Oerlikon W000377723 Operation instructions
CITOMIG 200MP
EN INSTRUCTIONS FOR USE AND MAINTENANCE
FR INSTRUCTIONS D’UTILISATION ET DE MAINTENANCE
DE BEDIENUNGS- UND WARTUNGSANLEITUNG
IT MANUALE D’USO E MANUTENZIONE
ES INSTRUCCIONES DE USO Y MANTENIMIENTO
PT INSTRUÇÕES DE UTILIZAÇÃO E MANUTENÇÃO
NL INSTRUCTIES VOOR GEBRUIK EN ONDERHOUD
SV ANVÄNDAR- OCH UNDERHÅLLSINSTRUKTIONER
Cat. nr. : 8695-8030
Rev.: A
Date : 11/2013
www.oerlikon-welding.com
PL
RO
RU
SK
DK BRUGS- OG VEDLIGEHOLDELSESANVISNING
CZ
NO INSTRUKSJONER FOR BRUK OG VEDLIKEHOLD
MULTIPROCESS POWER SOURCE
GÉNÉRATEUR MULTI-PROCÉDÉS
MULTIPROZESS STROMQUELLE
GENERATORE MULTIPROCESSO
FUENTE DE ALIMENTACIÓN MULTIPROCESO
FONTE DE ALIMENTAÇÃO MULTIPROCESSO
MULTIPROCESVOEDINGSBRON
MULTIFUNKTIONELL SVETSSTRÖMKÄLLA
WIELOPROCESOWE ŹRÓDŁO ZASILANIA
SURSĂ DE PUTERE MULTIPROCES
МНОГОЗАДАЧНЫЙ ИСТОЧНИК ПИТАНИЯ
MULTIPROCESNÝ ZDROJ
MULTIPROCES STRØMKILDE
MULTIPROCESNÍ ZDROJ NAPÁJENÍ
MULTIPROSESS STRØMKILDE
CITOMIG 200MP
MULTIPROCESS POWER SOURCE
EN INSTRUCTIONS FOR USE AND MAINTENANCE
Cat n° : 8695-8030
Rev : A
Date : 11/2013
www.oerlikon-welding.com
Arc welding and plasma cutting may be dangerous for the operator and
persons close to the work area.
Read the operating manual.
3 - EN
EN
CONTENTS
1 - GENERAL INFORMATION.........................................................................................3
1.1 - PRESENTATION OF THE INSTALLATION..................................................................3
1.2 - WELDING SET COMPONENTS ................................................................................3
1.3 - TECHNICAL SPECIFICATIONS..................................................................................3
1.3.1 - TECHNICAL CHARACTERISTICS OF THE PART OF WIRE FEED............................3
1.4 - INSTALLATION............................................................................................................3
1.4.1 - CONNECTIONS..........................................................................................................3
1.4.2 - STARTING UP.............................................................................................................4
2 - START-UP ...................................................................................................................4
2.1 - FRONT PANEL PRESENTATION................................................................................4
2.2 - BASIC SETUP MENU .................................................................................................4
3 - CONNECTION AND PREPARATION FOR MMA WELDING ....................................5
4 - CONNECTION AND SETUP FOR TIG WELDING .....................................................6
5 - MIG/MAG WELDING SETUP .....................................................................................7
5.0.1 - TORCH CONNECTION...............................................................................................9
5.0.2 - WIRE LOADING .........................................................................................................9
5.1 - MIG / MAG WELDING – SYNERGY OFF ..................................................................10
5.2 - MIG / MAG WELDING – SYNERGY ON ....................................................................10
5.3 - MIG/MAG SETUPS SAVE & RECALL .......................................................................11
5.4 - SYNERGIC PROGRAMS LIST .................................................................................11
6 - OPTIONS ................................................................................................................. 11
6.1 - WORKSHOP UNIVERSAL TROLLEY ......................................................................11
6.2 - DIAMETER 300 mm SPOOL OPTION KIT ...............................................................11
6.2.1 - HOW TO INSTALL THE SPOOL DIAMETER 300 mm KIT ........................................12
6.2.2 - HOW TO INSTALL THE WELDING UNIT ON THE UNIVERSAL TROLLEY ..............13
7 - FAULT LIST DESCRIPTION .................................................................................... 14
8 - TROUBLE SHOOTING ............................................................................................ 15
9 - MAINTENANCE....................................................................................................... 16
9.1 - ROLLERS AND WIRE GUIDE ...................................................................................16
9.2 - TORCH......................................................................................................................16
10 - SPARE PARTS LIST ................................................................................................ 17
11 - SPARE PARTS......................................................................................................... 18
12 - WIRING DIAGRAM.................................................................................................. 19
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1 - GENERAL INFORMATION
1.1 - PRESENTATION OF THE INSTALLATION
CITOMIG 200MP is a manual welding set multifunction that enables:
MIG-MAG welding with short arc using currents from 30 A to 200 A.
