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OPERATORS’ MANUAL

MULTIMIG 350F SYN

INVERTER Based Welding Machines

IMPORTANT: Read this Owner’s Manual Completely before attempting to use this
equipment. Save this manual and keep it handy for quick reference. Pay particular
attention to the safety instructions we have provided for your protection. Contact your
distributor if you do not fully understand this manual.
 CONTENT

CONTENT

§1 Safety 1
§2 Overview 9
§2.1 Features 9
§2.2 Brief Introduction 10
§2.3 Technical Data 11
§2.4 Duty cycle and Over-heat 11
§2.5 Working Principle 12
§2.6 Volt-Ampere Characteristic 12
§3 Panel Functions & Descriptions 13
§3.1 Machine Layout Description 13
§3.1.1 Front and rear panel layout of welding machine 13
§3.1.2 Front and rear panel layout of water cooling 14
§3.1.3 Wire feeder 15
§3.2 Front Panel Functions and Descriptions 16
§3.2.1 MMA control panel 16
§3.2.2 TIG Lift control panel 17
§3.2.3 MIG Manual control panel 20
§3.2.4 MIG SYN control panel 21
§3.2.5 System setting panel 23
§4 Installation & Operation 24
§4.1 Installation & Operation for MMA Welding 24
§4.1.1 Set up installation for MMA Welding 24
§4.1.2 MMA Welding 25
§4.1.3 MMA Welding Fundamentals 26
§4.2 Installation & Operation for TIG Welding 28
§4.2.1 Set up installation for TIG Welding 28
§4.2.2 DC TIG Welding 30
§4.2.3 TIG Welding Fusion Technique 32
§4.2.4 Tungsten Electrodes 33
§4.2.5 Tungsten Preparation 36
§4.3 Installation & Operation for MIG Welding 38
§4.3.1 Set up installation for MIG Welding 38
§4.3.2 Wire Feed Roller Selection 41
§4.3.3 Wire Installation and Set Up Guide 42
§4.3.4 MIG Torch Liner Types and Information 45
§4.3.5 MIG Welding 46
§4.4 Set up installation for Spool Gun 54
§4.5 Welding parameters 56
§4.6 Operation environment 57
§4.7 Operation Notices 57
§5 Welding trouble shooting 58
§5.1 MIG welding trouble shooting 58
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 CONTENT
§5.2 MIG wire feed trouble shooting 59
§5.3 DC TIG welding trouble shooting 60
§5.4 MMA welding trouble shooting 62
§6 Maintenance & Troubleshooting 63
§6.1 Maintenance 63
§6.2 Troubleshooting 64
§6.3 List of error code 66

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 SAFETY

§1 Safety
Notice: The instructions are for reference only. The manufacturer

reserves the right to explain the differences between the description

and the product due to product changes and upgrades!

The device is manufactured using state-of-the-art technology and

according to recognised safety standards. If used incorrectly or
misused, however, it can cause:
 Injury or death to the operator.
 Damage to the device and other material assets belonging to the
operating company.
 Inefficient operation of the device.
All persons involved in commissioning, operating, maintaining and
servicing the device must:
 Be suitably qualified.
 Have sufficient knowledge of welding.
General
 Read and follow these operating instructions carefully.
The operating instructions must always be at hand wherever the
device is being used. In addition to the operating instructions, attention
must also be paid to any generally applicable and local regulations
regarding accident prevention and environmental protection.
Before switching on the device, rectify any faults that could
compromise safety.
This is for your personal safety!

Environment Products are limited to use under suitable conditions. In extreme

cases, the use of products, such as high temperature, low temperature,
thunderstorm weather, will shorten the life of the machine and even

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 SAFETY

cause damage, please avoid the above situation.

Excessive ambient temperature will cause the machine heat
dissipation is not smooth, so that the internal components of the
machine heat seriously. Usually the maximum operating temperature is
104°F (40°C).
Low temperature may lead to performance degradation or damage of
components inside the product, resulting in ice inside the water tank.
Usually the lowest operating temperature is 14°F (-10°C). Please keep
warm and add antifreeze in the water tank if necessary.
Too humid environment may lead to rust of shell and circuit
components. In rainy weather, using products may lead to short circuit
and other abnormalities. Please try to avoid using in the above
environment. If the machine is wet, please dry in time.

Running parts and specific parts of risk will take damage for your body
Areas or others. The corresponding notices are as follows. It is quite a safe
operation after taking several necessary protection measures.
Items being welded generate and hold high heat and can cause severe
burns. Don’t touch hot parts with bare hands. Allow a cooling period
before working on the welding gun. Use insulated welding gloves and
clothing to handle hot parts and prevent burns.

A high risk of injury exists when the welding wire emerges from the
welding torch. Always keep the torch well away from the body.

Keep all equipment safety guards, covers and devices in position and
in good repair. Keep hands, hair, clothing and tools away from V-gears,
fans and all other moving parts when starting, operating or repairing
equipment, for example:
 Fans
 Cogs
 Rollers

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 SAFETY

 Shafts
 Wire spools and welding wire

Many harmful phenomena, such as noise, bright light and harmful gas,
will inevitably occur in the welding process. In order to avoid harmful
By product
phenomena causing harm to the human body, it is necessary to make
corresponding preparations in advance.
Arc rays from the welding process produce intense visible and invisible
ultraviolet and infrared rays that can burn eyes and skin.
 Use a shield with the proper filter and cover plates to protect your
eyes from sparks and the rays of the arc when welding or observing
open arc welding.
 Use suitable clothing made from durable flame-resistant material to
protect your skin and that of your helpers from the arc rays.
 Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.

Noise from some processes or equipment can damage hearing. You

must protect your ears from loud noise to prevent permanent loss of
hearing.
 To protect your hearing from loud noise, wear protective ear plugs
and/or ear muffs. Protect others in the workplace.
 Noise levels should be measured to be sure the decibels (sound) do
not exceed safe levels.

The build up of gas can causes a toxic environment, deplete the

oxygen content in the air resulting in death or injury. Many gases use in
welding are invisible and odorless.
 Shut off shielding gas supply when not in use.
 Always ventilate confine spaces or use approved air-supplied
respirator.
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 SAFETY

Welding may produce fumes and gases hazardous to health. Avoid

breathing these fumes and gases.
 Do not breathe the smoke and gas generated whilst welding or
cutting, keep your head out of the fumes. Use enough ventilation
and/or exhaust at the arc to keep fumes and gases away from the
breathing zone. Additional precautions are also required when
welding on galvanized steel.
 Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations. The heat
and rays of the arc can react with solvent vapors to form phosgene,
a highly toxic gas, and other irritating products.
 Shielding gases used for arc welding can displace air and cause
injury or death. Always use enough ventilation, especially in
confined areas, to insure breathing air is safe.
 Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the material
safety data sheet and follow your employer’s safety practices.

In the process of using, careless operation will lead to fire, explosion

Explosion and gas leakage or other dangers. Before using the product, we need to
know the correct preventive measures in order to avoid accidents.

Don’t add the fuel near an open flame welding arc or when the engine
is running. Stop the engine and allow it to cool before refueling to
prevent spilled fuel from vaporizing on contact with hot engine parts and
igniting.
Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not
start engine until fumes have been eliminated.

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 SAFETY

Flying sparks from the welding arc, hot work piece, and hot equipment
can cause fires and burns. Accidental contact of electrode to metal
objects can cause sparks, explosion, overheating or fire.
 Welding sparks and hot materials from welding can easily go
through small cracks and openings to adjacent areas.
 Avoid welding near hydraulic lines.
 Have a fire extinguisher readily available. Where compressed gases
are to be used at the job site, special precautions should be used to
prevent hazardous situation.
 Vent hollow castings or containers before heating, cutting or
welding. They may explode.
 Sparks and spatter are thrown from the welding arc. Wear oil free
protective garments such as leather gloves, heavy shirt, cuff less
trousers, high shoes and a cap over your hair.
 Connect the work cable to the work as close to the welding area as
practical. Work cables connected to the building framework or other
locations away from the welding area increase the possibility of the
welding current passing through lifting chains, crane cables or other
alternate circuits. This can create fire hazards or overheat lifting
chains or cables until they fail.
Shielding gas cylinders contain gas under high pressure. If damaged,
a cylinder can explode.
 Protect gas cylinders from excessive heat, mechanical shocks,
physical damage, slag, open flames sparks, and arcs.
 Insure cylinders are held secure and upright to prevent tipping or
falling over.
 Never allow the welding electrode or earth clamp to touch the gas
cylinder, do not drape welding cables over the cylinder.
 Open the cylinder valve slowly and turn your face away from the

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 SAFETY

cylinder outlet valve and gas regulator.

Use only compressed gas cylinders containing the correct shielding

gas for the process used and properly operating regulators designed for
the gas and pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
 Always keep cylinders in an upright position securely chained to an
undercarriage or fixed support.
 Cylinders should be located:
- Away from areas where they may be struck or subjected to
physical damage.
- A safe distance from arc welding or cutting operations and any
Cylinder other source of heat, sparks, or flame.
 Never allow the electrode, electrode holder or any other electrically
“hot” parts to touch a cylinder.
 Keep your head and face away from the cylinder valve outlet when
opening the cylinder valve.
 Valve protection caps should always be in place and hand tight
except when the cylinder is in use or connected for use.

Touching live electrical parts can cause fatal shocks or severe burns.
The electrode and work circuit is electrically live whenever the output is
Electricity
on. The input power circuit and internal machine circuits are also live
when power is on.
Different products have different requirements for input voltage, such
as single-phase and three-phase. If the machine with three-phase
electricity as input appears phase absence or voltage fluctuation, it may
cause serious damage to the product interior.
All products must be well grounded before they are connected to the
power supply. In case of abnormal case such as shell leakage, please
disconnect the power supply immediately and notify the professionals

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 SAFETY

for maintenance.
Don’t sling cables or leads around either the body or parts of the body.
The electrode (rod electrode, tungsten electrode, welding wire, etc)
must
 Never be immersed.
 Never be touched when current is flowing.
When the machine is connected to the power supply, there is
electricity inside the machine. Please do not touch the wires, circuit
boards and related electrical parts in order to avoid life hazards and
property losses.
During MIG/MAG or TIG welding, the welding wire, the wire spool, the
drive rollers and all metal parts that are in contact with the welding wire
are live. Always set the wire-feed unit up on a sufficiently insulated
surface or use a suitable, insulated wire-feed unit mount.

According to the domestic and international standards, the ambient

devices’ electromagnetism situation and anti-interference ability must be
checked:
EMC  Safety device.
 Power line, Signal transmission line and Date transmission line.
 Date processing equipment and telecommunication equipment.
 Inspection and calibration device.
Supporting measures for avoidance of EMC problems:
1. Mains supply
If electromagnetic interference arises despite correct mains
connection, additional measures are necessary.
2. Welding power leads must be kept as short as possible, must run
close together and be kept well apart from other leads
3. Equipotential bonding
4. Earthing of the workpiece
If necessary, establish an earth connection using suitable capacitors.

