OWNER'S MANUAL

THE IGBT SERIES OF MIG/MAG

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 CONTENTS
- 1.Safety……………………..………………..…………………………….…..……....……………………………………………………. 3

- 2.General Description……...………......……...…………………….………...……….....……………………………………….. 5

- 3.Main Parameter…….……...…...........…….....………………………………….…..……….…………………………………… 7

- 4.Structure of welder…….……...…...........………………………..…………….…..……….…………………………………… 8

- 5.Installtion ………………………………………………………………………………………………………………………………….. 9

- 6.Welding settings quick reference chart………………………………………………………………………………………. 15

- 7.Range of welding current and voltage in CO2 welding...……….…………………………………………………… 20

- 8.Welding parameters table.......…....................……………………….………..…………………………………………… 20

- 9.Caution……….....................…………………………………………...………………. .....…...................................... 22

- 10. Maintenance….………………………………………….……………….….……....….…………………………………………… 23

- 11. Daily checking……………………………………….….……....….………………………………………….…………………….. 24

- 12. Connection diagram of the machine………………………………….….……....….………………………………….. 27

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

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

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

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

This instruction manual is issued in January 2009.

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

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

Electric shock: It could be fatal!

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

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

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

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

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

Noise: possibly harmful to peoples’ hearing.

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

Machine fault:
·Consult this instruction manual.
·Contact your local dealer or supplier for further advice.

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

Unpacking your machine

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

No. Description Qty. Pic

1 MIG Welder 1set

3 Warranty Card 1pc

4 Operator’s Manual 1pc

5 Electrode Holder 1pc

6 Earth Clamp 1pc

7 3m MIG torch 1pc

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Operating environment
Adequate ventilation is required to provide proper cooling for the MIG-GS/GD. Ensure that the machine
is placed on a stable level surface where clean cool air can easily flow through the unit. The
MIG-GS/GD has electrical components and control circuit boards which will be damaged by
excessive dust and dirt, so a clean operating environment is essential

Block Diagram

INPUT

CONTROL

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 3.MAIN PARAMETER

TYPE MIG160 MIG200

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

Input current (A) 16 20

Power supply capacity (KVA) 5.6 7.7
Current adjustment range (A) 30～160 30～200
Output voltage (V) 15～22 15～24
Rated output current (A) 160 200
Rated output voltage (V) 22 24
Rated duty cycle (%) 60 60

Power factor 0.75 0.75

Efficiency (%) 85
Wire feeder type External/Internal
拉丝
Post-flow time (s) 1
分体
Welding wire diameter (mm) 0.6/0.8/1.0
Machine size (mm) 480×310×430
Machine weight (kg) 17
Plate thickness (mm) ≥0.8
Insulation class F
Protection class IP23

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

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 4.Structure of welder

2 1. multifunction digital display

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4 2. voltage digital display
5 3. welding parameter adjustment knob
6 4. welding mode selection button
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5. In MIG mode: micro voltage
adjustment/inductance adjustment/wire
diameter selection
8 In MMA mode: hot start/arc force
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6. VRD/2T/4T Selection function
10 7. quick wire check
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8. MIG Torch ‘Euro Style’ Connection Socket
9. Positive (-) Welding Output Terminal
10.Negative (+) Welding Output Terminal

13 12
14

15 19. Warning label

20. power switch
21. welding gas inlet
22. power cable

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17

12. Wire tension adjustment

18 13. Wire tension arm & support roller
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14. Wire input guide
20 15. Wire drive roller
16. Drive roller retainer
17. 21wire spool retainer
18. Spool brake adjustment
21
22

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 23

24

23. Torch trigger switch

24. Torch “Euro” connector
25. Workpiece earth clamp
26. Earth lead quick connector
25 27. Conical gas nozzle/shroud
28. Welding tip
26
29. Shroud spring
30. Tip adapter

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28 29
27

5.INSTALLTION

5.1. MIG Welding Set Up & Operation

5.1.1 Fitting the spool
5.1.1.1 open the cover door for the wire feed compartment. Remove the wire spool retainer(21) by threading off anti
clockwise.
5.1.1.2 fit the 200mm diameter wire spool to the spool holder, ensuring the end of the wires exits towards the wire
feeder from the bottom of the spool. Refit the wire spool retainer(21) and tighten finger tight.
5.1.1.3 set the spool brake tension by rotating the adjustment screw(22) using an Allen wrench. Clockwise to increase
brake tension, anti-clockwise to decrease brake tension. The spool brake tension should be set so that the spool can
rotate freely, but does not continue to rotate once the wire feed stops. This may need to be adjusted as the wire is used
up and the spool weight decreases.

