INVERTER SEMI-AUTOMATIC

WELDING MANUAL

Model
MIG 200AL-DP
Dual Pulse Synergy

The drawings and illustrations of the device included in this manual may differ from the original.

< Translation and adaptation of the original instructions by Satdream in English >

WARNING: Please use the welding station only after carefully reading this manual .

1. To ensure safe use, appoint qualified personnel responsible for the installation, maintenance, periodic inspection and repair of this equipment.
2. To ensure safety, before working with the device, read the following manual carefully.
3. After reading the following instruction manual, place it in a location accessible to other users of the device.

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Table of Contents
1. USAGE ............................................................................................................................................................................ 3
2. TECHNICAL DATA ........................................................................................................................................................... 4
3. SECURITY RULES ........................................................................................................................................................... 5
4. SYMBOLS ....................................................................................................................................................................... 8
5. FRONT PANEL AND CONTROL PANEL ............................................................................................................................ 9
6. REAR VIEW ...................................................................................................................................................................11
7. CONTROL PANEL - PROCESSES AND OPTIONS .............................................................................................................12
8. ACCESSORIES ...............................................................................................................................................................24
9. USAGE ..........................................................................................................................................................................24
10. CLEANING AND MAINTENANCE...................................................................................................................................36
11. OUTAGE .......................................................................................................................................................................37
12. STORAGE AND TRANSPORT .........................................................................................................................................38
13. USE ...............................................................................................................................................................................39
14. DECLARATION OF CONFORMITY .................................................................................................................................40
15. ANNEXES ......................................................................................................................................................................41

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 1. USAGE

The MIG 200AL-DP, is an OEM version, which is regularly marketed under different brand (eg. MAGNUM), and is intended
for MIG-MAG, MMA and TIG LIFT welding.

It is designed for manual and electrical welding of carbon and weakly alloy steels, highly allied steels, stainless and acid-
resistant steels, aluminum and its alloys, etc.

The MIG 200AL-DP is designed for all types of welding work in locksmith shops, repair shops, automotive industry,
factories, etc.

The power source was built with IGBT transistors that guarantee minimal electromagnetic interference, allowing for
increased efficiency and reliability of the power source.

Very high efficiency, which translates directly into reduced energy consumption, and a high switching frequency ensure
instantaneous adaptation of the current to changes in parameters during ...

The manufacturer is not liable for damage resulting from use contrary to the intended use.

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2. TECHNICAL DATA

Specifications changeable without notice.

Model MIG 200AL-DP

Dual Pulse Synergy
Power AC 230 [V], 50/60 [Hz]
Welding methods MIG-MAG, MMA, TIG DC Lift, TIG DC Lift Pulse, FLUX,
Pulse, Dual Pulse
Electrical protection 20 [A] Class C
MIG-MAG welding intensity 30 to 200 [A]
60%-200A/28V to 100%-155A/25V
MIG-MAG welding voltage 17.5 to 28 [V]
MMA Welding Intensity 20 to 180 [A]
Empty tension 70 [V]
COS power factor φ 0.73
Wire Diameter 0.8/1.0/1.2 [mm]
Max. reel diameter, (mass) 200 [mm], (5 kg)
Efficiency 85 %
Protective class of the case IP21S
Dimensions (PxLxH) 500x196x392 [mm]
Device mass 15 [kg]

* The range of adjustment varies depending on the method, the alloy and the diameter of the wire.
**All materials compatible in 0.8/1.0 mm, aluminum and aluminum alloy up to 1.2 mm

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 3. SECURITY RULES

Read all the safety regulations and instructions. Failure to comply with safety rules and instructions can
result in electric shock, fire and/or serious injury.

Keep all safety regulations and instructions for future use.

Children should not be allowed to work with this device. People with implanted pacemakers should consult
their doctor before working with the device. Any repairs to the device must be carried out by qualified
personnel in accordance with the working safety conditions applicable to electrical appliances.

Changes alone can alter the functional characteristics of the device or damage the welding settings. Any modifications to
the device alone not only nullify the warranty, but can also degrade the safety conditions of use and expose the user to
the risk of electric shock. Incorrect working conditions and improper use can damage the device and void the warranty.

3.1 General Considerations

a) You should start working well rested, sober, wear work clothes in fabric or fireproof leather, cover your hair, wear shoes
with fire retardant pants, welding gloves and individual protection - leather apron, welding mask, protective goggles,
personal breathing equipment.
b) Work on the installation, dismantling, repair and inspection of electrical welding equipment must be carried out by
employees with the appropriate qualifications.
c) Connecting multiple welding energy sources should not result in the allowable voltage between the output circuits of the
connected energy sources being exceeded empty.
d) The welding current circuit should not be grounded, except when the welding elements are connected to the ground.
e) Welding cables connecting the room to work with the energy source must be connected directly to the room or tooling,
as close as possible to the welding site.

3.2 Consideration before starting work

the welder must:
a) Read the documentation and assess the extent of the welding work,
b) Plan the execution sequence of individual welds,
c) Prepare a suitable binder,
d) Prepare adequate protection of the face and eyes,
e) Check the state of the welding facility and work torch connections,
(f) Ensure that the welding operation does not pose a threat to the environment (arc radiation, the possibility of ignition of
easily flammable elements),
g) Check to see if there is any ignition on the other side when welding to a wall

3.3 During welding

a) Secure the workplace unless there are fixed and mobile anti-reflective and anti-projection screens.
b) Use to weld electrical wires and work torch only in good technical condition (undamaged insulation).
c) Use only the correct thickness of the electrodes and wires for welding.
d) Secure and position the welding object reliably and solidly so that it is not damaged
e) Position the welding parts so that they do not move or tip over.
f) Use goggles to avoid slag.
g) When welding inside boilers, tanks or confined spaces, regardless of the ventilation used, use respiratory protection.

