OWNER'S MANUAL

THE IGBT SERIES OF MIG/MAG

 CONTENTS
- 1.Safety……………………..………………..…………………………….…..……....……………………………………………………. 2

- 2.General Description……...………......……...…………………….………...……….....……………………………………….. 4

-3.Main Parameter…….……...…...........…….....………………………………….…..……….…………………………………… 6

- 4.Structure of welder…….……...…...........………………………..…………….…..……….…………………………………… 7

- 5.Installation ……………………………………………………………………………………………………………………………….. 8

- 6.Welding settings quick reference chart………………………………………………………………………………………. 12

- 7.Range of welding current and voltage in CO2 welding...……….…………………………………………………… 17

- 8.Welding parameters table.......…....................……………………….………..…………………………………………… 17

- 9.Caution……….....................…………………………………………...………………. .....…...................................... 20

- 10. Maintenance….………………………………………….……………….….……....….…………………………………………… 21

- 11. Daily checking……………………………………….….……....….………………………………………….…………………….. 22

- 12. Connection diagram of the machine………………………………….….……....….………………………………….. 25

- 13. Explosion drawing…………………………..………………………………….….……....….………………………………….. 26

This welding machine for industrial and professional use is in conformity with IEC974 International
Safety Standard.

Hereby we state that we provide one year of guarantee for this welding machine since the date of
purchase.

Please read and understand this instruction manual carefully before the installation and operation
of this machine.

The contents of this manual may be revised without prior notice.

This instruction manual is issued in January 2019.

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 1.SAFETY
Welding and cutting is dangerous to the operator, people in or near the working area, and the surrounding,
if the machine is not correctly operated. Therefore, the performance of welding/cutting must only be
under the strict and comprehensive observance of all relevant safety regulations. Please read and
understand this instruction manual carefully before the installation and operation.

·The switching of function modes is possibly damaging to the machine, while the
welding operation is performed.
·Do disconnect the electrode-holder cable with the machine, before the
performance of welding.
·A safety switch is necessary to prevent the machine from electric-leakage.
·Welding tools should be of high quality.
·Operators should be qualified.

Electric shock: It could be fatal!

·Connect the earth cable according to standard regulation.
·Avoid all contact with live electrical parts of the welding circuit, electrodes and
wires with bare hands. It is necessary for the operator to wear dry welding
gloves while he performs the welding task.
·The operator should keep the working piece insulating from himself/herself.

Smoke and gas generated while welding or cutting: harmful to people’s health.
·Avoid breathing the smoke and gas generated while welding or cutting.
·Keep the working area well ventilated.

Arc rays: harmful to people’s eyes and skin.

·Wear welding helmet, anti-radiation glass and work clothes while the welding
operation is performed.
·Measures also should be taken to protect people in or near the working area.
.

Fire hazard
·The welding splash may cause fire, thus remove flammable material away from
the working place.
·Have a fire extinguisher nearby, and have a trained person ready to use it.

Noise: possibly harmful to peoples’ hearing.

·Noise is generated while welding/cutting, wear approved ear protection if noise
level is high.

Machine fault:
·Consult this instruction manual.
·Contact your local dealer or supplier for further advice.
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 2.GENERAL DESCRIPTION
This welding machine is composed of the inverter MIG welder power supply with invariable voltage output
external characteristics manufactured with advanced IGBT inverter technology designed by our company.
With high-power component IGBT, the inverter convert the DC voltage, which is rectified from input
50Hz/60Hz AC voltage, to high-frequency 20KHz AC voltage; as a consequence, the voltage is transformed
and rectified. The features of this machine are as follows:
● IGBT inverter technology, current control, high quality, stable performance;
● Closed feedback circuit, invariable voltage output, great ability of balance voltage up to ±15%;
● Electron reactor control, stable welding, little splash, deep molten pool, excellent welding bead shaping;
● Welding voltage can be preset, and the voltmeter displays the preset voltage value when not welding.
● Both welding current and welding voltage can be observed at the same time.
● Burnback time is adjustable.
● Slow wire feeding during arc starting, remove the melting ball after welding, reliable arc starting;
● Wire feeding part is separated from the welding machine, wide welding operation range.
● Small-sized, light-weighed, easy to operate, economical, practical.

