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
SECTION 1

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

CONSIGNES DE SCURIT ............................................................................................. 1
Symboles utiliss ................................................................ 1

1-1.

Symbol Usage

1-2.

Arc welding Hazards

1-3.

Safety Standards Normes de scurit ........................................................... 6

1-4.

EMF Information EMF Information .............................................................. 6

SECTION 2
SECTION 3

Dangers relatifs au soudage larc .................. 1

PACKING LIST ............................................................................................................... 7

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
SECTION 6

THEORY OF OPERATION ............................................................................................ 25

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
SECTION 9

ELECTRICAL DIAGRAMS ........................................................................................ 43

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
SECTION 11

WARRANTY POLICY ................................................................................................ 60

AUTHORIZED SERVICE CENTER .......................................................................... 61

1-1.

SECTION 1

SAFETY PRECAUTIONS

SECTION 1

CONSIGNES DE SCURIT

Symbol Usage

Symboles utiliss

Means Warning! Watch Out! There are

possible hazards with this procedure!
The possible hazards are shown in the
adjoining symbols.
Symbole
graphique
davertissement ! Attention ! Cette
procedure comporte des risques
possibles ! Les dangers ventuels
sont reprsents par les symboles
graphiques joints.

This group of symbols means Warning!

Watch Out possible ELECTRIC SHOCK,
MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions
below for necessary actions to avoid the
hazards

Marks a special safety message.

Indique un message de scurit particulier

Ce
groupe
de
symboles
signifie
Avertissement!
Attention!
Risques
dLECTROCUTION, ORGANES MOBILES
et PARTIES CHAUDES. Consulter les
symboles et les instructions afferents
ci-dessous concernant les mesures
prendre pour supprimer les dangers.

Means Note; not safety related.

Signifie NOTE ; nest pas relatif la
scurit.

1-2.

Arc welding Hazards

The symbols shown below are used

throughout this manual to call attention
to and identify possible hazards. When
you see the symbol, watch out, and
follow the related instructions to avoid
the hazard.
Only qualified persons should service,
test, maintain, and re- pair this unit.
During servicing, keep everybody,
especially children, away
Les symboles reprsents ci-dessous
sont utiliss dans ce manuelpour attirer
lattention et identifier les dangers
possibles. Enprsence de lun de ces
symboles, prendre garde et suivre
lesinstructions affrentes pour viter
tout risque. Les instructions enmatire
de scurit indiques ci-dessous ne
constituent
quun
sommaire
des
instructions de scurit plus compltes
fournies dans les normes de scurit
numres dans la Section 2-5. Lire et
observer toutes les normes de scurit.
Seul un personnel qualifi est autoris
installer, faire fonctionner, entretenir et
rparer cet appareil.
Pendant le fonctionnement, maintenir
distance
toutes
les
personnes,
notamment les enfants de lappareil.

ELECTRIC SHOCK can

kill.
UNE
DCHARGE
LECTRIQUE entraner
la mort.

MIGSONIC200cvcc SERVICE MANUAL

Dangers relatifs au soudage larc

y
y
y

y
y
y

Do not touch live electrical parts.

Wear dry, hole-free insulating gloves and
body protection.
Insulate yourself from work and ground
using dry insulating mats or covers big
enough to prevent any physical contact with
the work or ground.
Do not use AC output in damp areas, if
movement is confined, or if there is a
danger of falling.
Use AC output ONLY if required for the
welding process.
If AC output is required, use remote output
control if present on unit.
Additional safety precautions are required
when any of the following electrically
hazardous conditions are present: in damp
locations or while wearing wet clothing; on
metal structures such as floors, gratings, or
scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there
is a high risk of unavoidable or accidental
contact with the workpiece or ground. For
these conditions, use the following
equipment in order presented: 1) a
semiautomatic DC constant voltage (wire)
welder, 2) a DC manual (stick) welder, or 3)
an AC welder with reduced open-circuit
voltage. In most situations, use of a DC,
constant
voltage
wire
welder
is
recommended. And, do not work alone!
Disconnect input power or stop engine
before installing or servicing this equipment.
Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety
Standards).
Properly install and ground this equipment
according to its Owners Manual and

Manual no: WM070502

Page1

y
y
y
y

y
y
y

national, state, and local codes.

Always verify the supply ground check
and be sure that input power cord ground
wire is properly connected to ground
terminal in disconnect box or that cord plug
is connected to a properly grounded
receptacle outlet.
When making input connections, attach
proper grounding conductor first
double-check connections.
Frequently inspect input power cord for
damage or bare wiring replace cord
immediately if damaged bare wiring can
kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or
poorly spliced cables.
Do not drape cables over your body.
If earth grounding of the workpiece is
required, ground it directly with a separate
cable.
Do not touch electrode if you are in contact
with the work, ground, or another electrode
from a different machine.
Do not touch electrode holders connected
to two welding machines at the same time
since double open-circuit voltage will be
present.
Use only well-maintained equipment.
Repair or replace damaged parts at once.
Maintain unit according to manual.
Wear a safety harness if working above
floor level.
Keep all panels and covers securely in
place.
Clamp work cable with good metal-to-metal
contact to workpiece or worktable as near
the weld as practical.
Insulate work clamp when not connected to
workpiece to prevent contact with any metal
object.
Do not connect more than one electrode or
work cable to any single weld output
terminal.

SIGNIFICANT DC VOLTAGE exists

after removal of input power on
inverters.
y

Turn Off inverter, disconnect input power,

and discharge input capacitors according to
instructions in Maintenance Section before
touching any parts.

y
y

y
y
y

y
y
y

Ne pas toucher aux pices lectriques sous

tension.
Porter des gants isolants et des vtements
de protection secs et sans trous.
Sisoler de la pice couper et du sol en
utilisant des housses ou des tapis assez
grands afin dviter tout contact physique
avec la pice couper ou le sol.
Ne pas se servir de source lectrique
courant lectrique dans les zones humides,
dans les endroits confins ou l o on
risque de tomber.
Se servir dune source lectrique courant
lectrique UNIQUEMENT si le procd de
soudage le demande.
Si lutilisation dune source lectrique