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h) When working inside tanks, boilers and other metal parts, use electric lighting with a voltage of 24V or less.
i) Ensure that the welded element does not pose a risk of falling or moving dangerously for the welder.
j) When welding on scaffolding, check the safety of the scaffold
(k) Protect the airways, eyes, face and hands from burns and exposure to light produced using appropriate personal
protection.
l) Activate the individual air extraction, if there is one, so that the gas fumes are removed from the station.
(m) Use only undamaged, oil-free workshop tools and accessories.

3.4 Prohibited activities

A welder is prohibited from:
a) Use a hot metal prepared for welding or after welding.
b) Repair damaged electrical cables (electric system) yourself.
c) During work breaks, keep the electrode holder on you.
d) Move the welding mask too far from the face, lay it down before the bow goes out and turn on the arc without face
protection.
e) Weld without proper grounding of the room.
(f) Use non-welding protection.
g) Make workplace soil moist, slippery, irregular, contaminated with waste, obstructed.

3.5 Basic activities after work

The welder must:
a) Unplug the welding station from the area.
b) Check that no fires occurred during welding.
c) Clean the workplace, remove the electrode spikes and welding slag.
d) Store welding equipment..

3.6 Final remarks

(a) During welding work inside the tanks, boilers or other closed premises (up to 15 m3), the welder must be provided by another
person outside.

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 WARNINGS

ELECTRIC CHOCS CAN KILL: Welding equipment produces high voltages. Do not touch the welding torch
or connected welding equipment when the device is plugged in. All components of the welding current
system can cause an electric shock, so avoid touching them with your bare hands or through wet or
damaged protective clothing. It is forbidden to work on wet surfaces or to use damaged welding cables.
WARNING: It is forbidden to remove external hoods when the device is connected to the network, as
well as to use the device with the hoods removed!
Welding cables, mass cable, grounding clamp and welding equipment must be kept in good technical
condition to ensure safe operation.

THE VAPEURS AND THE GAZS CAN BE DANGEREUX: Welding generates fumes and gases that are
harmful to health. The workplace must be properly ventilated and equipped with a ventilation system. Do not
weld in closed rooms. Avoid inhaling fumes and gases. The surfaces of welding components must be free of
chemical contaminants such as degreasing substances (solvents), which decompose during welding,
producing toxic gases. .

ELECTRIC ARCS CAN BURN: It is forbidden to look directly at the welding arc with the naked eye. Always
use a mask or helmets with a proper filter. Protect people nearby with non-flammable screens that absorb
radiation. Protect exposed body parts with appropriate protective clothing made of flammable material.

MAGNETIC FIELD ARE DANGEROUS: The electrical current flowing through the welding cables creates
an electromagnetic field around it. Electromagnetic fields can interfere with pacemakers. Welding cables
Must be placed parallel, as close as possible to each other.

ELECTRICAL ARC CAN PROVOC FIRE: Welding sparks can cause a fire, explosion and burns on bare
skin. When welding, wear welding gloves and protective clothing. Remove or secure all flammable
materials and substances from the workplace. Do not weld closed containers or tanks containing flammable
liquids. These containers or tanks must be rinsed before welding to remove flammable liquids. Do not weld
near flammable gases, vapours or liquids. Firefighting equipment (fire blankets and fire extinguishers) must
be located near the workplace in a visible and easily accessible location.

POWER SUPPLY: Unplug the power supply area before starting any work or repair on the device. Check
welding cables regularly. If wire or insulation damage is found, it should be replaced
immediately. Welding cables should not be crushed, touch sharp edges or hot objects.

GAZ BOTTLES MAY EXPLODE: Use only approved bottles and a properly functioning
regulator. Bottles must be transported and stored standing up. Protect bottles from hot heat sources,
spillage and mechanical damage. Keep components of the gas system in good condition: bottle, hose,
fittings, gearbox.

WELDED PARTS CAN BURN: Never touch welded parts with unprotected parts of the body. Welding
gloves and pliers should always be used to touch and move the work piece.

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4. SYMBOLS

To reduce the risk of injury, the user must first read the entire manual.

A general warning sign draws each user's attention to the general hazards. It is used in conjunction with other
warnings or symbols that, if ignored, may result in personal injury or property damage.

The product complies with the requirements of the European Union Directives.

Élimination des appareils électriques et électroniques - voir la section ÉLIMINATION de ce manuel.

Use a screen or welding helmet.

Use welding gloves.

Wear safety shoes.

Use protective welding clothing.

Make sure that the gas bottle does not fall down.

Risk of electric shock.

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 5. FRONT PANEL AND CONTROL PANEL

1. Control panel.
2. DC (direct current) output sockets: positive terminal and negative terminal.
3. Cable with a plug to select polarity in MIG-MAG, and reverse in FLUX process

NOTE: When welding with the MIG-MAG method, the plug must be plugged into one of the sockets - it is necessary to
close the electrical circuit.

4. MB15/3 Euro torch socket

The protective gas inlet, the power cord socket and the main switch are located at the rear of the appliance.

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CONTROL PANEL

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6
7

1. Button / multifunction button.

Rotation - welding current regulation.

Slow rotation - fine adjustment
Fast rotation - fast jump.
Rotation after menu entry - selection of a parameter, method, function from the menu.

Press and hold - test thread feed.

2. Enter/Exit button - enter/exit the machine menu.

3. Button / multifunction button.

Rotate - correct the tension value (setting).

Rotation after entering the menu - change value, method, diameter for selected items.

Press and hold - gas flow test.

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 6. REAR VIEW

1. Gas holder heater power connector

NOTE: In the event of a significant gas flow, the holder may be frosted, the heater that some holders are equipped with will be
connected to this connector.

