Sherman DIGIMIG 200 PULSE User manual

SHERMAN DIGIMIG 200 PULSE
INSTRUCTIONS MANUAL
WARNING! FOR SAFETY REASON PLEASE READ AND UNDERSTAND
THE FOLLOWING INSTRUCTIONS BEFORE FIRST USE OF THE DEVICE.

1.General instructions
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products. An
incorrectly performed installation can result in material damage and injure persons as a
result. For this reason, we do not accept any responsibility or liability for losses, damages
or costs arising from incorrect installation, improper operation or incorrect usage and
maintenance or any actions connected to this in any way.
• Read the operating instructions for all system components!
• Observe accident prevention regulations!
• Observe all local regulations!
• Confirm with a signature where appropriate.

2. Safety instructions
DANGER!
Electromagnetic fields!
The power source may cause electrical or electromagnetic fields to be produced which
could affect the correct functioning of electronic equipment such as IT or CNC devices,
telecommunication lines, power cables, signal lines and pacemakers.
• Observe the maintenance instructions! (see Maintenance and Testing chapter)
• Unwind welding leads completely!
• Shield devices or equipment sensitive to radiation accordingly!
• The correct functioning of pacemakers may be affected (obtain advice from a doctor if necessary).
Do not carry out any unauthorised repairs or modifications!
To avoid injury and equipment damage, the unit must only be repaired or modified by
specialist, skilled persons! The warranty becomes null and void in the event of unauthorised
interference.
• Appoint only skilled persons for repair work (trained service personnel)!
Electric shock!
Welding machines use high voltages which can result in potentially fatal electric shocks
and burns on contact. Even low voltages can cause you to get a shock and lead to
accidents.
• Do not touch any live parts in or on the machine!
• Connection cables and leads must be free of faults!
• Switching off alone is not sufficient!
• Place welding torch and stick electrode holder on an insulated surface!
• The unit should only be opened by specialist staff after the mains plug has been
unplugged!
• Only wear dry protective clothing!
• Wait for 4 minutes until the capacitors have discharged!
WARNING!
Risk of injury due to radiation or heat!
Arc radiation results in injury to skin and eyes.
Contact with hot workpieces and sparks results in burns.
• Use welding shield or welding helmet with the appropriate safety level (depending on the
application)!
• Wear dry protective clothing (e.g. welding shield, gloves, etc.) according to the relevant
regulations in the country in question!
• Protect persons not involved in the work against arc beams and the risk of glare using
safety curtains!
Explosion risk!
Apparently harmless substances in closed containers may generate excessive pressure
when heated.
• Move containers with inflammable or explosive liquids away from the working area!
• Never heat explosive liquids, dusts or gases by welding or cutting!

WARNING!
Smoke and gases!
Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent
vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to
the ultraviolet radiation of the arc!
• Ensure that there is sufficient fresh air!
• Keep solvent vapour away from the arc beam field!
• Wear suitable breathing apparatus if appropriate!
Fire hazard!
Flames may arise as a result of the high temperatures, stray sparks, glowing-hot parts
and hot slag produced during the welding process.
Stray welding currents can also result in flames forming!
• Check for fire hazards in the working area!
• Do not carry any easily flammable objects such as matches or lighters.
• Keep appropriate fire extinguishing equipment to hand in the working area!
• Thoroughly remove any residue of flammable substances from the workpiece before
starting welding.
• Only continue work on welded workpieces once they have cooled down.
Do not allow to come into contact with flammable material!
• Connect welding leads correctly!
Risk of accidents if these safety instructions are not observed!
Non-observance of these safety instructions is potentially fatal!
• Carefully read the safety information in this manual!
• Observe the accident prevention regulations in your country.
• Inform persons in the working area that they must observe the regulations!
Danger when coupling multiple power sources!
Coupling multiple power sources in parallel or in series has to be carried out by
qualified personnel and in accordance with the manufacturer's guidelines. Before
bringing the power sources into service for arc welding operations, a test has to verify
that they cannot exceed the maximumallowed open circuit voltage.
• Connection of the machine may be carried out by qualified personnel only!
• When decommissioning individual power sources, all mains and welding current leads have
to be safely disconnected from the welding system as a whole. (Danger due to inverse
voltages!)
• Do not couple welding machines with pole reversing switch (PWS series) or machines for
AC welding, as a minor error in operation can cause the welding voltages to be combined.
WARNING!
Hazards due to improper usage!
Hazards may arise for persons, animals and material objects if the equipment is not
used correctly. No liability is accepted for any damages arising from improper usage!
• The equipment must only be used in line with proper usage and by trained or expert staff!
• Do not modify or convert the equipment improperly!