5.1.2 Loading wire feeder

5.1.2.1 release the wire feeder tension arm(19) by pivoting the wire feed tension adjuster(20) as pictured below

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5.1.2.2 check the wire drive roller(17) groove matches the selected MIG wire type and size. The drive roller will have two
different sized grooves, the size of the groove in use is stamped on the side of the drive roller. For flux cored ‘soft’
wire ,such as that used in gasless MIG welding, the drive roller groove has a serrated profit. For solid ‘hard’ MIG wire, the
roller groove has a ‘v’ shaped profile
5.1.2.3 the drive roller(17) is removed by threading the drive roller retainer(18) off in the anti-clockwise direction. Once
the correct drive roller profile is selected, re-fit the drive roller.
5.1.2.4 thread the MIG wire from the spool through the input guide tube(16), through the roller groove and into the
outlet guide tube
5.1.2.5 Replace the tension arm (19) and the tension adjustment (20). Double check the wire has located correctly in
the drive roller groove.
5.1.2.6 Adjusting wire feed tension: this is accomplished by winding the knob on the wire tension adjustment arm (20).
Clockwise will increase tension, anti-clockwise will decrease tension. There is a numbered scale on the tensioner to
indicate the position. Ideal tension should be as little as possible, while maintaining a consistent wire feed with no drive
roller slippage. Check all other possible causes of slippage, such as; incorrect/ worn drive roller, worn/ damaged torch
consumables, blocked/ damaged torch feed liner, before increasing feed tension.

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

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

5.1.3 setup for gasless MIG welding operation

5.1.3.1 Connect the MIG Torch Euro Connector (24) to the torch socket on the front of the welder (8). Secure by firmly
hand tightening the threaded collar on the MIG Torch Euro Connector clockwise.
5.1.3.2 Check that the correct flux cored, gasless wire, matching drive roller (17) and welding tip (28) are fitted
5.1.3.3 Connect Torch Connection Power Lead (11) to the negative (-) welding output terminal (9).
5.1.3.4 Connect Earth Lead Quick Connector (26) to the positive (+) output welding terminal (10). See picture below.

MIG Touch Earth lead

5.1.3.5 Connect Earth Clamp (25) to the work piece. Contact with workpiece must be strong contact with clean, bare
metal, with no corrosion, paint or scale at the contact point.

5.1.4 Setup for gas shielded MIG welding operation

Note - Gas shielded MIG welding requires a shielding gas supply, gas regulator and gas shielded MIG wire. These
accessories are not supplied standard with the RW1500MP. Please contact your local Repco branch for details
5.1.4.1 Connect the MIG Torch Euro Connector (24) to the torch socket on the front of the welder (8). Secure by firmly
hand tightening the threaded collar on the MIG Torch Euro Connector clockwise.
5.1.4.2 Check that the correct gas shielded wire, matching drive roller (17) and welding tip (28) are fitted
5.1.4.3 Connect Torch Connection Power Lead (11) to the positive (+) welding output terminal (10)
5.1.4.4 Connect Earth Lead Quick Connector (26) to the negative (-) output welding terminal (9). See picture below

Earth lead

MIG Touch

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5.1.4.5 Connect Earth Clamp (25) to the work piece. Contact with workpiece must be strong contact with clean, bare metal,
with no corrosion, paint or scale at the contact point.
5.1.4.6 Connect the gas regulator (optional) and gas line to the inlet on the rear panel (14). If the regulator is equipped
with a flow gauge, the flow should be set between 8 – 15 L/minute depending on application. If gas regulator is not
equipped with a flow gauge, adjust pressure so gas can just be heard coming out of the torch conical nozzle (27). It is
recommended that gas flow is checked again, just prior to starting weld This can be done by triggering the MIG torch with
the unit powered up.

Connection of Shield Gas

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

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

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

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

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5.1.5 Controls for MIG welding
5.1.5.1 Switch the machine on using the mains power switch (13). Wait 5 seconds for the digital control program to load
up.
5.1.5.2 Press the Welding Mode Selection Button (4) until the MIG indicator is lit

Wire feed symbol

Wire feed
Preset welding voltage

5.1.5.3 The multifunction digital display will show two numbers. On the left is the preset welding voltage, on the right is
the preset wire feeding speed. These values are adjusted by rotating the Welding Parameter Adjustment Knob (3).
Because of the synergic digital programming, both the voltage and the wirespeed will adjust together.