MIGSONIC200cvcc SERVICE MANUAL

y
y
y

courant lectrique savre ncessaire, se

servir de la fonction de tlcommande si
lappareil en est quip.
Dautres consignes de scurit sont
ncessaires dans les conditions suivantes :
risques lectriques dans un environnement
humide ou si lon porte des vtements
mouills ; sur des structures mtalliques
telles que sols, grilles ou chafaudages ; en
position coince comme assise, genoux
ou couche ; ou sil y a un risque lev de
contact invitable ou accidentel avec la
pice souder ou le sol. Dans ces
conditions, utiliser les quipements suivants,
dans lordre indiqu : 1) un poste souder
DC tension constante ( fil), 2) un poste
souder DC manuel (lectrode) ou 3) un
poste souder AC tension vide rduite.
Dans la plupart des situations, lutilisation
dun poste souder DC fil tension
constante est recommande. En outre, ne
pas travailler seul !
Couper lalimentation ou arrter le moteur
avant de procder linstallation, la
rparation ou lentretien de lappareil.
Dverrouiller lalimentation selon la norme
OSHA 29 CFR 1910.147 (voir normes de
scurit).
Installer le poste correctement et le mettre
la terre convenablement selon les
consignes du manuel de loprateur et les
normes nationales, provinciales et locales.
Toujours vrifier la terre du cordon
dalimentation. Vrifier et sassurer que le fil
de terre du cordon dalimentation est bien
raccord la borne de terre du sectionneur
ou que la fiche du cordon est raccorde
une prise correctement mise la terre.
En effectuant les raccordements dentre,
fixer dabord le conducteur de mise la
terre appropri et contre-vrifier les
connexions.
Vrifier
frquemment
le
cordon
dalimentation afin de sassurer quil nest
pas altr ou nu, le remplacer
immdiatement sil lest. Un fil nu peut
entraner la mort.
Lquipement doit tre hors tension lorsquil
nest pas utilis.
Ne pas utiliser des cbles uss,
endommags, de grosseur insuffisante ou
mal pisss.
Ne pas enrouler les cbles autour du corps.
Si la pice soude doit tre mise la terre,
le faire directement avec un cble distinct.
Ne pas toucher llectrode quand on est en
contact avec la pice, la terre ou une
lectrode provenant dune autre machine.
Ne pas toucher des porte lectrodes
connects deux machines en mme
temps cause de la prsence dune
tension vide double.
Nutiliser quun matriel en bon tat.
Rparer ou remplacer sur-lechamp les
pices endommages. Entretenir lappareil
conformment ce manuel.
Porter un harnais de scurit si lon doit
travailler au-dessus du sol.
Sassurer que tous les panneaux et
couvercles sont correctement en place.
Fixer le cble de retour de faon obtenir
un bon contact mtal-mtal avec la pice

Manual no: WM070502

Page2

souder ou la table de travail, le plus prs

possible de la soudure.
Isoler la pince de masse quand pas mis la
pice pour viter le contact avec tout objet
mtallique.
Ne pas raccorder plus dune lectrode ou
plus dun cble de masse une mme
borne de sortie de soudage.

y
y

Il reste une TENSION DC NON

NGLIGEABLE dans les sources de
soudage onduleur quand on a coupe
lalimentation.

Arrter les convertisseurs, dbrancher le

courant lectrique et dcharger les
condensateurs dalimentation selon les
instructions indiques dans la partie
Entretien avant de toucher les pices.

y Do not touches hot parts bare handed.

y Allow cooling period before working on
welding gun or torch
y Ne pas toucher des parties chaudes
mains nues.
y Prvoir une priode de refroidissement
avant dutiliser le pistolet ou la torche.

Put on grounded wrist strap BEFORE

handling boards or parts.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.

MAGNETIC FIELDS can

affect pacemakers.
LES
CHAMPS
MAGNTIQUES
peuvent affecter les
stimulateurs
cardiaques.

tablir la connexion avec la arrette de terre

avant de manipuler des cartes ou des
pices.
Utiliser des pochettes et des botes
antistatiques pour stocker, dplacer ou
expdier des cartes PC.

FIRE OR EXPLOSION
hazard.

y
y

Pacemaker wearers keep away.

Wearers should consult their doctor
before going near arc welding, gouging,
or spot welding operations.

Porteurs de stimulateur cardiaque, rester

distance.
Les porteurs dun stimulateur cardiaque
doivent dabord consulter leur mdecin
avant de sapprocher des oprations de
soudage larc, de gougeage ou de
soudage par points.

Risque DINCENDIE OU
DEXPLOSION.

y
y
y

Do not place unit on, over, or near

combustible surfaces.
Do not service unit near flammables
Do not overload building wiring be sure
power supply system is properly sized,
rated, and protected to handle this unit.

Ne pas placer lappareil sur, au-dessus ou

proximit de surfaces inflammables.
y Ne pas installer lappareil proximit de
produits inflammables.
y Ne pas surcharger linstallation lectrique
sassurer
que
lalimentation
est
correctement dimensionne et protge
avant de mettre lappareil en service.

Le soudage, lcaillement, le passage de la

pice la brosse en fil de fer, et le meulage
gnrent des tincelles et des particules
mtalliques volantes. Pendant la priode
de refroidissement des soudures, elles
risquent de projeter du laitier.
Porter des lunettes de scurit avec crans
latraux ou un cran facial.

HOT PARTS can cause

severe burns.
DES PICES CHAUDES
peuvent provoquer des
brlures graves.

STATIC
(ESD)
can
damage PC boards.
LES
CHARGES
LECTROSTATIQUES
peuvent endommager
les circuits imprims.
y

Wear safety glasses with side shields or

face shield during servicing.
Be careful not to short metal tools, parts, or
wires together during testing and servicing.

FLYING METAL can

injure eyes.
DES
PARTICULES
VOLANTES
peuvent
blesser les yeux.

MIGSONIC200cvcc SERVICE MANUAL

CYLINDERS can explode

if damaged.
LES
BOUTEILLES
peuvent exploser si elles
sont endommages.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode.
Since gas cylinders are normally part of the
welding process, be sure to treat them carefully.
y Protect compressed gas cylinders from
excessive heat, mechanical shocks, physical
damage, slag, open flames, sparks, and arcs.
y Install cylinders in an upright position by

Manual no: WM070502

Page3

y
y
y
y
y

y
y
y

securing to a stationary support or cylinder

rack to prevent falling or tipping.
Keep cylinders away from any welding or
other electrical circuits.
Never drape a welding torch over a gas
cylinder.
Never allow a welding electrode to touch any
cylinder.
Never weld on a pressurized cylinder
explosion will result.
Use only correct shielding gas cylinders,
regulators, hoses, and fittings designed for the
specific application; maintain them and
associated parts in good condition.
Turn face away from valve outlet when
opening cylinder valve.
Keep protective cap in place over valve except
when cylinder is in use or connected for use.
Use the right equipment, correct procedures,
and sufficient number of persons to lift and
move cylinders.
Read and follow instructions on compressed
gas cylinders, associated equipment, and
Compressed
Gas
Association
(CGA)
publication P-1 listed in Safety Standards.