2. Switch Toe/Stop

3. Power connector of the protective gas hose from the regulator

4. Power electronics heat extractor

5. Sector Connection Cable

6. Grounding connector

NOTE: The grounding connector is to be connected systematically in case of no soil on the power outlet on which the device is
connected).

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 7. CONTROL PANEL - PROCESSES AND OPTIONS

Note: The view may be different from the illustrations according to firmware
versions but the features remain the same!

7.1 Procédé MIG-MAG

After pressing the MENU button the first setting that can be set will be highlighted in red - for MIG-MAG methods, it
will be induction.

The inductance can be refined by turning the adjustment knob over a range: -50 to 50.

By turning the select button, the welding method can be selected.

By turning the select knob you can select the following methods : MIG / MAG, MMA, TIG (lift), TIG with Pulse (lift), MIG
with Pulse, MIG with Twin Pulse

For each of the MIG-MAG methods, select the type of material to be welded and the wire diameter in succession. This is
done in the same way by turning the knobs to select and change.

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The possibilities for selecting synergic programs are presented in the table below:

MIG-200AL DP Synergic programs

Process Combination Wire Diameter Description

Fe CO2 0,8 / 1,0 Carbon welding of carbon steels in MAG under CO2 gas.

Fe Ar 82% 0,8 / 1,0 Carbon steel welding with the MAG method under the protection
of an Ar-CO2 gas mixture.

MIG/MAG AlMg5 Ar 1,0 / 1,2 Welding aluminum alloys with magnesium, using the MIG
method, in an argon screen.
AlSi5 Ar 1,0 / 1,2 Welding silicon aluminum alloys, MIG method, under argon gas.

E308 Ar98% 0,8 / 1,0 Welding stainless steels by MIG method, under argon gas at 2%
CO2, or pure argon.
Welding stainless steels strongly allied with the MIG method,
E316 Ar98% 0,8 / 1,0 under 2% CO2 argon, or pure argon.

Fe Ar 82% 0,8 / 1,0 Welding carbon steels to carbon in MIG with a single pulse,
under an Ar-CO2 gas mixture.
AlMg5 Ar 1,0 / 1,2 Welding aluminum alloys to magnesium, in MIG with a single
pulse, under argon.
Pulse MIG AlSi5 Ar 1,0 / 1,2 Welding aluminum alloys with silicon, method
MIG with a single pulse, under argon.
Welding stainless steels in MIG with a single pulse, under Argon
E308 Ar98% 0,8 / 1,0 at 2% CO2, or pure argon.

Welding stainless steels heavily loaded with MIG and single

E316 Ar98% 0,8 / 1,0 pulse, under argon with 2% CO2, or pure argon.

Fe Ar 82% 0,8 / 1,0 Carbon steel welding in MAG with a double pulse, under Ar-CO2
gas mixture.
AlMg5 Ar 1,0 / 1,2 Welding aluminum alloys to magnesium, in double pulse MIG,
under argon.
Twin Pulse Welding silicon aluminum alloys, dual pulse MIG method, under
AlSi5 Ar 1,0 / 1,2
argon.
Welding stainless steels in double pulse MIG, under argon with
E308 Ar98% 0,8 / 1,0 2% CO2, or pure argon.

Welding of highly allied stainless steels in double pulse MIG,

E316 Ar98% 0,8 / 1,0 under 2% CO2 argon, or pure argon.

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 The next field is the selection of the control of the welding machine by pressing the button of
the welding handle.

You can choose from:

2T - two times,

4T - four times

S2T - two "special" times with the ability to adjust the initial current (hot start) and final, duration and voltage correction for
these currents.

S4T - four "special" times with the ability to adjust the initial current (hot start) and final, and voltage correction for these
currents. The initial current and final current last as long as the welding torch button is pressed.

SPOT - point welding with the ability to adjust welding time to focus.

Instructions for using different modes

2T mode: Press the trigger of the torch to start the gas supply, wait for the gas pre-flow time before creating a regulated
current arc, release the trigger of the torch for arc extinction and post-flow of gas.

2TOperation Mode

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4T mode:Press(and release)the trigger of the torch to start the gas supply, wait for the gas pre-flow time before creating
a tuned current arc. Press the trigger again for arc extinction and post-gas flow.

GPR I GPO t

4TOperation Mode

S2T mode:Pull the trigger of the torch to start the gas supply, wait for the gas pre-flow time before creating an initial
current arc, wait for the initial time before gradually increasing the regulated current and the gradual increase time is
SLOP; release the trigger of the torch and the regulated current will pass to the gradual extinction of the arc, wait for the
arc to extinguish before the arc is extinguished and the post-gas flow.

S2TOperation Mode

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S4T mode:Pull the trigger of the torch to start the gas supply, wait for the gas pre-flow time before creating an initial
current arc, wait for the initial time before gradually increasing the regulated current and the gradual increase time is
SLOP; release the trigger of the torch and the regulated current will pass to the gradual extinction of the arc, wait for the
arc to extinguish before the arc is extinguished and the post-gas flow.

S4TOperation Mode

SPOT mode (point welding):Press the trigger of the torch to start the gas pre-flow until the arc at the current set, wait for
the welding time by points for the arc to extinction and post-flow gas. If you release the trigger of the torch before the
point welding time, the arc will shut down immediately and the gas post-flow.

PreG Sptt PosG t

Spot Welding Operation Mode

Preg Pre flow gas duration and Posg post flow gas duration
HotI initial current and EndI final current
WeldI welding current
Hott start duration, Endt end duration
SLOP progressive change duration
Sptt point welding duration.

CPOT mode (continuous spot welding): Push the trigger on the torch and the unit will start intermittent spot
welding. The spot welding time is Sptt and the intermediate stop time is STOP. Release the torch trigger to stop
welding.

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Depending on the previously selected welding option, the following parameters will be available:

Burn Back [BurnBack] - Corrects the height of thread exhaustion.

