Stealth DIGI-MIG 200 LCD User manual

DIGI-MIG 200 LCD
Part No. 9005H
IMPORTANT
Please read these instructions carefully before attempting to use this equipment.
Retain this manual and keep it to hand for quick reference. Pay particular attention to the safety instructions.
Contact your distributor if you do not fully understand this manual.
OPERATORS’ MANUAL

- Ⅳ-
CONTENT
§1 Safety ............................................................................................1!
§1.1 Signal Explanation........................................................................................................1!
§1.2 Arc Welding Damage ...................................................................................................1!
§1.3 The knowledge of Electric and Magnetic Fields ........................................................5!
§2 Overview ......................................................................................7!
§2.1 Brief Introduction.........................................................................................................7!
§2.2 Working Principle ........................................................................................................8!
§2.3 Volt-Ampere Characteristic ........................................................................................8!
§3 Installation and Adjustment.....................................................10!
§3.1 Parameters...................................................................................................................10!
§3.2 Duty cycle and Over-heat...........................................................................................10!
§3.3 Equipment Connection...............................................................................................11!
§3.4 Maintenance of MIG Gun mechanism .....................................................................13!
§4 Operation ...................................................................................15!
§4.1 Layout for the front and rear panel: ........................................................................15!
§4.2Welding operation：...................................................................................................16!
§4.3Welding parameters ....................................................................................................23!
§4 .4Operation environment..............................................................................................23!
§4.5 Operation Notices .......................................................................................................23!
§5 Maintenance & Troubleshooting .............................................25!
§5.1 Maintenance ................................................................................................................25!
§5.2 Troubleshooting ..........................................................................................................26!
§5.3Electrical schematic drawing......................................................................................28!

SAFETY
- 1 -
§1 Safety
§1.1 Signal Explanation
!The above signals mean warning! Notice! Running parts and getting an electric
shock or thermal parts will take damage for your body or others. The corresponding
notices are as follows. It is quite a safe operation after taking several necessary
protection measures.
§1.2 Arc Welding Damage
!The following signals and word explanations are to some damages for your body
or others happening on the welding operation. While seeing these, please remind of
yourself or others to be dangerous.
!Only ones who are trained professionally can install, debug, operate, maintain and
repair the equipment.
!During the operation, non-concerned people should be lift, especially for children.
!After shut off the machine power, please maintain and examine the equipment
according to §5 because of the DC voltage existing in the electrolytic capacitors.
ELECTRIC SHOCK CAN KILL.
!Never touch electrical parts.
!Wear dry, hole-free gloves and clothes to insulate yourself.
!Insulate yourself from work and ground using dry insulation. Make certain the
insulation is large enough to cover your full area of physical contact with work and
ground.
!Take carefully when using the equipment in small place, falling-off and wet
circumstance.
!Never close the machine power before installation and adjustment.

SAFETY
- 2 -
Ensure to install the equipment correctly and ground the work or metal to be welded
to a good electrical (earth) ground according the operation manual.
!The electrode and work (or ground) circuits are electrically “hot” when the welder
is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry,
hole-free gloves to insulate hands.
!In semiautomatic or automatic wire welding, the electrode, electrode reel, welding
head, nozzle or semiautomatic welding gun are also electrically “hot”.
!Always be sure the work cable makes a good electrical connection with the metal
being welded. The connection should be as close as possible to the area being
welded.
!Maintain the electrode holder, work clamp, welding cable and welding machine in
good, safe operating condition. Replace damaged insulation.
!Never dip the electrode in water for cooling.
!Never simultaneously touch electrically “hot” parts of electrode holders connected
to two welders because voltage between the two can be the total of the open
circuit voltage of both welders.
!When working above the floor level, use a safety belt to protect yourself from a
fall should you get a shock.
FUMES AND GASES CAN BE DANGEROUS.
!Welding may produce fumes and gases hazardous to health. Avoid breathing these
fumes and gases. When welding, keep your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep fumes and gases away from the
breathing zone. When welding with electrodes which require special ventilation such
as stainless or hard facing or on lead or cadmium plated steel and other metals or
coatings which produce highly toxic fumes, keep exposure as low as possible and
below Threshold Limit Values using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a respirator may be required.
Additional precautions are also required when welding on galvanized steel.
!Do not weld in locations near chlorinated hydrocarbon vapors coming from

