Sherman digitec DIGIMIG 2OO PULSE Manual de usuario
V1.3 19.11.28
USER MANUAL
WELDING SYNERGIC RECTIFIER
INVERTER
DIGIMIG 2OO PULSE
ATTENTION!
Please read this manual carefully before installing and starting up the device
1. GENERAL REMARKS
Commissioning and operation of the device may only be performed after carefully reading these Operating
Instructions.
Due to the continuous technical development of the device, some of its functions may be modified and their operation
may differ in detail from the descriptions in the manual. This is not a device error, but the result of progress and
continuous modification of the device.
Damage to the device caused by improper operation results in the loss of warranty rights. Any modifications to the
charger are prohibited and will void the warranty.
2. SAFETY
Employees operating the device should have the necessary qualifications authorizing them to perform
welding works:
should have the qualifications of an electric welder in the field of gas-shielded welding, know the health and safety
rules for the operation of electrical power equipment such as welding devices and auxiliary equipment powered
by electricity
know the health and safety rules when handling cylinders and installations with compressed gas (argon),
know the content of this manual and use the device in accordance with its intended purpose.
WARNING
Welding may endanger the safety of the operator and other people in the vicinity. Therefore, special precautions
should be taken when welding. Before starting welding, familiarize yourself with the health and safety
regulations in force at the workplace. There are the following dangers during electric welding with the MIG /
MAG method:
ELECTRIC SHOCK
NEGATIVE EFFECT OF ARC ON HUMAN EYES AND SKIN POISONING BY STEAMS
AND GASES
BURNS
EXPLOSION AND FIRE HAZARDS NOISE
To prevent electric shock:
connect the device to a technically efficient electrical installation with appropriate protection and effectiveness
of zeroing (additional protection against electric shock); other devices at the welder's workplace should be
checked and properly connected to the network,
install the current cables with the device switched off,
do not touch the non-insulated parts of the electrode holder, electrode and workpiece at the same time,
including the device housing,
do not use holders and power cables with damaged insulation,
in conditions of particular risk of electric shock (work in environments with high humidity and closed tanks) work
with an assistant supporting the work of the welder and ensuring safety, use clothes and gloves with good
insulating properties,
if you notice any irregularities, please contact competent people to remove them,
It is forbidden to operate the device with the covers removed.
Preventing the negative effects of an electric arc on human eyes and skin:
Use protective clothes (gloves, apron, leather shoes), Use shields or helmets
with a properly selected filter,
Use protective curtains made of non-flammable materials and properly select the colors of walls that
absorb harmful radiation.
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Prevention of poisoning by vapors and gases released during welding from the electrode coating and metal
vaporization:
Use ventilation devices and exhausters installed at workstations with limited air exchange,
Blow out with fresh air when working in confined spaces (tanks), Use masks and respirators.
Burn prevention:
Use appropriate protective clothing and footwear to protect against burns from arc radiation and
spatter,
Avoid staining the clothes with grease and oils that can cause its ignition.
Preventing explosion and fire:
It is forbidden to use the device and weld in rooms at risk of explosion or fire,
The welding station should be equipped with fire extinguishing equipment,
The welding station should be at a safe distance from flammable materials.
Prevention of negative effects of noise:
Use earplugs or other noise protection measures. Warn about the
dangers of nearby people.
WARNING!
Do not use the power source to thaw frozen pipes.
Before starting the device, it is necessary to:
Check the condition of the electrical and mechanical connections. It is forbidden to use handles and power cables
with damaged insulation. Improper insulation of the handles and power cables may result in electric shock,
Ensure proper working conditions, i.e. ensure proper temperature, humidity and ventilation in the workplace.
Protect against rainfall outside closed rooms, Place the charger in a place that enables its easy operation.
Welder operators should:
have a qualification for electric welding with the MIG / MAG method,
know and follow the health and safety regulations in force when performing welding work,
use appropriate, specialized protective equipment: gloves, apron, rubber boots, shield or welding helmet with an
appropriately selected filter,
know the content of this manual and use the welding machine in accordance with its intended purpose.
Any repairs of the device may be made only after disconnecting the plug from the power socket.
When the device is connected to the mains, it is forbidden to touch any elements forming the welding current circuit
with your bare hand or through wet clothing.
It is forbidden to remove external covers when the device is connected to the network.
Any modifications to the rectifier on their own are forbidden and may deteriorate the safety conditions.
All maintenance and repair works may be carried out only by authorized persons, in compliance with the working safety
conditions applicable to electrical devices. It is forbidden to use the welder in explosion or fire hazardous rooms! The
welding station should be equipped with fire extinguishing equipment.
After finishing work, disconnect the device's power cord from the mains.