CAUTION!
Installation site!
The machine must not be operated in the open air and must only be set up and
operated on a suitable, stable and level base!
• The operator must ensure that the ground is non-slip and level, and provide sufficient
lighting for the place of work.
• Safe operation of the machine must be guaranteed at all times.
Equipment damage due to dirt accumulation!
Unusually high quantities of dust, acid, corrosive gases or substances may damage the
equipment.
• Avoid high volumes of smoke, vapour, oil vapour and grinding dust!
• Avoid ambient air containing salt (sea air)!
Non-permissible ambient conditions!
Insufficient ventilation results in a reduction in performance and equipment damage.
• Observe the ambient conditions!
• Keep the cooling air inlet and outlet clear!
• Observe the minimum distance of 0.5 m from obstacles!

1. Technical specification
Power supply
AC 230V / 50Hz (1ph)
Welding processes
MIG/MAG, MMA, TIG DC Lift
Technology
IGBT
Welding current MIG/MAG
24A - 200A
Welding current MMA
20A - 200A
Welding current TIG
10A - 200A
Duty cycle
100% (155A) / 60% (200A)
Current regulation
Stepless (fluent)
No load voltage
59V
Wire spool weight
5 kg
Compatible wire diameter
0.8 / 1.0 / 1.2 mm
Minimum fuse
20A
Protection class
IP21S
Weight
12 kg
Wire feeder
2 rollers
2. Applications
Device is intended for light industry applications and works with material thickness not greater than 10
mm depending on conditions and type of material. Welding process that can be conducted using the
device is manual coated electrode welding (MMA) and semi-automatic arc welding with synergic settings
(MIG/MAG) or a tungsten electrode welding with direct current (TIG DC Lift). The device works with wide
range of material from mild steel, stainless steel and aluminium.
The manufacturer is not liable for damage caused by improper use of the device.
3. Welding machine description
3.1 Front and back view
1. Torch socket Euro type
2. Spool gun connector socket
3. Positive polarization ( + ) socket
4. Polarization selector plug
5. Negative polarization ( - ) socket
6. ON/OFF Switch
7. Cooling fan
8. Shield gas inlet
9. Ground connection
10. Power cord
PLEASE NOTE! Polarization selector plug must be fitted into one of the sockets depending on the
welding method used.

3.2 Control panel description
A –Parameter display
B –Wire feeding button
C –Gas flow test button
D –Torch operating mode quick selector
E –Material type quick selector
H –Welding mode quick selector
I –Wire diameter selector
J –Loading previously saved set of parameters
K –Saving a set of parameters in memory
P –Right adjustment knob. Short press on the
knob selects next available parameter.
Turning it adjusts the value.
L –Left adjustment knob. When ‘welding’
parameter (pic. 3.2.5) is active the left knob
adjusts voltage. Pressing it enters advanced
menu with further parameters. Please note
that to enter advanced menu the ‘welding’
parameter (pic. 3.2.5) must be selected and a
corresponding light must be on
1 –Gas pre flow
2 –Hot start (only in MMA/Pulse MMA)
3 –Inductance in MIG / Arc Force in MMA
4 –Peak current / Pulse freq. / Pulse duty
5 –Welding current / Advanced menu
6 –End current value / End current time.
Available only in S2T and S4T modes. End
current time ( Endt ) can be accessed by
selecting the End current ( EndU ) and
pressing the left knob.
7 –Arc characteristics for End current EndU
8 –Burnback correction
9 –Gas post flow