SAFETY
- 3 -
degreasing, cleaning or spraying operations. The heat and rays of the arc can react
with solvent vapors to form phosgene, a highly toxic gas, and other irritating
products.
!Shielded gases used for arc welding can displace air and cause injury or death.
Always use enough ventilation, especially in confined areas, to insure breathing air
is safe.
!Read and understand the manufacturer’s instructions for this equipment and the
consumables to be used, including the material safety data sheet and follow your
employer’s safety practices.
ARC RAYS CAN BURN.
!Use a shield with the proper filter and cover plates to protect your eyes from
sparks and the rays of the arc when welding or observing open arc welding.
!Use suitable clothing made from durable flame-resistant material to protect your
skin and that of your helpers from the arc rays.
!Protect other nearby personnel with suitable, non-flammable screening and /or
warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter
or metal.
SELF-PROTECTION
!Keep all equipment safety guards, covers and devices in position and in good
repair. Keep hands, hair, clothing and tools away from V-belts, gears, fans and all
other moving parts when starting, operating or repairing equipment.
!Do not put your hands near the engine fan. Do not attempt to override the governor
or idler by pushing on the throttle control rods while the engine is running.
DO NOT adds the fuel near an open flame welding arc or
when the engine is running. Stop the engine and allow it to cool before refueling to
prevent spilled fuel from vaporizing on contact with hot engine parts and igniting.

SAFETY
- 4 -
Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.
WELDING SPARKS can cause fire or explosion.
!Remove fire hazards from the welding area. If this is not possible, cover them to
prevent the welding sparks from starting a fire. Remember that welding sparks and
hot materials from welding can easily go through small cracks and openings to
adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily
available.
!Where compressed gases are to be used at the job site, special precautions should
be used to prevent hazardous situation.
!When not welding, make certain no part of the electrode circuit is touching the
work or ground. Accidental contact can cause overheating and create a fire hazard.
!Do not heat, cut or weld tanks, drums or containers until the proper steps have
been taken to insure that such procedures will not cause flammable or toxic vapors
from substances inside. They can cause an explosion even though they have been
“cleaned”.
!Vent hollow castings or containers before heating, cutting or welding. They may
explode.
!Sparks and spatter are thrown from the welding arc. Wear oil free protective
garments such as leather gloves, heavy shirt, cuff less trousers, high shoes and a cap
over your hair. Wear ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a welding area.
!Connect the work cable to the work as close to the welding area as practical. Work
cables connected to the building framework or other locations away from the
welding area increase the possibility of the welding current passing through lifting
chains, crane cables or other alternate circuits. This can create fire hazards or
overheat lifting chains or cables until they fail.

SAFETY
- 5 -
Rotating parts may be dangerous.
!Use only compressed gas cylinders containing the correct shielding gas for the
process used and properly operating regulators designed for the gas and pressure
used. All hoses, fittings, etc. should be suitable for the application and maintained in
good condition.
!Always keep cylinders in an upright position securely chained to an undercarriage
or fixed support.
!Cylinders should be located:
-Away from areas where they may be struck or subjected to physical damage.
-A safe distance from arc welding or cutting operations and any other source of
heat, sparks, or flame.
!Never allow the electrode, electrode holder or any other electrically “hot” parts to
touch a cylinder.
!Keep your head and face away from the cylinder valve outlet when opening the
cylinder valve.
!Valve protection caps should always be in place and hand tight except when the
cylinder is in use or connected for use.
§1.3 The knowledge of Electric and Magnetic Fields
Electric current flowing through any conductor causes localized Electric and
Magnetic Fields (EMF). The discussion on the effect of EMF is ongoing all the
world. Up to now, no material evidences show that EMF may have effects on health.
However, the research on damage of EMF is still ongoing. Before any conclusion,
we should minimize exposure to EMF as few as possible.
In order to minimize EMF, we should use the following procedures:
!Route the electrode and work cables together – Secure them with tape when
possible.
!All cables should be put away and far from the operator.

SAFETY
- 6 -
!Never coil the power cable around your body.
!Make sure welding machine and power cable to be far away from the operator as
far as possible according to the actual circumstance.
!Connect the work cable to the work-piece as close as possible to the area being
welded.
!The people with heart-pacemaker should be away from the welding area.

