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Installation Instructions for 81540
MIG100 Gasless Welder
PLEASE READ MANUAL CAREFULLY BEFORE USING.
SAFETY INFORMATION
Before using welder, please ensure that you know:
1. Arc welding can be dangerous.
2. This welding machine must be connected to a power source in accordance with appliance electrical codes.
3. For safety turn off and unplug machine when installing new wire spool, adjusting wire tension roller or replacing
contact tip.
4. The contact tip is electrically “hot” and if it contacts the grounded work piece it will cause damage.
5. All installation, maintenance, repair operation of this equipment should be performed by qualified technicians in
accordance with national, state and local codes.
6. Electric shock could kill.
7. Disconnect from power source before assembling, disassembly or maintenance of the torch or contact tip or
changing wire spools.
8. Fumes and welding gases can be dangerous.
9. Welding sparks can cause fire or explosion.
10. Arc rays can burn.
11. Hot metal will burn.
12. Electromagnetic fields may be dangerous.
WARNING!
PLEASE BE REMINDED TO WEAR ALL PROTECTION DEVICES BEFORE WELDING IN A SAFE PLACE.
SPECIFICATION
Process(s)
Flux-Cored MIG
welding
GAS/FLUX
Flux
Input Voltage
110 V AC
Input Current
20 A
Input Frequency
60 Hz
Output Current Range
50-90A
Rated Duty Cycle
20% @90A
Open Circuit Voltage
27V AC
Wire Feed Speed
Infinite adjustable
Current Settings
4 Position
Flux cored welding wire dia.(inch)
0.03’’-0.035’’
Insulation class
F
Protection class
IP21S
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REMINDER:
1. MIG100 welder is a no gas (flux) function. It could weld max 1kgs (2.2lbs) welding wire. Please remember to
use the correct size wire.
2. The nozzle size and wire roller size should be the same. For example, 0.8mm (0.30’’) wire should use 0.8mm
(0.30’’) electrode in the torch and select 0.8mm (0.30”) side of feeding roller.
3. When torch nozzle touches the work piece, there will be an arc. When you press torch button, it starts feeding
wire and welding.
OPERATION
CONNECTING THE WELDER TO A POWER SOURCE
The MIG100 welder requires a dedicated 120 AC, 60 Hz power input. Do not use on power sources that have voltages
less than 105V AC or higher than 132V AC. If using an extension cord, use a minimum 12 AWG cord for up to 25 feet.
CHANGING THE DRIVE ROLLER
The MIG100 comes set up and ready to use 0.035" (0.9mm) Flux-Core Wire. If 0.03" (0.8mm) wire is to be used, the
drive roller needs to be adjusted. Adjust the drive roller according to the following procedure:
1. Open the top door of the welder.
2. Lift the Pressure Adjuster (PIC. C1) out of the way and move the Rocker Arm (PIC. C2) away from the drive
roller.
3. Remove the Drive Roller Thumb Screw (PIC. C3) by turning it counter clockwise and pulling it away from the
roller.
4. Remove the Drive Roller and view the wire sizes stamped on each side of the roller.
5. Install the Drive Roller in the orientation so that the size of the wire you are using is facing you on the side of
the drive roller.
6. Reinstall the Drive Roller Thumb Screw (PIC. C3).
7. Put the Rocker Arm (PIC. C2) back in place and reset the Pressure Adjuster (PIC. C1).
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INSTALLING THE WIRE
The MIG100 should be used with a 4” wire spool only. To install the wire spool follow the procedure listed below:
1. Open the door of the welder and remove the wing nut (PIC. C1) and spacer from the Wire Spool Spindle.
2. Slide the 4” Wire Spool onto the Wire Spindle and reinstall the spacer and wing nut.
THREADING WELDING WIRE THROUGH THE DRIVE MOTOR TO THE WELDING GUN
This welder uses only self-shielding flux-core wire in either 0.030" or 0.035" size (0.8 or 0.9mm). To install the welding
wire follow the procedure outlined below:
1. Turn the power switch to the off position and unplug the welder from the power supply.
2. Remove the contact tip and nozzle from the end of the torch.
3. Ensure that the drive roller is installed in the proper position for the wire size being used.
4. Unlock the Pressure Adjuster (PIC. C1) and lift up on the Rocker Arm (PIC. C2). Ensure that the wire drive
roller is appropriate to the welding wire size see the previous section describing the installation of the drive
roller. The drive roller comes installed for 0.035" (0.9mm) wire.
