Duralloy MULTIMIG 200 PFC MV, Owner'S Manual

Page 1: ...MULTIMIG 200 PFC MV OWNER S MANUAL www duralloy net au 1300 369 456 ...

Page 2: ...on DURALLOY product is subject to stringent quality control and designed and manufactured to EN60974 1 2012 standards Common use of DURALLOY products include Light Engineering Automotive Home Hobby Engineering Farming Industrial Maintenance Repairs For industrial welding solutions check out the DURALLOY at www duralloy net au DURALLOY is a market leading provider of innovative power equipment solu...

Page 3: ...t Guide Wiring Diagram Care Maintenance Welding Settings Basic MIG Welding Guide Effects of MMA Welding Various Metals Basic MMA Welding Guide MMA Welding Techniques MMA Troubleshooting Safety Warranty 5 7 9 10 10 11 15 16 17 21 22 27 3 MULTIMIG 200 PFC MV OWNER S MANUAL ...

Page 4: ...Inch Switch Gas Purge switch Quick connect gas fittings Protective front fascia cover IP23 rating Extension lead friendly up to 100m TIG STICK MIG EN60974 1 2012 SPECIFICATIONS Power Supply 90VAC 275VAC Supply Plug 15 Amp Frequency 50 60Hz 1 110 120 130V 10 1 220 230 240V 10 MIG MMA TIG MIG MMA TIG Input Power 4kW 3 5kW 3 2kW 6 2kW 6 2kW 4 2kW Input Current 37 8A 32A 29A 29A 30A 20A Duty Cycle 40o...

Page 5: ...A TIG welding current MIG Voltage MMA Arc Force Adjustment Knob In MIG mode this knob sets the welding voltage In MMA mode sets arc force In TIG mode sets downslope time Wire Feed Speed Current Display Meter In MIG mode displays wire feeding speed in m minute prior to welding during welding displays welding current output In MMA TIG mode displays welding current The display meter mode is shown by ...

Page 6: ...time and decreases the short circuit frequency rate This causes a wider and more penetrating arc useful for thicker weld joints Less inductance will create a narrow more focused arc This effect can also be used to fine tune the arc to produce less splatter Wire speed wire size and type shielding gas will all change the effect that the inductance setting has on the welding arc Inductance change wil...

Page 7: ... through the wire drive inlet guide through the drive roller grooves and into the brass outlet wire guide tube Ensuring that the wire is correctly seated in the drive roller grooves replace the wire feed tension arms and lock them into place by rotating the wire feed tension adjustment lever back to the vertical position Adjusting wire feed tension this is accomplished by winding the knob on the t...

Page 8: ... tip For this reason it is quite common for operators to have an extra MIG torch specifically set up for aluminium use if the machine is used for welding steel as well Another option to overcome the friction issues is using a spool gun which will give better results than a 3m push torch when welding aluminium www duralloy net au 1300 369 456 8 MULTIMIG 200 PFC MV OWNER S MANUAL 4 ARC MMA Welding O...

Page 9: ...www duralloy net au 1300 369 456 WIRING DIAGRAM 9 MULTIMIG 200 PFC MV OWNER S MANUAL ...

Page 10: ...pliance is manufactured in accordance with relevant safety standards Only experts must carry out repairing of electrical appliances otherwise considerable danger for the user may result Use only genuine replacement parts Do not use modified or non genuine parts Storing the Welder When not in use the welder should be stored in the dry and frost free environment WARNING Before performing cleaning ma...

Page 11: ...ocess which fuses together the parts to be welded by heating them with an arc between a continuous flux filled electrode wire and the work Shielding is obtained through decomposition of the flux within the tubular wire Additional shielding may or may not be obtained from an externally supplied gas or gas mixture The process is normally applied semi automatically however the process may be applied ...

Page 12: ...e GMAW process are controlled by these variables Preselected Variables Preselected variables depend upon the type of material being welded the thickness of the material the welding position the deposition rate and the mechanical properties These variables are Type of electrode wire Size of electrode wire Type of gas Gas flow rate Primary Adjustable Variables These control the process after presele...

Page 13: ...e Speed control and the welding Voltage Control The welding current is determined by the Current Wire Speed control the current will increase with increased Current Wire Speed resulting in a shorter arc Less Current Wire Speed will reduce the current and lengthen the arc Increasing the welding voltage hardly alters the current level but lengthens the arc By decreasing the voltage a shorter arc is ...