Unpacking your machine

When unpacking, inspect carefully for any damage that may have occurred during transit. Check
carefully to ensure all the contents on the list below have teen received in good condition
Included items:

No. Description Qty. Pic

1 MIG Welder 1set

2 Operator’s Manual 1pc

3 Electrode Holder 1pc

4 Earth Clamp 1pc

5 3m MIG Torch 1pc

Operating environment
Adequate ventilation is required to provide proper cooling for the MIG machine. Ensure that the
machine is placed on a stable level surface where clean cool air can easily flow through the unit.

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 The MIG machine has electrical components and control circuit boards which will be damaged by
excessive dust and dirt, so a clean operating environment is essential.

Block Diagram

IN PU T

C O N TR O L

Installation procedure for HF TIG

1) Connect machine with 220V single phase power supplies and proper shield gas source.
2) Then connect TIG torch quick connector to the negative output terminal, gas cable to quick-gas
connector, and aviation plug to aviation socket
3) Then connect earth clamp quick connector to the positive output terminal.

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 3.MAIN PARAMETER

TYPE MIG-270TPL

single-phase
Power supply voltage (V)
220V15%

Input current (A) 35

Power supply capacity (KVA) 8

Current adjustment range (A) 50～200

Output voltage (V) 15～24

Rated output current (A) 200

Rated output voltage (V) 24

Rated duty cycle (%) 30

Power factor 0.75

Efficiency (%) 85

Wire feeder type External/Internal

拉丝
Post-flow time (s) 1
分体
Welding wire diameter (mm) 0.6/0.8/1.0

Machine size (mm) 480×310×430

Machine weight (kg) 15

Plate thickness (mm) ≥0.8

Insulation class H

Protection class IP21S

Note: The welding duty cycle is the percentage of actual continuous welding time that can occur in a ten-minute cycle.
For example: 15% at 200amps- this means the welder can weld continuously at 200 amps for 1.5 minutes and then the
unit will need to be rested for 8.5 minutes.
The duty cycle can be affected by the environment in which the welder is used. In areas with temperatures exceeding
40℃, the duty cycle will be less than stated. In areas less than 40 ℃, higher duty cycles have been obtained.
All tests on duty cycles have been carried out at 40℃ with a 50%. So in practical working conditions the duty cycles
will be much greater than those stated above.

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 1 4.Structure of welder
15
2
14
3

13

6
12
7
11

8 10

1. Display: Welding voltage in MIG, Percentage in TIG, Low temperature time in TIG

2. Gas-check button

3. Wire-check button

4. Indicator for Cold welding in TIG

5. Function Selector: 2T/4T in MIG, 2T/4T in TIG, Cold welding, MMA

6. Indicator for Pulse in TIG

7. Selector: Wire diameter (Synergic mode)/Manual mode in MIG, Pulse in TIG

8. Parameter Selector in TIG

9. Parameter Adjust Knob

10. Parameter Selector in TIG

11. Gas Selector in MIG

12. Selector: Hot-start/Hot-start Time/Arc-force in MMA, Inductance in MIG

13. Job Channel Select button

14. Display for Job Channel

15. Display for Welding current/Wire diameter in MIG, Pulse Frequency in TIG

18 17

16

16. Rating label

17. Power switch
18. Welding gas inlet
19. Power cable

19

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 20. Wire tension adjustment
20
21. Wire tension arm & support roller
21 25
22. Wire input guide
26 23. Wire drive roller
24. Drive roller retainer
22 25. Wire spool retainer
23
26. Spool brake adjustment
24

27

28

27. Torch trigger switch

28. Torch “Euro” connector
29 29. Workpiece earth clamp
30. Earth lead quick connector
30 31. Conical gas nozzle/shroud
32. Welding tip
33. Shroud spring
34. Tip adapter

34
32 33
31

5.INSTALLATION

5.1. MIG Welding Set Up & Operation

5.1.1 Fitting the spool
5.1.1.1 open the cover door for the wire feed compartment. Remove the wire spool retainer(25) by threading off anti
clockwise.
5.1.1.2 fit the 200mm diameter wire spool to the spool holder, ensuring the end of the wires exits towards the wire
feeder from the bottom of the spool. Refit the wire spool retainer(25) and tighten finger tight.
5.1.1.3 set the spool brake tension by rotating the adjustment screw(26) using an Allen wrench. Clockwise to increase
brake tension, anti-clockwise to decrease brake tension. The spool brake tension should be set so that the spool can
rotate freely, but does not continue to rotate once the wire feed stops. This may need to be adjusted as the wire is used
up and the spool weight decreases.

