MIGS SS20 SONIC2 wire fe 52S po eeder ower so urce

Transcription

MIGS
SONIC252S po
ower source
SS20 wire fe
eeder
MIG
M (GMAW)
Flux
F
cored (FCA
AW)
Arc Weldin
ng Power Sourrce and wire feeder
Power Source Se
erial Number: ___
__________
_________
_________
______
Wire fe
eeder Seria
al Number:
___
__________
_________
_________
______
Where Purchase
e:
___
__________
_________
_________
______
Date off purchase
ed:
___
__________
_________
_________
______
Table of Contents
SECTION 1
SECTION 1
SAFETY PRECAUTIONS .............................................................................................. 1
CONSIGNES DE SÉCURITÉ ............................................................................................. 1
1-1.
Symbol Usage
1-2.
Arc welding Hazards
1-3.
Safety Standards Normes de sécurité ........................................................... 6
1-4.
EMF Information EMF Information .............................................................. 6
SECTION 2
SECTION 3
Symboles utilisés ................................................................ 1
Dangers relatifs au soudage à l’arc .................. 1
PACKING LIST ............................................................................................................... 7
INSTALLATIONS........................................................................................................... 8
3-1.
Welding power source and wire feeder specifications ............................. 8
3-2.
MIG torch specifications ................................................................................. 10
3-3.
MIG welding connection diagram ................................................................. 11
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) ............................................................... 14
3-9.
Electric service guide ...................................................................................... 14
3-10.
Extension Welding Cable Selection Chart ................................................. 16
3-11.
9-pin spool gun connection receptacle ...................................................... 16
3-12.
7-pin link cord receptacle ............................................................................... 17
SECTION 4
OPERATION .................................................................................................................... 18
4-1.
Power source panel layout and description .............................................. 18
4-2.
SS-2- wire feeder panel layout and description ........................................ 20
4-3.
Operation ............................................................................................................ 21
4-4.
Voltage/Wire speed selection chart.............................................................. 22
SECTION 5
TROUBLE SHOOTING................................................................................................... 23
5-1.
General trouble shooting ................................................................................ 23
5-2.
GMAW/FCAW welding trouble shooting ..................................................... 24
SECTION 6
MAINTENANCE ............................................................................................................ 27
6-1.
Maintenance ....................................................................................................... 27
6-2.
Safety precaution .............................................................................................. 28
SECTION 7
PARTS LIST ................................................................................................................. 29
7-1.
MigSonic252S Power Source......................................................................... 29
7-2.
SS-20 Wire feeder ............................................................................................. 33
7-3.
Wire driving system ......................................................................................... 37
7-4.
Spool holder module........................................................................................ 39
7-4.
MIG torch............................................................................................................. 39
SECTION 8
SECTION 9
SECTION 10
ELECTRIC DIAGRAM ................................................................................................ 44
WARRANTY POLICY ................................................................................................ 46
AUTHORIZED SERVICE CENTER .......................................................................... 47
1-1.
SECTION
S
N1
SAFETY
Y PRECA
AUTIONS
S
SECTION
N1
CO
ONSIGNE
ES DE SÉ
ÉCURITÉ
É
Sym
mbol Usage
Sym
mboles uttilisés
Means Warning! Wattch Out! There are
possible hazards with this procedurre! The
possible hazards are shown
s
in the ad
djoining
symbols.
Symbo
ole graphique d’avertissement
d
! Attention ! Ce
ette
proced
dure comporte des risques possibles ! Les
dangers éventuels so
ont représentéss par les symbo
oles
graphiques joints.
This group off symbols means Warning! Wattch
Out possible ELECTRIC SHO
OCK, MOVING
PARTS, and HOT PARTS ha
azards. Consultt
symbols and related instructions below for
necessary acctions to avoid th
he hazards
Ce groupe de
d symboles sig
gnifie Avertisse
ement!
Attention!
Risques
d
d’ÉLECTROCU
TION,
ORGANES MOBILES
M
et PARTIES
P
CHAU
UDES.
Consulter le
es symboles et les instru
uctions
afferents ci-d
dessous concerrnant les mesu
ures à
prendre pour supprimer les dangers.
d
M
Marks a specia
al safety messa
age.
IIndique un mes
ssage de sécurité particulier
M
Means “Note”; not safety rela
ated.
S
Signifie NOTE ; n’est pas rela
atif à la sécuritté.
1-2.
Arc
c welding Hazards

Dange
ers relatifs
s au souda
age à l’arc
c
The symbols sh
T
hown below arre used
t
throughout
this
s manual to call attention to
a identify po
and
ossible hazards
s. When you se
ee
t symbol, wa
the
atch out, and fo
ollow the relate
ed
instructions to avoid the haza
ard.
Only qualified persons
O
p
should
d service, test,,
m
maintain,
and rer pair this uniit.
During servicin
D
ng, keep everyb
body, especially
c
children,
away
L
Les
symboles représentés ci-dessous
c
so
ont
u
utilisés
dans ce
e manuelpour attirer
a
l’attentio
on
e
et
identifier
les
dange
ers
possible
es.
E
Enprésence
d
de
l’un de ces symbole
es,
p
prendre
garde
e et suivre lesinstruction
ns
a
afférentes
pour éviter tou
ut risque. Le
es
instructions en
nmatière de sécurité indiquée
es
c
ci-dessous
ne constituent qu’un
q
sommaiire
d
des
instruction
ns de sécurité plus complète
es
f
fournies
dans
s les norme
es de sécuriité
é
énumérées
da
ans la Sectio
on 2-5. Lire et
o
observer
toutes
s les normes de
d sécurité.
S
Seul
un perso
onnel qualifié est autorisé à
installer, faire
e fonctionner, entretenir et
r
réparer
cet app
pareil.
P
Pendant
le fonctionnemen
f
nt, maintenir à
d
distance
toute
es les personn
nes, notamme
ent
le
es enfants de l’appareil.
l
ELE
ECTRIC SHO
OCK can kill.
UNE
E DÉCHARG
GE
ÉLE
ECTRIQUE entraîner
e
la
morrt.
y
y
y
Do not touch live
D
e electrical partss.
W
Wear
dry, hole-free insulating gloves and body
p
protection.
Insulate yourselff from work and
d ground using dry
d
in
nsulating mats or covers big e
enough to preve
ent
a physical con
any
ntact with the wo
ork or ground.
MIGS
SONIC252S OWNER’S
O
MA
ANUAL
y
y
y
y
y
y
y
y
y
y
y
Do not use
e AC output in damp areas, if
movement iss confined, or iff there is a danger of
falling.
Use AC outp
put ONLY if req
quired for the welding
w
process.
If AC outpu
ut is required, use remote output
o
control if pre
esent on unit.
Additional sa
afety precaution
ns are required when
any of the
e following ele
ectrically haza
ardous
conditions are
a
present: in
n damp locatio
ons or
while wearin
ng wet clothing; on metal structures
such as floo
ors, gratings, or
o scaffolds; wh
hen in
cramped po
ositions such ass sitting, kneeling, or
lying; or whe
en there is a hig
gh risk of unavoidable
or accidenta
al contact with
h the workpiece or
ground. For these condition
ns, use the following
equipment
presented:
in
order
1
1)
a
semiautomatic DC constantt voltage (wire) welder,
w
2) a DC m
manual (stick) welder,
w
or 3) an
a AC
welder with reduced
r
open-ccircuit voltage. In
n most
situations, use
u
of a DC, constant
c
voltage
e wire
welder is rec
commended. An
nd, do not work alone!
a
Disconnect input power orr stop engine before
b
installing
or
servicing
this
equip
pment.
Lockout/tago
out input powerr according to OSHA
O
29 CFR 1910.147 (see Safe
ety Standards).
Properly ins
stall and grou
und this equip
pment
according to
o its Owner’s Manual
M
and national,
state, and local codes.
fy the supply gro
ound − check and
a be
Always verify
sure that input power cord ground wire
w
is
properly co
onnected to ground
g
termin
nal in
disconnect box
b or that cord plug is conneccted to
a properly grrounded recepta
acle outlet.
When makin
ng input connections, attach proper
p
grounding conductor firs
st − double--check
connections.
nspect input po
ower cord for da
amage
Frequently in
or bare wirring − replace cord immediately if
damaged − bare
b
wiring can kill.
Turn off all equipment
e
when
n not in use.
Do not use
e worn, damaged, undersize
ed, or
Ma
anual no: WM070101
Page1
1
y
y
y
y
y
y
y
y
y
y
poorly spliced ca
p
ables.
D not drape ca
Do
ables over your body.
b
Iff earth grounding of the workp
piece is require
ed,
g
ground
it directly
y with a separatte cable.
D not touch ele
Do
ectrode if you are
a in contact with
the work, groun
nd, or another electrode from a
d
different
machine.
D not touch ele
Do
ectrode holders connected to tw
wo
w
welding
machine
es at the same time
t
since doub
ble
o
open-circuit
volta
age will be pressent.
U only well-m
Use
maintained equipment. Repair or
r
replace
damage
ed parts at once. Maintain unit
a
according
to ma
anual.
W
Wear
a safety harness if worrking above flo
oor
le
evel.
K
Keep
all panels and covers seccurely in place.
C
Clamp
work cable with goo
od metal-to-metal
c
contact
to work
kpiece or worktable as near the
w
weld
as practica
al.
Insulate work clamp
c
when not
n
connected to
w
workpiece
to prevent
p
contactt with any metal
o
object.
D not connect more than one electrode or wo
Do
ork
c
cable
to any sing
gle weld output terminal.
SIGN
NIFICANT DC
C VOLTAGE
E exists after
remo
oval of inputt power on inverters.
Il rreste une TENSION DC NO
ON
NÉGLIGEABLE dans les sources de
d
soud
dage ondule
eur quand on a coup
pe
l’alim
mentation.
y
y
y
y
y
y
y
y
y
y
y
Turn Off inverte
T
er, disconnect input power, and
d
discharge
input capacitors according to
in
nstructions in Maintenance Section befo
ore
to
ouching any parts.
y
y
y
y
y
y
y
y
y
Ne pas touche
N
er aux pièces électriques sous
te
ension.
P
Porter
des gantts isolants et des
d
vêtements de
d
p
protection
secs et sans trous.
S
S’isoler
de la piè
èce à couper et du sol en utilisa
ant
d
des
housses ou des tapis asssez grands afin
d
d’éviter
tout con
ntact physique avec la pièce à
c
couper
ou le sol.
N pas se servir de source éle
Ne
ectrique à coura
ant
é
électrique
dans
s les zones hu
umides, dans les
e
endroits
confinés ou là où on rissque de tomberr.
S servir d’une
Se
e source électrique à coura
ant
é
électrique
UNIQ
QUEMENT si le procédé de
d
s
soudage
le dem
mande.
S l’utilisation d’une source éle
Si
ectrique à coura
ant
é
électrique
s’avè
ère nécessaire, se servir de la
fo
onction de télé
écommande si l’appareil en est
e
é
équipé.
