CONTENT

SECURITY WARNINGS ………………………………………………………………3
1. GENERAL DESCRIPTION ………………………………………………………5
2. INSTALLATION INSTRUCTION …………………………………………………5
3. OPERATING PRINCIPLE ………………………………………………………8
4. CONTROL PANEL OPERATION……………………………………………………8
5. MAIN SPECIFICATION ………………………………………………………13
6. USE AND MAINTENANCE ………………………………………………………14
7. TROUBLESHOOTING ……………………………………………………………14
8. TRANSPORTANTION AND STORAGE ……………………………………………17
 

This welding machine for industrial and professional use is in the conformity with IEC 60974 International Safety Standard. Hereby we state that we provide one year of guarantee for this welding machine since the date of purchase. Please read and understand this instruction manual carefully before the installation and operation of this machine. The contents of this manual may be revised without prior notice.

For you and others safety, please read this manual carefully before installation or operation. In the process of use, may cause injury to you and others, be protected when welding.

Electric shock—may lead to serious injury or even death. ·Install earthing device according to the application criteria. ·Never touch the live parts when skin bared or wearing wet gloves/clothes. ·Make sure that you are insulated from the ground and workpiece. ·Make sure that your working position is safe.

Smoke & gas—may be harmful to health. ·Keep the head away 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 spark may cause fire, please make sure no combustible materials nearby and pay attention to fire safety. ·Have a fire extinguisher nearby, and have a trained person to use it. ·Airtight container welding is forbidden ·Pipe thaw with this machine is forbidden.

Hot workpiece may cause severe scalding. ·Don’t contact hot workpiece 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 and in place.

Machine fault—seek professional help when encountering any difficulties. ·Consult the relevant contents of this manual If you encounter any difficulties in installation and operation. ·If you still do not fully understand after reading, or in accordance with the guide of this manual will not solve the problem. Contact with your supplier or KINGNOW’s service center, seek professional help immediately.