The above-mentioned risks and general health and safety rules do not exhaust the issues of the welder's work safety, as they
do not take into account the specificity of the workplace. An important supplement to them are workplace health and safety
instructions as well as training and instruction provided by supervision employees.
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3. GENERAL DESCRIPTION
The synergistic welding machine DIGIMIG 200 PULSE is used for manual welding of steel and non-ferrous metals. It
enables welding with MMA (coated electrode), MMA with pulse, TIG Lift, TIG Lift with pulse, and MIG / MAG. Welding with
the MIIG / MAG method can be carried out with the use of single and double pulse. The MIG / MAG method can be used
in manual and synergic mode, simplifying its operation and allowing the welding machine to be used by people with less
experience and hobbyists. Due to the change of polarity, the device allows welding with the MIG / MAG method using
both standard wires in a protective gas shield and self-shielding flux-cored wires.
The device allows you to connect a Spool Gun (SG) with a mini wire feeder and a D100 spool of steel or colored wire.
The device is made in IGBT technology, which allows for a significant reduction in the weight and dimensions of the welding
machine and an increase in efficiency while reducing energy consumption.
The welder is used in closed or roofed rooms, not exposed to
direct exposure to atmospheric influences.
4. TECHNICAL PARAMETERS
4.1 Welder
Supply voltage:
Maximum power consumption:
Rated welding current: / duty cycle Rated voltage in
no-load condition Wire spool diameters:
Maximum current consumption:
Weight:
Dimensions [mm]:
Level of security:
AC 230V 50Hz
7.7 kVA
MIG: 200A / 60%; MMA: 200A / 60%; TIG: 200A / 60%
56V (9V with VRD)
100mm, 200mm
MIG: 26.5 A; MMA: 33.7 A; TIG: 21.5 A
12 kg
495 x 210 x 345
IP21
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4.1.1 Adjustment ranges of parameters
Welding current:
Welding voltage:
Wire Feed Speed: Inductance:
Gas pre-flow
Gas post-flow
Pulse frequency
ARC FORCE (MMA):
HOT START (MMA) - electricity:
HOT START (MMA) - time:
MIG: 24 - 200 A; MMA: 20 - 200 A; TIG: 10 - 200 A.
MIG: 17.5 - 24.7 V
2 - 14 m / min
- 99 - + 50%
0 - 10 sec
0.1 - 50 s
TIG, MMA: 0.1 - 99 Hz; D-PULSE MIG: 0.5 - 5 Hz.
0 - 100%
20 - 200 A.
0 - 99 ms
4.2 MIG gun
Handle type:
Maximum current carrying capacity:
Type of cooling:
Cooling gas flow: Length:
TW-15
200 A (CO2)
gas
10-18 l / min
3 m
Work cycle
The duty cycle is based on a 10-minute period. 60% duty cycle means that after 6 minutes of operation, a 4-minute break
is required. Duty cycle of 100% means that the device can work continuously without interruption.
Attention! The heating tests were carried out at the ambient air temperature. The duty cycle at 20ºC has been
determined by simulation.
Level of security
The IP defines the degree to which the device is resistant to the ingress of solid and water contaminants. IP21 means
that the device is adapted to work in closed rooms.
Overheating protection
The IGBT module is protected against overheating by a protective system that turns off the power to the welding
machine. After a few minutes, the device cools down to a temperature that allows it to be switched on again
automatically. Do not disconnect the power supply during this time, because the continuously operating fan cools the
internal heat sinks of the device in order to reduce the temperature faster. After restarting, remember to limit the
welding parameters for further continuous operation of the device.
5. PREPARING THE DEVICE FOR WORK
If the device is stored or transported in frost, bring the device to a temperature above freezing before starting
work.
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1. MIG gun socket
2. Spool Gun remote control / holder socket
3. "+" socket
4. Polarity reversal plug
5. "-" socket
6. Power switch
7. Fan
8. Shielding gas connection stub
9. Earthing clamp
10. Power cord
11. Spool Gun switch
12. Wire feeder
13. Wire spool pin
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5.1 Connecting the wires
5.1.1 The MMA method
The ends of welding cables should be connected to sockets (3) and (5) on the front panel so that the electrode holder has
the correct pole for the electrode. The polarity of connecting the welding cables depends on the type of electrode used
and is indicated on the package of the electrodes (negative DCEN or positive DCEP). The return line clamp must be
carefully attached to the work piece. Connect the device's plug to a 230V mains socket
50Hz.
DCEN DCEP
5.1.2 TIG method
For welding with this method it is necessary to use an additional TIG torch. A gas-cooled torch with 200A amperage and
a shielding gas control valve is required.