Setting range: -50 to 50 [%].

Frequency [Freq] - Pulse frequency regulation.

Setting range: 0.5 to 5.0 [Hz].

Duty Ratio [Duty] - Pulse balance.

Setting range: 20 to 80 [%]. 50% is the center value.

Pulse Amplitude [Range] - Adjustment of the current amplitude.

Adjustment range: 5 to 50 [%].

Pulse Voltage [PeakU] - Peak current voltage correction.

Setting range: -50 to 50 [%].

Base Voltage [BaseU]- Correction of the base current voltage.

Setting range: 5 to 50 [%].

Creep speed - Regulation of the initial thread speed.

Setting range: 1.0 m to 15 m
The default travel speed is 4m.
Note: As soon as the arc is started, the wire speed increases and is automatically regulated.

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Preflow [] - Control of the gas flow time before welding.
Setting range: 0 to 10 [s].

Postflow []- Control of gas flow time after welding.

Adjustment range: 0.1 to 50 [s].

End Current [Ie] - Final current when welding with the S2T and S4T function.
Setting range: 24 to 200 [%].

Initial Current [Is] - regulation of the initial current (hot start) during welding with function
S2T to S4T.
Setting range: 24 to 200 [%].
Initial Time [Ts]- Duration of initial current (hot start) when welding with function S2T.
Setting range: 0 to 50 [s].

End Time [Te] - Residual current duration when welding with the S2T function.
Setting range: 0 to 50 [s].

End Voltage [Ue] - Correction of the final current voltage during welding with functions S2T
and S4T.
Setting range: -50 to 50 [%].

Initial Voltage [Us] - Correction of the starting current voltage during welding with functions S2T
and S4T.
Setting range: -50 to 50 [%].

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 Spot time [t] - Welding time control for spot welding.
Setting range: 0.1 to 9.9 [s].

Save Data* – Saving the parameters in one of the device's memories

Setting range: 1 to 18 [Memory].

Load Data* – Loading previously stored parameters Setting range: 1 to 18 [Memory].

Serial Number** – Serial number of the device

Note: The format of the No. is specific to each brand operating the OEM device.
** Depending on the firmware version, the S/N is displayed when the workstation is started.

RESET* : Resetting the values/firmware is done by holding down the two buttons when switching on the unit, enter
the parameters and adjust set1 to 66, then select Init, press the left encoder, the unit will display "InitData", indicating
that the factory settings have been restored, then restart the unit.

* The function is not active on all firmware versions.

NOTE : Thread speed

The MIG 200AL-DP automatically adjusts the yarn speed to the MIG-MAG process amperage, depending on the
delivered amperage the synergic system determines the optimal yarn speed value in real time.

The tension can be adjusted from the recommended setting without affecting the yarn speed/amperage, which will
be adapted automatically.

As the wire speed is not displayed, the user interface highlights the amperage allowing the 40 amp/mm material
thickness "rule" to be checked without having to worry about retaining all the different wire speeds for different
materials and wire diameters.

NOTE : Brazing

The MIG 200AL-DP is automatically in brazing mode when using CuSi3 or CuAl wire.

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7.2 MMA

After selecting the MMA method, the upper knob is used to set the
welding current and the lower knob to adjust the voltage.

After entering the menu, you can also set the value and duration of
the hot start current.

Initial Current (Hot Start) - Value of the hot start current. Function that allows easier priming.
Setting range: 20 to 180 [%].

Initial Time - Duration of the hot start current.

Setting range: 0 ÷ 50 [s].

Welding characteristics - Selecting the type of electrodes.

Ordinary [CC] - standard electrodes.
Cellulose [CP] – “difficult to weld" electrodes, including electrodes with cellulose
coating.

VRD (Voltage Reduction Device) On - active, Off - inactive.

Vacuum Voltage Reduction, protects the welder. The welding current is delivered only when the
electrode is in contact with the workpiece (low resistance). As soon as the electrode is removed the
VRD reduces the voltage to a very low value.

Inductance [Arc Force] - In MMA mode, the value under the inductance symbol represents the arc strength.
This function makes the arc more stable in all situations.
Setting range: 0 to 100 [%].

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7.3 TIG lift/TIG lift pulse

When welding with the "TIG lift" method, only the

intensity of the welding current can be adjusted.

If you choose the "TIG lift" method with pulse,

you can set the parameters related to the
welding current pulse.

Frequence [Freq] - Current ripple frequency.

Setting range: 0.1 to 99 [Hz].

Duty Ratio [Duty] - Pulse balance of the welding current.

Setting range: 5 to 95 [%].

Pulse Amplitude [Base current] - Amplitude

adjustment (peak current) of the welding current.
Adjustment range: 1 to 500 [%].

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7.4 Adjustment ranges per process

Process Combinaison Wire diameter Ajustement range

Fe CO2 0,8 20 - 200

1,0 52 - 200
Fe Ar 82% 0,8 44 - 200

MIG/MAG 1,0 52 - 200

AlMg5 Ar 1,0 64 - 200

1,2 72 - 200
AlSi5 Ar 1,0 56 - 200
1,2 64 - 200
E308 Ar98% 0,8 48 - 200
1,0 60 - 200
E316 Ar98% 0,8 48 - 200
1,0 56 - 200
Fe Ar 82% 0,8 16 - 200
1,0 24 - 200
Pulse MIG AlMg5 Ar 1,0 20 - 200
Twin Pulse
1,2 20 - 200
AlSi5 Ar 1,0 24 - 200
1,2 24 - 200
E308 Ar98% 0,8 24 - 200
1,0 24 - 200
E316 Ar98% 0,8 24 - 200
1,0 24 - 200
MMA 20 - 180

TIG 10 - 200

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7.5 Display in operation / Thread speed
During the welding phases, the on-screen display switches between current and voltage, allowing you to view the values
in real time, which are different from those selected (which is normal).

