You are on page 1of 65

MIGSONIC200 cvcc

SERVICE
MANUAL

MIG (GMAW)
Flux cored (FCAW)

Stick (SMAW)

TIG (GTAW)

Arc Welding Power Source and Wire Feeder

Machine Number: _________________________________


Where Purchase: _________________________________
Date of purchased: _________________________________
Table of Contents

SECTION 1 SAFETY PRECAUTIONS .............................................................................................. 1


SECTION 1 CONSIGNES DE SÉCURITÉ ............................................................................................. 1
1-1. Symbol Usage Symboles utilisés ................................................................ 1

1-2. Arc welding Hazards Dangers relatifs au soudage à l’arc .................. 1

1-3. Safety Standards Normes de sécurité ........................................................... 6

1-4. EMF Information EMF Information .............................................................. 6


SECTION 2 PACKING LIST ............................................................................................................... 7
SECTION 3 INSTALLATIONS........................................................................................................... 8
3-1. Welding power source specifications ........................................................... 8

3-2. Mig torch specifications .................................................................................... 9

3-3. MIG/MAG welding connection diagram ...................................................... 10

3-4. MIG/MAG Process/Polarity Table .................................................................. 12

3-5. General Installation procedure for MIG/MAG welding ............................ 12

3-6. How to Install the wire spool.......................................................................... 12

3-7. How to Adjust wire feed pressure ................................................................ 13

3-8. How to Install spool gun(optional) ............................................................... 13

3-9. LIFT-TIG welding connection diagram ........................................................ 14

3-10. General installation procedure for Lift-TIG welding ................................ 16

3-11. STICK welding connection diagram(115V input) ...................................... 17

3-12. General installation procedure for Stick welding ..................................... 19

3-13. Electric service guide ...................................................................................... 19

3-14. Extension Cable Selection Chart .................................................................. 20


SECTION 4 OPERATION .................................................................................................................... 21
4-1 Front panel Layout ........................................................................................... 21

4-2 Operation(MIG/MAG) ........................................................................................ 22

4-3 Operation(STICK/LIFT TIG)............................................................................. 22

4-4 Voltage/Wire speed selection chart .............................................................. 24


SECTION 5 THEORY OF OPERATION ............................................................................................ 25
SECTION 6 TROUBLE SHOOTING................................................................................................... 27
6-1 General trouble shooting ................................................................................ 27

6-2 MIG/MAG welding trouble shooting ............................................................. 28

6-3 Stick/TIG welding trouble shooting.............................................................. 31


6-4 Circuit board testing information ................................................................. 33
SECTION 7 MAINTENANCE ............................................................................................................ 41
7.1 Maintenance ....................................................................................................... 41

7.2 Safety precaution .............................................................................................. 42


SECTION 8 ELECTRICAL DIAGRAMS ........................................................................................ 43
SECTION 9 PARTS LIST ................................................................................................................. 46
9-1 Power Source..................................................................................................... 46

9-2 Wire feeder.......................................................................................................... 53

9-3 Spool holder module ........................................................................................ 55

9-4 Spool gun connector ....................................................................................... 56

9-5 Mig torch ............................................................................................................. 57


SECTION 10 WARRANTY POLICY ................................................................................................ 60
SECTION 11 AUTHORIZED SERVICE CENTER .......................................................................... 61
SECTION 1 SAFETY PRECAUTIONS

SECTION 1 CONSIGNES DE SÉCURITÉ


1-1. Symbol Usage Symboles utilisés
Means Warning! Watch Out! There are
possible hazards with this procedure!
The possible hazards are shown in the
adjoining symbols.

Symbole graphique
d’avertissement ! Attention ! Cette This group of symbols means Warning!
procedure comporte des risques Watch Out possible ELECTRIC SHOCK,
possibles ! Les dangers éventuels MOVING PARTS, and HOT PARTS hazards.
sont représentés par les symboles Consult symbols and related instructions
graphiques joints. below for necessary actions to avoid the
hazards
Marks a special safety message.
Ce groupe de symboles signifie
Indique un message de sécurité particulier
Avertissement! Attention! Risques
d’ÉLECTROCUTION, ORGANES MOBILES
Means “Note”; not safety related. et PARTIES CHAUDES. Consulter les
Signifie NOTE ; n’est pas relatif à la symboles et les instructions afferents
sécurité. ci-dessous concernant les mesures à
prendre pour supprimer les dangers.
1-2. Arc welding Hazards Dangers relatifs au soudage à l’arc

‘ The symbols shown below are used y Do not touch live electrical parts.
throughout this manual to call attention y Wear dry, hole-free insulating gloves and
to and identify possible hazards. When body protection.
you see the symbol, watch out, and y Insulate yourself from work and ground
follow the related instructions to avoid using dry insulating mats or covers big
the hazard. enough to prevent any physical contact with
the work or ground.
‘ Only qualified persons should service,
test, maintain, and re- pair this unit. y Do not use AC output in damp areas, if
movement is confined, or if there is a
‘ During servicing, keep everybody, danger of falling.
especially children, away
y Use AC output ONLY if required for the
‘ Les symboles représentés ci-dessous welding process.
sont utilisés dans ce manuelpour attirer
y If AC output is required, use remote output
l’attention et identifier les dangers
control if present on unit.
possibles. Enprésence de l’un de ces
symboles, prendre garde et suivre y Additional safety precautions are required
lesinstructions afférentes pour éviter when any of the following electrically
tout risque. Les instructions enmatière hazardous conditions are present: in damp
de sécurité indiquées ci-dessous ne locations or while wearing wet clothing; on
constituent qu’un sommaire des metal structures such as floors, gratings, or
instructions de sécurité plus complètes scaffolds; when in cramped positions such
fournies dans les normes de sécurité as sitting, kneeling, or lying; or when there
énumérées dans la Section 2-5. Lire et is a high risk of unavoidable or accidental
observer toutes les normes de sécurité. contact with the workpiece or ground. For
these conditions, use the following
‘ Seul un personnel qualifié est autorisé à
equipment in order presented: 1) a
installer, faire fonctionner, entretenir et
semiautomatic DC constant voltage (wire)
réparer cet appareil.
welder, 2) a DC manual (stick) welder, or 3)
‘ Pendant le fonctionnement, maintenir à an AC welder with reduced open-circuit
distance toutes les personnes, voltage. In most situations, use of a DC,
notamment les enfants de l’appareil. constant voltage wire welder is
recommended. And, do not work alone!
ELECTRIC SHOCK can y Disconnect input power or stop engine
before installing or servicing this equipment.
kill. Lockout/tagout input power according to
UNE DÉCHARGE OSHA 29 CFR 1910.147 (see Safety
ÉLECTRIQUE entraîner Standards).
la mort. y Properly install and ground this equipment
according to its Owner’s Manual and

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page1


national, state, and local codes. courant électrique s’avère nécessaire, se
y Always verify the supply ground − check servir de la fonction de télécommande si
and be sure that input power cord ground l’appareil en est équipé.
wire is properly connected to ground y D’autres consignes de sécurité sont
terminal in disconnect box or that cord plug nécessaires dans les conditions suivantes :
is connected to a properly grounded risques électriques dans un environnement
receptacle outlet. humide ou si l’on porte des vêtements
y When making input connections, attach mouillés ; sur des structures métalliques
proper grounding conductor first − telles que sols, grilles ou échafaudages ; en
double-check connections. position coincée comme assise, à genoux
ou couchée ; ou s’il y a un risque élevé de
y Frequently inspect input power cord for
contact inévitable ou accidentel avec la
damage or bare wiring − replace cord
pièce à souder ou le sol. Dans ces
immediately if damaged − bare wiring can
conditions, utiliser les équipements suivants,
kill.
dans l’ordre indiqué : 1) un poste à souder
y Turn off all equipment when not in use. DC à tension constante (à fil), 2) un poste à
y Do not use worn, damaged, undersized, or souder DC manuel (électrode) ou 3) un
poorly spliced cables. poste à souder AC à tension à vide réduite.
y Do not drape cables over your body. Dans la plupart des situations, l’utilisation
d’un poste à souder DC à fil à tension
y If earth grounding of the workpiece is
constante est recommandée. En outre, ne
required, ground it directly with a separate
pas travailler seul !
cable.
y Couper l’alimentation ou arrêter le moteur
y Do not touch electrode if you are in contact
avant de procéder à l’installation, à la
with the work, ground, or another electrode
réparation ou à l’entretien de l’appareil.
from a different machine. Déverrouiller l’alimentation selon la norme
y Do not touch electrode holders connected OSHA 29 CFR 1910.147 (voir normes de
to two welding machines at the same time sécurité).
since double open-circuit voltage will be
y Installer le poste correctement et le mettre
present.
à la terre convenablement selon les
y Use only well-maintained equipment. consignes du manuel de l’opérateur et les
Repair or replace damaged parts at once. normes nationales, provinciales et locales.
Maintain unit according to manual.
y Toujours vérifier la terre du cordon
y Wear a safety harness if working above d’alimentation. Vérifier et s’assurer que le fil
floor level. de terre du cordon d’alimentation est bien
y Keep all panels and covers securely in raccordé à la borne de terre du sectionneur
place. ou que la fiche du cordon est raccordée à
y Clamp work cable with good metal-to-metal une prise correctement mise à la terre.
contact to workpiece or worktable as near y En effectuant les raccordements d’entrée,
the weld as practical. fixer d’abord le conducteur de mise à la
y Insulate work clamp when not connected to terre approprié et contre-vérifier les
workpiece to prevent contact with any metal connexions.
object. y Vérifier fréquemment le cordon
y Do not connect more than one electrode or d’alimentation afin de s’assurer qu’il n’est
work cable to any single weld output pas altéré ou à nu, le remplacer
terminal. immédiatement s’il l’est. Un fil à nu peut
entraîner la mort.
SIGNIFICANT DC VOLTAGE exists y L’équipement doit être hors tension lorsqu’il
after removal of input power on n’est pas utilisé.
inverters. y Ne pas utiliser des câbles usés,
y Turn Off inverter, disconnect input power, endommagés, de grosseur insuffisante ou
and discharge input capacitors according to mal épissés.
instructions in Maintenance Section before y Ne pas enrouler les câbles autour du corps.
touching any parts. y Si la pièce soudée doit être mise à la terre,
le faire directement avec un câble distinct.
y Ne pas toucher l’électrode quand on est en
y Ne pas toucher aux pièces électriques sous contact avec la pièce, la terre ou une
tension. électrode provenant d’une autre machine.
y Porter des gants isolants et des vêtements y Ne pas toucher des porte électrodes
de protection secs et sans trous. connectés à deux machines en même
y S’isoler de la pièce à couper et du sol en temps à cause de la présence d’une
utilisant des housses ou des tapis assez tension à vide doublée.
grands afin d’éviter tout contact physique y N’utiliser qu’un matériel en bon état.
avec la pièce à couper ou le sol. Réparer ou remplacer sur-lechamp les
y Ne pas se servir de source électrique à pièces endommagées. Entretenir l’appareil
courant électrique dans les zones humides, conformément à ce manuel.
dans les endroits confinés ou là où on y Porter un harnais de sécurité si l’on doit
risque de tomber. travailler au-dessus du sol.
y Se servir d’une source électrique à courant y S’assurer que tous les panneaux et
électrique UNIQUEMENT si le procédé de couvercles sont correctement en place.
soudage le demande. y Fixer le câble de retour de façon à obtenir
y Si l’utilisation d’une source électrique à un bon contact métal-métal avec la pièce à