Des bouteilles de gaz protecteur contiennent du

gaz sous haute pression. Si une bouteille est
endommage, elle peut exploser. Du fait que les
bouteilles de gaz font normalement artie du
procd de soudage, les manipuler avec
prcaution.
y Protger les bouteilles de gaz comprim dune
chaleur excessive, des chocs mcaniques,
des dommages physiques, du laitier, des
flammes ouvertes, des tincelles et des arcs.
y Placer les bouteilles debout en les fixant dans
un support stationnaire ou dans un
porte-bouteilles pour les empcher de tomber
ou de se renverser.
y Tenir les bouteilles loignes des circuits de
soudage ou autres circuits lectriques.
y Ne jamais placer une torche de soudage sur
une bouteille gaz.
y Une lectrode de soudage ne doit jamais
entrer en contact avec une bouteille.
y Ne jamais souder une bouteille pressurise
risque dexplosion.
y Utiliser seulement des bouteilles de gaz
protecteur, rgulateurs, tuyaux et raccords
convenables pour cette application spcifique ;
les maintenir ainsi que les lments associs
en bon tat.
y Dtourner
votre
visage
du
dtendeur-rgulateur lorsque vous ouvrez la
soupape de la bouteille.
y Le couvercle du dtendeur doit toujours tre
en place, sauf lorsque la bouteille est utilise
ou quelle est relie pour usage ultrieur.
y Utiliser les quipements corrects, les bonnes
procdures et suffisamment de personnes
pour soulever et dplacer les bouteilles.
y Lire et suivre les instructions sur les bouteilles
de gaz comprim, lquipement connexe et le
dpliant P-1 de la CGA (Compressed Gas
Association) mentionn dans les principales
normes de scurit.

MIGSONIC200cvcc SERVICE MANUAL

FALLING
UNIT
cause injury.
LA
CHUTE
LAPPAREIL
blesser.
y

y
y

y
y

can
DE
peut

Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other
accessories.
Use equipment of adequate capacity to lift
and support unit.
If using lift forks to move unit, be sure forks
are long enough to extend beyond opposite
side of unit
Utiliser lanneau de levage uniquement
pour soulever lappareil, NON PAS les
chariots, les bouteilles de gaz ou tout autre
accessoire.
Utiliser un quipement de levage de
capacit suffisante pour lever lappareil.
En utilisant des fourches de levage pour
dplacer lunit, sassurer que les fourches
sont suffisamment longues pour dpasser
du ct oppos de lappareil.

MOVING PARTS can

cause injury.
DES
ORGANES
MOBILES
peuvent
provoquer
des
blessures.
y
y
y

y
y

Keep away from moving parts such as fans.

Keep all doors, panels, covers, and guards
closed and securely in place.
Have only qualified persons remove doors,
panels, covers, or guards for maintenance
as necessary.
Reinstall doors, panels, covers, or guards
when maintenance is finished and before
reconnecting input power.
Sabstenir de toucher des organes mobiles
tells que des ventilateurs.
Maintenir ferms et verrouills les portes,
panneaux, recouvrements et dispositifs de
protection.
Seules des personnes qualifies sont
autorises enlever les portes, panneaux,
recouvrements ou dispositifs de protection
pour lentretien.
Remettre
les
portes,
panneaux,
recouvrements ou dispositifs de protection
quand lentretien est termin et avant de
rebrancher lalimentation lectrique.

MOVING PARTS can

cause injury.
DES
ORGANES
MOBILES
peuvent
provoquer
des
blessures.
y
y

Keep away from moving parts

Keep away from pinch points such as drive
rolls

Ne pas sapprocher des organes mobiles.

Manual no: WM070502

Page4

Ne pas sapprocher des points

coincement tels que des rouleaux
commande.

de
de

OVERUSE can cause

OVERHEATING.
LEMPLOI
EXCESSIF
peut
SURCHAUFFER
LQUIPEMENT.

Allow cooling period; follow rated duty

cycle.
Reduce current or reduce duty cycle before
starting to weld again.
Do not block or filter airflow to unit

Keep high-frequency source doors and

panels tightly shut, keep spark gaps at
correct setting, and use grounding and
shielding to minimize the possibility of
interference.

Le rayonnement haute frquence (HF)

peut provoquer des interfrences avec les
quipements de radio-navigation et de
communication, les services de scurit
et les ordinateurs.
Demander seulement des personnes
qualifies
familiarises
avec
des
quipements lectroniques de faire
fonctionner linstallation.
Lutilisateur est tenu de faire corriger
rapidement par un electrician qualifi les
interfrences rsultant de linstallation.
Si le FCC signale des interfrences,
arrter immdiatement lappareil.
Effectuer rgulirement le contrle et
lentretien de linstallation.

Prvoir une priode de refroidissement ;

respecter le cycle opratoire nominal.

Rduire le courant ou le facteur de marche

avant de poursuivre le soudage.

Ne pas obstruer les passages dair du

poste.

Maintenir soigneusement ferms les

portes et les panneaux des sources de
haute frquence, maintenir les clateurs
une distance correcte et utiliser une terre
et un blindage pour rduire les
interfrences ventuelles.

H.F. RADIATION can

cause interference.
LE SOUDAGE LARC
risque de provoquer
des interfrences.
y

y
y

High-frequency (H.F.) can interfere with

radio
navigation,
safety
services,
computers,
and
communications
equipment.
Have only qualified persons familiar with
electronic
equipment
perform
this
installation.
The user is responsible for having a
qualified electrician promptly correct any
interference problem resulting from the
installation.
If notified by the FCC about interference,
stop using the equipment at once.
Have the installation regularly checked
and maintained.

MIGSONIC200cvcc SERVICE MANUAL

READ INSTRUCTIONS.
LIRE
LES
INSTRUCTIONS.
Consult the Owners
Manual for welding safety
precautions.
Use only genuine replacement parts

Lire le manuel dutilisation avant dutiliser

ou dintervenir sur lappareil.

Utiliser uniquement des pices de

rechange.

Manual no: WM070502

Page5

1-3.

Safety Standards

Normes de scurit

Safety in Welding, Cutting, and Allied Processes,

ANSI Standard Z49.1, from Global Engineering
Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).