4. Menu and functions description
4.1 Selecting welding mode
Welding mode can be selected using a quick selector (pic. 3.2.H). Further available parameters of each
mode are accessible in advanced menu by pressing the left knob (pic. 3.2.L). Please note that to enter
advanced menu the ‘Welding’ parameter (pic. 3.2.5) must be selected and a corresponding light must
be on
Full list of modes
Quick selector
Info
SYN MIG
Predefined programs for MIG
PULSE
Predefined programs for MIG with automatic pulse
D-PULSE
Predefined programs with adjustable dual pulse
SPL MIG
Welding with spool gun
PULSE TIG
Welding TIG DC Lift with adjustable pulse
LIFT TIG
Welding TIG DC Lift
PULSE MMA
Stick welding with adjustable pulse
MMA
Stick welding
4.2 Selecting predefined program
Selecting predefined programs takes place by pressing a quick selector button (pic. 3.2.E). Please note
that predefined programs are only available in MIG modes (SYN MIG, PULSE, D-PULSE).
Full list of predefined programs
Quick selector
Wire diameter (Size)
Info
Fe CO2
0.8mm / 1.0mm
Mild steel with CO2
Fe Mix
0.8mm / 1.0mm
Mild steel with Ar-82%/CO2-18%
AlMg5
1.0mm / 1.2mm
Al with 5%-Mg alloy, Ar-100%
AlSi5
1.0mm / 1.2mm
Al with 5%-Si alloy, Ar-100%
E308
0.8mm / 1.0mm
Stainless steel with Ar-98%/CO2-2%
E316
0.8mm / 1.0mm
Acid-resistant steel with Ar-98%/CO2-2%

4.3 Functions description
Selecting an appropriate function takes places either by pressing right knob (pic. 3.2.P) and selecting it
on the welding process diagram or by pressing the left knob (pic. 3.2.L) and entering advanced menu.
Please note that to enter advanced menu the ‘Welding’ parameter (pic. 3.2.5) must be selected and a
corresponding light must be on
Full list of welding functions
Advanced menu
Info
Burn
Burn back range ( -50% - 50% )
StFd
Soft start wire feed range ( 1m/min –15m/min )
Preg
Pre gas flow time range ( 0s –10s )
Post
Post gas flow time range ( 0.1s –50s )
Tick
Available material thickness. Varies depending of material type
FORC
ArcForce regulation ( range: 0A –200A )
Freq
Pulse frequency.
When in D-PULSE ( range: 0.5Hz –5Hz ), when in TIG and MMA ( range: 0.1Hz –99Hz )
Duty
Pulse duty.
When in D-PULSE ( range: 20% - 80% ), when in TIG and MMA ( range: 5% - 95% )
Ip-p
Peak current value.
D-PULSE: ( range: 5% - 50% ), TIG: ( range: 1% - 500% ), MMA: ( range: 1% - 50% )
PU
Arc length correction at peak current. ( range: -50% –50% )
BU
Arc length correction at base current. ( range: -50% –50% )
IND
Inductance regulation. ( range: -90% –50% )
Mode 2T
Two stroke operating mode. Holding the trigger continues welding however releasing it
ends welding
Mode 4T
Four stroke operating mode. Pressing and realising the trigger ignites the arc. Pressing
and releasing it again ends welding.

