Process: MIG (GMAW)
Flux cored (FCAW)
Arc Welding Power Source and Wire Feeder
MIGSONIC145
SERVICE MANUAL
www.weldking.com
Table of Contents
SECTION 1 SAFETY PRECAUTIONS ................................................................................. 1
SECTION 1 CONSIGNES DE SÉCURITÉ ............................................................................. 1
1-1. Symbol Usage ...................................................................................................... 1
Symboles utilisés .................................................................................................................. 1
1-2. Arc welding Hazards .......................................................................................... 1
Dangers relatifs au soudage à l’arc .................................................................................. 1
1-3. Safety Standards Normes de sécurité .................................................... 6
1-4. EMF Information EMF Information .......................................................... 6
SECTION 2 INSTALLATIONS ............................................................................................... 7
2-1. Welding power source specifications ........................................................... 7
2-2. Connection diagram ........................................................................................... 8
2-3. installing welding torch ................................................................................... 10
2-4. Ground cable installation ............................................................................... 11
2-5. Process/Polarity Table .................................................................................... 11
2-6. Install procedure ............................................................................................... 11
2-7. Electric service guide ...................................................................................... 12
2-8. Extension Cable Selection Chart .................................................................. 13
SECTION 3 OPERATION ....................................................................................................... 14
3-1 Front panel Layout ........................................................................................... 14
3-2 Operation ............................................................................................................ 15
3-3 Voltage/W ire speed selection c hart ............................................................. 16
SECTION 4 THEORY OF OPERATION ............................................................................... 17
SECTION 5 TROUBLE SHOOTING...................................................................................... 19
5-1 Trouble shooting check list ........................................................................... 19
5-2 Circuit board testing information ................................................................. 24
SECTION 6 MAINTENANCE ................................................................................................. 29
6.1. Maintenance ....................................................................................................... 29
6.2.
SECTION 7 ELECTRICAL DIAGRAMS ............................................................................. 31
SECTION 8 PARTS LIST ...................................................................................................... 33
SECTION 8 WARRANTY POLICY ...................................................................................... 41
SECTION 9 AUTHORIZED SERVICE CENTER ............................................................... 42
Safety precaution .............................................................................................. 30
SECTION 1 SAFETY PRECAUTIONS
SECTION 1 CONSIGNES DE SÉCURITÉ
1-1. Symbol Usage
Symboles utilisés
Means Warning! Watch Out! There are
possible hazards with this procedure!
The possible hazards are shown in the
adjoining symbols.
Symbole graphique
d’avertissement ! Attention ! Cette
procedure comporte des risques
possibles ! Les dangers éventuels
sont représentés par les symboles
graphiques joints.
Marks a special safety message.
Indique un message de sécurité particulier
Means “Note”; not safety related.
Signifie NOTE ; n’est pas relatif à la
sécurité.
1-2. Arc welding Hazards
Dangers relatifs au soudage à l’arc
The symbols shown below are used
throughout this manual to call attention
to and identify possible hazards. When
you see the symbol, watch out, and
follow the related instructions to avoid
the hazard.
Only qualified persons should service,
test, maintain, and re- pair this unit.
During servicing, keep everybody,
especially children, away
Les symboles représentés ci-dessous
sont utilisés dans ce man uelpour attirer
l’attention et identifier les dangers
possibles. Enprésence de l’un de ces
symboles, prendre garde et suivre
lesinstructions afférentes pour éviter
tout risque. Les instructions enmatière
de sécurité indiquées ci-dessous ne
constituent qu’un sommaire des
instructions de sécurit é plus complètes
fournies dans les normes de sécurité
énumérées dans la Section 2-5. Lire et
observer toutes les normes de sécurité.
Seul un personnel qualifié est autorisé à
installer, faire fonctionner, entretenir et
réparer cet appareil.
Pendant le fonctionnement , maintenir à
distance toutes les personnes,
notamment les enfants de l’appareil.
This group of symbols means Warning!
Watch Out possible ELECTRIC SHOCK,
MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions
below for necessary actions to avoid the
hazards
Ce groupe de symboles signifie
Avertissement! Attention! Risques
d’ÉLECTROCUTION, ORGANES MOBILES
et PARTIES CHAUDES. Consulter les
symboles et les instructions afferents
ci-dessous concernant les mesures à
prendre pour supprimer les dangers.
ELECTRIC SHOCK can
kill.
UNE DÉCHARGE
ÉLECTRIQUE entraîner
la mort.
y Do not touch live electrical parts.
y Wear dry, hole-free insulating gloves and
body protection.
y Insulate yourself from work and ground
using dry insulating mats or covers big
enough to prevent any physical contact with
the work or ground.
y Do not use AC output in damp areas, if
movement is confined, or if there is a
danger of falling.
y Use AC output ONLY if required for the
welding process.
y If AC output is required, use remote output
control if present on unit.
y Additional safety precautions are required
when any of the following electrically
hazardous conditions are present: in damp
locations or while wearing wet clothing; on
metal structures such as floors, gratings, or
scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there
is a high risk of unavoidable or accidental
contact with the workpiece or ground. For
these conditions, use the following
equipment in order presented: 1) a
semiautomatic DC constant voltage (wire)
welder, 2) a DC manual (stick) welder, or 3)
an AC welder with reduced open-circuit
Page 1
voltage. In most situations, use of a DC,
constant voltage wire welder is
recommended. And, do not work alone!
y Disconnect input power or stop engine
before installing or servicing this equipment.
Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety
Standards).
y Properly install and ground this equipment
according to its Owner’s Manual and
national, state, and local codes.
y Always verify the supply ground − check
and be sure that input power cord ground
wire is properly connected to ground
terminal in disconnect box or that cord plug
is connected to a properly grounded
receptacle outlet.
y When making input connections, attach
proper grounding conductor first −
double-check connections.
y Frequently inspect input power cord for
damage or bare wiring − replace cord
immediately if damaged − bare wiring can
kill.
y Turn off all equipment when not in use.
y Do not use worn, damaged, undersized, or
poorly spliced cables.
y Do not drape cables over your body.
y If earth grounding of the workpiece is
required, ground it directly with a separate
cable.
y Do not touch electrode if you are in contact
with the work, ground, or another electrode
from a different machine.
y Do not touch electrode holders connected
to two welding machines at the same time
since double open-circuit voltage will be
present.
y Use only well-maintained equipment.
Repair or replace damaged parts at once.
Maintain unit according to manual.
y Wear a safety harness if working above
floor level.
y Keep all panels and covers securely in
place.
y Clamp work cable with good metal-to-metal
contact to workpiece or worktable as near
the weld as practical.
y Insulate work clamp when not connected to
workpiece to prevent contact with any metal
object.
y Do not connect more than one electrode or
work cable to any single weld output
terminal.