Code for Safety in Welding and Cutting, CSA

Standard W117.2, from Canadian Standards
Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3
(phone: 8004636727 or in Toronto
4167474044, website:
www.csainternational.org).

Safety in Welding, Cutting, and Allied Processes,

ANSI Standard Z49.1, de Global Engineering
Documents (tlphone : 1-877-413-5184, site
Internet : www.global.ihs.com).

Code for Safety in Welding and Cutting, CSA

Standard W117.2, de Canadian Standards
Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3
(tlphone : 800-463-6727 ou Toronto
416-747-4044, site Internet :
www.csa-international.org).

1-4.

EMF Information

EMF Information

Considerations About Welding And The Effects

Of Low Frequency Electric And Magnetic Fields

1. Keep cables close together by twisting or

taping them.

Welding current, as it flows through welding

cables, will cause electro- magnetic fields. There
has been and still is some concern about such
fields. However, after examining more than 500
studies spanning 17 years of research, a special
blue ribbon committee of the National Research
Council concluded that: The body of evidence, in
the committees judgment, has not demonstrated
that exposure to power- frequency electric and
magnetic fields is a human-health hazard.
However, studies are still going forth and
evidence continues to be examined. Until the
final conclusions of the research are reached,
you may wish to minimize your exposure to
electromagnetic fields when welding or cutting.

2. Arrange cables to one side and away from the

operator.

To reduce magnetic fields in the workplace, use

the following procedures:
Considrations sur le soudage et les effets de
basse frquence et des champs magntiques et
lectriques.
Le courant de soudage, pendant son passage dans
les cbles de soudage, causera des champs
lectromagntiques. Il y a eu et il y a encore un
certain souci propos de tels champs. Cependant,
aprs avoir examine plus de 500 tudes qui ont t
faites pendant une priode de recherch de 17 ans,
un comit spcial ruban bleu du National Research
Council a conclu : Laccumulation de preuves,
suivant le jugement du comit, na pas dmontr
que lexposition aux champs magntiques et
champs lectriques haute frquence reprsente
un risque la sant humaine . Toutefois, des
tudes sont toujours en cours et les preuves
continuent tre examines. En attendant que les
conclusions finales de la recherch soient tablies,
il vous serait souhaitable de rduire votre
exposition aux champs lectromagntiques
pendant le soudage ou le coupage.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as far
away from operator as practical.
5. Connect work clamp to work piece as close to
the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If
cleared by your doctor, then following the above
procedures is recommended

2. Disposer les cbles dun ct et distance de

loprateur.
3. Ne pas courber pas et ne pas entourer pas les
cbles autour de votre corps.
4. Garder le poste de soudage et les cbles le plus
loin possible de vous.
5. Connecter la pince sur la pice aussi prs que
possible de la soudure.
En ce qui concer ne les sti mulateurs
cardiaques
Les porteurs de stimulateur cardiaque doivent
consulter leur mdecin avant de souder ou
dapprocher des oprations de soudage. Si le
mdecin approuve, il est recommand de suivre les
procdures prcdentes

Pour rduire les champs magntiques sur le poste

de travail, appliquer les procdures suivantes :
1. Maintenir les cbles ensemble en les tordant ou
en les enveloppant.

MIGSONIC200cvcc SERVICE MANUAL

Manual no: WM070502

Page6

SECTION 2

PACKING LIST

MIGSONIC200cvcc package (Part No: 07000385)

Part no

Quantity

n/a

07000412

Tweco 1 series 0.035/0.9 tip

11-35

Tweco 1 series 0.045/1.2 tip

11-45

07000510

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

connector on both end

n/a

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

lead

07000460

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

lead

07000461

Owners Manual

07000416

10 ft. (3 M) Power cord with NEMA 5-15P

115V AC Plug

n/a

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

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

07001820

Model
MigSonic200cvcc Power source
WeldKingTM 12 ft.(3.5 M) NT1-4E Mig torch,
Euro connection with Tweco style
consumables
Spare Contact tips:

Argon Regulator / Gauge

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
Power supply

MIG/Flux cored wire Mig

115V/60Hz

230V/60Hz
1

Phase
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
1-13 (40-500 IPM)

Wire feed speed(M/MIN)

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)

STICK/TIG

Welding Process
Power supply

115V/60Hz

230V/60Hz
1

Phase
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
TIG: 12-110

STICK:12-160
TIG: 12-160

Welding voltage(V)

STICK:20.5-23.6
TIG: 10.5-14.4

STICK:20.5-26.4
TIG: 10.5-16.4

Rated Duty cycle (%)

60

60

Rated welding current(A)

110

160

MIGSONIC200cvcc SERVICE MANUAL

Manual no: WM070502

Page8

62 x41 x57(24.4x16.1x22.4in)

Power source Dimension (HxWxD)(CM)

25(55lbs)

Power source Weight(KG)

69 48 63 (27.2x18.9x24.8in)

Packing Dimension(HxWxD)(CM)

35.5(78.1lbs)

Packing Weight(KG)
Operating temperature(C)

-20 to +40 (-4F to 104F)

Storage temperature(C)

-40 to +40 (-40F to 185F)

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

GMAWSolid wire
with shielding gas

DCEP Reverse
polarity

Connect to positive(+) output

terminal

Connect to negative(-)output
terminal

FCAW Self-shielding
wire- no shielding gas

DCENStraight
Polarity

Connect to negative(-) output

terminal

Connect to positive(+)output
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 ; 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 8 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 feeders 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)

only.

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

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 90 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 90 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
LALIMENTATION DOIT TRE CONFORME AUX CODES D LECTRICIT
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
AWG (mm2)

in

Maximum Cord Length allowed in Ft(M)

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
4-1

OPERATION

Front panel Layout

6
7
8

10
9
12

11

Figure 4.1
1. Welding voltage meter (digital)
2. Welding current meter (digital)
3. Welding process selector
4. Protection indication light

(Stick/TIG) adjustment knob

8. Inductance adjustment knob (MIG)
9. Earth clamp (MIG/Stick) or TIG torch
receptacle (TIG)

5. Power indication light

10. Electrode holder(STICK) or earth

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
1

2
Primary
Rectifier

Power switch

THEORY OF OPERATION
4

Capacitor PCB
DVI200-DR-B

Inverter
PCB
ZX7-400I-QQ-A2

23

115V/230V
power input
22

Amperage
meter

Voltage
meter

Main
transformer

DC
eliminate
PCB

Reactor

Secondary
rectifier

Feed motor

Torch
Trigger
21

20

Solenoid valve

Fan Motor

CONTROL PCB MIG-270I-KZ-A0

10

Switch PCB (MIG200STICK-A0)