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page2


souder ou la table de travail, le plus près y Wear safety glasses with side shields or
possible de la soudure. face shield during servicing.
y Isoler la pince de masse quand pas mis à la y Be careful not to short metal tools, parts, or
pièce pour éviter le contact avec tout objet wires together during testing and servicing.
métallique.
y Ne pas raccorder plus d’une électrode ou y Le soudage, l’écaillement, le passage de la
plus d’un câble de masse à une même pièce à la brosse en fil de fer, et le meulage
borne de sortie de soudage. génèrent des étincelles et des particules
Il reste une TENSION DC NON métalliques volantes. Pendant la période
de refroidissement des soudures, elles
NÉGLIGEABLE dans les sources de
risquent de projeter du laitier.
soudage onduleur quand on a coupe
y Porter des lunettes de sécurité avec écrans
l’alimentation. latéraux ou un écran facial.
y Arrêter les convertisseurs, débrancher le
courant électrique et décharger les
condensateurs d’alimentation selon les HOT PARTS can cause
instructions indiquées dans la partie
Entretien avant de toucher les pièces.
severe burns.
DES PIÈCES CHAUDES
peuvent provoquer des
STATIC (ESD) can brûlures graves.
damage PC boards.
y Do not touches hot parts bare handed.
LES CHARGES
y Allow cooling period before working on
ÉLECTROSTATIQUES welding gun or torch
peuvent endommager
les circuits imprimés. y Ne pas toucher des parties chaudes à
y Put on grounded wrist strap BEFORE mains nues.
handling boards or parts. y Prévoir une période de refroidissement
y Use proper static-proof bags and boxes to avant d’utiliser le pistolet ou la torche.
store, move, or ship PC boards.

y Établir la connexion avec la arrette de terre MAGNETIC FIELDS can


avant de manipuler des cartes ou des affect pacemakers.
pièces.
LES CHAMPS
y Utiliser des pochettes et des boîtes
antistatiques pour stocker, déplacer ou
MAGNÉTIQUES
expédier des cartes PC. peuvent affecter les
stimulateurs
cardiaques.
FIRE OR EXPLOSION
hazard. y Pacemaker wearers keep away.
y Wearers should consult their doctor
before going near arc welding, gouging,
Risque D’INCENDIE OU or spot welding operations.
D’EXPLOSION.
y Porteurs de stimulateur cardiaque, rester
y Do not place unit on, over, or near à distance.
combustible surfaces. y Les porteurs d’un stimulateur cardiaque
y Do not service unit near flammables doivent d’abord consulter leur médecin
y Do not overload building wiring − be sure avant de s’approcher des opérations de
power supply system is properly sized, soudage à l’arc, de gougeage ou de
rated, and protected to handle this unit. soudage par points.

y Ne pas placer l’appareil sur, au-dessus ou


à proximité de surfaces inflammables.
y Ne pas installer l’appareil à proximité de
produits inflammables. CYLINDERS can explode
y Ne pas surcharger l’installation électrique − if damaged.
s’assurer que l’alimentation est
correctement dimensionnée et protégée LES BOUTEILLES
avant de mettre l’appareil en service. peuvent exploser si elles
sont endommagées.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode.
FLYING METAL can Since gas cylinders are normally part of the
injure eyes. welding process, be sure to treat them carefully.
DES PARTICULES y Protect compressed gas cylinders from
VOLANTES peuvent excessive heat, mechanical shocks, physical
damage, slag, open flames, sparks, and arcs.
blesser les yeux.
y Install cylinders in an upright position by

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page3


securing to a stationary support or cylinder FALLING UNIT can
rack to prevent falling or tipping.
cause injury.
y Keep cylinders away from any welding or
other electrical circuits. LA CHUTE DE
y Never drape a welding torch over a gas L’APPAREIL peut
cylinder. blesser.
y Never allow a welding electrode to touch any y Use lifting eye to lift unit only, NOT running
cylinder. gear, gas cylinders, or any other
y Never weld on a pressurized cylinder − accessories.
explosion will result. y Use equipment of adequate capacity to lift
y Use only correct shielding gas cylinders, and support unit.
regulators, hoses, and fittings designed for the y If using lift forks to move unit, be sure forks
specific application; maintain them and are long enough to extend beyond opposite
associated parts in good condition. side of unit
y Turn face away from valve outlet when
opening cylinder valve. y Utiliser l’anneau de levage uniquement
y Keep protective cap in place over valve except pour soulever l’appareil, NON PAS les
when cylinder is in use or connected for use. chariots, les bouteilles de gaz ou tout autre
y Use the right equipment, correct procedures, accessoire.
and sufficient number of persons to lift and y Utiliser un équipement de levage de
move cylinders. capacité suffisante pour lever l’appareil.
y Read and follow instructions on compressed y En utilisant des fourches de levage pour
gas cylinders, associated equipment, and déplacer l’unité, s’assurer que les fourches
Compressed Gas Association (CGA) sont suffisamment longues pour dépasser
publication P-1 listed in Safety Standards. du côté opposé de l’appareil.

Des bouteilles de gaz protecteur contiennent du MOVING PARTS can


gaz sous haute pression. Si une bouteille est cause injury.
endommagée, elle peut exploser. Du fait que les
bouteilles de gaz font normalement artie du DES ORGANES
procédé de soudage, les manipuler avec MOBILES peuvent
précaution. provoquer des
y Protéger les bouteilles de gaz comprimé d’une blessures.
chaleur excessive, des chocs mécaniques,
y Keep away from moving parts such as fans.
des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs. y Keep all doors, panels, covers, and guards
closed and securely in place.
y Placer les bouteilles debout en les fixant dans
un support stationnaire ou dans un y Have only qualified persons remove doors,
porte-bouteilles pour les empêcher de tomber panels, covers, or guards for maintenance
ou de se renverser. as necessary.
y Tenir les bouteilles éloignées des circuits de y Reinstall doors, panels, covers, or guards
soudage ou autres circuits électriques. when maintenance is finished and before
reconnecting input power.
y Ne jamais placer une torche de soudage sur
une bouteille à gaz.
y Une électrode de soudage ne doit jamais y S’abstenir de toucher des organes mobiles
entrer en contact avec une bouteille. tells que des ventilateurs.
y Ne jamais souder une bouteille pressurisée − y Maintenir fermés et verrouillés les portes,
risque d’explosion. panneaux, recouvrements et dispositifs de
protection.
y Utiliser seulement des bouteilles de gaz
protecteur, régulateurs, tuyaux et raccords y Seules des personnes qualifiées sont
convenables pour cette application spécifique ; autorisées à enlever les portes, panneaux,
les maintenir ainsi que les éléments associés recouvrements ou dispositifs de protection
en bon état. pour l’entretien.
y Détourner votre visage du y Remettre les portes, panneaux,
détendeur-régulateur lorsque vous ouvrez la recouvrements ou dispositifs de protection
soupape de la bouteille. quand l’entretien est terminé et avant de
rebrancher l’alimentation électrique.
y Le couvercle du détendeur doit toujours être
en place, sauf lorsque la bouteille est utilisée MOVING PARTS can
ou qu’elle est reliée pour usage ultérieur. cause injury.
y Utiliser les équipements corrects, les bonnes
DES ORGANES
procédures et suffisamment de personnes
pour soulever et déplacer les bouteilles. MOBILES peuvent
y Lire et suivre les instructions sur les bouteilles provoquer des
de gaz comprimé, l’équipement connexe et le blessures.
dépliant P-1 de la CGA (Compressed Gas y Keep away from moving parts
Association) mentionné dans les principales
y Keep away from pinch points such as drive
normes de sécurité.
rolls

y Ne pas s’approcher des organes mobiles.