SIGNIFICANT DC VOLTAGE exists
after removal of input power on
inverters.
y Turn Off inverter, disconnect input power,
y Ne pas toucher aux pièces électriques sous
y Porter des gants isolants et des vêtements
y S’isoler de la pièce à couper et du sol en
and discharge input capacitors according to
instructions in Maintenance Section before
touching any parts.
tension.
de protection secs et sans trous.
utilisant des housses ou des tapis assez
grands afin d’éviter tout contact physique
avec la pièce à couper ou le sol.
y Ne pas se servir de source électrique à
courant électrique dans les zones humides,
dans les endroits confinés ou là où on
risque de tomber.
y Se servir d’une source électrique à courant
électrique UNIQUEMENT si le procédé de
soudage le demande.
y Si l’utilisation d’une source électrique à
courant électrique s’avère nécessaire, se
servir de la fonction de télécommande si
l’appareil en est équipé.
y D’autres consignes de sécurité sont
nécessaires dans les conditions suivantes :
risques électriques dans un environnement
humide ou si l’on porte des vêtements
mouillés ; sur des structures métalliques
telles que sols, grilles ou échafaudages ; en
position coincée comme assise, à genoux
ou couchée ; ou s’il y a un risque élevé de
contact inévitable ou accidentel avec la
pièce à souder ou le sol. Dans ces
conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder
DC à tension constante (à fil), 2) un poste à
souder DC manuel (électrode) ou 3) un
poste à souder AC à tension à vide réduite.
Dans la plupart des situations, l’utilisation
d’un poste à souder DC à fil à tension
constante est recommandée. En outre, ne
pas travailler seul !
y Couper l’alimentation ou arrêter le moteur
avant de procéder à l’installation, à la
réparation ou à l’entretien de l’appareil.
Déverrouiller l’alimentation selon la norme
OSHA 29 CFR 1910.147 (voir normes de
sécurité).
y Installer le poste correctement et le mettre
à la terre convenablement selon les
consignes du manuel de l’opérateur et les
normes nationales, provinciales et locales.
y Toujours vérifier la terre du cordon
d’alimentation. Vérifier et s’assurer que le fil
de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur
ou que la fiche du cordon est raccordée à
une prise correctement mise à la terre.
y En effectuant les raccordements d’entrée,
fixer d’abord le conducteur de mise à la
terre approprié et contre-vérifier les
connexions.
y Vérifier fréquemment le cordon
d’alimentation afin de s’assurer qu’il n’est
pas altéré ou à nu, le remplacer
immédiatement s’il l’est. Un fil à nu peut
entraîner la mort.
y L’équipement doit être hors tension lorsqu’il
n’est pas utilisé.
y Ne pas utiliser des câbles usés,
endommagés, de grosseur insuffisante ou
mal épissés.
y Ne pas enrouler les câbles autour du corps.
y Si la pièce soudée doit être mise à la terre,
le faire directement avec un câble distinct.
y Ne pas toucher l’électrode quand on est en
contact avec la pièce, la terre ou une
électrode provenant d’une autre machine.
y Ne pas toucher des porte électrodes
connectés à deux machines en même
Page 2
temps à cause de la présence d’une
tension à vide doublée.
y N’utiliser qu’un matériel en bon état.
Réparer ou remplacer sur-lechamp les
pièces endommagées. Entretenir l’appareil
conformément à ce manuel.
y Porter un harnais de sécurité si l’on doit
travailler au-dessus du sol.
y S’assurer que tous les panneaux et
couvercles sont correctement en place.
y Fixer le câble de retour de façon à obtenir
un bon contact métal-métal avec la pièce à
souder ou la table de travail, le plus près
possible de la soudure.
y Isoler la pince de masse quand pas mis à la
pièce pour éviter le contact avec tout objet
métallique.
y Ne pas raccorder plus d’une électrode ou
plus d’un câble de masse à une même
borne de sortie de soudage.
Il reste une TENSION DC NON
NÉGLIGEABLE dans les sources de
soudage onduleur quand on a coupe
l’alimentation.
y Arrêter les convertisseurs, débrancher le
courant électrique et décharger les
condensateurs d’alimentation selon les
instructions indiquées dans la partie
Entretien avant de toucher les pièces.
STATIC (ESD) can
damage PC boards.
LES CHARGES
ÉLECTROSTATIQUES
peuvent endommager
les circuits imprimés.
y Put on grounded wrist strap BEFORE
handling boards or parts.
y Use proper static-proof bags and boxes to
store, move, or ship PC boards.
y Établir la connexion avec la arrette de terre
avant de manipuler des cartes ou des
pièces.
y Utiliser des pochettes et des boîtes
antistatiques pour stocker, déplacer ou
expédier des cartes PC.
FIRE OR EXPLOSION
hazard.
Risque D’INCENDIE OU
D’EXPLOSION.
y Do not place unit on, over, or near
combustible surfaces.
y Do not service unit near flammables
y Do not overload building wiring − be sure
power supply system is properly sized,
rated, and protected to handle this unit.
y Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
y Ne pas installer l’appareil à proximité de
produits inflammables.
y Ne pas surcharger l’installation électrique −
s’assurer que l’alimentation est
correctement dimensionnée et protégée
avant de mettre l’appareil en service.
FLYING METAL can
injure eyes.
DES PARTICULES
VOLANTES peuvent
blesser les yeux.
y Wear safety glasses with side shields or
face shield during servicing.
y Be careful not to short metal tools, parts, or
wires together during testing and servicing.
y Le soudage, l’écaillement, le passage de la
pièce à la brosse en fil de fer, et le meulage
génèrent des étincelles et des particules
métalliques volantes. Pendant la période
de refroidissement des soudures, elles
risquent de projeter du laitier.
y Porter des lunettes de sécurité avec écrans
latéraux ou un écran facial.
HOT PARTS can cause
severe burns.
DES PIÈCES CHAUDES
peuvent provoquer des
brûlures graves.
y Do not touches hot parts bare handed.
y Allow cooling period before working on
welding gun or torch
y Ne pas toucher des parties chaudes à
mains nues.
y Prévoir une période de refroidissement
avant d’utiliser le pistolet ou la torche.
MAGNETIC FIELDS can
affect pacemakers.
LES CHAMPS
MAGNÉTIQUES
peuvent affecter les
stimulateurs
cardiaques.
Pacemaker wearers keep away.
Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
Porteurs de stimulateur cardiaque, rester à
distance.
Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de
s’approcher des opérations de soudage à l’arc,
de gougeage ou de soudage par points.
CYLINDERS can explode
Page 3
if damaged.
LES BOUTEILLES
peuvent exploser si elles
sont endommagées.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode.