Steel, stainless steel, aluminum and special wires
solid and cored wires
Coated electrode welding using currents from 5 A to 200 A.
TIG welding using currents from 5 A to 200 A.
1.2 - WELDING SET COMPONENTS
Power source
Primary cable length 3 m
Earth cable with clamps length 3 m
Gas hose length 2 m
Safety manual
1.3 - TECHNICAL SPECIFICATIONS
CITOMIG 200MP
W000377723
PRIMARY
1-phase primary power supply
230 V +/-10 %
Frequency 50 / 60 Hz
Power 8,6 kVA
SECONDARY MIG MMA TIG
No-load voltage 35 V 65 V 65 V
Current range 30 A – 200 A 5 A – 200 A 5 A – 200 A
Duty cycle 100 % at 40° C 105 A 95 A 120 A
Duty cycle 60 % at 40° C 130 A 120 A 130 A
Duty cycle 20 % at 40°C 200 A 200 A
200 A at 30%
Protection degree IP 22S
Isolation class H
Standard EN60974-1 / EN60974-5 / EN60974-10
500 x 280 x 420 mm
Net weight 15 kg
WARNING: WITH A 16 A FUSE, THE MAXIMUM WELDING CURRENT
IS 150 A. FOR POWER OVER 150 A , A 25 A FUSE AND A SUITABLE
POWER PLUG ARE REQUIRED.
WARNING: THE HANDLE IS NOT INTENDED FOR SLINGING THE
SET, BUT ONLY TO CARRY THE MACHINE AND FOR NEGOTIATING
EQUIPMENT HAS A PROTECTION DEGREE IP22S.IT CANNOT BE
USED UNDER RAIN OR SNOW. IT CAN BE STORED OUTSIDE BUT IT
IS NOT DESIGNED TO BE USED DURING PRECIPITATION WITHOUT
PROTECTION.
Code letter IP Degrees of protection
First digit 2≥12,5
mm
Second digit
1Against penetration of vertical drops of water with harmful
2
3
S
Indicates that testing for protection against the
with all parts of the equipment at idle.
1.3.1 - TECHNICAL CHARACTERISTICS OF THE PART OF
WIRE FEED
Wire feeding 2 rollers
Wire feed speed 1.6 →20 m/min
Wire diameter usable 0.6 →
Torch connection European type
1.4 - INSTALLATION
1.4.1 - CONNECTIONS
ELECTRICAL CONNECTIONS TO THE MAINS:
CITOMIG 200MP is a 230 V single phase welding set.
CITOMIG 200MP
CAUTION: THE ELECTRICAL CONNECTION OF THE POWER
SOURCE MUST BE DONE BY QUALIFIED TECHNICIANS AND
THE POWER SUPPLY INSTALLATION MUST BE CORRECTLY
DIMENSIONED REGARDING THE CHARACTERISTICS OF THE
IF IT IS CONNECTED TO A PUBLIC LOW VOLTAGE SYSTEM,
IT IS THE RESPONSIBILITY OF THE INSTALLER OR USER OF
THE EQUIPMENT TO ENSURE, BY CONSULTATION WITH THE
DISTRIBUTION NETWORK OPERATOR IF NECESSARY, THAT THE
EQUIPMENT MAY BE CONNECTED.
THIS CLASS A EQUIPMENT IS NOT INTENDED FOR USE IN
RESIDENTIAL LOCATIONS WHERE THE ELECTRICAL POWER
THERE MAY BE POTENTIAL DIFFICULTIES IN ENSURING
ELECTROMAGNETIC COMPATIBILITY IN THOSE LOCATIONS, DUE
TO CONDUCTED AS WELL AS RADIATED DISTURBANCES.
CONNECTION OF THE TORCH:
The MIG welding torch is connected to the front of generator, after
to the wire used for welding.
For this purpose, please refer to the torch instructions.