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page4


y Ne pas s’approcher des points de y Keep high-frequency source doors and
coincement tels que des rouleaux de panels tightly shut, keep spark gaps at
commande. correct setting, and use grounding and
shielding to minimize the possibility of
interference.
OVERUSE can cause
OVERHEATING.
y Le rayonnement haute fréquence (HF)
L’EMPLOI EXCESSIF peut provoquer des interférences avec les
peut SURCHAUFFER équipements de radio-navigation et de
L’ÉQUIPEMENT. communication, les services de sécurité
ƒ Allow cooling period; follow rated duty et les ordinateurs.
cycle. y Demander seulement à des personnes
ƒ Reduce current or reduce duty cycle before qualifiées familiarisées avec des
starting to weld again. équipements électroniques de faire
fonctionner l’installation.
ƒ Do not block or filter airflow to unit
y L’utilisateur est tenu de faire corriger
rapidement par un electrician qualifié les
interférences résultant de l’installation.
ƒ Prévoir une période de refroidissement ; y Si le FCC signale des interférences,
respecter le cycle opératoire nominal. arrêter immédiatement l’appareil.
ƒ Réduire le courant ou le facteur de marche y Effectuer régulièrement le contrôle et
avant de poursuivre le soudage. l’entretien de l’installation.

ƒ Ne pas obstruer les passages d’air du y Maintenir soigneusement fermés les


poste. portes et les panneaux des sources de
haute fréquence, maintenir les éclateurs à
une distance correcte et utiliser une terre
et un blindage pour réduire les
H.F. RADIATION can interférences éventuelles.
cause interference.
LE SOUDAGE À L’ARC
risque de provoquer READ INSTRUCTIONS.
des interférences. LIRE LES
y High-frequency (H.F.) can interfere with
INSTRUCTIONS.
radio navigation, safety services, ƒConsult the Owner’s
computers, and communications Manual for welding safety
equipment. precautions.
y Have only qualified persons familiar with ƒ Use only genuine replacement parts
electronic equipment perform this
installation.
y The user is responsible for having a ƒ Lire le manuel d’utilisation avant d’utiliser
qualified electrician promptly correct any ou d’intervenir sur l’appareil.
interference problem resulting from the
installation. ƒ Utiliser uniquement des pièces de
y If notified by the FCC about interference, rechange.
stop using the equipment at once.
y Have the installation regularly checked
and maintained.

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page5


1-3. Safety Standards Normes de sécurité

Safety in Welding, Cutting, and Allied Processes, Code for Safety in Welding and Cutting, CSA
ANSI Standard Z49.1, from Global Engineering Standard W117.2, from Canadian Standards
Documents (phone: 1-877-413-5184, website: Association, Standards Sales, 178 Rexdale
www.global.ihs.com). Boulevard, Rexdale, Ontario, Canada M9W 1R3
(phone: 800−463−6727 or in Toronto
416−747−4044, website:
www.csa−international.org).

Safety in Welding, Cutting, and Allied Processes, Code for Safety in Welding and Cutting, CSA
ANSI Standard Z49.1, de Global Engineering Standard W117.2, de Canadian Standards
Documents (téléphone : 1-877-413-5184, site Association, Standards Sales, 178 Rexdale
Internet : www.global.ihs.com). Boulevard, Rexdale, Ontario, Canada M9W 1R3
(téléphone : 800-463-6727 ou à Toronto
416-747-4044, site Internet :
www.csa-international.org).

1-4. EMF Information EMF Information

Considerations About Welding And The Effects 1. Keep cables close together by twisting or
Of Low Frequency Electric And Magnetic Fields taping them.

Welding current, as it flows through welding 2. Arrange cables to one side and away from the
cables, will cause electro- magnetic fields. There operator.
has been and still is some concern about such
fields. However, after examining more than 500 3. Do not coil or drape cables around your body.
studies spanning 17 years of research, a special
blue ribbon committee of the National Research 4. Keep welding power source and cables as far
Council concluded that: “The body of evidence, in away from operator as practical.
the committee’s judgment, has not demonstrated
that exposure to power- frequency electric and 5. Connect work clamp to work piece as close to
magnetic fields is a human-health hazard.” the weld as possible.
However, studies are still going forth and
evidence continues to be examined. Until the About Pacemakers:
final conclusions of the research are reached,
you may wish to minimize your exposure to
Pacemaker wearers consult your doctor first. If
electromagnetic fields when welding or cutting. cleared by your doctor, then following the above
procedures is recommended
To reduce magnetic fields in the workplace, use
the following procedures:

Considérations sur le soudage et les effets de 2. Disposer les câbles d’un côté et à distance de
basse fréquence et des champs magnétiques et l’opérateur.
électriques.
3. Ne pas courber pas et ne pas entourer pas les
Le courant de soudage, pendant son passage dans câbles autour de votre corps.
les câbles de soudage, causera des champs
électromagnétiques. Il y a eu et il y a encore un 4. Garder le poste de soudage et les câbles le plus
certain souci à propos de tels champs. Cependant, loin possible de vous.
après avoir examine plus de 500 études qui ont été
faites pendant une période de recherché de 17 ans, 5. Connecter la pince sur la pièce aussi près que
un comité spécial ruban bleu du National Research possible de la soudure.
Council a conclu : « L’accumulation de preuves,
suivant le jugement du comité, n’a pas démontré En ce qui concer ne les sti mulateurs
que l’exposition aux champs magnétiques et cardiaques
champs électriques à haute fréquence représente
un risque à la santé humaine ». Toutefois, des Les porteurs de stimulateur cardiaque doivent
études sont toujours en cours et les preuves consulter leur médecin avant de souder ou
continuent à être examinées. En attendant que les d’approcher des opérations de soudage. Si le
conclusions finales de la recherché soient établies, médecin approuve, il est recommandé de suivre les
il vous serait souhaitable de réduire votre procédures précédentes
exposition aux champs électromagnétiques
pendant le soudage ou le coupage.

Pour réduire les champs magnétiques sur le poste


de travail, appliquer les procédures suivantes :

1. Maintenir les câbles ensemble en les tordant ou


en les enveloppant.

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page6


SECTION 2 PACKING LIST

MIGSONIC200cvcc package (Part No: 07000385)

Model Part no Quantity

MigSonic200cvcc Power source n/a 1

WeldKingTM 12 ft.(3.5 M) NT1-4E Mig torch, 07000412 1


Euro connection with Tweco style
consumables

Spare Contact tips:

Tweco 1 series 0.035/0.9 tip 11-35 1

Tweco 1 series 0.045/1.2 tip 11-45 1

Argon Regulator / Gauge 07000510 1

10 ft. (3M) gas hose with Male 5/8-18 gas n/a 1


connector on both end

200 Amp electrode holder with 10 ft. (3 M) 07000460 1


lead

300 Amp ground clamp with 10 ft. (3 M) 07000461 1


lead

Owner’s Manual 07000416 1

10 ft. (3 M) Power cord with NEMA 5-15P n/a 1


115V AC Plug

Adapter cable 115V NEMA 5-15R to 230V 07001820 1


NEMA 6-50P, 2. Ft. (0.6 M)

Table 2.1

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page7


SECTION 3 INSTALLATIONS

3-1. Welding power source specifications

MIGSONIC200cvcc (Part No: 07000385)

Welding Process MIG/Flux cored wire Mig

Power supply 115V/60Hz 230V/60Hz

Phase 1

Input current @ Maximum output 25 25

Rated input (Kva) 2.8 5.6

Open circuit voltage(V) 62 62

Amperage range(A) 40-120 40-200

Welding voltage(V) 16-20 16-24

Rated Duty cycle (%) 60 60

Rated welding current(A) 120 200

Wire feed speed(M/MIN) 1-13 (40-500 IPM)

Wire Diameter(MM) Steel /Stainless Steel

Solid: 0.6-0.9mm (0.023-0.035in)

Flux cored: 0.8-1.2mm (0.030-0.045in)

Welding Process STICK/TIG

Power supply 115V/60Hz 230V/60Hz

Phase 1

Input current @ Maximum output 25 25

Rated input (Kva) 2.5 5.0

Open circuit voltage(V) 62 62

Amperage range(A) STICK:12-90 STICK:12-160


TIG: 12-110 TIG: 12-160

Welding voltage(V) STICK:20.5-23.6 STICK:20.5-26.4


TIG: 10.5-14.4 TIG: 10.5-16.4

Rated Duty cycle (%) 60 60

Rated welding current(A) 110 160

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page8


Power source Dimension (HxWxD)(CM) 62 x41 x57(24.4x16.1x22.4in)

Power source Weight(KG) 25(55lbs)

Packing Dimension(HxWxD)(CM) 69 × 48× 63 (27.2x18.9x24.8in)

Packing Weight(KG) 35.5(78.1lbs)

Operating temperature(°C) -20 to +40 (-4°F to 104°F)

Storage temperature(°C) -40 to +40 (-40°F to 185°F)

Table 3.1

CAUTION
WELDING LONGER THAN RATED DUTY CYCLE CAN DAMAGE GUN AND VOID
WARRANTY.

