THANK YOU FOR USING OUR PRODUCTS

OPERATORS’ MANUAL

MULTIMIG 400F 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 Technical Data ···················································································································10
§2.3 Brief Introduction ·············································································································10
§2.4 Duty cycle and Over-heat··································································································11
§2.5 Working Principle·············································································································11
§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 ·········································································15
§3.2.1 Front Panel Functions of welder····························································································· 15
§3.2.2 Front Panel Functions of wire feeder ····················································································· 19
§4 Installation & Operation ····························································································· 22
§4.1 Installation & Operation for MMA Welding ·····································································22
§4.1.1 Set up installation for MMA Welding ······················································································ 22
§4.1.2 MMA Welding ·························································································································· 23
§4.1.3 MMA Welding Fundamentals ·································································································· 24
§4.2 Installation & Operation for TIG Welding ·······································································26
§4.2.1 Set up installation for TIG Welding ························································································ 26
§4.2.2 DC TIG Welding························································································································ 29
§4.2.3 TIG Welding Fusion Technique ······························································································· 30
§4.2.4 Tungsten Electrodes ··············································································································· 31
§4.2.5 Tungsten Preparation ············································································································· 34
§4.3 Installation & Operation for MIG Welding·······································································36
§4.3.1 Set up installation for MIG Welding························································································ 36
§4.3.2 Wire Feed Roller Selection ····································································································· 39
§4.3.3 Wire Installation and Set Up Guide ························································································ 40
§4.3.4 MIG Torch Liner Types and Information ················································································ 43
§4.3.5 MIG Welding ···························································································································· 44
§4.4 Set up installation for Spool Gun ·····················································································51
§4.5 Standard welding programs ·····························································································54
§4.6 Welding parameters ·········································································································54
§4.7 Operation environment ····································································································55
§4.8 Operation Notices ·············································································································56
§5 Welding trouble shooting ···························································································· 57
§5.1 MIG welding trouble shooting ··························································································57

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§5.2 MIG wire feed trouble shooting ·······················································································58
§5.3 DC TIG welding trouble shooting ·····················································································59
§5.4 MMA welding trouble shooting ························································································61
§6 Maintenance & Troubleshooting ················································································ 62
§6.1 Maintenance ······················································································································62
§6.2 Troubleshooting ···············································································································63
§6.3 List of error code···············································································································65
§6.4 Electrical schematic drawing ···························································································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!

Products are limited to use under suitable conditions. In extreme cases,

the use of products, such as high temperature, low temperature,
Environment
thunderstorm weather, will shorten the life of the machine and even
cause damage, please avoid the above situation.

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 SAFETY

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
 Shafts
 Wire spools and welding wire

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 SAFETY

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 for
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 SAFETY

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:
 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,
EMC 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.
5. Shielding, if necessary
 Shield off other nearby devices.

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 SAFETY

 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. This
EMC Class
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 PWM technology and IGBT inverter technology.
 MIG/MAG with Manual and SYN function:
- Synergic programs for aluminum, mill
steel, stainless steel and CuSi.
 MMA function (Stick electrode)
- VRD (Voltage Reduction Device)
- 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.

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 OVERVIEW

§2.2 Technical Data

Models
MULTIMIG 400F SYN
Parameters
Input Voltage (V) 3~400±10%
Frequency (HZ) 50/60
MIG TIG MMA
Input Current (A) 26.7 22 27.8
Input Power (KW) 18.8 15.2 19.4
Welding Current (A) 40-400 10-400 10-400
Welding Voltage (V) 16-34 10.4-26 20.4-36
No-load Voltage (V) 75 73 12
60% 400A
Duty cycle (40℃)
100% 310A
Fe: 0.6/0.9/1.0/1.2/1.6
Diameter (mm) SS: 0.8/0.9/1.0/1.2/1.6
Flux-Cored: 0.6/0.8/0.9/1.0/1.2/1.6
Circuit Breaker Standard LW31-32B-4AB-04/2
Protection class IP21S
Dimensions (mm) 640*240*450
Weight (Kg) 26.5
Power Factor 0.8
Note: The above parameters are subject to change with future machine improvement!