D
D’autres
consign
nes de sécurité sont nécessairres
d
dans
les con
nditions suivantes : risques
é
électriques
danss un environnem
ment humide ou si
l’’on porte des vêtements mo
ouillés ; sur des
s
structures
métalliques telles qu
ue sols, grilles ou
o
é
échafaudages
; en position coincée comm
me
a
assise,
à genou
ux ou couchée
e ; ou s’il y a un
u
r
risque
élevé de contact inévita
able ou accidentel
a
avec
la pièce à souder ou le sol. Dans ces
c
conditions,
utiliser les équipe
ements suivants,
d
dans
l’ordre indiiqué : 1) un posste à souder DC
Cà
te
ension constan
nte (à fil), 2) un
n poste à soud
der
D manuel (éle
DC
ectrode) ou 3) un
u poste à soud
der
A à tension à vide
AC
v
réduite. Da
ans la plupart des
MIGS
SONIC252S OWNER’S
O
MA
ANUAL
y
y
y
y
y
y
situations, l’u
utilisation d’un poste à souder DC à
fil à tension
n constante es
st recommandé
ée. En
outre, ne pas
s travailler seul !
Couper l’alim
mentation ou arrrêter le moteur avant
de procéderr à l’installation, à la réparation
n ou à
de
l’appa
l’entretien
areil.
Déverrrouiller
l’alimentation
n selon la norrme OSHA 29 CFR
1910.147 (vo
oir normes de sécurité).
s
Installer le poste
p
correctem
ment et le mettrre à la
terre conven
nablement selo
on les consigne
es du
manuel de l’’opérateur et les normes nationales,
provinciales et locales.
vérifier
la
Toujours
c
cordon
terre
du
d’alimentatio
on. Vérifier et s’assurer que le
e fil de
terre du cord
don d’alimentation est bien racccordé
à la borne de
e terre du sectio
onneur ou que la
a fiche
du cordon est raccord
dée à une prise
correctemen
nt mise à la terre
e.
En effectuan
nt les raccordements d’entrée
e, fixer
d’abord le conducteur de mise à la terre
approprié et contre-vérifier les
l connexions.
quemment le cordon
c
d’alimen
ntation
Vérifier fréq
afin de s’ass
surer qu’il n’est pas altéré ou à nu, le
remplacer im
mmédiatement s’il l’est. Un fil à nu
peut entraîne
er la mort.
L’équipemen
nt doit être hors tension lorsqu’iil n’est
pas utilisé.
magés,
Ne pas utilisser des câbles usés, endomm
de grosseur insuffisante ou mal épissés.
Ne pas enrouler les câbles autour du corpss.
s
doit êtrre mise à la terre, le
Si la pièce soudée
faire directem
ment avec un câ
âble distinct.
Ne pas tou
ucher l’électrode quand on est
e en
contact avec
c la pièce, la te
erre ou une élecctrode
provenant d’’une autre mach
hine.
Ne pas touccher des porte électrodes
é
conn
nectés
à deux mach
hines en même temps à cause
e de la
présence d’u
une tension à vide doublée.
N’utiliser qu’’un matériel en bon état. Réparer ou
sur-lechamp
remplacer
p
les
p
pièces
endommagé
ées.
Entre
etenir
l’ap
ppareil
conforméme
ent à ce manuel.
Porter un ha
arnais de sécuritté si l’on doit tra
availler
au-dessus du sol.
S’assurer qu
ue tous les pan
nneaux et couvvercles
sont correcte
ement en place.
Fixer le câb
ble de retour de
e façon à obtenir un
bon contact métal-métal avvec la pièce à souder
s
ou la table de
d travail, le plu
us près possible
e de la
soudure.
nce de masse quand pas miss à la
Isoler la pin
pièce pour éviter le conttact avec tout objet
métallique.
ne électrode ou
u plus
Ne pas racccorder plus d’un
d’un câble de masse à une
u
même born
ne de
sortie de sou
udage.
Arrêter les co
onvertisseurs, débrancher
d
le co
ourant
électrique et
e décharger les condensa
ateurs
d’alimentatio
on selon les in
nstructions indiquées
dans la parrtie Entretien avant
a
de touche
er les
pièces.
STATIC (E
ESD) can
damage PC
P boards.
LES CHARGES
ÉLECTRO
OSTATIQUES
S
peuvent endommage
e
er
les circuitts imprimés
s.
Ma
anual no: WM070101
Page2
2
y
y
y
y
P
Put on grounded
d wrist strap BE
EFORE handling
g
b
boards or parts..
U
Use proper static-proof bags an
nd boxes to storre,
m
move, or ship PC boards.
É
Établir la conn
nexion avec la arrette de terrre
a
avant de manipu
uler des cartes ou des pièces.
U
Utiliser des poch
hettes et des bo
oîtes antistatiques
p
pour stocker, déplacer
d
ou exp
pédier des cartes
P
PC.
FIR
RE OR EXPL
LOSION
haz
zard.
Ris
sque D’INCE
ENDIE OU
D’E
EXPLOSION
N.
y
y
y Do not place unit on, over, or
o
n
near combustible surfaces.
D
Do not service unit
u near flamma
ables
D
Do not overload
d building wiring
g − be sure pow
wer
ssupply system is properly sized, rated, an
nd
p
protected to han
ndle this unit.
N
Ne pas placer l’appareil sur, au-dessus ou à
p
proximité de surrfaces inflamma
ables.
y N
Ne pas installer l’appareil à proxximité de produits
inflammables.
y N
Ne pas surcha
arger l’installattion électrique −
ss’assurer que l’alimentation est
e correcteme
ent
d
dimensionnée et protégée avant
a
de metttre
l’appareil en serrvice.
y
FLYING MET
F
TAL can
in
njure eyes.
D
DES
PARTIC
CULES
V
VOLANTES
p
peuvent
b
blesser
les yeux.
y
y
y
y
y
W
Wear safety glasses with side sshields or face
sshield during se
ervicing.
B
Be careful not to short meta
al tools, parts, or
w
wires together during
d
testing an
nd servicing.
L
Le soudage, l’’écaillement, le
e passage de la
p
pièce à la brossse en fil de fe
er, et le meulag
ge
g
génèrent des étincelles et des particules
m
métalliques vollantes. Pendan
nt la période de
d
rrefroidissement des soudures, elles risquent de
d
p
projeter du laitie
er.
P
Porter des lunettes de sécurité avec écrans
latéraux ou un écran
é
facial.
HOT PARTS can cause
e
severe burrns.
DES PIÈCE
ES CHAUDE
ES
peuvent prrovoquer de
es
brûlures grraves.
y D
Do not touches hot parts bare handed.
h
y A
Allow cooling period before wo
orking on welding
gun
n or torch
y N
Ne pas toucher des parties chaudes
c
à mains
nue
es.
y P
Prévoir une pé
ériode de refroidissement ava
ant
d’uttiliser le pistolet ou la torche.
MIGS
SONIC252S OWNER’S
O
MA
ANUAL
MAGNETIC
C FIELDS ca
an
affect pace
emakers.
LES CHAM
MPS
MAGNÉTIQ
QUES peuve
ent
affecter les
s stimulateu
urs
cardiaques
s.
y
y
Pacemaker wearers
w
keep away.
a
Wearers sho
ould consult their doctor before
going near arc
a welding, gou
uging, or spot
welding operrations.
y
Porteurs de stimulateur card
diaque, rester à
distance.
Les porteurs
s d’un stimulateu
ur cardiaque
doivent d’abord consulter le
eur médecin ava
ant
de s’approch
her des opératio
ons de soudage
eà
l’arc, de gougeage ou de so
oudage par poin
nts.
y
CYLINDERS
S can explo
ode if
damaged.
LES BOUTE
EILLES peuvent
exploser si elles sont
endommag
gées.
Shielding gas cylinders
c
contain gas under high
pre
essure. If dama
aged, a cylinderr can explode. Since
gass cylinders are normally
n
part off the welding pro
ocess,
be sure to treat the
em carefully.
y Protect compre
essed gas cylin
nders from exce
essive
heat, mechaniccal shocks, phy
ysical damage, slag,
open flames, sp
parks, and arcss.
y Install cylinderss in an upright position
p
by securring to
a stationary support or cylin
nder rack to prrevent
falling or tipping
g.
y Keep cylinderss away from any
a
welding or other
electrical circuits.
y Never drape a welding torch over
o
a gas cylind
der.
y Never allow a welding elecctrode to touch
h any
cylinder.
y Never weld on
n a pressurized cylinder − exp
plosion
will result.
y Use only correcct shielding gas cylinders, regulators,
hoses, and fittings
f
designe
ed for the sp
pecific
application; ma
aintain them and associated pa
arts in
good condition.
y Turn face awa
ay from valve outlet
o
when op
pening
cylinder valve.
y Keep protectivve cap in place
e over valve except
e
when cylinder is in use or conn
nected for use.
y Use the right equipment,
e
corrrect proceduress, and
sufficient number of person
ns to lift and move
cylinders.
y Read and follo
ow instructions on compresse
ed gas
cylinders, asso
ociated equipme
ent, and Comprressed
Gas Associatio
on (CGA) publlication P-1 listted in
Safety Standarrds.
es bouteilles de
e gaz protecteur contiennent du
d gaz
De
sou
us haute prression. Si une bouteille
e est
end
dommagée, ellle peut explosser. Du fait qu
ue les
bou
uteilles de gaz font normaleme
ent artie du procédé
de soudage, les manipuler
m
avec précaution.
p
y Protéger les bouteilles
b
de gaz
g
comprimé d’une
chaleur excesssive, des choc
cs mécaniquess, des
dommages ph
hysiques, du laitier,
l
des flammes
ouvertes, des étincelles
é
et dess arcs.
Ma
anual no: WM070101
Page3
3
y Placcer les bouteille
es debout en le
es fixant dans un
u
sup
pport stationnaire ou dans un
n porte-bouteilles
pou
ur les empêcherr de tomber ou de
d se renverserr.
y Ten
nir les bouteilles éloignées des circuits de
d
sou
udage ou autres
s circuits électriq
ques.
y Ne jamais placer une torche de soudage sur une
bou
uteille à gaz.
y Une
e électrode de soudage
s
ne doitt jamais entrer en
e
con
ntact avec une bouteille.
b
y Ne jamais soude
er une bouteille pressurisée −
que d’explosion.
risq
y Utiliser seulement des bouteilles de
d gaz protecteur,
x et raccords convenables
c
po
our
régulateurs, tuyaux
pécifique ; les maintenir
m
ainsi que
cettte application sp
les éléments assocciés en bon étatt.
y Déttourner votre visage
v
du déte
endeur-régulate
eur
lorssque vous ouvre
ez la soupape de la bouteille.
y Le couvercle du détendeur
d
doit toujours être en
e
placce, sauf lorsqu
ue la bouteille
e est utilisée ou
o
qu’e
elle est reliée po
our usage ultérieur.
y Utiliser les équip
pements correccts, les bonnes
our
proccédures et sufffisamment de personnes po
sou
ulever et déplace
er les bouteilless.
y Lire
e et suivre les instructions sur les bouteilles de
d
gazz comprimé, l’éq
quipement conn
nexe et le déplia
ant
P-1 de la CGA (Compressed
(
G
Gas
Associatio
on)
men
ntionné dans les
s principales no
ormes de sécuritté.
que des ventilateurs.
Maintenir fe
ermés et verrrouillés les portes,
p
panneaux, recouvrements
r
et dispositiffs de
protection.