Mode S2T
Advanced two stroke mode with hot start and end current. Holding the trigger activates
pre gas flow ( PreG ) and ignites the arc with a hot start current value ( HotI ) that goes
for selected time ( Hott ). After that the device sets predefined welding current value.
Releasing the trigger activates downslope phase ( Slope ) that stops after a preselected
time period and then end current is activated ( EndI ). End current time span is
determined by end current time setting ( Endt ). After that arc is terminated and welding
is finished.
Mode S4T
Advanced four stroke mode with hot start and end current. Holding the trigger activates
pre gas flow ( PreG ) and ignites the arc with a hot start current value ( HotI ) that lasts
until the trigger is being hold. When the trigger is released the device sets predefined
welding current value.
Pressing the trigger again activates downslope phase ( Slope ) that stops after a
preselected time period and then end current is activated ( EndI ). End current time span
is determined by the trigger and it last until the trigger is not released. After that arc is
terminated and welding is finished.

ModeSPOT
Basic spot welding. Pressing the trigger activates pre gas flow ( PreG ) and ignites the arc
with a defined welding current. Arc lasts for a specified time ( Sptt ) and after that time
the arc is terminated. Pressing the trigger again repeats the process.
ModeCPOT
Advanced/continuous spot welding. Pressing torch trigger ignites the arc that last for a
predefined time defined in parameter ‘spot time’ ( Sptt ). After that time device
terminates the arc and a pause begins that lasts for a time predefined in parameter ‘stop’
( Stop ). Parameter ‘stop’ last for a defined period from 0.1s to 25.5s. Following that
phase device ignites the arc again and the whole process repeats until the torch trigger
is not released.
EndI
End current (crater filling). Parameter is only available in S2T and S4T.
EndU
Arc length correction at the end current. This parameter allows to determine what arc
length percentage of the basic arc length is preferred. Parameter is only available in S2T
and S4T. ( range: -50% –50% )
Endt
End current time. It determines for how long the device keeps the ‘end current’ value.
HotI
Hot start current value. Available in MMA mode or in MIG S2T / MIG S4T modes as a
start current.
Hott
Hot start time. It determines for how long device keeps ‘Hot start’ current value ( HotI ).
In MMA ( 0s –99s ), in MIG S2T ( 0s –50s )
HotU
Arc length correction when Hot start ( HotI ) is active. Only in S2T and S4T.
( range: -50% –50% )
Sptt
Spot welding arc time span. Available only in SPOT and CPOT. ( range: 0.1s –9.9s )
Stop
Pause duration when spot welding. Only in CPOT. ( range: 0.1s –25.5s )
Slop CC
Basic MMA mode
Slop CP
Welding in MMA mode using cellulose electrodes
VRD
Voltage reduction device
Save
Saving predefined settings in memory
Load
Loading predefined settings from memory

5. Detailed technical specification
5.1 MMA welding process
Welding current ( A)
20A –200A
Arc Force ( FORC )
0A –200A
Hot Start current ( HotI )
0A –200A
Hot Start time ( Hot )
0s –0.099s
Arc characteristics ( Slop )
CC –basic characteristics
CP –characteristics for cellulose electrodes
VRD feature ( VRD )
ON / OFF
5.2 TIG DC Lift / TIG DC Lift with pulse welding process
Welding current ( A )
1A –200A
Pulse frequency ( Freq )
0.1Hz –99Hz
Pulse balance ( Duty )
5% –95%
Peak current ( Ip-p )
1% –500%
5.3 MIG/MAG welding process with single pulse
Welding current ( A )
24A –200A
Material thickness
0.8mm –4.5mm
Material thickness range varies depending on
material type and other parameters
Inductance regulation
( Forc )
0% - 100%
Torch control mode
( Mode )
2T, 4T, S2T, S4T, Spot, Cpot
Burn back time ( Burn )
-50% - 50%
Hot Start time ( Hott )
MMA: 0s –99ms, MIG: 0s –50s
End current time ( Endt )
0s –50s
Spot welding time ( Sptt )
0.1s –9.9s
Start feed range ( StFd )
1m/s –15m/s
Spot welding pause
duration (Stop )
1m/s –15m/s
Pre gas flow time ( Preg )
0s –10s
Post gas flow time
( Post )
0.1s –50s

