HZXVOGEN HVM200 110V MIG Welder Instruction Manual

OPERATION
INSTRUCTION
HVM200

SAFETY| PROFESSION| QUALITY

FOREWORD

Thanks for your purchase of Our inverter welder.
Please read this manual carefully to properly operate the ma­ chine before operation, and preserve it for reference in case.
The product has been designed according to national and in­ ternational standards, and meets relevant standards such as GB/T15579-1, IEC60974, EN60974, AS60974, UL60974 and so on.
The product conforms to equipment requirement of A in the EMC requirement.
The design and manufacturing technology of the product are patented.

Safety

Welding is dangerous, and may cause damage to you and others, so take good protection when welding. For details, please refer to the operator safety guidelines in conformity with the accident prevention requirements of the manufacturer.

Professional training is needed before operating the machine.

• Use labor protection welding supplies authorized by national security supervision department.
• The operator must be qualified personnel with a valid “metal welding (OFC) operations” operation certificate.
• Cut off power before maintenance or repair.

Electric shock-may lead to serious injury or even death.

• Install earth device according to the application criteria
• Never touch the live parts when skin bore or wearing wet gloves/clothes.
• Make sure that you are insulated from the ground and work piece.
• Make sure that your working position is safe.

Smoke & gas-may be harmful to health.

• Keep the head away from smoke and gas to avoid inhalation of exhaust gas from welding.
• Keep the working environment in good ventilation with exhaust or ventilation equipment when welding.

Arc radiation–may damage eyes or burn skin.

• Wear suitable welding masks and protective clothing to protect your eyes and body.
• Use suitable masks or screens to protect spectators from harm.

Improper operation may cause fire or explosion.

• Welding sparks may result in a fire, so please make sure no combustible materials nearby and pay attention to fire hazard.
• Have a fire extinguisher nearby, and have a trained person to use it.
• Airtight container welding is forbidden
• Must not use the machines for other purposes except welding, such as pipe thawing, battery charging, heating.

Hot work piece may cause severe scalding.

• Do not contact hot work piece with bare hands.
• Cooling is needed during continuous use of the welding torch.

Magnetic fields affect cardiac pacemaker.

• Pacemaker users should be away from the welding spot before medical consultation.

Moving parts may lead to personal injury.

• Keep yourself away from moving parts such as fan.
• All doors, panels, covers and other protective devices should be closed during operation.

Please seek professional help when encountering machine failure.

• Consult the relevant contents of this manual if you encounter any difficulties in installation and operation.
• Contact the service center of your supplier to seek professional help if you still cannot fully understand after reading the manual or still cannot solve the problem according to the manual.

Safe use of the welding torch.

• Parts of the machine, such as the end of the filler wire and welding torch become burning hot during use.
• The wire is also sharp and moves quickly, so be careful when threading it to place.
• Never carry the machine on your shoulder during welding, but place it on an even surface. Also, do not store the machine by hanging it from the shoulder strap. The shoulder strap is for carrying only.
• Do not keep the machine near or on hot objects, as the plastic cover may melt.
• Do not move the shielding gas bottle when the control valve is in place. Fix the gas bottle securely in an upright position to a separate wall rack or bottle cart.
• Always close the gas bottle after use.

General Description

This is an easy-to-use MIG welding machine suitable for both hobby and professional use. Before using or doing any maintenance work on the machine, please read the operating manual and keep it for further reference.

• This machine has the functions of Gasless and MMA.
• IGBT power device with unique control mode improves the reliability of machine.
• High duty cycle ensures long time operation.
• Closed loop feedback control, constant voltage output, workable under mains voltage fluctuation within ±10%.
• Adjustable welding voltage and current, excellent welding performance.
• Adopting unique welding dynamic characteristic control circuit in Gasless, stable arc, little spatter, beautiful weld bead, high efficiency
• Removing tip ball after welding; high no-load voltage and soft start wire feeding result in high successful rate of arc ignition.
• Stable welding current in MMA, excellent arc ignition.

