Magnum CARIMIG 202LCD User Manual

WE3107 v.110413

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If a part is damaged or missing, replacement parts can be
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For help with assembly, or for additional product
information, call our North American toll-free number:
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CARIMIG 202LCD

Multi-Process DC LCD Welder

Please read and save these instructions. Read through this owner’s manual carefully before
using product. Protect yourself and others by observing all safety information, warnings, and
cautions. Failure to comply with instructions could result in personal injury and/or damage to
product or property. Please retain instructions for future reference.

1

Operating Instructions and Parts Manual

GENERAL SAFETY INSTRUCTION

General Safety Information

1.1 Your Welding Environment

-Keep the environment you will be welding in free from flammable mat eri al s.

-Always keep a fire ext ingui s h er ac c essible to your welding environment.

-Always have a qualifie d pers on install and operate this equipment.

-Make sure the area is clean, dry and ventilated. Do not operate the welder in
humid, wet or poorly ventilated areas.

-Always have your welder maintained by a qualified technician in accor dance
with local, st ate and national codes.

-Always be aware of y our w o rk environment. Be sure to keep other people,
especially children, away from you while welding.

-Keep harmful arc rays shielded from the view of others.

-Mount the welder on a secure bench
or cart that will keep the welder secure and prevent it from tipping over or fall i ng.

1.2 Your Welder’s Condition

-Check ground cable, power cord and welding cable to be sure the insulation is
not damaged. Alw a ys replace or repair damaged components before using the
welder.

-Check all components to ensure they are clean and in good operatin g c ondition
before use.

1.3 Use of Your Welder

Do not operate the welder if the output cable, electrode, MIG gun, wire or wire
feed system is wet. Do not immerse them in water. These components and the
welder must be complet el y dry before attempting to use them .

-Follow the instructions in this manual.

-Keep welder in the off position when not in use.

-Connect ground lea d as cl ose to the area being weld e d as pos sible to ensure a
good ground.

-Do not allow any body part to come in contact with the welding wire if you are in
contact with the material being welded, ground or electrode from another welder.

-Do not weld if you ar e i n an awkward position. Always have a secure stance
while welding to prevent accidents. Wear a safety harness if working above
ground.

-Do not drape cables ov er or around your body.

-Wear a full coverage helmet with appropriate shade (see ANSI Z87.1 safe t y
standard) and safety glasses while welding.

GENERAL SAFETY INSTRUCTION

2

-Wear proper gloves and prot ective clothing to prev ent your skin from being
exposed to hot metals, UV and IR rays.

-Do not overuse or overheat your welder. Allow proper cooling time between duty
cycles.

-Keep hands and fingers away from moving parts and stay away from the drive
rolls.

-Do not point MIG gun at any body p ar t of yourself or anyone else.

-Always use this weld er in the rated duty cycle to prevent excessive heat and
failure.

1.4 Specific Areas of Danger, Caution or Warning

Electrical Sho ck

Electric arc welders can produce a shock that can cause injury or
death. Touching electrically live parts c an c ause fatal shocks and

severe burns. While welding, all m etal components connected to
the wire are electrically hot . Poor ground connections are a hazard, so secure the
ground lead before welding.

-Wear dry protective apparel: coat, shirt, gloves and insulat e d foot wear.

-Insulate yourself from the work piece. Avoid contacting the work piece or ground.

- Do not attempt to repair or maint a i n the welder while the power is on.

-Inspect all cables and cords for any exposed wire and repl ac e immediately if
found.

-Use only recommended re pl ac ement cables and cords .

-Always attach ground clam p t o the work piece or work table as c l ose to the weld
area as possible.

-Do not touch the weldi ng wire and the ground or grounded work piece at the
same time.

-Do not use a welder to thaw frozen pipes.

Fumes and Gases

-Fumes emitted from the welding process displace clean air and
can result in injury or death.

-Do not breathe in fumes emi tted by the welding process. M a k e

sure your breathing air is clean an d s af e.

-Work only in a well-ventilated area or use a ventilati on dev ice to remove welding
fumes from the environment where you will be working.

-Do not weld on coated mat e rials (galvanized, cadmium plated or containing z inc,
mercury or barium ). They will emit harmful fumes that are dangerous to breathe.
If necessary use a ventilator, respirator with air supply or rem ove the coating
from the material in the weld area.

-The fumes emitt ed from some metals when he at ed are extremely tox ic. Refer to
the material safety data sheet for the manufacturer’s instructions.

-Do not weld near materials that will emit toxic fumes when heated. Vapors from
cleaners, sprays and degreasers can be highly toxic when heated.

GENERAL SAFETY INSTRUCTION

3

UV and IR Arc Rays

The welding arc produces ultraviolet (UV) and infrared (IR) rays
that can cause injury to your eyes and skin. Do not look at the
welding arc without proper eye protection.

-Always use a helmet that c overs y our full face from the neck to top of head and
to the back of each ear.

-Use a lens that meets ANSI standards and safety glasses. For welders under
160 Amps output, use a shade 10 l ens ; for above 160 Amps, use a shade 12.
Refer to the ANSI standard Z87.1 for more information.

-Cover all bare skin areas ex pos e d t o t he arc wit h prot ec tive clothing and shoes.
Flame-retardant cloth or leather shirts, coats, pants or coveralls are available for
protection.

-Use screens or other barri er s to protect other people from the arc rays emitted
from your welding.

-Warn people in your welding area when you are going to strike an arc so they
can protect them selves.