GENERAL INFORMATION
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GAS INLET CONNECTION:
The gas hose is connecting to the power source. Simply connect it to the
pressure-regulator outlet of the gas cylinder.
If you use with the universal trolley W000375730, place the gas
cylinder on the trolley and fasten the cylinder using the strap.
Open the cylinder valve slightly to allow existing impurities to escape
and then reclose it. Do not stay in front of it.
Connect the gas hose to the regulator’s outlet.
WARNING: MAKE SURE THE GAS CYLINDER IS PROPERLY
SECURED ON THE TROLLEY BY ATTACHING THE SAFETY STRAP.
POSITIONING AND LOCATION OF THE MACHINE:
carriage unit.
Notes for positioning the machine:
The surface inclination should not exceed 15 degrees.
Ensure the free circulation of the cooling air. There must be at least
20 cm of free space in front of and behind the machine for cooling
air to circulate.
Protect the machine against heavy rain and direct sunshine.
1.4.2 - STARTING UP
The main switch is located at the rear of the
power source.
Flip this switch to turn the machine on.
welding.
2 - START-UP
2.1 - FRONT PANEL PRESENTATION
The man machine interface is located on the front panel of the power
source:
1
2
4
3
5
6
7
1Button for MIG/MAG, TIG or MMA
modes and synergies validation 4Button to select synergies
2Graphic screen 5Control button setup
3Tuning encoder / selection 6Save / recall program
7Tuning encoder / selection
2.2 - BASIC SETUP MENU
To enter the Basic Setup Menu, power the unit on.
While the display views the unit logo, press the setup button
5
.
Use the right setting knob
7
to adjust parameters:
1
5
6
7
MAX LINE CURRENT: L / H
Setting of the maximum current that the unit may absorb by the input
power supply according to the branch circuit capability. In order to utilize
the maximum output capability of the unit, a branch circuit capable of
automatically reduced. The letter will appear on the unit main screen if
selected.
INITIAL SPEED: REDUCED / NORMAL
Reduced Initial Speed reduces the speed of the wire at start up to provide
a soft start.
START-UP
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VRD (MMA): ON / OFF
Selection of the Voltage Reduction Device ON or OFF.
automatically restart when the electrode gets in touch with the work piece.
As default the device is OFF.
D.M. DIGITAL METER: ON / OFF
Set the digital display ON to view the real voltage and current values while
welding. As default this is ON.
LCD CONTRAST: 30 / 63
Setting of the LCD display contrast according to the environment
temperature and brightness.
UNITS: METERS / INCHES
Select the desired unit of length between meters or inches.
SAVE SETTINGS:
Press the mode button
1
to go back to the welding process screen and
save set parameters.
The display shows the screen of the last welding process performed by
the unit.
RESET:
Press button
6
to reset all parameters and go back to the parameters
set as default.
3 - CONNECTION AND PREPARATION FOR MMA
WELDING
Connect the earth cable to the negative output terminal on the front
Connect the work cable to the positive output terminal on the front of
Power the unit ON.The display shows the screen of the last welding
process performed by the unit.
Press the button
1
till the MMA Welding Screen is viewed on the display.
1
3
7
Left setting knob
3
Adjusts, in the start phase, the welding current increase percentage
variable from 0 to 50% of the set current.
Thanks to an initial peak current, this function makes the welding arc
Right setting knob
7
Electrode diameter Average intensity for
rutile electrode
1.6 mm 1.6 mm 40 A
2.0 mm 2.0 mm 55 A
2.0-3.0 mm 2.5 mm 70 A
3.0 – 5.0 mm 3.2 mm 110 A
6.0 – 10 mm 4.0 mm 160 A
>8 mm 5.0 mm 200 A
NOTE: ADJUST THE WELDING CURRENT ACCORDING TO THE
DIAMETER OF THE ELECTRODE TO BE USED.
CONNECTION AND PREPARATION FOR MMA WELDING
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4 - CONNECTION AND SETUP FOR TIG WELDING
Connect the earth cable to the positive output terminal on the front
of the unit.
Connect the TIG torch to the negative output terminal on the front
of the unit.
on the gas bottle.
mechanical valve on the torch handle.
Press the mode button
1
, till the TIG welding screen is viewed on the
display.
1
7
Right setting knob
7
Note: adjust the welding current according to the diameter of the electrode
to be used.
TIG Lift + :
As the torch is raised the electric arc is set up and the welding
current rises to the pre-set value.