5.4 MIG/MAG welding process with dual pulse
Pulse frequency ( Freq )
0.5Hz –5Hz
Pulse balance ( Duty )
20% –80%
Peak current ( Ip-p )
5% –50%
Arc length at peak current
( PU )
-50% - 50%
Arc length at base current
( BU )
-50% - 50%
6. Operating device memory
Device is equipped with 35 memory slots in which parameters can be stored.
Saving a predefined set of values conducts by pressing button Save (pic. 3.2.K) and selecting
required memory slot with right knob (pic.3.2.P). To confirm saving press right knob until SaveData
sign displays.
The same process must be repeated when trying to recall previously saved values. In that case a
button Load (pic. 3.2.J) must be selected following by required slot from available list and confirmed
with appropriate knob.
7. Working with Spool gun type torch
Device is compatible with spool gun type torch (not included in the set). To work with spool gun the
torch must be connected to Euro connector on the device front and a torch control plug fitted to
appropriate socket depicted with spool gun picture. In wire spool compartment there is a switch that
determines which torch type the device work with. In case of spool gun it must be switched to position
depicted with spool gun picture.

8. Preparing the device to work
- Before use please make sure that electric network you are going to use is corresponding to
technical specification of the device. Power supply voltage and frequency is provided in the
technical specification section of this manual.
- Please check if the power supply connection is grounded. Check if the fuse is sufficient and
not less than 20A.
- In case of changing the plug follow the instructions to connect the green/yellow wire to the
ground line in your socket.
9. Connecting welding cables and torch
- Before connecting welding cables make sure the device in not connected to power supply.
- Check if the ground cable is connected with ground clamp
- Ground plug should be connected to negative polarization socket (pic. 3.1.4). Insert plug and
turn it to tighten. Loosely connected plug may cause sparks and damage to socket.
In MIG/MAG process ground plug should be connected to negative socket ( - ) the other
empty socket must connected with polarization selector (pic. 3.1.4)
Please remember that you can’t leave empty sockets as the circuit won’t be closed
and welding won’t be possible.
- Make sure the contact tip and torch liner are compatible with the wire you are about to use.
10. Mounting wire spool into the feeder
- Please make sure that the roller installed in the drive assembly is corresponding to the type
and diameter of the wire.
- Attach the wire spool on the spool mount, taking care to ensure that the wire unwinding
direction was in line with entering of the feeder mechanism.
- Lock the spool by tightening the nut.
- Release roller locking mechanism on wire feeder to allow wire to enter the feeder.
- Insert the end of the wire into the guide located in the back of the feeder and carry it out
over the drive rollers into the welding torch. Make sure the wire is straight and has no
imperfections that may cause it to jam inside torch liner.
- By adjusting pressure on the locking mechanism you can either tighten or loosen wire
against roller grooves. It allows you to correct wire feeding if irregular feed occurs.
- Prepare torch before inserting welding wire. Torch cable must be put in straight line to
allow the wire to smoothly go through the liner. Remove the gas nozzle the contact tip to
allow the wire to exit the torch.
- By pressing the left knob (pic.3.2.5) activates wire feeder to insert the welding wire until it
pulls out of the tip of welding torch.
- Attach appropriate contact tip corresponding to wire diameter. Put the gas nozzle back on
and remove excessive wire.
- Turn the device ON.