Fire Hazards

Do not weld on containers or pipes that contain or hav e had
flammable, gaseous or li qui d c ombustibles in them. Welding creates
sparks and heat that can ignite flammable and explosive materials.

-Do not operate any elect r ic arc welder in areas where fl amm able or explosive
materials are prese nt.

-Remove all flammable materials within 35 feet of the welding arc. If removal is
not possible, tightly cover them with fireproof covers.

-Take precautions to ens ur e t hat flying sparks do not cause fi res or explosions in
hidden areas, cracks or areas you cannot see.

-Keep a fire extinguisher close in the case of fire.

-Wear garments that are oil-free with no pockets or c uff s t hat w il l col l ec t spark s.

-Do not have on your per son any items that are com bust i ble, such as lighters or
matches.

-Keep work lead connected as close to the weld area as possible to prevent any
unknown, unintended paths of electrical current from causing electrical shock
and fire hazards.

-To prevent any unintended arcs, cut wire back to ¼" stick out after welding.

Hot Materials

Welded materials are hot and can cause severe burns if handl ed
improperly.

-Do not touch welded materials with bare hands.

-Do not touch MIG gun nozzle after welding until it has had time to cool down.

GENERAL SAFETY INSTRUCTION

4

Sparks/Flying Debris

Welding creates hot s parks that can cause i nj u ry . C h ip ping slag off
welds creates flying debris.

-Wear protective apparel at all times: ANSI-approved safety glasses

or shield, welder’s hat and ea r pl ugs t o keep sparks out of ears and hair.

Electromagnetic Field

-Electromagnetic fi elds can interfere with various el ec trical and
electronic devices such as pacemakers.

-Consult your doctor before using any electric arc w el d er or c utting

device

-Keep people with pacemakers away from your welding area when welding.

-Do not wrap cable around your body while weldin g.

-Wrap MIG gun and ground cable together whenever possible.

-Keep MIG gun and ground cables on the same side of your body.

Shielding Gas Cylinders Can Explode

High pressure cylinders can explode if damaged, so treat them
carefully.

-Never expose cylinders to high heat, sparks, open flames,

mechanical shocks or arcs.

-Do not touch cylinder with MIG gun.

-Do not weld on the c y l inder

-Always secure cylinder upright to a cart or stationary object.

-Keep cylinders away from welding or electrical circuits.

-Use the proper regulators, gas hose and fittings for the specific application.

-Do not look into the valve when opening it.

-Use protectiv e c yl i nder c ap w he never possible

1.5 Proper Care, Maint enan ce and Repair

-Always have power disc o nnected when working on int e r n al components.

- Do not touch or handle PC board without being properly grounded with a wrist

strap. Put PC board in stati c proof ba g to move or ship.

-Do not put hands or fingers near moving parts such as drive rolls of fan

Please read and save these instructions. Read through this owner’s manual carefully before using product.
Protect yourself and others by observing all safety information, warnings, and cautions. Failure to comply
with instructions could result in personal injury and/or damage to product or property. Please retain
instructions for future reference.

1

Operating Instructions and Parts Manual

MIG WELDER

Description

The CARiMIG 202 LCD is a multi-process DC

inverter welder, with LCD screen. This unit uses

1~Phase 120V or 230V, 50/60HZ AC power. A 15

amp time delay fuse or circuit breaker is

recommended. The CARiMIG 202 LCD series is

ideal for Do-It-Yourself projects or for light

maintenance. MIG weld carbon steel, stainless

steel , AlMg and AlSi.

Unpacking

1.1 Remove cartons, bags or Styrofoam contai ning th e wel der and
accessories.

1.2 Check the contents with the packing list below.

ITEM QTY.

DC Inverter MIG Welder 1 unit

MIG gun 1pcs

Grounding cable with clamp 1pcs

Gas hose ф5.5

3m

Operator’s Manual 1set

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1.3 After unpacking unit, inspect carefully for any damage that may have

occurred during transit. Check for loose, missing, or damaged parts. Shipping

damage claim must be filed with carrier.

Operating Instructions and Parts Manual

Specifications and Dimension

Description Specification

Mod el CARiMIG 202 LCD

Input power V 120（110~130） 230（220~240）

Frequency Hz 50/60 50/60

Rated input current A 20 36

Rated input capacitance KVA 3.5 8.6

No-load voltage V 69 69

Rated working voltage V 18.5 24

MMA welding current A 10~70 10～180

LIFT Arc welding current A 10~90 10～180

MIG welding current A 40~90 40～200

Rated duty cycle % 40 20

Welding current（10min） A 40%@90 20%@200

10min/100% A 57 89

Efficiency η 85%

Power factor Cosφ 0.75

Insulation class H

Enclosure protection IP 21S

Cooling type

Fan cooled

Dimension L×W×H cm 73*32*48

Weight kg 18

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Removing from carton

1.1 Remove cartons, bags or Styrofoam containing the welder and accessories.

1.2 Check the contents with the packing list below.

z Factory standard：EN60974-1
z Optional accessories：Protective mask、tip、welding wire

Know your Welder

z GROUNDING CABLE

Use earth clamp to connect earth cable with work piece

z MIG GUN

The welding wire is driven through the welding cable and MIG gun to the work piece.
It is attached to the drive system.

z POWER SWITCH

In the “OFF” position no power is being supplied
In the “ON” position power is supplied to the main transformer and control circuit

Front Ctrl Panel

MIG Socket

MIG Gun

Grounding cable
With clamp

Torch Polarity
Change Cable

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z INPUT POWER CORD

The power cord connects the welder to the 120V/230 volt power supply. 14 amp
receptacle to supply power to the welder.

z Torch Polarity Change Cable

To change the polarity of gun for kinds of core wire welding.

z NAMEPALTE OF WELDER

The nameplate indicate the main electrical data of welder.

z Front Ctrl panel

1. LCD: Shows all process from function selection to welding.

2. LEFT ADJUST KNOB: Allows user to adjust the current and wire feeding speed

accurately.