§2.3 Brief Introduction

MULTIMIG F 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.
MULTIMIG F 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.
MULTIMIG F 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 alarm lamp on the front panel will be lit and output current
will be shut off automatically for the machine to protect itself and prolong the equipment
using life.
MULTIMIG F 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;

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 OVERVIEW
4. IGBT technology, low power consumption;
5. Rated Duty Cycle:
MULTIMIG 400F SYN= 400A @ 60% (40°C)
MULTIMIG F 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

§2.4 Duty cycle and Over-heat

The letter “X” stands for Duty Cycle,
which is defined as the portion of the time Relation of the welding current and duty
cycle for MULTIMIG 400F SYN
a welding machine can weld continuously
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 light the over-heat pilot lamp on the front panel. 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.

§2.5 Working Principle

The working principle of MULTIMIG F 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

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 OVERVIEW
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

MULTIMIG F 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).

Uo（V）
Volt-ampere characteristic
The relation between the rated loading
Working point voltage and welding current

44

14

0 600 Io（A）

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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. On/Off switch: Turn on power supply clockwise and turn off power supply
counterclockwise.
2. Negative Output: When MIG mode, this polarity must connect the work piece.
3. Gas outlet: Connect the inlet of TIG gun.
4. TIG gun control connector.
5. Positive Output: When TIG mode, this polarity must connect the work piece.
6. Gas Inlet: Connect the gas conduit.
7. Output anode: Used to connect to the welding cable of wire feeder.
8. Water box connector: To connect water box.
9. Aviation plug: Used to connect to the control cable of wire feeder.
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. Water inlet: From here, water or coolant, antifreeze, etc. can be injected into tank.
2. Water outlet for TIG (blue).
3. Backwater inlet for TIG (red).
4. The water cooling control connector.
5. Water outlet for MIG (blue).
6. Backwater inlet for MIG (red).
7. Water level calibration.

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 PANEL FUNCTIONS & DESCRIPTIONS

§3.1.3 Wire feeder

1. Spool Gun Power Supply Connection.
2. Mig Torch/Spool Gun connector.
3. Water outlet.
4. Backwater inlet.
5. Gas Inlet connector.
6. The wire feeder control connector.
7. “+” input terminal.
8. Backwater outlet.
9. Water inlet.
10. Spool holder assembly.
11. Spool gun button.
12. Wire feed tension adjustment.
13. Wire feed tension arm (2x).
14. Wire feed roller (2x).
15. Wire feeder inlet guide.
16. Wire drive roller.

§3.2 Front Panel Functions and Descriptions

§3.2.1 Front Panel Functions of welder

1. No water indicator: when the water cooling selected and no water flow, it light on.
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 PANEL FUNCTIONS & DESCRIPTIONS
2. Alarm indicator: When the abnormal conditions such as over-voltage, over-current,
over-heat occur, it light on.
3. Power indicator: When machine is powered on, it light on.
4. Digital display screen: Display voltage and current or other parameters.*
5. Hot Start indicator: When you adjust Hot Start, it light on.
6. Welding current indicator: When the welding current LED is on, it displays the
actual output welding current.
7. Arc Force indicator: When you adjust Arc Force, it light on.
8. Down Slope indicator: When you adjust Down Slope, it light on. Range: 0-10.0.
9. Welding mode key: Press it to select MIG/ MMA VRD /TIG welding mode.*
10. Trigger mode selecting key: Press it to select 2T or 4T mode.*
11. Cooling mode key: Press it to select water cooling or air cooling.
12. Parameter knob: Press down it to select parameters and rotate it to adjust
parameters.
*Denotes more detailed explanation of function to follow.