1. GENERAL DESCRIPTION  Advanced IGBT inverter technology  Inverter frequency is 20 KHz, greatly reducing the volume and weight of the welder.  Great reduction in metal loss obviously enhances the welding efficiency and energy saving effect.  Switching frequency is beyond audio range, which almost eliminates noise pollution.  Leading control mode  Closed loop feedback control, constant voltage output, fit for wide voltage range (±15%)  Adjustable welding voltage, precisely matching the welding current, excellent welding characteristics.  Unique welding dynamic characteristic control circuit, stable welding arc, little splash, beautiful shaping, high welding efficiency.  Function of removing the molten ball after welding available, slow wire feeding, high successful rate of arc starting.  CO2 welding and MAG welding available.  Welding wire with a diameter of Φ0.8-Φ1.2, such as AlSi,AlMg,CS,SS,Cu and special material can be used. 2. INSTALLATION & OPERATION 1) Environment: ·Please install the machine strictly according to the following steps. ·Electric connection operation should be after turning off the power supply switch of the switch box. ·The protection class of this machine is IP21, so avoid using it in rain, less sunshine, humidness, wind and dust. The temperature should be between -10℃~±40℃. ·Ground slope should be no more than 15°. ·The distance between machine and wall is not more than 20CM and the distance between 2 machines is more than 10CM. ·For welding machine with water cooler, please use antifreeze when the temperature below zero. When using water-cool welding torch, please be aware of antifreezing. 2)Voltage of power supply ·Wave form should be standard sine wave; effective value is 380V±10%; Frequency is 50/60 Hz. 6 INSTRUCTION MANUAL-MIG SERIES ·non-balance ratio of 3 phases voltage: ≤±5%. 3) Input power Model MIG218P MIG280P MIG350P MIG500P Input power 3 Phases AC380V 3 Phases AC380V 3 Phases AC380V 3 Phases AC380V Rated input power capacity 6.4KVA 9.2KVA 15.8KVA 24.4KVA Lowest input power capacity of generator 15KVA 20KVA 30KVA 50KVA Rated Input current 9.8A 14A 24A 37A Input cable ≥4mm² ≥4mm² ≥4mm² ≥6mm² Output cable 35mm² 35mm² 50mm² 70mm² Earth cable ≥2.5mm² ≥2.5mm² ≥2.5mm² ≥6mm² Remarks: above specification is for reference only. 3)Installation Instruction photo of cable connection （1） Welding power （2） Three-phase power supply connection （3） Earth cable. （4） Negative terminal of output welding cable. （5） Cable of wire feeder control, which connects the control socket of machine. （6） Output Positive terminal of welding cable. （7） Wire feeder 7 INSTRUCTION MANUAL-MIG SERIES （8） Workpiece （9） Welding torch （10）Wire feeder Control （11）Box of welding wire （12）Gas cylinder （13）Preheat cable, heating cable of gas regulator connects the socket of output power on the back of machine. （14）Gas pipe （15）Regulator of gas rate of flow （16）Gas Valve 4)Operation Closing the automatic air switch on switchboard, indicator of weld on the fan are working on. Press the button of manual wire feeding, the wire is moving quickly. According to the requirements set the controller and the knob on the front panel and switch positions. Press the torch switch and wire is feeding. Having gas flow from the torch nozzle, normal welding can be worked. After welding, the gas and power supply should be shut off. 3. Operating principle 3.1 functional block diagram Photo of the principle block-diagram 8 INSTRUCTION MANUAL-MIG SERIES The machine adopts IGBT soft switching inverter technology, first the three-phase 380VAC/50Hz power grid after power frequency rectifier filter, supply 20 KHZ IGBT inverter frequency conversion into intermediate frequency alternating current, then through intermediate frequency step-down transformer and rectifier filter, get the need of welding DC output. Through this process, improves the dynamic response of the welding machine speed, decrease the volume and weight of welding machine. The machine adopts closed loop control mode, make the welding power source has good adaptability for grid, excellent welding performance. 3.2 Features of output of the welding machine Features of welding machine output Photo of welder output 4. CONTROL PANEL OPERATION 4.1 Front panel structure 9 INSTRUCTION MANUAL-MIG SERIES 1.Process Button Short press shows. prg 00 x. x is the current application and selection process, current encoder Selection process, Press 5secs button turn out the current procedure number stored the welding parameters. Application Range: 000-005. 2.Save Button Saved welding state and parameters to the current program number. 3.Adjustment Button 1) Non-synergic state parameter Settings (Amateurs don't use, only for reference welding experiment) Switch the function keys to choose parameters (Adjust current knob to change the parameters) A) P -1 Total frequency Default: 100 Range: 1-300 B) P -2 Double pulse frequency Default: 100 Range: 1-300 C) P -3 Double pulse frequency of wire feed Default: 0 Range: 1—10 D) P -4 Single pulse voltage Default: 15 Range: 1-100 E) P -5 Double pulse voltage's welding time adjustment Default: 15 Range: 1-100 F) P -6 Inductance Default: 35 Range: 1-100 G) P -7 Double pulse high voltage Default: 19 Range: 1-10 - welding maximum output 2) Synergic state parameter Settings Switch the function keys to choose parameters (Adjust current knob to change the parameters) A) P -1 Total frequency Default: 0 Range: -20—20 B) P -2 Double pulse frequency Default: 0 Range: -20—20 C) P -3 Double pulse frequency of wire feed Default: 0 Range: 1—10 D) P -4 Single pulse voltage Default: 0 Range: -20—20 E) P -5 Double pulse voltage's welding time adjustment Default: 0 Range: -20—20 F) P -6 Inductance Default: 0 Range: -20—20 G) P -7 Double pulse high voltage Default: 0 Range: -20—20 Note: P2, P3, P5, P6, P7 work in double pulse mode, P1, P4, P6 work in single pulse mode. 3）Without pulse state parameter Settings Switch function keys to choose parameters (Adjust current knob to change the parameters) P -6 Inductance Default: 35 Range: 1-100 Adjust P-6 between 90 and 95 to get best welding effect in no pulse welding. 