Since gas cylinders are normally part of the
welding process, be sure to treat them carefully.
y Protect compressed gas cylinders from
excessive heat, mechanical shocks, physical
damage, slag, open flames, sparks, and arcs.
y Install cylinders in an upright position by
securing to a stationary support or cylinder
rack to prevent falling or tipping.
y Keep cylinders away from any welding or
other electrical circuits.
y Never drape a welding torch over a gas
cylinder.
y Never allow a welding electrode to touch any
cylinder.
y Never weld on a pressurized cylinder −
explosion will result.
y Use only correct shielding gas cylinders,
regulators, hoses, and fittings designed for the
specific application; maintain them and
associated parts in good condition.
y Turn face away from valve outlet when
opening cylinder valve.
y Keep protective cap in place over valve except
when cylinder is in use or connected for use.
y Use the right equipment, correct procedures,
and sufficient number of persons to lift and
move cylinders.
y Read and follow instructions on compressed
gas cylinders, associated equipment, and
Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
Des bouteilles de gaz protecteur contiennent du
gaz sous haute pression. Si une bouteille est
endommagée, elle peut exploser. Du fait que les
bouteilles de gaz font normalement artie du
procédé de soudage, les manipuler avec
précaution.
y Protéger les bouteilles de gaz comprimé d’une
chaleur excessive, des chocs mécaniques,
des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
y Placer les bouteilles debout en les fixant dans
un support stationnaire ou dans un
porte-bouteilles pour les empêcher de tomber
ou de se renverser.
y Tenir les bouteilles éloignées des circuits de
soudage ou autres circuits électriques.
y Ne jamais placer une torche de soudage sur
une bouteille à gaz.
y Une électrode de soudage ne doit jamais
entrer en contact avec une bouteille.
y Ne jamais souder une bouteille pressurisée −
risque d’explosion.
y Utiliser seulement des bouteilles de gaz
protecteur, régulateurs, tuyaux et raccords
convenables pour cette application spécifique ;
les maintenir ainsi que les éléments associés
en bon état.
y Détourner votre visage du
détendeur-régulateur lorsque vous ouvrez la
soupape de la bouteille.
y Le couvercle du détendeur doit toujours être
en place, sauf lorsque la bouteille est utilisée
ou qu’elle est reliée pour usage ultérieur.
y Utiliser les équipements corrects, les bonnes
procédures et suffisamment de personnes
pour soulever et déplacer les bouteilles.
y Lire et suivre les instructions sur les bouteilles
de gaz comprimé, l’équipement connexe et le
dépliant P-1 de la CGA (Compressed Gas
Association) mentionné dans les principales
normes de sécurité.
FALLING UNIT can
cause injury.
LA CHUTE DE
L’APPAREIL peut
blesser.
y Use lifting eye to lift unit
only, NOT running gear, gas cylinders, or
any other accessories.
y Use equipment of adequate
capacity to lift and support unit.
y If using lift forks to move unit, be sure forks
are long enough to extend beyond opposite
side of unit
y Utiliser l’anneau de levage uniquement
pour soulever l’appareil, NON PAS les
chariots, les bouteilles de gaz ou tout autre
accessoire.
y Utiliser un équipement de levage de
capacité suffisante pour lever l’appareil.
y En utilisant des fourches de levage pour
déplacer l’unité, s’assurer que les fourches
sont suffisamment longues pour dépasser
du côté opposé de l’appareil.
MOVING PARTS can
cause injury.
DES ORGANES
MOBILES peuvent
provoquer des
blessures.
y Keep away from moving parts such as fans.
y Keep all doors, panels, covers, and guards
closed and securely in place.
y Have only qualified persons remove doors,
panels, covers, or guards for maintenance
as necessary.
y Reinstall doors, panels, covers, or guards
when maintenance is finished and before
reconnecting input power.
y S’abstenir de toucher des organes mobiles
tells que des ventilateurs.
y Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de
protection.
y Seules des personnes qualifiées sont
autorisées à enlever les portes, panneaux,
recouvrements ou dispositifs de protection
pour l’entretien.
y Remettre les portes, panneaux,
recouvrements ou dispositifs de protection
quand l’entretien est terminé et avant de
rebrancher l’alimentation électrique.
Page 4
MOVING PARTS can
cause injury.
DES ORGANES
MOBILES peuvent
provoquer des
blessures.
y Keep away from moving parts
y Keep away from pinch points such as drive
rolls
y Ne pas s’approcher des organes mobiles.
y Ne pas s’approcher des points de
coincement tels que des rouleaux de
commande.
OVERUSE can cause
OVERHEATING.
L’EMPLOI EXCESSIF
peut SURCHAUFFER
L’ÉQUIPEMENT.
Allow cooling period; follow rated duty
cycle.
Reduce current or reduce duty cycle before
starting to weld again.
Do not block or filter airflow to unit
Prévoir une période
de refroidissement ; respecter le cycle
opératoire nominal.
Réduire le courant ou
le facteur de marche avant de poursuivre le
soudage.
Ne pas obstruer les
passages d’air du poste.
H.F. RADIATION can
cause interference.
LE SOUDAGE À L’ARC
risque de provoquer
des interférences.
y High-frequency (H.F.) can interfere with
radio navigation, safety services,
computers, and communications
equipment.
y Have only qualified persons familiar with
electronic equipment perform this
installation.
y The user is responsible for having a
qualified electrician promptly correct any
interference problem resulting from the
installation.
y If notified by the FCC about interference,
stop using the equipment at once.
y Have the installation regularly checked
and maintained.
y Keep high-frequency source doors and
panels tightly shut, keep spark gaps at
correct setting, and use grounding and
shielding to minimize the possibility of
interference.
y Le rayonnement haute fréquence (HF)
peut provoquer des interférences avec les
équipements de radio-navigation et de
communication, les services de sécurité
et les ordinateurs.
y Demander seulement à des personnes
qualifiées familiarisées avec des
équipements électroniques de faire
fonctionner l’installation.
y L’utilisateur est tenu de faire corriger
rapidement par un electrician qualifié les
interférences résultant de l’installation.
y Si le FCC signale des interférences,
arrêter immédiatement l’appareil.
y Effectuer régulièrement le contrôle et
l’entretien de l’installation.
y Maintenir soigneusement fermés les
portes et les panneaux des sources de
haute fréquence, maintenir les éclateurs à
une distance correcte et utiliser une terre
et un blindage pour réduire les
interférences éventuelles.
READ INSTRUCTIONS.
LIRE LES
INSTRUCTIONS.
Consult the Owner’s
Manual for welding safety
precautions.
Use only genuine replacement parts
Lire le manuel d’utilisation avant d’utiliser
ou d’intervenir sur l’appareil.
Utiliser uniquement des pièces de
rechange.
Page 5
1-3. Safety Standards
Normes de sécurité
Safety in Welding, Cutting, and Allied Processes,
ANSI Standard Z49.1, from Global Engineering
Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safety in Welding, Cutting, and Allied Processes,
ANSI Standard Z49.1, de Global Engineering
Documents (téléphone : 1-877-413-5184, site
Internet : www.global.ihs.com).
1-4. EMF Information
EMF Information
Considerations About Welding And The Effects
Of Low Frequency Electric And Magnetic Fields
Code for Safety in Welding and Cutting, CSA
Standard W117.2, from Canadian Standards
Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3
(phone: 800−463−6727 or in Toronto
416−747−4044, website:
www.csa−international.org).
Code for Safety in Welding and Cutting, CSA
Standard W117.2, de Canadian Standards
Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3
(téléphone : 800-463-6727 ou à Toronto
416-747-4044, site Internet :
www.csa-international.org).
1. Keep cables close together by twisting or
taping them.
Welding current, as it flows through welding
cables, will cause electro- magnetic fields. There
has been and still is some concern about such
fields. However, after examining more than 500
studies spanning 17 years of research, a special
blue ribbon committee of the National Research
Council concluded that: “The body of evidence, in
the committee’s judgment, has not demonstrated
that exposure to power- frequency electric and
magnetic fields is a human-health hazard.”
However, studies are still going forth and
evidence continues to be examined. Until the
final conclusions of the research are reached,
you may wish to minimize your exposure to
electromagnetic fields when welding or cutting.