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5.1.2 Loading wire feeder
5.1.2.1 release the wire feeder tension arm(21) by pivoting the wire feed tension adjuster(20) as pictured below.

5.1.2.2 check the wire drive roller(23) groove matches the selected MIG wire type and size. The drive roller will have two
different sized grooves, the size of the groove in use is stamped on the side of the drive roller. For flux cored ‘soft’ wire,
such as that used in gasless MIG welding, the drive roller groove has a serrated profit. For solid ‘hard’ MIG wire, the roller
groove has a ‘v’ shaped profile.
5.1.2.3 the drive roller(23) is removed by threading the drive roller retainer(24) off in the anti-clockwise direction. Once
the correct drive roller profile is selected, re-fit the drive roller.
5.1.2.4 thread the MIG wire from the spool through the input guide tube(22), through the roller groove and into the
outlet guide tube.
5.1.2.5 Replace the tension arm (21) and the tension adjustment (20). Double check the wire has located correctly in
the drive roller groove.
5.1.2.6 Adjusting wire feed tension: this is accomplished by winding the knob on the wire tension adjustment arm (20).
Clockwise will increase tension, anti-clockwise will decrease tension. There is a numbered scale on the tensioner to
indicate the position. Ideal tension should be as little as possible, while maintaining a consistent wire feed with no drive
roller slippage. Check all other possible causes of slippage, such as; incorrect/ worn drive roller, worn/ damaged torch
consumables, blocked/ damaged torch feed liner, before increasing feed tension.

Warning! - Before changing the feed roller or wire spool, ensure that the mains power is switched off

Warning! - The use of excessive feed tension will cause rapid and premature wear of the drive roller, the support
bearing and the drive motor.

5.1.3 Setup for gasless MIG welding operation

5.1.3.1 Connect the MIG Torch Euro Connector (28) to the torch socket on the front of the welder (11). Secure by firmly
hand tightening the threaded collar on the MIG Torch Euro Connector clockwise.
5.1.3.2 Check that the correct flux cored, gasless wire, matching drive roller (23) and welding tip (32) are fitted.
5.1.3.3 Connect Torch Connection Power Lead (14) to the negative (-) welding output terminal (13).
5.1.3.4 Connect Earth Lead Quick Connector (30) to the positive (+) output welding terminal (12). See picture below.

5.1.3.5 Connect Earth Clamp (29) to the work piece. Contact with workpiece must be strong contact with clean, bare

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metal, with no corrosion, paint or scale at the contact point.

5.1.4 Setup for gas shielded MIG welding operation

Note - Gas shielded MIG welding requires a shielding gas supply, gas regulator and gas shielded MIG wire. These
accessories are not supplied standard with the RW1500MP. Please contact your local Repco branch for details.
5.1.4.1 Connect the MIG Torch Euro Connector (28) to the torch socket on the front of the welder (11). Secure by firmly
hand tightening the threaded collar on the MIG Torch Euro Connector clockwise.
5.1.4.2 Check that the correct gas shielded wire, matching drive roller (23) and welding tip (32) are fitted.
5.1.4.3 Connect Torch Connection Power Lead (14) to the positive (+) welding output terminal (12).
5.1.4.4 Connect Earth Lead Quick Connector (30) to the negative (-) output welding terminal (13). See picture below.

5.1.4.5 Connect Earth Clamp (29) to the work piece. Contact with workpiece must be strong contact with clean, bare metal,
with no corrosion, paint or scale at the contact point.
5.1.4.6 Connect the gas regulator (optional) and gas line to the inlet on the rear panel (18). If the regulator is equipped
with a flow gauge, the flow should be set between 8 – 15 L/minute depending on application. If gas regulator is not
equipped with a flow gauge, adjust pressure so gas can just be heard coming out of the torch conical nozzle (31). It is
recommended that gas flow is checked again, just prior to starting weld This can be done by triggering the MIG torch with
the unit powered up.

5.1.5 Setup for MMA/STICK mode operation

Note - MMA/Stick Welding requires an MMA lead set.
5.1.5.1 Connect Electrode holder Quick Connector to the positive (+) welding output terminal (12).
5.1.6.2 Connect Earth Lead Quick Connector (30) to the negative (-) output welding terminal (13). See picture below.