3-2. Mig torch specifications


Model NT1-4E (Part no. 07000412 )

Rated currency(A) 200A/CO2,180A/MIX

Rated voltage(V) <=113V

Rated Duty cycle (%) 60%

Cool style Air cooled

Air consumption (l/min) 10-18

Cable length(M) 3.65(12ft)

Connection euro connection

Detailed gun specification please see separate gun manual

Table 3.2

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page9


3-3. MIG/MAG welding connection diagram
MIGSONIC200cvcc (115v input)

Gauge

Cylinder

Power
Cord

To 115 volt, 20 ampere


individual branch circuit

Torch

Earth
clamp

Figure 3.1

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page10


MigSonic200cvcc (208/230V input)

Gauge

Cylinder

Power
Cord

Torch

Earth
clamp

Figure 3.2

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page11


3-4. MIG/MAG Process/Polarity Table
Cable Connections
Process Polarity
Cable To Gun Cable To Work

GMAW-Solid wire DCEP – Reverse Connect to positive(+) output Connect to negative(-)output


with shielding gas polarity terminal terminal

FCAW – Self-shielding DCEN-Straight Connect to negative(-) output Connect to positive(+)output


wire- no shielding gas Polarity terminal terminal

Table 3.3

3-5. General Installation procedure for MIG/MAG welding


3-5.1.Welding machine should be installed in a stable position and with good ventilation.
Avoid direct sun outdoors. Use forklift to move, avoid transport in invert or side
position.

3-5.2.Be sure machine is well grounded. Connect the bolt marked “earth ” with earth in
network, then connect to network firmly

3-5.3.Before starting a new machine or the machine idled for a period, check the
insulation resistance of circuit which is connected to the network. The resistance
must be higher than 2.5M Ω; otherwise the machine must be dried.

3-5.4.Connect torch, earth cable, wire, regulator, cylinder according to connection


diagram. Note: Connection hardware must be tightened with proper tools.
Do not just hands tighten hardware! A loose electrical connection will
cause poor weld performance and excessive heating at the terminal block.

3-5.5.Make sure the spool gun selection switch set to “Mig Torch”. If this switch is set to
“spool gun”, the motor will not active when press the gun trigger.

3-5.6.Use Ф8 heat-resistant PVC hose connect the flow meter with the gas connection
nipple at rear of the machine.

3-5.7. Commission the machine after the machine is installed and tested:

‘ Release the pressure roller in the wire feeder, push the torch switch, and adjust
voltage switch from low to high, Open circuit voltage should rise.

‘ Evenly adjust the current knob, the wire feed speed should increase evenly.

3-6. How to Install the wire spool


3-6.1.Install a spool of welding wire on the hub as follows: Unscrew spool nut from hub.
Place wire spool on hub to rotate clockwise as wire is unwound; hub pin must
engage hole in spool. Install spool nut.

3-6.2.The drive roll has two grooves; the small groove feeds 0.035 in. diameter wire,
the large groove feeds 0.045 in. wire. The groove nearest the gear motor feeds
the wire.

3-6.3.Release pressure drive roll assembly and lift upward. Check that proper wire
diameter groove is in the inner position. Feed the wire from the spool through the
inlet guide, across the drive roll groove and into gun outlet guide. Lower
pressures roll assembly and secure. Check that the gears mesh. Feed wire
through to torch tip using the torch trigger.

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page12


3-7. How to Adjust wire feed pressure
Make sure that the wire moves smoothly through the wire guide. Then set the
pressure of the wire feeder’s pressure rollers. It is important that the pressure
is not too high. Feed out the wire against an insulated object, e.g. a piece of
wood. When you hold the gun approx. 5 mm from the object, the feed rollers
should slip. When hold the guan approx. 50mm from the object, the wire
should be fed out and band. Now the pressure is properly set. See Figure 2.3.

Figure 3.3

3-8. How to Install spool gun(optional)

MigSonic200CVCC use WeldKing™ SpoolKing-24D (Part no. 07NS1000)


only. Use other model may not work properly.

3-8.1.Connect spool gun to the euro receptacle. Connect control cable to “spool gun”
receptacle.

3-8.2. Toggle the spool gun selection switch to “spool gun” selection(see figure 2.4)

3-8.3.Install wire and commission according to spool gun instruction manual.

Spool gun
selection switch

Figure 3.4

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page13


3-9. LIFT-TIG welding connection diagram
MIGSONIC200cvcc (115v input)

Gauge

Cylinder

Power
Cord

To 115 volt, 20 ampere


individual branch circuit Earth
clamp

TIG Torch

Figure 3.5

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page14


MIGSONIC200cvcc (208/230v input)

Gauge

Cylinder

Power
Cord

Earth
clamp
TIG Torch

Figure 3.6

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page15


3-10. General installation procedure for Lift-TIG welding
3-10.1.Welding machine should be installed in a stable position and with good
ventilation. Avoid direct sun outdoors. Avoid transport in invert or side position.

3-10.2.Switch the ON/OFF Switch (located on the rear panel) to OFF.

3-10.3.Connect the work lead cable to the positive output terminal, and the LIFT TIG
Torch cable to the negative output terminal. Refer to Figure 2.6. Insert torch/earth
clamp quick connector into receptacle and turn 90º clockwise.

3-10.4.Connect the gas line/hose to the proper shielding gas source. Refer to Figure
2.4 and 2.5).

3-10.5.Slowly open the Argon Cylinder Valve to the fully open position.

3-10.6.Connect the work lead clamp to your work piece.

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page16


3-11. STICK welding connection diagram(115V input)
MIGSONIC200cvcc (115v input)

Power
Cord

To 115 volt, 20 ampere


individual branch circuit
Electrode
holder
Earth
clamp

Figure 3.7

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page17


MIGSONIC200cvcc (208/230v input)

Power
Cord

Electrode
holder

Earth
clamp

Figure 3.8

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page18


3-12. General installation procedure for Stick welding
3-12.1.Welding machine should be installed in a stable position and with good
ventilation. Avoid direct sun outdoors. Avoid transport in invert or side position.

3-12.2.Switch the ON/OFF Switch (located on the rear panel) to OFF.

3-12.3.Connect electrode holder, earth cable, according to connection diagram (refer to


Figuar2.6 and 2.7). Insert Electrode holder/earth clamp quick connector into
receptacle and turn 90º clockwise.

3-13. Electric service guide

CAUTION
WARNING: THIS WELDING MACHINE MUST BE CONNECTED TO POWER
SOURCE IN ACCORDANCE WITH APPLICABLE ELECTRICAL CODES

AVERTISSEMENT: LE RACCORDEMENT DE CETTE MACHINE DE SOUDAGE Á


L’ALIMENTATION DOIT ÉTRE CONFORME AUX CODES D’ ÉLECTRICITÉ
PERTINENTS

Use 115 volt single phase input, 25 ampere individual branch circuit protected by
time-delay fuses or circuit breaker is required.

Extension cord: 14 AWG

Extension length: 8m with 14AWG, 12 AWG for up to 10 m.

MigSonic200cvcc

Input voltage(V) 230

Frequency(Hz) 60

Input Amperes at maximum output(A) 25

Max recommended standard fuse Rating in Amperes

Circuit breaker, time delay 25

Normal operation 35

Min input conductor size in AWG 14

Min Grounding conductor Size in AWG 14

Table 3.4

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page19


3-14. Extension Cable Selection Chart

CAUTION
USE SHORTEST CABLE POSSIBLE

Input Conductor Size in Maximum Cord Length allowed in Ft(M)


AWG (mm2)

115V 230V

14(2.08) 23(7) 56(17)

12(3.31) 29(9) 90(27)

10(5.26) 43(13) 131(40)

8(8.36) 72(22) 160(50)

6(13.29) 105(32) 243(74)

Table 3.5

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page20


SECTION 4 OPERATION

4-1 Front panel Layout

2 3 4 5

10

12

11

Figure 4.1

1. Welding voltage meter (digital) (Stick/TIG) adjustment knob

8. Inductance adjustment knob (MIG)


2. Welding current meter (digital)
9. Earth clamp (MIG/Stick) or TIG torch
3. Welding process selector
receptacle (TIG)
4. Protection indication light
10. Electrode holder(STICK) or earth
5. Power indication light clamp receptacle (TIG)

6. Voltage adjustment knob (MIG) 11. Spool gun control receptacle (MIG)

7. Wire feed speed (MIG) and Current 12. MIG Torch receptacle (Euro style)

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page21


4-2 Operation(MIG/MAG)

USE SINGLE PHASE 115/208/230V POWER SUPPLY.

4-2.1 Switch on the power source.

4-2.2 Select MIG mode with the process selection control.

4-2.3 Set the welding voltage knob to proper position and wire feed speed knob to a
start value and refine during welding( referring to the voltage/wire feeding speed
selection chart)。

4-2.4 The display value of digital voltage meter will change when you turn the voltage
knob to pre-set the welding voltage. And during welding, the voltage meter will reflect
actual welding voltage. The display value of digital current meter will change when you
turn the wire feed knob to pre-set the wire feed speed. This value is estimated output
current. During welding, the current meter will reflect actual welding current.

4-2.5 Set the inductance knob at minimum value (far left) at start and you can adjust
the knob during welding to obtain best result. Inductance is the rate of current response
to a change in current. What this means is that when MIG welding with a short arc you
can adjust how fast current is applied to the shorts. The less inductance you have the
crisper the arc will appear and the wires will start easier. This will also make the bead
taller and narrower. More inductance will make the arc appear "softer" with a flatter
wider appearance and if too much is used, wires will stumble during starts. Typically
when short arcing steel only a little inductance is used in order to get a crisp arc. Low
thermal conductivity materials such as stainless need more inductance to get
acceptable wetting when short arcing.

4-2.6 Turn on the gas valve, adjust gas volume to 3-5L/MIN. Push the torch switch
check if wire feed and gas is normal, check if there is gas leaking.

4-2.7 Hold the torch and keep nozzle 8-12mm above the work piece, and tilt 10-20 ˚
to vertical direction. Aim wire to the welding seam.

4-2.8 Push torch switch, after arc is ignited, move the torch along seam evenly while
keeping the stick-out. Fine tune the welding parameter to obtain exquisite welding
seam. Release the torch switch to finish a welding cycle.