Further Controls Explained

Digital display screen (4)
When using MIG or spool gun mode, it will display the set voltage value or welding
voltage value; when choosing other mode, it will display the set current value or welding
current value; when choosing or calling parameters, it will display the selected
parameters and their value.

Welding mode key (9)

Four welding modes can be selected here: MIG, MMA VRD, and TIG.
MIG welding mode:
Metal inert-gas welding. Melting electrodes are used to protect metal droplets, weld
pools and high temperature metals in weld pools and high temperature metals in weld
zone with external gas as arc medium.
MMA welding mode:
MMA is an arc welding method using manual electrode. The high temperature
produced by burning between the end of the electrode and the workpiece melts the
electrode, and the melted electrode transits to the surface of the workpiece through the
arc column. Welding rod can not only provide filler metal, but also produce slag skin to
16
 PANEL FUNCTIONS & DESCRIPTIONS
protect molten pool without auxiliary gas protection.
VRD welding mode:
VRD mode is designed for human safety. It can reduce the output voltage of no-load
and effectively prevent the danger of electric shock.
TIG welding mode:
Tungsten inert gas welding. Inert gas shielded arc welding using pure tungsten or
activated tungsten as non-melting electrodes, using the arc between tungsten pole and
workpiece as heat source to melt the added welding wire, thus forming the weld. The
tungsten pole does not melt in the welding process and only acts as the electrode. At the
same time, argon or helium is fed into the nozzle of the torch for protection.

Trigger mode selecting key (10)

 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 (Iw or Ib)
from the min welding current.
(4) t2～t3: During the whole welding process, the gun switch is pressed and held without
17
 PANEL FUNCTIONS & DESCRIPTIONS
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
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 (Iw or Ib), the upslope time can be
adjusted;
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 PANEL FUNCTIONS & DESCRIPTIONS
(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 the post-gas time adjustment knob on the front
panel (0.0～10S);
(12) t7: Electromagnetic valve is closed and stop argon flowing. Welding is finished.

§3.2.2 Front Panel Functions of wire feeder

1. Synergic programs indicator.*

2. Welding voltage indicator.
3. Welding voltage display: It displays welding voltage and other parameters.*
4. Arc voltage indicator: Arc voltage is used to control the melting speed of the
welding wire before the end of welding. Range: 1-200%.
5. Time indicator: When adjust Pre Flow/Post Flow, it light on. Range: 0-10.
6. Wire feed indicator.
7. Arc current indicator: Arc current is used to adjust the speed of wire feeding before
the end of welding. Range: 1-200%.
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 PANEL FUNCTIONS & DESCRIPTIONS
8. Welding current display: It displays welding current and other parameters.*
9. Welding current indicator.
10. No water indicator: when the water cooling selected and no water flow, it light on.
11. Spool Gun indicator: When using Spool Gun mode, it lights on.
12. Alarm indicator: When the abnormal conditions such as over-voltage, over-current,
over-heat occur, it light on.
13. Air check key.*
14. Cooling mode selecting key.
15. Manual wire key.*
16. Trigger mode selecting key.
17. MIG mode selecting key: Pre flow/Post flow/Soft start/Burn back.*
18. Inductance adjusting knob: Rotate it to adjust, range: 0-10.*
19. Welding current and wire feed speed knob: Press it to select, rotate it to adjust.
20. Welding voltage and other parameter knob: Press it to select, rotate it to adjust.
*Denotes more detailed explanation of function to follow.