3. RIGHT ADJUST KNOB: Allows user to adjust the voltage accurately.

4. Home Key: Keep pressing home key, return to home page

5. Multi-function adjusting knob: For function selection; Press for confirming.

6. Return: Return to the previous step.

4

3

1

6

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z Interface description

1. Multi-functions selection: Total 9 functions, 8 welding functions and 1 setting.

Adjusting multi-function knob for selecting, press for confirming

2. Output setup: Shows output connection under different welding mode, press

multi-function knob for confirming

3. Electrode/ Wire diameter selection：Adjusting multi-function knob to select

different electrode/wire diameter, press for confirming

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4. Material thickness: Adjusting multi-function knob to select different material

thickness, press for confirming

5. Welding display：Shows all selected parameters.

a. Under MIG welding, user can set wire feeding speed and voltage. Adjusting

Multi-function knob to set electro-inductance, press the knob to progress basic
parameter setting.

Note:

Note 1. Basic parameter setting including：gas pre flow, slow wire feeding, gas post flow, operating, load and save

function. there is also spool gun function under Al welding

Note2: In the green range of current and voltage, it means recommended parameter.

b. Under TIG welding, user can set current parameter;

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c. Under Stick welding, user can set current, arc force parameter and hot start.

6. Setting interface: It shows language setting, units setting, light setting,

information and recover setting.

7. Alarm interface:It shows the machine is overloaded and the internal temperature

is too high. Weld output will turn off automatically but the fan will still be working.
When the internal temperature is decreased, the alarm interface will turn off and
the machine will be ready to weld.

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Installation

Outside Connection of the Machine

1. Power requirement

AC single phase 230V or 120V , 50/60HZ fused with a 15 amp time delayed fuse

or circuit breaker is required.

•High voltage danger from power source! Consult a qualified electrician for proper

installation of receptacle. This welder must be grounded while in use to protect

the operator from electrical shock.

• Do not remove grounding prong or alter the plug in any way. Do not use any

adapters between the welder’s power cord and the power source receptacle.

Make sure the POWER switch is OFF when connecting your welder’s power cord

to a properly grounded 120V/230Vac, 50/60Hz, single phase, 14 amp power

source.

2. Extension cord

During normal use an extension cord is not necessary. It is strongly

recommended that an extension cord should not be used because of the voltage

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drop they produce. This drop in voltage can affect the performance of the welder.

If you need to use an extension cord it must be a #12 gauge cord at the smallest.

-Do not use an extension cord over 25 ft. in length.

3. Setting up the work piece

3.1 Welding positions

There are two basic positions, for welding: Flat and Horizontal. Flat welding is

generally easier, faster, and allows for better penetration. If possible, the work

piece should be positioned so that the bead will run on a flat surface.

3.2 Preparing the Joint

Before welding, the surface of work piece needs to be free of dirt, rust, scale, oil

or paint. Or it will create brittle and porous weld. If the base metal pieces to be

joined are thick or heavy, it may be necessary to bevel the edges with a metal

grinder. The correct bevel should be around 60 degrees.

See following picture:

Based on different welding position, there are different welding joint, see following

images for more information

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4. Ground clamp connection

Clear any dirt, rust, scale, oil or paint on the ground clamp. Make certain you have
a good solid ground connection. A poor connection at the ground clamp will waste
power and heat. Make sure the ground clamp touches the metal.

5. Setting the wire tension

Arc flash can injure eyes! To reduce the risk of arc flash, make certain that the wire
coming out of the end of the torch does not come in contact with work piece, ground
clamp or any gr ounded material during the drive tension setting process or arcing
will occur.

5.1. Press the trigger on the torch.

5.2. Turn the drive tension adjustment knob clockwise, increasing the drive tension until the
wire seems to feed smoothly without slipping.

6.Gas installation

Shielding gas cylinders and high pressure cylinders can explode. if damaged, so
treat them carefully.

-Never expose cylinders to high heat, sparks, open flames, mechanical shocks or
arcs.

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-Do not touch cylinder with MIG gun.

-Do not weld on the cylinder.

-Always secure cylinder upright to a cart or stationary object.

-Keep cylinders away from welding or electrical circuits.

-Use the proper regulators, gas hose and fittings for the specific application.

When MIG (solid) wires are used, the shielding gas is required.

6.1

Settings of different wire welding ways

With gas shied welding output line-connection

without gas shield welding

6.1.1 Change the welding mode to the MIG welding mode;

6.1.2 While during the solid core with gas shield welding and the flux-cored welding, the
patch-plug from the machine insert in the positive polarity output socket of the machine,
and the ground cable connect to the negative polarity;

6.1.3 While using the self-shield without gas during the welding, the patch-plug from the
machine insert in the negative polarity output socket of the machine, and the ground cable
connect to the positive polarity;

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6.2.The gas hose, regulator and gas cylinder connection
Attach one end of the gas hose to the gas solenoid valve (gas inlet) located on the back
panel of the welder. Attach the other end to the gas regulator which is attached to the
shielding gas cylinder. See illustration below

1. Cylinder valve: Controls GAS CYLINDER
gas flow.

2. Cylinder pressure gauge

3. Gas flow gauge, set at 20 CFM

4. Regulator

5. Adjustment knob controls gas pressure to
the welder.

6. Gas hose

7. Gas cylinder

NOTE:

Slowly open the cylinder valve by turning it counterclockwise until the cylinder pressure
gauge registers on the first gauge of the regulator. Turn the adjustment knob clockwise
(right) slowly to increase gas flow to 20 cfm. To reduce the gas flow turn the adjustment
counterclockwise (left). The gas valve is located on the back panel of the welder and
activated by the trigger. Gas flow should be heard when the trigger is activated. No gas
flow will result in a harsh arc with excessive spatter, a smooth weld bead will be difficult to
obtain. Avoid unnecessary gas loss by closing the tank valve when finished welding.

