Weldman MISTRAL MIG 200 User manual

WELDMAN MISTRAL MIG 200
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!

3. Applications
WELDMAN MISTRAL MIG 200 is intended for welding processes like MIG/MAG, MMA, TIG Lift and
FLUX. The device is made for arc welding of steel alloys in all methods, and aluminium alloys in mig
mode only.
The manufacturer is not liable for damage caused by improper use of the device.
4. Technical specification

5. Preparing device to work
If the device is stored or transported in cold conditions it must be brought to a temperature above zero
before starting work.

5.1 Connecting torches and cables
Place the device on an even and dry surface in a ventilated room with good air circulation away from
flammable objects. Avoid contact of the inner components with dust, corrosive vapors, moisture, direct
rain, welding spatter, grinding dust etc.
CONNECTING TO POWER SUPPLY NETWORK
Before connecting to power supply make sure that supply network parameters correspond to the voltage
and frequency of the device. Check if the fuse values are consistent with those given in the technical
specification.
ELECTRICAL CONNECTIONS SHOULD BE MADE BY QUALIFIED PERSONNEL ONLY
5.1.1 Preparing device to work
1) Before connecting the welder to network make sure that the power switch located on the back panel
is in the OFF position
2) Ground clamp is attached to work material and the plug is connected to the negative socket ( - ) (13)
3) MIG torch plug is attached to the Euro socket (9) (MIG/MAG, FLUX)
4) TIG welding torch or MMA electrode holder is attached to the positive ( + ) socket (10)
5) Polarization connectors inside spool compartment should be connected parallel for MIG (pic. 1) or
crossed for gasless welding FLUX (pic. 2)
6) Ground clamp should be connected to socket on the front panel marked with picture of a clamp
6. Conducting welding process
6.1Welding with MIG/MAG and FLUX methods
6.1.2 MIG PROCESS
• turn the power switch to ON position
• set the welding method switch to MIG/TIG position (5)
• open the valve on the gas cylinder and set the appropriate gas flow on the gas regulator
• set the wire feed speed (6) and the desired welding voltage value (7)
• ignite the arc to conduct welding
• after welding is done close the gas valve on the cylinder (only when using shield gas)
• after welding is done leave the device for a while to cool down and then turn it OFF

6.1.3 TIG PROCESS
• turn on the main switch on the rear panel of the welding machine
• set the welding method switch in the MIG / TIG position (5)
• set the desired welding current (8)
• we start welding
Lift arc ignition
a) Touch the welded surface with the tip of the tungsten electrode
b) Lean the torch downwards to brake a contact with work piece until arc develops
c) If the arc is correctly developed put the torch to correct position and conduct welding
6.1.4 MMA process
• after connecting the welding cables turn on the main switch
• set the welding method switch to the MMA position (5)
• set the desired welding current (8)
• we start welding observing the relevant work rules
• after welding, leave the device turned on for a short period of time to cool it down by the fan
• we remove the slag

7. Troubleshooting
8. 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.
9. 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.
10. Declaration of conformity
LVD 2014/35/EU
EN 60974-1:2012
11. 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.
DELTA-TECHNIKA SP Z O.O.
Stanisława Lema 26
20-446 Lublin
POLAND