- 7 -
§2 Overview
§2.1 Brief Introduction
MIG SERIES arc welding machine adopts the latest pulse width modulation (PWM)
technology and insulated gate bipolar transistor (IGBT) power module, which can change work
frequency to medium frequency so as to replace the traditional hulking work frequency
transformer with the cabinet medium frequency transformer. Thus, it is characterized with
portable, small size, light weight, low consumption and etc.
MIG SERIES arc welding machine uses Mix gas as shielded gas to realize gas shielded
welding, active gas（Ar+O2、Ar+CO2）as shielded gas to realize MAG welding and inactive gas
（Ar）as shielded gas to realize MIG welding.
MIG SERIES arc welding machine has automatic protection functions with intelligent to
over-voltage, over-current and over-heat. If any one of the above problems happens, the alarm
lamp on the front panel will be lighted and output current will be shut off automatically to protect
itself and prolong the equipment using life.
MIG SERIES Features:
1. Digital control system, real-time display the welding parameters;
2. High performance multifunction power source (MMA/MIG/MAG);
3. Waveform control, stable welding arc;
4. IGBT technology, low power dissipation;
5. Rated duty circle is 40%(40℃).
MIG SERIES arc welding machine is suitable for all positions welding for various plates made
of stainless steel, carbon steel, alloyed steel, copper, titanium, etc, which is also applied to pipe
installment, mould mend, petrochemical, architecture decoration, car repair, bicycle, handicraft
and common manufacture.
MAG--Metal Active Gas Welding
MIG--Metal Insert Gas Welding

- 8 -
§2.2 Working Principle
The working principle of MIG SERIES arc welding machine is shown as the following figure.
Single-phase 110V/220V work frequency AC is rectified into DC, then is converted to medium
frequency AC by inverter device (IGBT), after reducing voltage by medium transformer (the main
transformer) and rectifying by medium frequency rectifier (fast recovery diodes), and is outputted
by inductance filtering. The circuit adopts current feedback control technology to insure current
output stably when MMA or TIG. And adopts voltage feedback control technology to insure
voltage output stably when MIG. Meanwhile, the welding current parameter can be adjusted
continuously and infinitely to meet with the requirements of welding craft.
Rectifier Inverter Transformer Rectifier Hall
Current
Feedback
control
Single-phase AC DC AC DC
220V 50Hz
AC DC
Welding current
regulate
(Wire feed speed)
Wire feeder
motor
PWM signal
CPU control
Voltage
Feedback
control
§2.3 Volt-Ampere Characteristic
MIG SERIES welding machine has an excellent volt-ampere characteristic, whose graph is shown as the
following figure. The relation between the rated loading voltage U2and welding current I2is as follows:
U2=14+0.05I2(V)
Single-phase
110V 50/60Hz
Single-phase
220V 50/60Hz
Current sensor

- 9 -
44
14
0600 Io（A）
Uo（V）
Working point
Volt-ampere characteristic The relation between the rated loading
voltage and welding current
§2.4Principles of welding

- 10 -
§3 Installation and Adjustment
§3.1 Parameters
Model
Parameters
POWER MIG 200 LCD
Input Voltage（V）
1~110/120/130±10%
1~220/230/240±10%
Input Current（A）
37 MIG 28 MMA 28 TIG
28 MIG 32 MMA 22 TIG
Input Power（KW）
4.0 MIG 3.1 MMA 3.1 TIG
6.2 MIG 7.3 MMA 4.9 TIG
Welding Current（A）
25-140 (MIG)
10~140 (TIG)
10~100 (MMA)
25-200 (MIG)
10~200(MMA/TIG)
Welding Voltage（V）
10-27 (MIG)
No-load Voltage（V）
67 (MIG) 14 (TIG/MMA)
Power Factor
0.99
Duty cycle（40℃）
40%140A
60%115A
100%90A
40%100A
60%85A
100%65A
40%140A
60%115A
100%90A
40%200A
60%165A
100%130A
Diameter(mm)
Fe ：0.6、0.9、1.0 Ss ：0.8、0.9、1.0
Flux-Cored：0.6、0.8、0.9、1.0
Protection class
IP23
Insulation class
H
Cooling
AF
Dimensions（mm）
505*210*330
Weight（Kg）
15.5
Note: The above parameters are subject to change with the improvement of machines.
§3.2 Duty cycle and Over-heat
The letter “X” stands for the duty cycle, which is defined as the proportion of the time that a
machine can work continuously within a certain time (10 minutes). The rated duty cycle means
the proportion of the time that a machine can work continuously within 10 minutes when it
outputs the rated welding current.