4-2.9 After finish operation, turn off the gas valve, loose the pressure handle at wire
feeder, push torch switch to clear the residual gas in the regulator. At the end, turn off
welding power source and wall switch.

4-3 Operation(STICK/LIFT TIG)

USE SINGLE PHASE 115/208/230V POWER SUPPLY.

4-3.1 Switch on the power source.

4-3.2 Set Welding Current to desired value (refer to 3-4. Welding Parameter
selection chart).

4-3.3 The display value of digital amperage meter will change when you turn the
current adjustment knob to pre-set the welding current. And during welding, the
amperage meter will reflect actual welding current output, and the voltage meter will
reflect actual welding voltage.

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page22


4-3.4 When stick welding, drag electrode across workpiece like striking a match; lift
electrode slightly after touching work. If arc goes out electrode was lifted too high. If
electrode sticks to workpiece, use a quick twist to free it.

4-3.5 When TIG welding. Turn on the gas valve on the torch; adjust gas volume to
3-5L/MIN. check if there is gas leaking.

4-3.6 Touch tungsten electrode to workpiece at weld start point. Hold electrode to
Workpiece for 1-2 seconds, and then slowly lift electrode. Arc is formed when
electrode is lifted. Aim Tungsten electrode to the welding seam.

4-3.7 After arc is ignited, move the torch along seam evenly. Fine tune the welding
parameter to obtain exquisite welding seam.

4-3.8 After finish operation, turn off the gas valve (for TIG). At the end, turn off
welding power source and wall switch.

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page23


4-4 Voltage/Wire speed selection chart

Table 4.1

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page24


SECTION 5 THEORY OF OPERATION
1 3 4 5 6 7 8
2
Power switch Primary Capacitor PCB Inverter PCB Main Secondary Reactor Polarity
Rectifier DVI200-DR-B ZX7-400I-QQ-A2 transformer rectifier Switch
DC
23 eliminate
115V/230V
PCB
power input Amperage Voltage 9
22 meter meter 27
25 Feed motor
Torch
Trigger
Solenoid valve CONTROL PCB MIG-270I-KZ-A0
21
Mig torch
Switch PCB (MIG200- 10
24
Fan Motor STICK-A0)
20 Spool gun
selection 11
26
switch
Protection
19 light Work
Piece

Power Light
18

12

Welding Welding
mode Current /wire Spool Gun
switch feed speed
Potentiometer

Induction Voltage Thermostat 14


potentiometer potentiometer
13
Control
17 16 15
circuit

Figure 5.1

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page25


(1) Power switch: control unit and fan motor on/off.
(2) Rectifier: Primary rectifier converts AC input into DC.
(3) Capacitor PCB (DVI200-DR-B): Smooth current from Primary Rectifier and Supply drive and
control voltage to Inverter Model and control PCB.
(4) Inverter PCB (ZX7-400I-QQ-A2): Convert DC current to high frequency (19 kHz) AC current,
output to main transformer. High frequency current can greatly reduce the size and weight of
the transformer and increase the machine efficiency.
(5) Main transformer: transform to welding voltage.
(6) Secondary rectifier: turn high frequency ac current from Inverter module into DC.
(7) Reactor: further smooth welding current.
(8) Polarity Switch: Polarity Changeover Block
(9) Feed motor: feed wire with the speed set by wire speed potential meter. Active by gun trigger.
(10)Spool gun selection switch: select use Mig torch or spool gun. Switch sent signal to Switch
PCB (MIG200- STICK-A0) and then control the wire feeding motor on/off.
(11)MIG torch.
(12)Spool gun.
(13)Welding Current Potentiometer: located in the front panel, adjust the output current in Stick/TIG
mode and wire feeding speed in MIG mode by providing a reference voltage to Switch PCB
(MIG200- STICK-A0).
(14)Welding mode switch: located in the front panel. Switch welding mode between
TIG/STICK/MIG.
(15)Thermostat: measure the temperature of the main transformer and provide reference voltage to
Control PCB(MIG-270I-KZ-A0)
(16)Voltage potentiometer: Located in the front panel, adjust the welding voltage by providing a
reference voltage to Control PCB (MIG-270I-KZ-A0)
(17)Induction potentiometer: located in the front panel. Adjust induction of the power source in MIG
mode.
(18)Power light: will turn on/off when machine is turned on/off
(19)Protection light: this light will turn on when machine is over heat and automatically shut off.
(20)Fan motor: Controlled by main power switch and power supplied direct with 230V AC. Fan
cools internal components
(21)Solenoid valve: Controls compressed air flow. Pressing gun trigger opens valve.
(22)Amperage meter: Digital meter display the actual welding current during welding. Receive
signal from Control PCB (MIG-270I-KZ-A0)
(23)Voltage meter: Digital meter display the actual welding voltage during welding and preset
welding voltage in MIG mode. Receive signal from Control PCB (MIG-270I-KZ-A0)
(24)Control PCB (MIG-270I-KZ-A0): Supply drive and control voltage to Inverter Model. Supply
control signal to capacitor PCB indicate input voltage (110V or 230V). Control solenoid valve,
power light and protection light. Take signal from Voltage control and induction control potential
meter. Control welding voltage and induction in MIG mode. Supply signal to digital current
meter and voltage meter in all welding mode.
(25)DC eliminates PCB: eliminate a DC offset from the high frequency AC wave out of IGBT
module.
(26)Switch PCB (MIG200- STICK-A0): Control fan motor, receive on/off signal from torch trigger
(both MIG torch and spool gun torch), On MIG mode, take signal from wire feed speed/Current
potential meter. Control wire feed speed by changing pulse width modulation signal, thereby
providing more or less voltage to the feed motor. On TIG/STICK mode, take signal from
Current/Wire feed speed potential meter and set CC current output. Take signal from welding
mode selection switch to change welding mode. Take signal from spool gun selection switch to
decide the wire is feed through machine motor or gun motor.
(27) Gun trigger.

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page26


SECTION 6 TROUBLE SHOOTING

6-1 General trouble shooting


No. Problem Cause Solution

1 Power Indication lamp does not on after Loose contact at input Check contact
switch on the main switch lead situation

Lamp malfunction, Check contact


poor contact situation. Replace
lamp

Main switch Check switch,


malfunction replace if
necessary

2 Cooling fan stops Power indication Cooling fan circuit Check fan circuit
to rotate after lamp on malfunction
machine has
Cool fan failure Check fan, replace
worked a period
if necessary

Power indication See No. 1


lamp off

11 Overheat light on Work excess the rate Use under rate


duty circle duty circle

Input voltage is too Use under rate


high input voltage

10 Power supply switch jump Rectifier short circuit Check and replace

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page27


Main transformer short Check and replace
circuit

Control transformer Check and replace


short circuit

Solenoid valve short Check and replace


circuit

Cooling fan short Check and replace


circuit

Table 6.1

6-2 MIG/MAG welding trouble shooting


No. Problem Cause Solution

3 No gas flow out after pushing Gas pressure not enough Check gas pressure
the gun trigger
Poor gas hose connection Check gas connection

Gun trigger failure Check gun trigger

Solenoid valve failure Check and replace


Solenoid valve

Gas passage problem Check and repair the


gas passage

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page28


Torch gas hose problem Check and repair
torch cable

Control circuit failure Replace circuit board

Control transformer failure Replace transformer

4 Failure of arc to ignite or does Fuse melt or poor contact Check and repair
not ignite properly
Main power switch failure Check, repair, replace

Control circuit board failure Check and repair the


circuit board

Welding cable broken or poor Check the connection


contact

Gun trigger wire broken Replace cable

Gun cable broken Replace cable

Voltage adjustment knob Check, repair, replace


failure or poor contact

Control transformer failure Check, repair, replace

Main transformer failure or Check, repair, replace


poor contact

5 Unstable arc Gas hose not installed Connect the gas hose
properly, gas mixed by air firmly

Gas not pure Changes gas

Wire liner or gun cable broken Check, repair, replace


and leak cause insufficient gas
volume.

Wire pressure not setup Adjust pressure


properly

Wire feed speed not stable See No.9

Control circuit failure Check, repair, replace


circuit board

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page29


Gas heating failure Check 20A Fuse,
repair, replace

the work piece surface Clean the workpiece


contaminated by oil surface

Poor contact inside the gun Check, repair, replace

6 Arc ignited but the wire does Rectifier tube failure Check, replace
not melt
Output reactor failure Check, replace

Output capacitor failure Check, replace

7 Wire does not feed while the Wire pressure not proper Adjust pressure
feed roller is rotating
Wire liner or contact tip Check, repair, replace
jammed

Used wrong groove at the Use the right groove


feeding roller

8 Cannot stop the gas Solenoid valve contaminated Check, repair, replace
solenoid

Contactor failure Check, replace the


contactor

Control board failure Check, repair, replace

9 Wire feeding not stable Wire out of feeding roller Put wire back
groove

Wire feed pressure not set Adjust pressure


properly

Feeding roller deformed Check and replace

Pressure roller deformed Check and replace

Feeding motor failure Check and replace

Current adjust potential meter Check and replace


failure

Circuit board plug socket not Check and repair or

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page30


properly contacted replace

Control circuit failure Check and repair or


replace

Welding hose deformed Check and replace

Input voltage fluctuated Use under rated input


voltage

Table 6.2

6-3 Stick/TIG welding trouble shooting


No. Problem Cause Solution

4 Erratic or improper weld Wrong cable size Choose the right cable
output. size

Cable or receptacle too hot. Wrong electrode holder size Choose the right size
electrode holder