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 8. ACCESSORIES

• MB24KD Euro torch 3m

• Electrode holder 3m
• Ground cable 1.5m (that's short!)
• Teflon sheath for Al wire up to 1.6 (pre-mounted ?!? Why not rather the metal sheath ...)
• Metal sheath for steel wire 0.8/1.0
• Roller 0.8/1.0 steel wire (pre-mounted) + Roller 0.8/1.0 filled wire
• Metal wire guide for Euro plugs
• 1x 0.8 tip (pre-mounted) + 1x 1.0 tip

WARNING !
For the safety of children, do not leave parts of the packaging freely accessible (plastic
bags, cardboard, polystyrene, etc.). Danger of suffocation

9. USAGE

9.1 Electrical connection

Before connecting this appliance to the mains, check the voltage, the number of phases and the
frequency..

- The supply voltage parameters are indicated in the technical data section of this manual and on the nameplate of the
unit.
- Check the connections of the equipment's grounding conductors to the mains.
- Make sure that the mains supply can cover the input power demand of this unit under normal operating conditions.
- Fuse sizing and power cord parameters are given in the technical data of this manual.
- The power supply network must be characterized by a stable voltage.
- The cross section of the power supply cables must not be less than 2.5 mm.

Connection and replacement of the power cord and plug must be carried out by a
qualified electrician..
The yellow-green wire is the earth and must always be connected to the socket marked with the earth symbol.

Grounding symbol.

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 9.2 MIG / MAG Welding

WARNING ! Disconnect the power supply before carrying out any work on the appliance.

1. Make sure that the unit is not connected to the mains.

2. Check that the ground cable is held by a clamp or screw clamp.
3. Connect the ground cable plug to the output socket with the correct polarity on the front panel, press down and
rotate.

If the connection is too loose, the plug and socket will burn prematurely. The ground cable in the MIG-MAG method is
usually connected to the "-" socket. When using cored wires, the ground cable is connected to the "+" socket. The
polarity is changed by switching the integrated plug to the "-" socket.

MIG-MAG (GAS) MIG-MAG (GAS-FREE / CORED WIRE)

Plug to "+" Plug to "-"

IN MIG-MMA THE POLARITY REVERSAL PLUG MUST ALWAYS

BE PLUGGED INTO ONE OF THE SOCKETS
IT IS NECESSARY TO CLOSE THE CIRCUIT!

25
 Before installing the welding wire and ensuring that the welding process runs smoothly, please make sure that the wire
guide and contact tube match the model of the welding torch.

The metal wire guide is compatible with the diameter of all welding wires used and the type of welding wire (excluding
aluminium); the wire guide is mounted on the Euro plug and must only be removed when using aluminium wire.

The metal sheath is suitable for hard welding wires, such as solid core carbon steel and stainless steel. The Teflon
sheath is suitable for soft wires, such as those made of aluminium and its alloys and those made of copper and its alloys.

When the wire feed conduit is too tight or too loose, the resistance of the wire feed will be increased and therefore the
wire feed will be unstable.

The steel wire feed pipe and its installation are shown in the figure below

Gaine

Metal sheath

Gaine métal

For Al welding,
remove the steel Conduit
wire guide. d'alimentation

Note: to facilitate their use, guide manufacturers apply a colour code to Teflon sheaths

For a wire with a diameter of 0.6 to 0.8 mm, the Teflon sheath is blue, for a wire with a diameter of 1.0 to 1.2 mm it is red, and for
electrode wire up to a diameter of 1.6 mm it is yellow.

The installation of the Teflon wire guide is necessary for welding alloy steels and aluminium.

The metal guide is used to weld low carbon steel, low alloy steel, copper, bronze, etc.

Do not forget to equip the welding torch with a contact tip adapted to the type and diameter of the electrode wire.

Tighten the quick connector of the "Euro-plug" torch into the socket (Euro plug) on the front panel of the welding station to
ensure that there is no voltage drop on the contact surface. The voltage drop caused by loose contact will cause the torch and
the reel to heat up.

26
9.3 Loading the wire.

1. Make sure that the rollers installed in the drive unit correspond to the type and
diameter of the inserted wire. If the groove of the roller differs from the diameter of
the electrode wire, adjust the groove by turning or replacing the roller. For steel
wires, use rollers with V-grooves and for aluminium wires with U-grooves.

2. Place the spool with the electrode wire on the spool mounting mechanism, making
sure that the direction in which the wire is unwound is consistent with the direction in
which the wire enters the drive unit.

3. Secure the spool against falling out by tightening the nut on the spool body.

4. With the end of the thread wound on the spool, straighten or cut the bent section
and file it so that it is not sharp.

5. To allow the wire to be fed into the feeder, release the pressure on the feed rollers.

6. Insert the end of the wire into the guide at the rear of the loader and guide it
over the drive rollers and into the socket leading to the welding holder

7. Press the wire into the grooves of the drive rollers while holding pressure.

8. Remove the gas nozzle and unscrew the contact tip.

9. Switch on the appliance.

10. Unfold the handle so that it is in a straight line, then press the button on
the handle or control panel (wire unwinding) until the wire appears in the outlet
(about 20 mm), release the button.

11. Screw on the contact tip, install the gas nozzle.

12. Adjust the pressure of the feed roller by turning the pressure knob. Too
little contact pressure will cause the feed roller to slip. Too high pressure force
will cause an increase in feed resistance and deformation of the wire, which
may cause it to cut.

The thread feeder mechanism is single-drive, as shown in the figure below.

