YesWelder MIG-205DS IGBT INVERTER MULTI FUNCTIONS WELDING MACHINE Instruction Manual

YesWelder MIG-205DS IGBT INVERTER MULTI FUNCTIONS WELDING MACHINE

PROMISE
We make a solemn promise: The machine is produced under Chinese & International quality standards, in accord with the IEC60974-l International safety standard. The design & technology of the products is protected by patent. The products are guaranteed for one year from the purchase date. Please read the user manual carefully before operation.

Safety tips

During the welding process, the work may cause some damage to you and other people, so please make some protection. For more details, please kindly read “operator safety manual” in accord with accident prevention of the manufacturer

Workers must receive professional training before the operation!

• Use welding safety products recognized by the national safety ministry of supervision.
• A worker must be a special operator with a valid certificate of metal welding work.
• During maintenance & repair, please disconnect the line of electricity.

Electric shock: it may cause some injuries and even fatal.

• Connect the earth cable according to standard regulations.
• Avoid all contact with live components of the welding circuit, electrodes, and wires with bare hands.
• The operator should keep the workpiece & earth insulating from himself or herself.
• Make sure the workplace is a safe situation.

Smoke may be bad for people’s health.

• Keep your head out of smoke & welding gas in order to avoid breathing it.
• Keep the working area in good ventilation during welding.

Arclight emission: harmful to people’s eyes & skin.

• To protect your eyes and body, please wear a welding helmet, work clothes & gloves.
• People in or near the working area should be protected under a welding helmet & other protection equipment.
• Fire or explosion hazards may be caused by misoperation.
• Welding fire flame may cause fire, please keep the inflammable substance far from a workpiece and keep fire safe.
• Make sure fire extinguishers are nearby with a professional fire worker here, who can be skillful with a fire extinguisher.
• Don’t weld the closed container.

Don’t use this machine for pipe unfreeze.

A hot workpiece may scald your hand.

• Don’t contact the hot workpiece with bare hands.
• Dunning welding continuously for a long time, the welding torch should have some time to release hot.

A magnetic field will affect the heart pacemaker.

• The heart pacemaker user will keep far away from the welding area before having some inquiry from the doctor

The moving components will cause some damage to people.

• Keep away from moving components, such as fans.
• Keep the panel, backplate, cover, and protection equipment fastened on the machine

Fault-you should look for some help from a professional worker when you face some trouble.

• If you face some trouble with installation and operation, please check the machine according to the operation manual.
• After reading on operation manual, still can’t understand something or can’t solve the trouble,
• please should contact your supplier or our company service center for professional help.

General introduction

MIG-205DS/MMA/LIFT TIG Welding Machines are manufactured based on internationally advanced inverter technology. The working principle is to invert 50/60Hz alternative current into direct current first. Then the direct current is inverted into a high-frequency alternative current (20K.Hz) by JGBT components before it is rectified. Machines in this series have features as follows:

• IGBT Inverter technology, current-mode control. Reliable quality and stable performance.
• Closed-circuit feedback with constant voltage output. Good resistance to voltage fluctuation. (±15%)
• Electric reactor control, stable welding process with a little splash, deep welding pool, and beautiful welding seam.
• Slow wire-feeding for arc start and tip ball removal after welding ensures a high success rate of arc start.
• Suitable for welding thin and medium metal sheets of above 8mm thickness.
• Small measurement, lightweight, easy operation, practical and economical.
• The efficiency of this machine is above 85%. It saves above 30% energy compared with conventional welding machines.

Electrical diagrams

MIG-205DS

Main Parameter

Installation

Power Input Cable
Each machine is equipped with a power input cable. Connect the cable to AC Single phase 110/220V±10% power supply.
Power Output Cable
Connect the CO2 gas bottle firmly with the CO2 inlet on the back of the welding machine by a gas-carrying hose. A gas regulator for the CO2 gas bottle is needed

1. Using CO2/MIG. MAG functions, please plug Dinse connector into socket and
   earth clamp into Socket, plug the welding torch into the on the front panel and screw it tight. Meanwhile, insert the welding wire into the welding torch by hand from the built-in wire feeder.

2. Using Gasless function, connect, please plug Dinse connector into socket and
   earth clamp into Socket, plug the welding torch into the on the front panel and screw it tight. Meanwhile, insert the welding wire into the welding torch by hand from the built-in wire feeder.

3. Using the MMA function. plug electrode holder into the socket and earth clamp into the Socket

4. Using the TIG LIFT function, plug in the additional WP-17V-35 TIG torch in a socket and earth clamp into the Socket

WIRE SETUP

1.  Mount the wire spool with welding wire to the shaft of the wire feeder. Lock the wire spool with the spool holder.
2. Choose a suitable contact tip according to the size of the welding wire.
3. Undo the screw of the wire pressure wheel and lead the wire into the groove of wire driving wheels via the wire guide tube. Adjust the pressure wheel to ensure no slippage of wire occurs. But too much pressure would cause deformation of welding wire and affect the wire feeding speed.
4. Release the welding wire roll in a counter clock-wise direction. The head part of the welding wire is always inserted into the fixing bore on the rim of the wire spool to ensure avoid the looseness of the wire. So please just cut the bent head part off while using it in order to avoid wire stuck.
5. Choose the correct track of the wire feeding groove by the welding wire diameter.