Poor contact between welding or Clean and tighten all


earth cable and receptacle at weld connections
machine

Poor connection between Clean and tighten


electrode hold and welding
cable

5 Failure of arc to ignite or Fuse melt or poor contact Check and repair
does not ignite properly
Main power switch failure Check, repair, replace

Control circuit board failure Check and repair the


circuit board

AC Contactor failure Check, repair, replace

Welding cable broken or poor Check the connection


contact

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page31


Gun cable broken Replace cable

Control transformer failure Check, repair, replace

Main transformer failure or poor Check, repair, replace


contact

6 Unstable or wandering arc Gas not pure Changes gas

Gas pressure too high Reduce pressure

Control circuit failure Check, repair, replace


circuit board

Welding cable size or type is not See table 2.3


proper

Electrode selection is not proper See Table 3.2

the work piece surface Clean the workpiece


contaminated by oil surface

Poor contact inside the gun Check, repair, replace

Rectifier tube failure Check, replace

Output reactor failure Check, replace

Output capacitor failure Check, replace

Remote control failure Check resistance and


connections for
remote Amperage
control potentiometer

7 Tungsten electrode Gas shield inadequate check nozzle


oxidizing( not bright) after
Gas not pure Check if there is water
welding
in torch and repair.
Check and tight all
gas fitting

Gas pressure inadequate Increase gas pressure

Table 6.3

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page32


6-4 Circuit board testing information

Figure 6.1

DVI200-DR-B (Capacitor PCB)

Connector Pin Value


CN101 1 AC 230V/115V, (reference to CN102-1,2,3,4)
2 AC 230V/115V
3 AC 230V/115V
4 AC 230V/115V
5 Not used
6 DC +325V (voltage output rectified by rectifier)
7 DC +325V
8 Not used
9 DC -325V(voltage output rectified by rectifier)
10 DC 1325V
CN102(similar 1 AC 230V/115V,
to CN101)
2 AC 230V/115V
3 AC 230V/115V
4 AC 230V/115V
5 Not used
6 DC +325V
7 DC +325V
8 Not used
9 DC -325V
10 DC -325V
CN105 1 DC +24V
2 GND
3 AC230V/115V switch signal
CN104 1 DC -325V(Common ground)

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page33


2 Not used
3 DC +325V
CN103 1 DC -325V
2 DC -325V
3 DC -325V
4 Not used
5 DC 325V
6 DC 325V
7 DC 325V

Table 6.4

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page34


Figure 6.2

ZX7-400I-QQ-A2(Inverter PCB)

Connector Pin Value


CN1 1 Connect to IGBT drive wire from Control PCB (DC12V)
2 Connect to IGBT drive wire from Control PCB (DC12V)
3 Not used
4 Connect to IGBT drive wire from Control PCB (DC12V)
5 Connect to IGBT drive wire from Control PCB (DC12V)
CN2 1 Connect to IGBT drive wire from Control PCB (DC12V)
2 Connect to IGBT drive wire from Control PCB (DC12V)
3 Not used
4 Connect to IGBT drive wire from Control PCB (DC12V)
5 Connect to IGBT drive wire from Control PCB (DC12V)

Table 6.5

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page35


Figure 6.3

MIG-270I-KZ-A0(Control PCB)

Connector Pin Value


CN1 1 GND
2 GND
3 GND
4 Connect to current meter
5 DC+5V Connect to current meter
CN2 1 Not used
2 GND. Connect to negative output (voltage feedback)
3 Connect positive output

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page36


4 Connect to shunt(current feedback)
5 Connect to shunt
CN3 1 Connect to IGBT drive wire from Control PCB (DC12V)
2 Connect to IGBT drive wire from Control PCB (DC12V)
3 Not used
4 Connect to IGBT drive wire from Control PCB (DC12V)
5 Connect to IGBT drive wire from Control PCB (DC12V)
CN4 1 GND. Connect to voltage meter
2 GND. Connect to voltage meter
3 Connect to voltage meter
4 DC+5V. Connect to voltage meter
CN5 1 Induction adjustment potentiometer
2 Induction adjustment potentiometer
CN6 1 Welding voltage adjustment potentiometer
2 Welding voltage adjustment potentiometer
3 DC+5V. Welding voltage adjustment potentiometer
CN7 1 Connect to over-current protection coil
2 Connect to over-current protection coil
CN8 1 DC+24V. Connect to protection light
2 Connect to protection light. DC +24V with thermostat open.
3 DC+24V. Connect to power light
4 Connect to power light
CN9 1 Connect to thermostat. Short to CN9-2 with thermostat
closed.
2 Connect to thermostat
CN10 1 Connect to CV/CC switch wire(This wire connect to CN11 and
then CN12 in MIG200-STICK-A0)
2 DC+24V. Connect to CV/CC switch wire
CN11 1 Connect to torch switch
2 Not used
3 Connect to torch switch
CN12 1 Short to CN12-2
2 Short to CN12-1
CN13 1 GND
2 Not used
3 Auxiliary power input. DC+325V
CN14 1 GND. Connect to solenoid valve
2 Connect to solenoid valve. DC+24V
CN15 1 Given welding current(TIG/STICK)
2 Given welding current(TIG)
3 DC+5V. Given welding current
CN16 1 Not used in this model
2 Not used in this model
CN17 1 Giving voltage for wire feed motor
2 Not used
3 Giving voltage for wire feed motor
CN17 1 GND
2 DC+12V
3 DC-12V
4 DC+24V
CN18 1 Connect to IGBT drive wire from Control PCB (DC12V)

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page37


2 Connect to IGBT drive wire from Control PCB (DC12V)
3 Not used
4 Connect to IGBT drive wire from Control PCB (DC12V)
5 Connect to IGBT drive wire from Control PCB (DC12V)

Table 6.6

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page38


Figure 6.4

MIG200-STICK-A0(Switch PCB)
Connector Pin Value
CN1 1 GND
2 DC+12V
CN2 1 Not used
2 AC230/115V switch signal
CN3 1 Positive output(output voltage feedback)
2 Not used
CN4 1 Connect to Wire feed motor (2.5V-17V)
2 Not used
3 Wire feed motor(2.5V-17V)
CN5 1 Auto reset toggle switch( torch/spool gun switch)
2 Auto reset toggle switch( torch/spool gun switch)
3 Auto reset toggle switch
CN6 1 Connect to pole 6 in spool gun receptacle( given voltage to
spool gun motor)
2 Not used
3 Connect to pole 9 in spool gun receptacle
CN7 1 DC+5V. connect to given welding current
2 connect to given welding current
3 connect to given welding current
CN8 1 DC+5V. connect to welding current potentiometer
2 connect to welding current potentiometer

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page39


3 connect to welding current potentiometer
CN9 1 Auto reset toggle switch(torch/spool gun switch)(+5V)
2 Auto reset toggle switch(torch/spool gun switch)
3 Auto reset toggle switch(torch/spool gun switch)
CN10 1 Connect to pole 8 in spool gun receptacle( given current to
spool gun) (+5V)
2 Connect to pole 2 in spool gun receptacle
3 Connect to pole 1 in spool gun receptacle
CN11 1 DC+24V. Connect to CC/CV switch wire from CN10 of
MIG-270I-KZ-A0
2 Connect to CC/CV switch wire
CN12 1 Connect to LIFT TIG/MIG/STICK switch
2 DC+24V. Connect to LIFT TIG/MIG/STICK switch
3 Connect to LIFT TIG/MIG/STICK switch
4 Connect to LIFT TIG/MIG/STICK switch
5 DC+24V. Connect to LIFT TIG/MIG/STICK switch
6 Connect to LIFT TIG/MIG/STICK switch
CN13 1 Connect to MIG torch trigger
2 Connect to MIG torch trigger
CN14 1 Connect to pole 5 in spool gun receptacle
2 Connect to pole 3 in spool gun receptacle
CN15 1 Connect to Spool gun trigger
2 Connect to Spool gun trigger
CN16 1 Connect wire feed motor given voltage
2 Not used
3 Connect wire feed motor given voltage

Table 6.7

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page40


SECTION 7 MAINTENANCE
7.1 Maintenance
Periodic maintenance is necessary for keeping the machine work properly.

CAUTION
DISCONNECT POWER INPUT AND SWITCH OFF THE MAIN POWER SWITCH
BEFORE START OF MAINTENANCE.

Regular Check and Inspection 6 Month Routine Maintenance

• Clean spatter inside the nozzle when • Blow out with dry clean pressure air or
continuously use the machine. vacuum inside machine, especially
transformer coil and power
• Check liner frequently, change if it has component.
been contaminated by oil or worn out.
• Check the electric connection of
• Check and change broken contact tip input/output bar to avoid bad contact
and nozzle to avoid damage to the caused by loose or rusted screw.
torch and machine.
• Check the lubrication of the gear box
• Check the function of all switches. in the feeder, replace or fill lubricates
oil if necessary.
• Check if the fan rotates properly and if
there is air venting out from back of • Check and clean the oil or other
the machine contamination in the feeding roller and
feeding tube. If the V grooves have
• Pay Attention to the abnormal worn out change feeding roller
vibration, noise, smell and gas immediately to avoid slipping or
leakage during operation unstable feeding

• Check if the welding cables are over


heated?

• Check if the cable connections are


over heated?

• Check if the cable is connected firmly


and properly, if it is broken and cause
bad insulation?

• Check the cover grounded properly

Table 7.1

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page41


7.2 Safety precaution
7.2.1 Welders must be equipped with welding mask, gloves and tie the sleeves and
collar properly. Use Table 5.2 to choose proper glass shade, also can reference
to ANSI Z49.1 listed in Safety Standards. There should be an arc shield around
welding field to protect others from arc shock.