Main Parameters

Operation Control and Description

9. Welding current press to switch the welding wire 0.8/1.01

Electric Block Diagram

Installation Debugging and Operation

Warning
Please install the machine strictly according to the following steps.
The protection class of this machine is IP21S, so avoid using it in rain.
Before using, please make sure the input voltage is in voltage range (200V-240\). Otherwise, the machine will be damaged.
6.1 Connection of Input cable

1. A primary power supply cable is available for this welding machine. Connect the power input cable to the rated input power. (Ground connection is needed for safety purpose.)
2. The primary cable should be tightly connected to the correct socket to avoid oxidization.
3. Check whether the voltage value varies in acceptable range with a multi-meter.

6.2 MMA installation

1. Two quick plugs are available for this machine. Insert the quick plugs into the quick sockets on the front panel of the machine, and tighten them to ensure good contact. Otherwise, the plugs and sockets will be burnt if the working time is long and the  working current is high.

2. insert the cable plug with electrode holder into the +” output terminal “g” on the front panel of the ma­ chine, and tighten it clockwise. Insert the cable plug with work clamp into the -” output terminal “f” on the front panel of the machine, and tighten it  clockwise.

3. Generally, DCEP connection and DCEN connection are available in MMA
   DCEP: Connect the electrode holder to +” output terminal, and the work clamp to “-” output terminal.
   DC EN: Connect the electrode holder to-” output terminal, and the work clamp to “+” output terminal.
   Operators may choose DCEP/DCEN according to workpiece and electrode application requirement. Phe­ nomena such as unstable arc, excessive spatter, and electrode sticking will occur when improper polarity is selected. Change the connection by  exchanging the quick plugs to solve the problem.

4. Select cable with larger cross-section to reduce the voltage drop if the secondary cables (welding cable and earth cable) are long.

6.3. Operation method

1. After being installed according to the above method, and with the power switch on, the machine starts with the power LED on and the fan working.
2. Turn on the MMA/MIG shift switch to MMA mode, and adjust the welding current with the current control knob according to the electrode diameter and the thickness of workpiece.
3. Generally, welding current should be as below according to the electrode diameter.
   2.5: 70-100A; 3.2: 110-160A; 04.0: 170-200A; 05.0: 230-280A

6.4 MIG installation

1. insert the cable plug with earth clamp into the.”,”f on the front panel of the welding machine, and tight­ en it clockwise.
2. Insert the quick plug of the wire feeder into the +”,”g” (GAS”) on the mid-clapboard of the welding ma­ chine, and tighten it clockwise.
3. Install the wire spool on the spindle adapter, ensuring that the groove size in the feeding position on the drive roll matches the contact tip size of the welding torch and the wire size. Release the pressure arm of the wire feeder to thread the wire through the  guide tube, and into the drive roll groove. Adjust the pressure arm, ensuring no sliding of the wire. Too high pressure will lead to wire distortion, which will affect wire feeding. Press the manual wire feeding button to thread the wire out of the torch contact  tip.
4. Connect the cylinder equipped with the gas regulator to the gas inlet on the back panel of the machine with a gas hose.

6.4.1 Sketch map of installation

6.4.2 Operation method

1. After being installed according to the above method, and with the power switch on, the machine starts with the power LED on and the fan working. Open the cylinder valve and adjust the flow regulator to get the proper gas flow.
2. Switch the MMA/Gasless shift switch to Gasless mode, and select proper welding voltage and welding current by adjusting the voltage control knob in Gasless and wire feed speed control knob in Gasless on the front panel of the machine.
3. Welding can be carried out by pushing the torch trigger on the welding torch.
4. 1 second after the arc stops, the gas supply will be cut off.

Caution

7.1 Working environment

1. The product shall be operated under dry environment with normal humidity under 90%.
2. The temperature of working environment should be between -10 and 40
3. Avoid welding in the open air unless sheltered from sunlight and rain. Keep it dry anytime and do not place it on wet ground or in puddles.
4. Avoid welding in dusty area or environment with corrosive chemical gas.
5. Avoid working in the environment where the air circulation is too strong
6. Gas shielded arc welding should be operated in environment without strong airflow.

7.2 Safety tips
Over-current/over-voltage/over-heating protection circuit is installed in this machine. If the input voltage or the out put current is too high or machine inside temperature over heating inside, the machine will stop automati­ cally. However, excessive use (e.g. too  high voltage) of machine may also damage machine, so please note:

1. Ventilation
   High current passes when welding is carried out, thus natural ventilation cannot satisfy the machine’s cooling requirement. Maintain good ventilation through the louvers of the machine. The minimum distance between the machine and any other objects  in or near the working area should be 30cm. Good ventilation is of critical importance for the normal perfonnance and lifespan of the machine.