Seules des personnes
p
qualifiées sont autorisées
à enlever less portes, panne
eaux, recouvrements
ou dispositifs de protection pour l’entretien.
Remettre les
s portes, panne
eaux, recouvrements
ou dispositifs de protection quand l’entretie
en est
a
de rebra
ancher l’alimen
ntation
terminé et avant
électrique.
y
y
y
MOVING
G PARTS can
n
cause in
njury.
DES ORG
GANES
MOBILES
S peuvent
provoquer des
blessure
es.
y
y
Keep away fro
om moving partts
Keep away fro
om pinch points
s such as drive rolls
r
y
y
Ne pas s’apprrocher des orga
anes mobiles.
Ne pas s’apprrocher des points de coinceme
ent tels
que des roule
eaux de commande.
OVERUSE can cause
OVERHEA
ATING.
L’EMPLOI EXCESSIF peut
p
SURCHAU
UFFER
L’ÉQUIPEM
MENT.
FA
ALLING UNIIT can cause
e
in
njury.
LA
A CHUTE DE
E
L’’APPAREIL peut blesse
er.
y
y
y
y
y
y
U
Use lifting eye to
o lift unit only, NOT
N
running gea
ar,
g
gas cylinders, or
o any other acce
essories.
U
Use equipment of adequate capacity to lift and
d
ssupport unit.
Iff using lift forkss to move unit, be sure forks are
a
long enough to extend beyond
d opposite side of
u
unit
y
y
y

Utiliser l’anneau
U
u de levage uniquement
u
po
our
ssoulever l’appareil, NON PAS les chariots, les
b
bouteilles de ga
az ou tout autre accessoire.
U
Utiliser
un équiipement de levvage de capacité
ssuffisante pour lever l’appareil.
E utilisant de
En
es fourches de
d levage po
our
d
déplacer l’unité,, s’assurer que les fourches so
ont
ssuffisamment lo
ongues pour dépasser
d
du cô
ôté
o
opposé de l’app
pareil.
MOVING
M
PARTS can
cause
c
injury
y.
DES
D
ORGAN
NES
MOBILES
M
pe
euvent
provoquer
p
d
des
blessures.
b
y
y

Ke
eep away from moving parts su
uch as fans.
Ke
eep all doors, pa
anels, covers, and
a guards close
ed
an
nd securely in place.
Ha
ave only qualifie
ed persons remo
ove doors, pane
els,
co
overs, or guardss for maintenancce as necessaryy.
Re
einstall doors, panels, covers,, or guards whe
en
maintenance is finished and beffore reconnecting
input power.
S’abstenir de tou
ucher des orga
anes mobiles te
ells
MIGS
SONIC252S OWNER’S
O
MA
ANUAL

Allow cooling
c
period; fo
ollow
rated duty cyycle.
Reduce currrent or reduce duty
d
cycle before
e
starting to weld
w
again.
Do not block
k or filter airflow
w to unit
Prévoir une période de refro
oidissement ;
e nominal.
respecter le cycle opératoire
Réduire le co
ourant ou le faccteur de marche avant
de poursuivrre le soudage.
Ne pas obstruer les passag
ges d’air du postte.
H.F. RAD
DIATION can
n
cause intterference.
LE SOUD
DAGE À L’A
ARC
risque de
e provoquerr
des interrférences.
y
y
y
y
y
y
ncy (H.F.) can interfere with rradio
High-frequen
navigation, safety servicess, computers, and
communications equipmentt.
Have only qualified perssons familiar with
electronic eq
quipment perforrm this installatio
on.
The user is responsible forr having a qualified
electrician promptly
p
correcct any interfere
ence
problem resu
ulting from the installation.
If notified by
y the FCC abou
ut interference, stop
using the equipment at once
e.
nstallation regu
ularly checked and
Have the in
maintained.
Keep high-frrequency source
e doors and pa
anels
tightly shut, keep spark gap
ps at correct settting,
ounding and sh
hielding to minim
mize
and use gro
Ma
anual no: WM070101
Page4
4
the possibility off interference.
y
y
y
y
y
y
Le rayonnemen
L
nt haute fréque
ence (HF) peut
p
provoquer
des
s interférence
es avec less
é
équipements
d
de
radio-navig
gation et de
e
c
communication,
les services de
e sécurité et less
o
ordinateurs.
D
Demander
seu
ulement à des
d
personness
q
qualifiées
familia
arisées avec de
es équipementss
é
électroniques
de
e faire fonctionn
ner l’installation.
L
L’utilisateur
esst tenu de faire corriger
r
rapidement
parr un electricia
an qualifié less
in
nterférences réssultant de l’insta
allation.
S le FCC sign
Si
nale des interfé
érences, arrêter
im
mmédiatement l’appareil.
E
Effectuer
régu
ulièrement le contrôle et
l’’entretien de l’in
nstallation.
Maintenir soigne
M
eusement fermé
és les portes et
le
es panneaux de
es sources de haute fréquence,
m
maintenir
les éclateurs à une diistance correcte
e
MIGS
SONIC252S OWNER’S
O
MA
ANUAL
et utiliser une terre et un bliindage pour réd
duire
les interféren
nces éventuelles.
READ IN
NSTRUCTION
NS.
LIRE LES
S
INSTRUC
CTIONS.

Consult th
he Owner’s Man
nual for welding safety
precaution
ns.
Use only genuine
g
replacement parts
nuel d’utilisation
n avant d’utiliserr ou
Lire le man
d’intervenir sur l’appareil.
Utiliser uniquement des pièces de rechan
nge.
Ma
anual no: WM070101
Page5
5
1-3..
Safety Standard
ds Normes
s de sécurité
Safetyy in Welding, Cu
utting, and Allied
d Processes, AN
NSI
Standa
ard Z49.1, from Global Enginee
ering Documentts
(phone
e: 1-877-413-5184, website: ww
ww.global.ihs.co
om).
Code
e for Safety in Welding
W
and Cuttting, CSA Standard
W117.2, from Canad
dian Standards Association,
Stand
dards Sales, 17
78 Rexdale Boulevard, Rexdale
e,
Onta
ario, Canada M9
9W 1R3 (phone:: 800−463−6727
7 or in
Toronto 416−747−4044, website:
www
w.csa−internation
nal.org).
Safetyy in Welding, Cu
utting, and Allied
d Processes, AN
NSI
Standa
ard Z49.1, de Global
G
Engineering Documents
(téléph
hone : 1-877-413-5184, site Inte
ernet :
www.g
global.ihs.com).
Code
e for Safety in Welding
W
and Cuttting, CSA Standard
W117.2, de Canadia
an Standards Asssociation, Stan
ndards
Saless, 178 Rexdale Boulevard, Rexxdale, Ontario,
Cana
ada M9W 1R3 (téléphone : 800
0-463-6727 ou à
Toronto 416-747-4044, site Internett :
www
w.csa-internation
nal.org).
1-4..
EMF In
nformation
n EMF Infformation
n
Consid
derations Aboutt Welding And The
T Effects Of
Low Frrequency Electrric And Magnetic Fields
Weldin
ng current, as it
i flows through
h welding cable
es,
will ca
ause electro- magnetic
m
fields. There has bee
en
and still is some conccern about such
h fields. Howeve
er,
after e
examining more
e than 500 stud
dies spanning 17
years of research, a special
s
blue ribbon committee of
the Na
ational Researc
ch Council conccluded that: “The
body o
of evidence, in the committee
e’s judgment, has
not de
emonstrated tha
at exposure to powerp
frequency
electricc and magnetic fields is a human-health hazarrd.”
Howevver, studies are
e still going forrth and evidence
continu
ues to be exam
mined. Until the final conclusions
of the research
r
are rea
ached, you mayy wish to minimize
your exposure to elec
ctromagnetic fie
elds when welding
or cutting.
To red
duce magnetic fiields in the workkplace, use the
following procedures:
Consid
dérations sur le soudage et les effets de basse
e
fréquence et des cham
mps magnétique
es et électriques.
urant de soudag
ge, pendant son passage dans les
Le cou
câbless de soudage, ca
ausera des cha
amps
électro
omagnétiques. Il y a eu et il y a encore un certa
ain
souci à propos de tels
s champs. Cepe
endant, après avvoir
examin
ne plus de 500 études qui ont été
é faites penda
ant
une pé
ériode de recherrché de 17 ans,, un comité spéccial
ruban bleu du Nationa
al Research Cou
uncil a conclu : «
umulation de pre
euves, suivant le
e jugement du
L’accu
comité
é, n’a pas démontré que l’expossition aux champs
magné
étiques et champs électriques à haute fréquence
représente un risque à la santé huma
aine ». Toutefois
s,
udes sont toujours en cours et les preuves
des étu
continu
uent à être exam
minées. En attendant que les
conclu
usions finales de
e la recherché soient
s
établies, il
vous sserait souhaitablle de réduire vo
otre exposition aux
a
champ
ps électromagné
étiques pendantt le soudage ou le
coupag
ge.
1. Keep cables clo
ose together by twisting or tapin
ng
the
em.
2. Arrange
A
cables to one side and
d away from the
e
ope
erator.
3. Do not coil or drape cables aro
ound your body.
p
source an
nd cables as far away
4. Keep welding power
p
from operator as practical.
c
to work piece
p
as close to the
5. Connect work clamp
eld as possible.
we
Ab
bout Pacemake
ers:
Pa
acemaker weare
ers consult your doctor first. If clleared
by your doctor, the
en following the
e above procedu
ures is
reccommended
2. Dissposer les câble
es d’un côté et à distance de
l’opérateur.
e pas courber pas et ne pas en
ntourer pas les câbles
c
3. Ne
autou
ur de votre corp
ps.
4. Ga
arder le poste de soudage et le
es câbles le pluss loin
possible de vous.
onnecter la pincce sur la pièce aussi
a
près que
5. Co
possible de la soudu
ure.
n les sti mula
ateurs cardiaqu
ues
En ce qui concer ne
p
de stim
mulateur cardiaq
que doivent conssulter
Les porteurs
leur médecin
m
avant de
d souder ou d’’approcher des
opéra
ations de souda
age. Si le médeccin approuve, il est
recom
mmandé de suivvre les procédu
ures précédentes
Pour ré
éduire les cham
mps magnétique
es sur le poste de
d
travail,, appliquer les procédures
p
suivantes :
1. Main
ntenir les câbless ensemble en les tordant ou en
e
les envveloppant.
MIGS
SONIC252S OWNER’S
O
MA
ANUAL
Ma
anual no: WM070101
Page6
6
SECT
TION 2
PAC
CKING LIST
L
MigSoniic252S+SS2
20 package (Part
(
No: 07
7000340)
Desc
cription
Partt no
Quantity
MigS
Sonic252S Power
P
sourc
ce come witth 10 ft. (3 M) Power cord
c
and N
NEMA 6-50P
P 230V AC Plug
P
07000
0342
1
SS-20 wire feede
er
07000
0343
1
15 ft.. (4.6M) Weld
dKing® NT2
2-15E industtrial MIG torrch w/ .035-.045
in (0..9-1.2 mm) liner.
