SUNGOLD POWER AK-MIG/MMA 200A BIVOLT User manual

OWNER’S MANUAL
AK-MIG/MMA200ABIVOLT
Please read instruction manual carefully and retain for future reference
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MIG-200

Table of Contents
Safety .................................................................................................................................................................. 2
General Description............................................................................................................................................. 4
Main Parameters ................................................................................................................................................. 5
Operation Control and Description..................................................................................................................6
Installation Debugging and Operation.............................................................................................................7
Caution................................................................................................................................................................ 9
Maintenance ..................................................................................................................................................... 10
Troubleshooting ................................................................................................................................................ 11
Exploded Drawing
........................................................................................................................................... 13
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MIG-200

1. Safety
Welding is dangerous, and may cause damage to you and others, so take good protection when welding. For
details, please refer to the operator safety guidelines in conformity with the accident prevention requirements
of the manufacturer.
Professional training is needed before operating the machine.
●
Use labor protection welding supplies authorized by national security supervision department.
●
The operator must be qualified personnel with a valid “metal welding (OFC) operations” operation certificate.
●
Cut off power before maintenance or repair.
Electric shock—may lead to serious injury or even death.
●
Install earth device according to the application criteria.
●
Never touch the live parts when skin bore or wearing wet gloves/clothes.
●
Make sure that you are insulated from the ground and work piece.
●
Make sure that your working position is safe.
Smoke & gas—may be harmful to health.
●
Keep the head away from smoke and gas to avoid inhalation of exhaust gas from welding.
●
Keep the working environment in good ventilation with exhaust or ventilation equipment when welding.
Arc radiation—may damage eyes or burn skin.
●
Wear suitable welding masks and protective clothing to protect your eyes and body.
●
Use suitable masks or screens to protect spectators from harm.
Improper operation may cause fire or explosion.
●
Welding sparks may result in a fire, so please make sure no combustible materials nearby and pay attention
to
firehazard.
●
Have a fire extinguisher nearby, and have a trained person to use it.
●
Airtight container welding is forbidden
●
Must not use the machines for other purposes except welding, such as pipe thawing, battery charging,
heating.
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Hot work piece may cause severe scalding.
●
Do not contact hot work piece with bare hands.
●
Cooling is needed during continuous use of the welding torch.
Magnetic fields affect cardiac pacemaker.
●
Pacemaker users should be away from the welding spot before medical consultation.
Moving parts may lead to personal injury.
●
Keep yourself away from moving parts such as fan.
●
All doors, panels, covers and other protective devices should be closed during operation.
Please seek professional help when encountering machine failure.
●
Consult the relevant contents of this manual if you encounter any difficulties in installation and operation.
●
Contact the service center of your supplier to seek professional help if you still cannot fully understand after
reading the manual or still cannot solve the problem according to the manual.
Safe use of the welding torch.
●
Parts of the machine, such as the end of the filler wire and welding torch become burning hot during use.
The wire is also sharp and moves quickly, so be careful when threading it to place.
●
Never carry the machine on your shoulder during welding, but place it onan even surface. Also, do not store
the machine by hanging it from the shoulder strap. The shoulder strap is for carrying only.
●
Do not keep the machine near or on hot objects, as the plastic cover may melt.
●
Do not move the shielding gas bottle when the control valve is in place. Fix the gas bottle securely in an
upright position to a separate wall rack or bottle cart.
●
Always close the gas bottle after use.
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2. GeneralDescription
The MIG is a new inverter-based portable MIG welding machine with added MMA function.
The MIG function allows you to weld with both Gas Shielded and Gas-less wire applications.
Easy step-less adjustment of voltage and wire feed make for easy setting of welding parameters giving excel-
lent welding results. Wire Inch gives easy feeding of the wire during set up without gas wastage and the Burn
Back adjustment leaves the wire out ready for the next weld. MMA welding capability delivers easy electrode
welding with high quality results, including cast Iron and stainless. Great versatility. Ideal for DIY and home
workshop. Designed and built to our specification.
●
Working frequency is beyond the audio range, which almost eliminates noise pollution.
●
Industry leading control system
●
Advanced control technology meets the welding applications and provides excellent welding performance.
●
It can be used with a wide range of welding electrodes.
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Easy arc starting, less spatter, stable current and goodweld bead shaping.
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Modern high tech design
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Streamline design of front and rear panels.
●
Front and rear panels made of high-intensity plastics
●
Excellent insulating property.weld bead, high efficiency.
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MIG-200

3. Main Parameters
Model AK-MIG/MMA 200A BIVOLT
1PAC110V / 220V, 50/60Hz
Rated Input Voltage (V)
110V 220V
MIG MMA MIG MMA
Rated Input Power (KVA) 3.8 3.8 7.9 7
Rated Input Current (A) 37 31 33 30
Rated Output Current & Voltage 120A/20V 100A/24V 200A/24V 160A/27.2V
Output Current (A) 50~120 20~100 50~200 20~160
No-load Voltage (V)50
Rated Duty Cycle (%) 60
Efficiency (%) 85
Power Factor (cosø) 0.73
Protection Class IP21S
Insulation Class F
Wire Feeding Speed Range (m/min)1.5-14
Welding Wire Diameter (mm) 0.6/0.8/1.0
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MIG-200