To reduce magnetic fields in the workplace, use
the following procedures:
Considérations sur le soudage et les effets de
basse fréquence et des champs magnétiques et
électriques.
Le courant de soudage, pendant son passage dans
les câbles de soudage, causera des champs
électromagnétiques. Il y a eu et il y a encore un
certain souci à propos de tels champs. Cependant,
après avoir examine plus de 500 études qui ont été
faites pendant une période de recherché de 17 ans,
un comité spécial ruban bleu du National Research
Council a conclu : « L’accumulation de preuves,
suivant le jugement du comité, n’a pas démontré
que l’exposition aux champs magnétiques et
champs électriques à haute fréquence représente
un risque à la santé humaine ». Toutefois, des
études sont toujours en cours et les preuves
continuent à être examinées. En attendant que les
conclusions finales de la recherché soient établies,
il vous serait souhaitable de réduire votre
exposition aux champs électromagnétiques
pendant le soudage ou le coupage.
Pour réduire les champs magnétiques sur le poste
de travail, appliquer les procédures suivantes :
2. Arrange cables to one side and away from the
operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far
away from operator as practical.
5. Connect work clamp to work piece as close to
the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If
cleared by your doctor, then following the above
procedures is recommended
1. Maintenir les câbles ensemble en les tordant ou
en les enveloppant.
2. Disposer les câbles d’un côté et à distance de
l’opérateur.
3. Ne pas courber pas et ne pas entourer pas les
câbles autour de votre corps.
4. Garder le poste de soudage et les câbles le plus
loin possible de vous.
5. Connecter la pince sur la pièce aussi près que
possible de la soudure.
En ce qui concer ne les sti mulateurs
cardiaques
Les porteurs de stimulateur cardiaque doivent
consulter leur médecin avant de souder ou
d’approcher des opérations de soudage. Si le
médecin approuve, il est recommandé de suivre les
procédures précédentes
Page 6
SECTION 2 INSTALLATIONS
2-1. Welding power source specifications
Type
Power supply
Phase
Input current @ Maximum output
Rated input (Kva)
Open circu it voltage(v)
Amperage range(A)
Welding voltage(V)
Rated Duty cycle (%)
Rated welding current(A)
Wire feed speed(IPM)
Dimension(HxWxD)(CM)
Weight(KG)
Wire Diameter(MM)
MIGSONIC145
115V/60Hz 230V/60Hz
1
20 21
2.3 4.8
44 44
40-110 40-180
16-18.5 16-21.3
60 60
90 145
40-310 (0.8-9.5 m/min)
52 x25.5 x51
20
Steel /Stainless Steel
Solid: 0.6-0.9mm (0.023-0.035in)
Flux cored: 0.8-1.2mm (0.030-0.045in)
Operating temperature
Storage temperature
Table 2.1
-4°F to 104°F(-20 to +40°C)
-40°F to 185°F (-40°C to +40°C)
CAUTION
WELDING LONGER THAN RATED DUTY CYCLE CAN DAMAGE GUN AND VOID
WARRANTY.
Page 7
r
2-2. Connection diagram
MIGSONIC145 (115v input)
Gauge
Cylinder
Power
d
Co
To 115 volt, 20 ampere
individual branch circuit
To rc h
Figure 2.1
Page 8
MigSonic145(208/230V input)
Gauge
Cylinder
Power
Cord
Figure 2.2
To rc h
Page 9
2-3. installing welding torch
Correct Incorrect
Figure 2.3
1. Gun Securing Knob
2. Gun End: Loose knob. Insert gun end through opening until it bottoms against
drive assembly. Tighten knob.
3. Gun Trigger connector: Insert into receptacle, and tighten. Close door.
Page 10
2-4. Ground cable installation
Figure 2.4
1. Ground cable
2. Output Terminal Block
3. Insert ground cable through opening in front panel and route along back of front
panel to output terminal block. Close door.
2-5. Process/Polarity Table
Process Polarity
GMAW－Solid wire
with shielding gas
FCAW – Self-shielding
wire- no shielding gas
DCEP – Reverse
polarity
DCEN－Straight
Polarity
Cable To Gun Cable To Work
Connect to positive(+) output
terminal
Connect to negative(-) output
terminal
Table 2.2
Cable Connections
Connect to negative(-)output
terminal
Connect to positive(+)output
terminal
2-6. Install procedure
2-6.1. Welding machine should be installed in a stable position and with good
ventilation. Avoid direct sun outdoors. Use forklift to move, avoid transport in
invert or side position.
2-6.2. Be sure machine is well grounded. Connect the bolt marked “earth ” with earth
in network, then connect to network firmly
2-6.3. Before starting a new machine or the machine idled for a period, check the
insulation resistance of circuit which is connected to the network. The
resistance must be higher than 2.5M Ω; otherwise the machine must be dried.
2-6.4. Connect torch, earth cable, wire, regulator, cylinder according to connection
diagram. Note: Connection hardware must be tightened with proper tools.
Do not just hands tighten hardware! A loose electrical connection will
cause poor weld performance and excessive heating at the terminal
Page 11
block.
2-6.5. Use Ф8 heat-resistant PVC hose connect the flow meter with the gas
connection nipple at rear of the machine.
2-6.6. Install wire spool.
4 in (100mm) wire spool:
Figure 2.5
8 in (200mm) wire spool:
Figure 2.6
Commission the machine after the machine is installed and tested:
Release the pressure roller in the wire feeder, push the torch switch, and adjust
voltage switch from low to high, Open circuit voltage should rise.
Evenly adjust the current knob, the wire feed speed should increase evenly.
2-7. Electric service guide
CAUTION
WARNING: THIS WELDING MACHINE MUST BE CONNECTED TO POWER
SOURCE IN ACCORDANCE WITH APPLICABLE ELECTRICAL CODES
AVERTISSEMENT: LE RACCORDEMENT DE CETTE MACHINE DE SOUDAGE Á
L’ALIMENTATION DOIT ÉTRE CONFORME AUX CODES D’ ÉLECTRICITÉ
PERTINENTS
Use 115 volt single phase input, 20 ampere individual branch circuit protected by
time-delay fuses or circuit breaker is required.
Extension cord: 14 AWG
Extension length: 8m with 14AWG, 12 AWG for up to 10 m.
Page 12
MigSonic145
Input voltage(V)
Frequency(Hz)
Input Amperes at rated output(A)
Max recommended standard fuse Rating in Amperes
Circuit breaker, time delay
Normal operation
Min input conductor size in AWG
Min Grounding conductor Size in AWG
Table 2.3
2-8. Extension Cable Selection Chart
CAUTION
USE SHORTEST CABLE POSSIBLE
230
60
24
25
35
14
14
Input Conductor Size in
AWG (mm
2
)
115V 230V
14(2.08) 23(7) 56(17)
12(3.31) 29(9) 90(27)
10(5.26) 43(13) 131(40)
8(8.36) 72(22) 160(50)
6(13.29) 105(32) 243(74)
Maximum Cord Length allowed in Ft(M)
Table 2.2
Page 13
SECTION 3 OPERATION
3-1 Front panel Layout
8
2
3 1
7
5
4
6
1. Power indicator
2. welding current adjust knob
3. Over-heat protection indicator
4. Torch terminal
Figure 3.1
5. Control receptacle
6. Earth clamp
7. Main switch
8. Voltage adjust knob
Page 14
3-2 Operation
3-2.1 Check the connection of work piece, earth cable, welding torch, wire feeder,
gas cylinder, regulator and hose, make sure they are firm and reliable.
