INVERTER WELDING MACHINE

INSTRUCTION MANUAL

MIG-230/280/350/500
MFR-230/280/350/500

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 CONTENT

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

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This welding machine for industrial and professional use is in the conformity
with IEC 60974 International Safety Standard.

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

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

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

SECURITY

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

Professional training is needed before

operation.
·Use labor protection welding supplies
authorized by national security supervision
department.
·The operator must be special personnel with
a valid "metal welding (OFC) operations"
operation certificate.
·Cut off power before maintenance or repair.
Electric shock—may lead to serious injury
or even death.
·Install earthing device according to the
application criteria.
·Never touch the live parts when skin bared or
wearing wet gloves/clothes.
·Make sure that you are insulated from the
ground and work piece.
·Make sure that your working position is safe.
Smoke & gas—may be harmful to health.

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 ·Keep the head away smoke and gas to avoid
inhalation of exhaust gas from welding.
·Keep the working environment in good
ventilation with exhaust or ventilation
equipment when welding.
Arc radiation—may damage eyes or burn
skin.
·Wear Suitable welding masks and protective
clothing to protect your eyes and body.
·Use suitable masks or screens to protect
spectators from harm.

Improper operation may cause fire or

explosion.
·Welding spark may cause fire, please make
sure no combustible materials nearby and
pay attention to fire safety.
·Have a fire extinguisher nearby, and have a
trained person to use it.
·Airtight container welding is forbidden
·Pipe thaw with this machine is forbidden.
Hot workpiece may cause severe
scalding.
·Don’t contact hot workpiece with bare
hands.
·Cooling is needed during continuous use of
the welding torch.

Magnetic fields affect cardiac pacemaker.

·Pacemaker users should be away from the
welding spot before medical consultation.

Moving parts may lead to personal injury.

·Keep yourself away from moving parts such
as fan.
·All doors, panels, covers and other
protective devices should be closed and in
place.
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 Machine fault—seek professional help
when encountering any difficulties.
·Consult the relevant contents of this manual
If you encounter any difficulties in installation
and operation.
·If you still do not fully understand after
reading, or in accordance with the guide of
this manual will not solve the problem.
Contact with your supplier service center,
seek professional help immediately.

1. GENERAL DESCRIPTION
 Advanced IGBT inverter technology
 Inverter frequency is 20 KHz, greatly reducing the volume and
weight of the welder.
 Great reduction in metal loss obviously enhances the welding
efficiency and energy saving effect.
 Switching frequency is beyond audio range, which almost
eliminates noise pollution.
 Leading control mode
 Closed loop feedback control, constant voltage output, fit for wide
voltage range (±15%)
 Adjustable welding voltage, precisely matching the welding current,
excellent welding characteristics.
 Unique welding dynamic characteristic control circuit, stable
welding arc, little splash, beautiful shaping, high welding
efficiency.
 Function of removing the molten ball after welding available, slow
wire feeding, high successful rate of arc starting.
 CO2 welding and MAG welding available.
 Welding wire with a diameter of Φ0.8-Φ1.2, such as
AlSi,AlMg,CS,SS,Cu and special material can be used.

2. INSTALLATION & OPERATION

1) Environment:

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·Please install the machine strictly according to the following steps.
·Electric connection operation should be after turning off the power supply
switch of the switch box.
·The protection class of this machine is IP21, so avoid using it in rain, less
sunshine, humidness, wind and dust. The temperature should be between
-10℃~±40℃.
·Ground slope should be no more than 15°.
·The distance between machine and wall is not more than 20CM and the
distance between 2 machines is more than 10CM.
·For welding machine with water cooler, please use antifreeze when the
temperature below zero. When using water-cool welding torch, please be
aware of antifreezing.

2)Voltage of power supply

·Wave form should be standard sine wave; effective value is 380V±10%;
Frequency is 50/60 Hz.
·non-balance ratio of 3 phases voltage: ≤±5%.

3) Input power

Model MIG230P MIG350P MIG500P

1 Phase 3 Phases 3 Phases
Input power
AC220V AC380V AC380V
Rated input power
6.4KVA 15.8KVA 24.4KVA
capacity
Lowest input power
15KVA 30KVA 50KVA
capacity of generator
Rated Input current 9.8A 24A 37A
Input cable ≥4mm² ≥4mm² ≥6mm²
Output cable 35mm² 50mm² 70mm²
Earth cable ≥2.5mm² ≥2.5mm² ≥6mm²
Remarks: above specification is for reference only.