(1) Clamping handle

(2) Galet

(3) Drive wheel

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Selection of reel roller/pressure adjustment

The wire feed pressure scale is located on the pressure handle, and the pressure levels are different for the welding wires
depending on the materials and the different diameters, as shown in the table and illustrated below
The values in the table are for guidance only and the actual pressure setting specifications must be adjusted according to the
welding torch cable length, welding torch type, wire feed condition and welding wire type.

Type 1: Hard welding wires, such as solid core carbon steel and stainless steel.
Type 2: Hard welding wires, such as solid carbon steel and stainless steel.
Type 3: cored welding wires.

Use the pressure handle to adjust the pressure of the wire feed wheel to feed the welding wire into the conduit and let the
welding wire with some braking force at the contact tube outlet, which will prevent the wire feed wheel from backing up.

Note: Excessive pressure will cause the welding wire to flatten and the coating to be damaged, resulting in rapid wear of the
wire feed wheel and increased resistance to the wire feed.
Welding wire
diameter
Pressure
φ 0.8 φ 1.0 φ 1.2
Wire feeding
wheel type scale

1 3 3 2.5

2 1. 5 1. 5 1. 5

3 2

Roller type / Thread diameter / Pressure adjustment

U-shaped
wheel Flat wheel
Flat wheel
1
2
3
4 U-shaped wheel
V-shaped wheel U-shaped wheel
Pressure handle scale

Type 1 Type 2 Type 3

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 Use a spanner to turn the brake force control screw (1) to adjust the brake force (as shown in the figure below); the brake
force should be moderate.

Adjust the braking force to a level so that the welding wire on the wire coil is not too loose, thus preventing the welding wire
from scattering when the wire coil stops; however, the braking force should not be too high, otherwise the motor load will be
increased.

9.4 Protective gas connection.

1. The cylinder containing the protective gas must be placed on the trolley of the semi-automatic station (if present).
or against a wall and secured against tilting by fixing it to the support with a chain.
2. 2. Remove the cap that protects it and unscrew the valve from the bottle for a moment to remove any
contamination.
3. 3. Install the regulator so that the gauges are vertical.
4. 4. Connect the semi-automatic station from the gearbox outlet to the gearbox with a suitable hose. The
connection
protective gas is located at the back of the appliance.
5. Unscrew the regulating valve only before starting welding. When welding is finished, the
Bottle valve must be closed.
6. Avoid welding in an open space or in a draught - a jet of air can disturb the flow of gas from the cylinder to the
cylinder protection and deprive the molten metal of protection.

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9.5 Practical recommendations for MIG / MAG welding.

Butt welds in the inclined position must be carried out using the "pull" technique for thicker elements.

Vertical butt welds for thin elements should be made from top to bottom.

Lateral fillet welds should be made using the push technique, but taking into account the additional inclination of the
welding torch in the plane perpendicular to the welding direction.

When filling wide grooves in horizontal or vertical position, perform transverse swinging movements with the end of the
handle.

During welding, the welding torch must be at a right angle to the welded parts - too large an angle of inclination can cause
air to be sucked into the molten metal bath (the angle of inclination of the torch to the vertical must be ≤ 10°).

Long arc welding reduces the depth of penetration - the weld is wide and flat and welding is accompanied by increased
spatter.

Welding with a short arc (at the same current density) increases the depth of penetration - the weld is narrower and
material spatter becomes smaller.

Welding speed is a result parameter for a given arc current and voltage and the maintenance of the correct shape of the
weld bead and when the welding speed has to be changed even slightly, the arc current or voltage must be changed
accordingly.

Increasing the welding speed makes the weld narrower and reduces the depth of fusion, and with further growth, face
clearance occurs.

The highest welding speeds without face clearance can be achieved by increasing the free electrode output and tilting the
workpiece up and down or by tilting the torch in the welding direction.

Low welding speeds increase the depth of fusion, the face width and the height of the riser.

Inductance also affects the shape of the spine and the amount of spatter. A higher inductance (soft arc) results in a larger
melt pool and less spatter. Conversely, the lower inductance produces a stable, focused arc.

Excessive arc lengthening or shortening can cause arc instability and poor weld quality.

L1, L2 - arc length

The welding direction also has a significant impact on the depth of penetration - the guidance of the welding torch.

H1, H2 - penetration depth

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Because of the type of shielding gas used and the electrical parameters of the welding process (voltage and current),
there are three ways to change the state of the metal in the welding arc :

THICKNESS - used in the MIG / MAG method with low current densities and long arcs
- not recommended in forced position

VAPORISATION - used in the MAG method with gas mixtures

- not recommended in forced position

SHORT-CIRCUIT - used in the MAG method with a short arc

- recommended for the welding of thin elements and in forced position

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9.6 MMA
The MIG 200AL-DP is capable of welding with coated electrodes. It has two modes to optimally adjust the parameters to
the type of electrode.

Ordinary mode for basic electrode types and Cellulose mode for cellulose coated electrodes and other "difficult to weld"
electrodes.
In addition, you can set the arc force, the value and duration of the hot start function and use the VRD function to
increase safety during welding work.

The recommended welding current, polarity and electrode drying requirements are usually indicated by the manufacturers
on their packaging.

Plug the welding cables into the corresponding sockets (electrode holder at most and ground at least).

Connect the ground clamp to the element to be welded and place the electrode in the electrode wire.

In order to avoid spatter during welding and to obtain good weld quality, follow the recommendations given by
the electrode manufacturer: welding current, welding positions, drying time and temperature. This is particularly
important when using alkaline or acid-coated electrodes (EB, EA).

The basic parameters of the MMA welding process are :

- Welding current intensity,
- Welding speed,
- Thickness, type of electrode and material to be welded

The size of the current is regulated so that the arc can be reliably ignited and, during welding, it is uniform and stable.

