Top Gun MIG 200i User manual

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MIG 200i
Inverter MIG/MAG Semi-auto ARC Welding Machine
Operating Manual
(Read the manual carefully before installation, operation and
maintenance)
Advanced
Product

1
SAFETY PRECAUTIONS
Follow these precautions carefully. Improper use of any welder can result in injury or death.
1. ONLY CONNECT WELDER TO A POWER SOURCE FOR WHICH IT WAS DESIGNED.
The specification plate on the welder lists this information. When welding outdoors, only
use an extension cord intended for such use.
2. ONLY OPERATE WELDER IN DRY LOCATIONS and on concrete floor. Keep area
clean and uncluttered.
3. KEEP ALL COMBUSTIBLES AWAY FROM WORK SITE.
4. DO NOT WEAR CLOTHING THAT HAS BEEN CONTAMINATED with grease or oil.
5. KEEP CABLES DRY AND FREE FROM OIL AND GREASE and never coil around
shoulders.
6. SECURE WORK WITH CLAMPS or other means; don't over reach when working.
7. NEVER STRIKE AN ARC ON A COMPRESSED GAS CYLINDER
8. DON'T ALLOW THE INSULATED PORTION OF THE ELECTRODE HOLDER TO
TOUCH THE WELDING GROUND WHILE CURRENT IS FLOWING.
9. SHUT OFF POWER AND UNPLUG MACHINE WHEN REPAIRING OR ADJUSTING.
Inspect before every use. Only use identical replacement parts.
10. FOLLOW ALL MANUFACTURER'S RULES on operating switches and making
adjustments.
11. ALWAYS WEAR PROTECTIVE CLOTHING when welding. This includes: long
sleeved shirt (leather sleeves), protective apron without pockets, long protective pants and
boots. When handling hot materials, wear asbestos gloves.
12. ALWAYS WEAR A WELDER'S HELMET WITH PROTECTIVE EYE PIECE when welding.
Arcs may cause blindness. Wear a protective cap underneath the helmet.
13. WHEN WELDING OVERHEAD, BEWARE OF HOT METAL DROPPINGS. Always
protect the head, hand, feet and body.
14. KEEP A FIRE EXTINGUISHER CLOSE BY AT ALL TIMES.
15. DO NOT EXCEED THE DUTY CYCLE OF THE MACHINE. The rated cycle of a
welding machine is the percentage of a ten minute period that the machine can operate
safely at a given output setting.
16. KEEP ALL CHILDREN AWAY FROM WORK AREA. When storing equipment, make
sure it is out of reach of children.
17. GUARD AGAINST ELECTRIC SHOCK. Do not work when tired. Do not let body come
in contact with grounded surfaces.

2
1. Main characteristic and suitable range
The MIG 200i encompasses integrated controlling and advanced inverter technology. The
IGBT and alloy magnectic core ensure a reliable high quality weld with reduced spatter.
1.1 Structure of the MIG 200i MIG/MAG semi-auto Arc welding machine a. The
name of the model
MIG 200i
Model improvement
max welding current
Semi-auto MIG/MAG Arc welding machine
b. Composing of the product
This product is composed by three parts as following
★Power source (MIG 200i)
★welding gun
1.2 Suitable range of the MIG 200i
★Suitable material: low-carbon steel, stainless steel
★Thickness of the material: low-carbon steel and stainless: more than 0.5mm
★Suitable position: all positions
★Suitable wire: φ0.6,0.8, solid wire/flux cord wire.
1.3 Characteristic of MIG 200i
★Wide output current 30-200A: 0.6 -----------30-100A
0.8------------50-200A
★Steady welding process, low splash, easy control, good welding form.
★High efficiency: 200A/23V the duty cycle is 35%
150A/21.5V the duty cycle is 60%
120A/20V the duty cycle is 100%
continuous wire feed, the max speed of wire feed is -330(12m)/min