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 SAFETY

5. Shielding, if necessary
 Shield off other nearby devices.
 Shield off entire welding installation.
Radiation Class A Device.
 Only can be used in the industrial area.
 If it is used in other area, it may cause connection and radiation
problems of circuit.
Radiation Class B device.
 Satisfy the emissions criteria for residential and industrial areas.
EMC Class
This is also true for residential areas in which the energy is supplied
from the public low-voltage mains.
EMC device classification as per the rating plate or technical data.

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 OVERVIEW

§2 Overview
§2.1 Features
 New panel design: More trendy and humanized.
 LCD screen for accurate setting &
feedback of welding output.
 New PWM technology and IGBT inverter
technology.
 MIG/MAG with Manual and SYN function:
-Synergic programs for aluminum, mill
steel, stainless steel and CuSi
- 2T/ 4T welding mode
- function parameter adjustment
 MMA function (Stick electrode)
- Hot start (improves electrode starting)
- Adjustable Arc Force
 DC TIG
- Lift Arc ignition (prevents tungsten
sticking during arc ignition)
- 2T/4T Trigger Control
- Adjustable Down slope
-Water/air cooling mode
 Internal wire feeder, gear driven for up to
300mm Ø spool.
 Euro style MIG torch connection.
 IP21S rating for environmental/safety protection.
 Tolerant to variable power supply.
 Spool Gun Connection.
 Integrated heavy duty industrial trolley and water cooler (optional).

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 OVERVIEW

§2.2 Brief Introduction

MIG series of welding machines adopts the latest Pulse Width Modulation (PWM)
technology and the Insulated Gate Bipolar Transistor (IGBT) power modules. It uses
switching frequencies in the 20KHz-50KHz range so as to replace the traditional line-
frequency transformer type welding machines. Thus, machines are characterized with
excellent dynamic response, portability, small size, lightweight, low energy consumption,
etc.
MIG series of welding machines uses Mix gases as shielding gas to realize gas
shielded welding, active gas (Ar+O2, Ar+CO2) as shielded gas to realize MAG welding
and inactive gas (Ar) as shielded gas to realize MIG welding.
MIG series of welding machines has built-in automatic protection functions to protect
the machines from over-voltage, over-current and over-heat. If any one of the above
problems happens, the error code is displayed on the screen and output current will be
shut off automatically for the machine to protect itself and prolong the equipment using
life.
MIG series Features:
1. Digital control system, real-time display the welding parameters;
2. High performance multifunction power source (MIG/MAG);
3. Waveform control, stable welding arc;
4. IGBT technology, low power consumption;
MIG series of arc welding machine is suitable for all positions welding for various
plates made of stainless steel, carbon steel, alloyed steel etc. Applications applied to
pipe installment, petrochemical, architecture equipment, car repair, bicycle repair,
handicraft and common steel fabrication.
MAG = Metal Active Gas Welding
MIG = Metal Inert Gas Welding

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 OVERVIEW

§2.3 Technical Data

Models
MULTIMIG 350 SYN
Parameters
Input Voltage (V) 3~400±10%
Frequency (HZ) 50/60
MIG TIG MMA
Input Current (A) 22.7 19.0 24.0
Input Power (kVA) 15.7 13.2 16.6
Welding Current (A) 30-350 10-350 10-350
No-load Voltage (V) 77 73 77
60% 350A
Duty cycle (40℃)
100% 275A
Efficiency (%) 90% 87.7% 90.7%
Fe: 0.8/0.9/1.0/1.2
SS: 0.9/1.0/1.2
Diameter (mm) Flux-Cored: 0.9/1.0/1.2
AlMg: 1.0/1.2
CuSi: 1.0
Circuit Breaker Standard LW31-32B-4AB-04/2
Protection class IP21S
Dimensions (mm) 640*250*460
Weight (Kg) 26.5
Power Factor 0.78 0.73 0.79
Note: The above parameters are subject to change with future machine improvement!

§2.4 Duty cycle and Over-heat

The letter “X” stands for Duty Cycle,
which is defined as the portion of the time The relation of the welding current
and duty cycle for MULTIMIG
a welding machine can weld continuously 350FSYN
with its rated output current within a
certain time cycle (10 minutes).
The relation between the duty cycle “X”
and the output welding current “I” is shown
as the right figure.
If the welding machine is overheating,
the IGBT over-heat protection sensing will
send a signal to the welding machine
control unit to cut the output welding
current OFF and the error code is displayed on the screen. In that case, the machine
should not be welding for 10~15 minutes to cool down with the fanrunning. When
operating the machine again, the welding output current or the duty cycle should be
reduced.

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 OVERVIEW

§2.5 Working Principle

The working principle of MIG series welding machine is shown as the following figure.
Three-phase 400V work frequency AC is rectified into DC (530V), then is converted to
medium frequency AC (about 20KHz) by inverter device (IGBT), after reducing voltage
by medium transformer (the main transformer) and rectifying by medium frequency
rectifier (fast recovery diodes), and is outputted by inductance filtering. The circuit
adopts current feedback control technology to insure current output stably when MMA or
TIG. And adopts voltage feedback control technology to insure voltage output stably
when MIG. Meanwhile, the welding current parameter can be adjusted continuously and
infinitely to meet with the requirements of welding craft.

§2.6 Volt-Ampere Characteristic

MIG series of welding machines has an excellent volt-ampere characteristic, whose
graph is shown as the following figure. The relation between the rated loading voltage
U2 and welding current I2 is as follows: U2=14+0.05I2 (V).

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 PANEL FUNCTIONS & DESCRIPTIONS

§3 Panel Functions & Descriptions

§3.1 Machine Layout Description
§3.1.1 Front and rear panel layout of welding machine

1. TIG gun control connector.

2. Negative (-) welding power output connection socket.
3. TIG torch gas connector.
4. Positive (+) welding power output connection socket.
5. Gas Inlet: Connect the gas conduit.
6. Positive output anode: Used to connect to the welding cable of wire feeder.
7. Water box connector: To connect water box.
8. Wire feeder connector: Used to connect to the control cable of wire feeder.
9. Power switch: Turn on power supply clockwise and turn off power supply
counterclockwise.
10. Power source input: To connect power source.

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 PANEL FUNCTIONS & DESCRIPTIONS

§3.1.2 Front and rear panel layout of water cooling

1 Intake: From here, water or coolant, antifreeze, etc. can be injected into tank.
2 Backwater inlet for TIG (red).*
3 Water outlet for TIG (blue).*
4 Water outlet for MIG (blue).*
5 Backwater inlet for MIG (red).*
6 Water cooling control connector.*
7 Water level calibration.*
The words marked * are explained in detail below.
Further Controls Explained
Inlet (2) and outlet (3) for TIG
The two nozzles on the same side of the intake (2) are used for TIG operation and can
be connected to the nozzles on TIG welding torch. Blue corresponds to the outlet: cold
water is delivered from the tank; red corresponds to the backwater inlet: hot water is
flowed into the tank for cooling.
Note: Blue outlet and red backwater inlet must not be wrong!
Inlet (5) and outlet (4) for MIG
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 PANEL FUNCTIONS & DESCRIPTIONS
The two nozzles on the same side of Control connector (6) are used for MIG operation
and can be connected to the nozzles on the wire feeder. Blue corresponds to the outlet:
cold water is delivered from the tank; red corresponds to the backwater inlet: hot water
is flowed into the tank for cooling.
Note: Blue outlet and red backwater inlet must not be wrong!
Control connector (6)
Water tank control connector is used for inserting the connecting line. And connection
line is used to connect the water tank with welding machine. It supplies power to the
water tank through the connection line and receives control and detection signals in
time.
Water level calibration (7)
This is a hollow trough, you can clearly observe the water volume in the tank, the
highest marking the highest water level: water volume should not exceed the highest
water level; the lowest marking the lowest water level: when the water volume is lower
than the lowest water level, the water tank will not work properly, need to replenish
water from the intake in time.

§3.1.3 Wire feeder

1. MIG gun connector.
2. 9 core air sock for Spool gun.
3. Backwater inlet (red).
4. Water outlet (blue).
5. Gas connector.
6. Wire feeder control anode.
7. Positive output anode.
8. Backwater outlet (red).
9. Water inlet (blue).
10. Wire reel Shaft.
11. Wire feed tension adjustment.
12. Wire feed tension arm (2x).
13. Wire feed roller (2x).
14. Wire feeder inlet guide.
15. Wire drive roller.

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 PANEL FUNCTIONS & DESCRIPTIONS

§3.2 Front Panel Functions and Descriptions

§3.2.1 MMA control panel

1. Welding mode button: Press it to select MMA welding mode.

2. L parameter knob: Rotate it to adjust welding current.
1. R parameter knob: Press it to select Hot Start or Arc Force and rotate it to adjust
values.
Hot start
Hot start provides extra power when the weld starts to counteract the high resistance
of the electrode and workpiece as the arc is started. Setting range: 0~10.
Arc force
An MMA welding power source is designed to produce constant output current. This
means with different types of electrode and arc length; the welding voltage varies to
keep the current constant. This can cause instability in some welding conditions as
MMA welding electrodes will have a minimum voltage they can operate with and still
have a stable arc.
Arc Force control boosts the welding power if its senses the welding voltage is getting
too low. The higher the arc force adjustment, the higher the minimum voltage that the
power source will allow. This effect will also cause the welding current to increase. 0 is
Arc Force off, 10 is maximum Arc Force. This is practically useful for electrode types
that have a higher operating voltage requirement or joint types that require a short arc
length such as out of position welds.

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 PANEL FUNCTIONS & DESCRIPTIONS

§3.2.2 TIG Lift control panel

1. Welding mode button: Press it to select TIG Lift welding mode.

2. L parameter knob: Rotate it to adjust welding current. In functional parameter
interface, rotate it to select parameters.
3. R parameter knob: Rotate it to adjust Down Slope time and other parameters.
4. Functional parameter button.
5. Cooling mode button: Press it to select water cooling mode.

TIG functional parameter interface:

1. Trigger mode: 2T or 4T.

2. Pre flow time: 0~2s.
3. Post flow time: 0~10s.

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 PANEL FUNCTIONS & DESCRIPTIONS

Trigger mode select:

 2T Mode
The trigger is pulled and held on to activate the welding circuit, when the trigger is
released, the welding circuit stops.
This function without the adjustment of start current and crater current is suitable for
the Re-tack welding、transient welding、thin plate welding and so on.

Introduction:
(1) 0: Press the gun switch and hold it. Electromagnetic gas valve is turned on. The
shielding gas stars to flow.
(2) 0～t1: Pre-gas time (0.1~2.0s)
(3) t1～t2: Arc is ignited and the output current rises to the setting welding current (I w or
Ib) from the min welding current.
(4) t2 ～ t3: During the whole welding process, the gun switch is pressed and held
without releasing.
Note: Select the pulsed output, the base current and welding current will be outputted
alternately; otherwise, output the setting value of welding current;
(5) t3: Release the gun switch, the welding current will drop in accordance with the
selected down-slope time.
(6) t3～t4: The current drops to the minimum welding current from the setting current
(Iw or Ib), and then arc is turned off.
(7) t4～t5: Post-gas time, after the arc is turned off. You can adjust it (0.0~10s) through
turnning the knob on the front panel.
(8) t5: Electromagnetic gas valve turned off, the shield gas stops to flow, and welding
is finished.