Further Controls Explained

Synergic programs indicator (1)
MIG 400F has 21 programs that parameters (MIG 500F has 24 programs that
parameters, MIG 350F has 18 programs that parameters, please refer to §4.5) can be
saved to for easy recall. To access a saved program, press the control knob (20) to enter
programs selecting mode. When Synergic programs indicator light on, the program
number will show on the Welding voltage display. Adjust to the program number required
by rotating the control knob (20). Once the program is accessed, it will automatically
load.
Welding voltage display (3)
Before welding this displays the setting selected/being adjusted using the control knob
(20). During welding it displays welding voltage. The parameter setting displayed is
indicated by the indicators below the display: Program (P), Voltage (V), Arc voltage and
Time (S). If left inactive for several seconds, display will revert back to main welding
voltage setting.
Welding current display (8)
Before welding this displays the setting selected/being adjusted using the control knob
(19). During welding it displays welding current. The parameter setting displayed is
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 PANEL FUNCTIONS & DESCRIPTIONS
indicated by the indicators below the display: Wire speed, Arc voltage, Current (A) and
Spool Gun setting. If left inactive for several seconds, display will revert back to main
welding current setting.
Air check key (13)
The key is used to check whether the gas supply is normal. After pressing the key, if the
gas supply is normal, there will be a jet at the welding gun. If the gas supply is abnormal,
there will be no gas flow at the muzzle of the welding gun.
Manual wire key (15)
The key is used for manual wire feeding. In general, when replacing the new welding
wire, it will be used when it is installed and will be more convenient. In addition, during
wire feeding, the welding wire has not been output, which increases the safety.
MIG mode selecting key (17)
Pre flow
It can ensure that the welding gun is full of protective gas before the start of welding
work and prevent the welding wire from being oxidized. It can be adjusted by rotating the
control knob (20). Unit (S).Range: 0-5.
Post flow
It means to send a protective gas for a period of time after the end of welding to protect
the weld from oxidation. Therefore, do not immediately raise the gun when the end of
welding. It can be adjusted by rotating the control knob (20). Unit (S).Range: 0-10.
Soft start
This function is used to regulate the speed of wire feeding increasing. Range: 0-10.
Burn back
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.
Inductance adjusting knob (18)
Inductance slows the rate of current rise. A high inductance setting (+10) increases the
time of each arc cycle creating more penetration. A low inductance setting (0) decreases
the time of each individual arc cycle creating a narrow bead or less blow-through on thin
material.

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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 MIG/ MMA/ VRD/ TIG key 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.

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 INSTALLATION & OPERATION

The covering on a shielded metal arc welding electrode is

called Flux. The flux on the electrode performs many different
functions. These include:
● 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
>8.0mm 5.0 mm general purpose type 6013 electrode.

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 INSTALLATION & OPERATION

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

3.2 mm 100-130
experienced in striking and maintaining
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
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
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 INSTALLATION & OPERATION
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.

§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 socket on the front of the machine.
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 INSTALLATION & OPERATION
(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.
NOTE: Air cooling mode without cooling device，and the water pipe is not needed for the
air cooling mode.

(10) Carefully open the valve of the gas (11) Select TIG function using the button.
cylinder and set the required gas flow rate.

(12) Select 2T or 4T trigger as required (13) Select water cooling mode.

using the key.

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 INSTALLATION & OPERATION

(14) Select the required Amperage and (15) Assemble front end parts of the TIG
Down slope Time using the control knob. torch, fitting a sharpened tungsten suitable
for the material to be welded.

(16) Lay the outside edge of the cup on (17) 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.

(18) Now rotate the Gas Cup in the reverse (19) 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.
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 INSTALLATION & OPERATION

§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 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
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 INSTALLATION & OPERATION
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.

tungsten touches
gas flow
the work established
tungsten off arc ignition TIG arc
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 oxidized 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
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 INSTALLATION & OPERATION
required and whether you are using AC or DC welding current. Tungsten 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

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 INSTALLATION & OPERATION
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
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

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 INSTALLATION & OPERATION
2.4mm 150-250 140-235 100-180
3.2mm 250-400 225-325 160-250
4.0mm 400-500 300-400 200-320

§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.

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 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 the Constant Included Current Range Current Range
Diameter 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

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 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

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 INSTALLATION & OPERATION
welding machine.
(10) Connect the power cable of welding machine with the output switch in electric box
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 contact

tip from the front end of the MIG torch.