3
2. Main technical Data:
★Input Voltage 1~220V/230V/240V; 50/60Hz
★Rated Input current 30 A
★Rated Input power 6.6KVA
★No-load Voltage 55~75V
★Voltage adjusting Range 14±3V~23.5±3V
★Current output Range 30~200A (MIG/MAG)
★
Suitable wire
0.6 , 0.8
★
Duty cycle
200A/23V the duty cycle is 35%
★Efficiency
★Power factor
150A/21.5V the duty cycle is 60%
120A/20V the duty cycle is 100%
η≥0.85
λ=0.8
★Insulation class F
★Protection class of shell fan cooling
Note: (1) Adjust the no-load voltage according to the requirements. Normally it is 70V.
3. Function
3.1 Adjusting function for the welding voltage and welding current
3.1.1 MIG 200i supply the adjusting range at MIG/MAG as following,
Welding voltage: 14V±3V~23.5V±3V use the voltage adjusting knob
Welding current: 30A~200A use the current adjusting knob

4
4. Indicators and warning lights on the MIG 200i control panel
4.1 Indicating and adjusting
FRONT PANEL BACK PANEL
MIG 200i
4
5
6
11
12
14
1
2
13
8
15
-
9
16
4.1.1 MIG Voltage regulator
4.1.2 MIG Current regulator
4.1.4 Power indicating
If the indicating light is on the control circuit connects the power already.
4.1.5 MIG over heat indicating
4.1.6 over current indicating
4.1.8 MIG torch CONNECTOR
4.1.9 output"-"
4.1.11 incoming line of the power
4.1.12 power switch

5
4.1.13 Gas inlet
4.1.14 name plate
4.1.15 FAN (DC12V)
4.1.16 grounding column
5. Operating Instructions
★Check for any damage before use.
★Ensure power capacity of more than 30A.
★Ensure power source is grounded (diagram 6)
★Remove any combustible goods from the area.
★The welder is to be only be used by trained personnel.
★Do not operate without appropriate safety gear such safety boots, welding gloves,
welding jackets and welding helmets.
6. MIG/MAG Welding
Turn the switch "7" MIG/MMA SWITCH to "MIG"
★Check to ensure all parts are included when opening the package.
★Grounding protection. Please see attached Diagram 6
The power source is 220Vac/ (50~60Hz) .The yellow/green double cable is grounding
cable. Be sure to connect the yellow/green double cable into the grounding connection on the
welder. Another way is to select the M8 bolt on the back of the machine and connecting the
grounding cable as per the diagram below.
★Install the welding gun on the front panel, connect the welding gun and lock the bolt.
★Connect the gas pipe to the gas bottle.

-
Flow meter
CO2
11
12
14
13
Gas inlet
15
16
air breaker
Yellow/green double cable
or
Diagram 6
MIG 200i
1 2
GAS
8
9
9
Working piece
Diagram 7 NO GAS
9

7
7. Operation
★"ON" and "OFF" indicating switch is located on the back panel.
★Preset the welding voltage, welding current (wire speed) and arc force (Diagram 4).
★Confirm the specification of the wire feed hose
★Confirm the specification of nib base. It affects the extended length of the wire.
★Confirm the specification of nib. It affects the electric resistance.
★Ensure the wire slot of the roller is suitable for the diameter of the wire.
★Confirm the pressure of the roller to avoid slipping.
If the pressure is too low, the wire feed will slow down. If
the pressure is too high, the wire will bend.
★Confirm the flow of the gas.
★Straighten the hose of the welding gun as much as possible. The bending radius
cannot be less than 160mm. Otherwise it will affect the speed of the wire feeder.
7.1 Working process
Press the switch and start welding. If you release the switch, the arc will stop.
7.2 Gas inspection
Preset the gas flow through the meter and check that it is flowing.
7.3 Select the wire
Open side panel. Remove spool nut, align spool properly and place wire onto spool
holder. Replace spool nut. Feed wire through rear guide into front guide. Tobe wire should
feed through hand piece.