 4T Mode
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 PANEL FUNCTIONS & DESCRIPTIONS
This is known as ’latching’ mode. The trigger is pulled once and released to activate
the welding circuit, pulled and released again to stops the welding circuit. This function
is useful to longer welds as the trigger is not required to be held on continuously. TIG
series of welding machines also has more current control options that can be used in 4T
mode.
The start current and crater current can be pre-set. This function can compensate the
possible crater that appears at the beginning and end of the welding. Thus, 4T is
suitable for the welding of medium thickness plates.

Introduction:
(1) 0: Press and hold the gun switch, Electromagnetic gas valve is turned on. The
shielding gas stars to flow;
(2) 0～t1: Pre-gas time (0.1~2.0S);
(3) t1～t2: Arc is ignited at t1 and then output the setting value of start current;
(4) t2: Loosen the gun switch, the output current slopes up from the start current;
(5) t2～t3: The output current rises to the setting value (I w or Ib), the upslope time can be
adjusted;
(6) t3～t4: Welding process. During this period, the gun switch is loosen;
Note: Select the pulsed output, the base current and welding current will be outputted
alternately; otherwise, output the setting value of welding current;
(7) t4: Press the torch switch again, the welding current will drop in accordance with the
selected down-slope time.
(8) t4～t5: The output current slopes down to the crater current. The downslope time can
be adjusted;
(9) t5～t6: The crater current time;
(10) t6: Loosen the gun switch, stop arc and keep on argon flowing;
(11)t6～t7: Post-gas time can be set by post-gas time adjustment knob on front panel;
(12) t7: Electromagnetic valve is closed and stop argon flowing. Welding is finished.
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 PANEL FUNCTIONS & DESCRIPTIONS

§3.2.3 MIG Manual control panel

1. Welding mode button: Press it to select MIG Manual welding mode.

2. L parameter knob: Rotate it to adjust wire feeding speed. In functional parameter
interface, rotate it to select parameters.
3. R parameter knob: Rotate it to adjust parameters.
4. Functional parameter button.
5. Cooling mode button: Press it to select water cooling mode.
6. Manual shield gas check button.
7. Manual wire feed button.

MIG Manual functional parameter interface:

1.
T

rigger mode: 2T/ 4T.

2. Pre flow time: 0~5s.
3. Post flow time: 0~10s.
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 PANEL FUNCTIONS & DESCRIPTIONS
4. Burnback: 0~10.
5. Slow feed: 0~5.
6. Spool gun: ON/OFF.

Burnback
Short-circuit between welding wire and molten pool leads to the increase of current,
which leads to the melting speed of welding wire too fast, and the wire feeding speed
cannot keep up with, which makes the welding wire and workpiece disconnected. This
phenomenon is called “burn back”. This function is to ensure the welding seam is not
beautiful after welding. Range: 0-10.

Slow feed
This function is used to regulate the speed of wire feeding increasing. Range: 0-5.

§3.2.4 MIG SYN control panel

The operator simply sets the welding current like MIG welding and the machine
calculates the optimal voltage and wire speed for the material type, wire type and size
and shielding gas being used. Obviously other variables such as welding joint type and
thickness, air temperature affect the optimal voltage and wire feed setting, so the
program provides a voltage fine tuning function for the synergic program selected. Once
the voltage is adjusted in a synergic program, it will stay fixed at this variation when the
current setting is changed. To reset the voltage for a synergic program back to factory
default, change to another program and back again.

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 PANEL FUNCTIONS & DESCRIPTIONS

1. Welding mode button: Press it to select MIG SYN welding mode.

2. L parameter knob: Rotate it to adjust wire feeding speed. In functional parameter
interface, rotate it to select parameters.
3. R parameter knob: Rotate it to adjust parameters.
4. Functional parameter button.
5. Cooling mode button: Press it to select water cooling mode.
6. Manual shield gas check button.
7. Manual wire feed button.

MIG SYN functional parameter interface:

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 PANEL FUNCTIONS & DESCRIPTIONS
1. Trigger mode: 2T/ 4T
2. Wire material: SS solid-cored/ Fe solid-cored/ Fe flux-cored/ Al-Mg solid-cored/
CuSi.
3. Wire diameter: 0.8~1.2mm
4. Shield gas: CO2 / 80%Ar+20%CO2 / 98%Ar+2%CO2.
5. Pre flow time: 0~5s.

§3.2.5 System setting panel

Press the functional parameter button and hold it for 3s to enter the system interface.
Here you can adjust the language, the unit and the brightness setting by L parameter
knob and R parameter knob.

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 INSTALLATION & OPERATION

§4 Installation & Operation

§4.1 Installation & Operation for MMA Welding
§4.1.1 Set up installation for MMA Welding
(1) Connection of Output Cables
Two sockets are available on this welding machine. For MMA welding the electrode
holder is shown be connected to the positive socket, while the earth lead (work piece) is
connected to the negative socket, this is known as DCEP. However various electrodes
require a different polarity for optimum results and careful attention should be paid to
the polarity, refer to the electrode manufacturer’s information for the correct polarity.
DCEP: Electrode connected to “+” output socket.
DCEN: Electrode connected to “-” output socket.

(2) Turn the power source on and press the welding mode button to select the MMA
function.
(3) Set the welding current relevant to the electrode type and size being used as
recommended by the electrode manufacturer.
(4) Set the Hot Start and Arc Force using the knob.
(5) Place the electrode into the electrode holder and clamp tight.
(6) Strike the electrode against the work piece to create and arc and hold the electrode
steady to maintain the arc.

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 INSTALLATION & OPERATION

§4.1.2 MMA Welding

One of the most common types of arc welding is manual metal arc welding (MMA) or
stick welding. An electric current is used to strike an arc between the base material and
a consumable electrode rod or ‘stick’. The electrode rod is made of a material that is
compatible with the base material being welded and is covered with a flux that gives off
gaseous vapours that serve as a shielding gas and providing a layer of slag, both of
which protect the weld area from atmospheric contamination. The electrode core itself
acts as filler material the residue from the flux that forms slag covering over the weld
metal must be chipped away after welding.

● The arc is initiated by momentarily touching the electrode

to the base metal.
● The heat of the arc melts the surface of the base metal to
form a molten pool at the end of the electrode.
● The melted electrode metal is transferred across the arc
into the molten pool and becomes the deposited weld
metal.
● The deposit is covered and protected by a slag which comes from the electrode
coating.
● The arc and the immediate area are enveloped by an
atmosphere of protective gas
Manual metal arc (stick) electrodes have a solid metal wire
core and a flux coating. These electrodes are identified by the
wire diameter and by a series of letters and numbers. The letters and numbers identify
the metal alloy and the intended use of the electrode.
The Metal Wire Core works as conductor of the current that maintains the arc. The
core wire melts and is deposited into the welding pool.
The covering on a shielded metal arc welding electrode is called Flux. The flux on the
electrode performs many different functions. These include:
25
 INSTALLATION & OPERATION
● producing a protective gas around the weld area
● providing fluxing elements and deoxidizer
● creating a protective slag coating over the weld as it cools
establishing arc characteristics
● adding alloying elements
Covered electrodes serve many purposes in addition to filler
metal to the molten pool. These additional functions are provided mainly by the covering
on the electrode.

§4.1.3 MMA Welding Fundamentals

Electrode Selection
As a general rule, the selection of an electrode is straight forward, in that it is only a
matter of selecting an electrode of similar composition to the parent metal. However, for
some metals there is a choice of several electrodes, each of which has particular
properties to suit specific classes of work. It is recommend to consult your welding
supplier for the correct selection of electrode.
Electrode Size
Average Maximum The size of the electrode generally
Thickness of Recommended depends on the thickness of the section
Material Electrode Diameter
being welded, and the thicker the section
1.0-2.0 mm 2.5 mm the larger the electrode required. The
2.0-5.0 mm 3.2 mm table gives the maximum size of
electrodes that may be used for various
5.0-8.0 mm 4.0 mm
thicknesses of section base on using a
>8.0 mm 5.0 mm general purpose type 6013 electrode.

Welding Current (Amperage)

Electrode Size Current Range Correct current selection for a particular
ø mm (Amps) job is an important factor in arc welding.
2.5 mm 60-95 With the current set too low, difficulty is
experienced in striking and maintaining
3.2 mm 100-130
astable arc. The electrode tends to stick
4.0 mm 130-165
to the work, penetration is poor and
5.0 mm 165-260 beads with a distinct rounded profile will
be deposited. Too high current is
accompanied by overheating of the electrode resulting undercut and burning through of
26
 INSTALLATION & OPERATION
the base metal and producing excessive spatter. Normal current for a particular job may
be considered as the maximum, which can be used without burning through the work,
over-heating the electrode or producing a rough spattered surface. The table shows
current ranges generally recommended for a general purpose type 6013 electrode.

Arc Length
To strike the arc, the electrode should be gently scraped on the work until the arc is
established. There is a simple rule for the proper arc length; it should be the shortest arc
that gives a good surface to the weld. An arc too long reduces penetration, produces
spatter and gives a rough surface finish to the weld. An excessively short arc will cause
sticking of the electrode and result in poor quality welds. General rule of thumb for down
hand welding is to have an arc length no greater than the diameter of the core wire.

Electrode Angle
The angle that the electrode makes with the work is important to ensure a smooth,
even transfer of metal. When welding in down hand, fillet, horizontal or overhead the
angle of the electrode is generally between 5and 15 degrees towards the direction of
travel. When vertical up welding, the angle of the electrode should be between 80 and
90 degrees to the work piece.

Travel Speed
The electrode should be moved along in the direction of the joint being welded at a
speed that will give the size of run required. At the same time, the electrode is fed
downwards to keep the correct arc length at all times. Excessive travel speeds lead to
poor fusion, lack of penetration etc, while too slow a rate of travel will frequently lead to
arc instability, slag inclusions and poor mechanical properties.

Material and Joint Preparation

The material to be welded should be clean and free of any moisture, paint, oil, grease,
mill scale, rust or any other material that will hinder the arc and contaminate the weld
material. Joint preparation will depend on the method used include sawing, punching,
shearing, machining, flame cutting and others. In all case, sedges should be clean and
free of any contaminates. The type of joint will be determined by the chosen application.