Press the button to lead the wire out of the welding torch. WEDDING PERFORMING

Including Accessories

• 1 0feet cable with 300A electrode holder 1 Offset cable with 300A earth damp
• Gas hose
• Brush&hammer
• Power Adaptor C 110/220V) Manual

Operation

1. Turn over displays(Welding Current. Workpiece Thickness. Welding Voltage, inductance)
2. Adjusting knob for value
3. Gas checking
4. Wire feeding by manual
5. Welding wire select
6. Welding method selected on CO2/MIG, MAG, DC stick(MMA), Tig Lift, Gasless Flux Welding.
7. 2steps and 4steps select

Setup of the Welding Current
The welding current and arc voltage have a direct influence on the stability, quality, and efficiency
of welding. So good coordination of the welding current and arc voltage is required for high-quality welding. It is decided by the diameter of the welding wire, mode of droplet transfer, and requirement of welding efficiency. Regarding the setup of current and voltage for general welding, please consult the form below. Regarding the different welding requirements, please refer to the “Zoom Table of Welding Parameter”.

Welding Parameter List. (For Low-carbon Steel)

Setup of Welding Speed
The welding speed affects the welding quality and efficiency. Higher welding speed means less
gas protection, accelerated cooling speed, lower flexibility, and forming of the welding seam. Lower welding speed is likely to cause burning through the workpiece and a puffy welding seam. In the actual production, please keep the welding speed less than 30m/h.
Setup of Dry Extension of Welding Wire
A longer dry extension of welding wire means deeper penetration, a faster melting of welding wire, and higher production efficiency. But an excessive length of the dry extension is likely to cause burnout of wire and splash of droplets. So 10 times the length of the welding wire diameter is always chosen in the actual welding operation.
Setup of CO2 Flow
The CO2 flow is rated to the gas protection effect. Besides, the gas protection of inside fillet welding is better than that of outside fillet welding. So a lower gas flow shall be chosen. For specific digits, please consult the form below.

Choice of CO2 Flow

Welding Mode| Thin Wire/CO2 Shield| Thick Wire/CO2 Shield| Thick Wire/High Current

/CO2 Shield

---|---|---|---
CO2 Flow (Umin)| 5- 15| 15- 25| 25-50

Attention

Work Environment.

1. The environment should be dry and the air humidity didn’t exceed 90%.
2. The temperature should be from -10’C to 40’C.
3. Avoid welding under rain or hot sunshine, don’t let water or rain into the machine.
4. Don’t work under dust areas or aggressive fume.
5. Avoid using the machine under strong airflow.

Safe tips.
The machine is equipped with an over-voltage, over-current, and overheat protection device. If the voltage, output current, and temperature exceed the standard, the machine will stop working. Besides, overusing the machine based on
exceeded voltage, the machine will be damaged, so please kindly note as below:
Ensure Good Airiness.
During the working, the machine will generate high temperature and it needs help from a fan to cool the machine. So users please make sure the ventilation inlet is not stuck or covered. Meanwhile, keep the objects around the machine at a distance of no less than 0.3m. Keeping airiness helps to lower the temperature more quickly and ensures a longer service life for the machine.
Current Overloading Prohibited
Close attention should be paid to the permissible loading current(the available duty cycle) to ensure the welding current is under the maximum permissible current. Current overloading shortens the service life of a machine greatly or even damages the machine.
Voltage Overloading Prohibited
For the power supply voltage, please refer to the “Main Parameter Table”. Under normal circumstances, the auto-compensation circuit in the machine will help to keep the welding current within a permissible range. Voltage overload damages the machine, so preventive measures are needed.
Earth cable connects to the ground. There is a mark near the earth screw on the back panel. Before using the machine, please choose a wire (cross- sectional area above 6 mm2) to connect the earth screw to the ground to avoid electricity leakage accidents and release static electricity.
No overload of the standard rated duty cycle. When it overloads the standard, the machine will stop working due to overheating inside the machine. After stopping and resting for some time, the machine can be started to work again.

Maintenance

1. Below operation should be done by a professional operator with electrical engineering & safe knowledge and ability qualify certificate. Before opening the machine, please make sure the machine inputs the power wire is unconnected to the power supply.
2. Check junction circuit inside of welding machine on time, make sure all the junctions are right, stable connector (especially on plug connector or component). If anyone is rust or loose, please get rid of the rust or oxide film with sandpaper, reconnect it and make the connection fastened up.
3. Don’t be close to the electron component (such as the fan) inside of the machine by hand, hair, and other tools when the machine is energized.
4. Get rid of the dust with dry compressed clean air in general. If machines work under dense smoke & polluted air, please get rid of the dust every day. The compressed pressure should be at a workable level to avoid component damage.
5. Try your best to keep the water & water vapor from inside the machine. If the water comes inside of a machine, please kindly dry the machine immediately. Then, please test the insulation situation of the welding machine (including each connection or between connections and shell.) firstly, if ok, please continue to work.
6. Check all the covers of the welding cable general. Any wear out, please bind up or change it.
7. Please keep the welding machine in the original package in a dry place for a long time no use.