Page 14: ...oblem the result is usually porosity within the weld metal Porosity always stems from some contaminant within the molten weld pool which is in the process of escaping during solidification of the molten metal Contaminants range from no gas around the welding arc to dirt on the workpiece surface Porosity can be reduced by checking the following points MIG WELDING TROUBLESHOOTING WARNING Disengage t...

Page 15: ...distribute the heat Cast Iron Most types of cast iron except white iron are weldable White iron because of its extreme brittleness generally cracks when EFFECTS OF MMA WELDING VARIOUS MATERIALS attempts are made to weld it Trouble may also be experienced when welding white heart malleable due to the porosity caused by gas held in this type of iron Copper and Alloys The most important factor is the...

Page 16: ...ration For heavier sections and for repair work on castings etc it will be necessary to cut or grind an angle between the pieces being joined to ensure proper penetration of the weld metal and to produce sound joints In general surfaces being welded should be clean and free of rust scale dirt grease etc Slag should be removed from oxy cut surfaces Typical joint designs are shown in Figure 1 19 ...

Page 17: ...lf in a comfortable position before beginning to weld Get a seat of suitable height and do as much work as possible sitting down Don t hold your body tense A taut attitude of mind and a tensed body will soon make you feel tired Relax and you will find that the job becomes much easier You can add much to your peace of mind by wearing a leather apron and gauntlets You won t be worrying then about be...

Page 18: ...t Contact or touch weld electrodes such as E7014 Stick electrodes do not stick in this way and make welding much easier Rate of Travel After the arc is struck your next concern is to maintain it and this requires moving the electrode tip towards the molten pool at the same rate as it is melting away At the same time the electrode has to move along the plate to form a bead The electrode is directed...

Page 19: ...gle iron is a suitable specimen with which to begin or two lengths of strip steel may be tacked together at right angles Using a 3 2mm 6012 Stick electrode at 100 amps position angle iron with one leg horizontal and the other vertical This is known as a horizontal vertical HV fillet Strike the arc and immediately bring the electrode to a position perpendicular to the line of the fillet and about 4...

Page 20: ... at an angle of about 45º 3 Overhead Welds Apart from the rather awkward position necessary overhead welding is not much more difficult that down hand welding Set up a specimen for overhead welding by first tacking a length of angle iron at right angles to another piece of angle iron or a length of waste pipe Then tack this to the work bench or hold in a vice so that the specimen is positioned in ...

Page 21: ...www duralloy net au 1300 369 456 21 MULTIMIG 200 PFC MV OWNER S MANUAL MMA TROUBLESHOOTING ...

Page 22: ...bare hands Do not wear wet or damaged gloves 6 Protect yourself from electric shock Do not use the welder outdoors Insulate yourself from the work piece and the ground Use non flammable dry insulating material if possible or use dry rubber mats dry wood or plywood or other dry insulating material large enough to cover the area of contact with the work or the ground 7 Avoid inhaling dust Some dust ...

Page 23: ...nt serviced by a qualified repair person using identical replacement parts This will ensure that the safety of the power tool is maintained www duralloy net au 1300 369 456 Personal Safety CAUTION Keep the work area well lit Make sure there is adequate space surrounding the work area Always keep the work area free of obstructions grease oil trash and other debris Do not use equipment in areas near...

Page 24: ...ing welding or cutting www duralloy net au 1300 369 456 Electricity Can Kill DANGER Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semi automatic or automatic wire welding the wire wire reel drive roll housing a...

Page 25: ... confined space only if it is well ventilated or while wearing an air supplied respirator Shielding ga es used for welding can displace air causing injury or death Be sure the breathing air is safe 6 Do not weld in locations near degreasing cleaning or spraying operations The heat and rays of the arc can react with vapours to form highly toxic and irritating gases 7 Do not weld on coated metals su...

Page 26: ...a welder to thaw frozen pipes 10 Remove the stick electrode from the holder or cut off the welding wire at the contact tip when not in use Sparks Hot Metal WARNING Chipping and grinding causes flying metal and as welds cool they can throw off slag 1 Wear an AS NZS approved face shield or safety goggles Side shields are recommended 2 Wear appropriate safety equipment to protect the skin and body ww...

Page 27: ...llary Equipment 3 months WARRANTY Duralloy Welding Equipment Plasma Cutting Range The Obligation of Duralloy Industrial Supply under this warranty is limited to the circumstance set out above and is subject to The customer being able to provide proof of purchase of the relevant equipment A defect in either material or workmanship The customer returning the product to Duralloy Industrial supply or ...

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