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 INSTALLATION & OPERATION

§4.2 Installation & Operation for TIG Welding

§4.2.1 Set up installation for TIG Welding

(1) Insert the earth cable plug into the positive socket on the front of the machine and
tighten it.
(2) Plug the welding torch into the negative socket on the front panel, and tighten it.
(3) Connect the gas line of TIG Gun to outlet gas connector on the front of the machine.
Check for Leaks!
(4) Connect the control cable of torch switch to aero socket on the front of the machine.
(5) Connect the water inlet and outlet pipe of TIG Gun to inlet and outlet water
connector on the front of the cooling water.
(6) Connect the gas regulator to the Gas Cylinder and connect the gas line to the Gas
Regulator. Check for Leaks!
(7) Connect the gas line to the machine inlet gas connector via the quick push lock
connector located on the rear panel. Check for Leaks!
(8) Connect the control cable of cooling water with the aero socket on the rear panel of
welding machine.
(9) Connect the power cable of welding machine with the output switch in electric box
on site.
(10) Carefully open the valve of the gas cylinder, set the required gas flow rate.

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 INSTALLATION & OPERATION
(11) Select TIG welding mode on the front panel.
(12) Set torch operation 2T/4T.
 When 2T operation is selected press trigger Gas starts, touch and lift arc start,
release trigger Gas and Arc stops.
 When 4T operation is selected press and release trigger Gas starts, touch and lift
arc start, press and release trigger Gas and Arc stops.
(13) Select water cooling mode on the front panel.

LIFT ARC DC TIG Operation

Lift Arc ignition allows the arc to be started easily in DC TIG by simply touching the
tungsten to the work piece and lifting it up to start the arc. This prevents the tungsten tip
sticking to the work piece and breaking the tip from the tungsten electrode. There is a
particular technique called “rocking the cup” used in the Lift Arc process that provides
easy use of the Lift Arc function.
(1) Select welding current and Down slope Time as required on the front panel. The
selected welding current and Down slope Time will show on the screen.
(2) Assemble front end parts of the TIG torch making sure they are correctly
assembled, use the correct size and type of tungsten electrode for the JOB, the
tungsten electrode requires a sharpened point for DC welding.
(3) Lay the outside edge of the Gas Cup on the work piece with the Tungsten
Electrode 1- 2mm from the work piece. Press and hold the torch switch to activate
to gas flow and welding power.
(4) With a small movement rotate the Gas Cup forward so that the Tungsten Electrode
touches the work piece.
(5) Now rotate the Gas Cup in the reverse direction to lift the Tungsten electrode from
the work piece to create the arc.
(6) Release the trigger to stop the welding.

(2) Assemble front end parts of the TIG

torch, fitting a sharpened tungsten suitable
for the material to be welded.

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 INSTALLATION & OPERATION

(3) Lay the outside edge of the cup on (4) With a small movement rotate the gas
work piece with the tungsten Electrode cup forward so that the tungsten electrode
1-2mm from the work piece. Press and touches the work piece.
hold the trigger button on TIG torch to
start the gas flow.

(5) Now rotate the Gas Cup in the reverse (6) Release the trigger to stop the welding.
direction to lift the Tungsten electrode from
the work piece to create the arc.

IMPORTANT! - We strongly recommend that you check for gas leaks prior to operation
of your machine. We recommend that you close the cylinder valve when the machine is
not in use.

§4.2.2 DC TIG Welding

The DC power source uses what is known as DC (direct
current) in which the main electrical component known as
electrons flow in only one direction from the negative pole
(terminal) to the positive pole (terminal). In the DC electrical
circuit there is an electrical principle at work which should
always be taken into account when using any DC circuit. With
a DC circuit 70% of the energy (heat) is always on the

30
 INSTALLATION & OPERATION
positive side. This needs to be understood because it determines what terminal the TIG
torch will be connected to (this rule applies to all the other forms of DC welding as well).
DC TIG welding is a process in which an arc is struck between a TUNGSTEN
electrode and the metal work piece. The weld area is
shielded by an inert gas flow to prevent contamination of the
tungsten, molten pool and weld area. When the TIG arc is
struck the inert gas is ionized and superheated changing its
molecular structure which converts it into a plasma stream.
This plasma stream flowing between the tungsten and the
work piece is the TIG arc and can be as hot as 19,000°C. It is a very pure and
concentrated arc which provides the controlled melting of most metals into a weld pool.
TIG welding offers the user the greatest amount of flexibility to weld the widest range of
material and thickness and types. DC TIG welding is also the cleanest weld with no
sparks or spatter.
The intensity of the arc is proportional to the current
that flows from the tungsten. The welder regulates
the welding current to adjust the power of the arc.
Typically thin material requires a less powerful arc
with less heat to melt the material so less current
(amps) is required, thicker material requires a more
powerful arc with more heat so more current (amps) are necessary to melt the material.

LIFT ARC IGNITION for TIG (tungsten inert gas) Welding

Lift Arc is a form of arc ignition where the machines have low voltage on the electrode
to only a few volts, with a current limit of one or two amps (well below the limit that
causes metal to transfer and contamination of the weld or electrode). When the
machine detects that the tungsten has left the surface and a spark is present, it
immediately (within microseconds) increases power, converting the spark to a full arc. It
is a simple, safe lower cost alternative arc ignition process to HF (high frequency) and a
superior arc start process to scratch start.

31
 INSTALLATION & OPERATION

tungsten touches
gas flow
the work established
arc ignition TIG arc
tungsten off
the work

Lay the nozzle on the Rock the torch sideways Rock the torch back in Lift the torch to
job without the tungsten so that the tungsten the opposite direction, maintain the arc.
touching the work. touches the work & hold the arc will ignite as
momentarily. the tungsten lifts off.

§4.2.3 TIG Welding Fusion Technique

Manual TIG welding is often considered the most difficult of all
the welding processes. Because the welder must maintain a short
arc length, great care and skill are required to prevent contact
between the electrode and the work piece. Similar to Oxygen
Acetylene torch welding, TIG welding normally requires two hands
and in most instances requires the welder to manually feed a filler
wire into the weld pool with one hand while manipulating the welding torch in the other.
However, some welds combining thin materials can be accomplished without filler metal
like edge, corner, and butt joints. This is known as Fusion welding where the edges of
the metal pieces are melted together using only the heat and arc force generated by the
TIG arc. Once the arc is started the torch tungsten is held in place until a weld pool is
created, a circular movement of the tungsten will assist is creating a weld pool of the
desired size. Once the weld pool is established tilt the torch at about a 75° angle and
move smoothly and evenly along the joint while fusing the materials together.

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 INSTALLATION & OPERATION

TIG Welding with Filler Wire Technique

It is necessary in many situations with TIG welding to add a
filler wire into the weld pool to build up weld reinforcement
and create a strong weld. Once the arc is started the torch
tungsten is held in place until a weld pool is created, a
circular movement of the tungsten will assist is creating a
weld pool of the desired size. Once the weld pool is
established tilt the torch at about a 75° angle and move smoothly and evenly along the
joint. The filler metal is introduced to the leading edge of the weld pool. The filler wire is
usually held at about a 15° angle and fed into the leading edge of the molten pool, the
arc will melt the filler wire into the weld pool as the torch is moved forward. Also a
dabbing technique can be used to control the amount of filler wire added, the wire is fed
into the molten pool and retracted in a repeating sequence as the torch is moved slowly
and evenly forward. It is important during the welding to keep the molten end of the filler
wire inside the gas shield as this protects the end of the wire from being oxidised and
contaminating the weld pool.

§4.2.4 Tungsten Electrodes

Tungsten is a rare metallic element used for manufacturing TIG welding electrodes.
The TIG process relies on tungsten’s hardness and high-temperature resistance to
carry the welding current to the arc. Tungsten has the highest melting point of any
metal, 3,410 degrees Celsius. Tungsten electrodes are non-consumable and come in a
variety of sizes, they are made from pure tungsten or an alloy of tungsten and other rare
earth elements. Choosing the correct tungsten depends on the material being welded,
amps required and whether you are using AC or DC welding current. Tungsten

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 INSTALLATION & OPERATION
electrodes are color-coded at the end for easy identification. Below are the most
commonly used tungsten electrodes found in the New Zealand and Australian market.

Thoriated
Thoriated tungsten electrodes (AWS classification EWTh-2) contain a minimum of
97.30 percent tungsten and 1.70 to 2.20percent thorium and are called 2 percent
thoriated. They are the most commonly used electrodes today and are preferred for
their longevity and ease of use. Thorium however is a low-level radioactive hazard and
many users have switched to other alternatives. Regarding the radioactivity, thorium is
an alpha emitter but when it is enclosed in a tungsten matrix the risks are negligible.
Thoriated tungsten should not get in contact with open cuts or wounds. The more
significant danger to welders can occur when thorium oxide gets into the lungs. This can
happen from the exposure to vapours during welding or from ingestion of material/dust
in the grinding of the tungsten. Follow the manufacturer’s warnings, instructions, and
the Material Safety Data Sheet (MSDS) for its use.

E3 (Color Code: Purple)

E3 tungsten electrodes (AWS classification EWG) contain a minimum of 98% percent
tungsten and up to 1.5 percent Lanthanum and small percentages of Zirconium and
Yttrium they are called E3 Tungsten. E3 Tungsten Electrodes provide conductivity
similar to that of thoriated electrodes. Typically, this means that E3 Tungsten Electrodes
are exchangeable with thoriated electrodes without requiring significant welding process
changes. E3 deliver superior arc starting, electrode lifetime, and overall cost-
effectivenes. When E3 Tungsten Electrodes are compared with 2% thoriated tungsten,
E3 requires fewer re-grinds and provides a longer overall lifetime. Tests have shown
that ignition delay with E3 Tungsten Electrodes actually improves over time, while 2%
thoriated tungsten starts to deteriorate after only 25 starts. At equivalent energy output,
E3 Tungsten Electrodes run cooler than 2% thoriated tungsten, thereby extending
overall tip lifetime. E3 Tungsten Electrodes work well on AC or DC. They can be used
DC electrode positive or negative with a pointed end, or balled for use with AC power
sources.

Ceriated (Color Code: Orange)

Ceriated tungsten electrodes (AWS classification EWCe-2) contain a minimum of
97.30 percent tungsten and 1.80 to 2.20percent cerium and are referred to as 2 percent
ceriated. Ceriated tungstens perform best in DC welding at low current settings. They

34
 INSTALLATION & OPERATION
have excellent arc starts at low amperages and become popular in such applications as
orbital tube welding, thin sheet metal work. They are best used to weld carbon steel,
stainless steel, nickel alloys, and titanium, and in some cases it can replace 2 percent
thoriated electrodes. Ceriated tungsten is best suited for lower amperages it should last
longer than Thoriated tungsten higher amperage applications are best left to Thoriated
or Lanthanated tungsten.

Lanthanated (Color Code: Gold)

Lanthanated tungsten electrodes (AWS classification EWLa-1.5) contain a minimum of
97.80 percent tungsten and 1.30percent to 1.70 percent lanthanum, and are known as
1.5 percent lanthanated. These electrodes have excellent arc starting, a low burn off
rate, good arc stability, and excellent re-ignition characteristics. Lanthanated tungstens
also share the conductivity characteristics of 2 percent thoriated tungsten. Lanthanated
tungsten electrodes are ideal if you want to opti-mise your welding capabilities. They
work well on AC or DC electrode negative with a pointed end, or they can be balled for
use with AC sine wave power sources. Lanthanated tungsten maintains a sharpened
point well, which is an advantage for welding steel and stainless steel on DC or AC from
square wave power sources.