The torch's current clamp should be connected to the negative polarity socket (5), and the gas hose to the regulator on
the gas cylinder. The positive pole of the source (3) should be connected to the work piece by means of a wire with a
clamp. Connect the device plug to a 230V 50Hz mains socket.
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5.1.3 MIG method and braze welding
5.1.3.1 Welding and braze welding in protective gas shield
The torch current clamp should be connected to the MIG torch socket (1). The gas line from the regulator should be lead
and fastened to the gas connector (8) on the rear wall of the device. Plug the polarity change (4) into the socket (3). The
negative pole of the source (5) should be connected to the work piece by means of a wire with a clamp. Connect the
device plug to a 230V 50Hz mains socket.
5.1.3.2 Welding with self-shielding steel wire
The torch current clamp should be connected to the MIG torch socket (1). Plug the polarity change (4) into the socket (5).
The positive pole of the source (3) should be connected to the work piece with a wire with a clamp. Connect the device
plug to a 230V 50Hz mains socket.
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5.1.3.3 Welding with Spool Gun (optional)
The torch current clamp should be connected to the MIG torch socket (1). Plug the polarity change (4) into the socket (3).
Connect the negative pole of the source (5) to the work piece with a wire with a clamp. Connect the device plug to a 230V
50Hz mains socket. Set the switch (11) inside the feeder chamber to the Spool Gun position.
5.2 Connecting the shielding gas
1. Attach the cylinder and secure it against falling over.
2. Open the cylinder valve for a moment to remove any contamination.
3. Install the regulator on the cylinder.
4. Connect the hose with the reducer to the gas connector (8) on the rear wall of the welding machine.
5. Unscrew the valve of the cylinder and the regulator.
5.3 Connection to the mains
1. The device should only be used in a single-phase, three-wire system with an earthed neutral
point.
2. The DIGIMIG 200 PULSE inverter rectifier is adapted to work with a 230V50 Hz network protected by 25 A time-
delay fuses. The power supply should be stable, without voltage drops.
3. The device is equipped with a power cord and plug. Before connecting the power supply, make sure that
the power switch (6) is in the OFF position (turned off).
5.4 Loading the wire spool
1. Open the side cover of the housing.
2. Check that the drive rolls are suitable for the wire type and diameter. Install the correct roller if necessary. For
steel wires, use rolls with V-grooves, and for aluminum wires with U-grooves.
3. Place the spool with the filler wire on the spindle.
4. Secure the spool against falling.
5. Release the pressure on the feed rolls.
6. Dull the end of the electrode wire.
7. Introduce the wire through the feeder drive roller into the holder.
8. Press the wire into the grooves of the drive roll.
9. Unscrew the contact tip from the gun, turn on the power supply to the welder and pull the wire into the
welding gun with the quick wire inch function.
10. After the wire appears in the gun outlet, release the button and screw on the contact tip.
11. Adjust the pressing force of the feed roller by turning the pressure knob. Too little pressure force will result in
slippage of the drive roller, too high pressure force will increase the feeding resistance, which may lead to
deformation of the wire and damage to the feeder.
5.5 Preparing the MIG gun to work
Depending on the type of material to be welded and the diameter of the electrode wire, attach a suitable contact tip and
a wire guide to the MIG torch.
When welding steel, use contact tips for welding steel and a steel insert. When welding aluminum, use contact tips for
aluminum welding and a Teflon insert.
5.5.1 Rapid wire inch
The device has the function of a quick wire inch. Pressing the button (B) causes the wire to advance quickly, allowing it to
be easily inserted into the holder.
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6. SERVICE
6.1 Front panel
A - Display
The display shows the names and values of the parameters, the numbers of the sets of settings stored in memory, and the
error codes.
The voltage (arc length) of the base current.
Only for the D-PULSE MIG method.
Adjustment range: -50 - 50%.
Burnback - time for which the wire feed continues after the arc has been extinguished.
Adjustment range: -50 - 50% of factory setting. Welding
current
Pulse width - pulse duration, allows you to adjust the depth of penetration. Increasing the
width increases the penetration depth, reducing the amount of heat introduced into the
material, reducing the risk of burning through thinner sheets or smaller components.
Lower pulse width values should be used for higher currents. A larger pulse width should
be used for small currents, for example a width greater than 50% should be used for
currents below 100A.
Only for D-PULSE MIG, PULSE TIG and PULSE MMA methods.
Adjustment range: PULSE TIG, PULSE MMA: 5 - 95%; D-PULSE MIG: 20 - 80%. Final current
(crater filling)
Only for MIG / MAG method in S2T and S4T modes.
The adjustment range depends on the type of material to be welded and the wire
diameter. The duration of the final current (crater filling).
Only for MIG method in S2T mode
Adjustment range: 0 - 50 s
BU
Burn
Cur
Duty
EndI
Endt
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