07000
0411
1
Argo
on Regulatorr / Gauge/ Flow meter
07000
0510
1
Wire feeder Link
k cord assem
mbly 10 ft (3
3M)
07001
1830
1
300 A
Amp ground
d clamp with
h 10 ft (3 M) lead
07000
0462
1
Owne
er’s Manual
07000
0417
1
Table 2.1
MIGS
SONIC252S OWNER’S
O
MA
ANUAL
Ma
anual no: WM070101
Page7
7
SECT
TION 3
INST
TALLATIONS
3-1. Welding
g power so
ource and
d wire feed
der specifiications
MigSonic
c252S powe
er source
Weld
ding Process
s
Powe
er supply
Phas
se
MIG/Fllux cored wirre Mig
200(208)V/230
0V
Single
Rated
d output
curre
ent(A)
250
Inputt Amps @
rated
d output(A)
50
Rated
d input (KW
W)
7.8
Open
n circuit
volta
age(V)
47
Amperage range
e(A)
50-300
Weld
ding voltage
e(V)
13.5-26.5
60%
%@250A /26..5V
Duty cycle (%)
@ 40
0℃
100
0%@200A /24V
Powe
er factor
0.72
Prote
ection class
s
IP23
Insullation class
H
Operrating
temp
perature (°C))
-20 to +40
+ (-4°F to 104°F)
1
Stora
age
temp
perature (°C))
-40 to +8
85 (-40°F to 185°F)
Mach
hine dimens
sion
(HxW
WxD) (CM)
47.5x24x43(18.7x9.4
4x17in)
Powe
er source
weight (KG)
Pack
king dimension
(HxW
WxD)(CM)
MIGS
SONIC252S OWNER’S
O
MA
ANUAL
19.5(43lbs)
63x38
8x50(25x15x2
20in)
Ma
anual no: WM070101
Page8
8
2
23.5(51.8lbs)
)
Pack
king
weight(KG)
Table 3.1
CA
AUTION!
WEL
LDING LONG
GER THAN RATED
R
DUT
TY CYCLE C
CAN DAMAG
GE GUN AND
D VOID
WAR
RRANTY.
SS--20 wire feed
der
Type
e of Input po
ower
24 Volts
V
DC Sin
ngle Phase 60
6 Hz
1.5-18(59
9-709ipm)
Wire Feed Speed
d Range(M/M
MIN)
0.6-1.2(0.0
023-0.045in)
Wire Diameter Range(MM)
R
IP
P23
Prote
ection class
s
27 (6
60lbs) coil
Max Spool Size Capacity(KG
C
G)
H
Insullation class
Operrating tempe
erature (°C)
- to +40 (--4°F to 104°F
-20
F)
Stora
age tempe
erature (°C)
-40 to +85 (-4
40°F to 185°F)
Dime
ension (HxW
WxD) (CM)
60x29x46(2
24x11x18in)
8.2(1
18lbs)
weight (KG)
63x30x50(2
25x12x20in)
Pack
king dimension (HxWxD
D)(CM)
8.5(18
8.7lbs)
Pack
king weight(KG)
Table 3.2
MIGS
SONIC252S OWNER’S
O
MA
ANUAL
Ma
anual no: WM070101
Page9
9
3-2. MIG torc
ch specifications
Mode
el
NT2-15E (Part no.070
000411)
Rated
d currency(A
A)
200A/CO2,150A/MIX
Rated
d Duty cycle
e (%)
60
Cool style
Air cooled
d
Wire diameter(m
mm)
0.6-1.2(0..023-0.045in
n)
Cable
e length(M)
4.6(15ft)
Conn
nection
euro conn
nection
Detailed
D
gun
n specification please see
e separate to
orch manual.
Table 3.3
MIGS
SONIC252S OWNER’S
O
MA
ANUAL
Ma
anual no: WM070101
Page1
10
3-3. MIG wellding conn
nection diagram
Mig
gSonic252S (208/230v in
nput)
Gauge
Cylinder
T gas regulator
To
Power cord
d
T main pow
To
wer
Contro
ol cable
Earth cable
Gas hose
MIG to
orch
W
Work
piece
Figure 3.1
MIGS
SONIC252S OWNER’S
O
MA
ANUAL
Ma
anual no: WM070101
Page1
11
AG Process/Polarity Table
3-4. MIG/MA
Process
Pola
arity
Cable Co
onnections
s
Cable To
o Gun
Cable To Work
GMAW
W－Solid wire
with shielding ga
as
DCE
EP –
Rev
verse
pola
arity
Connect to positive(+)
C
p
output terminal
Co
onnect to
negative(-)output term
minal
FCAW –
Self-sshielding wirreno sshielding gas
s
DCE
EN－
Stra
aight
Pola
arity
Connect to negative(-)
C
n
output terminal
Co
onnect to
positive(+))output term
minal
Table 3.4
3-5. Generall Installatio
on proced
dure for MIG/MAG
M
welding
w
3-5.1.Welding ma
achine should
d be installed in a stable
e position and
d with good ventilation.
v
A
Avoid
direct sun outdoors.
o
Avo
oid transport in invert or side
s
position.
achine is well grounded.
3-5.2.Be sure ma
m
or the machine
e idled for a period, che
eck the insulation
3-5.3.Before startting a new machine
resistance of
o circuit which is conne
ected to the network. Th
he resistance
e must be higher
than 2.5M Ω;
Ω otherwise the machine
e must be dried.
ower source and
a wire feed
d with the lin
nk cord provid
ded.
3-5.4.Connect po
able, wire, regulator,
r
cyylinder accorrding to connection diag
gram.
3-5.5.Connect torch, earth ca
Note: Connection hardw
ware must be
e tightened with
w proper to
ools. Do not just hands tig
ghten
hardware! A loose electtrical connecction will causse poor weld
d performancce and excesssive
heating at th
he terminal block.
b
t spool gun selection switch
s
locate
e inside drive
e motor comp
partment is set
s to
3-5.6.Make sure the
“Mig gun”. If this switch is set to “spo
ool gun”, the
e motor will not
n active when press the
e gun
trigger.
at-resistant PVC
P
hose connect the flow meter with
h the gas con
nnection nipp
ple at
3-5.7.Use Ф8 hea
rear of the wire
w feeder.
on the machine after the machine is installed and tested:
3-5.8. Commissio

Release the pressure roller in the wire feeder, push
R
p
the torcch switch, an
nd adjust voltage
switch from low to high, Open circuitt voltage sho
ould rise.
E
Evenly
adjust the current knob, the wire
w feed spee
ed should inccrease evenly.
3-6. How to Install the
e wire spool
3-6.1.Install a spo
ool of welding wire on the
e hub as folllows: Press the
t upper sid
de of spool case,
c
and then pu
ull the latch to
t open the cover.
c
Unscrrew spool nu
ut from hub. Place wire spool
s
on hub to ro
otate clockwiise as wire iss unwound; hub
h pin mustt engage hole in spool. In
nstall
spool nut.
3-6.2.The drive ro
oll has two grooves;
g
the small groove
e feeds 0.03
35 in. diamete
er wire, the large
groove feed
ds 0.045 in. wire.
w
The gro
oove nearestt the gear mo
otor feeds the
e wire.
3-6.3.Release pre
essure drive
e roll assemb
bly and lift upward.
u
Check that prop
per wire diam
meter
MIGS
SONIC252S OWNER’S
O
MA
ANUAL
Ma
anual no: WM070101
Page1
12
groove is in the inner po
osition. Feed the wire from
m the spool th
hrough the in
nlet guide, accross
d into gun ou
utlet guide. Lo
ower pressures roll assembly and seccure.
the drive rolll groove and
Check that the gears me
esh. Feed wire through to
o torch tip ussing the torch
h trigger.
Press down
P the latch
Pull
Figure 3.2
3-7. How to Adjust
A
wirre feed pre
essure
Make
e sure that th
he wire move
es smoothly through the wire guide. Then set the
e pressure of
o the
wire ffeeder’s presssure rollers.. It is importa
ant that the pressure
p
is no
ot too high. Feed
F
out the
e wire
again
nst an insulatted object, e..g. a piece off wood. When you hold th
he gun appro
ox. 5 mm from
m the
objecct, the feed ro
ollers should
d slip. When hold the gua
an approx. 50
0mm from the object, the
e wire
shoulld be fed outt and band. Now
N
the presssure is properly set. See
e Figure 2.3.
Figure 3.3
MIGS
SONIC252S OWNER’S
O
MA
ANUAL
Ma
anual no: WM070101
Page1
13
3-8. How to Install spo
ool gun(op
ptional)
MigS
Sonic252S use
u
WeldKing® SpoolK
King-24DL (Part no. 07NS1010)
0
o
only.
Use other
o
mode
el may not work
w
properrly.
3-8.1.Connect sp
pool gun to tthe euro recceptacle. Con
nnect contro
ol cable to control recep
ptacle
located at frront penal off SS20 wire feeder.
f
s
gun se
election switc
ch to “spool gun”
g
selectio
on(see figure 3.4)
3-8.2.Toggle the spool
a commisssion accordin
ng to spool gun
g instructio
on manual.
3-8.3.Install wire and
Spoo
ol gun selecttion
switch
Figure 3.4
3-9. Electric service guide
g
CA
AUTION!
WAR
RNING: THIS
S WELDING MACHINE MUST
M
BE CO
ONNECTED
D TO POWER
R SOURCE IN
ACC
CORDANCE WITH APPL
LICABLE EL
LECTRICAL CODES
AVERTISSEMEN
NT: LE RACCORDEMEN
NT DE CETT
TE MACHINE
E DE SOUDA
AGE Á
L’AL
LIMENTATIO
ON DOIT ÉTR
RE CONFOR
RME AUX CODES D’ ÉL
LECTRICITÉ
É PERTINEN
NTS
Inputt voltage(V)
208
23
30
Frequ
uency(Hz)
60
60
0
Inputt Amperes at
a rated
outpu
ut(A)
41
37
7
Circu
uit breaker, time
t
delay
45
40
0
Norm
mal operatio
on
55
50
0
Max recommend
ded
stand
dard fuse Ra
ating in
Amp
MIGS
SONIC252S OWNER’S
O
MA
ANUAL
Ma
anual no: WM070101
Page1
14
Min input condu
uctor size
in AW
WG
8
8
Min G
Grounding conductor
c
Size in AWG
10
10
0
Table 3.5
MIGS
SONIC252S OWNER’S
O
MA
ANUAL
Ma
anual no: WM070101
Page1
15
3-10
0. Extensio
on Weldin
ng Cable Selection
S
C
Chart
CAU
UTION!
U
USE
SHORT
TEST CABLE
E POSSIBLE
E
Welding Amperes (A
A)
100
150
1
200
Cable Size
S
(AWG)
Maximum Cable Leng
gth
a
allowed in Weld
W
Circuitt* (Ft)
<=10
00 (30 m)
4 (20mm2
2)
3 (30
0 mm2)
3 (30 mm2
2)
150
0 (45 m)
4 (20 mm2
2)
2 (35
5 mm2)
1 (50 mm2
2)
200
0 (60 m)
3 (30 mm2
2))
1 (50
0 mm2)
1/0 (60 mm
m2)
* The
e Cable Leng
gth in Weld Circuit
C
is totall of both weld
d cables and
d earth cables.