4. Operation Control and Description
●
Front panel
1.
MMA welding current adjustment knob
2.
MIGVoltage adjustmentknob
3. Power LED
4. Overheat LED
5.
Wire feed speed adjustment
6.
Standard/Push-pulltorchswitch
7.
MMA/MIG switch
8.
“ － ”out put terminal
9.
Power supply of the push-pull torch
10.
“ + ”out put terminal
11.
Torch socket
●
Back panel
12.
Power switch
13.
Power cable
14.Gas in
15.
Groundscrew
16.Fan
12=
16 =
13 =
Front Panel Back Panel
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MIG-200

5. Installation Debugging and Operation
Warning
Please install the machine strictly according to the following steps. The protection class of this machine
is IP21S, so avoid using it in rain. Before using, please make sure the input voltage is in voltage range
(200V-240V).Otherwise,themachinewillbedamaged.
5.1 Connection of input cable
1) A primary power supply cable is available for this welding machine. Connect the power input cable to the
rated input power. (Ground connection is needed for safety purpose.)
2) The primary cable should be tightly connected to the correct socket to avoid oxidization.
3) Check whether the voltage value varies in acceptable range with a multi-meter.
5.2 MMA installation
1) Turn MMA/MIG switch to MMA
2) The electrode holder and earth clamp are easily connected to the machine by inserting the quick connector
and twisting it clockwise. Always ensure a tight fit.
Generally, DCEP connection and DCEN connection are available in MMA.
DCEP: Connect the electrode holder to “+” output terminal, and the work clamp to “-” output terminal.
DCEN: Connect the electrode holder to “-” output terminal, and the work clamp to “+” output terminal.
Operators may choose DCEP/DCEN according to work piece and electrode application requirement.
Phenomena such as unstable arc, excessive spatter, and electrode sticking occur when improper polarity is
selected. Change the connection by exchanging the quick plugs to solve the problem.
3) Set the amperage knob according to type and size of welding rod being used and the arc force to the desired.
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MIG-200

5.3. MIG Installation
1) Select the MIG function with the MMA/MIG switch.
2) Connect the electrode holder to the Negative socket and tighten it.
3) Connect the earth clamp into the Positive socket and tighten it.
4) Plug the welding torch into the Torch socket on the front panel, and tighten it.
IMPORTANT
When connecting the torch, be sure to tighten the connection. A loose connection can result in the connector
arcing and damage to the machine and gun connector. This damage is not covered under warranty.
5) Check the electrode holder is connected to the Negative socket.
6) Fit the correct size of knurled drive roller for Gas Less Flux Core wire.
7) Place the wire spool onto the spool holder
Note
The spool retaining nut is left hand thread. Snip the wire from the spool being sure to hold the wire to prevent
rapid uncoiling. Feed the wire into the wire feeder inlet guide tube through to the drive roller.
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6. Caution
6.1 Working environment
1) The product shall be operated under dry environment with normal humidity under 90%.
2) The temperature of working environment should be between -10 ℃ and 40 ℃ .
3) Avoid welding in the open air unless sheltered from sunlight and rain. Keep it dry anytime and do not place
it
on wet ground or in puddles.
4) Avoid welding in dusty area or environment with corrosive chemical gas.
5) Avoid working in the environment where the air circulation is too strong
6) Gas shielded arc welding should be operated in environment without strong airflow.
6.2 Safety tips
Over-current/over-voltage/over-heating protection circuit is installed in this machine. If the input voltage or the
output current is too high or machine inside temperature over heating inside, the machine will stop automati-
cally. However, excessive use (e.g. too high voltage) of machine may also damage machine, so please note:
1) Ventilation
High current passes when welding is carried out, thus natural ventilation cannot satisfy the machine’s
cooling requirement. Maintain good ventilation through the louvers of the machine. The minimum distance
between the machine and any other objects in or near the working area should be 30cm. Good ventilation
is of critical importance for the normal performance and lifespan of the machine.
2) Welding operation is forbidden while the machine is overload.
Remember to observe the max load current at any moment (refer to the corresponding duty cycle). Make
sure that the welding current should not exceed the max load current. Overload could obviously shorten
the machine’s lifespan, or even damage the machine.
3) Over-voltage is forbidden.
Regarding the power supply voltage range of the machine, please refer to “Main Parameters” table. This
machine is of automatic voltage compensation, which enables the maintaining of the voltage range within
the given range. In case that the input voltage exceeds the stipulated value, it would possibly damage the
components of the machine.
4) Make sure earth connected before operation
There is a grounding screw on the back of machine with a grounding sign beside. Before using, make sure
earth connected well to prevent the operator from getting electric shock or electricity leak. Please use
10mm
2
cable to connect the case of the machine to earth.
5) Operation over max duty cycle
When using the machine over max duty cycle, inside overheating circuit causes the temperature switch to
be open-circuit, which finally prevents the product from working on. This can be judged from the yellow
light LED on face panel. Under this circumstance, no need to pull off the plug from the power and keep
power on to let the fan cool down the machine. When the yellow LED turns off, welding can be continued.
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MIG-200