3-2.2 Install the wire spool to the wire spool spin, select correct feeding roller and tip
according to the wire diameter. Manually put wire into liner. Set back the
pressure roller with proper pressure.
3-2.3 Switch on the power source. Set the welding voltage switch to proper position
and current knob to a start value and refine during welding( referring to the
voltage/wire feeding speed selection chart)
3-2.4 Turn on the gas valve, adjust gas volume to 3-5L/MIN. Push the torch switch
check if wire feed and gas is normal, check if there is gas leaking.
3-2.5 Hold the torch and keep nozzle 8-12mm above the work piece, and tilt 10-20 ˚
to vertical direction. Aim wire to the welding seam.
3-2.6 Push torch switch, after arc is ignited, move the torch along seam evenly while
keeping the stick-out. Fine tune the welding parameter to obtain exquisite
welding seam. Release the torch switch to finish a welding cycle.
3-2.7 Adjust the crater fill knob located above the polarity stud inside the machine
(see Figure 3.2) if there is a crater left at the end of the welding seam. This
knob Adjust current decline time (in second) after the gun switch is released.
Crater
Adjust(S)
3-2.8 After finish operation, turn off the gas valve, loose the pressure handle at wire
feeder, push torch switch to clear the residual gas in the regulator. At the end,
turn off welding power source and wall switch.
Figure 3.2
Page 15
3-3 Voltage/Wire speed selection chart
Wire feed speed 200/19 ∅ Voltage “V”
- : setting not recommended
The setting in the following chart is just for start only and can be fine tune during welding.
MIGSONIC145
Material
Wire type
Solid ER70S-6(DCEP) Flux core E71T-1(DCEN) ER308,ER308L,ER 308LSi(DCEP)
Steel Stainless steel
Wire size (in)
(mm)
3/16” (4.8mm)
1/8” (3.2mm)
14ga. (2.0mm)
16ga. (1.6mm)
18ga. (1.2mm)
20ga. (0.9mm)
22ga. (0.8mm)
24ga. (0.6mm)
0.023”
0.6
- - - 250/19.5 - -
310/21 280/19.5 280/19.5 250/19.5 320/21.5 300/21
200/18.5 160/18.5 120/18.5 100/18.5 230/21 210/20
120/17.5 100/17.5 80/17.5 70/17.5 120/19 110/18
80/17.5 70/17 50/17.5 45/17 100/17.5 90/16.5
60/16 50/15.5 - - 80/16.5 80/16
50/15 40/14 - - - -
40/13 35/13 - - - -
0.035”
0.9
Table 3.1
0.030”
0.8
0.035”
0.9mm
0.023”
0.6
0.035”
0.9
Page 16
SECTION 4 THEORY OF OPERATION
115V/230V
power input
2
Power switch
18
17
16
fuse
19
Fan Motor
Voltage
potentiometer
Torch trigger
Rectifier PCB
MIG145C-ZL
CONTROL PCB MIG200-KZ-A
15 14
Solenoid valve
CapacitorPCB
MIG145C-DR
Wire speed
potentiometer
Inverter PCB
MIG145C-NB
13 12
Power light
Main
transformer
Protection
light
1
76543
Secondary
rectifier
10
Polarity -
11
Feed motor
Reactor
+
8
Mig torch
Work
Piece
9
Ignition
resistance
Figure 4.1
Control circuit
Welding current
Page 17
(1) Control PCB (MIG200-KZ-A): Supply drive and control voltage to Inverter Model.
Supply control signal to capacitor PCB indicate input voltage(110V or 230V).
Control fan motor, Torch trigger, Solenoid valve, power light and protection light.
Take signal from Voltage control and Wire speed control potential meter. Controls
wire feed speed by changing pulse width modulation signal, there by providing
more or less voltage to the feed motor.
(2) Power switch: control unit and fan motor on/off.
(3) Rectifier PCB (MIG145C-ZL): Primary rectifier converts AC input into DC.
(4) Capacitor PCB (MIG145C-ZL): Smooth current from Rectifier PCB and output to
Inverter Module.
(5) Inverter PCB ( MIG145C-NB): Convert DC current to high frequency(20khz) AC
current, output to main transformer. High frequency current can greatly reduce the
size and weight of the transformer and increase the machine efficiency.
(6) Main transformer: transform to welding voltage.
(7) Secondary rectifier: turn high frequency ac current from Inverter module into DC.
(8) Reactor: further smooth welding current.
(9) Ignition resistance:
(10) Polarity Changeover Block
(11) Feed motor: feed wire with the speed set by wire speed potential meter. Active by
gun trigger.
(12) Protection light: this light will turn on when machine is over heat and automatically
shut off.
(13) Power light: will turn on/off when machine is turned on/off.
(14) Wire speed potentiometer: located in the front panel, adjust the wire feed motor
speed by providing a reference voltage to Control PCB MIG200-KZ-A
(15) Solenoid valve: Controls shielding gas flow. Pressing gun trigger opens valve.
(16) Gun trigger: Turns unit and fan motor on and off.
(17) Voltage potentiometer: Located in the front panel, adjust the welding voltage by
providing a reference voltage to Control PCB MIG200-KZ-A
(18) Fan motor: Controlled by gun trigger. Fan cools internal components.
Page 18
SECTION 5 TROUBLE SHOOTING
5-1 Trouble shooting check list
No. Problem Cause Solution
1 Power Indication lamp does not on
after switch on the main switch
2 Cooling fan stops to
rotate after machine
has worked a period
Power
indication
lamp on
Loose contact at input lead Check contact
situation
Lamp malfunction, poor
contact
Main switch malfunction Check switch
Cooling fan circuit
malfunction
Cool fan failure Check fan,
Check contact
situation. Replace
lamp
Check fan circuit
replace if
necessary
3 No gas flow out after
pushing the gun
trigger
Power
indication
lamp off
Gas pressure not enough Check gas
Poor gas hose connection Check gas
See No. 1
connection
Gun trigger failure Check gun trigger
Solenoid valve failure Check and
replace Solenoid
pressure
Page 19
valve
Gas passage problem Check and repair
the gas passage
Torch gas hose problem Check and repair
torch cable
Control circuit failure Replace circuit
board
Control transformer failure Replace
transformer
4 Failure of arc to ignite or does not
ignite properly
Fuse melt or poor contact Check and repair
Main power switch failure Check, repair,
replace
Control circuit board failure Check and repair
the circiut board
Welding cable broken or
poor contact
Gun trigger wire broken Replace cable
Gun cable broken Replace cable
Voltage adjustment knob
failure or poor contact
Check the
connection
Check, repair,
replace
Control transformer failure Check, repair,
replace
Page 20
Main transformer failure or
Check, repair,
poor contact
5 Unstable arc Gas hose not installed
properly, gas mixed by air
Gas not pure Changes gas
Wire liner or gun cable
broken and leak cause
insufficient gas volume.