Fault and repair

In order to optimize the machine’s function and ensure a safe working condition, maintenance and troubleshooting are critical. When performing maintenance and troubleshooting, please focus on and check the following parts and points: welding torch, wear of spare parts in the wire feeding device, deformation, and gas hole. Clean the dust of some parts or replace them if necessary. To keep the original function of the machine, please purchase the genuine spare parts only from
our company.
Welding Power Supply

2. Check and make sure the power-on indicator works properly.

|
Cooling

Fan

| 1. Check whether the fan works properly or there is too

mu c h noise .

| Checking is needed if abnormal

noise or non-rotating is found.

Power Supply| 1.  Check the unusual vibration or bumming while working

2.  Check the peculiar smell while working

3.  Check the overheating trace like color change

|
Outer Area| 1. Check the wear of the gas-carrying hose and looseness of connectors.

2. Check the looseness of the shelf and other fastened parts.

|

Welding Torch

Nozzle

| 1. Whether it is installed firmly or the front-end is

deformed

| It leads to bubbles.

2. Whether it is attached with some splashes.

| It leads to the burning of the welding torch. (Application of anti- spattering agent is

recommended.)

Contact Tip

| 1. Whether it is installed firmly| Cause of the damage to the torch

thread

2. Damage of the end, wear or stuck of the bore.| Cause of unstable arc or breaking arc

Conductor Tube

| ****

1. Check the size of the extrusion part

| Replace it when it is less than 6mm long. Too short extrusion may cause an unstable arc. (Make it a little longer than the regulated

length when replacing.)

2. Check the consistency of the welding wire

diameter and inner diameter of the contact tube.

| Their unsuitability of them may cause

an unstable arc. Change it into a suitable tub.

3. Check the bending or extended parts,| Cause of bad wire-feeding or

unstable arc. Please replace it.

4. Check the filth inside the tube and the residue of wire

cladding

| Cause of bad wire-feeding or unstable arc.

Please clean with coal oil or replace it.

5. Check damage to the tube and wear of the

0-shaped ring.

| It may cause a splash. Please replace

the damaged one.

Gas Diffuser

| 1. Check whether it is inserted in or blocked. Check the suitability if is purchased from other suppliers.| It may cause a bad gas shield, defect of welding or burning of welding torch, and so on. Please handle it

properly.

Wire Feeder

Tension Arm| 1. Whether it is set at a suitable pressure.| Cause of unstable wire-feeding or unstable

arc.

---|---|---

Wire Guide Tube

| 1. Check the welding wire fragment and powder at the inlet of the wire guide tube and the rim of the wire feeding

wheel.

| Clean the fragment. Find out the cause and rectify it.
2. Check the consistency of the welding wire

diameter and inner diameter of the contact tube.

| Cause of unstable arc, welding wire

fragment or powder.

3. Check the consistency of the inlet center of the wire guide tube and the groove center of the wire feeding wheel

by eyes.

| The inconsistency of them may cause welding wire powder and unstable arc.

Wire DrivingWheel

| 1. Check the consistency of the actual diameter of the welding wire and the nominal diameter of the wire feeding g

wheel.

| 1. lt causes the wire to power, jam of wire feeding tube, and unstable arc.
2. Check the jam of the groove of the wire feeding

wheel.

| 2. replace it if an unusual phenomenon is found.
Pressure Wheel| 1. Check the stability of rotation, and wear of the press

plane and the narrowing-down of the contact plane.

| It causes bad wire-feeding.

Furthermore, it causes an unstable arc.

Power Output Cable

The cable of Welding Torch

| 1. Whether the cable of the welding torch is bent too much. 2. Check the looseness of the metal connector of the fast coupling device.| 1.     Cause of bad wire-feeding

2.     Too much wire fed with bent cable may

cause an unstable arc. So please straighten it while welding.

The cable of Power Output

| 1. Check the wear and damage of the insulation layer. 2. Check the nudity(insulation Damaged) and looseness of the cable connection(connector of welding power supply and cable connection to the

workpiece).

| Proper measures of inspection shall be used for body safety and welding stability.

Usual inspection-general and simple Regular inspection-thorough and complete

Cable Power Input

| 1.  Check whether the input and output terminals of the distribution box are connected Firmly.

2.  Whether the fuse is connected reliably.

3.  Check the connection of the input terminal of the welding power supply.

4.  Whether the insulation layer is worn out, damaged, or

nude.

|

Ground Cable

| 1.     Check the circuit break and connection of the earth cable of the welding power supply.

2.        Check the circuit break and connection of the earth

cable of a workpiece.

| To avoid power leakage and ensure safety, the general inspection must be performed.

References

• Welder, Plasma Cutter, Welding Helmet, Welding Equipment – YesWelder

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