4) MMA welding state Press the 5 sec adjustment button, switch to manual welding electrode. 10 INSTRUCTION MANUAL-MIG SERIES 4.SYN (Synergic/Non-synergic) Button Switch welding state Synergic/ Non-synergic, once the Synergic indicator light on, it will be in the Synergic state. 5. "V" voltmeter Display given voltage when Static, press the welding torch or welding displayed the actual output voltage. 6."A" amperemeter Displayed current given when Static, press the welding torch or welding displayed the actual output current. 7. Remote welding parameter Settings 1) Welding auxiliary parameter Settings Remote and Strong arc buttons to switch the auxiliary parameters back and forth. Pr1 Gas pre time (gas light on) Default: 0.2S Range: 0.2S-10S Pr2 Arc starting current (arc light on) Default: 16V/50A Volt Range: 10 v - welding maximum output Current Range: 10 a - welding maximum output Pr3 Current rising speed (rise light on) Default: 0.2S Range: 0.2S-10S Pr4 Welding current( light on when welding) Adjust the welding current Pr5 current drop speed (fall light on) Default: 0.2S Range: 0.2S-10S Pr6 Arc ending current ( arc lights on) Default: 16V/50A Volt Range: 10 v - welding maximum output Current Range: 10 a - welding maximum output Pr7 Post flow time(post flow light on) Default: 0.2S Range: 0.2S-10S 2) Wire feeding machine control function Long press 5 sec Remote button, switch wire feeding machine control state, Lights out for the control panel, light for the wire feeding machine control. Default: panel control 3) Arc state switch function Long press 5 sec moves to the Strong arc button, switch arc state, lights 11 INSTRUCTION MANUAL-MIG SERIES out as the weak state of arc, bright as strong arc state. Default: weak state of electric arc 8. The Welding Voltage Encoder Adjust the given voltage 9. Welding Current Encoder Adjust the given current 10. Wire Material Selection Button Welding material selection, provide 6 kinds of material. 11. Wire Diameter Selection Button Wire diameter selection, provide four switch wire diameter. 12. Pulse Selection Button Welding with or without pulse, can use single or double pulse welding. Press this button to eliminate single and double light at the same time, pulse is turned off and change into DC arc welding at this time. 13. Crater Arc Button Welding torch 2 T / 4T state switch, corresponding 2 T(no crater arc), 4T ( crater arc) indicator will light up. 14. Abnormal Temperature Indicator Light When the temperature of the host machine is abnormal indicator light is up. 4.2 Back panel structure MIG218P/280P 1. OUTPUT POWER 2. AIR SWITCH 3. INPUT POWER 4. FAN 12 INSTRUCTION MANUAL-MIG SERIES MIG218PE/280PE 1. INPUT POWER 2. OUTPUT POWER 3. CONTROL CABLE 1 4. CONTROL CABLE 2 5. AIR SWITCH 6. FAN 7. OUTPUT + MIG 350PE 1. INPUT POWER 2. OUTPUT POWER 3. FUSE OF SOCKET 4. AIR SWITCH 5. CONTROL CABLE 1 6. CONTROL CABLE 2 7. OUTPUT + 8. FAN 13 INSTRUCTION MANUAL-MIG SERIES MIG 350PW/500PW 1. AIR SWITCH 2. FUSE OF WATER COOLER 3. SWITCH OF WATER COOLER 4. WATER INLET 5. WATER OUTLET 6. INPUT POWER 7. OUTPUT POWER 8. FUSE OF SOCKET 9. CONTROL CABLE 1 10. CONTROL CABLE 2 11. OUTPUT + 12. FAN 13. INTAKE OF WATER TANK 5. MAIN SPECIFICATION DESRIPTION SM-230 SM-280 SM-350 SM-500 Power voltage/frequency 三 380V±15% 50Hz 三 380V±15% 50Hz 三 380V±15% 50Hz 三 380V±15% 50Hz Rated input Capacity 6.4KVA 9.2KVA 15.8KVA 24.4KVA Rated input current 9.8A 14A 24A 37A Rated Duty Cycle 60% 60% 60% 60% Output Current Range 50-210A 50-250A 50-350A 50-500A No-load Voltage 45V 45V 65V 65V Efficiency ≥85% ≥85% ≥85% ≥85% Power factor( cos𝜑) ≥0.93 ≥0.93 ≥0.93 ≥0.93 Diameter Of Rod Φ0.8-1.2 Φ0.8-1.2 Φ1.0-1.6 Φ1.0-1.6 Rate of gas flow 15-20L/min 15-20L/min 15-20L/min 15-20L/min Insulation class F F F F 14 INSTRUCTION MANUAL-MIG SERIES 6. MAINTENANCE 1. Check periodically whether inner circuit connection is ok (esp. plugs). Tighten the loose connection. If there is oxidization, remove it with sandpaper and then reconnect. 2. Keep hands, hair and tools away from the moving parts such as the fan to avoid personal injury or machine damage. 3. Clean the dust periodically with dry and clean compressed air. If welding in environment with heavy smoke and pollution, the machine should be cleaned daily. The pressure of compressed air should be at a proper lever lest the small parts inside the machine be damaged. 4. Avoid rain, water and vapor infilter the machine. If there is, dry it and check the insulation with a megger. Only when there is no abnormal phenomena can welding be continued. 5. Check periodically whether the insulation skin of all cables are in good condition. If there is any dilapidation, wrap it or replace it. 6. Check periodically whether the gas hose has any cracks. If any, get them replaced. 