- 11 -
The relation between the duty cycle “X”
and the output welding current “I” is
shown as the right figure.
If transformer is over-heat, the heat relay
inside it will open and will output an
instruction to circuit board, cut AC relay
and the output welding current, and
brighten the over-heat pilot lamp in the
front panel. At this time, the machine
should be relaxed for 15 minutes to cool the fan. When operating the machine again, the welding
output current or the duty cycle should be reduced.
§3.3 Equipment Connection

- 12 -
Operation Steps：
1、Connect the power source input cable of welding machine with the output port of air switch in
electric box on the spot.
2、Connect the cable plug of wire feeder to the positive output of welding machine.
3、Connect the control cable plug of wire feeder to the aero socket on the front board of welding
machine.
4、Connect the negative pole of welding machine to the work piece (base metal).
5、Connect the output pipe of gas cylinder to the input joint of gas valve on the wire feeder and
clamp it.
6、Insert the torch joint into the output of wire feeder unit and keep the wire aim at the wire
feeder mouth.
Note: The plane of the joint should be aimed at screw, plugged tightly and rotated 90º, then
screw the bolt tightly to ensure the gun contacting closely.
7、Connect the shielded gas pipe of torch with the output of front panel on wire feeder.
8、Connect the control cable pin of torch with the two-lead aero socket of front panel on wire
feeder.
9、Notice that the wire diameter should be accordant with the wire wheel and torch tip and press
the wire properly with the handle.

- 13 -
§3.4 Maintenance of MIG Gun mechanism
§3.4.1 Dissection graphics for the MIG GUN
标准化
工艺
批准
日期
设计
制图
校对
审合
处数
标记 更改文件号 重量(g)
共页共
日期
签字
上海亿诺科技有限公司
零部件描述 参考编号 材料
公差选择范围
页
外形尺寸
ICT2098
描 述
图 号
序号 备 注
焊枪15/3米/弹性针/蓝色手柄 -------
上海市顾戴路2535弄99号3号楼2楼
16
图 号
序号
1
2
9
3
6
7
8
11
10
12
13
描 述 数量 备 注
1
2
3
4
7
11
1213
14
15
1617
I CS0063
ICU0003-08
ICZ6087
ICV0685
IHQ0070
IFT0874
IHJ0715
IHJ0782
14
IHJ0028
IHJ0645
IFT0063
IZT0071
1
1
1
1
3
1
1
1
1
1
1
1
18
17 送丝管锁紧螺母
带绝缘层送丝管0. 6- 0. 8 3米 蓝色IIC0500
导电嘴 0. 8/ M6* 25
喷嘴 D. 1 2 14- 15AK
螺丝 M4 X 6 UNI 6107
15AK 枪 颈 (包括六角适配器和塑料适配器)
MI G蓝色手柄
焊枪用开关 21. 8mm
螺丝 D. 3 x 1 0
电缆护套 12- 16- 25 MMQ
电缆支撑用球节 15AK
手柄锁紧环
二氧化碳欧式后把套
数量
1
1
19
18
10
95 6
8
塑料适配器
六角适配器
IZH0667
IHJ0030
5
4
1
15
ITB0059 欧式中央插头/弹性针 1
ICG6000
19 导电嘴扳手 1
IHJ0063 焊枪锁紧螺母/塑料螺纹 1
ICN0663 同轴电缆组/16mmq/3米1
3. 1 ICZ0087 15AK 枪 颈 1
3.1
§3.4.2 The parts list for the MIG GUN
NO.
Description
QTY.
Remark
1
Tip D.12 14-15AK
1
2
Electric nozzle 0.8/M6*25
1
3
15AK Goose gun neck（Hexangular adapter and Plastic adapter）
1
3.1
15AK Goose gun
1
4
Hexangular adapter
1
5
Plastic adapter
1
6
MIG blue handle
1
7
Torch Switch 21.8mm
1
8
Screw D.3*10
3
9
Handle locking ring
1
10
Cable fixing joint 15AK
1
11
Coaxial cable team /16mmq/3m
1
12
Cable thimble 12-16-25 MMQ
1
13
CO2Euro-rear thimble
1
14
Screw M4*6 UNI 6107
1
15
Torch locknut /plastic screw thread
1
16
Euro-main socket/flexibility pin
1
17
Feeding pipe locknut
1
18
Insulating feed pipe 0.6-0.8 3m, Blue
1
19
Spanner for the electric nozzle
1