8
8. Working elements
Diagram for the MIG 180i working elements.Digram9
input rectifier
filter
inverter
circuit
rectifier
filter
wire
working piece
input IGBT output feeder welding gun
+
control circuit
panel indictor
Diagram 9

9
Input AC 220V/230V/240V,rectifier and filter it into 300VDC.
Control the IGBT by PWM+PFM, inverter the 300VDC to 20KHZ AC.
High frequency transformer passes the power by insulation and voltage reducing with
high efficiency.
Output the second rectifier and the second filter. Output the required welding current
and voltage.
9.Maintenance
Check the safety measure is efficient.
Get rid of the dust for the power source (for example, dry compressed air)
Before operating, check the "work piece", "torch" and connectors
Check the connection between the grounding cable and plug (if relaxed, the serious
heating will damage the quick connectors)
Check that the fan is working.
Check the insulation and for any breakage on the input
power cord/ lead
Replace any broken leads
Check if there is any noisy in the wire feed motor.
Remove any splash from inside the nib regularly.
Check the abrasion of the nib. Change it in time (suggest 5~10pieces nibs/40kg wire).

10
10. Troubles and Remedy
Troubles and remedy and remedy are as the form 10 as following
Troubles
Cause
Remedy
1.Fan not works
properly
1.the fan line lose
2.Fan breakage
1.Connect the line
2.Change the fan
2.No indicating on
the front panel
1.the power line lose
2.Indicating light broken
1.Check the power, Connect the line
2.Change it(φ8)
3.Over heating light
on (use mig)
1.aeration is not good
2.The temperature is too high
3.over-load use
4.Thermostat broken
5.Control plate broken
1.get rid of the bar 0.5m around
2.Reduce the temperature
3.Reduce the use loading
4.Change the thermostat(JUC-OF)
5.Check and change the
control plate
4.warning led lights
RED color (use MM
A)
1.aeration is not good
2.The temperature is too high
3.over-load use
4.Thermostat broken
5.Control plate broken
6.output shorted (holder)
1.get rid of the bar 0.5m around
2.Reduce the temperature
3.Reduce the use loading
4.Change the thermostat(JUC-OF)
5.Check and change the
control plate
6.remove holder
5.Wire feeder not
work (welding
current not
adjustable)
1.the fuse broken
2.Potentiometer line fall down
or Potentiometer broken
3.the wire blocked
4.the drive circuit broken
5. no output
6.other reasons
1.Change the fuse 5A/250V
(on left panel, open wire feeder case)
2.Connect the lines or Change it
3.Check the gun
4.Change the control panel
5.Contact with the manufacturer
6.Contact with the manufacturer
6.Welding Voltage
not adjustable
1.Potentiometer line fall down
2.Potentiometer broken
3.The circuit broken
1.Connect the lines
2.Change it
3.Change the control pcb

11
11. Transportation, storage and environmental conditions
★The package (Wooden cases or cartons) of the manufacturer is suitable for air, sea,
railway and highway (three classes more) transportation..
★Pay attention to the indication on the package during the transportation.
★The environment conditions
A Temperature range operating 0℃~ 40℃
transportation -25℃~+55℃
B The air humidity 40℃
20℃
50%RH
90%RH
12. Quality
Guaranteed
This product is sold subject to the understanding that if any defects in manufacture or
material shall appear within 24 months from date of consumer purchase/sale, the manufacturer
will arrange for such defects to be rectified without charge on the sales invoice and warranty
card (except for any damage caused by neglect).

13. ACCESSORIES: SEE PACKING LIST PLEASE
PACKING LIST
★★★★★★★★★★★★★★★★★★★★★★★★
MIG 200i
Welding machine
1
Connector+cable+ground pliers
1
MIG welding torch(AK15 3m)
1
Gas hose
1
flow meter
1
optional accessory
Operation instructions
1
Certificate of quality
1
No.
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Certificate of quality
─ ─ ─ ─ ──── ─ ──── ─ ──── ─ ────
Name of product: MIG/MAG Semi-auto ARC Welding Machine
Type of product: MIG 200i
Packing No:
Test results of this welder fulfills _
_technical requirements and its release from the works is
granted.