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 Connection of Shield Gas

Connect the CO2 hose, which come from the wire feeder to the copper
nozzle of gas bottle. The gas supply system includes the gas bottle, the
air regulator and the gas hose, the heater cable should be inserted into
the socket of machine’s back, and use the hose clamp to tighten it to
prevent leaking or air-in, so that the welding spot is protected.
Please note:

1) Leakage of shielding gas affects the performance of arc welding.

2) Avoid the sun shine on the gas cylinder to eliminate the possible
explosion of gas cylinder due to the increasing pressure of gas
1) resulted from the heat.
3) It is extremely forbidden to knock at gas cylinder and lay the
cylinder horizontally.
4) Ensure no person is up against the regulator, before the gas
release or shut the gas output.
5) For MIG-250GW and MIG-250GF, insert the power supply plug of
the heater into the 36 VAC (5A) socket on the back panel of the
welding machine.
6) The gas output volume meter should be installed vertically to
ensure the precisely measuring.
7) Before the installation of gas regulator, release and shut the gas
for several time in order to remove the possible dust on the sieve
to avail the gas output.

Note: Since the arc of MIG welding is much strong than that of MMA welding, please wear welding helmet and protective
clothing.

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6.Welding settings quick reference chart

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Basic welding guide
MIG (GMAW/FCAW) Basic Welding Technique
Two different welding processes are covered in this section (GMAW and FCAW), with the intention providing the very basic
concepts in using the MIG mode of welding, where a welding gun is hand held, and the electrode (welding wire) is fed into
a weld puddle, and the arc is shielded by an inert welding grade shielding gas or inert welding grade shielding gas mixture.

GAS METAL ARC WELDING (GMAW): This process, also known as MIG welding, CO2 welding, Micro Wire Welding, short arc
welding, dip transfer welding, wire welding etc., is an electric arc welding process which fuses together the parts to be
welded by heating them with an arc between a solid continuous, consumable electrode and the work. Shielding is
obtained from an externally supplied welding grade shielding gas or welding grade shielding gas mixture. The process is
normally applied semi automatically; however, the and fairly thick steels, and some non-ferrous metals in all positions.

FLUX CORED ARC WELDING (FCAW): This is an electric arc welding process which fuses together the parts to be welded by
heating them with wan arc between a continuous flux filled electrode wire and the work. Shielding is obtained through
decomposition of the flux within the tubular wire. Additional shielding may or may not be obtained from an externally
supplied gas or gas mixture. The process is normally applied semi automatically; however, the process may be applied
automatically or by machine. It is commonly used to weld large diameter electrodes in the flat and horizontal position and
small electrode diameters in all positions. The process is used to a lesser degree for welding stainless steel and for overlay
work.

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Position of MIG Torch
The angle of MIG torch to the weld has an effect on the width of the weld.

The welding gun should be held at an angle to the weld joint. (See Secondary Adjustment Variables below) Hold the gun
so that the welding seam is viewed at all times. Always wear the welding helmet with proper filter lenses and use the
proper safety equipment.

CAUTION
Do not pull the welding gun back when the arc is established. This will create excessive wire extension (stick-out) and
make a very poor weld.
The electrode wire is not energized until the gun trigger switch is depressed. The wire may therefore be placed on the
seam or joint prior to lowering the helmet.

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Distance from the MIG Torch Nozzle to the Work Piece
The electrode wire stick out from the MIG Torch nozzle should be between 10mm to 20.0mm. This distance may vary
depending on the type of joint that is being welded.

Travel Speed
The speed at which the molten pool travels influences the width of the weld and penetration of the welding run

MIG Welding (GMAW) Variables

Most of the welding done by all processes is on carbon steel. The items below describe the welding.
variables in short-arc welding of 24gauge (0.024”, 0.6mm) to ¼” (6.4mm) mild sheet or plate. The applied techniques
and end results in the GMAW process are controlled by these variables.