6.3.Gas selection.
Different materials require different shielding gas when MIG welding, refer to the set up
chart inside the wire feed compartment.

Mild steel: Use 75% Argon and 25% for reduced spatter and reduced penetration for

thinner materials. Do NOT USE Argon gas concentrations higher than 75% on steel. The
result will be extremely poor penetration, porosity, and brittleness of weld.

Mild Steel: Use CO2 for deeper penetration but increased spatter.
Stainless steel: Use a mixed gas consisting of Helium, Argon and CO2. Aluminum or
bronze: Use 100% Argon

7

32

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7 Installation of Wire Spool

7.1 Open the turning plate of the machine, rotate the adjusting nut on the wire shaft anti­clockwise to remove it from the wire spool screw, and then take down the wire spool block
seat;

7.2 Let the inner hole of the wire spool which is equipped with wire cover the end of
block seat in the wire spool(100m or 200mm wire spool will be chosen )

7.3 Then install the wire spool block seat, put the wire spool block seat to the other hole
of the wire spool inner hole;

7.4 After the installation of wire spool, rotate clockwise the adjusting nut to be re-installed
in the wire spool nut;

7.5 higher of the pressing pressure for the adjusting nut, then the greater of the wire
spool rotating resistance. On the opposite, the the smaller the pressing pressure for the
adjusting nut, then the smaller of the wire spool rotating resistance. User can adjust it
according to the wire spool diameter and the self-habit.

Notice:

While adjusting the tightness of the nut, have to make sure the wire spool is at effective
fixing of the wire spool block seat and wire block seat end, or it will damage the wire spool
or the spool shaft and it will not feed the wire steadily.

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8 Installation of wire feeder and connection of welding stick

8.1 While installing the wire spool, check previously that wire feeding roller in the wire

feeder is suitable for the contact tip in the torch and wire diameter

8.2 After the confirmation or the replacement of the wire feeding roller and contact tip,
put the press roller adjusting to the machine behind. Open the pressure roller, and remind
that do not put hands on the top of the pressure roller when it is open to avoid being hurt
when it is up spring.

8.3 Insert the wire starting end to the wire feeder through the wire tube, insert the torch
socket through suitable wire feeding roller groove;

8.4 When the wire is led to the torch socket, press the pressure roller again, and then
restore the pressure roller adjusting rod to press the roller.

9 Replacement of roller

9.1 open the turning plate of the machine shell. Please remove the wire first if there is
still wire on the wire feeder;

9.2 rotate anti-clockwise the cover of the wire feeder to dispatch it;

9.3 grab the wire feeder with hands to pull it out slightly, then install the needed wire
feeder and wire feeding roller from the shaft;

Notice: when re-install the wire roller, it must follow the shaft. Do not use tools to

hammer it, just to avoid damaging.

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9.4 after the installation of wire roller, screw the cover clockwise tightly. Make sure the
screw thread connection is correct, to avoid damaging of the screw thread due to the
connection deviation.

Remark: he spec marked on the front of the roller is the size of roller groove in

the back of the roller. Mind the direction during the operation.

Operation

High voltage dang e r from power source! C onsult a qualif i ed el ectrician for pr o p er
installation of receptacle at the power source. This welder must be grounded while
in use to protect the operator from electrical shock. If you are not sure if your outlet
is properly grounded, have it checked by a qualified electrician. Do not cut off the
grounding prong or alter the plug in any way and do not us e any adapters between
the welder’s power cord and the power source receptacle. Make sure the POWER
switch is OFF before connecting your welder’s power cord to a properly grounded
120V/230VAC, 50/60Hz, single phase,14 amp power source.

Part1 The MIG welding operation

1. Main control component
Power switch - The power switch supplies electrical current to the welder. Whenever the

power switch is in the ON position, the welding circuit is activated. ALWAYS turn the power
switch to the OFF position and unplug the welder before performing any maintenance.

Voltage selector - The voltage selector controls the welding heat. This unit has infinite

voltage control. Refer to the label inside the welder side door for recommended voltage
selector settings for your welding job.

Wire speed control - The wire speed control adjusts the speed at which the wire is fed out

of the welding torch. The wire speed needs to be closely matched (tuned-in) to the rate at
which it is being melted off. Some things that affect wire speed selection are the type and
diameter of the wire being used, the heat setting selected, and the welding position to be
used.
Note: The wire will feed faster without an arc. When an arc is being drawn, the wire speed
will slow down.

2. Hold the torch

The best way to hold the welding torch is the way that feels most comfortable to you.
While practicing to use your new welder, experiment holding the torch in different positions
until you find the one that seems to work best for you.

3. Position the torch to the work piece

There are two angles of the torch nozzle in relation to the work piece that must be
considered when welding.