- Adjust the downforce of the feed roller by turning the pressure knob. Too low contact force,
causes sliding of the drive roller. Too much force increases the resistance in the feeder
and can deform the wire.
11. Connecting shield gas bottle
- Place the shield gas bottle close the device.
- Attach a gas regulator type depending on shield gas type.
- Connect the regulator outlet with gas supply connector at the back of the welder using a
gas hose.
- Open gas bottle valve and a gas regulator valve. After the welding is finished close the
bottle valve to terminate gas flow.
- Please notice to avoid using the welder in windy conditions as it may cause the gas shield
to dissipate.
12. MIG/MAG welding tips
- Welding horizontal butt joints of thin materials should be carried out using push technique.
However for thick material it should be a pull technique.
- For vertical butt joints of thin elements place the joint from up to down.
- Horizontal corner joints should be carried out using push technique compensating by
placing the torch at an appropriate angle towards welding material.
- In case of filling wider joints carry the oscillating move of the welding tip.
- During the welding torch tip should be placed at an appropriate angle. If the angle is not
right it may cause air to be sucked into welding puddle resulting in joint imprefections. The
proper angle is lower or equal to 10 degrees for vertical position.
Too long or too short arc can result in unstable arc and joint
imprefections.
L1, L2 –arc length
The penetration depth can differ according to welding
technique and torch position
H1, H2 –penetration depth
13. Welding using MMA process
The welding device can also be used for a stick electrode welding. To use that process choose
setting MMA/TIG Lift on quick selector. Connect the electrode holder plug into the positive socket
( + ) and the ground cable plug into the negative socket ( - ) leaving the polarization selector
unconnected. Using the welding current regulation knob (pic.3.2.5) set the desirable welding current.

Please note that different electrode manufacturers may advise other polarization connections. In
such case please refer to electrode manufacturers information.
14. Cleaning and maintaining the device
The protection class of this device is IP21S. Do not use the device in the rain, nor expose it to
extensive moisture.
WARNING!
Device based on electronic components. Metal grinding and cutting close to the welder may
cause contamination of the inside of the device, thus causing its damage.
The damage mentioned above is not covered by the warranty. If you need to work in such
an environment, please clean device before use by blowing the inside of the welding
machine with compressed air.
To prolong the life and reliable operation of the device, several rules must be observed:
1. The device should be placed in a well-ventilated room where there is free air circulation.
2. Do not place the device on a wet surface.
3. Use a wire diameter and spool weight according to the table.
4. Check the technical condition of the device and welding cables.
5. Remove any flammable materials from the welding area.
6. Use suitable protective clothing for welding: gloves, apron, safety boots and welding helmet
15. Troubleshooting
Symptoms
Possible cause
Remedy
Wire feed does not feed the wire or
feeding is irregular (feeder motor is
working)
- Feeding roll grooves are dirty
- Contact tip is damaged
- Locking mechanism is not
tighten
- Torch liner is stuck with debris
- Feeder roll type is wrong
- Contact tip diameter is wrong
- Clean or change roll
- Change contact tip
- Tighten the locking mechanism
- Clean or change the liner
- Mount appropriate roll
- Check the contact tip and
change for a right one if needed
Wire feed does not feed the wire
(feeder motor is not working)
- Faulty feeding motor
- Control module failure
- Turn directly to the service
centre
Arc is not igniting
- Ground clamp not connected or
connected improperly
- Polarization selector cable not
connected
- Check the connection of the
ground clamp
- Plug the selector to the
appropriate socket
Arc is too long and irregular
- Welding current is to high
- Wire feed is too slow
- Adjust the current value
- Change wire feed speed
Arc is too short
- Welding current to low
- Wire feed to fast
- Adjust the current value
- Change wire feed speed
ON/OFF button does not light up
- No electric supply
- Fuse failure
- Switch malfunction
- Check the power connections
- Replace the fuse
- Replace the switch

16. Transporting and storage
Always store the devices in a dry, ventilated place, out of reach of children and
bystanders. Protect the device against vibrations and shocks during transport.
17. Recycling
The packaging and device materials are suitable for recycling use. Disposal of the packaging and
device must be done in accordance with local regulations. The packaging materials should be
protected against children as they are potential source of danger.
18. Warranty
The manufacturer of the device provides full warranty service for the power supply unit within 24
months from the day device was purchased. An individual warranty card is issued for each device.
Warranty is valid only if all conditions listed in the instructions manual were fulfilled. If the device
was used inappropriate or against instructions the warranty becomes invalid. Service centre does
not cover the postage cost for sending the device for repairs or sending it back after repairs.
SPAW S.C.
ul. Kosiarzy 3
30-371 Kraków
Poland
www: www.spawsc.pl