Wire pressure not setup
properly
Wire feed speed not stable See No.9
Control circuit failure Check, repair,
replace
Connect the gas
hose firmly
Check, repair,
replace
Adjust pressure
replace circuit
board
Gas heating failure Check 20A Fuse,
repair, replace
the work piece surface
contaminated by oil
Poor contact inside the gun Check, repair,
6 Arc ignited but the wire does not melt Rectifier tube failure Check, replace
Output reactor failure Check, replace
Clean the
workpiece
surface
replace
Page 21
Output capacitor failure Check, replace
7 Wire does not feed while the feed
roller is rotating
8 Can not stop the gas Solenoid valve
Wire pressure not proper Adjust pressure
Wire liner or contact tip
jammed
Used wrong groove at the
feeding roller
contaminated
Contactor failure Check, replace
Control board failure Check, repair,
Check, repair,
replace
Use the right
groove
Check, repair,
replace solenoid
the contactor
replace
9 Wire feeding not stable Wire out of feeding roller
groove
Wire feed pressure not set
properly
Feeding roller deformed Check and
Pressure roller deformed Check and
Feeding motor failure Check and
Current adjust potential Check and
Put wire back
Adjust pressure
replace
replace
replace
Page 22
meter failure replace
Circuit board plug socket
not properly contacted
Control circuit failure Check and repair
Welding hose deformed Check and
Input voltage fluctuated Use under rated
10 Power supply switch jump Rectifier short circuit Check and
Main transformer short
Check and repair
or replace
or replace
replace
input voltage
replace
Check and
circuit
Control transformer short
circuit
Solenoid valve short circuit Check and
Cooling fan short circuit Check and
11 Overheat light on Work excess the rate duty
circle
Input voltage is too high Use under rate
replace
Check and
replace
replace
replace
Use under rate
duty circle
input voltage
Table 5.1
Page 23
5-2 Circuit board testing information
1 2 3 1 2 3 1 2 3 1 2 3 4 5 1 2 3 4
CN118 CN111 CN112 CN113 CN109
1
CN101
2
3
MIG-200C-KZ-A
1
CN115
2
1
CN105
2
CN116 CN122 CN103 CN106 CN102 CN104 CN114
1 2 1 2 3 1 2 3 1 2 3 1 2 3 4 1 2 3 1 2 3 4
CN110
CN117
CN107
CN108
2
1
2
1
2
1
2
1
Figure 5.1
Page 24
MIG-200C-KZ-A
CONNECTOR PIN VALUE
CN101 1 Circuit common
2 Not used
3 DC +325V, reference to CN101-1
CN102 1 Motor power supply(DC+2V-19V),reference to CN102-3 and CN102-4
2 Motor power supply(DC+2V-19V), reference to CN102-3 and CN102-4
3 Motor power supply(DC-2V-19V),reference to CN102-1 and CN102-2
4 Motor power supply(DC-2V-19V), reference to CN102-1 and CN102-2
CN103 1 Short to CN103-3
2 Not used
3 DC+12, reference to CN116-2
CN104 1 Connect to wire feed speed adjust potential meter
2 Connect to wire feed speed adjust potential meter
3 DC+5V Connect to wire feed speed adjust potential meter, reference
to CN116-2
CN105 1 DC +24V Fan power supply, reference to CN105-2
2 Circuit common
CN106 1 Connect to burn back time adjust potential meter
2 Connect to burn back time adjust potential meter
3 Connect to burn back time adjust potential meter
CN107 1 DC +24V, reference to CN107-2
2 DC +24V with thermostat open. Supply to protection light, reference
to CN107-1
CN108 1 Connect to Thermostat, short to CN108-2 with thermostat closed.
2 Circuit common
CN109 1 DC+5V, reference to CN109-2
2 Circuit common
3 Not used
4 Circuit common
CN110 1 Current divider feed back
2 Circuit common
CN111 1 Connect to voltage adjustment potential meter.
2 Connect to voltage adjustment potential meter.(DC 4-7.5V), reference
to CN118-2
3 Connect to voltage adjustment potential meter.
CN112 1 Not used
2 Not used
3 Not used
CN113 1 Not used
2 Circuit common
Page 25
3 Circuit common
4 Not used
5 Circuit common
CN114 1 Drive signal(DC16.5V when gun trigger closed),reference to CN114-2
2 Drive signal(DC16.5V when gun trigger closed), reference to CN114-1
3 300:1 inductor signal feed back(Voltage signal)
4 300:1 inductor signal feed back(Voltage signal)
CN115 1 Power supply to solenoid valve. When gun trigger closed,
DC+24V,refence to CN115-2
2 When gun trigger closed. Circuit common
CN116 1 Circuit common
2 Not used
CN117 1 DC+24V supply to power light, reference to CN117-2
2 DC -24V supply to power light, reference to CN117-1
CN118 1 DC+24V, reference to CN118-2. power supply to Capacitor PCB
2 Circuit common
3 230V-115V switch signal（DC24V when input 115V, 0V when input
230V）, reference to CN118-2
CN122 1 Connect to hand trigger
2 Not used
3 Connect to hand trigger
Table 5.2
Page 26
1 2 3 4 5 6 7 1 2 3
CN107 CN106
DVI200-DR-A
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
CN105
CN102
CN103
1 2 3
1
2
3
Figure 5.2
MIG175-ZL-A
CN301
CN302
1 2 3
Page 27
DVI200-DR-A
V
V
CONNECTOR PIN
CN102 1 DC-325V, reference to CN102-4,5
2 DC-325V, reference to CN102-4,5
3 Not used
4 DC +325V, reference to CN102-1,2
5 DC +325V, reference to CN102-1,2
6 Not used
7 AC 230V/115V, DC-325V, reference to CN103-7,8,9,10
8 AC230V/115V, DC-325V, reference to CN103-7,8,9,10
9 AC 230V/115V, DC-325V, reference to CN103-7,8,9,10
10 AC230V/115V, DC-325V, reference to CN103-7,8,9,10
CN103 1 DC-325V, reference to CN103-4,5
2 DC-325V, reference to CN103-4,5
3 Not used
4 DC +325V, reference to CN103-1,2
5 DC +325V, reference to CN103-1,2
6 Not used
7 AC 230V/115V, reference to CN102-7,8,9,10
8 AC230V/115V, reference to CN102-7,8,9,10
9 AC 230V/115V, reference to CN102-7,8,9,10
10 AC230V/115V, reference to CN102-7,8,9,10
CN105 1 DC+24V, reference to CN105-2
2 Circuit common
230V-115V switch signal（DC24V when input 115V, 0V when
3
CN106 1 DC -325V, reference to CN106-3.Power supply to control PCB
2 Not used
3 DC +325V, reference to CN106-1, Power supply to control PCB
CN107 1 DC -325V, reference to CN107-5,6,7. Power supply to inv PCB
2 DC -325V, reference to CN107-5,6,7. Power supply to inv PCB
3 DC -325V, reference to CN107-5,6,7. Power supply to inv PCB
4 Not used
5 DC +325V, reference to CN107-1,2,3. Power supply to inv PCB
6 DC +325V, reference to CN107-1,2,3. Power supply to inv PCB
7 DC +325V, reference to CN107-1,2,3. Power supply to inv PCB
input 230V）, reference to CN105-2
ALUE
Table 5.3
MIG175-ZL-A
CONNECTOR PIN
CN301 1 Output current positive feed back signal(0-75MV DC)
2 output current passive feed back signal
3 Not used
CN302 1 Not used
2 Not used
3 Not used
Table 5.4
ALUE
Page 28
SECTION 6 MAINTENANCE
6.1. Maintenance
Periodic maintenance is necessary for keeping the machine work properly.