Arc extinguishing:
To exit the welding phase, the operator can use the conventional lift
method or, alternatively, a new method that simulates the torch button.
This method, called “TIG LIft+” enables a down slope without torch button
to be obtained. During the welding phase the operator only has to move
away from the work piece to start a down slope. To interrupt the slope
Sharpening the electrode:
The tip of the electrode is sharpened into a cone so that the arc will be
stable and the energy concentrated on the area to be welded.The length
of the sharpened section depends on the electrode diameter.
With a low current use a pointed tip: l = 3 x d
With a high current use a rounded tip: l = 1 x d
CONNECTION AND SETUP FOR TIG WELDING
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EN
5 - MIG/MAG WELDING SETUP
Press the mode button
1
till the MIG/MAG Welding Screen is viewed on
the display.
Normal MIG
Synergic MIG
Follow carefully the following instructions paying particular attention to the
pictures.
1
MIG/MAG Function Setup Key
5
In MIG/MAG mode press the setup key
6
to enter the parameters change
screen.
Use the setup key
5
to run through the parameters and adjust their
values by turning the right setting knob
7
.
welding.
1
4
5
6
7
Unit ready for NORMAL MIG/MAG welding, voltage
and wire speed are adjustable.
Unit ready for SYNERGIC mode welding.
Trigger Mode:
Selection of the 2 strokes / 4 strokes / spot welding
mode.
Spot Time:
Adjustable only when Spot Welding Mode is set:
regulation of the maximum duration of the Spot
Slope Up:
Adjustment of the time the wire needs from the
BBT “Burn Back Time”:
Adjustment of the length of the wire protruding from
Inductance:
- Low Value = more spatters
- High Value = less spatters
Post Gas:
HOT-START:
Percentage of increase of welding current to make
Hot-Start time.
HOT-START and CRATER FILLER:
Percentage of increase of welding current to make
Percentage of reduction of the welding current
Once a Synergic Curve is selected, Slope, BBT and Inductance settings
go back to their default values.
SAVE / RECALL key
6
:
Use this key to save and recall the points that the
operator can customize. Refer to paragraph 5.3
MATERIAL Key
4
:
Adjustment of the electronic inductance.
Access to the screen for the synergic program
adjustment.
MIG/MAG WELDING SETUP
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GRAPHIC DISPLAY FOR MIG/MAG WELDING SETTING:
NOTE: BASED ON THE SET WELDING MODE, SOME DATA ON THE
MIG/MAG SCREEN CANNOT BE VISUALIZED.
Digital ammeter / voltmeter
Trigger mode : 2T / 4T / SPOT
SYNERGY OFF: voltage setting
SYNERGY ON: thickness setting
MIG/MAG mode:
SYNERGY OFF, SYNERGY ON
Regulation scale:
SYNERGY OFF: electronic inductance
SYNERGY ON: arc length adjustment
Synergic program information
Wire speed pre-setting
MIG/MAG WELDING SETUP
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5.0.1 - TORCH CONNECTION
Plug the torch hose into the socket on the front of the welder having care
to not damage the contacts and secure by hand screwing in the threaded
connection.
5.0.2 - WIRE LOADING
ENSURE THE GAS AND ELECTRICAL SUPPLIES ARE
DISCONNECTED.
BEFORE PROCEEDING, REMOVE THE NOZZLE AND THE CONTACT
TIP FROM THE TORCH.
Open the side panel.
the case you are replacing the wire spool, extract it by pushing the
The unit can also accept 100
mm diameter wire spools.
For the mounting follow these
instructions:
remove the spool holder
Insert on the pivot the
100mm diameter wire
and the spring.
Tighten nut (A) to appropriate tightness.Excessive pressure strains
the wire feeding motor.
Too little pressure does not allow the immediate stop of the wire
spool at the end of the welding.
Loosen and lower the
the pressure arm of the
feeder. Extract the wire
from the torch liner.
When the wire is
disconnected, grasp it
with pliers so that it cannot
exit from the spool. If
necessary, straighten it
before inserting it in the
wire input guide.
Insert the wire on the lower roll and in the torch liner.
WARNING: KEEP THE TORCH STRAIGHT. WHEN FEEDING A NEW
WIRE THROUGH THE LINER, MAKE SURE THE WIRE IS CUT
THESE INSTRUCTIONS COULD CAUSE DAMAGE TO THE LINER.
Lower the pressure arm and place the pressure knob.