7.2.2 Do not weld near flammable, explosive materials or gases.

7.2.3 Gas cylinder must be located at a safe and steady place to avoid injury others.

7.2.4 Keep finger, hair and clothing away from the rotating fan.

7.2.5 The power source must be grounded when welding.

7.2.6 Welding machine should not work in a flammable and toxic environment,
avoid moisture, rain, and do not directly expose to sun.

7.2.7 Periodically maintain the machine and clean the dust inside.

Lens Shade Selector Guide


Minimum Suggested*
Operation Electrode Size in. Arc Current
Protective Shade No.
/Process (mm) (Amperes)
Shade (Comfort)
Less than 3/32(2.5) Less than 60 7 —
Shielded metal
3/32−5/32 (2.5−4) 60−160 8 10
arc welding
5/32−1/4 (4−6.4) 160−250 10 12
(SMAW)
More than 1/4 (6.4) 250−550 11 14
Gas metal arc
welding Less than 60 7 —
(GMAW) and 60−160 10 11
flux cored arc 160−250 10 12
welding 250−550 10 14
(FCAW)
Gas tungsten Less than 50 8 10
arc welding 50−150 8 12
(GTAW) 150−500 10 14
AWS F2.2:2001 (R2010), Adapted with permission of the American Welding Society
(AWS), Miami, Florida

Table 7.2

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page42


SECTION 8 ELECTRICAL DIAGRAMS

ZX7-400I-QQ-A0

2
A P1
7 IGBT:FGL60N600BNTD
INPUT 115V/230V 6 1 1
5
B CN103
P2 4
VH-07
3
1 2

2
3

2
3
2 1
3
1 1
4
5
6
BRIDGE1 CN101
7
VH-10

3
8 X1 X1
9 VH-05(4) VH-05(4)
10

1
2
3
4
5

1
2
3
4
5
1
2 3
CN105
3 2
VH-03
4 1
CN102
5
VH-10
6
BRIDGE1
7

1
2
3
4
5

1
2
3
4
5
8 CN104 3 1
CN13
9 VH-03 2 X13 X13
VH-03(2)
10 1 3 VH-05(4) VH-05(4)

M2 JP2 CZ-02
4
12038 DC24V/0.5A
3
2
CN19
VH-04 J1 CZ-03 MIG-270I-
1 风风
JP2 CZ-02

1
CN17
2
VH-03(2)
3
CN16 CN15 CN14 CN11 CN12 CN4 C
XH-02 XH-03 VH-02 VH-03(2) VH-02 XH-04 X
2
1

1
2
3

2
1

1
2
3

1
2

1
2
3
4
7
6

3
2
1
7
M2
DC24V,ZCT-2.5
LED2 L

2W/1K 1 2

1 CN1
3
2
1

3
2
1

2
1

2
1

2
XH-02 CN7 CN8 CN14 CN15
XH-03 XH-03 XH-02 XH-02
CN2
1
XH-02
2

1 CN3
2 XH-02

1 CN16
2
VH-03
3 CN5 CN9 CN12
VH-03 XH-03 XH-06
1
2
3

1
2
3

1
2

B B

STICK

Figure 8.1

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page43


T38x22x15 T=300:1

3
MIG-270I-XS-A0

2
1 4
OUT +
ESA D92-02

R1 C1

MIG200-XH-A0
2 3 300R
472/3KV
BYQ5

R2
MIG-400I-ZL-A0 300R C2

472/3KV

M1
OUT
_
1
2

CN7 D4 L≥35uH 300A/75mV


VH-02
4 O.C
3
CN8
2
XH-04
1 POWER
-KZ-A0 CN9 2 CN10
VH-02 1
75℃
2
1
CN10
CN1 CN2 CN5 CN6
XH-05 VH-05 XH-02 XH-03
1
2
3
4
5

1
2
3
4
5

1
2

1
2
3
7
6

3
2
1

L3

LED1

RT1 RT2
2W/10K 2W/10K

M1
CN4 3
2
1

VH-03 2
M

CN11
1
XH-02 SSJ-18

CN13 2
XH-02 1 1
2
3
3
CN10 4
2
XH-03 5
1
6
7
3 8
CN16
2 9
VH-03
1
3
4
5
6

K/CO2/TIG

Figure 8.2

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page44


NOTES
WELDKING™ MIGSONIC200cvcc

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page45


SECTION 9 PARTS LIST
9-1 Power Source
Item Order No. Description Note Quantity
Y16010440 JKJ-A241-A1(AH2351)(SY 1
1 Front
-A1134-A1)
panel(grey/Canada)
Y09020014 LX5135V-2V 2
2 Digital display panel
Y08070008 RN-110Z 3
3 Knob
DADANMAI(black/red)
Y07060002 10-25 2
4 Quick connector
Y07080007 10P 1
5 Control receptacle
Y16030499 JKJ-A237-A1(CH4198)(wit 1
6 Left panel
hout silk screen)
(blue/MigSonic200cvcc)
B03011011 ZX7-300C(DKQ-008) 1
7 Reactor
Y25050047 JYJ-A129-A1 2
8 MIG270I rib
B01031042 ZX7-400I(export) 1
9 Rectifier PCB
Y23010107 SRQ-A041-A1 1
10 Heat sink
(Migsonic200cvcc)
Y26030001 WJJ-252 2
11 ZX7-400C(fix bar)
B01081019 S200I 1
12 Full bridge Rectifier PCB
Y22030016 SSJ-18with0.035/0.045V 1
13 Driving system with
central connection(euro groove driver roller (guide
tube length 120mm)
style)
B03041024 MigSonic 200 CV 1
14 Main transformer
CC(Canada)(37:7)
Y22010004 12038 DC24V/0.5A 1
15 Fan
Y16020186 JKJ-A242-A1(AH2351)(SY 1
16 Rear
-A2067-A2)
panel(grey/Canada)
Y21010029 ZCT-2.5/DC24V(brass 1
17 Solenoid valve
bas,Φ6)
Y26050021 WJJ-115 1
18 CUT45-Switch bracket
Y08030006 DZ47-40/2P 1
19 air-break switch
Y16050074 JKJ-A244-A1(AH2351) 1
20 middle
panel(grey/Canada)(1)
Y16050071 JKJ-A245-A1(AH2351) 1
21 middle
panel(grey/Canada)(2)
B02030041 LJJ-A041-A1 1
22 MIG200 fastener(1)

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page46


Y10030017 300A-75mV(non-standard) 1
23 Shunt
B02030041 LJJ-A041-A1 1
24 MIG200 fastener(1)
Y25050514 1
25 Plastic connection panel
B01051010 MIG200 1
26 Absorb PCB
B01081021 MIG200I 1
27 Lift-arc strike PCB
B01041032 MIG-270I 1
28 Control PCB
Y25050544 MIG-270I (hole 4*Φ8. Al 1
29 Damping wire spool
base, black plastic bar,
open style)
Y26090008 WJJ-A286-A1(AH2351) 1
30 MIG-270 (Handle(grey)
Y16030499 JKJ-A237-A1(CH4198)(no 1
31 Right panel
silk screen)
(blue/MigSonic200cvcc)
Y16030500 JKJ-A236-A1(CH4198) 1
32 Right bottom panel
(blue/MigSonic200cvcc)
Y16040178 JKJ-A243-A2(AH2351) 1
33 Bottom panel
(grey/Canada)
B01051009 MIG270I Absorb PCB 1
34 Absorb PCB
B01021012 DVI200 1
35 Capacitor PCB
B0108100 ZX7-250I 1
36 DC isolation PCB
Y27020012 EER43-140:20:11:10 1
37 HF transformer
Y27020030 EI33-40:20:20:20:20 1
38 HF transformer
Y22020001 120mm 1
39 Fan protection screen
Y25050516 SR-T83 1
40 Wire fixer
Y26100003 CONNECTOR(EXPORT)- 1
41 Gas inlet
01-A1(CGA5/8"-18Unf)
Y25050507 Φ50*35 4
42 Foot Pad
Y25050545 M10*15 1
43 Wire guide tube
Y08060002 KN3-3 220V 1
44 Toggle switch
3A(6pin/2position)
Y07100020 5mm 2
45 luminescent diode
Y08060009 T80-T
46 Toggle switch 1
Y12060163 AWG14-3
47 Power cable 1
Y02010018 106/630V
48 CBB Capacitor 1
Y04070001 25A/1000V(square)
49 Rectifier bridge 2

Table 9.1

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page47


Figure 9.1

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page48


46 45

13

Figure 9.2

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page49


19
29

47

41

15

Figure 9.3

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page50


23

28

17

27

12

26
10

7
48

36

Figure 9.4

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page51


25 44 14

13

35

49

Figure 9.5

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page52


9-2 Wire feeder
SSJ-18 with bracket, Order No. Y22030016

Figure 9.6

ITEM DESCRIPTION QUANTITY


1 Protection cap 1
2 Euro connection 1
3 Drive roller bracket 1
4 Pressure adjustment component 1
5 50W Motor 1
6 Wire in guide hose L=120mm 1
7 Bracket 1
8 Support 1
9 Shaft sleeve 1
10 Roller(0.9/0.8mm/1.2)(.035/.045) 1
11 Drive roller press nut 1
12 Protect plate 1

Table 9.2

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page53


Drive roller selection

ITEM DESCRIPTION ORDER NO NOTE


1 V groove (0.9/1.2mm)(0.035/0.045)(default) 072611020 For solid wire

2 V groove (0.6/0.8mm)(0.023/0.030) 072611021 For solid wire

3 Knurled groove (0.9/1.2mm)(0.035/0.045) 072611022 For flux cored wire

Table 9.3

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page54


9-3 Spool holder module
(SSJ-18 with bracket) , Order No. Y22030016

Figure 9.7

ITEM DESCRIPTION ORDER NO QUANTITY


1 axle cap 2401709 1

2 Washer 6 n/a 1

3 spring 2401710 1

4 Screw M6x25 n/a 1

5 Cap bracket 2401708 1

6 Washer 2401707 1

7 Screw M8x30 n/a 1

8 Spring 2401706 1

9 Separation ring 2401705 1

10 Shaft sleeve 2401704 1

11 Nut M14 n/a 1

12 Axle seat 2401701 1

13 Axle 2401703 1

Table 9.4

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page55


9-4 Spool gun connector

Trigger switch

Potentiometer

Motor drive

10 pin connector

Figure 9.8

SOCKET PIN FUNCTION

1 Spool gun C.C.W potentiometer(3)

2 Spool gun wiper potentiometer(2)

3 Spool gun switch

4 Not used

5 Spool gun switch

6 Spool gun motor (+)

7 Not used

8 Spool gun C.W potentiometer(1)

9 Spool gun motor (-)

10 Not used

Table 9.5

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page56


9-5 Mig torch
WeldKingTM NT1-4E, Order No. 07000412

Figure 9.9

Nozzles

ITEM DESCRIPTION ORDER NO.