5. Pull out the welding wire from the wire spool carefully. NOTE: Do not let go of the wire or the entire spool could
unravel.
6. Cut off a small piece of the curved segment at the front of welding wire and straighten the welding wire to
approximately 3" long.
7. Thread the welding wire through the Guide Pipe (PIC. C4) and over the wire Drive Roller and into the torch
hole.
8. Reattach the Rocker arm and reset the Pressure Adjuster.
9. Turn on the machine and set the wire speed.
10. With the gun pointed away from you and others, depress the trigger to begin feeding wire. NOTE: Watch the
drive roller to see if any slippage is occurring between the roller and wire, if so, turn the machine off and tighten
the Pressure Adjuster turn and test again.
11. Once the wire exits the end of the torch, install the contact tip and nozzle. Cut the wire about 1/4" from the end
of the contact tip.
USAGE
Your MIG100 can be used to perform a large number of different types of welds, all of which will require practice and
testing before using on an actual project piece. This following welding process is just a baseline to get you started.
1. Connect your ground clamp to the work pieces that are to be welded. Make sure the ground clamp contacts are
placed on a clean piece of metal free of paint, grease, rust, oils, etc. It is recommended to place your ground
clamp as close to the weld area as possible.
2. Assess your weld area and make sure the welding area is also cleaned of any paint, grease, rust, oils, etc.
3. Plug in the welder and switch to the ON position.
4. Depress the Welding Gun trigger pointing the welding gun away from your body and then let go of the trigger
and cut the wire back to ~1/4" stick out length.
5. Wearing your welding helmet, gloves, long sleeve shirt and pants, put the end of the wire sticking out of the gun
into the joint to be welded.
6. Position the Welding Gun so that it is perpendicular to the base metal with 15~20° tilt back.
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7. When torch nozzle touches the work piece, there will be an arc starting. Depress the trigger to start the wire
feed. NOTE: A push, perpendicular, or drag technique can be used to weld the pieces together.
8. Once you depress the trigger and the arc has started, you will notice a molten puddle will form; this puddle is
the weld bead and will follow the motion of the Welding Gun. Watching the size of the puddle dictates how fast
you should be moving with the torch. If you burn through the material you are either moving to slow or you need
to set the machine to “LOW” voltage. If you’re not penetrating the base metal you’re either moving too fast or
you need to set the machine to “HIGH” voltage.
9. Release the trigger on the Welding Gun to stop the weld.
10. After finished welding, turn off the welder.
TROUBLE SHOOTING
Problem
Possible Causes
Arc unable, excessive spatter
Welding output too high
Torch moved too slowly
Lack of weld penetration
Welding output too low
Torch moved too fast
Input voltage too low
Burning holes in work piece
Welding output too high
Torch moved too slowly
Welder does not operate(mains
indicator not lit, no arc produced)
Check main supply connection
Check supply fuse
Welder does not operate with trigger
pressed
Check main supply connection
Check supply fuse
Check torch trigger and it's connections
Thermal overload cut out - allow welder to cool
Check PCB correct or not – replace PCB
Break in welding circuit
Incorrect size of contact tip for wire
Contact tip damaged – replace contact tip
Contact tip loose – tighten contact tip
Feed rollers worn – replace feed rollers
Welding wire corroded – replace welding wire
Pressure roller adjustment incorrect – adjust roller
Pressure roller sticking – lubricate or replace roller
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