Zirconiated (Color Code: White)

Zirconiated tungsten electrodes (AWS classification EWZr-1) contain a minimum of
99.10 percent tungsten and 0.15 to 0.40percent zirconium. Most commonly used for AC
welding Zirconiated tungsten produces a very stable arc and is resistant to tungsten
spitting. It is ideal for AC welding because it retains a balled tip and has a high
resistance to contamination. Its current-carrying capacity is equal to or greater than that
of thoriated tungsten. Zirconiated tungsten is not recommended for DC welding.
Tungsten Electrodes Rating for Welding Currents
Tungsten DC Current Amps AC Current Amps AC Current Amps
Diameter Torch Negative Un-Balanced Wave Balanced Wave
mm 2% Thoriated 0.8% Zirconiated 0.8% Zirconiated
1.0mm 15-80 15-80 20-60
1.6mm 70-150 70-150 60-120
2.4mm 150-250 140-235 100-180
3.2mm 250-400 225-325 160-250
4.0mm 400-500 300-400 200-320

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 INSTALLATION & OPERATION

§4.2.5 Tungsten Preparation

Always use DIAMOND wheels when grinding and cutting. While tungsten is a very
hard material, the surface of a diamond wheel is harder, and this makes for smooth
grinding. Grinding without diamond wheels, such as Aluminum oxide wheels, can lead
to jagged edges, imperfections, or poor surface finishes not visible to the eye that will
contribute to weld inconsistency and weld defects.
Always ensure to grind the tungsten in a longitudinal direction on the grinding wheel.
Tungsten electrodes are manufactured with the molecular structure of the grain running
lengthwise and thus grinding crosswise is “grinding against the grain.” If electrodes are
ground crosswise, the electrons have to jump across the grinding marks and the arc can
start before the tip and wander. Grinding longitudinally with the grain, the electrons flow
steadily and easily to the end of the tungsten tip. The arc starts straight and remains
narrow, concentrated, and stable.

Electrode Tip/Flat
The shape of the tungsten electrode tip is an important process variable in precision
arc welding. A good selection of tip/flat size will balance the need for several
advantages. The bigger the flat, the more likely arc wander will occur and the more
difficult it will be to arc start. However, increasing the flat to the maximum level that still
allows arc start and eliminates arc wonder will improve the weld penetration and
increase the electrode life. Some welders still grind electrodes to a sharp point, which
makes arc starting easier. However, they risk decreased welding performance from
melting at the tip and the possibility of the point falling off into the weld pool.

36
 INSTALLATION & OPERATION
Electrode Included Angle/Taper - DC Welding
Tungsten electrodes for DC welding should be ground longitudinally and concentrically
with diamond wheels to a specific included angle in conjunction with the tip/flat
preparation. Different angles produce different arc shapes and offer different weld
penetration capabilities. In general, blunter electrodes that have a larger included angle
provide the following benefits:
• Last Longer
• Have better weld penetration
• Have a narrower arc shape
• Can handle more amperage without eroding.
Sharper electrodes with smaller included angle provide:
• Offer less arc weld
• Have a wider arc
• Have a more consistent arc
The included angle determines weld bead shape and size. Generally, as the included
angle increases, penetration increases and bead width decreases.
Tungsten Diameter at Constant Included Current Range Current Range
Diameter the Tip - mm Angle - Degrees Amps Pulsed Amps
1.0mm .250 20 05 - 30 05 - 60

1.6mm .500 25 08 - 50 05 - 100

1.6mm .800 30 10 - 70 10 - 140

2.4mm .800 35 12 - 90 12 - 180
2.4mm 1.100 45 15 - 150 15 - 250
3.2mm 1.100 60 20 - 200 20 - 300
3.2mm 1.500 90 25 - 250 25 - 350

37
 INSTALLATION & OPERATION

§4.3 Installation & Operation for MIG Welding

§4.3.1 Set up installation for MIG Welding

(1) Insert the earth cable plug into the negative socket on the front of the machine and
tighten it.
(2) Plug the welding torch into the MIG torch connection socket on the front panel of the
wire feeder, and tighten it.
IMPORTANT: When connecting the torch be sure to tighten the connection. A loose
connection can result in the connector arcing and damaging the machine and gun
connector.
(3) Connect the water inlet and outlet pipe of MIG Gun to the water inlet and outlet
connectors on the front of the wire feeder.
(4) Connect the gas line to gas connector on the rear panel of wire feeder. Check for
Leaks!
(5) Connect the control cable of wire feeder with the aero socket on the rear panel of
welding machine.
(6) Connect the cable of wire feeder with the positive output of welding machine.
(7) Connect the water inlet and outlet pipe of wire feeder with the water inlet and outlet
connectors on the rear front of cooling water.
(8) Connect the gas regulator to the Gas Cylinder and connect the gas line to the Gas
Regulator. Check for Leaks!
(9) Connect the control cable of cooling water with the aero socket on the rear panel of
welding machine.
(10) Connect the power cable of welding machine with the output switch in electric box
38
 INSTALLATION & OPERATION
on site.
NOTE: Air cooling mode without cooling device，and the water pipe is not needed for
the air cooling mode.

(11) Place wire onto spool holder - (spool

retaining nut is left hand thread) Feed wire
through the inlet guide tube on to the drive roller.

(12) Feed wire over the drive roller into the

outlet guide tube, Push the wire through
approx 150mm.

(13) Close down the top roller bracket

and clip the pressure arm into place with
a medium amount of pressure applied.

(14) Remove the gas nozzle and (15) Press and hold the manual wire button
contact tip from the front end of to feed the wire down the torch cable
the MIG torch. through to the torch head.

(16)
(18) FitCarefully
the correctopen
size contact
the gastip 39
(19)
(17)Select
Fit theyour desiredtoMIG
gas nozzle the function.
torch head.
over
cylinder
the valve
wire and
andfasten
set the
tightly
required
into
the
gastip
flow
holder.
rate.
 INSTALLATION & OPERATION
(20) Select torch trigger mode: 2t or 4T.
(21) Select water cooling mode.
(22) Select the required welding parameters using the knobs and buttons.

§4.3.2 Wire Feed Roller Selection

The importance of smooth consistent wire feeding during MIG welding cannot be
emphasized enough. Simply put the smoother the wire feed then the better the welding
will be.
Feed rollers or drive rollers are used to feed the wire mechanically along the length of
the welding gun. Feed rollers are designed to be used for certain types of welding wire
and they have different types of grooves machined in them to accommodate the
different types of wire. The wire is held in the groove by the top roller of the wire drive
unit and is referred to as the pressure roller, pressure is applied by a tension arm that
can be adjusted to increase or decrease the pressure as required. The type of wire will
determine how much pressure can be applied and what type of drive roller is best suited
to obtain optimum wire feed.
Solid Hard Wire - like Steel, Stainless Steel requires a drive roller with a V shape
groove for optimum grip and drive capability. Solid wires can have more tension applied
to the wire from the top pressure roller that holds the wire in the groove and the V shape
groove is more suited for this. Solid wires are more forgiving to feed due to their higher
cross sectional column strength, they are stiffer and don’t bend so easy.
Soft Wire - like aluminum requires a U shape groove. Aluminum wire has a lot less
column strength, can bend easily and is therefore more difficult to feed. Soft wires can
easily buckle at the wire feeder where the wire is fed into inlet guide tube of the torch.
The U-shaped roller offers more surface area grip and traction to help feed the softer
wire. Softer wires also require less tension from the top pressure roller to avoid
deforming the shape of the wire, too much tension will push the wire out of shape and
cause it to catch in the contact tip.
Flux Core / Gasless Wire - these wires are made up of a thin metal sheath that has
fluxing and metal compounds layered onto it and then rolled into a cylinder to form the
finished wire. The wire cannot take too much pressure from the top roller as it can be
crushed and deformed if too much pressure is applied. A knurled drive roller has been
developed and it has small serrations in the groove, the serrations grip the wire and
assist to drive it without too much pressure from the top roller. The down side to the
knurled wire feed roller on flux cored wire is it will slowly over time eat away at the
surface of the welding wire, and these small pieces will eventually go down into the
40
 INSTALLATION & OPERATION
liner. This will cause clogging in the liner and added friction that will lead to welding wire
feed problems. A U groove wire can also be used for flux core wire without the wire
particles coming of the wire surface. However it is considered that the knurled roller will
give a more positive feed of flux core wire without any deformation of the wire shape.

§4.3.3 Wire Installation and Set Up Guide

Again the importance of smooth consistent wire feeding during MIG welding cannot be
emphasized enough. The correct installation of the wire spool and the wire into the wire
feed unit is critical to achieving an even and consistent wire feed. A high percentage of
faults with MIG welders emanate from poor set up of the wire into the wire feeder. The
guide below will assist in the correct setup of your wire feeder.

(1) Remove the spool retaining nut. (2) Note the tension spring adjuster and
spool locating pin.

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 INSTALLATION & OPERATION

(3) Fit the wire spool onto the spool holder (4) Snip the wire carefully, be sure to
fitting the locating pin into the location hold the wire to prevent the spool
holeon the spool. Replace the spool uncoiling. Carefully feed the wire into the
retaining nut tightly. inlet guide tube of the wire feed unit.

(5) Feed the wire through the drive roller (6) Lock down the top pressure roller and
into the outlet guide tube of the wire and apply a medium amount of pressure
feeder. Using the tension adjustment knob.

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 INSTALLATION & OPERATION

(7) Check that the wire passes through the centre of the outlet guide tube without
touching the sides. Loosen the locking screw and then loosen the outlet guide tube
retaining nut too make adjustment if required. Carefully retighten the locking nut and
screw to hold the new position.

(8) A simple check for the correct drive tension is

to bend the end of the wire over hold it about
100mm from your hand and let it run into your
hand, it should coil round in your hand without
stopping and slipping at the drive rollers,
increase the tension if it slips.

(9) The weight and speed of the wire spool

turning creates an inertia that can cause the
spool to run on and the wire loop over the
side of the spool and tangle.
if this happens increase the pressure on the
tension spring inside the spool holder assembly
using the tension adjustment screw.