OPERATION
- 14 -
§3.4.3 The operation for the MIG GUN
1. Service the wire feed mechanism at least every time the reel is changed.
·Check the wear of the feed roll groove and change the feed roll when necessary.
·Clean the welding gun wire guide with compressed air.
2. Cleaning the wire guide
Pressure of the feed rolls remove metal dust from the filler wire’s surface which then finds its
way to the wire guide. If the wire guide is not cleaned, it gradually clogs up and causes wire feed
malfunctions. Clean the wire guide in the following manner：
Remove the welding gun’s gas nozzle, contact tip and contact tip’s adapter.
With a pneumatic pistol, below compressed air through the wire guide.
Blow the wire feed mechanism and reel housing clean with compressed air.
Reattach the welding gun’s parts. Tighten the contact tip and contact tip’s adapter to spanner
tightness.
3. Changing the wire guide
If the wire guide is too worn or totally clogged, change it to a new one according to the
following instructions.
Open the mounting nut of the wire guide which exposes the end of the wire guide.
Straighten the welding gun’s cable and withdraw the wire guide from the gun.
Push a new wire guide in to the gun. Make sure that the wire guide enters all the way into the
contact tip’s adapter and that there is an O-ring at the machine-end of the guide.
Tighten the wire guide in place with the mounting nut.
Cut the wire guide 2mm from the mounting nut and file the sharp edges of the cut round.
Reattach the gun in place and tighten the parts to spanner tightness.

OPERATION
- 15 -
§4 Operation
§4.1 Layout for the front and rear panel:
1. MIG GUN Connect.
2. Output anode: When TIG mode, this polarity must connect the work piece
3. TIG gun control connector.
4.TIG GAS Connector
5. Output cathode：When MIG mode, this polarity must connect the work piece
6. Wire feeder switch & spool Gun switch: up for spool Gun and down for Wire feeder.

OPERATION
- 16 -
§4.2Welding operation：
Main Start-up Interface (POWER MIG 200 LCD):
1. Function selection interface: rotate L Knob in the interface to choose from the four welding
methods of MIG/MAG Synergic, MIG/MAG Manual, Stick and TIG Lift.
2. Synergic parameter selection interface: a synergic parameter may be selected by rotating L
Knob in the interface.
3. Welding parameter setting interface: a welding parameter and its corresponding value may
be selected and set by rotating L Knob and R Knob in the interface.
4. System setting interface: a system parameter and its corresponding value may be selected and
set by rotating L Knob and R Knob in the interface shown below:
System parameters available
by rotating L Knob
System parameters available
by rotating R Knob
Language
English/Simplified Chinese...
Unit
English/Metric
Beeper On/off
Brightness
1 - 10
Factory Reset
Press
5. Function icon display interface: an interface displaying the icon of the welding method
currently used.
6. Welding mode icon display interface: an interface displaying the icon of the welding mode

OPERATION
- 17 -
currently used (2T/4T).
7. Synergic parameter display interface: an interface displaying the synergic parameters
currently used (only available when MIG/MAG Synergic welding method is selected).
8. Multifunction display interface: an interface displaying the contents corresponding to those
selected by users, such as icons of welding method, welding mode and parameter, parameter
values, etc.
§4.2.1Operation of MIG/MAG Synergic welding method:
1. Selection of the welding method:
1) In the main interface, press the MENU key to enter the function selection interface;
2) In the function selection interface, rotate L Knob to select the MIG/MAG Synergic welding
method and press the knob for confirmation in the interface shown below:
Fig. 1
2. Selection of synergic parameters:
1) In the main interface, press the MENU key to enter the synergic parameter selection interface;
2) In the synergic parameter selection interface, rotate L Knob to select the required synergic
parameters and press it for confirmation in the interface shown below:

OPERATION
- 18 -
3. Selection and setting of welding parameters:
1) In the main interface, press the MENU key to enter the welding parameter setting interface;
2) In the welding parameter setting interface, rotate L Knob to select the parameter as required
and rotate R Knob to set a value for the parameter. Press L Knob or R Knob for confirmation in
the interface shown below:
Welding parameters
available by rotating L Knob
Welding parameters
available by rotating R Knob
Two/four Stroke
2T/4T
Burn Back
0-10
Slow Feed
0-10
Pre-flow
0-2 S
Post Flow
0-10 S
Inductance
0-10
Fig. 2
4. Setting of welding current and voltage
1) Press the ENTER key to enter the welding interface shown below:
2) In the welding interface, rotate L Knob to set the welding current, for which the adjustable
scope is different with the welding wires and gases as described in §4.3;
3) The welding voltage will be automatically set as the value corresponding to that of the welding
current set by rotating L Knob.
4) When the programmed welding current does not meet user requirements, the setting is
available by rotating R Knob;
5) After the setting, press L Knob and R Knob for confirmation;