CAUTION
DISCONNECT POWER INPUT AND SWITCH OFF THE MAIN POWER SWITCH
BEFORE START OF MAINTENANCE.
Regular Check and Inspection 6 Month Routine Maintenance
• Clean spatter inside the nozzle when
continuously use the machine.
• Check liner frequently, change if it has
been contaminated by oil or worn out.
• Check and change broken contact tip
and nozzle to avoid damage to the torch
and machine.
• Check the function of all switches.
• Check if the fan rotates properly and if
there is air venting out from back of the
machine
• Pay Attention to the abnormal vibration,
noise, smell and gas leakage during
operation
• Check if the welding cables are over
heated?
• Check if the cable connections are over
heated?
• Check if the cable is connected firmly
and properly, if it is broken and cause
bad insulation?
• Blow out with dry clean pressure air or
vacuum inside machine, especially
transformer coil and power component.
• Check the electric connection of
input/output bar to avoid bad contact
caused by loose or rusted screw.
• Check the lubrication of the gear box in
the feeder, replace or fill lubricates oil if
necessary.
• Check and clean the oil or other
contamination in the feeding roller and
feeding tube. If the V grooves have worn
out change feeding roller immediately to
avoid slipping or unstable feeding
• Check the cover grounded properly
Table 6.1
Page 29
6.2. Safety precaution
5.2.1. Welders must be equipped with welding mask, gloves and tie the sleeves
and collar properly. There should be an arc shield around welding field to
protect others from arc shock.
5.2.2. Do not weld near flammable, explosive materials or gases.
5.2.3. Gas cylinder must be located at a safe and steady place to avoid injury
others.
5.2.4. Keep finger, hair and clothing away from the rotating fan.
5.2.5. The power source must be grounded when welding.
5.2.6. Welding machine should not work in a flammable and toxic environment,
avoid moisture, rain, and do not directly expose to sun.
5.2.7. Periodically maintain the machine and clean the dust inside.
Page 30
Port
INPUT 115V/230V
Port
POWER SWITCH
S2
4
4
SECTION 7 ELECTRICAL DIAGRAMS
1
2
S25VB
3
1
2
S25VB
3
protect LED
POWER LED
1
2
3
4
5
6
CN102-103
7
8
9
10
MIG 145 capacito r board
Voltage regu lator
2W10K
123
CN104
Current regulator
2W1K
1
2
CN111
3
1
2 CN107
1
CN117
2
CN106
CN303
123
1
2
3
CN107
4
5
6
7
CN101
CN106
123
123
123
123
CN101
CN118
123
MIG 145 control board
CN105
115
1
2
1
1
2
3
4
CN203
5
6
7
8
9
MIG 145 inverter bo ard
CN204
123
4
the input side of transformer
4
3
CN114
2
1
MIG 145 rectifier of board
3
2
CN110
CN308
CN302
1
2
2
123
1
CN318
4
123
1
CN301
2
3
CN202
1234567
Port
+
OUT
Port
-
2W10K
BURN BACK reg ulator
DC 24V
+
FAN
-
A
Solenoid
thermostat
M
Feed motor
gun torch
Figure 7.1
Page 31
NOTES
WELDKING™ MIGSONIC145
Page 32
SECTION 8 PARTS LIST
Item Order No. Description Note Quantity
1 Y0161001 Potentiometer WH118 2W 1K carbon film 1
2 Y0161002 Potentiometer WH118 2W 10K carbon film 2
3 B0103030 MIG-200C Control
PCB
4 B0100025 MIG-145C Inverter
PCB
5 Y0701015 Mosfet FMH23N50E 8
6 Y1602003 Solenoid Valve VZCT-2.5 DC24V(copper
7 Y2515009 Gas inlet Connector(Export)-01-A1 1
8 Y0311013 MIG-145C reactor DKQ-002 1
9 Y0108121 Ignition resistance 9T 0.5Ω 1
10 Y2516002 Wire feed motor MIG-145(US) 1
11 B0101044 DVI-200 Capacitor
PCB (new)
12 B0102029 MIG-145C rectifier
PCB
13 Y0401040 Rectifier D92-02 8
14 Y1801001/2 ARC-160C Heat sink WJJ-031/032 2
MIG200-KZ-B 1
MIG-145C 1
1
base∅6)
DVI200-DR 1
MIG-145C rectifier PCB 1
15 Y2517037 Circuit breaker KuoYuH-25A/AC250V 1
16 Y1301004 Fan 12038 DC24V 1
17 Y2517036 Spool holder 1Kg/5Kg 1
18 Y2508007 Knob
19 Y2517034 Plastic wiring
terminal
20 Y0401006 luminescent diode
21 Y0401005 luminescent diode
22 Y1101001 Toggle switch R210-C5L-BR(25A) 1
23 Y2517038 Control receptacle AANWAN-4 hole 1
24 B0201050 Earth clamp 005 10mm, 2/3m 1
25 Y04070001 Rectifier bridge 25A/1000V(Square) 2
Table 8.1
RN-110Z（black/red）
Plastic control connector 1
∅5 yellow
∅5 red
3
1
1
Page 33
1
2
3
6 5 4
7
15
16
8
9
10
Figure 8.1
11 12
13
14
25
Page 34
18
20
21
22
24
23
Figure 8.2
Page 35
17
19
18
Figure 8.3
Page 36
Wire feeder(HANWAN-4D/24V) , Order No. 2611017
Figure 8.4
ITEM DESCRIPTION ORDER NO. QUANTITY
1 Clamp 200A(Black) 2301006 1
1 Electric Machinery 26110171 1
2 Gearbox 26110172 1
3 #18 Bracket 26110173 1
4 Roller(0.6/0.8mm)(.023/.030) Y2517047 1
5 #18 Pressure shell components 26110175 1
6 #6 Pressure 26110176 1
Page 37
WeldKingTM NT1 Mig Torch, Order No. 07000422
Figure 8.5
Nozzles
ITEM DESCRIPTION ORDER NO.
1 Nozzle Self Insulated 21-37 A
2 Nozzle Self Insulated 21-50* A
3 Nozzle Self Insulated 21-62 A
4 Nozzle Self Insulated 21-37F A
5 Nozzle Self Insulated 21-50F A
6 Nozzle Self Insulated 21-62F A
7 Nozzle Self Shielding LA8201 B
Contact Tips
ITEM DESCRIPTION ORDER NO.
1 Contact Tip 0.023”/0.6mm Ecu 11-23 C
Page 38
2 Contact Tip 0.030”/0.8mm Ecu 11-30* C
3 Contact Tip 0.035”/0.9mm Ecu 11-35 C
4 Contact Tip 0.040”/1.0mm Ecu 11-40 C
5 Contact Tip 0.045”/1.2mm Ecu 11-45 C
Liners
ITEM DESCRIPTION ORDER NO.