Preselected Variables
Preselected variables depend upon the type of material being welded, the thickness of the material, the welding position,
the deposition rate and the mechanical properties. These variables are:
Type of electrode wire
Size of electrode wire
Type of gas (not applicable to self-shielding wires FCAW)
Gas flow rate (not applicable to self-shielding wires FCAW)

Primary Adjustable Variables

These control the process after preselected variables have been found. They control the penetration, bead width, bead
height, arc stability, deposition rate and weld soundness. They are:
Arc Voltage
Welding current (wire feed speed)
Travel speed

Secondary Adjustable Variables

These variables cause changes in primary adjustable variables which in turn cause the desired change in the bead
formation. They are:
1.Stick-out (distance between the end of the contact tube (tip) and the end of the electrode wire). Maintain at about
10mm stick-out.
2. Wire Feed Speed. Increase in wire feed speed increases weld current, Decrease in wire feed speed decreases weld
current.

3. Nozzle Angle. This refers to the position of the welding gun in relation to the joint. The transverse angle is usually one
half the included angle between plates forming the joint. The longitudinal angle is the angle between the center line of
the welding gun and a line perpendicular to the axis of the weld. The longitudinal angle is generally called the Nozzle
Angle and can be either trailing (pulling) or leading (pushing). Whether the operator is left handed or right handed has to
be considered to realize the effects of each angle in relation to the direction of travel.

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Establishing the Arc and Making Weld Beads
Before attempting to weld on a finished piece of work, it is recommended that practice welds be made on a sample
metal of the same material as that of the finished piece.

The easiest welding procedure for the beginner to experiment with MIG welding is the flat position. The equipment is
capable of flat, vertical and overhead positions.

For practicing MIG welding, secure some pieces of 16 or 18 gauge (0.06” 1.5mm or 0.08” 2.0mm) mild steel plate 6” x 6”
(150 x 150mm). Use 0.030” (0.8mm) flux cored gasless wire or a solid wire with shielding gas.

Setting of the Power Source

Power source and wirefeeder setting requires some practice by the operator, as the welding plant has two control settings
that have to balance. These are the wirespeed control and the welding voltage Control. The welding current is determined
by the wirespeed control, the current will increase with increase wirespeed, resulting in a shorter arc. Less wire speed will
reduce the current and lengthen the increasing the welding voltage hardly alters the current level, but lengthens the arc.
By decreasing voltage, a shorter arc is obtained with a little change in current level.

When changing to a different electrode wire diameter, different control settings are required. A thinner electrode wire
needs more wirespeed to achieve the same current level

A satisfactory weld cannot be obtained if the wirespeed and voltage settings are not adjusted to suit the electrode wire
diameter and the dimensions of the work piece.

If the wirespeed is too high for the welding voltage, “stubbing” will occur as the wire dips into the molten pool and does
not melt. Welding in these conditions normally produces a poor weld due to lack of fusion. If, however, the welding
voltage is too high, large drops will form on the end of the wire, causing spatter. The correct setting of voltage and
wirespeed can be seen in the shape of the weld deposit and heard by a smooth regular arc sound. Refer to the Weld Guide
located on the inside of the wirefeed compartment door for setup information.

Electrode Wire Size Selection

The choice of Electrode wire size and shielding gas used depends on the following:
Thickness of the metal to be welded
Capacity of the wire feed unit and Power Source
The amount of penetration required
The deposition rate required
The bead profile desired
The position of welding
Cost of the wire

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 7.Range of welding current and voltage in CO2 welding
Short circuit transition Granular transition
Wire φ(mm)
Current（A） Voltage (V) Current（A） Voltage (V)
0.6 40~70 17~19 160~400 25~38
0.8 60~100 18~19 200~500 26~40
1.0 80~120 18~21 200~600 27~40

-The option of the welding speed

The welding quality and productivity should be taken into consideration for the option of welding speed. In case that the
welding speed increases, it weakens the protection efficiency and speeds up the cooling process. As a consequence, it is
not optimal for the seaming. In the event that the speed is too slow, the work piece will be easily damaged, and the
seaming is not ideal. In practical operation, the welding speed should not exceed 1m/min.

-The length of wire stretching out

The length of wire stretching out the nozzle should be appropriate. The increase of the length of wire stretching out of the
nozzle can improve the productivity, but if it is too long, excessive spatter will occur in the welding process. Generally, the
length of wire stretching out the nozzle should be 10 times as the welding wire diameter.

-The setting of the C02 flow volume

The protection efficiency is the primary consideration. Besides, inner-angle welding has better protection efficiency than
external-angel welding. For the main parameter, refer to the following figure.