Table 3.6
3
3-11. 9-pin sp
pool gun connection
c
n receptac
cle
Gree
en
Red
Brow
wn red
Yellow
w
Blue
Figure 3.5
Soc
cket pin
Notes
Fu
unction
1
Spool gun motor
m
(-)
2
Not used
3
Not used
4
Spool gun motor
m
(+)
Red
5
Spool gun C.C.W
C
potenttiometer(3)
Brow
wn red
6
Spool gun C.W
C
potentiom
meter(1)
Blue
7
Spool gun wiper
w
potentio
ometer(2)
Yello
ow
MIGS
SONIC252S OWNER’S
O
MA
ANUAL
Gree
en
Ma
anual no: WM070101
Page1
16
8
Not used
9
Not used
3
Table 3.7
3-12
2. 7-pin lin
nk cord rec
ceptacle
Figure 3.6
Soc
cket pin
Notes
Fu
unction
1
Drive motor ground
Blackk
2
Solenoid vallve ground
3
Mig gun swittch
4
Voltage and wire feeding
g speed signa
al
5
Common gro
ound for voltage, wire fee
eding speed
signal and gun switch
6
Power supplly to drive mo
otor and sole
enoid valve
7
To purge sw
witch
2.5V--24V DC
referrence to pin 1
+24V
V DC referen
nce
to pin
n1 and pin2
Table 3.8
MIGS
SONIC252S OWNER’S
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MA
ANUAL
Ma
anual no: WM070101
Page1
17
SE
ECTION 4
4-1.
1
OPERATIO
ON
Power source
s
pa
anel layout and desc
cription
2
3
4
5
6
7
1. We
elding voltage meter (digital)
play indicatio
on light
4. Current disp
2. We
elding curren
nt/wire feedin
ng speed
meter (digital)
5. Power indication light
ndication ligh
ht
6. Protection in
3. Wire feeding sp
peed displayy indication
light
7. Inductance adjustment knob
k
MIGS
SONIC252S OWNER’S
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MA
ANUAL
Ma
anual no: WM070101
Page1
18
12
11
8
9
10
egative outpu
ut (Earth clam
mp)
8. Ne
conne
ection
10
0. Positive ou
utput (to wire
e feeder)
11. Power cord
d
9. 9 p
pin control co
onnection (to
o wire feeder)
12
2. Main switc
ch
Figure 4.1
MIGS
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MA
ANUAL
Ma
anual no: WM070101
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19
4-2.
SS-2- wire
w
feederr panel lay
yout and descriptio
d
on
1
2
4
3
1. We
elding voltage adjustmen
nt knob
3
3. Jog toggle switch
2. We
elding curren
nt/wire feedin
ng speed
adjusstment knob
4
4. Purge togg
gle switch
7
5
8
6
9
5. Sp
pool gun conttrol connectio
on
8
8. 9 pin contrrol connection (to power
ssource)
6. MIG torch euro
o connection
9
9. Positive input (to powe
er source)
7. Ga
as inlet
Figure 4.2
MIGS
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Ma
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Page2
20
4-3.
Operatiion
USE SING
GLE PHASE 208/230V
V POWER SU
UPPLY.
4-3.1.Switch on th
he power sou
urce.
4-3.2.Set the weld
ding voltage knob to prop
per position and
a wire feed
d speed knob to a start value
v
and refine during
d
weldin
ng( referring to
t the voltage/wire feedin
ng speed selection chart))。
4-3.3.The display
y value of digital voltage meter
m
will cha
ange when you
y turn the voltage
v
knob
b to
pre-set the welding
w
volta
age. And during welding, the voltage meter will reflect actua
al
welding volttage. The dissplay value of
o digital currrent meter wiill change wh
hen you turn the
wire feed kn
nob to pre-se
et the wire fe
eed speed. The feeding speed
s
light will
w illuminate
indicating th
he meter is displaying
d
wirre feeding sp
peed in inche
es per minute
e. The curren
nt light
will illuminatte and current meter will reflect actua
al welding cu
urrent during welding.
uctance) kno
ob to a start value
v
according to the vo
oltage/wire fe
eeding
4-3.4.Set the Arc control (indu
speed selec
ction chart yo
ou can adjusst the knob du
uring welding
g to obtain best result.
Inductance is the rate off current resp
ponse to a change in currrent. What th
his means iss that
w
with a short arc you
y can adjust how fast current
c
is app
plied to the shorts.
s
when MIG welding
The less ind
ductance you
u have the crrisper the arcc will appearr and the wire
es will start easier.
e
This will also make the bead
b
taller an
nd narrower.. More inducttance will ma
ake the arc appear
a
h a flatter wid
der appearan
nce and if too
o much is used, wires will stumble during
"softer" with
starts. Typiccally when sh
hort arcing steel only a litttle inductanc
ce is used in
n order to gett a
crisp arc. Lo
ow thermal conductivity
c
materials
m
succh as stainles
ss need morre inductance
e to
get accepta
able wetting when
w
short arcing.
a
eed set on Wire
W Speed co
ontrol
4-3.5.Push up “jog” switch to momentarilyy feed welding wire at spe
as valve. Pus
sh up “purge”” switch to
without energizing welding circuit or shielding ga
y energize ga
as valve to purge
p
air from
m gun or adju
ust gas regulator.
momentarily
e gas valve, adjust
a
gas vo
olume to 3-5L
L/MIN. Presss the torch sw
witch check ifi wire
4-3.6.Turn on the
feed and ga
as is normal, check if therre is gas leakking.
p nozzle 8-12
2mm above the
t work piec
ce, and tilt 10
0-20 ˚ to verttical
4-3.7.Hold the torrch and keep
direction. Aim wire to the
e welding se
eam.
s
evenlyy while keepin
ng the
4-3.8.Press torch switch, afterr arc is ignited, move the torch along seam
welding para
ameter to obttain exquisite
e welding seam. Release
e the
stick-out. Fine tune the w
h to finish a welding
w
cycle
e.
torch switch
o
tu
urn off the ga
as valve, loosse the pressu
ure handle att wire feederr,
4-3.9.After finish operation,
press torch switch to cle
ear the residu
ual gas in the
e regulator. At
A the end, tu
urn off weldin
ng
power sourc
ce and wall switch.
s
MIGS
SONIC252S OWNER’S
O
MA
ANUAL
Ma
anual no: WM070101
Page2
21
4-4.
Voltage
e/Wire spe
eed selecttion chart
- : setting not recommend
ded.
T
The setting in
n the followin
ng chart is jusst for start on
nly and can be
b fine tune during
d
weldin
ng.
6
6.5(Wire feed
d speed∅)/4.5(Voltage “V
V”)/7.5(Inducttion)
Po
olarity setting: DC
CRP(wire positive); Shield gas for steel:
s
80% Ar, 20
0%CO2. Stainlesss
ste
eel and Al: 100%
% Ar.
MIG/MAG
G WELDING
Materiaal
Steel
S
Solid
ER70S-6
Wire typpe
Flux core E71T-1
1
Stainless steeel
Aluminum
ER
R308,ER308L,ER
R 308LSi
ER4043
Wire size (in)
(mm)
0.023”
0.6
0.035”
0.9
0..045”
1.2
0.023””
0.6
0.035”
0.9
0.045”
1.2
0.02
23”
0.6
6
0.035”
0.9
0.045”
1.2
0.035”
0.9
0.04
45”
1.2
2
1/2” (12.7mm)
-
-
4.5
5/7.5/9
-
-
-
-
-
-
-
-
3/8” (9.5m
mm)
-
5.5/6.5/9
3.5
5/6.5/9
-
-
2
2.5/6/9
-
5.2/6.2/9
9
3.2/6.2/9
5
5.1/6.3/8
3.1/6..2/9
1/4” (6.4m
mm)
-
4.5/5.5/7.5 3.5//5.5/7.5
-
3/16” (4.8mm) 6.5/4.5/7.5 3.5/4.5/7.5 2.5//4.5/7.5
5/4/7.5
5
1/8” (3.2m
mm) 5.5/4.5/7.5 3.5/4.5/7.5 2.5//4.5/7.5 4.5/4/7..5
3.5/5.2/7 2.5
5/5.3/7.5
-
4.3/5.3/7..5 3/5.2/7.5 4.2/5.2/7.5 3.1/5..2/7
2.5/4/7
1.5
5/4.2/7.5
6/4.2
2/7
3.3/4.3/7
7
2.3/4.2/7 3.2/4.1/7.5 2.1/4..2/7
2.5/4/7
1.5
5/4.2/7.5
5/4.2
2/7
3.2/4.3/7
7
2.3/4.3/7
3
3/4.2/7.
2.1/4..2/7
4/3
3/4
2.2/3.3/5
5
2.2/3.3/5
2
2.1/3.2/5
2.1/3..2/5
3.2/3
3.4/3
2.2/3.3/4
4
2.2/3.3/4
-
-
14ga. (2.0mm)
4.5/3.5/5
2.5/3.5/5
2.5
5/3.5/5
3.5/3.2//5
1.5/3/5 1.5
5/3.2/5
16ga. (1.6mm)
3.5/3.5/4
2.5/3.5/4
2.5
5/3.5/4
2.5/3.3//4
1.5/3/4
-
18ga. (1.2mm) 3.5/3.5/2.5 2.5/3.5/2.5 1.5//3.5/2.5
-
-
-
3.2/3.4
4/2.5 2.3/3.5/2..5
1.3/3/2
-
-
20ga (0.9m
mm) 2.5/2.5/1.5 1.5/2.5/1.5
-
-
-
-
2.3/2.5
5/1.5 1.3/2.5/1..5
-
-
-
-
-
-
-
2.2/2.5
5/1.5
-
-
-
22ga. (0.8mm) 2.5/2.5/1.5
-
-
Table 4.1
MIGS
SONIC252S OWNER’S
O
MA
ANUAL
Ma
anual no: WM070101
Page2
22
SECTIO
ON 5
5-1.
Genera
al trouble s
shooting
N
No.
1
TROUBLE SHOO
OTING
Problem
Ca
ause
Solu
ution
P
Power
Indicattion lamp doe
es not on
Loose con
ntact at
Check co
ontact
affter switch on the main switch
input lead
d
situation
Lamp mallfunction,
Check co
ontact
poor conta
act
situation.
Replace lamp
Main switcch
Check sw
witch,
malfunctio
on
replace iff
necessarry
2
C
Cooling
fan
Power indication
Cooling fa
an circuit
sttops to rotate
e
lamp on
o
malfunctio
on
affter machine
e
Cool fan failure
f
Check fan circuit
Check fan,
has worked a
replace iff
period
necessarry
Power indication
See No. 1
lamp off
o
11
10
O
Overheat
light on
P
Power
supplyy switch jump
p
Work exce
ess the
Use unde
er rate
rate duty circle
c
duty circle
e
Input volta
age is too
Use unde
er rate
high
input volttage
Rectifier short
s
circuit
Check an
nd
replace
MIGS
SONIC252S OWNER’S
O
MA
ANUAL
Main transsformer
Check an
nd
short circu
uit
replace
Ma
anual no: WM070101
Page2
23
Control tra
ansformer
Check an
nd
short circu
uit
replace
Solenoid valve
v
short
Check an
nd
circuit
replace
Cooling fa
an short
Check an
nd
circuit
replace
Table 5.1
5-2.