Tighten slightly. If tightened too much, the wire gets locked and could
cause motor damage. If not tighten enough, the rolls will not feed the wire.
WARNING: WHEN CHANGING THE WIRE DIAMETER BEING
USED OR REPLACING THE WIRE FEED ROLL, BE SURE THAT
THE CORRECT GROOVE FOR THE WIRE DIAMETER SELECTED
IS INSIDE, CLOSEST TO THE MACHINE. THE WIRE IS DRIVEN BY
THE INSIDE GROOVE. FEED ROLLS ARE MARKED ON THE SIDE
IDENTIFYING THE GROOVE NEAREST THAT SIDE.
Close the side panel of the machine.
Connect the power supply cable to the power output line.Turn on the
switch. Press the torch switch.
The wire fed by the wire feeding motor at variable speed must slide through
the liner. When it exits from the torch neck, release the torch switch.
NOTE: AFTER THREE SECONDS TORCH TRIGGER IS PRESSED
WIRE FEEDING SPEED INCREASES TO ALLOW A FAST EXIT OF
THE WIRE ON THE TORCH NECK.
Mount the contact tip and the nozzle.
WHEN CHECKING THE CORRECT EXIT OF THE WIRE FROM THE
TORCH DO NOT BRING YOUR FACE NEAR THE TORCH, YOU MAY
RUN THE RISK TO BE WOUNDED BY THE OUTGOING WIRE.
DO NOT BRING YOUR FINGERS CLOSE TO THE FEEDING
MECHANISM WHEN WORKING!
THE ROLLS, WHEN MOVING, MAY CRUSH THE FINGERS.
PERIODICALLY, CHECK THE ROLLS. REPLACE THEM WHEN THEY
ARE WORN AND COMPROMISE THE REGULAR FEEDING OF THE
WIRE.
Figure 16
Figure 17
MIG/MAG WELDING SETUP
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5.1 - MIG / MAG WELDING – SYNERGY OFF
core wire. As default unit is ready for gas welding, so for welding without
gas, welding current polarity has to be changed according to the following
steps.
WARNING: ELECTRIC SHOCK CAN KILL!
ALWAYS TURN THE POWER OFF AND UNPLUG THE POWER CORD
FROM THE POWER SOURCE BEFORE CHANGING POLARITY.
For welding without gas, change the
power polarity as following:
Connect the earth cable to the
positive output terminal on the
front of the unit.
Connect the torch terminal
ring to the negative mounting
post on the voltage.
just over the wire feeding
For gas welding remember to reinitiate the default polarity setting as
following:
Connect the earth cable to the negative output terminal on the front
of the unit.
Connect the torch terminal ring to the positive mounting post on the
voltage.
NOTE: REMOVE DIFFUSER WHEN WELDING WITHOUT GAS TO
AVOID EXCESSIVE HEATING OF THE TORCH.
1
4
3
5
6
7
Mode Key
1
Press the mode key till the MIG/MAG welding screen is viewed on the
display.
MIG/MAG Function Setup Key
5
Press the setup key
5
in MIG/MAG mode to access the parameters’
setup screen.
Use the right setting knob
7
to select “SYN OFF” Mode.
Use the mode key
1
to go back to the MIG/MAG main screen.
Refer to paragraph -
7
for the other parameters’ setting.
Right Setting Knob
7
Use the right setting knob to adjust the welding voltage.
Material Key
4
Use the Material Key to adjust the electronic inductance value.
This setting allows to stabilize the arc by adapting it to the type of material
and to the operator’s hand.
Low inductance = Cold arc, more spatters.
High inductance = Hot arc, few spatters.
Left Setting Knob
3
Use the left setting knob to adjust the wire
speed.
5.2 - MIG / MAG WELDING – SYNERGY ON
With the torch connected, the wire installed and the gas connection done,
earth cable to the negative output terminal on the front of the unit.
1
4
3
5
6
7
Mode Key
1
Press the mode key till the MIG/MAG welding screen is viewed on the
display.
MIG/MAG Function Setup Key
5
Press the setup key
5
in MIG/MAG mode to access the parameters’
setup screen.
Use the right setting knob
7
to select the “SYN ON” mode for normal
welding.
Use the mode key
1
to go back to the MIG/MAG main screen.
Refer to paragraph
7
for the other parameters’ setting.
Right Setting Knob
7
Use the right setting knob to select the thickness of the material to be
welded.
Material Key
4
Use the material key to view the synergic welding curves available on the
unit.