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3.1. Angle A can be varied, but in most cases the optimum angle will be 60 degrees, the
point at which the torch handle is parallel to the work piece. If angle A is increased,
penetration will increase. If angle A is decreased, penetration will decrease also.

3.2. Angle B can be varied for two reasons: to improve the ability to see the arc in relation
to the weld puddle and to direct the force of the arc.

4. Distance from the work piece

If the nozzle is held off the work piece, the distance between the nozzle and the work
piece should be kept constant and should not exceed 1/4 inch or the arc may begin
sputtering, signaling a loss in welding performance.

5. Tuning in the wire speed

This is one of the most important parts of MIG welder operation and must be done
before starting each welding job or whenever any of the following variables are changed:
heat setting, wire diameter, or wire type.

EXPOSURE TO A WELDING ARC IS EXTREMELY HARMFUL TO THE EYES AND
SKIN!
Prolonged exposure to the welding arc can cause blindness and burns. Never strike
an arc or begin welding until you are adeq uat ely protected. Wear flameproof welding
gloves, a heavy long sleeved shirt, trousers with no cuffs, high topped shoes, and
an ANSI approved welding helmet.

5.1. Connect the Ground Clamp to a scrap piece of the same type of material which you
will be welding. It should be equal to or greater than the thickness of the actual work piece,
and free of oil, paint, rust, etc.

5.2. Select a heat setting. Refer to set up chart

5.3. Hold the torch in one hand, allowing the nozzle to rest on the edge of the work piece
farthest away from you, and at an angle similar to that which will be used when welding.
(See HOLDING THE TORCH if you are uncertain of the angle at which you will be welding).

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5.4. With your free hand, turn the Wire Speed Dial to maximum and continue to hold onto
the knob.

5.5. Lower your welding helmet and pull the trigger on the torch to start an arc, then begin
to drag the torch toward you while simultaneously turning the Wire Speed Dial counter­clockwise.

5.6. LISTEN! As you decrease the wire speed, the sound that the arc makes will change
from a sputtering to a high-pitched buzzing sound and then will begin sputtering again if
you decrease the wire speed too much. The point on the wire speed adjustment where the
high-pitched buzzing sound is achieved is the correct setting. You can use the wire speed
control to slightly increase or decrease the heat and penetration for a given heat setting by
selecting higher or lower wire speed settings. Repeat this tune-in procedure if you select a
new heat setting, a different diameter wire, or a different type of welding wire.

6. Welding Techniques

EXPOSURE TO A WELDING ARC IS EXTREMELY HARMFUL TO THE EYES AND
SKIN! Prolonged exposure to the welding arc can cause blindness and burns. Never
strike an arc or begin welding until you are adequately protected. Wear flameproof
welding gloves, a heavy long sleeved shirt, trousers with out cuffs, high topped
shoes and an ANSI approved welding helmet.
ELECTRIC SHOCK CAN KILL! To prevent ELECTRIC SHOCK, do not perform any
welding while standing, kneeling, or lying directly on the grounded work.

6.1 Moving the to rch

Torch travel refers to the movement of the torch along the weld joint and is broken into two
elements: Direction and Speed. A solid weld bead requires that the welding torch be
moved steadily and at the right speed along the weld joint. Moving the torch too fast, too
slow, or erratically will prevent proper fusion or create a lumpy, uneven bead.

Travel direction is the direction the torch is moved along the weld joint in relation to the

weld puddle. The torch is either PUSHED into the weld puddle or PULLED away from the
weld puddle.

For most welding jobs you will pull the torch along the weld joint to take advantage of the
greater weld puddle visibility.

Travel speed is the rate at which the torch is being pushed or pulled along the weld joint.

For a fixed heat setting, the faster the travel speed, the lower the penetration and the lower
and narrower the finished weld bead. Likewise, the slower the travel speed, the deeper the
penetration and the higher and wider the finished weld bead.

6.2 Types of welding beads

As you become more familiar with your new welder and better at laying some simple weld
beads, you can begin to try some different weld bead types.

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18

The STRINGER BEAD Is formed by traveling with the torch in a straight line while keeping
the wire and nozzle centered over the weld joint (See following figure)

The WEAVE BEAD Is used when you want to deposit metal over a wider space than would
be possible with a stringer bead. It is made by weaving from side to side while moving with
the torch. It is best to hesitate momentarily at each side before weaving back the other way.

6.3 Welding position

FLAT POSITION Is easiest of the welding positions and is most commonly used. It is best
if you can weld in the flat position if at all possible as good results are easier to achieve.

HORIZONTAL POSITION Is performed very much the same as the flat weld except that
angle B (see HOLDING THE TORCH) is such that the wire, Directed more toward the
metal above the weld joint is to help prevent the weld puddle from running downward while
still allowing slow enough travel speed .A good starting point for angle B is about 30

degrees DOWN from being perpendicular to the work piece

.

VERTICAL POSITION Is easier for many people to Pull the torch from top to bottom. It can
be difficult to prevent the puddle from running downward. Pushing the torch from bottom to
top may provide better

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19

puddle control and allow slower rates of travel speed to achieve deeper penetration. When
vertical welding, angle B (see HOLDING THE TORCH) is usually always kept at zero, but
angle A will generally range from 45 to 60 degrees to provide better puddle control.
OVERHEAD POSITION Is the most difficult welding position. Angle A (see HOLDING THE
TORCH) should be maintained at 60 degrees. Maintaining this angle will reduce the
chances of molten metal falling into the nozzle. Angle B should be held at zero degrees so
that the wire is aiming directly into the weld joint. If you experience excessive dripping of
the weld puddle, select a lower heat setting. Also, the weave bead tends to work better
than the stringer.