1 Nozzle Self Insulated 21-37 A
2 Nozzle Self Insulated 21-50* A
3 Nozzle Self Insulated 21-62 A
4 Nozzle Self Insulated 21-37F A
5 Nozzle Self Insulated 21-50F A
6 Nozzle Self Insulated 21-62F A
7 Nozzle Self Shielding LA8201 B

Table 9.6

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page57


Contact Tips

ITEM DESCRIPTION ORDER NO.


1 Contact Tip 0.023”/0.6mm Ecu 11-23 C
2 Contact Tip 0.030”/0.8mm Ecu 11-30* C
3 Contact Tip 0.035”/0.9mm Ecu 11-35 C
4 Contact Tip 0.040”/1.0mm Ecu 11-40 C
5 Contact Tip 0.045”/1.2mm Ecu 11-45 C

Table 9.7

Liners

ITEM DESCRIPTION ORDER NO.


1 Steel Liner 0.030”-0.035”/0.8-0.9mm X15ft 42-3035-12* C
2 Teflon Liner 0.030”-0.035”/0.8-0.9mm X15ft 42T-3035-12 C

Table 9.8

* Default

Component

ITEM DESCRIPTION PART No. QTY


1 Gas Diffuser 51 1
2 Goose neck(45̊ ) 61-45 1
Goose neck(55̊ ) 61-55 1
3 Handle locking Nut EH1111 1
4 Gun Handle (Front) EH1101 1
5 Trigger Assembly EJ0003 1
6 Gun &Cable Assembly.3.65M TEL1012-H 1
7 Rear spring protective sleeve ES2201
8 Rear cover EH2201 1
9 Screw(M4X6) EH2211 1
10 Rear lock nut EP2001 1
11 Euro connector(Tweco) ETU001 1
12 O ring 4x1 Q504010 1
13 O ring 4x8 Q504018 1
14 Nut M11X1 TEU1011 1

Table 9.9

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page58


NOTES
WELDKING™ MIGSONIC200cvcc

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page59


SECTION 10 WARRANTY POLICY

Malo Welding Products Ltd., Warranty Policy


Effective August 1st, 2004, revision at April 1st, 2011
LIMITED WARRANTY - Subject to the terms and PRODUCTS ARE FOR COMMERCIAL/INDUSTRIAL USE
conditions below, Malo Welding Products AND PERSONS TRAINED AND EXPERIENCED IN THE
Ltd.(WELDKING™ ) endeavors to provide high quality USE AND MAINTENANCE OF WELDING/PLASMA
products and product support to its customers and CUTTING EQUIPMENT.
therefore backs up all of its new products purchased from
In the event of a warranty claim covered by this warranty,
Malo Welding Products Ltd.(WELDKING™ ) or any
the exclusive remedies shall be, at Malo Welding Products
authorized Malo Welding Products Ltd.(WELDKING™ )
Ltd.(WELDKING™ )'s option: (1) repair; or (2) replacement;
distributor/service center after the effective date of this
or, where authorized in writing by Malo Welding Products
limited warranty and is free of defects in material and
Ltd.(WELDKING™ ), in appropriate cases, (3) the
workmanship at the time it is shipped. THERE ARE NO
reasonable cost of repair or replacement at an authorized
WARRANTIES WHICH EXTEND BEYOND THE FACE OF
service station; or (4) payment of or credit for the purchase
THE MALO WELDING PRODUCTS LTD.(WELDKING™ )
price (less reasonable depreciation based upon actual use)
WARRANTY. MALO WELDING PRODUCTS
upon return of the goods at customer's risk and expense.
LTD.(WELDKING™ ) DISCLAIMS ALL OTHER
No compensation or reimbursement for transportation
WARRANTIES, EXPRESS OR IMPLIED, REGARDING
costs of any kind will be allowed.
THE PRODUCTS, INCLUDING ANY IMPLIED
WARRANTIES OF MERCHANTABILITY, FITNESS FOR A LIMITATION OF DAMAGES: THE REMEDY OF
PARTICULAR PURPOSE OR NONINFRINGEMENT. IN REPLACEMENT OR REPAIR OF ANY DEFECTIVE
THE UNITED STATES, SOME STATES DO NOT ALLOW GOODS SHALL BE THE EXCLUSIVE REMEDY UNDER
THE EXCLUSION OF THE IMPLIED WARRANTIES, SO ANY WARRANTY MADE BY MALO WELDING
THE ABOVE EXCLUSION MAY NOT APPLY TO YOU. PRODUCTS LTD.(WELDKING™ ), WHETHER EXPRESS
OR IMPLIED. IN NO EVENT SHALL MALO WELDING
Malo Welding Products Ltd.(WELDKING™ ) shall honor
PRODUCTS LTD.(WELDKING™ ) BE LIABLE FOR ANY
warranty claims on warranted equipment listed below in the
INCIDENTAL OR CONSEQUENTIAL DAMAGES,
event of such a failure within the warranty time periods. All
PROPERTY DAMAGES, OR PERSONAL INJURIES.
warranty time periods start on the date that the equipment
was delivered to the original retail purchaser, or one year ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
after the equipment is sent to a North American distributor. AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
(1) 3 Years - Parts and Labor
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
Power Sources OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION,
Wire Feeders
OPERATION OF LAW, CUSTOM OF TRADE OR
(2) 90 Days - Parts (No Labor) COURSE OF DEALING, INCLUDING ANY IMPLIED
WARRANTY OF MERCHANTABILITY OR FITNESS FOR
Guns
PARTICULAR PURPOSE, WITH RESPECT TO ANY AND
Remote Controls ALL EQUIPMENT FURNISHED BY MALO WELDING
PRODUCTS LTD.(WELDKING™ ), IS EXCLUDED AND
Accessory Kits
DISCLAIMED BY MALO WELDING PRODUCTS
Replacement Parts (No labor) LTD.(WELDKING™ ).
Malo Welding Products Ltd.(WELDKING™ )'s limited If any provision or portion of this limited warranty policy is
Warranty shall not apply to: found to be unenforceable, then the remaining provisions
and portions shall remain valid and enforceable. If any
(1) Consumable components; such as contact tips, cutting provision or portion of this limited warranty policy is found
nozzles, contactors, brushes, slip rings, relays or parts that to be limited by law, then that provision or portion shall be
fail due to normal wear. construed to make it effective within the bounds of law.
(2) All limited warranties are void for, and Malo Welding To obtain warranty service you must active your
Products Ltd.(WeldKing™ ) does not warrant in any way, product(s)'s warranty online at weldking.com or mail the
any product that evidences misapplication, improper product registration card included in the package to Malo
installation, abuse, lack of maintenance, negligence in use Welding Products Ltd.(WELDKING™ ) right after the
or care, abnormal use, alteration of design, use of purchase. When there is a warranty issue, return the
incompatible or corrosive chemicals, and/or servicing, defective welding machine or plasma cutting machine
installation of parts, or repairs by anyone other than Malo along with proof of purchase to any WeldKing™
Welding Products Ltd.(WELDKING™ ) or a Malo Welding Authorized Warranty Depot. For the location of the
Products Ltd.(WELDKING™ ) authorized distributor or nearest WeldKing™ Authorized Warranty depot or for
service center. Malo Welding Products Ltd.(WELDKING™ ) service information in the United States or Canada,
may make changes in products it manufactures and please telephone toll free: 1-866-686-5088 or visit www.
markets at any time; these changes are made without weldking.com (USA & Canada).available, but may vary
obligation to change, retrofit, or upgrade any product from province to province.
previously sold or manufactured.
MALO WELDING PRODUCTS LTD.(WELDKING™) 'S

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page60


SECTION 11 AUTHORIZED SERVICE CENTER

Please go to our website www.weldking.com to fill the warranty registration


form. Malo Welding Products Ltd. will not distribute of disclose customer's
private information to any third party and will not sent promotion material to the
customer.
Find your nearest warranty center at:

http://www.weldking.com/servicelocations.aspx

MIGSONIC200cvcc SERVICE MANUAL Manual no: WM070502 Page61


MALO WELDING PRODUCTS LTD.
3275, 14th ave, Unit A, Markham, Ontario, Canada, L3R 0H3

Tel: 1 866 686 5088

Fax: 1 866 686 5090

www.malowelding.com

Printed November 29, 2012