24

Spool gun
selection
switch

26
19

18

Polarity
Switch

27

25

Protection
light

Mig torch
11
Work
Piece

Power Light
12
Welding
mode
switch
Induction
potentiometer
17

Thermostat

Voltage
potentiometer

Manual no: WM070502

Spool Gun

14
13

16

15

Figure 5.1
MIGSONIC200cvcc SERVICE MANUAL

Welding
Current /wire
feed speed
Potentiometer

Page25

Control
circuit

(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
6-1

General trouble shooting

No.
1

TROUBLE SHOOTING

Problem

Cause

Solution

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

Cooling fan stops

Power indication

Cooling fan circuit

to rotate after

lamp on

malfunction

machine has

Check fan circuit

Check fan, replace

Cool fan failure

worked a period

if necessary
Power indication

See No. 1

lamp off

11

10

Overheat light on

Power supply switch jump

MIGSONIC200cvcc SERVICE MANUAL

Work excess the rate

Use under rate

duty circle

duty circle

Input voltage is too

Use under rate

high

input voltage

Rectifier short circuit

Check and replace

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
No.
3

MIG/MAG welding trouble shooting

Problem
No gas flow out after pushing
the gun trigger

Cause

Solution

Gas pressure not enough

Check gas pressure

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

Failure of arc to ignite or does

not ignite properly

Control circuit failure

Replace circuit board

Control transformer failure

Replace transformer

Fuse melt or poor contact

Check and repair

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

Arc ignited but the wire does

not melt

Wire does not feed while the

feed roller is rotating

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

Wire pressure not proper

Adjust pressure

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

Wire feeding not stable

Control board failure

Check, repair, replace

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

MIGSONIC200cvcc SERVICE MANUAL

Manual no: WM070502

Check and repair or

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.
4

Problem
Erratic or improper weld

Cause
Wrong cable size

output.

Cable or receptacle too hot.

Solution
Choose the right cable
size

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

Failure of arc to ignite or

does not ignite properly

Fuse melt or poor contact

Check and repair

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

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

Tungsten electrode
oxidizing( not bright) after
welding

Gas shield inadequate

check nozzle

Gas not pure

Check if there is water

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
CN101

CN102(similar
to CN101)

CN105

CN104

Pin
1
2
3
4
5
6
7
8
9
10
1

Value
AC 230V/115V, (reference to CN102-1,2,3,4)
AC 230V/115V
AC 230V/115V
AC 230V/115V
Not used
DC +325V (voltage output rectified by rectifier)
DC +325V
Not used
DC -325V(voltage output rectified by rectifier)
DC 1325V
AC 230V/115V

2
3
4
5
6
7
8
9
10
1
2
3
1

AC 230V/115V
AC 230V/115V
AC 230V/115V
Not used
DC +325V
DC +325V
Not used
DC -325V
DC -325V
DC +24V
GND
AC230V/115V switch signal
DC -325V(Common ground)

MIGSONIC200cvcc SERVICE MANUAL

Manual no: WM070502

Page33

CN103

2
3
1
2
3
4
5
6
7

Not used
DC +325V
DC -325V
DC -325V
DC -325V
Not used
DC 325V
DC 325V
DC 325V
Table 6.4

MIGSONIC200cvcc SERVICE MANUAL

Manual no: WM070502

Page34

Figure 6.2
ZX7-400I-QQ-A2(Inverter PCB)
Connector
CN1

CN2

Pin
1
2
3
4
5
1
2
3
4
5

Value
Connect to IGBT drive wire from Control PCB (DC12V)
Connect to IGBT drive wire from Control PCB (DC12V)
Not used
Connect to IGBT drive wire from Control PCB (DC12V)
Connect to IGBT drive wire from Control PCB (DC12V)
Connect to IGBT drive wire from Control PCB (DC12V)
Connect to IGBT drive wire from Control PCB (DC12V)
Not used
Connect to IGBT drive wire from Control PCB (DC12V)
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
CN1

CN2

Pin
1
2
3
4
5
1
2
3

Value
GND
GND
GND
Connect to current meter
DC+5V Connect to current meter
Not used
GND. Connect to negative output (voltage feedback)
Connect positive output

MIGSONIC200cvcc SERVICE MANUAL

Manual no: WM070502

Page36

CN9

4
5
1
2
3
4
5
1
2
3
4
1
2
1
2
3
1
2
1
2
3
4
1

CN10

2
1

CN3

CN4

CN5
CN6

CN7
CN8

CN11

CN12
CN13

CN14
CN15

CN16
CN17

CN17

CN18

2
1
2
3
1
2
1
2
3

Connect to shunt(current feedback)

Connect to shunt
Connect to IGBT drive wire from Control PCB (DC12V)
Connect to IGBT drive wire from Control PCB (DC12V)
Not used
Connect to IGBT drive wire from Control PCB (DC12V)
Connect to IGBT drive wire from Control PCB (DC12V)
GND. Connect to voltage meter
GND. Connect to voltage meter
Connect to voltage meter
DC+5V. Connect to voltage meter
Induction adjustment potentiometer
Induction adjustment potentiometer
Welding voltage adjustment potentiometer
Welding voltage adjustment potentiometer
DC+5V. Welding voltage adjustment potentiometer
Connect to over-current protection coil
Connect to over-current protection coil
DC+24V. Connect to protection light
Connect to protection light. DC +24V with thermostat open.
DC+24V. Connect to power light
Connect to power light
Connect to thermostat. Short to CN9-2 with thermostat
closed.
Connect to thermostat
Connect to CV/CC switch wire(This wire connect to CN11 and
then CN12 in MIG200-STICK-A0)
DC+24V. Connect to CV/CC switch wire
Connect to torch switch
Not used
Connect to torch switch
Short to CN12-2
Short to CN12-1
GND
Not used
Auxiliary power input. DC+325V

GND. Connect to solenoid valve

Connect to solenoid valve. DC+24V

Given welding current(TIG/STICK)

Given welding current(TIG)

DC+5V. Given welding current

Not used in this model

Not used in this model

Giving voltage for wire feed motor

Not used

Giving voltage for wire feed motor

GND

DC+12V

DC-12V

DC+24V

Connect to IGBT drive wire from Control PCB (DC12V)