Turn the right setting key
7
or press the material key
4
to choose the
desired synergic curve, suitable to the type of wire and to the gas going to
be used for welding.
1
to go back to the
main screen.
MIG/MAG WELDING SETUP
12 - EN
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Material
GAS Program number
Welding wire thickness
Once a synergic curve is selected, slope, BBT, inductance, wire speed
balance and material thickness settings go back to their default values.
Left Setting Knob
3
Use the left setting key to balance the
decrease the arc length.
5.3 - MIG/MAG SETUPS SAVE & RECALL
Prog Save & Recall Key
6
Use the Prog Save & Recall key to save and recall the parameters set by
the operator.
To save the setup, proceed as follows:
Press the SAVE / RECALL
6
.
Turn the right setting knob
7
to choose the program number to save
in.
To save the program keep the SAVE / REC.
To recall a saved program, proceed as follows:
Press the SAVE / RECALL
6
.
Turn the right setting knob
7
to choose the desired program number.
Press the SAVE / RECALL
6
the program loading.
Use the mode key
1
to go back to the MIG/MAG main screen.
5.4 - SYNERGIC PROGRAMS LIST
In “SYNERGIC ON” mode use the material key
4
to enter the synergic
programs list.
Synergic ON
Program
number
Material Gas Diameter
01 Fe CO20.6
02 Fe CO20.8
03 Fe CO21.0
04 Fe Ar CO20.6
05 Fe Ar CO20.8
06 Fe Ar CO21.0
07 CrNi Ar CO20.8
08 CrNi Ar CO21.0
09 Al Ar 0.8
10 Al Ar 1.0
11 CuSi Ar 0.8
12 CuSi Ar 1.0
6 - OPTIONS
6.1 - WORKSHOP universal TROLLEY
Catalogue number: W000375730²
6.2 - Diameter 300 mm SPOOL OPTION KIT
Catalogue number: W000378662
OPTIONS
13 - EN
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OPTIONS
HOW TO INSTALL THE SPOOL DIAMETER 300 MM
KIT
14 - EN
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HOW TO INSTALL THE WELDING UNIT ON THE
UNIVERSAL TROLLEY
OPTIONS
15 - EN
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7 - FAULT LIST DESCRIPTION
caution.If a displayed fault doesn’t belong to this list below, please contact
the after sales services.
SERVICING OF ELECTRICAL EQUIPMENT MUST BE PERFORMED
BY QUALIFIED PERSONNEL ONLY.
WARNING: ANY INTERVENTION REQUIRING THE OPENING OF
THE CASING OF THE GENERATOR OR ONE OF ITS PERIPHERALS
MUST BE EXCLUSIVELY MADE BY AN AGENT APPOINTED OR
AUTHORIZED BY AIR LIQUIDE WELDING.
“MAX I. (max current)”
This alarm appears when the machine is running for more than
2 sec. with a higher output current to 240 A.This alarm causes
“OVER T. (over temperature)”
the indication disappears, the machine returns operative,
stops the intermittent beeping.
“OVER V. (over voltage)”
Alarm displayed when the input voltage of the power source
The machine will automatically reset after 30 seconds by the
disappearance of overvoltage.
“Iout (output current)”
Appears in the center of the alpha numeric screen with a long
symbol stops the loading of wire.The symbol is displayed for 2
seconds of releasing the torch button.To restart the loading of
the wire, the operator must release and press the torch trigger
again.
“RELEASE TORCH TRIGGER”
Appears on the alpha numeric screen when the MIG torch
set or is working in MMA or TIG welding processes. The
appearance of this info does not stop the welding process in
progress.Att.:If you release the MIG torch trigger the message
disappear, hence you can change the welding process or to
enter the setup menu.
FAULT LIST DESCRIPTION
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8 - TROUBLE SHOOTING
This chart will assist you in resolving common problems you may
encounter.
PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION
No “life” from welder. Input cable or plug malfunction. Check for proper input cable connection.
Wrong size fuse. Check fuse and replace as necessary.
Fan operates normally, but when gun trigger
pulled, there is no wire feed, weld output or
Faulty trigger on gun. Replace torch trigger.
Thermostat intervention. Allow welder to cool.The extinguishing of the pilot lamp / switch on
the front panel indicates the thermostat has closed.
Feed motor operates but wire will not feed.
Replace wire feeding motor.
Increase roller pressure.
Burr on end of wire. Re-cut wire square with no burr.