7. Put the machine into the original packing in dry location if it is not to be used for a long time. 7. TROUBLESHOOTING Common failure phenomena, reasons and solutions Fault Reasons Solutions The protection Light turns on. 1.Overheating protection 2.Over-current protection 1. Check the welding current and welding time. Operate according to the requirement of the instruction manual. 2.Check the fan’s running status when welding. If the fan does not work, check if there is a power supply of 220V: If the power supply is normal, check the fan; if the power supply is abnormal, check the connecting cable of the power supply. 15 INSTRUCTION MANUAL-MIG SERIES 3. Replace the thermal switch if it is damaged. After startup, The control panel display light is not bright 1.Lack Power supply phase 1.Check the power supply 2.Damage of automatic air switch on the rear panel 2.Replace the automatic air switch When connected to welder power supply, automatic air switch on the rear panel power off immediately 1.Automatic air switch failure 1.Replace air switch 2 IGBT module damage 2.Replace IGBT module, and replace the driver circuit board 3.Three-phase rectifier bridge damage 3.Replace of three-phase rectifier bridge 4.Varistor damage 4.Replace varistor 5.Welding machine control board damage 5.Replace welding machine control During the welding process, welding power source automatic air switch on the rear panel power off automatically 1.Long-term overload running 1.According to the welding machine load factor 2.Air switch is damaged 2.Replace the air switch The welding current cannot adjust 1.Wire feeding machine control cable is broken or controller damaged 1.Replace wire feeding machine control cable or controller 2.Welding machine control circuit board is broken 2.Replace the control panel 3.The wire of both ends of the shunt in welding machine is broken 3.Reconnect the wire Arc instability, big splash 1.Welding do not conform to the specifications 1.Fine adjustment welding specification 2.Conductive nozzle serious wear out 2.Change conductive nozzle CO2 gas regulator is not heated 1 CO2 gas regulator damaged 1.Replace CO2 gas regulator 2.Heating cable broken or short circuit 2.Repair heating cable 3.The heating power thermistor damaged 3.Change the thermistor 16 INSTRUCTION MANUAL-MIG SERIES Press the torch switch, wire feeding is normal, but the gas path is obstructed 1.Control circuit board damaged 1.Change control circuit board 2.Solenoid valve damaged 2.Replace solenoid valve Press the torch switch and wire feeding machine doesn't work, and no no-load voltage indicator 1.Welding torch switch damaged 1.Replace welding torch 2.Wire feeding machine control cable is broken 2.Repair wire feeding machine control cable 3.Control circuit board is broken 3.Change control circuit board Common process phenomena, defects and reasons Defects Reasons Blow Hole 1. The gas is not pure or insufficient gas supply 2. Inlet air when welding 3. The heater doesn't work 4. Windy, protection is not completely 5. The nozzle is splash block, not smooth 6. The distance between nozzle and workpiece is too large 7. The welding area surface is pollution, oil, rust, moisture, not clear 8. Arc is too long, arc voltage is too high 9. Wire lack of silicon, manganese content Undercut 1. The arc is too long, the arc voltage is too high 2. Welding speed too fast 3. The welding current is too big 4. Improper position of welding wire 5. Improper swing welding wire incomplete penetration 1. The welding current is too small, wire feeding is not uniform 2. The arc voltage is too low or too high 3. Welding speed too fast or too slow (in the groove) 4. Small bevel Angle, gap is too small 5. Improper position of welding wire Bad Appearance 1. Process parameter is not appropriate 2. Improper position of welding wire 3. Center offset of the feed roller 4. improper adjustment of welding wire straightening mechanism 5. conductive nozzle loose Crack 1. The welding current is too large 2. The groove too narrow 3. The arc voltage is too low 17 INSTRUCTION MANUAL-MIG SERIES 4. The inappropriate position of welding wire Arc unstable 1. The conductive nozzle loose, or wear, or diameter is too large (Compared with the wire) 2. Wire reel rotating non-uniform, groove of the wire feeding roller has wear out, pressure roller not strong enough, large resistance of conductive tube 3. Low welding current, arc voltage fluctuation 4. Wire stem elongation is too large 5. Welding pieces has the rust, paint and grease 6. Improper position of earth cable welding spatter 1. Short circuit transition inductance is not proper, too big or too small 2. The welding current and arc voltage mismatch 3. Poor cleaning of the welding wire and welding pieces 8. TRANSPORTATION AND STORAGE 1. This welding equipment belong to the precision equipment, strong vibration or impact may result in damage to equipment. 2. The welding equipment adopts the cartons/wooden box packaging, can be used during transit artificial/forklift, but should avoid tilt, shall not be partial to pour and strong impact and vibration. 3. The welding equipment shall be deposited in the shelter and dry ventilated environment, storage environment temperature 25 ℃ ~ 55 ℃. NOTE: This machine is in continuous improvement, so other parts may be different except the function and operation. Your understanding would be greatly appreciated.