MIGSONIC200cvcc SERVICE MANUAL

Manual no: WM070502

Page37

Connect to IGBT drive wire from Control PCB (DC12V)

Not used

Connect to IGBT drive wire from Control PCB (DC12V)

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
CN1

Value

GND

DC+12V

CN2

Not used

AC230/115V switch signal

CN3

Positive output(output voltage feedback)

Not used

Connect to Wire feed motor (2.5V-17V)

Not used

Wire feed motor(2.5V-17V)

Auto reset toggle switch( torch/spool gun switch)

Auto reset toggle switch( torch/spool gun switch)

CN4

CN5

CN6

CN7

CN8

Auto reset toggle switch

1
2

Connect to pole 6 in spool gun receptacle( given voltage to

spool gun motor)
Not used

Connect to pole 9 in spool gun receptacle

DC+5V. connect to given welding current

connect to given welding current

connect to given welding current

DC+5V. connect to welding current potentiometer

connect to welding current potentiometer

MIGSONIC200cvcc SERVICE MANUAL

Manual no: WM070502

Page39

CN9

CN10

CN11

connect to welding current potentiometer

Auto reset toggle switch(torch/spool gun switch)(+5V)

Auto reset toggle switch(torch/spool gun switch)

Auto reset toggle switch(torch/spool gun switch)

1
2

Connect to pole 8 in spool gun receptacle( given current to

spool gun) (+5V)
Connect to pole 2 in spool gun receptacle

Connect to pole 1 in spool gun receptacle

DC+24V. Connect to CC/CV switch wire from CN10 of

MIG-270I-KZ-A0
Connect to CC/CV switch wire

2
CN12

CN13
CN14
CN15
CN16

Connect to LIFT TIG/MIG/STICK switch

DC+24V. Connect to LIFT TIG/MIG/STICK switch

Connect to LIFT TIG/MIG/STICK switch

Connect to LIFT TIG/MIG/STICK switch

DC+24V. Connect to LIFT TIG/MIG/STICK switch

Connect to LIFT TIG/MIG/STICK switch

Connect to MIG torch trigger

Connect to MIG torch trigger

Connect to pole 5 in spool gun receptacle

Connect to pole 3 in spool gun receptacle

Connect to Spool gun trigger

Connect to Spool gun trigger

1
2
3

Connect wire feed motor given voltage

Not used
Connect wire feed motor given voltage

Table 6.7

MIGSONIC200cvcc SERVICE MANUAL

Manual no: WM070502

Page40

SECTION 7
7.1

MAINTENANCE

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

continuously use the machine.

Blow out with dry clean pressure air or

vacuum inside machine, especially
transformer
coil
and
power
component.

Check liner frequently, change if it has

been contaminated by oil or worn out.
Check and change broken contact tip
and nozzle to avoid damage to the
torch and machine.
Check the function of all switches.
Check if the fan rotates properly and if
there is air venting out from back of
the machine
Pay Attention to the abnormal
vibration, noise, smell and gas
leakage during operation

Check the electric connection of

input/output bar to avoid bad contact
caused by loose or rusted screw.
Check the lubrication of the gear box
in the feeder, replace or fill lubricates
oil if necessary.
Check and clean the oil or other
contamination in the feeding roller and
feeding tube. If the V grooves have
worn out change feeding roller
immediately to avoid slipping or
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
7.2.7

Welding machine should not work in a flammable and toxic environment,

avoid moisture, rain, and do not directly expose to sun.
Periodically maintain the machine and clean the dust inside.

Lens Shade Selector Guide

Operation
/Process

Electrode Size in.

(mm)

Arc Current
(Amperes)

Shielded metal
arc welding
(SMAW)

Less than 3/32(2.5)

3/325/32 (2.54)
5/321/4 (46.4)
More than 1/4 (6.4)

Less than 60
60160
160250
250550

Minimum
Protective
Shade
7
8
10
11

Suggested*
Shade No.
(Comfort)

10
12
14

Gas metal arc

welding
Less than 60
7

(GMAW) and
60160
10
11
flux cored arc
160250
10
12
welding
250550
10
14
(FCAW)
Gas tungsten
Less than 50
8
10
arc welding
50150
8
12
(GTAW)
150500
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

P1

X1
VH-05(4)

CN105
VH-03

CN104
VH-03

1
2
3
4
5

X1
VH-05(4)

3
2
1

3
2
1

1
3

CN13
VH-03(2)

M2
4
3
2
1

12038 DC24V/0.5A

1
2
3
4
5

BRIDGE1

1
2
3
4
CN102
5
VH-10
6
7
8
9
10

1
2
3
4
5

BRIDGE1

1
2
3
4
5
6
CN101
7
VH-10
8
9
10

2
3

CN103
VH-07

P2

1
2
3
4
5

IGBT:FGL60N600BNTD
1

7
6
5
4
3
2
1

2
3

INPUT 115V/230V

ZX7-400I-QQ-A0
A

X13
VH-05(4)

X13
VH-05(4)

CZ-02

JP2
CN19
VH-04

CZ-03

J1

MIG-270ICZ-02

JP2

CN4
XH-04

M2
DC24V,ZCT-2.5
2W/1K

3
2
1

2
1

2
1

CN8
XH-03

CN14
XH-02

CN15
XH-02

3
2
1
7

CN3
XH-02
CN16
VH-03

CN5
VH-03

CN9
XH-03

CN12
XH-06

1
2

1
2
3

XH-02 CN7
XH-03
CN2
XH-02

1
2
3

1
2

LED2
1

3
2
1

1
2

CN1

1
2
3

1
2

C
X

1
2
3
4

CN12
VH-02

7
6

CN11
VH-03(2)

1
2

CN14
VH-02

1
2
3

CN15
XH-03

2
1

CN16
XH-02

2
1

CN17
VH-03(2)

1
2
3

1
2
3

STICK

Figure 8.1

MIGSONIC200cvcc SERVICE MANUAL

Manual no: WM070502

Page43

2
1

OUT

4
ESA D92-02

3
BYQ5

MIG-400I-ZL-A0

MIG200-XH-A0

MIG-270I-XS-A0

T38x22x15 T=300:1

R1
300R

R2
300R

C1
472/3KV

C2
472/3KV

1
2

M1
D4

CN7
VH-02

4
3
2
1

CN8
XH-04

-KZ-A0

CN9
VH-02

L35uH

OUT

300A/75mV

O.C

POWER

CN10

2
1
75
2
1
CN10

1
2
3

1
2

CN6
XH-03

3
2
1

7
6

CN5
XH-02

1
2
3
4
5

CN2
VH-05

1
2
3
4
5

CN1
XH-05

L3

LED1

2
1

RT1
2W/10K

3
4
5
6

CN4
VH-03

3
2
1

CN13
XH-02

2
1

CN10
XH-03

3
2
1

CN16
VH-03

3
2
1

M1
M

CN11
XH-02

RT2
2W/10K

SSJ-18
1
2
3
4
5
6
7
8
9

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
1
2
3
4
5
6
7
8
9
10
11
12
13