For example, the "Pink 6012" electrode requires :

- 2.0 mm 40 to 60 A,
- 2.5 mm 50 to 70 A,
- 3.25 mm 70 to 110 A,
- 4.0 mm 110 to 160 A,
- 5.0 mm 160 to 220

32
Operating mode MMA

• Keeping the mask IN FRONT OF THE FACE, scratch the tip of the electrode on the workpiece with a movement as if to
"light a match"; this is the most correct method to start the arc.

• WARNING: DO NOT TAP the electrode on the workpiece, as this may damage the coating and make arcing more
difficult.

• As soon as the arc is ignited, try to maintain a distance from the workpiece equivalent to the diameter of the electrode
used and keep this distance as constant as possible during the welding process; remember that the inclination of the
electrode in the direction of travel should be about 20-30 degrees.

• At the end of the weld bead, bring the end of the electrode slightly backwards with respect to the direction of advance,
over the crater to carry out the filling, then quickly lift the electrode from the molten pool to extinguish the arc.

MMA WELD INSPECTION

Feed too low Arc too short Current too low

Advance too fast Arc too long Current too strong

Correct

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 9.7 Welding with the TIG LIFT method

MIG 200AL-DP can be used for TIG LIFT welding (the arc is struck by contact with the welded material).

For this purpose, you must purchase an optional torch designed for this method - this is a torch equipped with a
mechanical shielding gas valve located in the handle.

Operating mode TIG LIFT

• Insert the plugs of the welding cables into the appropriate sockets and lock them (ground on (+), TIG torch on (-)). In the
case of a TIG torch with Euro plug, connect the changeover plug to (-).
• Connect the gas hose of the TIG torch directly to the outlet opening of the protective gas regulator (ARGON).
• Connect the working tongs to the workpiece.
• Check the tungsten electrode for leaks.
• Insert the plug of the power cord into a power socket.
• Switch on the supply voltage of the unit with the power switch.
• Select the TIG or Pulse TIG function on the control panel.
• Set the required welding parameters.
• Open the valve of the shielding gas regulator and the valve of the TIG torch, the shielding gas will flow.
• L'arc est frappé en frottant l'électrode non consommable avec le matériau soudé.

• Lightly touch the workpiece with the electrode (1), detach the electrode from the workpiece by tilting the holder so
that the gas nozzle touches the workpiece (2 and 3), which will ignite the arc.

Then straighten the electrode by 2 to 3 mm (4) and start welding.

To finish welding, the torch must be "disconnected" from the material to be welded.

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 SUGGESTED VALUES FOR TIG WELDING

CONTROL OF THE ELECTRODE TIP IN TIG

Exact Current Insufficient Current Excessive Current

PRÉPARATION DES BORDS RELEVÉS (Soudage sans matériau d’apport)

PRÉPARATION DES BORDS POUR JOINTS DE TÊTE (Soudage avec matériau d’apport)

35
 10. CLEANING AND MAINTENANCE

The protection class of this unit is IP21S, so do not use the unit in the rain or expose it to moisture.

Caution

The device is based on electronic components. Grinding and cutting metal in the vicinity
of the welding machine can contaminate the interior of the device with filings and
damage it.

The above-mentioned damage is not covered by the warranty!

If you have to work in such an environment, clean the device by blowing out the inside of
the welding machine with compressed air.

In order to prolong the life and operation of the device, several rules must be followed:
1. The appliance must be placed in a well-ventilated room with free air circulation.
2. Do not place the appliance on a wet floor.
3. 3. Use wire with a diameter and weight of the spool in accordance with the capacity of the unit.
4. Place the protective gas cylinder on the shelf at the back of the appliance and secure it with a chain against tipping over.
5. Check the condition of the appliance and the welding cables.
6. Remove any flammable material from the welding area.
7. Use suitable protective clothing for welding: gloves, apron, work shoes, mask or visor.

When planning the maintenance of the device, take into account its use and conditions of use. Correct use of the appliance
and regular maintenance will prevent unnecessary disruptions and work interruptions.

Systematically :

➢ Clean the grounding handle and the gas nozzle from splashes, lubricate with a
splash guard.
➢ Check that the cables are correctly connected.
➢ Check the condition of the cables. Replace damaged cables.
➢ Make sure that air can circulate freely around the appliance.
➢ Replace or repair damaged or worn parts.

Regularely :

➢ Check the condition of the electrical connections inside the power source.
➢ Oxidised surfaces must be cleaned and spare parts must be tightened.
➢ Clean the inside of the unit with compressed air.

36
 11. OUTAGE

Symptoms Cause Resolution

Collar too loose Tighten the collar correctly

Dirty wire guide Clean the wire guide.

No electrode wire supply
(charger motor is on).
Roller unsuitable for the wire diameter Replace the supply tip.

Electrode wire blocked in the tip. Replace tip

No electrode wire supply Damaged motor Return the station to the after-sales service.
(charger motor does not
work).
Defective control system. Return the station to the after-sales service.

Contact point damaged. Replace tip

Irregular supply of electrode
wire. Damaged spring in the holder. Replace tip

Replace the roller or select a roller

The groove of the feed roller is dirty,
corresponding to the wire diameter.
damaged or does not match the wire
diameter.
Poor ground cable contact Check the connection
Arcing does not occur

Reverse polarity plug disconnected. Insert the plug into the correct socket.

Welding current too high. Reduce the welding current.

Arc too long and irregular.
Thread feeding speed too slow. Increase the feed speed of the thread.

Welding current too low. Augmentez le courant de soudage.

Arc too short
Thread feeding speed too fast. Reduce the feed speed of the thread.

No supply voltage. Connect/check the power supply.

After switching on the power,
the indicator light does not Power supply fuse blown Replace the fuse
come on.

Broken switch. Replace the main switch.

37
 12. STORAGE AND TRANSPORT

It is recommended to keep the cleaned appliance in its original packaging.

Always store the appliance in a dry, ventilated place out of the reach of children and unauthorised persons.