3)Installation

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 Instruction photo of cable connection

（1） Welding power

（2） Three-phase power supply connection
（3） Earth cable.
（4） Negative terminal of output welding cable.
（5） Cable of wire feeder control, which connects the control socket of
machine.
（6） Output Positive terminal of welding cable.
（7） Wire feeder
（8） Workpiece
（9） Welding torch
（10） Wire feeder Control
（11） Box of welding wire
（12） Gas cylinder
（13） Preheat cable, heating cable of gas regulator connects the socket
of output power on the back of machine.
（14） Gas pipe
（15） Regulator of gas rate of flow
（16） Gas Valve

4)Operation

Closing the automatic air switch on switchboard, indicator of weld on the

fan are working on. Press the button of manual wire feeding, the wire is
moving quickly. According to the requirements set the controller and the
knob on the front panel and switch positions. Press the torch switch and

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 wire is feeding. Having gas flow from the torch nozzle, normal welding can
be worked. After welding, the gas and power supply should be shut off.

3. Operating principle
3.1 functional block diagram

Photo of the principle block-diagram

The machine adopts IGBT soft switching inverter technology, first the
three-phase 380VAC/50Hz power grid after power frequency rectifier filter,
supply 20 KHZ IGBT inverter frequency conversion into intermediate
frequency alternating current, then through intermediate frequency step-down
transformer and rectifier filter, get the need of welding DC output. Through this
process, improves the dynamic response of the welding machine speed,
decrease the volume and weight of welding machine. The machine adopts
closed loop control mode, make the welding power source has good
adaptability for grid, excellent welding performance.

3.2 Features of output of the welding machine

Features of welding machine output

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 4 20= ) )1 4+ 0 .0 5I2
I(A
U(V
2
0
6
8
U

Photo of welder output

4. CONTROL PANEL OPERATION

4.1 Front panel structure

1.Process Button
Short press shows. prg 00 x. x is the current application and selection
process, current encoder Selection process, Press 5secs button turn
out the current procedure number stored the welding parameters.
Application Range: 000-005.
2.Save Button
Saved welding state and parameters to the current program number.
3.Adjustment Button
1) Non-unified state parameter Settings (Amateurs don't use, only for reference
welding experiment)
Switch function button to choose parameters (Adjust current knob to change the
parameters)

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 A) P -1 Total frequency Default: 100 Range: 1-300
B) P -2 Double pulse frequency Default: 100 Range: 1-300
C) P -3 Double pulse frequency of wire feed Default: 0 Range: 1—10
D) P -4 Single pulse voltage Default: 15 Range: 1-100
E) P -5 Double pulse voltage's welding time
Default: 15 Range: 1-100
adjustment
F) P -6 Inductance Default: 35 Range: 1-100
1-10 - welding
G) P -7 Double pulse high voltage Default: 19 Range: maximum
output
2) Unified state parameter Settings
Switch function keys to choose parameters (Adjust current knob to change the
parameters)
A) P -1 Total frequency Default: 0 Range: -20—20
B) P -2 Double pulse frequency Default: 0 Range: -20—20
C) P -3 Double pulse frequency of wire feed Default: 0 Range: 1—10
D) P -4 Single pulse voltage Default: 0 Range: -20—20
E) P -5 Double pulse voltage's welding time
Default: 0 Range: -20—20
adjustment
F) P -6 Inductance Default: 0 Range: -20—20
G) P -7 Double pulse high voltage Default: 0 Range: -20—20
Note:P2,P3,P5,P6,P7 work in double pulse mode, P1,P4,P6 work in single pulse mode.
3）Without pulse state parameter Settings
Switch function keys to choose parameters (Adjust current knob to change the
parameters)
P -6 Inductance Default: 35 Range: 1-100
Adjust P-6 between 90 and 95 to get best welding effect in no pulse
welding.
4) DC MMA welding state
Press the adjustment button for 5 seconds, it willswitch to manual welding
electrode.
4.SYN (united/non-united) Button
Switch welding state unified set, and the unified indicator light on as a
unified state.
5. "V" voltmeter
Display given voltage when Static, press the welding torch or welding
displayed the actual output voltage.
6."A" amperemeter
Displayed current given when Static, press the welding torch or welding
displayed the actual output current.
7. Remote welding parameter Settings