Liner blocked or damaged. Clear with compressed air or replace liner.
Lack of penetration.
Voltage or wire feed speed too low. Re-adjust the welding parameters.
Clear with compressed air and tighten all connections.
Worn or wrong size contact tip. Replace the contact tip.
Loose gun connection or faulty gun assembly. Tighten or replace torch.
Wrong size wire. Use correct size welding wire.
Torch moved too fast. Move the gun smoothly and not too fast.
Wire is birdnesting at the drive roller.
Eccessive pressure on drive roller. Adjust pressure on drive roller.
Gun liner worn or damaged. Replace wire liner.
Contact tip clogged or damaged. Replace contact tip.
Liner stretched or too long. Cut wire liner at the right lenght.
Wire burns back to contact tip.
Contact tip clogged or damaged. Replace the contact tip.
Wire feed speed to slow. Increase wire speed.
Wrong size contact tip. Use correct size contact tip.
Bad connection from cable to clamp. Tighten connection or replace cable.
Slag buildup inside nozzle or nozzle is shorted. Clean or replace nozzle.
Workpiece clamp and/or cable gets hot. Wire feed speed too fast. Decrease wire feed speed.
Gun nozzle arcs to work surface. Nozzle clogged. Clean or replace nozzle.
Wire pushes torch back from the workpiece.
Torch held too far from the workpiece. Hold the torch at the right distance.
Bad connection between earth clamp and
workpiece. Clean and deoxidate the contact area of the earth clamp.
The workpiece is excessively oxidized or painted. Brush carefully the point to be welded.
Poor quality welds.
Check that the gas is not being blown away by drafts and if so move
to more sheltered weld area. If not check gas cylinder contents
gauge, regulator setting and operation of gas valve.
Rusty, painted, damp, oil or greasy workpiece. Ensure workpiece is clean and dry.
Rusty or dirty wire. Ensure wire is clean and dry.
Poor ground contact. Check ground clamp/workpiece connection.
Incorrect gas / wire combination. Check on the manual for the correct combination
Weld deposit “stringy” and incomplete. Torch moved over workpiece too quickly. Move the torch slower.
Gas mixture incorrect. See shielding gas table.
Weld deposit too thick. Torch moved over workpiece too slowly. Move the torch faster.
Welding voltage too low. Increase welding voltage.
Display not clear. Set display contrast.
When welder is turned on, the display shows
ERR1 and / or ERR2. Failure of system memory. Contact the service center.
TROUBLE SHOOTING
17 - EN
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9 - MAINTENANCE
Twice a year, depending on the use of the device, inspect the following:
cleanliness of the power source
electrical and gas connections
WARNING
NEVER CARRY OUT CLEANING OR REPAIR WORK INSIDE THE
DEVICE BEFORE MAKING SURE THAT THE UNIT HAS BEEN
COMPLETELY DISCONNECTED FROM THE MAINS.
DISMANTLE THE GENERATOR PANELS AND USE SUCTION
TO REMOVE DUST AND METAL PARTICLES ACCUMULATED
BETWEEN THE MAGNETIC CIRCUITS AND THE WINDINGS OF THE
TRANSFORMER.
WORK MUST BE PERFORMED USING A PLASTIC TIP TO AVOID
DAMAGE TO THE INSULTATION OF THE WINDINGS.
WARNING
THE CLOGGING OF THE DUST FILTER MAY LEAD TO THE
DECREASE OF THE DUTY CYCLE OF THE GENERATOR.
WARNING : TWICE A YEAR
COMPRESSED AIR BLOWING.
PERFORM CALIBRATION OF THE CURRENT AND VOLTAGE
SETTINGS.
CHECK ELECTRICAL CONNECTIONS OF THE POWER,
CONTROL AND POWER SUPPLY CIRCUITS.
CHECK THE CONDITION OF INSULATION, CABLES,
CONNECTIONS AND PIPES.
WARNING :
CALLING CUSTOMER SUPPORT FOR TECHNICAL SERVICING,
PLEASE CHECK THAT:
POWER TERMINALS ARE NOT IMPROPERLY TIGHTENED.
THE SELECTED MAINS VOLTAGE IS CORRECT.
THERE IS PROPER GAS FLOW.
TORCH CONDITION.
TYPE AND DIAMETER OF THE WIRE.
9.1 - ROLLERS AND WIRE GUIDE
Under normal conditions of use, these accessories have a long serviceable
life before their replacement becomes necessary.