GMAW//FCAW we
elding trou
uble shoo
oting
N
No.
3
Problem
Cause
Solutiion
No
N gas flow out
o after
Gas prressure not enough
e
Check gas pressure
p
pushing the gun trigger
Poor gas hose connection
Check gas
connection
Gun triigger failure
Check gun trigger
t
Soleno
oid valve failu
ure
Check and replace
r
Solenoid valve
Gas pa
assage probllem
Check and repair
r
the gas passsage
Torch gas
g hose pro
oblem
Check and repair
r
torch cable
Contro
ol circuit failure
Replace circcuit
board
4
Contro
ol transformer failure
Replace tran
nsformer
Failure of arc to ignite or
Fuse melt
m or poor contact
c
Check and repair
r
does not ignite properly
Main power
p
switch failure
Check, repa
air,
MIGS
SONIC252S OWNER’S
O
MA
ANUAL
Ma
anual no: WM070101
Page2
24
replace
Contro
ol circuit boarrd failure
Check and repair
r
the circuit bo
oard
Weldin
ng cable brokken or
Check the
poor co
ontact
connection
Gun triigger wire broken
Replace cab
ble
Gun ca
able broken
Replace cab
ble
Voltage
e adjustmentt knob
Check, repa
air,
failure or poor conttact
replace
Contro
ol transformer failure
Check, repa
air,
replace
5
Unstable
U
arc
Main trransformer fa
ailure or
Check, repa
air,
poor co
ontact
replace
Gas ho
ose not insta
alled
Connect the
e gas
properly, gas mixed
d by air
hose firmly
Gas no
ot pure
Changes ga
as
Wire lin
ner or gun ca
able
Check, repa
air,
broken
n and leak ca
ause
replace
insufficcient gas volu
ume.
Wire pressure not setup
s
Adjust presssure
properly
Wire fe
eed speed no
ot stable
See No.9
Contro
ol circuit failure
Check, repa
air,
replace circu
uit board
Gas he
eating failure
e
Check 20A Fuse,
repair, repla
ace
the work piece surfface
Clean the workpiece
w
contam
minated by oiil
surface
Poor contact inside
e the gun
Check, repa
air,
replace
6
7
Arc
A ignited bu
ut the wire do
oes
Rectifie
er tube failurre
Check, repla
ace
not melt
Outputt reactor failu
ure
Check, repla
ace
Outputt capacitor fa
ailure
Check, repla
ace
Wire
W does nott feed while the
t
Wire pressure not proper
p
Adjust presssure
fe
eed roller is rotating
r
Wire lin
ner or contacct tip
Check, repa
air,
jamme
ed
replace
Used wrong
w
groove
e at the
Use the righ
ht groove
feeding
g roller
MIGS
SONIC252S OWNER’S
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MA
ANUAL
Ma
anual no: WM070101
Page2
25
8
Cannot
C
stop the
t gas
Soleno
oid valve
Check, repa
air,
contam
minated
replace sole
enoid
Contacctor failure
Check, repla
ace the
contactor
Contro
ol board failurre
Check, repa
air,
replace
9
Wire
W feeding not stable
Wire out of feeding
g roller
Put wire bacck
groove
e
Wire fe
eed pressure
e not set
Adjust presssure
properly
Feedin
ng roller defo
ormed
Check and replace
r
Pressu
ure roller defo
ormed
Check and replace
r
Feedin
ng motor failu
ure
Check and replace
r
Curren
nt adjust pote
ential
Check and replace
r
meter failure
f
Circuit board plug socket
s
Check and repair
r
or
not pro
operly contaccted
replace
Contro
ol circuit failure
Check and repair
r
or
replace
Weldin
ng hose deformed
Check and replace
r
Input voltage
v
fluctu
uated
Use under rated
input voltage
e
Table 5.2
MIGS
SONIC252S OWNER’S
O
MA
ANUAL
Ma
anual no: WM070101
Page2
26
SECT
TION 6
6-1.
MAIINTENAN
NCE
Mainten
nance
Perio
odic maintena
ance is nece
essary for kee
eping the ma
achine work properly.
CAU
UTION!
DISC
CONNECT POWER
P
INPU
UT AND SW
WITCH OFF THE MAIN POWER SW
WITCH BEFORE
STAR
RT OF MAIN
NTENANCE.
Regu
ular Check and
a Inspectiion
Powe
er source
Wirre feeder
• Che
eck the functtion of all sw
witches.
•T
The pressure of the wire feeder’s
f
presssure
ro
ollers must be
b set properrly.
• Che
eck if the fan
n rotates prop
perly and if there is
air venting out from
f
back of the machine
e.
• Payy Attention to
o the abnorm
mal vibration, noise,
sme
ell and gas le
eakage durin
ng operation.
• Che
eck if the we
elding cables are over hea
ated.
• Che
eck if the cab
ble connectio
ons are over
hea
ated?
• Che
eck if the cab
ble is conneccted firmly an
nd
pro
operly, if it is broken
b
and cause
c
bad
insu
ulation?
• Che
eck the cove
er grounded properly
p
• Iff metal chips or dust pile up between the
guide tube an
nd feeding ro
oller, clean an
nd check
iff the feeding tube diameter is proper and
a is
aligned with the center of the feeding roller.
A
Also
check if the feeding roller
r
groove is same
as the wire diameter and if there are objects
o
in
nside groove
e.
•C
Check pressu
ure roller rollss smoothly and
a if it
has been worrn out.
•C
Check if straig
ghtening rolle
er it has bee
en
contaminated
d by oil, dust or metal chip
ps.
Table 6.1
Regu
ular Check and
a Inspectiion
MIG torch
t
Cab
ble
• Cle
ean spatter in
nside the nozzzle when
con
ntinuously usse the machin
ne.
• Check
C
if the welding
w
cable
es are over heated.
h
• Che
eck liner freq
quently, chan
nge if it has been
b
con
ntaminated by
b oil, deform
med or worn out.
o
• Che
eck and chan
nge broken or
o deformed
con
ntact tip and nozzle to avoid damage to the
torcch and mach
hine.
•C
Check if the cable
c
connecctions are over
heated?
•C
Check if the cable
c
is conn
nected firmly and
properly, if it is broken and
d cause bad
in
nsulation?
Table 6.2
MIGS
SONIC252S OWNER’S
O
MA
ANUAL
Ma
anual no: WM070101
Page2
27
6 Month Routine Maintenance
e
6 Mo
onth Routine
e Maintenance
• Blo
ow out with dry clean presssure air or vacuum
v
insid
de machine, especially
e
tra
ansformer co
oil and
pow
wer compone
ent.
• Che
eck the electtric connectio
on of input/output bar to avoid
a
bad co
ontact caused
d by loose or rusted
scre
ew.
• Che
eck the conta
actors and re
elays in the machine
m
or on
o the PCB work
w
properly
y.
• Che
eck the lubriccation of the gear box in the feeder, replace
r
or fill lubricates oil
o if necessarry.
• Che
eck and clea
an the oil or other
o
contam
mination in the
e feeding roller and feediing tube. If th
he V
gro
ooves have worn
w
out chan
nge feeding roller immed
diately to avo
oid slipping or unstable fe
eeding
Table 6.3
6-2.
Safety precautio
p
n
6-2.1.Welders mu
ust be equip
pped with welding
w
maskk, gloves an
nd tie the sle
eeves and collar
c
properly. Us
se Table 6.4 to choose proper
p
glass shade, also can referenc
ce to ANSI Z49.1
Z
listed in Saffety Standarrds. There sh
hould be an arc shield arround weldin
ng field to prrotect
others from arc shock.
d near flamm
mable, explossive materialss or gases.
6-2.2.Do not weld
er must be located at a sa
afe and stead
dy place to avoid
a
injury others.
o
6-2.3.Gas cylinde
othing away from the rota
ating fan.
6-2.4.Keep fingerr, hair and clo
s
mustt be grounded when weld
ding.
6-2.5.The power source
w protection light is enlig
ghtened durin
ng welding, it
i is indicating that the we
elder
6-2.6.When yellow
is over currrent or overr heat, and automatic
a
protection will be triggere
ed. Stop we
elding
immediately
y and wait un
ntil welder co
ool down.
achine should
d not work in
n a flammable and toxic environmentt, avoid moissture,
6-2.7.Welding ma
rain, and do
o not directly expose to sun.
elder during welding!
w
6-2.8.Do not switcch off the we
y maintain the
e machine an
nd clean the dust inside.
6-2.9.Periodically
Lens
s Shade Sele
ector Guide
Operation
n
/Process
s
Gass metal arc welding
w
(GM
MAW) and flu
ux cored
arcc welding (FC
CAW)
Arc Currrent
(Amperres)
Minimum
m
Protective Shade
P
Sug
ggested* Sh
hade
No.
N (Comforrt)
L
Less
than 60 60−160
160−25
50
250−55
50
7
10
10
10
—
11
12
14
Table 6.4
MIGS
SONIC252S OWNER’S
O
MA
ANUAL
Ma
anual no: WM070101
Page2
28
SECTION 7
7-1.
PA
PARTS
LIIST
MigSonic252S Power
P
Sou
urce
Item
m
Order No
o.