Protect the appliance from vibrations and shocks during transport.

38
 13. USE

Packaging materials can be used as a secondary raw material. Dispose of the packaging in accordance with local
regulations.

Keep packaging materials out of the reach of children as they are a potential source of danger.

Disposal of the appliance :

1. In accordance with the DEEE 2012/19 / EC Directive, the crossed-out wheeled bin symbol (as shown below)
denotes all electrical and electronic equipment that is collected separately.

2. At the end of its service life, this product must not be disposed of with normal household waste, but must be transported to a
collection point for the recycling of electrical and electronic appliances.

This is indicated by the circular container symbol, placed on the product, manual or packaging.

3. The materials used in the appliance may be reused in accordance with their marking.

4. By reusing, using materials or other forms of use of used appliances, you make a significant contribution to the protection of
our environment.

5. Information on the appropriate point of disposal for used electrical appliances will be provided by the municipal administration
or the seller of the appliance.

39
14. DECLARATION OF CONFORMITY

The product is declared compliant with European Union standards by its manufacturer, in particular the EU standard EN
60974-1 (listed under the French standard NF EN IEC 60974-1).

40
15. ANNEXES

LCD SCREEN: PROCESS ABBREVIATION

Code Abreviation Name of the welding mode
FastPulse FMIG High speed pulsed gas shielded arc welding
PulseMIG PMIG Pulsed gas shielded arc welding
FastTwin Ftwi High-speed, double-pulse shielded-gas arc welding

TwinPulse Twin Double impulse gas shielded arc welding

FastArc Farc High speed shielding gas arc welding
MIG/MAG YMIG Gas-shielded arc welding
FastUp F-UP High speed internal welding

MMA MMA Manual welding with coated electrodes

FastRoot Root Fast initial welding

TIG Mode TIG Argon arc welding DC (TIG Lift)

FastCold Cold High speed cold welding
PulseTIG PTIG Pulsed TIG arc welding under argon
SYNC MIG MIG Synergistic arc welding under protective gas

41
 LCD SCREEN: WIRE ABBREVIATION
Code Abreviation Welding mode
Fe CO2 FeCO Carbon steel welding wire under CO2
Fe Ar82 FeA8 Carbon steel welding wire under Ar 82%+CO2 18%.
Fe Ar92 FeA9 Carbon steel welding wire under Ar 92%+CO2 8%.
Al Ar Al Pure aluminium welding wire Ar
AlMg4.5Ar AlM4 Aluminium-magnesium welding wire ( ER 5183) under Ar
AlMg5 Ar AlMg Aluminium-magnesium welding wire ( ER 5356) under Ar
AlSi5 Ar AlSi Aluminium-silicon welding wire (ER 4043) under Ar
CuSi3 Ar CuSi Silicon-bronze welding wire under Ar
CuAl8 Ar CuAl Aluminium-bronze welding wire under Ar
CuSiAr98 CuS9 Silicon-bronze welding wire Ar 98%+CO2 2%.
CuAlAr98 CuA9 Aluminium-bronze welding wire Ar 98%+CO2 2%.
E308Ar98 E308 Stainless steel welding wire (ER 308) Ar 98%+CO2 2%.
E316Ar98 E316 Stainless steel welding wire (ER 316) Ar 98%+CO2 2%.
RutilFlux Ruti Rutile cored flux
BasicFlux Basi Basic cored wire
MetalFlux Meta Ferrous cored wire
E309CrNi CrNi Flux cored wire for stainless steel welding
Flux
ER2319Ar 2319 Aluminium-copper welding wire under Ar

42
 LCD SCREEN: PARAMETER ABBREVIATION
Code Signification Detail
Size Wire diameter Supports 3 wire diameters: 0.8, 1.0 and 1.2

Mode Mode of operation Support for 6 torch switching modes: 2T, 4T, S4T, S2T, spot
welding and continuous spot welding
EndI Quenching arc current The function is to fill the arc crater for S4T and S2T.
The function is to increase the heat input at the start of welding,
HotI
Initial Current for S4T and S2T.
Burn Downtime It is used to adjust the effect of cutting into small balls at the end of
the weld.
Hott Initial duration The initial arc duration, only for S2T.
Endt Extinguishing time The final duration of the arc, only for S2T.
Switching time of both currents (e.g. initial current and welding
current); selection of characteristics for manual welding: DC
Slop Transition time
constant current, CP constant power (for cellulose), 1 - 20
slow descent
Sptt Duration by points Duration of spot welding

Freq Pulse frequency Frequency of double pulse shielding gas welding, high speed
double pulse shielding gas welding and high speed welding in
vertical position
Duty Utilization rate Utilization rates of double pulse shielding gas, high speed double
pulse shielding gas and high speed welding in vertical position

Ip-p Pulse amplitude Peak current amplitudes for double pulse shielding gas welding
and high speed double pulse shielding gas welding
HotU Initial arc length Length of the initial arc
PU Length of crest arc Arc length in crest
BU Final arc length Final arc length
StFd Soft start Soft start feed rate
VRD Low/no load VRD mode switching
Stop Stopping interval Stopping interval in continuous spot welding
Preg Pre-welding gas Duration of pre-welded gas flow
Post Post-welding gas Gas Postflow Time
EndU Length of the extinguishing Length of the extinguishing arc
arc
Under gas protection MIG-MAG = inductance
FORC Arc force Under gas protection TIG= peak current
MMA = arc force

43
2021 - Voluntary (non-commercial) translation of the original instructions by Satdream, based on existing documents in Polish, Chinese and English, from various distributors of
this OEM station, among others under the following brands: Magnum, Trafilux, Sherman, Kramer etc.

The indications, characteristics and various elements are given "as is", subject to errors or omissions.

© the respective trademarks and their assignees are the owners of the information and illustrations.

44