5.1.5.4 To adjust the voltage independently, press the Data Selection Button (5) once. This will change and give the display
screen as below.

You and then use the Adjustment

Knob (3) to adjustse the welding
voltage +/- 5V from the standard
synergic setting. This will not
change the wire speed. It is
recommended for ease of use that
the wirefeed target speed is
adjusted first and then the voltage
setting fine- tuned if necessary.
Refer to the Welding Settings Quick
Reference Chart on page 20 and
inside the wirefeed door for
recommended common settings.

5.1.5.5 Press the Data Selection Button (5) again to adjust the inductance of the welding arc. Use the Adjustment Knob (3)
to adjust the inductance from -10 (less inductance) to +10 (more inductance).

A quick note regarding inductance

– this effectively adjusts the
Inductance symbol intensity of the welding
Inductance adjustment
arc.inductance makes the arc
‘softer’, with less weld spatter.
Higher inductance gives a stronger
driving arc which can increase
penetration. Optimum inductance
settings are affected by many
welding variables such as: material
type, shielding gas joint type,
welding amperage, wire size.
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Because of this it is recommended that unless the operator is an experienced welder, the inductance adjustment is left in
the neutral (0) position.
5.1.5.6 Press the Data Selection Button (5) again to return to the main wirespeed/voltage adjustment screen. If the control
panel is not adjusted after 5 seconds it will also return to the primary MIG adjustment mode.
5.1.5.7 During welding the screen display will change to show the actual welding voltage and welding current
as pictured below

Actual welding voltage Actual welding current

5.1.5.8 2T/4T function: press the 2T/4T Selection Switch to move between 2T and 4T modes. 4T operation means the
trigger is pulled once to start welding and pulled again to stop. This is useful for long weld joints. 2T mode, the trigger
must be depressed and held during welding.

5.1.6 Feeding the wire

1.6.1 Remove the conical nozzle (27) and the welding tip (28) from the torch. The conical nozzle is removed by turning
clockwise and pulling off simultaneously. The welding tip threads out of the tip adapter.
5.1.6.2 With the wire feed cover door still open pull the torch trigger (23) and check that the wire is feeding smoothly
through the feed roller and into the torch
5.1.6.3 Now stretch the torch lead and handle out as straight as possible from the machine and press the Automatic Wire
Feed Button (5) once. This will start the feed motor running at full speed to feed the wire through the torch liner.
5.1.6.4 Once the wire comes out past the end of the torch neck, pull the torch trigger or press any button on the display to
stop the automatic wire feed.
5.1.6.5 Close the wire feed cover door
5.1.6.6 Replace the welding tip (28) and conical nozzle (27) back onto the torch neck and trim off any excess wire
You are now ready to weld!

5.1.7 MMA/STICK mode operation

Note - MMA/Stick Welding requires an MMA lead set and welding electrodes. These accessories are not
included standard with RW1400i; please contact your supplier for further details.
5.1.7.1 Connect Earth Lead Quick Connector (26) to the negative (-) output welding terminal (9).
5.1.7.2 Connect Earth Clamp (25) to the work piece. Contact with workpiece must be strong contact with clean, bare
metal, with no corrosion, paint or scale at the contact point

5.1.7.3 Connect the ARC/electrode holder lead (optional) to the positive (+) welding output terminal Note – some welding
electrode types utilize different connection polarity. If in doubt, contact the electrode manufacturer
5.1.7.4 Turn the machine on at the Mains Power Switch (13).
5.1.7.5 Press the Welding Mode Selection Button (4) until the stick indicator is lit. See illustration below.

The screen will show the preset

MMA welding current. This can
be adjusted by rotating the
Welding Parameter Adjustment
Knob (3).

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5.1.7.6 When welding the display will change to show actual welding volts and amperage.