Option of C02 flow volume

Thick wire, big current
Welding mode Thin wire C02 welding Thick wire C02 welding
C02 welding
C02（L/min） 5～15 15～25 25～50

8.WELDING PARAMETERS TABLE

The option of the welding current and welding voltage directly influences the welding stability, welding quality and
productivity. In order to obtain the good welding quality, the welding current and welding voltage should be set optimally.
Generally, the setting of weld condition should be according to the welding diameter and the melting form as well as the
production requirement.
The following parameter is available for reference.

Parameter for butt-welding (Please refer to the following figure.)

Plate Gas
Gap Wire Welding Welding voltage Welding speed
thickness volume
g(mm) φ(mm) current（A） （V） （cm/min）
t（mm） （L/min）
0.8 0 0.8~0.9 60~70 16~16.5 50~60 10
1.0 0 0.8~0.9 75~85 17~17.5 50~60 10~15
1.2 0 1.0 70~80 17~18 45~55 10

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 1.6 0 1.0 80~100 18~19 45~55 10~15
2.0 0~0.5 1.0 100~110 19~20 40~55 10~15
2.3 0.5~1.0 1.0 or 1.2 110~130 19~20 50~55 10~15
3.2 1.0~1.2 1.0 or 1.2 130~150 19~21 40~50 10~15
4.5 1.2~1.5 1.2 150~170 21~23 40~50 10~15
Gasless
2.3 0.5~1.0 0.8/1.0 110~130 14~16 30~40/20~30 \
3.2 1.0~1.2 0.8/1.0 130~150 15~17 50~60/40~50 \
4.5 1.2~1.5 0.8/1.0 150~190 16~18 60~70/50~60 \

Parameter for flat fillet welding (Please refer to the following figure.)

Welding Welding
Plate thickness Corn size Wire Welding speed Gas volume
current voltage
t（mm） I (mm) φ(mm) （cm/min） （L/min）
（A） （V）
1.0 2.5~3.0 0.8~0.9 70~80 17~18 50~60 10~15
1.2 2.5~3.0 1.0 70~100 18~19 50~60 10~15
1.6 2.5~3.0 1.0 ~ 1.2 90~120 18~20 50~60 10~15
2.0 3.0~3.5 1.0 ~ 1.2 100~130 19~20 50~60 10~20
2.3 2.5~3.0 1.0 ~ 1.2 120~140 19~21 50~60 10~20
3.2 3.0~4.0 1.0 ~ 1.2 130~170 19~21 45~55 10~20
4.5 4.0~4.5 1.2 190~230 22~24 45~55 10~20
Gasless
2.3 2.5~3.0 0.8/1.0 120~140 14~16 30~40/20~30 \
3.2 3.0~4.0 0.8/1.0 140~160 15~17 50~60/40~50 \
4.5 4.0~4.5 0.8/1.0 150~190 16~18 60~70/50~60 \

Parameter for fillet welding in the vertical position (Please refer to the following figure.)

Plate Welding Welding Welding

Corn size Wire Gas volume
thickness current voltage speed
I (mm) φ(mm) （L/min）
t（mm） （A） （V） （cm/min）

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 1.2 2.5~3.0 1.0 70~100 18~19 50~60 10~15
1.6 2.5~3.0 1.0 ~ 1.2 90~120 18~20 50~60 10~15
2.0 3.0~3.5 1.0 ~ 1.2 100~130 19~20 50~60 10~20
2.3 3.0~3.5 1.0 ~ 1.2 120~140 19~21 50~60 10~20
3.2 3.0~4.0 1.0 ~ 1.2 130~170 22~22 45~55 10~20
4.5 4.0~4.5 1.2 200~250 23~26 45~55 10~20
Gasless
2.3 0.5~1.0 0.8/1.0 120~140 14~16 30~40/20~30 \
3.2 1.0~1.2 0.8/1.0 140~160 15~17 50~60/40~50 \
4.5 1.2~1.5 0.8/1.0 150~190 16~18 60~70/50~60 \

Parameter for Lap Welding (Please refer to the following figure.)