D
Description
Note
Qty
1
7.305.132
2
Shunt
FL-1 75mv 300A
A short
1
2
8.055RM.227-CA
Bottom plate
MIG 250F-1
2
c/w
(S.004
4RM.227)
1
3
8.065RM.078-B
Front output panel
p
MIG 250F-1
2
c/w
(S.004
4RM.227-CA
A）
1
4
8.069.004
4
Front panel
Lincoln(arcweld 25
50i-ST
DV）c
c/w(3.111.004
4）
1
5
7.152.312
2-A
Quick
Q
co
onnector/Fem
male(zhengyyun)
CX58 35-70MM
2
6
7.132.055
5
7 pin receptaccle
YD20K
K7Z(black）
1
7
7.458.220
0-R
K
Knob
2004-3
3(ID20)(KNO
OBS
ERIES
S）(black/red
d with red
needle
e white line)
1
8
8.306RM.152
C
Control
panel
S.00R
RRM.227-CA control
penal
1
9
W.496RM
M.135-G
Front panel
Base board:B.067
b
RM.135-G
1
10
8.301RM.229
C
Cover
MIG-3
315F c/w 3.00
04RM.229
1
11
8.253.035
5
H
Handle
lincoln
n（arcweld 250i-ST
2
DV）c
c/w(3.111.004
4）
1
12
W.496RM
M.142-C
MIG250/315/3
M
350F power
PCB
Base board(B.067
b
RM.142-C)
1
13
8.123RM.052
Seal box
MIG-2
250 c/w 3.004
4RM.204
1
14
8.124RM.227-CA
Separating pla
ate
MIG 315F
3
1
15
8.123RM.904
Supporting pla
ate
Nylon c/w 3.004RM
M.203
3.004R
RM.204
1
16
8.422RM.054
IG
GBT heat sin
nk(1)
168*61*44 (section bar
7.800..063） c/w
3.004R
RM.206
1
MIGSONIC252S OWNER’S MANUAL
M
M
Manual
no: WM070101
W
Page
e29
17
7.425RM.001
Single IGBT
FGH60N60SMD
8
18
7.411.010
0
R
Rectifier
bridg
ge
GBPC
C5010(plug tyyple)
2
19
7.231.061
1
Thermostat (cconstant open)
TH-B2
2D75̊-K（c/w metal press
plate ）（SY）
2
20
7.155.021
1
C
Cable
brackett
M2012
2B6-12
1
21
7.205.212
2
C
Circuit
breake
er
DZ47--60-2P
UL.SJ00W 12/3AW
WG (300V)
105/XN650P-A plu
ug
UL322
2682 Cable
UL313
3867,3.3M
D6
63A/(60A)
1
22
7.154.438
8-G
Power cord with
w plug
23
8.123RM.064
C
Circuit
breake
er bracket
24
8.068RM.227
R
Real
penal
MIG 250F-1
2
c/w
（S.00
04RM.227）
1
25
8.304RM.004
Fan mesh
92 fan
n mesh.123*1
100*58.5
with trrench. c/w
(3.004
4RM.206)(3.0
004RM.207)
2
26
7.720.280
0-A
fa
an
3610S
SB05WB60EOO cable
length 300（XinW
Wei）
2
27
5.496RM.091-B
D
Drive
PCB forr MIG250S
Base board
b
（8.067
7RM.091-B） 1
28
8.713RM.204
In
nsulator
0.3 po
olyester film 162.3*249
1
（MIG
G-250）
1
29
5.496RM.059-A
M
MIG250
MUR
R PCB
Base board
b
8.067R
RM.059-A
1.6*17
70*121mm PCB
4
30
8.423RM.007
M
MUR
heat sink(1)
168*61*44（7.800
0.064）
6
31
8.422RM.055
IG
GBT heat sin
nk(2)
64.5*6
61*44 （section bar
7.800..063） c/w
3.004R
RM.206
1
32
7.421.690
0
Fast restore diode
d
STTH6
60P03SW
8
33
8.423RM.008
M
MUR
heat sink(2)
168*61*44（7.800
0.064）
1
34
8.422RM.056
IG
GBT heat sin
nk(3)
76.5*6
61*44 （section bar
7.800..063）c/w 3.004RM.206
1
M
galvan
nized sheet 1.0
1
3.004R
RM.206
M
Manual
no: WM070101
W
c/w
1
1
Page
e30
35
6.185RM.206
M
Main
transform
mer
MIG-2
250S c/w 3.00
04RM.206
1
36
7.321.130
0
in
nductor
270mm
m length with
h cable
0.3sq mm 200roun
nd
1
37
6.271RM.203
in
nductance
MIG-2
250 c/w 3.004
4RM.023
3.004R
RM.204
1
38
7.731.031
1
C
Control
transfformer
220V input, 36V ou
utput(50W)
1
39
W.496RM
M.387
Push-pull gun
n/spool gun
se
election PCB
B, 3
fu
unction,50V power
p
supplyy
Base board
b
1
B.06
67RM.387
Table 7.1
M
M
Manual
no: WM070101
W
Page
e31
Figure 7.1
M
Manual
no: WM070101
Page
e32
7-2.
Item
m
SS-20 Wire feed
der
Orde
er No.
1
Descriiption
R
Right
side pla
ate
8.051RM.901-CA
2
Qty
S.054RM..901-CA rig
ght side
plate
1
H
Hinge
2
7.686.048
8
3
CL219-3 black
b
matt(ou
ubao)
L side platte
Left
S.054RM..901-CA
plate
8.050RM.901-CA
4
le
eft
side
L
Latch
5
MS725-2 electric cabin
net lock
T
Toggle
switch
R13 12A 125VAC 6A 250VAC
2*2
7.227RM.001-A
6
1
1
7.686.300
0
1
W.496RM
M.364
MIG250F-1
M
push/pull
t
torch
convertt PCB
Base plate
e：B.067RM
M.364
Solenoid va
S
alve attach
p
plate
Box style
e wire feeder(c/w
S.054RM..901-CA）
1
8.123RM.220
1
7.253.014
4
S
Solenoid
valv
ve
Model:YG
G2T-2,working
g
pressure:0
0-0.8MPa,po
ower
supply:DC
C24V(gas inle
et φ8）
1
M
Middle
separrating plate
S.054RM..901-CA
separating
g plate
middle
8.124RM.901-CA
1
8.069RM.906-D
F
Front
panel
Box
styyle
wire
feeder
（ S.054R
RM.901-CA ） front
penal
7.456.905
5
c
carbon
poten
ntiometer
RV24YN/2
20S B502（T
TOCOS）
C
Control
Pane
el
Box
style
wire
feeder(c/w
wS.054RM.901-CA）
1
8.123RM.221
2
7.458.360
0-R
K
Knob
2004-1（e
extra largeφ
φ36*23）
(black/red with nee
edle and
white line))
7.227.017
7
T
Toggle
switch
h
R9-32B/2A
A250V 1×2
7.132.009
9
9 pin recepta
acle
WEIPU
SERIES CE
C
7.667RM.203-A
E
Euro
torch co
onnection
Box
styyle
S.054RM..901
7.510RM.001
Insulation flange
MIG160R
7
8
9
10
11
Note
12
13
1
14
2
2
15
16
SP
P2112/S9
wire
feeder
17
1
1
1
M
plastic ABS
A
M
Manual
no: WM070101
W
Page
e33
18
feeder
1
C
Connection
bar
b
Box
styyle
S.054RM..901
wire
8.177RM.203-A
feeder
1
W guide tu
Wire
ube
Box
styyle
S.054RM..901
wire
8.178RM.203-A
8.462RM.030
WEIPU
W
locking nut
M21*1 S2
27
8.940.001
C
Copper
nut
M10×1
8.123RM.920-A
Euro conne
E
ector attach
p
plate
ABS with attach hole
7.682.112
2
c
caster
2#Polyure
ethane, brow
wn red
1
C
Caster
attach
h plate
Box
styyle
S.054RM..901
feeder
8.123RM.176
1
8.713RM.207
Insulation film
m
Single driive motor in
nsulation
film 50*1
110, heat resistant
polyester filmδ0.3
8.712.002
2
Insulation sle
eeve
Φ22/Φ10.2
7.662.801
Insulation cap
JYM
7.710.887
7
M
Motor
76YZ01 c/w 0.9-1.2 wire
feeding rroller, motorr at left
side
7.132.507
7
7 pin recepta
acle
YD20K7Z(black）
7.152.312
2-A
Quick
Q
connector
f
female(zheng
gyuan)
CX58 35-7
70MM
7.682.012
2
W
Wheel
2#Polyure
ethane, brow
wn red
8.123RM.177
W
Wheel
attach
h plate
Box
styyle
S.054RM..901
8.055RM.901-CA
B
Bottom
plate
S.054RM..901-CA botttom PCB
7.803.002
2
E
Europe
spoo
ol box
Nanjing Dingrui 2 HOL
LE
7.803.203
3
E
Europe
spoo
ol axle
Nanjing Dingrui 2 AXL
LE
7.626.204
4
H
Handel
cover
Nanjing Dingrui 651
19
20
receptacle
1
21
1
22
1
23
2
24
25
wire
26
2
L=15mm
27
2
28
29
30
1
1
1
31
2
32
wire
feeder
33
1
1
34
1
35
1
36
1
M
M
Manual
no: WM070101
W
Page
e34
37
8.303RM.901
M
Middle
separrating plate
Box
styyle
S.054RM..901
8.068RM.901-CA
R
Rear
plate
S.054RM..901-CA
PLATE
7.941.009
9
N
Nut
GB/T6170
0 M12
8.462.641
G inlet
Gas
GT-2000
38
wire
39
feeder
1
REAR
1
1
40
1
Table 7.2
M
M
Manual
no: WM070101
W
Page
e35
Figure 7.2
M
Manual
no: WM070101
Page
e36
7-3.
Wire driving sys
stem
Mod
del 60/76ZY-0
01 with brackket.
Figure 7.3
ITEM
M
DESCRIPTION
N
OR
RDER NO
QUANTIT
NOTE
60/76ZY01 servo mo
otor
1
Motor
82
2010019
1
2
Handle assembly
a
06
603033
1
3
Pressure
e roller assem
mbly
06
603035
1
4
Inlet wire
e guide
06
603019
1
5
Hex nut
19
911019
1
6
Outlet wiire guide
04
400093
1
7
Press kn
nob
06
603016
1
M
M
Manual
no: WM070101
W
Page
e37
8
Drive roller
15
507xxx
1
9
connection sleeve
06
603015
1
10
Insulation sleeve
06
603022
2
11
Bracket
06
603031
1
12
Torch
06
603017
1
conne
ection
Default0.9//1.2(0.035/0..045)
bl
Table 7.3
Drive
e roller selecction
ITE
EM
DES
SCRIPTION
ORDE
ER NO
NOTE
1
V groov
ve (0.9/1.2m
mm)(0.035/0.0
045)(default))
0726
61030
For solid wiire
2
V groov
ve (0.6/0.8m
mm)(0.023/0.0
030)
0726
61031
For solid wiire
3
Knurled
d groove (0.9
9/1.2mm)(0.0
035/0.045)
0726
61032
Fo
or flux cored wire
4
U groove drive 0.9//1.2mm (0.03
35 /0.045)
0726
61033
Fo
or Aluminum wire
Table 7.4
M
M
Manual
no: WM070101
W
Page
e38
7-4. Spool holder mod
dule
Figure 7.4
ITE
EM
DE
ESCRIPTION
N
OR
RDER NO
QUANTIT
TY
1
Axle
0
071709
1
2
Axle seat
s
inside
0
071715
1
3
Axle seat
s
outside
0
071710
1
4
Damp
ping washer
0
071711
1
5
Cap bracket
b
0
071708
1
6
Lock spring
s
0
071707
1
7
Lock nut
n
0
071703
1
8
Cap
0
071706
1
Table 7.5
7-4.
MIG to
orch
Weld
dKing® NT2--15E, Order No.
N 0700041
11
M
M
Manual
no: WM070101
W
Page
e39
Figure 7.5
Nozzzles
ITE
EM
DESCRIP
PTION
ORDER NO.
N
1
Nozzle Adjustable
22-50**
A
2
Nozzle Adjustable
22-62
2
A
3
Nozzle Self Insulate
ed
22-50F
F
B
4
Nozzle Fixed Coarsse Thread
24CT60
0S
C
5
24CT62
2S
C
6
24CT75
5S
C
7
Nozzle Self Shielding
23-50
0
D
8
ed
23-62
2
D
9
ed
23-75
5
D
M
M
Manual
no: WM070101
W
Page
e40
10
0
Nozzle Adjustable
24A50
0
E
11
1
Nozzle Adjustable
24A62
2
E
12
2
Nozzle Adjustable
24A75
5
E
Table 7.6
Contacct Tips
ITE
EM
DESCRIP
PTION
ORDER NO.
1
Contacct Tip 0.023”//0.6mm Ecu
14-23
3
F
2
14-30
0
F
3
14-35**
F
4
14-40
0
F
5
14-45
5
F
Table 7.7
Liners
ITEM
M
DESC
CRIPTION
OR
RDER NO.