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 INSTALLATION & OPERATION

(15) Press and hold the manual wire key to (16) Fit the correct size contact tip over
feed the wire down the torch cable through to the wire and fasten tightly into the tip
the torch head. holder.

(17) Fit the gas nozzle to the torch head. (18) Carefully open the gas cylinder valve
and set the required gas flow rate.

(19) Select torch switch mode: 2t or 4T. (20) Select program number using the
knob, it will show on the digital meter.

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 INSTALLATION & OPERATION

(21) Select water cooling mode. (22) Select the required welding
parameters using the knobs.

§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.

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 INSTALLATION & OPERATION
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 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.

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§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 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

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 INSTALLATION & OPERATION
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 careful inspect
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,
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 INSTALLATION & OPERATION
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
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.

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 INSTALLATION & OPERATION
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
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.

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 INSTALLATION & OPERATION

Flat even weld profile Narrower weld profile Narrow higher

light penetration even penetration weld profile more
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 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.

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 INSTALLATION & OPERATION

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.

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

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 INSTALLATION & OPERATION
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.
Too Fast Travel Speed
high narrow bead porosity

undercut spatter

lack of fusion lack of joint penetration

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
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.
Correct Travel Speed

even shaped bead good toe fusion

good side wall fusion good penetration

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 INSTALLATION & OPERATION
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
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

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 INSTALLATION & OPERATION
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

§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.

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 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) Press the Spool Gun button to

switch to Spool gun welding mode.

(10) Remove the spool cover by pressing (11) Place a spool of wire onto the spool
button and lifting off the cover. holder.

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 INSTALLATION & OPERATION

(12) Feed the wire through the drive (13) 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.

(14) Carefully open the gas cylinder (15) Set welding parameters using the
valve, set the required gas flow rate on knobs.
the regulator.

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 INSTALLATION & OPERATION

§4.5 Standard welding programs

§4.6 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

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 INSTALLATION & OPERATION

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 (L/MIN)
(MM) (MM) (A) (V) (CM/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
1.6 1.0/1.2 100-110 18-19.5 50-60 10-15
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
Corner joint 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

§4.7 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.

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 INSTALLATION & OPERATION

§4.8 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
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
flow 6-12 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 10
flow - 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,
4 failure of weld Contaminated base metal oil, and dirt, including mill scale from
metal to fuse base metal

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 WELDING TROUBLE SHOOTING
completely with Select a higher voltage range and/or
base metal or a Not enough heat input
adjust the wire speed to suit
proceeding weld
Keep the arc at the leading edge of the
bead.
weld pool.
Gun angle to work should be between
5 & 15° Direct the arc at the weld joint
Improper welding technique
Adjust work angle or widen groove to
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
Be sure to adjust the wire feed and
voltage dials for MIG welding. The
Adjusting wrong dial
amperage dial is for MMA and TIG
welding mode
Select the correct polarity for the wire
Inconsistent / Wrong polarity selected
being used - see machine setup guide
2 interrupted
Incorrect wire speed setting Adjust the wire feed speed
wire feed
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
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 WELDING TROUBLE SHOOTING
MIG torch lead kinked or too sharp Remove the kink, reduce the angle or
angle being held bend
Contact tip worn, wrong size, wrong
Replace the tip with correct size and type
type
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 to
Drive roller pressure too high 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 if
Incorrect tungsten being used
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
Contaminated Touching tungsten into the puddle. Raise the torch so that the
2
tungsten weld pool tungsten is off of the work piece 2 -
5mm

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 WELDING TROUBLE SHOOTING
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
Use pure argon. Gas is connected,
check hoses, gas valve and torch are
Wrong gas / poor gas flow /gas
not restricted. Set the gas flow
leak
between 6-12 l/min. Check hoses and
fittings for holes, leaks et
Porosity - poor weld
Remove moisture and materials like
3 appearance and
Contaminated base metal paint, grease, oil, and dirt from base
color
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 all
filler wire
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 flow
7 or will not start DC 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 the
work work piece wherever possible

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 WELDING TROUBLE SHOOTING

§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.