6.4 Multiple pass welding
Butt Weld Joints When butt welding thicker materials you will need to prepare the edges

of the material to be joined by grinding a bevel on the edge of one or both pieces of the

metal being joined. When this is done, a “V” is created between the two pieces of metal

that will have to be welded closed. In most cases more than one pass or bead will need to

be laid into the joint to close the “V”.

Laying more than one bead into the same weld joint is known as a multiple-pass weld.
The illustrations in following figure show the sequence for laying multiple pass beads into a
single “V” butt joint.

NOTE:

WHEN USING SELF-SHIELDING FLUX-CORE WIRE it is very important to thoroughly
chip and brush the slag off each completed weld bead before making another pass or the
next pass will be of poor quality.

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20

Fillet Weld Joints. Most fillet weld joints, on metals of moderate to heavy thickness, will

require multiple pass welds to produce strong joint. The illustrations in Figure 19 show the
sequence of laying multiple pass beads into a T fillet joint and a lap fillet joint.

6.5 Spot welding

There are three methods of spot welding: Burn-Through, Punch and Fill, and Lap. Each
has advantages and disadvantages depending on the specific application as well as
personal preference.

1. The BURN-THROUGH METHOD welds two overlapped pieces of metal together by
burning through the top piece and into the bottom piece. With the burn-through method,
larger wire diameters tend to work better than smaller diameters. Wire diameters that tend
to work best, with the burn-through method are 0.035 inch self-shielding flux-core wire. Do
not use .030 inch self-shielding flux core wires when using the burn-through method unless
the metal is VERY thin or excessive filler metal build-up and minimal penetration is
acceptable. Always select the HIGH heat setting with the burn-through method and tune in
the wire speed prior to making a spot weld.

2. The PUNCH AND FILL METHOD produces a weld with the most finished appearance of
the three spot weld methods. In this method, a hole is punched or drilled into the top piece
of metal and the arc is directed through the hole to penetrate into the bottom piece. The
puddle is allowed to fill up the hole leaving a spot weld that is smooth and flush with the
surface of the top piece. Select the wire diameter, heat setting, and tune in the wire speed
as if you were welding the same thickness material with a continuous bead.

3. The LAP SPOT METHOD directs the welding arc to penetrate the bottom and top pieces,
at the same time, right along each side of the lap joint seam. Select the wire diameter, heat
setting, and tune in the wire speed as if you were welding the same thickness material with
a continuous bead.

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21

6.6 SPOT WELDING INSTRUCTIONS

1. Select the wire diameter and heat setting recommended above for the method of spot
welding you intend to use.

2. Tune in the wire speed as if you were going to make a continuous weld.

3. Hold the nozzle piece completely perpendicular to and about 1/4 inch off the work piece.

4. Pull the trigger on the torch and release it when it appears that the desired penetration
has been achieved.

5. Make practice spot welds on scrap metal, varying the length of time you hold the trigger,
until a desired spot weld is made.

6. Make spot welds on the actual work piece at desired locations.

7. Electrode

The welding electrode is a rod coated with a layer of flux. When welding, electrical
current flows between the electrode (rod) and the grounded metal work piece.
The intense heat of the arc between the rod and the grounded metal melts the
electrode and the flux. The most popular electrodes are:

-E6011 60,000 PSI tensile strength deep penetrating applications.

-E6013 60,000 PSI tensile strength used for poor fit up applications

-E7014 70,000 PSI tensile strength used for high deposition and fast travel
speeds with light penetration

-E7018 70,000 PSI tensile strength,
Used for out of position and tacking.

8. Selecting the proper electrode

There is no golden rule that determine the exact rod or heat setting required for
every situation. The type and thickness of metal and the position of the work
piece determine the electrode type and the amount of heat needed in the welding
process. Heavier and thicker metals
required more amperage. It is best to
practice your welds on scrap metal which
matches the metal you intend to work with to
determine correct heat setting and
electrode choice. See following some helpful

trouble shooting tips to determine if you

are using a correct electrode

1. When proper rod is used:

a. The bead will lay smoothly over the work without ragged edges
b. The base metal puddle will be as deep as the bead that rises above it
c. The welding operation will make a crackling sound similar to the sound of eggs
frying

2. When a rod too small is used

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22

a. The bead will be high and irregular
b. The arc will be difficult to maintain

3. When the rod is too large

a. The arc will burn through light metals
b. The bead will undercut the work
c. The bead will be flat and porous
d. Rod may be freeze or stick to work piece

Note: Rate of travel over the work also affects the weld. To ensure proper

penetration and enough deposit of rod, the arc must be moved slowly and evenly
along the weld seam.

Operation

1.Setting the amperage control

The welder has an infinite output current control. It is capable of welding with
1/16" and 5/64" and 3/32" electrodes.
here is no golden rule that determines the exact amperage required for every
situation. It is best to practice your welds on scrap metal which matches the
metals you intend to work with to determine correct setting for your job. The
electrode type and the thickness of the work piece metal determine the amount of
heat needed in the welding process. Heavier and thicker metals require more
voltage (amperage), whereas lighter and thinner metals require less voltage
(amperage).

2.Welding techniques

The best way to teach yourself how to weld is with short periods of practice at
regular intervals. All practice welds should be done on scrap metal that can be
discarded. Do not attempt to make any repairs on valuable equipment until you
have satisfied yourself that your practice welds are of good appearance and free
of slag or gas inclusions.