§4.3.4 MIG Torch Liner Types and Information

MIG Torch Liners
The liner is both one of the simplest and most important components of a MIG gun. Its
sole purpose is to guide the welding wire from the wire feeder, through the gun cable

43
 INSTALLATION & OPERATION
and up to the contact tip.

Steel Liners
Most MIG gun liners are made from coiled steel wire also known as piano wire, which
provides the liner with good rigidity and flexibility and allows it to guide the welding wire
smoothly through the welding cable as it bends and flex during operational use. Steel
liners are primarily used for feeding of solid steel wires, other wires such as Aluminum,
Silicon Bronze etc, will perform better using a Teflon or Polyamide line. The internal
diameter of the liner is important and relative to the wire diameter being used and will
assist in smooth feeding and prevention of the wire kinking and birdnesting at the drive
rollers. Also bending the cable too tightly during welding increases the friction between
the liner and the welding wire making it more difficult to push the wire through the liner
resulting in poor wire feeding, prematureliner wear and birdnesting. Dust, grime and
metal particles can accumulate inside the liner over time and cause friction and
blockages, it is recommended to periodically blow out the liner with compressed air.
Small diameter welding wires, 0.6mm through 1.0mm have relatively low columnar
strength, and if matched with an oversized liner, can cause the wire to wander or drift
within the liner. This in turn leads to poor wire feeding and premature liner failure due to
excessive wear. By contrast, larger diameter welding wires, 1.2mm through 2.4mm have
much higher columnar strength but it is important to make sure the liner has enough
internal diameter clearance. Most manufacturers will produce liners sized to match wire
diameters and length of welding torch cable and most are color coded to suit.
Steel Liners
Blue-0.6mm-0.8mm

Red - 0.9mm - 1.2mm

Yellow - 1.6mm

Green - 2.0mm - 2.4mm

Teflon and Polyamide (PA) Liners

Teflon liners are well suited for feeding soft wires with poor column strength like
Aluminum wires. The interiors of these liners are smooth and provide stable feed ability,
especially on small diameter welding wire Teflon can be good for higher heat
applications that utilize water-cooled torches and brass neck liners. Teflon has good
abrasion resistance characteristics and can be used with a variety of wire types such as
silicon bronze, stainless steel as well as Aluminum. A note of caution to carefully inspect
44
 INSTALLATION & OPERATION
the end of the welding wire prior to feeding it down the liner. Sharp edges and burrs can
score the inside of the liner and lead to blockages and accelerated wear. Polyamide
Liners (PA) are made of carbon infused nylon and ideal for softer aluminum, copper
alloy welding wires and push pull torch applications. These liners are generally fitted
with a floating collet to allow the liner to be inserted all the way to the feed rollers.

Teflon Liners
Blue-0.6mm-0.8mm

Red - 0.9mm - 1.2mm

Yellow - 1.6mm

PA Liner
Black-1.0mm-1.6mm

Copper - Brass Neck Liners

For high heat applications fitting brass or copper wound jumper or neck liner on the
end of the liner at the neck end will increase the working temperature of the liner as well
as improve the electrical conductivity of the welding power transfer to the wire.

Neck Liner

§4.3.5 MIG Welding

Definition of MIG Welding
MIG (metal inert gas) welding also known as GMAW (gas metal arc welding) or MAG
(metal active gas welding), is a semi-automatic or automatic arc welding process in
which a continuous and consumable wire electrode and a shielding gas are fed through
a welding gun. A constant voltage, direct current power source is most commonly used
with MIG welding. There are four primary methods of metal transfer in MIG welding,
called short circuit (also known as dip transfer) globular transfer, spray transfer and
pulsed-spray, each of which has distinct properties and corresponding advantages and
limitations. To perform MIG welding, the basic necessary equipment is a welding gun, a
wire feed unit, a welding power supply, an electrode wire, and a shielding gas supply.
Short Circuit Transfer - Short circuit transfer is the most common used method
whereby the wire electrode is fed continuously down the welding torch through to and
exiting the contact tip. The wire touches the work piece and causes a short circuit the
45
 INSTALLATION & OPERATION
wire heats up and begins to form a molten bead, the bead separates from the end of the
wire and forms a droplet that is transferred into the weld pool. This process is repeated
about 100 times per second, making the arc appear constant to the human eye.

The wire approaches the work The wire cannot support all The current flow creates a
piece and touches the work the current flow, resistance magnetic field that begins to
creating a short circuit between builds up and the wire pinch the melting wire
the wire and the base metal, becomes hot and weak and forming it into droplet.
because there is no space begins to melt.
between the wire and the base
metal there is no arc and current
flows through the wire.

The pinch causes the forming An arc is created at the The wire feed speed
droplet to separate and fall separation of the droplet and overcomes the heat of the
towards the now creating weld the heat and force of the arc arc and the wire again
pool. flattens out the droplet into the approaches the work to
weld pool. The heat of the arc short circuit and repeat the
melts the end of the wire cycle.
slightly as it feeds towards the
base metal.

Basic MIG Welding

Good weld quality and weld profile depends on gun angle, direction of travel, electrode
extension (stick out), travel speed, thickness of base metal, wire feed speed and arc
voltage. To follow are some basic guides to assist with your setup.
Gun Position - Travel Direction, Work Angle: Gun position or technique usually refers
to how the wire is directed at the base metal, the angle and travel direction chosen.
Travel speed and work angle will determine the characteristic of the weld bead profile
46
 INSTALLATION & OPERATION
and degree of weld penetration.
Push Technique - The wire is located at the leading edge of the weld pool and pushed
towards the un-melted work surface. This technique offers a better view of the weld joint
and direction of the wire into the weld joint. Push technique directs the heat away from
the weld puddle allowing faster travel speeds providing a flatter weld profile with light
penetration - useful for welding thin materials. The welds are wider and flatter allowing
for minimal clean up/grinding time.
Perpendicular Technique - The wire is fed directly into the weld, this technique is used
primarly for automated situations or when conditions make it necessary. The weld
profile is generally higher and a deeper penetration is achieved.
Drag Technique - The gun and wire is dragged away from the weld bead. The arc and
heat is concentrated on the weld pool, the base metal receives more heat, deeper
melting, more penetration and the weld profile is higher with more build up.

Flat even weld Narrower weld profile Narrow higher

profile light even penetration weld profile more
penetration penetration

Travel Angle - Travel angle is the right to left angle relative to the direction of welding.
A travel angle of 5°- 15° is ideal and produces a good level of control over the weld
pool. A travel angle greater than 20° will give an unstable arc condition with poor weld

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 INSTALLATION & OPERATION
metal transfer, less penetration, high levels of spatter, poor gas shield and poor quality
finished weld.

Angle 5°- 15° Not enough angle Angle more than 20°

Good level of control Less control over the Poor control, unstable
over the weld pool, weld pool more spatter. arc, less penetration, lots
even flat weld. of spatter.

Angle to Work - The work angle is the forward back angle of the gun relative to the
work piece. The correct work angle provides good bead shape, prevents undercut,
uneven penetration, poor gas shield and poor quality finished weld.
Correct angle Not enough angle Too much angle

Good level of control Less control over the Poor control, unstable
over the weld pool, weld pool more spatter. arc, less penetration, lots
even flat weld. of spatter.

Stick Out- Stick out is the length of the unmelted wire protruding from the end of the
contact tip. A constant even stick out of 5-10mm will produce a stable arc, and an even
current flow providing good penetration and even fusion. Too short stick out will cause
an unstable weld pool, produce spatter and over heat the contact tip. Too long stick out
will cause an unstable arc, lack of penetration, lack of fusion and increase spatter.

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 INSTALLATION & OPERATION

Normal stick out Too short Too long

Even arc, good Unstable arc, spatter, Unstable arc, spatter,

penetration even over heat contact tip. poor penetration and
fusion, good finis. fusion.

Travel Speed - Travel speed is the rate that the gun is moved along the weld joint and
is usually measured in mm per minute. Travel speeds can vary depending on conditions
and the welder’s skill and is limited to the welder’s ability to control the weld pool. Push
technique allows faster travel speeds than Drag technique. Gas flow must also
correspond with the travel speed, increasing with faster travel speed and decreasing
with slower speed. Travel speed needs to match the amperage and will decrease as the
material thickness and amperage increase.

Too Fast Travel Speed - A too fast travel speed produces too little heat per mm of
travel resulting in less penetration and reduced weld fusion, the weld bead solidifies
very quickly trapping gases inside the weld metal causing porosity. Undercutting of the
base metal can also occur and an unfilled groove in the base metal is created when the
travel speed is too fast to allow molten metal to flow into the weld crater created by the
arc heat.
Normal stick out Too short Too long

Even arc, good Unstable arc, spatter, Unstable arc, spatter,

penetration even over heat contact tip. poor penetration and
fusion, good finis. fusion.

Too Slow Travel Speed - A too slow travel speed produces a large weld with lack of
penetration and fusion. The energy from the arc dwells on top of the weld pool rather
49
 INSTALLATION & OPERATION
than penetrating the base metal. This produces a wider weld bead with more deposited
weld metal per mm than is required resulting in a weld deposit of poor quality.
Too Slow Travel Speed

large wide bead

porosity

lack of fusion cold lap

lack of joint penetration

Correct Travel Speed - The correct travel speed keeps the arc at the leading edge of
the weld pool allowing the base metal to melt sufficiently to create good penetration,
fusion and wetting out of the weld pool producing a weld deposit of good quality.
Too Slow Travel Speed

large wide bead

porosity

lack of fusion cold lap

lack of joint penetration

Wire types and sizes - Use the correct wire type for the base metal being welded. Use
stainless steel wire for stainless steel, Aluminum wires for Aluminum and steel wires for
steel.
Use a smaller diameter wire for thin base metals. For thicker materials use a larger
wire diameter and larger machine, check the recommended welding capability of your
machine. As a guide refer to the “Welding Wire Thickness Chart” below.

WELDING WIRE DIAMETER CHART

MATERIALTHICKNESS RECOMMENDED WIRE DIAMETERS

0.8 0.9 1.0 1.2 1.6
0.8mm
0.9mm
1.0mm
1.2mm
1.6mm
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 INSTALLATION & OPERATION
2.0mm
2.5mm
3.0mm
4.0mm
5.0mm
6.0mm
8.0mm
10mm
14mm
18mm
22mm

For material thickness of 5.0mm and greater, multi-pass runs or a beveled joint design may be
required depending on the amperage capability of your machine.
Gas selection - The purpose of the gas in the MIG process is to protect / shield the
wire, the arc and the molten weld metal from the atmosphere. Most metals when heated
to a molten state will react with the air in the atmosphere, without the protection of the
shielding gas the weld produced would contain defects like porosity, lack of fusion and
slag inclusions. Additionally some of the gas becomes ionized (electrically charged) and
helps the current flow smoothly.
The correct gas flow is also very important in protecting the welding zone from the
atmosphere. Too low flow will give inadequate coverage and result in weld defects and
unstable arc conditions. Too high flow can cause air to be drawn into the gas column
and contaminate the weld zone.
Use the correct shielding gas. CO2 is good for steel and offers good penetration
characteristics, the weld profile is narrower and slightly more raised than the weld profile
obtained from Argon CO2 mixed gas. Argon CO2 mix gas offers better weld ability for
thin metals and has a wider range of setting tolerance on the machine. Argon 80% CO2
20% is a good all round mix suitable for most applications.