1 Steel Liner 0.030”-0.035”/0.8-0.9mm X15ft 42-3035-15 D
2 Teflon Liner 0.030”-0.035”/0.8-0.9mm X15ft 42T-3035-15 D
* Default
Component
ITEM DESCRIPTION PART No. QTY
1 Gun&Cable Assembly 2011008 1
2
3 Trigger Assembly 2011010 1
4 Hook 2011011 1
5 Locking Nut 2011012 1
6 Gas Diffuser 51 1
7 Contact Tip.030 See above 1
8 Gas Nozzle See above 1
9 Control Assembly 2011059 1
10 Control Wire Cord 2011016 1
11 Cable Boot 2011017 1
12 Liner 0.6-0.8 / 10FT See above 1
Gun Handle (Left ＆Right)
2011009 1
Page 39
NOTES
WELDKING™ MIGSONIC145
Page 40
SECTION 8 WARRANTY POLICY
Malo Welding Products Ltd., Warranty Policy
Effective August 1
LIMITED WARRANTY - Subject to the terms and
conditions below, Malo Welding Products
Ltd.(WELDKING™ ) endeavors to provide high
quality products and product support to its
customers and therefore backs up all of its new
products purchased from Malo Welding Products
Ltd.(WELDKING™ ) or any authorized Malo
Welding Products Ltd.(WELDKING™ )
distributor/service center after the effective date of
this limited warranty and is free of defects in
material and workmanship at the time it is shipped.
THERE ARE NO WARRANTIES WHICH EXTEND
BEYOND THE FACE OF THE MALO WELDING
PRODUCTS LTD.(WELDKING™ ) WARRANTY.
MALO WELDING PRODUCTS
LTD.(WELDKING™ ) DISCLAIMS ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED,
REGARDING THE PRODUCTS, INCLUDING ANY
IMPLIED WARRANTIES OF MERCHANTABILITY,
FITNESS FOR A PARTICULAR PURPOSE OR
NONINFRINGEMENT. IN THE UNITED STATES,
SOME STATES DO NOT ALLOW THE
EXCLUSION OF THE IMPLIED WARRANTIES,
SO THE ABOVE EXCLUSION MAY NOT APPLY
TO YOU.
Malo Welding Products Ltd.(WELDKING™ ) shall
honor warranty claims on warranted equipment
listed below in the event of such a failure within the
warranty time periods. All warranty time periods
start on the date that the equipment was delivered
to the original retail purchaser, or one year after the
equipment is sent to a North American distributor.
(1) 3 Years - Parts and Labor
Power Sources
Wire Feeders
(2) 90 Days - Parts (No Labor)
Guns
Remote Controls
Accessory Kits
Replacement Parts (No labor)
Malo Welding Products Ltd.(WELDKING™ )'s
limited Warranty shall not apply to:
(1) Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
(2) All limited warranties are void for, and Malo
Welding Products Ltd.(WeldKing™ ) does not
warrant in any way, any product that evidences
misapplication, improper installation, abuse, lack of
maintenance, negligence in use or care, abnormal
use, alteration of design, use of incompatible or
corrosive chemicals, and/or servicing, installation of
parts, or repairs by anyone other than Malo
Welding Products Ltd.(WELDKING™ ) or a Malo
Welding Products Ltd.(WELDKING™ ) authorized
distributor or service center. Malo Welding
Products Ltd.(WELDKING™ ) may make changes
in products it manufactures and markets at any
time; these changes are made without obligation to
change, retrofit, or upgrade any product previously
sold or manufactured.
MALO WELDING PRODUCTS
LTD.(WELDKING™ )'S PRODUCTS ARE FOR
st
, 2004, revision at April 1st, 2011
COMMERCIAL/INDUSTRIAL USE AND
PERSONS TRAINED AND EXPERIENCED IN
THE USE AND MAINTENANCE OF
WELDING/PLASMA CUTTING EQUIPMENT.
In the event of a warranty claim covered by this
warranty, the exclusive remedies shall be, at Malo
Welding Products Ltd.(WELDKING™ )'s option: (1)
repair; or (2) replacement; or, where authorized in
writing by Malo Welding Products
Ltd.(WELDKING™ ), in appropriate cases, (3) the
reasonable cost of repair or replacement at an
authorized service station; or (4) payment of or
credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of
the goods at customer's risk and expense. No
compensation or reimbursement for transportation
costs of any kind will be allowed.
LIMITATION OF DAMAGES: THE REMEDY OF
REPLACEMENT OR REPAIR OF ANY
DEFECTIVE GOODS SHALL BE THE EXCLUSIVE
REMEDY UNDER ANY WARRANTY MADE BY
MALO WELDING PRODUCTS
LTD.(WELDKING™ ), WHETHER EXPRESS OR
IMPLIED. IN NO EVENT SHALL MALO WELDING
PRODUCTS LTD.(WELDKING™ ) BE LIABLE
FOR ANY INCIDENTAL OR CONSEQUENTIAL
DAMAGES, PROPERTY DAMAGES, OR
PERSONAL INJURIES.
ANY EXPRESS WARRANTY NOT PROVIDED
HEREIN AND ANY IMPLIED WARRANTY,
GUARANTY OR REPRESENTATION AS TO
PERFORMANCE, AND ANY REMEDY FOR
BREACH OF CONTRACT TORT OR ANY OTHER
LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR
COURSE OF DEALING, INCLUDING ANY
IMPLIED WARRANTY OF MERCHANTABILITY
OR FITNESS FOR PARTICULAR PURPOSE,
WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MALO WELDING PRODUCTS
LTD.(WELDKING™ ), IS EXCLUDED AND
DISCLAIMED BY MALO WELDING PRODUCTS
LTD.(WELDKING™ ).
If any provision or portion of this limited warranty
policy is found to be unenforceable, then the
remaining provisions and portions shall remain
valid and enforceable. If any provision or portion of
this limited warranty policy is found to be limited by
law, then that provision or portion shall be
construed to make it effective within the bounds of
law.
To obtain warranty service you must active your
product(s)'s warranty online at weldking.com or
mail the product registration card included in the
package to Malo Welding Products
Ltd.(WELDKING™ ) right after the purchase. When
there is a warranty issue, return the defective
welding machine or plasma cutting machine along
with proof of purchase to any WeldKing™
Authorized Warranty Depot. For the location of the
nearest WeldKing™ Authorized Warranty depot or
for service information in the United States or
Canada, please telephone toll free:
1-866-686-5088 or visit www. weldking.com (USA
& Canada).available, but may vary from province to
province
Page 41
SECTION 9 AUTHORIZED SERVICE
CENTER
Please go to our website www.weldking.com to fill the warranty
registration form. Malo Welding Products Ltd. will not distribute
of disclose customer's private information to any third party and
will not sent promotion material to the customer.
Find your nearest warranty center at:
http://www.weldking.com/servicelocations.aspx
MALO WELDING PRODUCTS LTD.
3275, 14th Ave, Unit A, Markham, On, L6G 1B1
Tel: 1 866 686 5088
Fax: 1 866 686 5090
www.malowelding.com
Printed April 13, 2011
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