2.1 Holding the electrode

The best way to grip the electrode holder is the way that feels most comfortable to
you. To Position the Electrode to the work piece when striking the initial arc it may
be necessary to hold the electrode perpendicular to the work piece. Once the arc
is started the angle of the electrode in relation to the work piece should be
between 10 and 30 degrees. This will allow for good penetration, with minimal
spatter.

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23

2.2 Striking the arc

EXPOSURE TO A WELDING ARC IS EXTREMELY HARMFUL TO THE EYES
AND SKIN.

•Never strike an arc or begin welding until you have adequate protection.

• Wear flameproof welding gloves, heavy long-sleeved shirt, cuffless trousers,
high-topped shoes and a welding helmet or shield.
Scratch the work piece with the end of electrode to start arc and then raise it
quickly about 1/8 inch gap between the rod and the work piece. See following
picture

It is important that the gap be maintained during the welding process and it should
be neither too wide or too narrow. If too narrow, the rod will stick to the work piece.
If too wide, the arc will be extinguished. It needs much practice to maintain the
gap.Beginners may usually get sticking or arc extinguishing. When the rod sticks
to the work piece, gently rock it back and forth to make them separate. If not, the
circuit is short connection,
and it will overload the welder. A good arc is accompanied by a crisp, cracking
sound. The sound is similar to that made by eggs frying. To lay a weld bead, only
2 movements are required; downward and in the direction the weld is to be laid,
as in following figure:

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24

2.3 Types of weld bead

The following paragraphs discuss the most commonly used arc welding beads.

The stringer bead Formed by traveling with the electrode in a straight line while

keeping it centered over the weld joint.

The weave bead Used when you want to deposit metal over a wider space than

would be possible with a stringer bead. It is made by weaving from side to side

while moving with the electrode. It is best to hesitate momentarily at each side

before weaving back the other way to improve penetration.

2.4 Welding position

Flat position is the easiest of the welding positions and is most commonly used. It

is best if you can weld in the flat position if at all possible as good results are

easier to achieve.

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25

The horizontal positionis is performed very much the same as the flat weld

except that the angle is different such that the electrode, and therefore the arc

force, is directed more toward the metal above the weld joint. This more direct

angle helps prevent the weld puddle from running downward while still allowing

slow enough travel speed to achieve good penetration. A good starting point for

your electrode angle is about 30 degrees DOWN from being perpendicular to the

work piece.

2.5 Judge a good weld bead

When the trick of establishing and holding an arc has been learned, the next step

is learning how to run a good bead. The first attempts in practice will probably fall

short of acceptable weld beads. Too long of an arc will be held or the travel speed

will vary from slow to fast (see following)

A. Weld speed is too fast.

B. Weld speed is too slow.

C. Arc is too long.

D. Ideal weld.

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26

A solid weld bead requires that the electrode be moved slowly and steadily along

the weld seam. Moving the electrode rapidly or erratically will prevent proper

fusion or create a lumpy, uneven bead. To prevent

ELECTRIC SHOCK, do not perform any welding while standing, kneeling, or lying

directly on the grounded work.

2.6 Finish the bead

As the coating on the outside of the electrode burns off, it forms an envelope of

protective gasses around the weld. This prevents air from reaching the molten

metal and creating an undesirable chemical reaction. The burning coating,

however, forms slag. The slag formation appears as an accumulation of dirty

metal scale on the finished weld. Slag should be removed by striking the weld

with a chipping hammer.

9.LIFT-TIG

9.1 ACCESORY
Tears off the main attaching plug，Turn off the power source.The ground cable
connect the positive electrode and screw it tighter.The end of the ground cable
connect the work piece.The torch cable connect the cathode and screw it
clockwise.Tighter the gas tube bolt which connect the protection gas
cylinder.Inserts the main attaching plug.

9.2 The touch pilot arc Warning! Turn on the power source , Welding
torch's tungstic electrode already charged. The tungstic electrode could not touch
anything.this series welding machine TIG weld uses contact striking the arc way:

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27

Striking the arc method following step:

A.Turns on the welding torch built-in air valve
Approaches the striking the arc spot the spray nozzle to cause the
tungstic electrode and the work piece is separated 2~3mm

B.Slowly lifts the welding torch to cause the tungstic electrode contact
work piece

C.Lifts the welding torch to the normal position, starts to weld

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28

Trouble shooting Chart

NO Breakdown Analysis

Solutions

Voltage is too high

(≥15%)

Voltage is too low

(≤15%)

Switch off power source; Check

the main supply; Restart welder

when power recovers to normal

state.

Bad power

ventilation lead to

over-heat protection

Improve the ventilation condition.

Circumstance

temperature is too

high.

It will automatically recover when

the temperature low down.

1

Alarm
interface

Using over the rated

duty-cycle.

It will automatically recover when

the temperature low down.

Potentiometer not in

the proper status

Change potentiometer

Nozzle is blocked up

Change nozzle

2

Wire feeding

motor don’t

work

Feed roller is loosen

Firm the bolts

Switch broken Replace the switch

Fan broken Replace or repair the fan

3

Cooling Fan

not working

or turning

very slowly

Wire broken or falling

off

Check the connection

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29

Too large contact tip

makes the current

unsteady

Change the proper contact tip or

roller

Too thin power cable

makes the power

astaticism

Change the power cable

Too low input voltage Enhance the input voltage

4

Arc is not
stable and
splash is
large

Wire feeding

resistance is too

large

Clean or replace the liner and the

torch cable had better in the line

direction.