1
Steel Lin
ner 0.030”-0.035”/0.8-0.9
9mm X15ft
42
2-3035-15
G
1
Steel Lin
ner 0.040”-0.045”/1.0-1.2
2mm X15ft
42
2-4045-15*
G
2
Teflon Liner 0.035”-0
0.045”/0.9-1.2mm X15ft
42
2T-3545-15
G
Table 7.8
* Defau
ult
Compo
onent
ITEM
M
DESC
CRIPTION
PA
ART No.
1
Adjusttable Nozzle
e Insulator
32
2*
2
Nozzle
e Insulator Coarse
C
thread
d
34
4CT
3
Adjusttable Nozzle
e Insulator
34
4A
M
M
Manual
no: WM070101
W
Page
e41
4
Gas Diffuser
D
52
2
5
Gas Diffuser
D
52
2FN
6
Jacke
eted goose he
eck 45̊
62
2A45J
Jacke
eted goose he
eck 60̊
62
2A60J*
goose
e heck 45̊
62
2A45
goose
e heck 60̊
62
2A60
7
Gas Nipple
N
TE
EF2212
8
O-Ring 8x1.5
Q5
508015S
9
Handle
TE
EH2101
10
Hange
er Hook
TE
EG2001
11
Switch
h, OMRON
Q7
711
12
Trigge
er
KJJ3003
13
Trigge
er Spring
Q6
60512
14
Front Spring Cable
e Support
HS
S2101
15
Cable
e assembly 15’
TE
EL2015
16
Back Spring
S
Cable
e Support
ES
S2201
17
Gun Plug
P
Housing
g
EH
H2201
18
Screw
w M4X6
EH
H2211
19
Gun Plug
P
Nut
EP
P3001
20
Tweco
o Euro Gun Plug
P
TE
EU1001
21
O-Ring 4x1
Q5
504010
22
O-Ring 4x1.8
Q5
504018
23
Nut M11X1
M
TE
EU1011
Table 7.9
M
M
Manual
no: WM070101
Page
e42
NOTES
N
S
WE
ELDKING® MigSonic252
M
2S power so
ource and SS20 wire fee
eder
M
M
Manual
no: WM070101
W
Page
e43
SECTIO
ON 8
ELECT
TRIC DIA
AGRAM
Figure 8.1
M
M
Manual
no: WM070101
W
Page
e44
Figure 8.2
M
Manual
no: WM070101
Page
e45
SECTIO
ON 9
WARR
RANTY POLICY
P
Malo We
elding Pro
oducts Ltd
d., Warranty Policy
Effective August
A
1st, 2004, reviision at April 1st, 2011
LIMITED WARRANTY - Subject to the
e terms and conditions
NG® )
below, Malo Welding Products Ltd.(WELDKIN
endeavorrs to provide high quality products
p
and product
support tto its customers and therefo
ore backs up all
a of its
new pro
oducts purchassed from Malo Welding Products
P
Ltd.(WEL
LDKING® ) or
o any autho
orized Malo Welding
W
Products Ltd.(WELDKIN
NG® ) distributtor/service centter after
arranty and is free of
the effecctive date of this limited wa
defects in material an
nd workmansh
hip at the tim
me it is
RE NO WA
ARRANTIES WHICH
shipped. THERE AR
EXTEND
D BEYOND THE FACE OF THE
T
MALO WE
ELDING
PRODUC
CTS LTD.(WE
ELDKING® ) WARRANTY. MALO
WELDING PRODUCTS
S LTD.(WELDKING® ) DISC
CLAIMS
ALL OTHER WARRA
ANTIES, EXPR
RESS OR IM
MPLIED,
REGARD
DING THE PRODUCTS, INCLUDING
G ANY
IMPLIED
D
WARRANT
TIES
OF
MERCHANTA
ABILITY,
FITNESS
S FOR A PARTICULAR PURPOSE OR
NONINFR
RINGEMENT. IN THE UNIT
TED STATES, SOME
STATES DO NOT AL
LLOW THE EXCLUSION OF
O THE
IMPLIED
D WARRANTIE
ES, SO THE ABOVE
A
EXCL
LUSION
MAY NOT APPLY TO YOU.
Y
Malo We
elding Productts Ltd.(WELDK
KING® ) shall honor
warranty claims on warrranted equipm
ment listed below
w in the
event of such a failure within the warranty time periods. All
warranty time periods start
s
on the da
ate that the equ
uipment
urchaser, or on
ne year
was delivvered to the original retail pu
after the equipment is sent
s
to a North American distrributor.
(1) 3 Yea
ars - Parts and Labor
Power So
ources
Wire Fee
eders
(2) 90 Da
ays - Parts (No Labor)
Guns
Remote C
Controls
Accessorry Kits
Replacem
ment Parts (No
o labor)
Malo W
Welding Products Ltd.(WEL
LDKING® )'s limited
Warrantyy shall not apply
y to:
(1) Consumable compo
onents; such as
a contact tips, cutting
ushes, slip ring
gs, relays or pa
arts that
nozzles, contactors, bru
fail due to
o normal wear..
(2) All lim
mited warrantie
es are void fo
or, and Malo Welding
W
Products Ltd.(WeldKing
g® ) does nott warrant in an
ny way,
oduct that ev
vidences misa
application, im
mproper
any pro
installatio
on, abuse, lack
k of maintenan
nce, negligence
e in use
or care, abnormal use, alteration of design, use of
osive chemica
als, and/or se
ervicing,
incompattible or corro
installatio
on of parts, or repairs by anyyone other tha
an Malo
Welding Products Ltd.((WELDKING® ) or a Malo Welding
W
KING® ) auth
horized distributor or
Products Ltd.(WELDK
service center.
c
Malo Welding
W
Productts Ltd.(WELDK
KING® )
may ma
ake changes in products it manufacture
es and
markets at any time; these change
es are made without
obligation
n to change, retrofit, or upgrade
u
any product
previouslly sold or manu
ufactured.
MALO W
WELDING PR
RODUCTS LT
TD.(WELDKING
G®) 'S
PRODUC
CTS ARE FOR
R COMMERCIA
AL/INDUSTRIA
AL USE
PULSEW
WAVE200 OW
WNER’S MAN
NUAL
S TRAINED AND
A
EXPERIEN
NCED IN THE
E
AND PERSONS
M
E OF WELD
DING/PLASMA
A
USE AND MAINTENANCE
CUTTING EQUIIPMENT.
n the event of a warranty cla
aim covered byy this warranty,
In
th
he exclusive remedies shall be,
b at Malo We
elding Productss
Lttd.(WELDKING
G® )'s option: (1) repair; or (2
2) replacementt;
orr, where autho
orized in writing
g by Malo We
elding Productss
Lttd.(WELDKING
G® ), in ap
ppropriate ca
ases, (3) the
e
re
easonable costt of repair or replacement att an authorized
d
se
ervice station; or
o (4) paymentt of or credit fo
or the purchase
e
prrice (less reaso
onable depreciation based up
pon actual use)
up
pon return of the
t goods at customer's
c
riskk and expense.
No compensatio
on or reimburse
ement for transsportation costss
b allowed.
off any kind will be
LIIMITATION OF
O
DAMAGE
ES: THE REMEDY
R
OF
F
REPLACEMENT
T OR REPA
AIR OF ANY
Y DEFECTIVE
E
GOODS SHALL
L BE THE EXC
CLUSIVE REM
MEDY UNDER
R
ANY WARRA
ANTY MADE BY MALO
O WELDING
G
PRODUCTS LT
TD.(WELDKING
G® ), WHETHER EXPRESS
S
OR IMPLIED. IN
I NO EVENT
T SHALL MA
ALO WELDING
G
PRODUCTS LT
TD.(WELDKING
G® ) BE LIAB
BLE FOR ANY
Y
NCIDENTAL
OR
CONS
SEQUENTIAL
DAMAGES,
IN
PROPERTY DA
AMAGES, OR PERSONAL
P
IN
NJURIES.
ANY EXPRESS
S WARRANTY
Y NOT PROVIIDED HEREIN
N
MPLIED WAR
RRANTY, GUARANTY OR
R
AND ANY IM
TION AS TO PERFORMANC
P
CE, AND ANY
Y
REPRESENTAT
REMEDY FOR BREACH OF CONTRACT TORT
T
OR ANY
Y
AL THEORY WHICH, BUT
T FOR THIS
S
OTHER LEGA
RISE
BY
IMPLICATION,
MIGHT
AR
PROVISION,
O
LAW, CUSTOM
C
OF TRADE OR
R
OPERATION OF
NCLUDING ANY
A
IMPLIED
D
COURSE OF DEALING, IN
W
WARRANTY
OF
F MERCHANT
TABILITY OR FITNESS
F
FOR
R
PA
ARTICULAR PURPOSE,
P
WITH RESPECT
T TO ANY AND
D
AL
LL EQUIPME
ENT FURNISH
HED BY MAL
LO WELDING
G
PRODUCTS LT
TD.(WELDKING
G® ), IS EXC
CLUDED AND
D
S
DISCLAIMED BY MALO WELDING PRODUCTS
TD.(WELDKING® ).
LT
If any provision or portion of this
t
limited warranty policy iss
ound to be une
enforceable, th
hen the remain
ning provisionss
fo
an
nd portions sh
hall remain va
alid and enforrceable. If anyy
prrovision or porttion of this limitted warranty po
olicy is found to
o
be
e limited by la
aw, then that provision
p
or portion shall be
e
co
onstrued to ma
ake it effective within
w
the boun
nds of law.
To
o obtain warrranty service
e you must active your
prroduct(s)'s warrranty online at
a weldking.com
m or mail the
prroduct registrattion card includ
ded in the package to Malo
W
Welding
Produc
cts Ltd.(WELD
DKING® ) rig
ght after the
pu
urchase. When there is a warranty
w
issue
e, return the
de
efective weldin
ng machine or
o plasma cuttting machine
along with pro
oof of purch
hase to any WeldKing®
uthorized Warranty Depot. For the loca
ation of the
Au
ne
earest WeldKing® Authorize
ed Warranty depot
d
or for
se
ervice informa
ation in the United
U
States or Canada,
please telephon
ne toll free: 1-8
866-686-5088 o
or visit www.
weldking.com (U
USA & Canad
da).available, but
b may vary
fro
om province to
o province.
Manual no
o: WM07030
01
Pa
age46
SEC
CTION 10
1
AU
UTHORIIZED SERVICE CENTER
C
se go to our
o websitte www.we
eldking.co
om to fill th
he warranty registra
ation form
m.
Pleas
Malo
o Welding Products Ltd. will not
n distrib
bute of dis
sclose cus
stomer's p
private
inforrmation to
o any third
d party and
d will not sent prom
motion material to th
he
customer.
Find your nearest warra
anty cente
er at:
http
p://www
w.weldkiing.com
m/servic
celocations.asp
px
PULSE
EWAVE200 OWNER’S
O
MA
ANUAL
Manual no: WM070
0301
Page47
MALO
O WELDIN
NG PRODU
UCTS LTD
D.
271, Amber
A
Streett, Unit#10,M
Markham, ON
N L3R 3J7
Tel:
1 866 686 5088
Fax:
1 866 686 5090
www.w
weldking.co
om
Printed February 6, 2015
PULSE
EWAVE200 OWNER’S
O
MA
ANUAL
Manu
ual no: WM0
070301