14
15
16
17
18
19
20
21
22

Order No.
Y16010440
Y09020014
Y08070008
Y07060002
Y07080007
Y16030499
B03011011
Y25050047
B01031042
Y23010107
Y26030001
B01081019
Y22030016

B03041024
Y22010004
Y16020186
Y21010029
Y26050021
Y08030006
Y16050074
Y16050071
B02030041

Note

Quantity

JKJ-A241-A1(AH2351)(SY
-A1134-A1)

LX5135V-2V

RN-110Z
DADANMAI(black/red)
10-25

3
2

10P

JKJ-A237-A1(CH4198)(wit
hout silk screen)

ZX7-300C(DKQ-008)

JYJ-A129-A1

ZX7-400I(export)

SRQ-A041-A1

WJJ-252

S200I

SSJ-18with0.035/0.045V
groove driver roller (guide
tube length 120mm)

MigSonic
200
CC(Canada)(37:7)
12038 DC24V/0.5A

Description
Front
panel(grey/Canada)
Digital display panel
Knob
Quick connector
Control receptacle
Left panel
(blue/MigSonic200cvcc)
Reactor
MIG270I rib
Rectifier PCB
Heat sink
(Migsonic200cvcc)
ZX7-400C(fix bar)
Full bridge Rectifier PCB
Driving system with
central connection(euro
style)
Main transformer
Fan
Rear
panel(grey/Canada)
Solenoid valve
CUT45-Switch bracket
air-break switch
middle
panel(grey/Canada)(1)
middle
panel(grey/Canada)(2)
MIG200 fastener(1)

MIGSONIC200cvcc SERVICE MANUAL

CV

JKJ-A242-A1(AH2351)(SY
-A2067-A2)

ZCT-2.5/DC24V(brass
bas,6)
WJJ-115

DZ47-40/2P

JKJ-A244-A1(AH2351)

JKJ-A245-A1(AH2351)

LJJ-A041-A1

Manual no: WM070502

Page46

23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49

Y10030017
B02030041
Y25050514
B01051010
B01081021
B01041032
Y25050544
Y26090008
Y16030499
Y16030500
Y16040178
B01051009
B01021012
B0108100
Y27020012
Y27020030
Y22020001
Y25050516
Y26100003
Y25050507
Y25050545
Y08060002
Y07100020
Y08060009
Y12060163
Y02010018
Y04070001

Shunt
MIG200 fastener(1)

300A-75mV(non-standard)

LJJ-A041-A1

1
1

Plastic connection panel

Absorb PCB
Lift-arc strike PCB
Control PCB
Damping wire spool
MIG-270 (Handle(grey)
Right panel
(blue/MigSonic200cvcc)
Right bottom panel
(blue/MigSonic200cvcc)
Bottom panel
(grey/Canada)
Absorb PCB
Capacitor PCB
DC isolation PCB
HF transformer
HF transformer
Fan protection screen
Wire fixer
Gas inlet
Foot Pad
Wire guide tube
Toggle switch
luminescent diode
Toggle switch

MIG200

MIG200I

MIG-270I

MIG-270I (hole 4*8. Al

base, black plastic bar,
open style)
WJJ-A286-A1(AH2351)

JKJ-A237-A1(CH4198)(no
silk screen)

JKJ-A236-A1(CH4198)

JKJ-A243-A2(AH2351)

MIG270I Absorb PCB

DVI200

ZX7-250I

EER43-140:20:11:10

EI33-40:20:20:20:20

120mm

SR-T83

CONNECTOR(EXPORT)01-A1(CGA5/8"-18Unf)
50*35

M10*15

KN3-3
3A(6pin/2position)
5mm

220V

CBB Capacitor
Rectifier bridge

T80-T

106/630V

25A/1000V(square)

Manual no: WM070502

Table 9.1

MIGSONIC200cvcc SERVICE MANUAL

AWG14-3

Power cable

Page47

Figure 9.1

MIGSONIC200cvcc SERVICE MANUAL

Manual no: WM070502

Page48

45

46

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

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
1

DESCRIPTION
Protection cap

QUANTITY
1

Euro connection

Drive roller bracket

Pressure adjustment component

50W Motor

Wire in guide hose L=120mm

Bracket

Support

Shaft sleeve

10

Roller(0.9/0.8mm/1.2)(.035/.045)

11

Drive roller press nut

12

Protect plate

1
Table 9.2

MIGSONIC200cvcc SERVICE MANUAL

Manual no: WM070502

Page53

Drive roller selection

ITEM

ORDER NO

DESCRIPTION
V groove (0.9/1.2mm)(0.035/0.045)(default)

072611020

NOTE
For solid wire

V groove (0.6/0.8mm)(0.023/0.030)

072611021

For solid wire

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

axle cap

2401709

QUANTITY
1

Washer 6

n/a

spring

2401710

Screw M6x25

n/a

Cap bracket

2401708

Washer

2401707

Screw M8x30

n/a

Spring

2401706

Separation ring

2401705

10

Shaft sleeve

2401704

11

Nut M14

n/a

12

Axle seat

2401701

13

Axle

2401703

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

Spool gun C.C.W potentiometer(3)

Spool gun wiper potentiometer(2)

Spool gun switch

Not used

Spool gun switch

Spool gun motor (+)

Not used

Spool gun C.W potentiometer(1)

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
1

DESCRIPTION
Nozzle Self Insulated

ORDER NO.
21-37

Nozzle Self Insulated

21-50*

Nozzle Self Insulated

21-62

Nozzle Self Insulated

21-37F

Nozzle Self Insulated

21-50F

Nozzle Self Insulated

21-62F

Nozzle Self Shielding

LA8201

Table 9.6

MIGSONIC200cvcc SERVICE MANUAL

Manual no: WM070502

Page57

Contact Tips
ITEM
1

DESCRIPTION
Contact Tip 0.023/0.6mm Ecu

ORDER NO.
11-23

Contact Tip 0.030/0.8mm Ecu

11-30*

Contact Tip 0.035/0.9mm Ecu

11-35

Contact Tip 0.040/1.0mm Ecu

11-40

Contact Tip 0.045/1.2mm Ecu

11-45

Table 9.7
Liners
ITEM
1

DESCRIPTION
Steel Liner 0.030-0.035/0.8-0.9mm X15ft

ORDER NO.
42-3035-12*

Teflon Liner 0.030-0.035/0.8-0.9mm X15ft

42T-3035-12

Table 9.8
* Default
Component
ITEM

DESCRIPTION

PART No.