Plate Welding Welding

Welding Wire Welding speed Gas volume
thickness current voltage
position φ(mm) （cm/min） （L/min）
t（mm） （A） （V）
0.8 A 0.8~0.9 60~70 16~17 40~45 10~15
1.2 A 1.0 80~100 18~19 45~55 10~15
1.6 A 1.0 ~ 1.2 100~120 18~20 45~55 10~15
2.0 A or B 1.0 ~ 1.2 100~130 18~20 45~55 15~20
2.3 B 1.0 ~ 1.2 120~140 19~21 45~50 15~20
3.2 B 1.0 ~ 1.2 130~160 19~22 45~50 15~20
4.5 B 1.2 150~200 21~24 40~45 15~20
Gasless
2.3 B 0.8/1.0 120~140 14~16 30~40/20~30 \
3.2 B 0.8/1.0 140~160 15~17 50~60/40~50 \
4.5 B 0.8/1.0 150~190 16~18 60~70/50~60 \

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 9.CAUTION
1. Working environment
⑴ Welding should be carried out in a relatively dry environment with its humidity of 90% or less.
⑵ The temperature of the working environment should be within -10C to 40C.
⑶ Avoid welding in the open air unless sheltered from sunlight and rain, and never let rain or water infiltrate the machine.
⑷ Avoid welding in dusty area or environment with corrosive chemical gas.
⑸ Avoid gas shielded arc welding in environment with strong airflow.

2. Safety tips
Over-current/overheating protection circuit is installed in this welding machine. If the output current is too high or
overheating generated inside this welding machine, this welding machine will stop automatically. However, inappropriate
use will still lead to machine damage, so please note:
1. Ventilation
High current passes when welding is carried out, thus natural ventilation cannot satisfy the welding machine’s
cooling requirement. Maintain good ventilation of the louvers of this welding machine. The minimum distance
between this welding machine and any other objects in or near the working area should be 30cm. Good ventilation
is of critical importance for the normal performance and service life of this welding machine.
2. No over-current.
Remember to observe the max load current at any moment (refer to the optioned duty cycle). Make sure that the
welding current should not exceed the max load current.
If welding is carried out under a current which is higher than the max current, over-current protection will occur; the
output voltage of the welding machine will be not stable; arc interruption will occur. In this case, please lower the
current.
3. No over-load.
Over-load current could obviously shorten the welding equipment’s life, or even damage the machine.
A sudden halt may occur while the welding operation is carried out while this welding machine is of over-load status.
Under this circumstance, it is unnecessary to restart this welding machine. Keep the built-in fan working to bring
down the temperature inside the welding machine.
4. Avoid electric shock.
An earth terminal is available for this welding equipment. Connect it with the earth cable to avoid the static and
electric shock.

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 10.MAINTENANCE

1. Disconnect input plug or power before maintenance or repair on

machine.
2. Be sure input ground wire is properly connect to a ground
terminal.
3. Check whether the inner gas-electricity connection is well (esp.
the plugs), and tighten the loose connection; if there is
oxidization, remove it with sand paper and then re-connect.

4. Keep hands, hair, loose clothing, and tools away from electrical
parts such as fans, wires when the machine is switched on.

5. Clear the dust at regular intervals with clean and dry compressed
air; if the working condition is with heavy smoke and air pollution,
the welding machine should be cleaned daily.
6. The compressed air should be reduced to the required pressure
lest the little parts in the welding machine be damaged.

7. To avoid water and rain, if there is, dry it in time, and check the
insulation with mega-meter (including that between the
connection and that between the case and the connection). Only
when there is no abnormal phenomenon should the welding
continue.
8. If the machine is not used for a long time, put it into the original
packing in dry condition.

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 11.DAILY CHECKING
To make best use of the machine, daily checking is very important. During the daily checking, please check in the order of
torch, wire-feeding vehicle, all kinds of PCB, the gas hole, and so on. Remove the dust or replace some parts if necessary.
To maintain the purity of the machine, please use original welding parts.
Cautions：Only the qualified technicians are authorized to undertake the repair and check task of this welding equipment
in case of machine fault.

11.1. Power supply

Part Check Remarks
1. Operation, replacement and installation of Switch.
Control panel
2. Switch on the power, and check if the power
indicator is on.

1. Check if the fan is functioning and the sound If the fan doesn’t work or the sound is
Fan
generated is normal. abnormal, do inner check.

1. Switch on the power supply, and check if abnormal

Power supply vibration, heating of the case of this equipment,
variation of colors of case or buzz presents.

1. Check if gas connection is available, case and other

Other parts
joints are in good connection.