Earth cable break Connect earth cable

5

Aarc can’t be
pilot

Work piece has

much greasy dirty or

rusty stain

Clean greasy dirty or rusty stain

Torch is not

connected well

Connect the torch again

Gas pipe is pressed

or blocked up

Check gas system

6

No shielded
gas

Gas system rubber

pipe break

Connect gas system and bind

firmly

7 Others Please connect with our company

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30

Main Circuit chart

1 2

1 2

SW1

30A 250VAC

EARTH

AC1

AC2

115V/230VAC

C8

MPX/MKP X2 1 0 5 K 2 7 5 VAC P=22 . 5

YM1

471KD 20

AC1

AC2

C4

D11

M7

R17

PTC MZ32 47R

G

CE

T1

G

CE

T4

6

7

4

5

1

2

ZBYQ1

7:3:3

EARTH

+

1

­2

O

3

G

4

HE1

YNC-200R

3

R9

33R

C2

102 4KV

3

R12

33R

C10

102 4KV

C3

475 400V

C12

R7

51K

R13

51K

R15

51K

R14

51K

R8

51K

R11

51K

TR1

200

：

1

3

5412

J1

JQC3FB-24V

2

1

3 4

D1

STTH6003CW

2

1

3 4

D2

STTH6003CW

2

1

3 4

D6

STTH6003CW

2

1

3 4

D8

STTH6003CW

VCC

SGND

R16

PTC MZ32 47R

G

CE

T3

IKW50N60H3

G

CE

T6

IKW50N 60 H3

R3

5R1

R1

5R1

R18

5R1

R20

5R1

G1 E1

G2 E2

-

NTC1

5K

D3

1N5819

D4

1N5819

D9

1N5819

D71N5819

C5

2200uF 200V

C6

C13

NTC2

5K

AC1AC

2

+

3

-

4

Z2

S35VB 100

C14

475 400V

1

2

CN2

2PIN/2.54

12

3

FAN

FAN1

+24V

PM H200.10.12P23

IGP+SUP-0 1

PM H200.10.12P23

DIS

PMH 200.10.12P23

MAIN

G1 E1 G2 E2

3

R22

33R

C18

471 2KV

3

R23

33R

C19

471 2KV

2

2

C1 10 2 4 KV Y2

C11 1 0 2 4 KV Y2

EARTH

+

-

R10

2K 3W

C15

102 4KV Y2

1
2
3
4
5
6
7
8

1CN6

8PIN/2.54

1

2

3

4

5

6

7

8

2CN4

8PIN/2.54

C20

2200uF 200V

C21C22

475 400V

V-

V+

GND

IFB

-15V

+15V

GND

IFB

-15V

+15V

1

2

3

1CN4

1

2

1CN3

QF

QF1

SW4

M

-

+

M1

B2

V+

V-

1
2
3
4

2CN7

1

2

2CN6

1
2

2CN4

1
2
3
4

2CN5

V+

V-

3

541 2

J2

JQC3FB-24V

AC1AC

2

+

3

-

4

Z1

S35VB 100

D12

M7

G

CE

T2

R2

5R1

D5

1N5819

G

CE

T5

R19

5R1

D10

1N5819

123

1CN8

123

3CN3

+24V

R25

51K

R26

51K

R27

51K

R28

51K

SGND

VCC

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31

Spare Part List

Repair Parts List

Serial number Code Definition Quantity

1 2.05.08.115 Holder 1
2 2.05.17.012 Hinge 2
3 1.1.01.01.0890 Case 1
4 1.1.01.05.3233 Riser 1
5 1.2.02.01.6569 Backboard 1
6 2.03.05.275 Power line 1
7 2.04.30.102 Fixed head of cable 1
8 2.07.55.021 Gas valve 1

9 2.07.80.001 Power switch 1
10 2.07.89.057 Fan 1
11 2.02.02.044 Qas connector 1
12 1.1.05.02.0819 Mainboard 1
13 1.1.02.01.0226 Fixed plate of mainboard 1
14 2.05.05.999 Machine leg 4
15 1.1.05.07.0269 Control panel 1

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32

16 1.1.01.04.1537 Baseboard 1

17 2.05.05.519 Front plastic board 1

18 2.07.57.960 Rapid socket 2

19 2.07.54.019 Aerial socket 1

20 1.2.07.02.3975 Umpolung cable 1

21 2.07.11.021 Potentiometer knob 2

22 1.1.05.07.0268 Panel support plate 1

23 1.1.05.07.0268 LCD control panel 1

24 1.1.02.01.9637 Fixed plate of wire feeder 1

25 1.1.02.01.9636 Subplate of wire feeder 1

26 2.20.02.261 Central socket 1

27 2.07.40.775 Wire feeder 1

28 1.2.01.01.5139 Scroll roller 1

29 1.1.02.01.9635 Duplicate 1

30 2.08.07.001 Bolt 1

Service， Maintenance, Transportation and Storage

The welder needs regular maintenance as following: Periodically clean dust, dirt,

grease, etc. from your welder. Every six months, or as necessary, remove the

cover panel from the welder and air-blow any dust and dirt that may have

accumulated inside the welder. Replace power cord, ground cable, ground clamp,

or electrode assembly when damaged or worn.

MINOR AND ROUTINE MAINTENANCE Store in a clean dry

Store in a clean dry

facility free from corrosive gas, excess dust and high humidity. Temperature

range from 10F°~120°F and the relative humidity not more than 90%.

When transporting or storing the welder after use, it is recommended to repack

the product as it was received for.

protection. (Cleaning is required before storage and you must seal the plastic bag

in the box for storage.