5.1.7.7 VRD: VRD stands for Voltage Reduction Device. The open circuit voltage at the output terminals of an MA welding
power source is high enough to potentially cause an electric shock to a person if they come into contact with the live
terminals. VRD is a safety system that reduces this open circuit voltage to a level where the risk of electric shock is
minimized. It does, however, make striking of the arc more difficult. To switch VRD on/off press the 2T/4T/VRD button (6)

5.1.8 Lift TIG operation

Note - TIG operation requires an argon gas supply, TIG torch, consumables and gas regulator. These accessories are not
included standard with the MIG200GD; contact your supplier for further details.
5.1.8.1 Connect Earth Lead Quick Connector (26) to the positive (+) output welding terminal (10).
5.1.8.2 Connect Earth Clamp (25) to the work piece. Contact with workpiece must be strong contact with
clean, bare metal, with no corrosion, paint or scale at the contact point.
5.1.8.3 Connect the TIG torch power lead to the negative (-) welding output terminal (9).
1.8.4 Connect the gas supply to the TIG torch.
5.1.8.5 Turn the machine on at the Mains Power Switch (13).
5.1.8.6 Press the Welding Mode Selection Button (4) until the Lift TIG indicator is lit. See illustration below.

The screen will show the preset MMA welding current. This can be adjusted by rotating the Welding Parameter
Adjustment Knob (3)
5.1.8.7 When welding the display will change to show actual welding volts and amperage.

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6.Welding settings quick reference chart

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

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

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

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

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

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

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

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

MIG Welding (GMAW) Variables

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

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

Primary Adjustable Variables

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

Secondary Adjustable Variables

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

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

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

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

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

Setting of the Power Source

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

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

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

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

Electrode Wire Size Selection

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

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

-The option of the welding speed

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

-The length of wire stretching out

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

-The setting of the C02 flow volume

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

Option of C02 flow volume

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

8.WELDING PARAMETERS TABLE

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

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

Plate Welding Welding Welding

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

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 1.2 0 1.0 70~80 17~18 45~55 10
1.6 0 1.0 80~100 18~19 45~55 10~15
2.0 0~0.5 1.0 100~110 19~20 40~55 10~15
2.3 0.5~1.0 1.0 or 1.2 110~130 19~20 50~55 10~15
3.2 1.0~1.2 1.0 or 1.2 130~150 19~21 40~50 10~15
4.5 1.2~1.5 1.2 150~170 21~23 40~50 10~15

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

Plate Welding Welding Welding

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

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

Plate Welding Welding Welding

Corn size Wire Gas volume
thickness current voltage speed
I (mm) φ(mm) （L/min）
t（mm） （A） （V） （cm/min）
1.2 2.5~3.0 1.0 70~100 18~19 50~60 10~15
1.6 2.5~3.0 1.0 ~ 1.2 90~120 18~20 50~60 10~15
2.0 3.0~3.5 1.0 ~ 1.2 100~130 19~20 50~60 10~20
2.3 3.0~3.5 1.0 ~ 1.2 120~140 19~21 50~60 10~20
3.2 3.0~4.0 1.0 ~ 1.2 130~170 22~22 45~55 10~20
4.5 4.0~4.5 1.2 200~250 23~26 45~55 10~20

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

Plate Welding Welding Welding

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

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

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

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 An earth terminal is available for this welding equipment. Connect it with the earth cable to avoid the static and
electric shock.

10.MAINTENANCE

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

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

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

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

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

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

11.1. Power supply

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

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

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

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

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

Other parts
joints are in good connection.

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 11.2. Welding torch
Part Check Remarks

1. Check if the nozzle is fixed firmly

Possible gas leakage occurs due to the unfixed nozzle.
and distortion of the tip exists.
Nozzle
2. Check if there is spatter sticking on Spatter possibly leads to the damage of torch. Use
the nozzle. anti-spatter to eliminate the spatter.
1. Check if the contact tip is fixed
Unfixed contract tip possibly leads to unstable arc.
firmly.
Contact tip
2. Check if the contact tip is physically The physically incomplete contact tip possibly leads to
complete. unstable arc and arc automatically terminating.
1. Make sure that there is the Disagreement of the diameters of wire and wire feed tube
agreement of wire and wire feed possibly leads to the unstable arc. Replace it/them if
tube. necessary.
2. Make sure that there is no bending Bending and elongation of wire feed tube possibly leads to
or elongation of wire feed tube. the unstable wire feed and arc. Replace it if necessary.

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

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

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

Part Check Remarks

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

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

3. Check if rod and wire feeding groove are

Unstable arc possibly occurs.
concentric.

Non-agreement of wire diameter and

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

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

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

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

1. Check if the cable is physically complete.

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

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12.CONNECTION DIAGRAM OF THE MACHINE

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