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 11.2. Welding torch
Part Check Remarks

1. Check if the nozzle is fixed firmly

Possible gas leakage occurs due to the unfixed nozzle.
and distortion of the tip exists.
Nozzle
2. Check if there is spatter sticking on Spatter possibly leads to the damage of torch. Use
the nozzle. anti-spatter to eliminate the spatter.

1. Check if the contact tip is fixed

Unfixed contract tip possibly leads to unstable arc.
firmly.
Contact tip
2. Check if the contact tip is physically The physically incomplete contact tip possibly leads to
complete. unstable arc and arc automatically terminating.
1. Make sure that there is the Disagreement of the diameters of wire and wire feed tube
agreement of wire and wire feed possibly leads to the unstable arc. Replace it/them if
tube. necessary.
2. Make sure that there is no bending Bending and elongation of wire feed tube possibly leads to
or elongation of wire feed tube. the unstable wire feed and arc. Replace it if necessary.

Wire feeding 3. Make sure that there is no dust or

hose spatter accumulated inside the
If there is dust or spatter, remove it.
wire feed tube, which makes the
wire feed tub blocked.

4. Check if the wire feed tube and The Physically incomplete wire feed tube or O-shaped seal
O-shaped seal ring are ring possibly leads to the excessive spatter. Replace the wire
physically complete. feed tube or O-shaped seal ring if necessary.

Part Check Remarks

1. Make sure that the diffuser of
Defection weld or even the damage of torch occurs due to
Diffuser required specification is installed
the non-installation of diffuser or the unqualified diffuser.
and is unblocked.

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11.3. Wire feeder
Part Check Remarks
Pressure
1. Check if the pressure-adjusting handle is The unfixed pressure-adjusting handle leads
adjusting
fixed and adjusted to the desired position. to the unstable welding output.
handle
1. Check if there is dust or spatter inside the
Remove the dust.
hose or beside wire-feeding wheel.
Non-agreement of the diameter of wire and
Wire-feeding 2. Check if there is a diameter agreement of
wire-feeding hose possibly leads to the
hose wire and wire-feeding hose.
excessive spatter and unstable arc.

3. Check if rod and wire feeding groove are

Unstable arc possibly occurs.
concentric.

Non-agreement of wire diameter and

1. Check if there is an agreement of wire
wire-feeding wheel possibly leads to the
Wire-feeding diameter and wire-feeding wheel.
excessive spatter and unstable arc.
wheel
2. Check if the wire groove is blocked. Replace it if necessary.

Pressure 1. Check if the pressure adjusting wheel can Unstable rotation or physically
adjusting rotate smoothly, and it’s physically incompleteness of the wheel possibly leads to
wheel complete. unstable wire feeding and arc.

11.4. Cables
Part Check Remarks
1. Check if the cable of torch is twisted.
Torch The twisted torch cable leads to unstable wire
cable 2. Check if the coupling plug is in loose connection. feeding and arc.

1. Check if the cable is physically complete. Relevant measures should be taken to obtain
Output
stable weld and prevent the possible electric
cable 2. Check if insulation damage or loose connection shock.
exists.

1. Check if the cable is physically complete.

Input
cable 2. Check if insulation damage or loose connection
exists.
1. Check if the earth cables are well fixed and not
Earth short-circuited. Relevant measures should be taken to prevent
cable the possible electric shock.
2. Check if this welding equipment is well grounded.

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12.CONNECTION DIAGRAM OF THE MACHINE

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 13.EXPLOSION DRAWING

1 power cable 22 front panel

2 wire buckle 23 upper plastic panel
3 solenoid valve 24 knob
4 power switch 25 downward plastic panel
5 upper plastic panel 26 wire buckle
6 downward plastic panel 27 polar conversion line
7 real panel 28 35-50 quick connector
8 fan support 29 rubber support
9 fan 30 base plate
10 clapboard 31 fixed beam
11 machine cover 32 block plate
12 handle 33 radiator
13 side plate 34 rectifier diode
14 hinge 35 circuit board support
15 lock 36 main circuit board
16 wire spool 37 radiator
17 wire spool shaft 38 rectifier bridge
18 wire feeder 39 IGBT
19 insulation plate 40 thermistor
20 wire feeder support 41 compressed spring
21 check circuit board 42 EMC circuit board

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