Argon CO2 CO2

Penetration Pattern for Steel

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 INSTALLATION & OPERATION

§4.4 Set up installation for Spool Gun

(1) Insert the earth cable plug into the Negative socket on the front of the machine and
tighten it.
(2) Connect the Spool Gun to the MIG torch connection socket on the front panel of the
wire feeder, and tighten it.
IMPORTANT: When connecting the torch be sure to tighten the connection. A loose
connection can result in the connector arcing and damaging the machine and gun
connector.
(3) Connect the Spool Gun control cable to the multipin receptacle on the front panel of
the wire feeder.
52
 INSTALLATION & OPERATION
(4) Connect the gas line to gas connector on the rear panel of wire feeder.
(5) Connect the control cable of wire feeder with the aero socket on the rear panel of
welding machine.
(6) Connect the cable of wire feeder with the positive output of welding machine.
(7) Connect the gas regulator to the Gas Cylinder and connect the gas line to the Gas
Regulator.
(8) Connect the power cable of welding machine with the output switch in electric box
on site.

(9) Remove the spool cover by pressing (10) Place a spool of wire onto the spool
button and lifting off the cover. holder.

(11) Feed the wire through the drive (12) Pull the trigger to drive the wire
rolls into the inlet guide tube. Swing through the neck until it exits the contact
back and clip down the wire tension tip holder.
swing arm.

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 INSTALLATION & OPERATION

(13) Carefully open the gas cylinder valve, set the

required gas flow rate on the regulator.

(14) Select spool gun mode using the knob. Set welding parameters using the knobs.

§4.5 Welding parameters

Process reference for CO2 butt welding of low carbon steel solid welding wire

Material Root Wire Welding Welding Welding Gas-flow

thickness gap diameter current voltage speed rate
(MM) G (MM) (MM) (A) (V) (CM/MIN) (L/MIN)

0.8 0 0.8 60-70 16-16.5 50-60 10

1.0 0 0.8 75-85 17-17.5 50-60 10-15
1.2 0 0.8 80-90 17-18 50-60 10-15
2.0 0-0.5 1.0/1.2 110-120 19-19.5 45-50 10-15
Butt-joint 3.2 0-1.5 1.2 130-150 20-23 30-40 10-20
4.5 0-1.5 1.2 150-180 21-23 30-35 10-20
6 0 1.2 270-300 27-30 60-70 10-20
6 1.2-1.5 1.2 230-260 24-26 40-50 15-20
8 0-1.2 1.2 300-350 30-35 30-40 15-20
8 0-0.8 1.6 380-420 37-38 40-50 15-20
12 0-1.2 1.6 420-480 38-41 50-60 15-20

Process reference for CO2 corner welding of low carbon steel solid welding wire
Material Wire Welding Welding Welding Gas-flow
thickness diameter current voltage speed rate
(MM) (MM) (A) (V) (CM/MIN) (L/MIN)
1.0 0.8 70-80 17-18 50-60 10-15
1.2 1.0 85-90 18-19 50-60 10-15
Corner joint 1.6 1.0/1.2 100-110 18-19.5 50-60 10-15
54
 INSTALLATION & OPERATION
1.6 1.2 120-130 19-20 40-50 10-20
2.0 1.0/1.2 115-125 19.5-20 50-60 10-15
3.2 1.0/1.2 150-170 21-22 45-50 15-20
3.2 1.2 200-250 24-26 45-60 10-20
4.5 1.0/1.2 180-200 23-24 40-45 15-20
4.5 1.2 200-250 24-26 40-50 15-20
6 1.2 220-250 25-27 35-45 15-20
6 1.2 270-300 28-31 60-70 15-20
8 1.2 270-300 28-31 60-70 15-20
8 1.2 260-300 26-32 25-35 15-20
8 1.6 300-330 25-26 30-35 15-20
12 1.2 260-300 26-32 25-35 15-20
12 1.6 300-330 25-26 30-35 15-20
16 1.6 340-350 27-28 35-40 15-20
19 1.6 360-370 27-28 30-35 15-20

§4.6 Operation environment

 Height above sea level ≤1000 M.
 Operation temperature range -10～+40°C.
 Air relative humidity is below 90% (20°C).
 Preferable site the machine some angles above the floor level, the maximum angle
does not exceed 15℃.
 Protect the machine against heavy rain and against direct sunshine.
 The content of dust, acid, corrosive gas in the surrounding air or substance cannot
exceed normal standard.
 Take care that there is sufficient ventilation during welding. There must be at least
30cm free distance between the machine and wall.

§4.7 Operation Notices

 Read Section §1 carefully before starting to use this equipment.
 Connect the ground wire with the machine directly.
 Ensure that the input is three-phase: 50/60Hz, 400V ±10%.
 Before operation, none concerned people should not be around the working area
55
 INSTALLATION & OPERATION
and especially children. Do not watch the arc in unprotected eyes.
 Ensure good ventilation of the machine to improve Duty Cycle.
 Turn off the engine when the operation finished for energy consumption efficiency.
 When power switch shuts off protectively because of failure. Don’t restart it until
problem is resolved. Otherwise, the range of problem will be extended.
 In case of problems, contact your local dealer if no authorized maintenance staff is
available!

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 WELDING TROUBLE SHOOTING

§5 Welding trouble shooting

§5.1 MIG welding trouble shooting
The following chart addresses some of the common problems of MIG welding. In all
cases of equipment malfunction, the manufacturer’s recommendations should be strictly
adhered to and followed.

NO. Trouble Possible Reason Suggested Remedy

Wire feed speed set too high Select lower wire feed speed
Voltage too high Select a lower voltage setting
select the correct polarity for the wire
Wrong polarity set
being used - see machine setup guide
Stick out too long Bring the torch closer to the work
Remove materials like paint, grease,
Contaminated base metal oil, and dirt, including mill scale from
Excessive base metal
1
Spatter Use clean dry rust free wire. Do not
Contaminated MIG wire
lubricate the wire with oil, grease etc
Check the gas is connected, check
hoses, gas valve and torch are not
Inadequate gas flow or too much gas restricted. Set the gas flow between 6-
flow 12 l/min flow rate. Check hoses and
fittings for holes, leaks. Protect the
welding zone from wind and drafts
Check that the correct gas is being
Wrong gas
used
Check the gas is connected, check
hoses, gas valve and torch are not
Inadequate gas flow or too much gas restricted. Set the gas flow between
flow 10 - 15 l/min flow rate. Check hoses
and fittings for holes, leaks etc. Protect
the welding zone from wind and drafts
Porosity - small Remove all moisture from base metal
cavities or holes Moisture on the base metal
before welding
2 resulting from
Remove materials like paint, grease,
gas pockets in
Contaminated base metal oil, and dirt, including mill scale from
weld metal.
base metal
Use clean dry rust free wire. Do not
Contaminated MIG wire
lubricate the wire with oil, grease etc
Gas nozzle clogged with spatter,
Clean or replace the gas nozzle
worn or out of shape
Missing or damaged gas diffuser Replace the gas diffuser
MIG torch euro connect O-ring
Check and replace the O-ring
missing or damaged
Bring the torch closer to the work and
Holding the torch too far away
Wire stubbing maintain stick out of 5-10mm
3
during welding Welding voltage set too low Increase the voltage
Wire Speed set too high Decrease the wire feed speed
Lack of Fusion − Remove materials like paint, grease,
failure of weld Contaminated base metal oil, and dirt, including mill scale from
4 metal to fuse base metal
completely with Select a higher voltage range and/or
Not enough heat input
base metal or a adjust the wire speed to suit

57
 WELDING TROUBLE SHOOTING
Keep the arc at the leading edge of
the weld pool.
Gun angle to work should be between
5 & 15° Direct the arc at the weld joint
Improper welding technique
proceeding weld Adjust work angle or widen groove to
bead. access bottom during welding
Momentarily hold arc on side walls if
using weaving technique
Excessive
Penetration − Select a lower voltage range and /or
5 weld metal Too much heat adjust the wire speed to suit Increase
melting through travel speed
base metal
Material too thick. Joint preparation
and design needs to allow access to
bottom of groove while maintaining
proper welding wire extension and arc
Poor in incorrect joint preparation
Lack of characteristics Keep the arc at the
Penetration − leading edge of the weld pool and
shallow fusion maintain the gun angle at 5 & 15°
6
between weld keeping the stick out between 5-10mm
metal and base Select a higher voltage range and /or
metal Not enough heat input adjust the wire speed to suit Reduce
travel speed
Remove materials like paint, grease,
Contaminated base metal oil, and dirt, including mill scale from
base metal

§5.2 MIG wire feed trouble shooting

The following chart addresses some of the common WIRE FEED problems during MIG
welding. In all cases of equipment malfunction, the manufacturer’s recommendations
should be strictly adhered to and followed.

NO. Trouble Possible Reason Suggested Remedy

Check that the TIG/MMA/MIG selector
Wrong mode selected
switch set to MIG position
Check that the Wire Feeder /Spool Gun
1 No wire feed
selector switch is set to Wire Feeder
Wrong torch selector switch
position for MIG welding and Spool Gun
when using the Spool gun
2 Inconsistent / Be sure to adjust the wire feed and
interrupted voltage dials for MIG welding. The
Adjusting wrong dial
wire feed amperage dial is for MMA and TIG
welding mode
Select the correct polarity for the wire
Wrong polarity selected
being used - see machine setup guide
Incorrect wire speed setting Adjust the wire feed speed
Voltage setting incorrect Adjust the voltage setting
Small diameter wires and soft wires like
Aluminum don’t feed well through long
MIG torch lead too long
torch leads - replace the torch with a
lesser length torch
MIG torch lead kinked or too sharp Remove the kink, reduce the angle or
angle being held bend
Contact tip worn, wrong size, Replace the tip with correct size and type
wrong type
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 WELDING TROUBLE SHOOTING
Try to clear the liner by blowing out with
Liner worn or clogged (the most
compressed air as a temporary cure, it is
common causes of bad feeding)
recommended to replace the liner
Wrong size liner Install the correct size liner
Blocked or worn inlet guide tube Clear or replace the inlet guide tube
Wire misaligned in drive roller Locate the wire into the groove of the
groove drive roller
Fit the correct size drive roller eg; 0.8mm
Incorrect drive roller size
wire requires 0.8mm drive roller
Fit the correct type roller (e.g. knurled
Wrong type of drive roller selected
rollers needed for flux cored wires
Worn drive rollers Replace the drive rollers
Can flatten the wire electrode causing it
Drive roller pressure too high to lodge in the contact tip - reduce the
drive roller pressure
Too much tension on wire spool
Reduce the spool hub brake tension
hub
Wire crossed over on the spool or Remove the spool untangle the wire or
tangled replace the wire
Use clean dry rust free wire. Do not
Contaminated MIG wire
lubricate the wire with oil, grease etc

§5.3 DC TIG welding trouble shooting

The following chart addresses some of the common problems of DC TIG welding. In all
cases of equipment malfunction, the manufacturer’s recommendations should be strictly
adhered to and followed.

