. Connect the ground cable to the (+) B9 socket and the mass clamp B11 to the
B7 welded workpiece or to the welding table.
3. Connect the device to the power supply and run the main switch A9 on the rear panel to the ON
position.
4. Connect the gas hose to socket A11 and adjust the argon flow in accordance with Chapter 6.6. on
gas flow adjustment
5. In the method selection submenu pick TIG Lift, see Fig. 4
.
6. Use the A4 knob to adjust the welding current.
7. In submenu for auxiliary welding parameters settings, you can set the time of current descent,
value of gas pre-flow time and gas outflow.
BASIC TIG WELDING SETTINGS - STAINLESS STEEL, DC CURRENT
Workpiece
thickness
[mm]
Tungsten
electrode
diameter
[mm]
Workpiece
diameter
[mm]
Welding
current
[A]
Argon
flow
[l/min]
Gas
nozzle
[mm]
1 1
1.5 40-60 3 10
1.5 1.5
1.5 50-90 4 10
2 2
2 80-100 4 12
3 2-3 2-3 90-140 5 12
4-5 3-4 3-4 110-180 5 12
Table 11: Selection of parameters for DC TIG welding
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