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 steady
7 Unsteady hand, wavering hand
appearance 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 arc Incorrect polarity
manufacturer for correct polarity
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 items

Observe that the knobs and switches in the front and at the back of arc welding machine
are flexible and put correctly in place. If any knob has not been put correctly in place,
please correct. If you can't correct or fix the knob, please replace immediately; If any
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 if the arc-welding machine has shaking, whistle calling
or peculiar smell. If there is one of the above problems, find out the reason and clear it. If
you can't find out the reason, please contact your local service repair station or
distributor/Agent.
Observe that the display value of LED is intact. If the display number is not intact, please
replace the damaged LED. If it still doesn’t work, please maintain or replace the display
Daily PCB.
examination Observe that the min./max.Values on LED agree with the set value. If there is any
difference and it has affected the normal welding results, please adjust it.
Check whether the fan is damaged and whether it is normal to rotate or control. If the
fan is damaged, please change immediately. If the fan does not rotate after the machine
is overheated, observe if there is something blocking the blade. If it is blocked, please
clear the problem. 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 whether the fast connector is loose or overheated. If the arc-welding machine
has the above problems, it should be fastened or changed.
Observe whether the current output cable is damaged. If it is damaged, it should be
insulated or changed.
Using the dry compressed air to clear the inside of arc welding machine. Especially for
clearing up the dusts on radiator, main voltage transformer, inductors, IGBT modules,
Monthly
fast recover diodes, PCB’s, etc.
examination
Check the screws and bolts in the machine. If any is loose, please screw it tight. If it is
shaved, please replace. If it is rusty, please erase rust on all bolts to ensure it works well.
Quarter- Check whether the actual current accords with the displaying value. If they did not
yearly accord, they should be regulated. The actual welding current value can be measured by
examination and adjusted by 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
Wire-feeder
4 The press wheel is loosen or
doesn’t work Press it tightly again
Wire reel weld wire skids
works The wheel doesn’t fit with the
Change the wheel
diameter of weld wire
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 MAINTENANCE & TROUBLESHOOTING

Wire reel damaged Change it

Wire feed pipe is jammed Repair or change it

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
The potentiometer damaged Check or change it
Welding current is run away
7
and can be not controlled
The control circuit damaged Check the circuit
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 Lamp status
Yellow lamp (thermal
E01 Over-heating (1st thermal relay)
protection) always on
Yellow lamp (thermal
E02 Over-heating (2nd thermal relay)
protection) always on
Yellow lamp (thermal
Thermal relay E03 Over-heating (3rd thermal relay)
protection) always on
Yellow lamp (thermal
E04 Over-heating (4th thermal relay)
protection) always on
Yellow lamp (thermal
E09 Over-heating (Program in default)
protection) always on
Yellow lamp (thermal
E10 Phase loss
protection) always on
Yellow lamp (lack water)
E11 No water
always on
E12 No gas Red lamp always on
Yellow lamp (thermal
Welding machine E13 Under voltage
protection) always on
Yellow lamp (thermal
E14 Over voltage
protection) always on
Yellow lamp (thermal
E15 Over current
protection) always on
E16 Wire feeder over load
Button fault on operating panel when Yellow lamp (thermal
E20
switch on the machine protection) always on
Other faults on operating panel when Yellow lamp (thermal
E21
switch on the machine protection) always on
Switch
Torch fault when switch on the Yellow lamp (thermal
E22
machine protection) always on
Torch fault during normal working Yellow lamp (thermal
E23
process protection) always on
E30 Cutting torch disconnection Red lamp blink
Accessory Yellow lamp (lack water)
E31 Water cooler disconnection
always on
Connection problem between wire
E40
Communication feeder and power source
E41 Communication error

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 MAINTENANCE & TROUBLESHOOTING

§6.4 Electrical schematic drawing

66