NO. Trouble Possible Reason Suggested Remedy

Use pure Argon. Check cylinder has

Incorrect Gas or No Gas gas, connected, turned on and torch
valve is open
Check the gas is connected, check
Inadequate gas flow hoses, gas valve and torch are not
restricted.
Make sure the torch back cap is fitted
Tungsten burning Back cap not fitted correctly so that the O-ring is inside the torch
1
away quickly body
Connect the torch to the DC- output
Torch connected to DC +
terminal
Check and change the tungsten type
Incorrect tungsten being used
if necessary
Keep shielding gas flowing 10–15
Tungsten being oxidized after
seconds after arc stoppage. 1 second
weld is finished
for each 10amps of welding current.
Keep tungsten from contacting weld
Touching tungsten into the puddle. Raise the torch so that the
weld pool tungsten is off of the work piece 2 -
Contaminated 5mm
2
tungsten Keep the filler wire from touching the
Touching the filler wire to the tungsten during welding, feed the filler
tungsten wire into the leading edge of the weld
pool in front of the tungsten
3 Porosity - poor weld Wrong gas / poor gas flow /gas Use pure argon. Gas is connected,
appearance and leak check hoses, gas valve and torch are
color not restricted. Set the gas flow
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 WELDING TROUBLE SHOOTING
between 6-12 l/min. Check hoses and
fittings for holes, leaks et
Remove moisture and materials like
Contaminated base metal paint, grease, oil, and dirt from base
metal
Remove all grease, oil, or moisture
Contaminated filler wire
from filler metal
Check the filler wire and change if
Incorrect filler wire
necessary
Incorrect Gas Use pure Argon gas
Yellowish residue /
Set the gas flow between 10 - 15 l/min
smoke on the Inadequate gas flow
4 flow rate
alumina nozzle &
Increase the size of the alumina gas
discolored tungsten Alumina gas nozzle too small
nozzle
Connect the torch to the DC- output
Torch connected to DC +
terminal
Remove materials like paint, grease,
Contaminated base metal oil, and dirt, including mill scale from
Unstable Arc during
5 base metal.
DC welding
Remove 10mm of contaminated
Tungsten is contaminated
tungsten and re grind the tungsten
Lower torch so that the tungsten is off
Arc length too long
of the work piece 2 - 5mm
Check and set the gas flow between
Poor gas flow
10 - 15 l/min flow rate
Lower torch so that the tungsten is off
Incorrect arc length
of the work piece 2 - 5mm
Check that correct type of tungsten is
Tungsten incorrect or in poor being used. Remove 10mm from the
condition weld end of the tungsten and re
Arc wanders during sharpen the tungsten
6
DC welding Grind marks should run lengthwise
Poorly prepared tungsten with tungsten, not circular. Use proper
grinding method and wheel.
Remove contaminating materials like
paint, grease, oil, and dirt, including
Contaminated base metal or
mill scale from base metal. Remove
filler wire
all grease, oil, or moisture from filler
metal
Incorrect machine set up Check machine set up is correct
Check the gas is connected and
cylinder valve open, check hoses, gas
No gas, incorrect gas flow valve and torch are not restricted. Set
Arc difficult to start the gas flow between 10 - 15 l/min
7 or will not start DC flow rate
welding Check and change the size and or the
Incorrect tungsten size or type
tungsten if required
Loose connection Check all connectors and tighten
Earth clamp not connected to Connect the earth clamp directly to
work the work piece wherever possible

§5.4 MMA welding trouble shooting

The following chart addresses some of the common problems of MMA welding. In all
cases of equipment malfunction, the manufacturer’s recommendations should be strictly
adhered to and followed.

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 WELDING TROUBLE SHOOTING

NO. Trouble Possible Reason Suggested Remedy

Check earth lead is connected. Check
Incomplete welding circuit
all cable connections
Check the MMA selector switch is
1 No arc Wrong mode selected
selected
Check that the machine is switched on
No power supply
and has a power supply
Arc length too long Shorten the arc length
Porosity − small
Remove moisture and materials like
cavities or holes Work piece dirty, contaminated
2 paint, grease, oil, and dirt, including mill
resulting from gas or moisture
scale from base metal
pockets in weld metal
Damp electrodes Use only dry electrodes
Decrease the amperage or choose a
Amperage too high
3 Excessive Spatter larger electrode
Arc length too long Shorten the arc length
Increase the amperage or choose a
Insufficient heat input
larger electrode
Remove moisture and materials like
Work piece dirty, contaminated
Weld sits on top, lack paint, grease, oil, and dirt, including mill
4 or moisture
of fusion scale from base metal
Use the correct welding technique or
Poor welding technique seek assistance for the correct
technique
Increase the amperage or choose a
Insufficient heat input
larger electrode
Use the correct welding technique or
Poor welding technique seek assistance for the correct
5 Lack of penetration technique
Check the joint design and fit up, make
sure the material is not too thick. Seek
Poor joint preparation
assistance for the correct joint design
and fit up
Reduce the amperage or use a smaller
Excessive penetration Excessive heat input
6 electrode
- burn through
Incorrect travel speed Try increasing the weld travel speed
Uneven weld Use two hands where possible to
7 Unsteady hand, wavering hand
appearance steady up, practise your technique
Reduce the amperage or use a smaller
Excessive heat input
electrode
Use the correct welding technique or
Distortion − movement Poor welding technique seek assistance for the correct
8 of base metal during technique
welding Check the joint design and fit up, make
Poor joint preparation and or sure the material is not too thick. Seek
joint design assistance for the correct joint design
and fit up
Electrode welds with
Change the polarity, check the electrode
9 different or unusual Incorrect polarity
manufacturer for correct polarity
arc characteristic

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 MAINTENANCE & TROUBLESHOOTING

§6 Maintenance & Troubleshooting

§6.1 Maintenance
In order to guarantee safe and proper operation of welding machines, they must be
maintained regularly. Let customers understand the maintenance procedure of welding
machines. Enable customers to carry on simple examination and inspections. Do your
best to reduce the fault rate and repair times of welding machines to lengthen service
life of arc welding machine. Maintenance items in detail are in the following table.
● Warning: For safety while maintaining the machine, please shut off the main
input power and wait for 5 minutes, until capacitors voltage already drop to safe
voltage 36V!

date Maintenance item

Observe that whether panel knob and switch in the front and at the back of arc welding
machine are flexible and put correctly in place. If the knob has not been put correctly in
place, please correct. If you can't correct or fix the knob, please replace immediately.
If the switch is not flexible or it can't be put correctly in place, please replace
immediately. Please get in touch with maintenance service department if there are no
accessories.
After turn-on power, watch/listen to that whether the arc welding machine has shaking,
whistle calling or peculiar smell. If there is one of the above problems, find out the
reason to get rid of. If you can't find out the reason, please contact local this area agent
or the branch company.
Observe that whether the display value of LCD is intact. If the display number is not
Daily intact, please adjust it. If it still doesn’t work, please maintain or replace the display PCB.
examination Observe that whether the min/max value on LCD accords with the set value. If there is
any difference and it has affected the normal welding craft, please adjust it.
Check up that Whether fan is damaged and is normal to rotate or control. If the fan is
damaged, please change immediately. If the fan does not rotate after the arc welding
machine is overheated, observe that whether there is something blocked in the blade, if
it is blocked, please get rid of; If the fan does not rotate after getting rid of the above
problems, you can poke the blade by the rotation direction of fan. If the fan rotates
normally, the start capacity should be replaced; If not, change the fan.
Observe that whether the fast connector is loose or overheated. If the arc welding
machine has the above problems, it should be fastened or changed.
Observe that whether the current output cable is damaged. If it is damaged, it should be
wrapped up, insulated or changed.
Use the dry compressed air to clear the inside of arc welding machine. Especially for
clearing up the dusts on radiator, main voltage transformer, inductance, IGBT module,
Monthly
the fast recover diode and PCB, etc.
examination
Check up the bolt in arc welding machine, if it is loose, please screw down it. If it is
skid, please replace. If it is rusty, please erase rust on bolt to ensure it works well.
Quarter- Whether the actual current accords with the displaying value. If they does not accord,
yearly they should be regulated. The actual current value can be measured by the adjusted
examination plier-type ampere meter.
Measure the insulating impedance among the main circuit, PCB and case, if it below
Yearly
1MΩ, insulation is thought to be damaged and need to change, and need to change or
examination
strengthen insulation.

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 MAINTENANCE & TROUBLESHOOTING

§6.2 Troubleshooting
 Before the welding machines are dispatched from the factory, they have
already been tested and calibrated accurately. It is forbidden for anyone who
is not authorized by our company to do any change to the equipment!
 Maintenance course must be operated carefully. If any wire becomes flexible or is
misplaced, it maybe potential danger to user!
 Only professional maintenance staff that is authorized by our company could
overhaul the machine!
 Be sure to shut off the Main Input Power before doing any repair work on the
welding machine!
 If there is any problem and there is no authorized professional maintenance
personal on site, please contact local agent or the distributor!

If there are some simple troubles with the welding machine, you can consult the
following Chart:

NO. Troubles Reasons Solution

Breaker damaged Change it

Close the breaker, but the
1 Fuse damaged Change it
power light isn’t on
Input power damaged Change it

After welding machine is Fan damaged Change it

2 over-heat, the fan doesn’t
work The cable is loose Screw the cable tight

No gas in the gas cylinder Change it

No output
gas when Gas hose leaks gas Change it
Press the
gun switch, test gas Electromagnetic valve
3 Change it
no output damaged
shielded gas Output gas Control switch damaged Repair the switch
when test
gas Control circuit damaged Check the PCB

Wire reel Motor damaged Check and change it

doesn’t
work Control circuit damaged Check the PCB
The press wheel is loosen or
Press it tightly again
Wire-feeder weld wire skids
4
doesn’t work The wheel doesn’t fit with
Wire reel Change the wheel
the diameter of weld wire
works
Wire reel damaged Change it

Wire feed pipe is jammed Repair or change it

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 MAINTENANCE & TROUBLESHOOTING
Tip is jammed because of
Repair or change it
splash
Output cable is connected
Screw it down or change it
No striking arc and no incorrectly or loosen
5
output voltage
Control circuit damaged Check the circuit
Check over-voltage, over-current,
Welding stops, and alarm
6 Machine has self-protection over-temperature, lower-voltage
light is on
and over-temperature, and solve it
Welding current is run The potentiometer damaged Check or change it
7 away and can be not
The control circuit
controlled Check the circuit
damaged
The crater current can be
8 The PCB damaged Check it
not adjusted
9 No post-gas The PCB damaged Check it

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 MAINTENANCE & TROUBLESHOOTING

§6.3 List of error code

Error Type Error code Description

E01 Over-heating (1st thermal relay)
E02 Over-heating (2nd thermal relay)
Thermal relay E03 Over-heating (3rd thermal relay)
E04 Over-heating (4th thermal relay)
E09 Over-heating (Program in default)
E10 Phase loss
E11 No water
E12 No gas
Welding machine E13 Under voltage
E14 Over voltage
E15 Over current
E16 Wire feeder over load
Button fault on operating panel when switch on
E20
the machine
Other faults on operating panel when switch on
Switch E21
the machine
E22 Torch fault when switch on the machine
E23 Torch fault during normal working process
E30 Cutting torch disconnection
Accessory
E31 Water cooler disconnection
Connection problem between wire feeder and
E40
Communication power source
E41 Communication error

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