2. Welding operation is forbidden while the machine is overload.
   Remember to observe the max load current at any moment (refer to the corresponding duty cycle). Make sure that the welding current should not exceed the max load current. Overload could obviously shorten the machine’s lifespan, or even damage the  machine.

3. Over-voltage is forbidden.
   Regarding the power supply voltage range of the machine, please refer to Main Parameters” table. This machine is of automatic voltage compensation, which enables the maintaining of the voltage range within the given range. In case that the input voltage  exceeds the stipulated value, it would possibly damage the components of the machine.

4. Make sure earth connected before operation
   There is a grounding screw on the back of machine with a grounding sign beside. Before using, make sure earth connected well to prevent the operator from getting electric shock or electricity leak. Please use 10mm cable to connect the case of the machine  to earth.

5. Operation over max duty cycle
   When using the machine over max duty cycle, inside overheating circuit causes the temperature switch to be open-circuit, which finally prevents the product from working on. This can be judged from the yellow light LED on face panel. Under this  circumstance, no need to pull off the plug from the power and keep power on to let the fan cool down the machine. When the yellow LED turns off, welding can be continued.

Maintenance

Warning

This machine will produce electric and magnetic fields, so the operator should ensure proper protection and screening while using it.
Earth leakage-circuit breaker should be used with this machine.

• During operation, DO NOT pull out or insert any plugs or cables. It can lead to fatal danger and cause dam­ age to the machine.
  Before connecting cables, make sure the power is off. (The correct way is to connect the cables to the ma­ chine first, and make sure they are firmly tightened and then connect the power plug to the power source.)

• Before maintenance and checking, power must be tumed off,

• Before opening the cover, disconnect the ma chine from power source.

1. Remove dust with dry and clean compressed air regularly If the welding machine is operated in polluted area with smoke and dust, the machine needs to be cleaned regularly.
2. Pressure of compressed air must not be higher than 5 bars in order to prevent damage to small compo­ nents inside the machine.
3. Check inside the welding machine regularly and make sure the output terminals are connected tightly and connectors are not damaged. If burnt, loose or damaged, please tighten or replace them if necessary.
4. Avoid water and steam entering into the machine. If the welding machine gets wet, please dry inside of the machine and check the insulation status.
5. If the machine will not be used for long time, it should be put into a box or covered and stored in cool and dry area.
6. When power is on, do not let hand or hair touch electrification device in the machine such as fan to avoid injury or damage to machine.

Troubleshooting

Warning
Experimentation and careless maintenance may lead to more problems to the machine. This will make pro­ fessional diagnosis and repair more difficult. When the machine is open, there may be exposed connections containing life- threatening voltages. Any  direct or indirect touch will cause electric shock, and severe electric shock will lead to death.

Common Malfunction Analysis and Solution:

Refer to the manual, and operate according to the duty cycle requirement.
2. Check the running status of the fan when welding. If the fan does not work, check if the power supply of the fan is 220V: If the power supply is normal, check the fan; if the power supply is abnormal, check the connecting cable of the power supply.
3. Replace the thermal switch if it is damaged.
The power LED is off, and there is no output current| 1. Check if the fan works. If it does not work, it indicates that the power cord is not in good contact.
2. If the fan works, it indicates that the control PCB inside the machine fails.
There is no response when pushing the torch trigger, and the protection LED is off.| 1. Check if the gun trigger is in good contact.
2. Check if the welding torch is well connected to the European connector, and check the control jack of the European corrector
3. The control PCB inside the machine fails.
When torch trigger is pressed, wire feeder works and gas comes out, but there is no output current, and the protection LED is off.| 1. Check the wire feeder for clogging or damage.
2. Check the contact tip of welding torch for clogging or damage.
3. The control PCB inside the machine fails.
There is output current when pushing the torch trigger to feed gas, but the wire feeder does not feed wire.| 1. Check if all cables are connected properly.
2. Output connectors are disconnected or damaged.
3. Control circuit might be faulty.
Welding can be carried out when pushing the torch trigger, but the voltage cannot be adjusted.| 1. Check if the voltage feedback wire inside the machine is in good condition.
2. Thecontrol PCB nside the machine fails.

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