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1) Welding auxiliary parameter Settings
Remote and Strong arc buttons to switch the auxiliary parameters back and
forth.
Pr1 Gas pre time (gas light on) Default: 0.2S Range: 0.2S-10S
10 v - welding maximum
Volt Range:
Pr2 Arc starting current (arc light output
Default: 16V/50A
on) Current 10 a - welding maximum
Range: output
Pr3 Current rising speed (rise
Default: 0.2S Range: 0.2S-10S
light on)
Pr4 Welding current( light on
Adjust the welding current
when welding)
Pr5 current drop speed (fall light
Default: 0.2S Range: 0.2S-10S
on)
10 v - welding maximum
Volt Range:
Pr6 Arc ending current ( arc output
Default: 16V/50A
lights on) Current 10 a - welding maximum
Range: output
Pr7 Post flow time(post flow light
Default: 0.2S Range: 0.2S-10S
on)
2) Wire feeding machine control function
Long press 5 sec Remote button, switch wire feeding machine control state,
Lights out for the control panel, light for the wire feeding machine control.
Default: panel control
3) Arc state switch function
Long press 5 sec moves to the Strong arc button, switch arc state, lights out as
the weak state of arc, bright as strong arc state.
Default: weak state of electric arc
8. The Welding Voltage Encoder
Adjust the given voltage
9. Welding Current Encoder
Adjust the given current
10. Wire Material Selection Button
Welding material selection, provide 6 kinds of material.

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11. Wire Diameter Selection Button
Wire diameter selection, provide four switch wire diameter.
12. Pulse Selection Button
Welding with or without pulse, can use single or double pulse welding. Press
this button to eliminate single and double light at the same time, pulse is turned
off and change into DC arc welding at this time.
13. Crater Arc Button
Welding torch 2 T / 4T state switch, corresponding 2 T(no crater arc), 4T
( crater arc) indicator will light up.
14. Abnormal Temperature Indicator Light
When the temperature of the host machine is abnormal indicator light is up.
4.2 Back panel structure
MIG230P/280P

1. OUTPUT POWER

2. AIR SWITCH

3. INPUT POWER

4. FAN

MIG230PE/280PE

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 1. INPUT POWER

2. OUTPUT POWER

3. CONTROL CABLE 1

4. CONTROL CABLE 2

5. AIR SWITCH

6. FAN

7. OUTPUT +

MIG 350PE

1. INPUT POWER

2. OUTPUT POWER

3. FUSE OF SOCKET

4. AIR SWITCH

5. CONTROL CABLE 1

6. CONTROL CABLE 2

7. OUTPUT +

8. FAN

MIG 350PW/500PW

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 1. AIR SWITCH

2. FUSE OF WATER COOLER

3. SWITCH OF WATER COOLER

4. WATER INLET

5. WATER OUTLET

6. INPUT POWER

7. OUTPUT POWER

8. FUSE OF SOCKET

9. CONTROL CABLE 1

10. CONTROL CABLE 2

11. OUTPUT +

12. FAN

13. INTAKE OF WATER TANK

5. MAIN SPECIFICATION
DESRIPTION MIG-230 MIG-280 MIG-350 MIG-500
Power 三 380V±15% 三 380V±15% 三 380V±15% 三 380V±15%
voltage/frequency 50Hz 50Hz 50Hz 50Hz
Rated input Capacity 6.4KVA 9.2KVA 15.8KVA 24.4KVA
Rated input current 9.8A 14A 24A 37A
Rated Duty Cycle 60% 60% 60% 60%
Output Current Range 50-210A 50-250A 50-350A 50-500A
No-load Voltage 45V 45V 65V 65V
Efficiency ≥85% ≥85% ≥85% ≥85%
Power factor( cos ) ≥0.93 ≥0.93 ≥0.93 ≥0.93
Diameter Of Rod Φ0.8-1.2 Φ0.8-1.2 Φ1.0-1.6 Φ1.0-1.6
Rate of gas flow 15-20L/min 15-20L/min 15-20L/min 15-20L/min
Insulation class F F F F

6. MAINTENANCE
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1. Check periodically whether inner circuit connection is ok (esp. plugs).
Tighten the loose connection. If there is oxidization, remove it with
sandpaper and then reconnect.
2. Keep hands, hair and tools away from the moving parts such as the fan to
avoid personal injury or machine damage.
3. Clean the dust periodically with dry and clean compressed air. If welding in
environment with heavy smoke and pollution, the machine should be
cleaned daily. The pressure of compressed air should be at a proper lever
lest the small parts inside the machine be damaged.
4. Avoid rain, water and vapor infilter the machine. If there is, dry it and check
the insulation with a megger. Only when there is no abnormal phenomena
can welding be continued.
5. Check periodically whether the insulation skin of all cables are in good
condition. If there is any dilapidation, wrap it or replace it.
6. Check periodically whether the gas hose has any cracks. If any, get them
replaced.
7. Put the machine into the original packing in dry location if it is not to be used
for a long time.

7. TROUBLESHOOTING

Common failure phenomena, reasons and solutions

Fault Reasons Solutions

1. Check the welding current and

welding time. Operate according to the
requirement of the instruction manual.