QTY

Gas Diffuser

51

Goose neck(45 )

61-45

Goose neck(55 )

61-55

Handle locking Nut

EH1111

Gun Handle (Front)

EH1101

Trigger Assembly

EJ0003

Gun &Cable Assembly.3.65M

TEL1012-H

Rear spring protective sleeve

ES2201

Rear cover

EH2201

Screw(M4X6)

EH2211

10

Rear lock nut

EP2001

11

Euro connector(Tweco)

ETU001

12

O ring 4x1

Q504010

13

O ring 4x8

Q504018

14

Nut M11X1

TEU1011

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
conditions
below,
Malo
Welding
Products
Ltd.(WELDKING ) endeavors to provide high quality
products and product support to its customers and
therefore backs up all of its new products purchased from
Malo Welding Products Ltd.(WELDKING ) or any
authorized Malo Welding Products Ltd.(WELDKING )
distributor/service center after the effective date of this
limited warranty and is free of defects in material and
workmanship at the time it is shipped. THERE ARE NO
WARRANTIES WHICH EXTEND BEYOND THE FACE OF
THE MALO WELDING PRODUCTS LTD.(WELDKING )
WARRANTY.
MALO
WELDING
PRODUCTS
LTD.(WELDKING
)
DISCLAIMS
ALL
OTHER
WARRANTIES, EXPRESS OR IMPLIED, REGARDING
THE
PRODUCTS,
INCLUDING
ANY
IMPLIED
WARRANTIES OF MERCHANTABILITY, FITNESS FOR A
PARTICULAR PURPOSE OR NONINFRINGEMENT. IN
THE UNITED STATES, SOME STATES DO NOT ALLOW
THE EXCLUSION OF THE IMPLIED WARRANTIES, SO
THE ABOVE EXCLUSION MAY NOT APPLY TO YOU.
Malo Welding Products Ltd.(WELDKING ) shall honor
warranty claims on warranted equipment listed below in the
event of such a failure within the warranty time periods. All
warranty time periods start on the date that the equipment
was delivered to the original retail purchaser, or one year
after the equipment is sent to a North American distributor.
(1) 3 Years - Parts and Labor
Power Sources
Wire Feeders
(2) 90 Days - Parts (No Labor)
Guns
Remote Controls
Accessory Kits
Replacement Parts (No labor)
Malo Welding Products Ltd.(WELDKING )'s limited
Warranty shall not apply to:
(1) Consumable components; such as contact tips, cutting
nozzles, contactors, brushes, slip rings, relays or parts that
fail due to normal wear.
(2) All limited warranties are void for, and Malo Welding
Products Ltd.(WeldKing ) does not warrant in any way,
any product that evidences misapplication, improper
installation, abuse, lack of maintenance, negligence in use
or care, abnormal use, alteration of design, use of
incompatible or corrosive chemicals, and/or servicing,
installation of parts, or repairs by anyone other than Malo
Welding Products Ltd.(WELDKING ) or a Malo Welding
Products Ltd.(WELDKING ) authorized distributor or
service center. Malo Welding Products Ltd.(WELDKING )
may make changes in products it manufactures and
markets at any time; these changes are made without
obligation to change, retrofit, or upgrade any product
previously sold or manufactured.

PRODUCTS ARE FOR COMMERCIAL/INDUSTRIAL USE

AND PERSONS TRAINED AND EXPERIENCED IN THE
USE AND MAINTENANCE OF WELDING/PLASMA
CUTTING EQUIPMENT.
In the event of a warranty claim covered by this warranty,
the exclusive remedies shall be, at Malo Welding Products
Ltd.(WELDKING )'s option: (1) repair; or (2) replacement;
or, where authorized in writing by Malo Welding Products
Ltd.(WELDKING ), in appropriate cases, (3) the
reasonable cost of repair or replacement at an authorized
service station; or (4) payment of or credit for the purchase
price (less reasonable depreciation based upon actual use)
upon return of the goods at customer's risk and expense.
No compensation or reimbursement for transportation
costs of any kind will be allowed.
LIMITATION OF DAMAGES: THE REMEDY OF
REPLACEMENT OR REPAIR OF ANY DEFECTIVE
GOODS SHALL BE THE EXCLUSIVE REMEDY UNDER
ANY WARRANTY MADE BY MALO WELDING
PRODUCTS LTD.(WELDKING ), WHETHER EXPRESS
OR IMPLIED. IN NO EVENT SHALL MALO WELDING
PRODUCTS LTD.(WELDKING ) BE LIABLE FOR ANY
INCIDENTAL
OR
CONSEQUENTIAL
DAMAGES,
PROPERTY DAMAGES, OR PERSONAL INJURIES.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR
COURSE OF DEALING, INCLUDING ANY IMPLIED
WARRANTY OF MERCHANTABILITY OR FITNESS FOR
PARTICULAR PURPOSE, WITH RESPECT TO ANY AND
ALL EQUIPMENT FURNISHED BY MALO WELDING
PRODUCTS LTD.(WELDKING ), IS EXCLUDED AND
DISCLAIMED BY MALO WELDING PRODUCTS
LTD.(WELDKING ).
If any provision or portion of this limited warranty policy is
found to be unenforceable, then the remaining provisions
and portions shall remain valid and enforceable. If any
provision or portion of this limited warranty policy is found
to be limited by law, then that provision or portion shall be
construed to make it effective within the bounds of law.
To obtain warranty service you must active your
product(s)'s warranty online at weldking.com or mail the
product registration card included in the package to Malo
Welding Products Ltd.(WELDKING ) right after the
purchase. When there is a warranty issue, return the
defective welding machine or plasma cutting machine
along with proof of purchase to any WeldKing
Authorized Warranty Depot. For the location of the
nearest WeldKing Authorized Warranty depot or for
service information in the United States or Canada,
please telephone toll free: 1-866-686-5088 or visit www.
weldking.com (USA & Canada).available, but may vary
from province to province.

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