Sometimes, however, after being used over a period of time, excessive
wear or clogging due to adhering deposits may be noted.
clean.
The motor reduction unit requires no maintenance.
inlet guide roller outlet guide
STEEL
STAINLESS
STELL
FLUX
CORED
WIRE
0.6 / 0.8 mm
W000378664
+
W000378665
W000378667
W000378663
0.8 / 1.0 mm W000378666
ALUMINIUM
0.8 / 1.0 mm W000378668
1.2 mm W000378669
9.2 - TORCH
Regularly check the proper tightness of the connections of the welding
current supply. Mechanical stresses related to thermal shocks tend to
loosen some parts of the torch, particularly:
The contact tube
The coaxial cable
The welding nozzle
The quick connector
Check that the gasket of the gas inlet tip is in good condition.
Remove the spatter between the contact tube and the nozzle and between
the nozzle and the skirt.
Spatter is easier to remove if the procedure is repeated at short intervals.
Do not use hard tools that may scratch the surface of these parts and
cause spatter to become attached to it.
SPRAYMIG SIB: W000011093
SPRAYMIG H20: W000010001
Blow out the liner after each change of a spool of wire. Carry out this
If necessary, replace the wire inlet guide of the torch.
Severe wear of the wire guide may cause gas leaks towards the rear of
the torch.
The contact tubes are designed for long use.Nevertheless, the passage of
tolerances for good contact between the tube and the wire.
The need to replace them becomes clear when the metal transfer process
becomes unstable, all the settings of the work parameters remaining
otherwise normal.
Recommended MIG/MAG torches
WMT 2-15A – Air cooled
WMT 2-25A – Air cooled
See user’s instructions for detailed characteristics, consumables and
wear parts.How to install the spool diameter 300 mm kit
MAINTENANCE
18 - EN
EN
10 -SPARE PARTS LIST
REP.
ITEM
ITEM
REFERENCE
DESCRIPTION
1 W000378637
SLIDE CLIP
2 W000379792
BLUE LEFT SIDE PANEL
3 W000378639
KIT SPOOL HOLDER WITH RING FOR 5KG SPOOL
4 W000378640
BLACK DIVIDING PANEL
5 W000378642
KIT GAS / NO GAS CHANGE BOARD
6 W000378643
4 LOBES D30 HAND-WHEEL
7 W000378644
WIRE FEEDER PLAST/AL D40 2 ROLLS 0,8-1,0
8 W000378645
MOTOR MBT D40 + STEEL PIGNON
9 W000378663
WIRE GUIDE CAPILLARY TUBE D 2X5 L=71
10 W000378664
INLET GUIDE L=17 MM
11 W000378665
MINEURO CONNECTOR WITHOUT INLET GUIDE
12 On request
FRONT FRAME
13 W000378763
RED KNOB FOR POTENTIOMETER
14 On request
FRONT PLATE LABEL CITOMIG 200MP
15 W000378646
FRONT PANEL PCB 200MP
16 W000378647
COMPLETE ASSEMBLY INVERTER 200A
17 W000378648
CONTROL PCB 200 MP
18 W000378649
SUPPORT BRACKET
19 W000378650
SOLENOIDE VALVE 230V 50-60Hz©
20 W000378670
CABLE CLAMP FOR HOLE D20
21 W000010099
INPUT CABLE 3 X 2,5mm2
22 W000378652
SWITCH KNOB D38
23 On request
BACK FRAME
24 W000379793
BLACK BACK PANEL
25 W000378654
SWITCH 17A A 1702
26 W000378655
COOLING FAN 120 X 120 24VDC + WIRE HARNESS
27 W000378656
PLASTIC HINGE FOR ACCESS PANEL 20X30
28 W000379794
BLUE LOWER PANEL
29 W000379795
BLUE UPPER PANEL
30 W000379796
BLACK FRONT PANEL
31 W000378660
FEMALE DINSE PLUG 50SQMM C X 22
32 Page 17
WIRE FEED ROLL D30
33 W000378661
WIRE BLOCK ROLL D 17 X 30 H=9
34 W000378666
BLACK HANDEL
38 W000378764
FLAT KEY TO BLOCK ROLLER
SPARE PARTS LIST
19 - EN
EN
11 -SPARE PARTS
38
34
SPARE PARTS
20 - EN
EN
12 -WIRING DIAGRAM
WIRING DIAGRAM
This manual suits for next models
1
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