The protection 1.Overheating protection 2.Check the fan’s running status when
Light turns on. 2.Over-current protection welding. If the fan does not work, check
if there is a power supply of 220V: If the
power supply is normal, check the fan; if
the power supply is abnormal, check
the connecting cable of the power
supply.

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 3. Replace the thermal switch if it is
damaged.
1.Lack Power supply
1.Check the power supply
After startup, The phase
control panel 2.Damage of automatic air
display light is not 2.Replace the automatic air switch
switch on the rear panel
bright

1.Automatic air switch

1.Replace air switch
failure
When connected
2.Replace IGBT module, and replace
to welder power 2 IGBT module damage
the driver circuit board
supply, automatic
air switch on the 3.Three-phase rectifier 3.Replace of three-phase rectifier
rear panel power bridge damage bridge
off immediately 4.Varistor damage 4.Replace varistor
5.Welding machine control
5.Replace welding machine control
board damage
During the welding 1.Long-term overload 1.According to the welding machine
process, welding running load factor
power source
automatic air
switch on the rear 2.Air switch is damaged 2.Replace the air switch
panel power off
automatically
1.Wire feeding machine
1.Replace wire feeding machine control
control cable is broken or
cable or controller
controller damaged
The welding
2.Welding machine control
current cannot 2.Replace the control panel
circuit board is broken
adjust
3.The wire of both ends of
the shunt in welding 3.Reconnect the wire
machine is broken
1.Welding do not conform
1.Fine adjustment welding specification
Arc instability, big to the specifications
splash 2.Conductive nozzle
2.Change conductive nozzle
serious wear out
1 CO2 gas regulator
1.Replace CO2 gas regulator
damaged
CO2 gas
2.Heating cable broken or
regulator is not 2.Repair heating cable
short circuit
heated
3.The heating power
3.Change the thermistor
thermistor damaged
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Press the torch 1.Control circuit board
1.Change control circuit board
switch, wire damaged
feeding is normal,
but the gas path is 2.Solenoid valve damaged 2.Replace solenoid valve
obstructed
Press the torch 1.Welding torch switch
1.Replace welding torch
switch and wire damaged
feeding machine 2.Wire feeding machine 2.Repair wire feeding machine control
doesn't work, and control cable is broken cable
no no-load voltage 3.Control circuit board is
indicator 3.Change control circuit board
broken

Common process phenomena, defects and reasons

Defects Reasons
1. The gas is not pure or insufficient gas supply
2. Inlet air when welding
3. The heater doesn't work
4. Windy, protection is not completely

Blow Hole 5. The nozzle is splash block, not smooth

6. The distance between nozzle and workpiece is too large

7. The welding area surface is pollution, oil, rust, moisture, not clear

8. Arc is too long, arc voltage is too high

9. Wire lack of silicon, manganese content
1. The arc is too long, the arc voltage is too high
2. Welding speed too fast
Undercut 3. The welding current is too big
4. Improper position of welding wire
5. Improper swing welding wire

1. The welding current is too small, wire feeding is not uniform

incomplete 2. The arc voltage is too low or too high

penetration 3. Welding speed too fast or too slow (in the groove)
4. Small bevel Angle, gap is too small
5. Improper position of welding wire
1. Process parameter is not appropriate
2. Improper position of welding wire

Bad Appearance 3. Center offset of the feed roller

4. improper adjustment of welding wire straightening mechanism

5. conductive nozzle loose

1. The welding current is too large
Crack 2. The groove too narrow
3. The arc voltage is too low

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 4. The inappropriate position of welding wire
1. The conductive nozzle loose, or wear, or diameter is too large
(Compared with the wire)
2. Wire reel rotating non-uniform, groove of the wire feeding roller
has wear out, pressure roller not strong enough, large resistance
Arc unstable of conductive tube
3. Low welding current, arc voltage fluctuation
4. Wire stem elongation is too large
5. Welding pieces has the rust, paint and grease
6. Improper position of earth cable
1. Short circuit transition inductance is not proper, too big or too
small
welding spatter
2. The welding current and arc voltage mismatch
3. Poor cleaning of the welding wire and welding pieces

8. TRANSPORTATION AND STORAGE

1. This welding equipment belong to the precision equipment, strong vibration
or impact may result in damage to equipment.
2. The welding equipment adopts the cartons/wooden box packaging, can be
used during transit artificial/forklift, but should avoid tilt, shall not be partial to
pour and strong impact and vibration.
3. The welding equipment shall be deposited in the shelter and dry ventilated
environment, storage environment temperature 25 ℃ ~ 55 ℃.

NOTE: This machine is in continuous improvement, so other parts may

be different except the function and operation. Your understanding
would be greatly appreciated.

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