7. Maintenance
Warning
This machine will produce electric and magnetic fields, so the operator should ensure proper protection and
screening while using it.
●
Earth leakage-circuit breaker should be used with this machine.
●
During operation, DO NOT pull out or insert any plugs or cables. It can lead to fatal danger and cause dam-
age to the machine.
●
Before connecting cables, make sure the power is off. (The correct way is to connect the cables to the ma-
chine first, and make sure they are firmly tightened and then connect the power plug to the power source.)
●
Before maintenance and checking, power must be turned off,
●
Before opening the cover, disconnect the ma chine from power source.
1) Remove dust with dry and clean compressed air regularly. If the welding machine is operated in polluted
area with smoke and dust, the machine needs to be cleaned regularly.
2) Pressure of compressed air must not be higher than 5 bars in order to prevent damage to small compo-
nents inside the machine.
3) Check inside the welding machine regularly and make sure the output terminals are connected tightly and
connectors are not damaged. If burnt, loose or damaged, please tighten or replace them if necessary.
4) Avoid water and steam entering into the machine. If the welding machine gets wet, please dry inside of the
machine and check the insulation status.
5) If the machine will not be used for long time, it should be put into a box or covered and stored in cool and
dryarea.
6) When power is on, do not let hand or hair touch electrification device in the machine such as fan to avoid
injury or damage to machine.
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8. Troubleshooting
Warning
Experimentation and careless maintenance may lead to more problems to the machine. This will make pro-
fessional diagnosis and repair more difficult. When the machine is open, there may be exposed connections
containing life-threatening voltages. Any direct or indirect touch will cause electric shock, and severe electric
shock will lead to death.
Common Malfunction Analysis and Solution:
Malfunction Cause and Solution
The overheating LED is on.
1.
Check the welding current and welding time. Refer to the manual, and
operate according to the duty cycle requirement.
2.
Check the running status of the fan when welding. If the fan does not
work, check if the power supply of the fan is 220V: If the power supply
is normal, check the fan; if the power supply is abnormal, check the
connecting cable of the power supply.
3.
Replace the thermal switch if it is damaged.
The power LED is off, and there is no output current.
1.
Check if the fan works. If it does not work, it indicates that the power
cord is not in good contact.
2.
If the fan works, it indicates that the control PCB inside the machine fails.
There is no response when pushing the torch trigger, and the protection
LED is off.
1.
Check if the gun trigger is in good contact.
2.
Check if the welding torch is well connected to the European connector,
and check the control jack of the European connector.
3.
The control PCB inside the machine fails.
1. Check if the cable to the workpiece is in good contact.
When torch trigger is pressed, wire feeder works and gas comes out, but 2. Check if the quick plug is connected to correct quick socket.
there is no output current, and the protection LED is off. 3.
Check the welding torch for damage.
4.
The control PCB inside the machine fails.
There is output current when pushing the torch trigger to feed gas, but
the wire feeder does not feed wire.
1.
Check the wire feeder is clogged or damaged.
2.
Check the contact tip of welding torch for clogging or being damaged.
3.
The control inside the machine fails.
Welding can be carried out when pushing the torch trigger, but the
voltage cannot be adjusted.
1.
Check if the voltage feedback wire inside the machine is in good
condition.
2.
The control inside the machine fails.
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Malfunction Cause and Solution
Welding current is unstable.
1.
Check the pressure arm on the wire feeder for proper pressure.
2.
Check if the drive roll matches the wire size being used.
3.
Check the contact tip of the welding torch for wear. Replace it and
tighten it if necessary.
4.
Check the welding wire for good quality.
5.
Check if the torch cable is too twisted.
6.
Check if the quick plug is loose.
Weld bead is not well protected.
1.
Do not move the welding torch away immediately when stopping weld-
ing, so that the shielded gas can protect the weld bead.
2.
Prolong the post-flow time of the shield gas, and contact our company.
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MIG-200

9. Exploded Drawing
1
2
8
3
4
7
5
6
33
34
12
11 13 14
10
9 15
16
17
18
19
20
31
32
30
29 28
21
22 23
27 24
25
26
1. Plastic handle
2. Cover
3. Side door
4. Hinge
5. Hinge
6. Iron box
7. Wirefeeding shaft
8. Middle plate
9. Magnetic valve
10.Ventilationhood
11.Radiators
12.Thermalcut
13. Relay
14. MainPCB
15. Silicon bridge
16. Transformer
17. Potentiometer
18. Wirefeederinching button
19. Wire feeder
20. Fixedbase
21. Front panel
22. Display control
23. Iron front panel
24. Output board
25. Euro socket
26. Screwed union
27. Base
28. Fan
29.Groundingscrew
30. Fancover
31. Power cable
32. Back panel
33. Air inlet
34. ON/OFFswitch
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